CNC Multispindles： Are They For You
Programming rough machining operations for efficient removal of large volumes of material is crucial when preparing a mold, pattern or other workpiece for finish machining. However, the strategies for traditional roughing operations, which are mainly based on rest roughing, require that each tool be programmed separately.
Modacam Inc. (Denver, North Carolina), a pattern, mold and production job shop, is experiencing substantial time savings with an alternative to rest roughing from Surfware Inc. (Westlake Village, California). Step Reduction Milling (SRM) is an integrated component in the SurfCAM CAD/CAM system, which creates a single roughing program that can be used for machining molds and patterns, in addition to forging dies and parts.
"We estimate that SRM has cut our rough machining programming time in half," says Bud Tschudin, president of Modacam. "Because we can be more aggressive, rough machining cycle time has been reduced by 30 percent."
Shorter programming and machining cycle times are the result of the programmer working with a single dialog box and intelligent knowledge base. The technology analyzes the capabilities and limitations of all tools in the list and uses them together, as a cohesive group, to produce the appropriate roughing program.
In moldmaking and pattern making, traditional roughing methods used for machining complex surfaces leave behind excess material in the form of steps. Rest roughing requires that each cutting tool be programmed independently, with the NC programmer having sole knowledge of the other cutting tools being used. Then, a time-consuming analysis must be performed for each cutting tool to determine the location of the excess material. At this point, preparing the material for subsequent tools becomes problematic because individual cutting tools have no knowledge of which tools will follow. This necessitates smaller tools removing more material than recommended, while the larger tools remove less material than they should. Typically, the remaining steps do not have a uniform height, making it difficult to maintain an even cutting load during the finishing process. Tool load, and therefore tool wear, varies, and the possibility of broken tools increases. To minimize the impact of these problems, programmers often rely on smaller tools and less Shallow Hole Indexable Insert aggressive cutting, which further increases machining cycle time.
According to the Modacam, SRM eliminates the need for rest roughing. Using a combination of multiple tools, automation and shop-floor machining logic, the component creates a roughing program that produces uniform step heights, regardless of the sizes and number of tools used. This results in shorter programming and machining cycle times. The process also promotes the use of larger cutting tools to remove more stock with reductions in the number of steps required to prepare for the following tool. A uniform amount of material is left behind for finishing, thus accommodating the application of constant loads to the cutting tools, all of which minimizes tool wear and the likelihood of tool breakage.
Lights-out machining is an essential strategy employed by the company to sustain its competitive edge. "For us, lights-out machining is a big deal,&#CNMG Insert 34; says Jonathan Elrod, a programmer at the company."We have confidence that the finishing operation is going to run smoothly overnight, when no one is here. A consistent step is being removed, so we can take roughing operations down to the finished cutting tool size. In essence, it's like adding a second or third shift without increasing labor costs."
"SurfCAM with SRM has been essential in cutting our costs and improving our delivery time," Mr. Tschudin says. With optimized operations, the company is able to take on jobs that were otherwise unattainable, while maximizing profits.
The Cemented Carbide Blog: Cemented Carbide Inserts
Programming rough machining operations for efficient removal of large volumes of material is crucial when preparing a mold, pattern or other workpiece for finish machining. However, the strategies for traditional roughing operations, which are mainly based on rest roughing, require that each tool be programmed separately.
Modacam Inc. (Denver, North Carolina), a pattern, mold and production job shop, is experiencing substantial time savings with an alternative to rest roughing from Surfware Inc. (Westlake Village, California). Step Reduction Milling (SRM) is an integrated component in the SurfCAM CAD/CAM system, which creates a single roughing program that can be used for machining molds and patterns, in addition to forging dies and parts.
"We estimate that SRM has cut our rough machining programming time in half," says Bud Tschudin, president of Modacam. "Because we can be more aggressive, rough machining cycle time has been reduced by 30 percent."
Shorter programming and machining cycle times are the result of the programmer working with a single dialog box and intelligent knowledge base. The technology analyzes the capabilities and limitations of all tools in the list and uses them together, as a cohesive group, to produce the appropriate roughing program.
In moldmaking and pattern making, traditional roughing methods used for machining complex surfaces leave behind excess material in the form of steps. Rest roughing requires that each cutting tool be programmed independently, with the NC programmer having sole knowledge of the other cutting tools being used. Then, a time-consuming analysis must be performed for each cutting tool to determine the location of the excess material. At this point, preparing the material for subsequent tools becomes problematic because individual cutting tools have no knowledge of which tools will follow. This necessitates smaller tools removing more material than recommended, while the larger tools remove less material than they should. Typically, the remaining steps do not have a uniform height, making it difficult to maintain an even cutting load during the finishing process. Tool load, and therefore tool wear, varies, and the possibility of broken tools increases. To minimize the impact of these problems, programmers often rely on smaller tools and less Shallow Hole Indexable Insert aggressive cutting, which further increases machining cycle time.
According to the Modacam, SRM eliminates the need for rest roughing. Using a combination of multiple tools, automation and shop-floor machining logic, the component creates a roughing program that produces uniform step heights, regardless of the sizes and number of tools used. This results in shorter programming and machining cycle times. The process also promotes the use of larger cutting tools to remove more stock with reductions in the number of steps required to prepare for the following tool. A uniform amount of material is left behind for finishing, thus accommodating the application of constant loads to the cutting tools, all of which minimizes tool wear and the likelihood of tool breakage.
Lights-out machining is an essential strategy employed by the company to sustain its competitive edge. "For us, lights-out machining is a big deal,&#CNMG Insert 34; says Jonathan Elrod, a programmer at the company."We have confidence that the finishing operation is going to run smoothly overnight, when no one is here. A consistent step is being removed, so we can take roughing operations down to the finished cutting tool size. In essence, it's like adding a second or third shift without increasing labor costs."
"SurfCAM with SRM has been essential in cutting our costs and improving our delivery time," Mr. Tschudin says. With optimized operations, the company is able to take on jobs that were otherwise unattainable, while maximizing profits.
The Cemented Carbide Blog: Cemented Carbide Inserts
Programming rough machining operations for efficient removal of large volumes of material is crucial when preparing a mold, pattern or other workpiece for finish machining. However, the strategies for traditional roughing operations, which are mainly based on rest roughing, require that each tool be programmed separately.
Modacam Inc. (Denver, North Carolina), a pattern, mold and production job shop, is experiencing substantial time savings with an alternative to rest roughing from Surfware Inc. (Westlake Village, California). Step Reduction Milling (SRM) is an integrated component in the SurfCAM CAD/CAM system, which creates a single roughing program that can be used for machining molds and patterns, in addition to forging dies and parts.
"We estimate that SRM has cut our rough machining programming time in half," says Bud Tschudin, president of Modacam. "Because we can be more aggressive, rough machining cycle time has been reduced by 30 percent."
Shorter programming and machining cycle times are the result of the programmer working with a single dialog box and intelligent knowledge base. The technology analyzes the capabilities and limitations of all tools in the list and uses them together, as a cohesive group, to produce the appropriate roughing program.
In moldmaking and pattern making, traditional roughing methods used for machining complex surfaces leave behind excess material in the form of steps. Rest roughing requires that each cutting tool be programmed independently, with the NC programmer having sole knowledge of the other cutting tools being used. Then, a time-consuming analysis must be performed for each cutting tool to determine the location of the excess material. At this point, preparing the material for subsequent tools becomes problematic because individual cutting tools have no knowledge of which tools will follow. This necessitates smaller tools removing more material than recommended, while the larger tools remove less material than they should. Typically, the remaining steps do not have a uniform height, making it difficult to maintain an even cutting load during the finishing process. Tool load, and therefore tool wear, varies, and the possibility of broken tools increases. To minimize the impact of these problems, programmers often rely on smaller tools and less Shallow Hole Indexable Insert aggressive cutting, which further increases machining cycle time.
According to the Modacam, SRM eliminates the need for rest roughing. Using a combination of multiple tools, automation and shop-floor machining logic, the component creates a roughing program that produces uniform step heights, regardless of the sizes and number of tools used. This results in shorter programming and machining cycle times. The process also promotes the use of larger cutting tools to remove more stock with reductions in the number of steps required to prepare for the following tool. A uniform amount of material is left behind for finishing, thus accommodating the application of constant loads to the cutting tools, all of which minimizes tool wear and the likelihood of tool breakage.
Lights-out machining is an essential strategy employed by the company to sustain its competitive edge. "For us, lights-out machining is a big deal,&#CNMG Insert 34; says Jonathan Elrod, a programmer at the company."We have confidence that the finishing operation is going to run smoothly overnight, when no one is here. A consistent step is being removed, so we can take roughing operations down to the finished cutting tool size. In essence, it's like adding a second or third shift without increasing labor costs."
"SurfCAM with SRM has been essential in cutting our costs and improving our delivery time," Mr. Tschudin says. With optimized operations, the company is able to take on jobs that were otherwise unattainable, while maximizing profits.
The Cemented Carbide Blog: Cemented Carbide Inserts
Seven Flute Cutters Maximize High Efficiency Machining Benefits
Sandvik Coromant introduces its CoroBore rough-boring tools, which are designed to address vibration, chip breaking and process security while delivering high productivity. The tools are available in single, twin and triple edge. The tools are said to offer high performance in ISO P (steel), M (stainless steel), K (cast iron), N (nonferrous), S (heat-resistant super alloy and titanium) and ISO H (hardened steel).
To support these tools, the company has also introduced CoroBore 111 four-edged inserts, which are designed to provide optimized grade selection, good chip-formation qualities and increased tool life.
The Carbide Drilling Inserts CoroBore BR20 twin-edge tool has a differential pitch to reduce pitch vibration and enable use at longer overhangs and larger cut depths. It enables built-in step-boring without the need for an extra shim, and coolant nozzles which handle coolant pressure ranging to 70 bar (1,015 psi) to evacuate chips. The BR20 is available with vibration-damping Silent Tools technology for long overhangs or where additional stability is needed, and is said to increase cut depth while maintaining security. According to the company, the BR20 can increase overhang by 30 percent compared to its DuoBore tool and tool life by 75 percent.
The single-edge BR10 is said to be ideal for back boring with its back-boring slide and cover. The three-edge BR30 has a short, rigid design and differential pitch for high productivity and Carbide Milling Inserts low vibration.
These tools can be combined with the company’s Capto and EG modular systems for flexibility. Each solution is available separately or as part of a complete tool assembly kit.
The Cemented Carbide Blog: Carbide Turning Inserts
Sandvik Coromant introduces its CoroBore rough-boring tools, which are designed to address vibration, chip breaking and process security while delivering high productivity. The tools are available in single, twin and triple edge. The tools are said to offer high performance in ISO P (steel), M (stainless steel), K (cast iron), N (nonferrous), S (heat-resistant super alloy and titanium) and ISO H (hardened steel).
To support these tools, the company has also introduced CoroBore 111 four-edged inserts, which are designed to provide optimized grade selection, good chip-formation qualities and increased tool life.
The Carbide Drilling Inserts CoroBore BR20 twin-edge tool has a differential pitch to reduce pitch vibration and enable use at longer overhangs and larger cut depths. It enables built-in step-boring without the need for an extra shim, and coolant nozzles which handle coolant pressure ranging to 70 bar (1,015 psi) to evacuate chips. The BR20 is available with vibration-damping Silent Tools technology for long overhangs or where additional stability is needed, and is said to increase cut depth while maintaining security. According to the company, the BR20 can increase overhang by 30 percent compared to its DuoBore tool and tool life by 75 percent.
The single-edge BR10 is said to be ideal for back boring with its back-boring slide and cover. The three-edge BR30 has a short, rigid design and differential pitch for high productivity and Carbide Milling Inserts low vibration.
These tools can be combined with the company’s Capto and EG modular systems for flexibility. Each solution is available separately or as part of a complete tool assembly kit.
The Cemented Carbide Blog: Carbide Turning Inserts
Sandvik Coromant introduces its CoroBore rough-boring tools, which are designed to address vibration, chip breaking and process security while delivering high productivity. The tools are available in single, twin and triple edge. The tools are said to offer high performance in ISO P (steel), M (stainless steel), K (cast iron), N (nonferrous), S (heat-resistant super alloy and titanium) and ISO H (hardened steel).
To support these tools, the company has also introduced CoroBore 111 four-edged inserts, which are designed to provide optimized grade selection, good chip-formation qualities and increased tool life.
The Carbide Drilling Inserts CoroBore BR20 twin-edge tool has a differential pitch to reduce pitch vibration and enable use at longer overhangs and larger cut depths. It enables built-in step-boring without the need for an extra shim, and coolant nozzles which handle coolant pressure ranging to 70 bar (1,015 psi) to evacuate chips. The BR20 is available with vibration-damping Silent Tools technology for long overhangs or where additional stability is needed, and is said to increase cut depth while maintaining security. According to the company, the BR20 can increase overhang by 30 percent compared to its DuoBore tool and tool life by 75 percent.
The single-edge BR10 is said to be ideal for back boring with its back-boring slide and cover. The three-edge BR30 has a short, rigid design and differential pitch for high productivity and Carbide Milling Inserts low vibration.
These tools can be combined with the company’s Capto and EG modular systems for flexibility. Each solution is available separately or as part of a complete tool assembly kit.
The Cemented Carbide Blog: Carbide Turning Inserts
Extreme Tool Setting
Mazak Optonics’ Optiplex 4020 CO2 laser-cutting system features an expanded workspace for larger jobs in a 6 × 12-ft. format. The system can process materials ranging from thin-gage steel to 1"-thick mild steel, with a workpiece weight capacity of 3,527 lbs. The laser-cutting system is equipped with the company’s automated AO|5 setup, said to improve productivity and maintain cutting conditions when using various workpiece materials. A 4,000-W Type-10 resonator featuring an efficient Eco mode is said to lower operation costs. The machine features the PreView control with a 15" touchscreen and a graphical interface that visualizes the cutting path. The control automatically determines process conditions, including the required lens, nozzle federate and laser output for tube process inserts different Carbide Drilling Inserts materials and thicknesses.
The Cemented Carbide Blog: tungsten carbide stock
Mazak Optonics’ Optiplex 4020 CO2 laser-cutting system features an expanded workspace for larger jobs in a 6 × 12-ft. format. The system can process materials ranging from thin-gage steel to 1"-thick mild steel, with a workpiece weight capacity of 3,527 lbs. The laser-cutting system is equipped with the company’s automated AO|5 setup, said to improve productivity and maintain cutting conditions when using various workpiece materials. A 4,000-W Type-10 resonator featuring an efficient Eco mode is said to lower operation costs. The machine features the PreView control with a 15" touchscreen and a graphical interface that visualizes the cutting path. The control automatically determines process conditions, including the required lens, nozzle federate and laser output for tube process inserts different Carbide Drilling Inserts materials and thicknesses.
The Cemented Carbide Blog: tungsten carbide stock
Mazak Optonics’ Optiplex 4020 CO2 laser-cutting system features an expanded workspace for larger jobs in a 6 × 12-ft. format. The system can process materials ranging from thin-gage steel to 1"-thick mild steel, with a workpiece weight capacity of 3,527 lbs. The laser-cutting system is equipped with the company’s automated AO|5 setup, said to improve productivity and maintain cutting conditions when using various workpiece materials. A 4,000-W Type-10 resonator featuring an efficient Eco mode is said to lower operation costs. The machine features the PreView control with a 15" touchscreen and a graphical interface that visualizes the cutting path. The control automatically determines process conditions, including the required lens, nozzle federate and laser output for tube process inserts different Carbide Drilling Inserts materials and thicknesses.
The Cemented Carbide Blog: tungsten carbide stock
Long Lasting Insert Turns Around Tough Inconel Job
In 1987, Century Tool and Gage Co. (Fenton, Michigan) bought its first Heyligenstaedt vertical mill equipped with the first Fidia CNC system that was available in North America. Mickey Guckian, manufacturing manager of programming for Century Tool, was there. “I remember when we purchased the first Fidia control. It was installed on a two-spindle Heyligenstaedt vertical mill. I was running that machine at the time,” he says. “The new control had dual 8-inch floppy drives, which was unique back then, and it gave us the ability to gun drilling inserts gun drilling inserts greatly improve the feed rate for the complex milling routines we were running for the large compression molds we were manufacturing.”
Century Tool was founded in 1974 and has experienced consistent growth over most of its history. According to Vice President Kevin Cummings, this is due in part to expanding the manufacturing of composite compression molds to produce sheet molding compound (SMC), reaction injection molding (RIM) and urethane parts for various sectors of the transportation industry. The company specializes in compression-molded, exterior Class A, and reinforcement panels for truck and trim applications. It also makes 75 percent of the exterior body panel molds. “We have become a major builder of molds and secondary tooling for the automotive, heavy truck, aerospace and personal watercraft rod peeling inserts industries,” Mr. Cummings says. With that growth came the company’s move to a new, 125,000-square-foot facility that is capable of handling 60-ton machine block sizes that are as wide as 100 inches and as long as 300 inches. The plant is equipped with four, five-axis CNC machining centers; seven heavy-duty vertical and horizontal machines; three multi-spindle, traveling-column gundrills; 29 CAD/CAM workstations; and a try-out press facility with capacities of 500, 600, 1,500 and 3,000 tons.
“Before Fidia started developing a complete line of five-axis milling machines, it was building CNC controls,” Mr. Guckian says. “Dr. Giuseppe Morfino, Fidia CEO, was the young controls engineer who started it all, and he has been the guiding influence in the CNC machine control design that has played a significant role in making Century Tool and Gage a manufacturing and production success. All of our milling machines are CNC programmable and use Fidia controllers for high-level accuracy, dependability and productivity.”
But it has been a long time since 1987, and floppy drives will no longer cut it for Century Tool’s needs three decades later. That is where regular retrofitting of the Fidia controllers comes in.
Jorge Correa, Fidia’s vice president of sales in North America, says, “Century Tool is a great example of what can be done with control retrofits to bring existing CNC machine tools to state-of-the-art levels.” Since 1987, Century Tool has used Fidia’s CK10, CK20, Compac, C2, C20, a couple of Fidia’s tracing systems, and more recently, Fidia’s C40 controls. Today, the company has 25 Fidia CNCs, but with ongoing control upgrades and the addition of new CNC machine tools, Mr. Correa says the actual number is well over 30 controls.
In concert with the Fidia controllers, Century Tool uses Tebis V4.OR2 software for five-axis machining. Tebis V4 software can translate software formats such as Catia, Iges, Parasolid, STEP and NX to create the best tool paths. It is said to be the only software that can generate the tool path right off the surface. “It creates a greater amount of contact points, producing a more accurate part,” Mr. Guckian says.
On each of Century Tool’s CNC mills, the Fidia control provides automatic scaling features for each axis to translate CNC program parameters to fit the size of the workpiece. The control is connected via Ethernet to the company’s programming computers for continuous transfer of CAD data. “This allows Century Tool to have the flexibility to expand the customer’s product design ideas, but also the ability to communicate in direct language formats,” Mr. Guckian says.
Century Tool first encountered the Fidia C40 Vision Control, with its ViMill anti-collision software, at the International Manufacturing Technology Show (IMTS) in 2014. The company purchased the hardware and software components on a new Fidia GTFM.V3 five-axis milling machine right after the show. “What immediately impressed us about the C40 control is that it can handle very large data programs of 50 megabytes or more. Some mold surfaces are very complex and rich with detail. The Fidia controls can handle the data file sizes and still provide smooth and accurate finishes,” Mr. Guckian says. “At Century Tool, we also work on older compression molds that need to be reworked with new engineering changes, which typically involves more blending of surface cuts. Excellent finish is a must for these types of projects. The Fidia controls have vastly improved this capability by increasing their look-ahead from 300 to 1,000 lines of point data, which gives the machine the capability to prepare itself better for the upcoming shapes it is about to create.”
For example, high machining speed and excellent surface finish are the desire of any mold shop using five-axis milling machines, and Mr. Guckian says that Century Tool attains excellent surface finish because of its ability to precisely control acceleration and deceleration. According to Mr. Correa, the C40 Vision Control’s multi-processor architecture manages user interface, axis and toolpath control, as well as ViMill real-time, anti-collision software, which together work to produce the fast machining speeds and high-quality surface finishes. “It’s one thing to have fast processors, but you need very good communication software parameters to enable the drives and motors to communicate at these fast feed rates,” he says. “The Fidia control allows the machine to be fine-tuned for various dynamics, such as part weight, length and width, spindle speeds, rigidity—basically anything needed to achieve a very accurate finish in a shorter period of time.”
According to Mr. Guckian, Fidia’s ViMill software in the C40 Vision Control is user-friendly and easy to train operators to use. Its anti-collision feature provides safe milling conditions for very complex mold machining by projecting 1,000 lines of code. That projection prevents any collision between the tool, the machine and the workpiece in real time during milling operations and in both jog- and part-program execution mode. “The operator has the ability to use the handwheel on the fly for the X, Y, Z, A and C axes and normal-to-vector compound angles. We are not aware of any other control that has that feature,” Mr. Guckian says.
Typically, Fidia GTFM five-axis milling machines are outfitted with the Head Measuring System (HMS), which has greatly reduced the time it takes for Century Tool machinists to verify the accuracy of heads and tilting rotary tables. The HMS reduced that time from one day to less than an hour. “The HMS is a high-precision alternative to the traditional dial gages and is a very important facet of the five-axis cutting technology. The HMS keeps the five-axis head as accurate as possible, usually within 10 microns. This is vitally important when the mold is being machined unattended, which is usually at night,” Mr. Correa explains. He adds, “The Fidia measurement software within the control manages the mold cutting. The software is equipped with three high-precision displacement measuring devices and is allocated to measuring 3D volumetric errors. By processing incoming data in real time, the software can check and compensate for limited geometric error, avoiding costly corrective mechanical interventions.” Users can save the desired settings and trust them to be maintained to within 5 microns. As a result, “the machine ran for eight months without having to change calibration parameters on the head,” Mr. Guckian reports.
A laser powers the Rotation Tool Center Point (RTCP) function, which is another feature managed by Fidia control software. The laser accurately measures the length and diameter of the cutter at each tool change, which provides for a continuously accurate height setting on the mold from cutter to cutter.
Multi-processor architecture in the control allows for updates and empowers the system through the partial or total replacement of the PC (memory, hard discs, adapters, etc.) without modifying other computer components. The GTFM machine has three central processing units. As a result, it is possible to keep the CNC constantly up to date with the most recent hardware and software developments.
One such upgrade, Fidia’s Velocity Five multi-axis trajectory control technology, provides a dynamic-selectable set of roughing and finishing parameters. These parameters are said to enable the user to execute fast and highly accurate milling by improving the acceleration control techniques. At the time of writing, Century Tool estimates the Velocity Five upgrade can reduce finish milling time on 3D profiles between 15 and 20 percent and roughing between 30 and 40 percent. The machined surface quality shows significant improvement and faster execution of machining for small radii areas.
With plans to add this update to another finish milling machine and to install three more C40 Vision CNCs to other machines, Century Tool’s continuous-improvement strategy makes the most of retrofits and upgrades.
The Cemented Carbide Blog: tungsten tig inserts
In 1987, Century Tool and Gage Co. (Fenton, Michigan) bought its first Heyligenstaedt vertical mill equipped with the first Fidia CNC system that was available in North America. Mickey Guckian, manufacturing manager of programming for Century Tool, was there. “I remember when we purchased the first Fidia control. It was installed on a two-spindle Heyligenstaedt vertical mill. I was running that machine at the time,” he says. “The new control had dual 8-inch floppy drives, which was unique back then, and it gave us the ability to gun drilling inserts gun drilling inserts greatly improve the feed rate for the complex milling routines we were running for the large compression molds we were manufacturing.”
Century Tool was founded in 1974 and has experienced consistent growth over most of its history. According to Vice President Kevin Cummings, this is due in part to expanding the manufacturing of composite compression molds to produce sheet molding compound (SMC), reaction injection molding (RIM) and urethane parts for various sectors of the transportation industry. The company specializes in compression-molded, exterior Class A, and reinforcement panels for truck and trim applications. It also makes 75 percent of the exterior body panel molds. “We have become a major builder of molds and secondary tooling for the automotive, heavy truck, aerospace and personal watercraft rod peeling inserts industries,” Mr. Cummings says. With that growth came the company’s move to a new, 125,000-square-foot facility that is capable of handling 60-ton machine block sizes that are as wide as 100 inches and as long as 300 inches. The plant is equipped with four, five-axis CNC machining centers; seven heavy-duty vertical and horizontal machines; three multi-spindle, traveling-column gundrills; 29 CAD/CAM workstations; and a try-out press facility with capacities of 500, 600, 1,500 and 3,000 tons.
“Before Fidia started developing a complete line of five-axis milling machines, it was building CNC controls,” Mr. Guckian says. “Dr. Giuseppe Morfino, Fidia CEO, was the young controls engineer who started it all, and he has been the guiding influence in the CNC machine control design that has played a significant role in making Century Tool and Gage a manufacturing and production success. All of our milling machines are CNC programmable and use Fidia controllers for high-level accuracy, dependability and productivity.”
But it has been a long time since 1987, and floppy drives will no longer cut it for Century Tool’s needs three decades later. That is where regular retrofitting of the Fidia controllers comes in.
Jorge Correa, Fidia’s vice president of sales in North America, says, “Century Tool is a great example of what can be done with control retrofits to bring existing CNC machine tools to state-of-the-art levels.” Since 1987, Century Tool has used Fidia’s CK10, CK20, Compac, C2, C20, a couple of Fidia’s tracing systems, and more recently, Fidia’s C40 controls. Today, the company has 25 Fidia CNCs, but with ongoing control upgrades and the addition of new CNC machine tools, Mr. Correa says the actual number is well over 30 controls.
In concert with the Fidia controllers, Century Tool uses Tebis V4.OR2 software for five-axis machining. Tebis V4 software can translate software formats such as Catia, Iges, Parasolid, STEP and NX to create the best tool paths. It is said to be the only software that can generate the tool path right off the surface. “It creates a greater amount of contact points, producing a more accurate part,” Mr. Guckian says.
On each of Century Tool’s CNC mills, the Fidia control provides automatic scaling features for each axis to translate CNC program parameters to fit the size of the workpiece. The control is connected via Ethernet to the company’s programming computers for continuous transfer of CAD data. “This allows Century Tool to have the flexibility to expand the customer’s product design ideas, but also the ability to communicate in direct language formats,” Mr. Guckian says.
Century Tool first encountered the Fidia C40 Vision Control, with its ViMill anti-collision software, at the International Manufacturing Technology Show (IMTS) in 2014. The company purchased the hardware and software components on a new Fidia GTFM.V3 five-axis milling machine right after the show. “What immediately impressed us about the C40 control is that it can handle very large data programs of 50 megabytes or more. Some mold surfaces are very complex and rich with detail. The Fidia controls can handle the data file sizes and still provide smooth and accurate finishes,” Mr. Guckian says. “At Century Tool, we also work on older compression molds that need to be reworked with new engineering changes, which typically involves more blending of surface cuts. Excellent finish is a must for these types of projects. The Fidia controls have vastly improved this capability by increasing their look-ahead from 300 to 1,000 lines of point data, which gives the machine the capability to prepare itself better for the upcoming shapes it is about to create.”
For example, high machining speed and excellent surface finish are the desire of any mold shop using five-axis milling machines, and Mr. Guckian says that Century Tool attains excellent surface finish because of its ability to precisely control acceleration and deceleration. According to Mr. Correa, the C40 Vision Control’s multi-processor architecture manages user interface, axis and toolpath control, as well as ViMill real-time, anti-collision software, which together work to produce the fast machining speeds and high-quality surface finishes. “It’s one thing to have fast processors, but you need very good communication software parameters to enable the drives and motors to communicate at these fast feed rates,” he says. “The Fidia control allows the machine to be fine-tuned for various dynamics, such as part weight, length and width, spindle speeds, rigidity—basically anything needed to achieve a very accurate finish in a shorter period of time.”
According to Mr. Guckian, Fidia’s ViMill software in the C40 Vision Control is user-friendly and easy to train operators to use. Its anti-collision feature provides safe milling conditions for very complex mold machining by projecting 1,000 lines of code. That projection prevents any collision between the tool, the machine and the workpiece in real time during milling operations and in both jog- and part-program execution mode. “The operator has the ability to use the handwheel on the fly for the X, Y, Z, A and C axes and normal-to-vector compound angles. We are not aware of any other control that has that feature,” Mr. Guckian says.
Typically, Fidia GTFM five-axis milling machines are outfitted with the Head Measuring System (HMS), which has greatly reduced the time it takes for Century Tool machinists to verify the accuracy of heads and tilting rotary tables. The HMS reduced that time from one day to less than an hour. “The HMS is a high-precision alternative to the traditional dial gages and is a very important facet of the five-axis cutting technology. The HMS keeps the five-axis head as accurate as possible, usually within 10 microns. This is vitally important when the mold is being machined unattended, which is usually at night,” Mr. Correa explains. He adds, “The Fidia measurement software within the control manages the mold cutting. The software is equipped with three high-precision displacement measuring devices and is allocated to measuring 3D volumetric errors. By processing incoming data in real time, the software can check and compensate for limited geometric error, avoiding costly corrective mechanical interventions.” Users can save the desired settings and trust them to be maintained to within 5 microns. As a result, “the machine ran for eight months without having to change calibration parameters on the head,” Mr. Guckian reports.
A laser powers the Rotation Tool Center Point (RTCP) function, which is another feature managed by Fidia control software. The laser accurately measures the length and diameter of the cutter at each tool change, which provides for a continuously accurate height setting on the mold from cutter to cutter.
Multi-processor architecture in the control allows for updates and empowers the system through the partial or total replacement of the PC (memory, hard discs, adapters, etc.) without modifying other computer components. The GTFM machine has three central processing units. As a result, it is possible to keep the CNC constantly up to date with the most recent hardware and software developments.
One such upgrade, Fidia’s Velocity Five multi-axis trajectory control technology, provides a dynamic-selectable set of roughing and finishing parameters. These parameters are said to enable the user to execute fast and highly accurate milling by improving the acceleration control techniques. At the time of writing, Century Tool estimates the Velocity Five upgrade can reduce finish milling time on 3D profiles between 15 and 20 percent and roughing between 30 and 40 percent. The machined surface quality shows significant improvement and faster execution of machining for small radii areas.
With plans to add this update to another finish milling machine and to install three more C40 Vision CNCs to other machines, Century Tool’s continuous-improvement strategy makes the most of retrofits and upgrades.
The Cemented Carbide Blog: tungsten tig inserts
In 1987, Century Tool and Gage Co. (Fenton, Michigan) bought its first Heyligenstaedt vertical mill equipped with the first Fidia CNC system that was available in North America. Mickey Guckian, manufacturing manager of programming for Century Tool, was there. “I remember when we purchased the first Fidia control. It was installed on a two-spindle Heyligenstaedt vertical mill. I was running that machine at the time,” he says. “The new control had dual 8-inch floppy drives, which was unique back then, and it gave us the ability to gun drilling inserts gun drilling inserts greatly improve the feed rate for the complex milling routines we were running for the large compression molds we were manufacturing.”
Century Tool was founded in 1974 and has experienced consistent growth over most of its history. According to Vice President Kevin Cummings, this is due in part to expanding the manufacturing of composite compression molds to produce sheet molding compound (SMC), reaction injection molding (RIM) and urethane parts for various sectors of the transportation industry. The company specializes in compression-molded, exterior Class A, and reinforcement panels for truck and trim applications. It also makes 75 percent of the exterior body panel molds. “We have become a major builder of molds and secondary tooling for the automotive, heavy truck, aerospace and personal watercraft rod peeling inserts industries,” Mr. Cummings says. With that growth came the company’s move to a new, 125,000-square-foot facility that is capable of handling 60-ton machine block sizes that are as wide as 100 inches and as long as 300 inches. The plant is equipped with four, five-axis CNC machining centers; seven heavy-duty vertical and horizontal machines; three multi-spindle, traveling-column gundrills; 29 CAD/CAM workstations; and a try-out press facility with capacities of 500, 600, 1,500 and 3,000 tons.
“Before Fidia started developing a complete line of five-axis milling machines, it was building CNC controls,” Mr. Guckian says. “Dr. Giuseppe Morfino, Fidia CEO, was the young controls engineer who started it all, and he has been the guiding influence in the CNC machine control design that has played a significant role in making Century Tool and Gage a manufacturing and production success. All of our milling machines are CNC programmable and use Fidia controllers for high-level accuracy, dependability and productivity.”
But it has been a long time since 1987, and floppy drives will no longer cut it for Century Tool’s needs three decades later. That is where regular retrofitting of the Fidia controllers comes in.
Jorge Correa, Fidia’s vice president of sales in North America, says, “Century Tool is a great example of what can be done with control retrofits to bring existing CNC machine tools to state-of-the-art levels.” Since 1987, Century Tool has used Fidia’s CK10, CK20, Compac, C2, C20, a couple of Fidia’s tracing systems, and more recently, Fidia’s C40 controls. Today, the company has 25 Fidia CNCs, but with ongoing control upgrades and the addition of new CNC machine tools, Mr. Correa says the actual number is well over 30 controls.
In concert with the Fidia controllers, Century Tool uses Tebis V4.OR2 software for five-axis machining. Tebis V4 software can translate software formats such as Catia, Iges, Parasolid, STEP and NX to create the best tool paths. It is said to be the only software that can generate the tool path right off the surface. “It creates a greater amount of contact points, producing a more accurate part,” Mr. Guckian says.
On each of Century Tool’s CNC mills, the Fidia control provides automatic scaling features for each axis to translate CNC program parameters to fit the size of the workpiece. The control is connected via Ethernet to the company’s programming computers for continuous transfer of CAD data. “This allows Century Tool to have the flexibility to expand the customer’s product design ideas, but also the ability to communicate in direct language formats,” Mr. Guckian says.
Century Tool first encountered the Fidia C40 Vision Control, with its ViMill anti-collision software, at the International Manufacturing Technology Show (IMTS) in 2014. The company purchased the hardware and software components on a new Fidia GTFM.V3 five-axis milling machine right after the show. “What immediately impressed us about the C40 control is that it can handle very large data programs of 50 megabytes or more. Some mold surfaces are very complex and rich with detail. The Fidia controls can handle the data file sizes and still provide smooth and accurate finishes,” Mr. Guckian says. “At Century Tool, we also work on older compression molds that need to be reworked with new engineering changes, which typically involves more blending of surface cuts. Excellent finish is a must for these types of projects. The Fidia controls have vastly improved this capability by increasing their look-ahead from 300 to 1,000 lines of point data, which gives the machine the capability to prepare itself better for the upcoming shapes it is about to create.”
For example, high machining speed and excellent surface finish are the desire of any mold shop using five-axis milling machines, and Mr. Guckian says that Century Tool attains excellent surface finish because of its ability to precisely control acceleration and deceleration. According to Mr. Correa, the C40 Vision Control’s multi-processor architecture manages user interface, axis and toolpath control, as well as ViMill real-time, anti-collision software, which together work to produce the fast machining speeds and high-quality surface finishes. “It’s one thing to have fast processors, but you need very good communication software parameters to enable the drives and motors to communicate at these fast feed rates,” he says. “The Fidia control allows the machine to be fine-tuned for various dynamics, such as part weight, length and width, spindle speeds, rigidity—basically anything needed to achieve a very accurate finish in a shorter period of time.”
According to Mr. Guckian, Fidia’s ViMill software in the C40 Vision Control is user-friendly and easy to train operators to use. Its anti-collision feature provides safe milling conditions for very complex mold machining by projecting 1,000 lines of code. That projection prevents any collision between the tool, the machine and the workpiece in real time during milling operations and in both jog- and part-program execution mode. “The operator has the ability to use the handwheel on the fly for the X, Y, Z, A and C axes and normal-to-vector compound angles. We are not aware of any other control that has that feature,” Mr. Guckian says.
Typically, Fidia GTFM five-axis milling machines are outfitted with the Head Measuring System (HMS), which has greatly reduced the time it takes for Century Tool machinists to verify the accuracy of heads and tilting rotary tables. The HMS reduced that time from one day to less than an hour. “The HMS is a high-precision alternative to the traditional dial gages and is a very important facet of the five-axis cutting technology. The HMS keeps the five-axis head as accurate as possible, usually within 10 microns. This is vitally important when the mold is being machined unattended, which is usually at night,” Mr. Correa explains. He adds, “The Fidia measurement software within the control manages the mold cutting. The software is equipped with three high-precision displacement measuring devices and is allocated to measuring 3D volumetric errors. By processing incoming data in real time, the software can check and compensate for limited geometric error, avoiding costly corrective mechanical interventions.” Users can save the desired settings and trust them to be maintained to within 5 microns. As a result, “the machine ran for eight months without having to change calibration parameters on the head,” Mr. Guckian reports.
A laser powers the Rotation Tool Center Point (RTCP) function, which is another feature managed by Fidia control software. The laser accurately measures the length and diameter of the cutter at each tool change, which provides for a continuously accurate height setting on the mold from cutter to cutter.
Multi-processor architecture in the control allows for updates and empowers the system through the partial or total replacement of the PC (memory, hard discs, adapters, etc.) without modifying other computer components. The GTFM machine has three central processing units. As a result, it is possible to keep the CNC constantly up to date with the most recent hardware and software developments.
One such upgrade, Fidia’s Velocity Five multi-axis trajectory control technology, provides a dynamic-selectable set of roughing and finishing parameters. These parameters are said to enable the user to execute fast and highly accurate milling by improving the acceleration control techniques. At the time of writing, Century Tool estimates the Velocity Five upgrade can reduce finish milling time on 3D profiles between 15 and 20 percent and roughing between 30 and 40 percent. The machined surface quality shows significant improvement and faster execution of machining for small radii areas.
With plans to add this update to another finish milling machine and to install three more C40 Vision CNCs to other machines, Century Tool’s continuous-improvement strategy makes the most of retrofits and upgrades.
The Cemented Carbide Blog: tungsten tig inserts
Device Automatically Lubricates HSK Tool Clamping Sets
6 Questions and Answers Help You Know Endmills
End mills are currently widely used in various sectors such as automobile manufacturing, logistics, molds, machinery, etc., and because of the increasing use of various aspects, the application requirements are also increasing. Therefore, various problems that are common in the use of end mill applications are summarized and answered.
[Q] How should the ?12 of the two teeth of the end mill be ground?
[Answer] First, the sand wheel should be ground, the edge of the grinding is a little angled, the milling cutter, the blade should pay attention, the outside should be higher than the inside… The slope inside should not be too oblique, probably just like this, this still has to grind more Practice only.
[Q] What is an end mill and what is a disc milling cutter? What is the deep hole drilling inserts difference?
[Answer] End mills are generally used for milling end faces, rather than keyway cutters for milling slots. The disc milling cutter is mainly used for milling large end faces, because the straight milling of the disc milling cutter is generally large, the milling end face is faster for milling, and the saw blade milling cutter is generally used for milling.
[Q] Why can’t the end mill cut vertically?
[Answer] When the end mill rotates, the midpoint of the bottom edge is relatively static. It does not have any machinability and chip removal, so it cannot be cut vertically.
[Q] How is the feed rate of the end mill determined?
[Answer] The selection of cutting amount should be considered together with the factors such as tool, workpiece and machine tool. The main cutting edge of the end mill is the peripheral edge. The feed per tooth deep hole drilling inserts is generally about 0.1 during finishing. The amount is generally selected from 0.25 to 0.3 mm. Specifically, it should be matched with the cutting parameters such as cutting speed, axial depth of cut and radial depth of cut.
[Q] What is the difference between the end mill and the ball end mill and its selection principle?
[Answer] End mills and ball end mills, one is the ball head, one is the flat bottom, the end mill is mainly for conventional machining, and the ball end milling cutter can be used for milling the surface.
[Q] What is the difference between the collet for the end mill and the collet for the tap? Do you have to use the company handle when tapping?
[Answer] Although the collet for holding the straight shank end mill can be used to hold the tap for rigid tapping, the effect is not good, generally the small diameter tap is no problem; the ER collet for the tap is with a square groove That is, the flat-tailed limit function of the tap handle is now available in general tool manufacturers.
The Cemented Carbide Blog: APKT Insert
6 Questions and Answers Help You Know Endmills
End mills are currently widely used in various sectors such as automobile manufacturing, logistics, molds, machinery, etc., and because of the increasing use of various aspects, the application requirements are also increasing. Therefore, various problems that are common in the use of end mill applications are summarized and answered.
[Q] How should the ?12 of the two teeth of the end mill be ground?
[Answer] First, the sand wheel should be ground, the edge of the grinding is a little angled, the milling cutter, the blade should pay attention, the outside should be higher than the inside… The slope inside should not be too oblique, probably just like this, this still has to grind more Practice only.
[Q] What is an end mill and what is a disc milling cutter? What is the deep hole drilling inserts difference?
[Answer] End mills are generally used for milling end faces, rather than keyway cutters for milling slots. The disc milling cutter is mainly used for milling large end faces, because the straight milling of the disc milling cutter is generally large, the milling end face is faster for milling, and the saw blade milling cutter is generally used for milling.
[Q] Why can’t the end mill cut vertically?
[Answer] When the end mill rotates, the midpoint of the bottom edge is relatively static. It does not have any machinability and chip removal, so it cannot be cut vertically.
[Q] How is the feed rate of the end mill determined?
[Answer] The selection of cutting amount should be considered together with the factors such as tool, workpiece and machine tool. The main cutting edge of the end mill is the peripheral edge. The feed per tooth deep hole drilling inserts is generally about 0.1 during finishing. The amount is generally selected from 0.25 to 0.3 mm. Specifically, it should be matched with the cutting parameters such as cutting speed, axial depth of cut and radial depth of cut.
[Q] What is the difference between the end mill and the ball end mill and its selection principle?
[Answer] End mills and ball end mills, one is the ball head, one is the flat bottom, the end mill is mainly for conventional machining, and the ball end milling cutter can be used for milling the surface.
[Q] What is the difference between the collet for the end mill and the collet for the tap? Do you have to use the company handle when tapping?
[Answer] Although the collet for holding the straight shank end mill can be used to hold the tap for rigid tapping, the effect is not good, generally the small diameter tap is no problem; the ER collet for the tap is with a square groove That is, the flat-tailed limit function of the tap handle is now available in general tool manufacturers.
The Cemented Carbide Blog: APKT Insert
6 Questions and Answers Help You Know Endmills
End mills are currently widely used in various sectors such as automobile manufacturing, logistics, molds, machinery, etc., and because of the increasing use of various aspects, the application requirements are also increasing. Therefore, various problems that are common in the use of end mill applications are summarized and answered.
[Q] How should the ?12 of the two teeth of the end mill be ground?
[Answer] First, the sand wheel should be ground, the edge of the grinding is a little angled, the milling cutter, the blade should pay attention, the outside should be higher than the inside… The slope inside should not be too oblique, probably just like this, this still has to grind more Practice only.
[Q] What is an end mill and what is a disc milling cutter? What is the deep hole drilling inserts difference?
[Answer] End mills are generally used for milling end faces, rather than keyway cutters for milling slots. The disc milling cutter is mainly used for milling large end faces, because the straight milling of the disc milling cutter is generally large, the milling end face is faster for milling, and the saw blade milling cutter is generally used for milling.
[Q] Why can’t the end mill cut vertically?
[Answer] When the end mill rotates, the midpoint of the bottom edge is relatively static. It does not have any machinability and chip removal, so it cannot be cut vertically.
[Q] How is the feed rate of the end mill determined?
[Answer] The selection of cutting amount should be considered together with the factors such as tool, workpiece and machine tool. The main cutting edge of the end mill is the peripheral edge. The feed per tooth deep hole drilling inserts is generally about 0.1 during finishing. The amount is generally selected from 0.25 to 0.3 mm. Specifically, it should be matched with the cutting parameters such as cutting speed, axial depth of cut and radial depth of cut.
[Q] What is the difference between the end mill and the ball end mill and its selection principle?
[Answer] End mills and ball end mills, one is the ball head, one is the flat bottom, the end mill is mainly for conventional machining, and the ball end milling cutter can be used for milling the surface.
[Q] What is the difference between the collet for the end mill and the collet for the tap? Do you have to use the company handle when tapping?
[Answer] Although the collet for holding the straight shank end mill can be used to hold the tap for rigid tapping, the effect is not good, generally the small diameter tap is no problem; the ER collet for the tap is with a square groove That is, the flat-tailed limit function of the tap handle is now available in general tool manufacturers.
The Cemented Carbide Blog: APKT Insert
CNC Carbide Cutoff Systems For Automatic Cycles
In today's competitive climate, cutting tool manufacturers have to do more than just produce tools—they have to help customers use those tools effectively. At least that's the philosophy adopted by metalworking companies such as Mar-Metal, Inc. (Upper Sandusky, Ohio), a maker of thermoform tooling for packaging and other industries.
"We realized that in order to continue moving ahead, we had to build partnerships with suppliers," says Craig Marshall, vice president of Mar-Metal.
After interviewing representatives of tooling manufacturers, Carboloy, with its line of Seco-Carboloy tooling, was chosen as Mar-Metal's prospective partner. It was then up to Carboloy to prove that the decision was the right one.
First came an initial series of discussions including Frank Weeks, the local Carboloy technical specialist, Mr. Marshall and key Mar-Metal personnel. Mr. Weeks' aim was to gain an understanding of Mar-Metal's business direction, to identify business concerns and to explain Carboloy's approach to identifying opportunities for productivity improvements and cost savings.
Mr. Weeks assembled a process improvement team comprised of several Carboloy tech specialists based in Ohio. The team conducted a process survey of the entire machining operation at Mar-Metal. Based on the results, Mr. Weeks and his team devised a multifaceted approach to help maximize productivity while maintaining Mar-Metal's high level of product quality. A key part of this approach was training.
"I spent a great deal of time on the shop floor, working with each and every machine operator in the plant," says Mr. Weeks. "We worked on the determination of cutting parameters, the methods of analyzing insert life and tool failure, as well as the key principles of milling and turning."
Springing from the training and the initial process survey came several specific improvement initiatives. These included a new way of machining the critical die plates. Made of 6061 aluminum, they ranged from 3 to 4 inches thick and from 48 to 72 inches square, holding from 48 to 72 cavities.
"Mar-Metal had been using an indexable insert drill to drill initial holes in all these cavities, then roughing out the hole by making 8-inch-deep circular passes with an indexable carbide end mill," says Mr. Weeks. "We suggested that we try helical milling with our Seco-Carboloy Super Turbo mills, eliminating the drilling altogether."
Designed for medium depths of cut and higher feeds, Super Turbo is suited for helical interpolation, plunge milling and a number of other cutting procedures. "We were able to shave approximately 40 hours off the machining time of each batch of die plates," says Mr. Weeks. "In addition, helical milling with the Super Turbo allowed us to go longer before indexing inserts.
"We had similar successes in tool steel," he continues. "The mold plates tube process inserts themselves are made of aluminum, but the shoes and the base plates and other components are made out of A2 or D2 tool steel, and our productivity increases with these components have been substantial. With the old method and tool, their depth of cut in D2 steel machining had been approximately 0.120 inch, with a feed rate of approximately 0.003 inch/tooth and about 300 surface feet per minute. Now we are taking a 0.200-inch depth of cut with a feed rate of 0.006 inch/tooth at 550 surface feet per minute—more than 100 percent increase in metal removal. To top it off, we are getting approximately three times the tool life."
Next came the introduction of Carboloy's new router cutter. The results have been described as impressive. The company is now using this tool on all its larger aluminum cavities.
Mr. Marshall bar peeling inserts says, "The rigidity and spindle combination of the Mori Seiki SV500 complemented this tooling application. We are roughing at 17,500 rpm and completing in approximately 15 minutes the roughing operations that previously took as long as 4 hours.
"Frank Weeks and his process improvement team have methodically introduced new methods and tooling throughout our shop, resulting in very substantial improvements to our productivity and, ultimately, to our bottom line," says Mr. Marshall.
The Cemented Carbide Blog: deep hole drilling Inserts
In today's competitive climate, cutting tool manufacturers have to do more than just produce tools—they have to help customers use those tools effectively. At least that's the philosophy adopted by metalworking companies such as Mar-Metal, Inc. (Upper Sandusky, Ohio), a maker of thermoform tooling for packaging and other industries.
"We realized that in order to continue moving ahead, we had to build partnerships with suppliers," says Craig Marshall, vice president of Mar-Metal.
After interviewing representatives of tooling manufacturers, Carboloy, with its line of Seco-Carboloy tooling, was chosen as Mar-Metal's prospective partner. It was then up to Carboloy to prove that the decision was the right one.
First came an initial series of discussions including Frank Weeks, the local Carboloy technical specialist, Mr. Marshall and key Mar-Metal personnel. Mr. Weeks' aim was to gain an understanding of Mar-Metal's business direction, to identify business concerns and to explain Carboloy's approach to identifying opportunities for productivity improvements and cost savings.
Mr. Weeks assembled a process improvement team comprised of several Carboloy tech specialists based in Ohio. The team conducted a process survey of the entire machining operation at Mar-Metal. Based on the results, Mr. Weeks and his team devised a multifaceted approach to help maximize productivity while maintaining Mar-Metal's high level of product quality. A key part of this approach was training.
"I spent a great deal of time on the shop floor, working with each and every machine operator in the plant," says Mr. Weeks. "We worked on the determination of cutting parameters, the methods of analyzing insert life and tool failure, as well as the key principles of milling and turning."
Springing from the training and the initial process survey came several specific improvement initiatives. These included a new way of machining the critical die plates. Made of 6061 aluminum, they ranged from 3 to 4 inches thick and from 48 to 72 inches square, holding from 48 to 72 cavities.
"Mar-Metal had been using an indexable insert drill to drill initial holes in all these cavities, then roughing out the hole by making 8-inch-deep circular passes with an indexable carbide end mill," says Mr. Weeks. "We suggested that we try helical milling with our Seco-Carboloy Super Turbo mills, eliminating the drilling altogether."
Designed for medium depths of cut and higher feeds, Super Turbo is suited for helical interpolation, plunge milling and a number of other cutting procedures. "We were able to shave approximately 40 hours off the machining time of each batch of die plates," says Mr. Weeks. "In addition, helical milling with the Super Turbo allowed us to go longer before indexing inserts.
"We had similar successes in tool steel," he continues. "The mold plates tube process inserts themselves are made of aluminum, but the shoes and the base plates and other components are made out of A2 or D2 tool steel, and our productivity increases with these components have been substantial. With the old method and tool, their depth of cut in D2 steel machining had been approximately 0.120 inch, with a feed rate of approximately 0.003 inch/tooth and about 300 surface feet per minute. Now we are taking a 0.200-inch depth of cut with a feed rate of 0.006 inch/tooth at 550 surface feet per minute—more than 100 percent increase in metal removal. To top it off, we are getting approximately three times the tool life."
Next came the introduction of Carboloy's new router cutter. The results have been described as impressive. The company is now using this tool on all its larger aluminum cavities.
Mr. Marshall bar peeling inserts says, "The rigidity and spindle combination of the Mori Seiki SV500 complemented this tooling application. We are roughing at 17,500 rpm and completing in approximately 15 minutes the roughing operations that previously took as long as 4 hours.
"Frank Weeks and his process improvement team have methodically introduced new methods and tooling throughout our shop, resulting in very substantial improvements to our productivity and, ultimately, to our bottom line," says Mr. Marshall.
The Cemented Carbide Blog: deep hole drilling Inserts
In today's competitive climate, cutting tool manufacturers have to do more than just produce tools—they have to help customers use those tools effectively. At least that's the philosophy adopted by metalworking companies such as Mar-Metal, Inc. (Upper Sandusky, Ohio), a maker of thermoform tooling for packaging and other industries.
"We realized that in order to continue moving ahead, we had to build partnerships with suppliers," says Craig Marshall, vice president of Mar-Metal.
After interviewing representatives of tooling manufacturers, Carboloy, with its line of Seco-Carboloy tooling, was chosen as Mar-Metal's prospective partner. It was then up to Carboloy to prove that the decision was the right one.
First came an initial series of discussions including Frank Weeks, the local Carboloy technical specialist, Mr. Marshall and key Mar-Metal personnel. Mr. Weeks' aim was to gain an understanding of Mar-Metal's business direction, to identify business concerns and to explain Carboloy's approach to identifying opportunities for productivity improvements and cost savings.
Mr. Weeks assembled a process improvement team comprised of several Carboloy tech specialists based in Ohio. The team conducted a process survey of the entire machining operation at Mar-Metal. Based on the results, Mr. Weeks and his team devised a multifaceted approach to help maximize productivity while maintaining Mar-Metal's high level of product quality. A key part of this approach was training.
"I spent a great deal of time on the shop floor, working with each and every machine operator in the plant," says Mr. Weeks. "We worked on the determination of cutting parameters, the methods of analyzing insert life and tool failure, as well as the key principles of milling and turning."
Springing from the training and the initial process survey came several specific improvement initiatives. These included a new way of machining the critical die plates. Made of 6061 aluminum, they ranged from 3 to 4 inches thick and from 48 to 72 inches square, holding from 48 to 72 cavities.
"Mar-Metal had been using an indexable insert drill to drill initial holes in all these cavities, then roughing out the hole by making 8-inch-deep circular passes with an indexable carbide end mill," says Mr. Weeks. "We suggested that we try helical milling with our Seco-Carboloy Super Turbo mills, eliminating the drilling altogether."
Designed for medium depths of cut and higher feeds, Super Turbo is suited for helical interpolation, plunge milling and a number of other cutting procedures. "We were able to shave approximately 40 hours off the machining time of each batch of die plates," says Mr. Weeks. "In addition, helical milling with the Super Turbo allowed us to go longer before indexing inserts.
"We had similar successes in tool steel," he continues. "The mold plates tube process inserts themselves are made of aluminum, but the shoes and the base plates and other components are made out of A2 or D2 tool steel, and our productivity increases with these components have been substantial. With the old method and tool, their depth of cut in D2 steel machining had been approximately 0.120 inch, with a feed rate of approximately 0.003 inch/tooth and about 300 surface feet per minute. Now we are taking a 0.200-inch depth of cut with a feed rate of 0.006 inch/tooth at 550 surface feet per minute—more than 100 percent increase in metal removal. To top it off, we are getting approximately three times the tool life."
Next came the introduction of Carboloy's new router cutter. The results have been described as impressive. The company is now using this tool on all its larger aluminum cavities.
Mr. Marshall bar peeling inserts says, "The rigidity and spindle combination of the Mori Seiki SV500 complemented this tooling application. We are roughing at 17,500 rpm and completing in approximately 15 minutes the roughing operations that previously took as long as 4 hours.
"Frank Weeks and his process improvement team have methodically introduced new methods and tooling throughout our shop, resulting in very substantial improvements to our productivity and, ultimately, to our bottom line," says Mr. Marshall.
The Cemented Carbide Blog: deep hole drilling Inserts
Versatile Inserts Reduce Need For Secondary Processes
Saint-Gobain Abrasives will showcase its Norton Quantum3 (NQ3) depressed-center grinding wheels, which feature a special grain along with a tough bond system containing fillers and bonding agents that allow for much better mix quality in manufacturing. These wheels are said to provide faster grinding for more metal removal tungsten carbide inserts and longer wheel life with less operator fatigue, increasing overall grinding output.
The wheels are constructed using a precisely engineered iron, sulfur and chlorine-free resin technology to provide a uniform abrasive distribution throughout the wheel. This bond was designed for retaining the grains long enough during and after grain fractures, boosting cut rate and wheel life. The company says that this grain tends to be more rounded than precision-shaped ceramic grain, enabling a more robust, sharper cutting action with less vibration for much easier operator control. The company says that the wheels don’t grab or dig when used in any direction, and that free cutting control can boost the amperage on its own without additional pressure needed on the tool.
The new wheels are offered in 12 Type-27 all-purpose gravity turning inserts grinding application SKUs, one Type-28 all-purpose and two Type-27 SKUs for foundry applications. Sizes range from 4" × ¼" × 3/8" to 9" × ¼" to 7/8".
The Cemented Carbide Blog: carbide insert blade
Saint-Gobain Abrasives will showcase its Norton Quantum3 (NQ3) depressed-center grinding wheels, which feature a special grain along with a tough bond system containing fillers and bonding agents that allow for much better mix quality in manufacturing. These wheels are said to provide faster grinding for more metal removal tungsten carbide inserts and longer wheel life with less operator fatigue, increasing overall grinding output.
The wheels are constructed using a precisely engineered iron, sulfur and chlorine-free resin technology to provide a uniform abrasive distribution throughout the wheel. This bond was designed for retaining the grains long enough during and after grain fractures, boosting cut rate and wheel life. The company says that this grain tends to be more rounded than precision-shaped ceramic grain, enabling a more robust, sharper cutting action with less vibration for much easier operator control. The company says that the wheels don’t grab or dig when used in any direction, and that free cutting control can boost the amperage on its own without additional pressure needed on the tool.
The new wheels are offered in 12 Type-27 all-purpose gravity turning inserts grinding application SKUs, one Type-28 all-purpose and two Type-27 SKUs for foundry applications. Sizes range from 4" × ¼" × 3/8" to 9" × ¼" to 7/8".
The Cemented Carbide Blog: carbide insert blade
Saint-Gobain Abrasives will showcase its Norton Quantum3 (NQ3) depressed-center grinding wheels, which feature a special grain along with a tough bond system containing fillers and bonding agents that allow for much better mix quality in manufacturing. These wheels are said to provide faster grinding for more metal removal tungsten carbide inserts and longer wheel life with less operator fatigue, increasing overall grinding output.
The wheels are constructed using a precisely engineered iron, sulfur and chlorine-free resin technology to provide a uniform abrasive distribution throughout the wheel. This bond was designed for retaining the grains long enough during and after grain fractures, boosting cut rate and wheel life. The company says that this grain tends to be more rounded than precision-shaped ceramic grain, enabling a more robust, sharper cutting action with less vibration for much easier operator control. The company says that the wheels don’t grab or dig when used in any direction, and that free cutting control can boost the amperage on its own without additional pressure needed on the tool.
The new wheels are offered in 12 Type-27 all-purpose gravity turning inserts grinding application SKUs, one Type-28 all-purpose and two Type-27 SKUs for foundry applications. Sizes range from 4" × ¼" × 3/8" to 9" × ¼" to 7/8".
The Cemented Carbide Blog: carbide insert blade
High Performance Coolant Through Tooling
SolidCAM will showcase its CAM programming solution for CNC machines directly integrated within SolidWorks and Autodesk Inventor. SolidCAM users can create prototypes, molds and production parts without having to leave the SolidWorks and Inventor design software environments, gravity turning inserts reducing programming time and file import/export challenges. Changes to the design model can therefore automatically update CNC machine tool paths.
SolidCAM also offers the slot milling cutters iMachining intelligent toolpath generator and machine cutting conditions wizard, speeding toolpath generation, and providing guided cutting parameters and complex turn-mill and multi-axis machine compatibility.
The Cemented Carbide Blog: parting tool Inserts
SolidCAM will showcase its CAM programming solution for CNC machines directly integrated within SolidWorks and Autodesk Inventor. SolidCAM users can create prototypes, molds and production parts without having to leave the SolidWorks and Inventor design software environments, gravity turning inserts reducing programming time and file import/export challenges. Changes to the design model can therefore automatically update CNC machine tool paths.
SolidCAM also offers the slot milling cutters iMachining intelligent toolpath generator and machine cutting conditions wizard, speeding toolpath generation, and providing guided cutting parameters and complex turn-mill and multi-axis machine compatibility.
The Cemented Carbide Blog: parting tool Inserts
SolidCAM will showcase its CAM programming solution for CNC machines directly integrated within SolidWorks and Autodesk Inventor. SolidCAM users can create prototypes, molds and production parts without having to leave the SolidWorks and Inventor design software environments, gravity turning inserts reducing programming time and file import/export challenges. Changes to the design model can therefore automatically update CNC machine tool paths.
SolidCAM also offers the slot milling cutters iMachining intelligent toolpath generator and machine cutting conditions wizard, speeding toolpath generation, and providing guided cutting parameters and complex turn-mill and multi-axis machine compatibility.
The Cemented Carbide Blog: parting tool Inserts
New Modular Tool Options for Small Spindle Milling
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According to the manufacturer, Flow International, the Paser 4 system is an efficient, integrated abrasive waterjet cutting system that is capable of unattended operation. The machine will either shut itself down or notify users in the case of abrasive waterjet gun drilling inserts gun drilling inserts failure.
A redesigned cutting head features a mixing Carbide Milling Inserts chamber for efficient abrasive entrainment and extended orifice life.
Other features include an on/off valve, better cut quality, and an abrasive metering valve that is said to enable a more consistent garnet flow. An abrasive flow sensor is engineered to shut the system down in the event of a clog or if the machine runs out of abrasive. If there are overflow conditions, there is a sensor that will automatically shut the machine down should an unexpected event occur.
The Cemented Carbide Blog: tungsten carbide cutting tools
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According to the manufacturer, Flow International, the Paser 4 system is an efficient, integrated abrasive waterjet cutting system that is capable of unattended operation. The machine will either shut itself down or notify users in the case of abrasive waterjet gun drilling inserts gun drilling inserts failure.
A redesigned cutting head features a mixing Carbide Milling Inserts chamber for efficient abrasive entrainment and extended orifice life.
Other features include an on/off valve, better cut quality, and an abrasive metering valve that is said to enable a more consistent garnet flow. An abrasive flow sensor is engineered to shut the system down in the event of a clog or if the machine runs out of abrasive. If there are overflow conditions, there is a sensor that will automatically shut the machine down should an unexpected event occur.
The Cemented Carbide Blog: tungsten carbide cutting tools
?
According to the manufacturer, Flow International, the Paser 4 system is an efficient, integrated abrasive waterjet cutting system that is capable of unattended operation. The machine will either shut itself down or notify users in the case of abrasive waterjet gun drilling inserts gun drilling inserts failure.
A redesigned cutting head features a mixing Carbide Milling Inserts chamber for efficient abrasive entrainment and extended orifice life.
Other features include an on/off valve, better cut quality, and an abrasive metering valve that is said to enable a more consistent garnet flow. An abrasive flow sensor is engineered to shut the system down in the event of a clog or if the machine runs out of abrasive. If there are overflow conditions, there is a sensor that will automatically shut the machine down should an unexpected event occur.
The Cemented Carbide Blog: tungsten carbide cutting tools
Milling Inserts Increase Machining Stability, Chip Evacuation
Walter USA has expanded its family of Xtra-Tec insert drills gravity turning inserts with the addition of the Walter Capto clamping system and indexable inserts with Tiger-Tec Silver cutting tool material. The Xtra-Tec insert drills range in diameter from 16 to 45 mm, with a depth of cut of 3×D, and feature optimized chip clearance for reliable chip evacuation. They can be used on a variety of materials ranging from steel and cast iron to stainless and difficult-to-cut materials, and can handle chain drilling, sloping and convex surfaces, the company says.
With the addition of the Walter Capto clamping system, the drills are said to provide higher transmission of force via the system’s polygonal interface, high process reliability due to the positive locking of the indexable inserts with TorxPlus screws, and faster tool changing. In addition, the system’s hard-nickel plated surface bar peeling inserts provides protection against corrosion and wear, and its cylindrical collar promotes straightforward measurement of the tool diameter.
The high-performance Tiger-Tec Silver cutting tool material also helps improve the performance of the new drill. The indexable inserts, available in three different geometries and four different grades, have four cutting edges, enabling high cutting parameters and reducing the number of additional operations necessary. The ground indexable inserts are also fitted with a wiper edge, ensuring quality surface finish.
The Cemented Carbide Blog: http://arthuryves.mee.nu/
Walter USA has expanded its family of Xtra-Tec insert drills gravity turning inserts with the addition of the Walter Capto clamping system and indexable inserts with Tiger-Tec Silver cutting tool material. The Xtra-Tec insert drills range in diameter from 16 to 45 mm, with a depth of cut of 3×D, and feature optimized chip clearance for reliable chip evacuation. They can be used on a variety of materials ranging from steel and cast iron to stainless and difficult-to-cut materials, and can handle chain drilling, sloping and convex surfaces, the company says.
With the addition of the Walter Capto clamping system, the drills are said to provide higher transmission of force via the system’s polygonal interface, high process reliability due to the positive locking of the indexable inserts with TorxPlus screws, and faster tool changing. In addition, the system’s hard-nickel plated surface bar peeling inserts provides protection against corrosion and wear, and its cylindrical collar promotes straightforward measurement of the tool diameter.
The high-performance Tiger-Tec Silver cutting tool material also helps improve the performance of the new drill. The indexable inserts, available in three different geometries and four different grades, have four cutting edges, enabling high cutting parameters and reducing the number of additional operations necessary. The ground indexable inserts are also fitted with a wiper edge, ensuring quality surface finish.
The Cemented Carbide Blog: http://arthuryves.mee.nu/
Walter USA has expanded its family of Xtra-Tec insert drills gravity turning inserts with the addition of the Walter Capto clamping system and indexable inserts with Tiger-Tec Silver cutting tool material. The Xtra-Tec insert drills range in diameter from 16 to 45 mm, with a depth of cut of 3×D, and feature optimized chip clearance for reliable chip evacuation. They can be used on a variety of materials ranging from steel and cast iron to stainless and difficult-to-cut materials, and can handle chain drilling, sloping and convex surfaces, the company says.
With the addition of the Walter Capto clamping system, the drills are said to provide higher transmission of force via the system’s polygonal interface, high process reliability due to the positive locking of the indexable inserts with TorxPlus screws, and faster tool changing. In addition, the system’s hard-nickel plated surface bar peeling inserts provides protection against corrosion and wear, and its cylindrical collar promotes straightforward measurement of the tool diameter.
The high-performance Tiger-Tec Silver cutting tool material also helps improve the performance of the new drill. The indexable inserts, available in three different geometries and four different grades, have four cutting edges, enabling high cutting parameters and reducing the number of additional operations necessary. The ground indexable inserts are also fitted with a wiper edge, ensuring quality surface finish.
The Cemented Carbide Blog: http://arthuryves.mee.nu/
