Improving throughput in grinding takes more than direct increases to material removal rate. It also requires careful consideration of the factors behind the operation’s stability.
Adding pallet systems brought Mach Machine success and additional productivity. The shop has since furthered its automation goals while adding new capabilities. cnc lathe
Pacon Mfg, Inc. has not rested on its laurels as the 2020 Top Shop Honoree for Shopfloor Practices and Performance. In the years since, it has refined its processes to continue excelling in a volatile market.
Facing increasing competition from lower-cost imports, Suburban Tool made a move toward large-scale, in-house machining. By identifying a niche in large, precision angle plates and tombstones, the company has strengthened its ability to control quality and protect its reputation.
Soraluce’s wide range of machine heads and the ability to have multiple heads on a single machine (with automatic changing stations) provides flexibility and reduced setups for large-format machining.
Xcelicut is a startup shop that has grown thanks to the right machines, cutting tools, grants and other resources.
Determining whether to use high-density fixtures or to simplify workholding requires a deeper look into the details of your parts and processes.
The new space includes a showroom, office spaces and an auditorium that will enhance its work with its technical partners.
Decker Machine Works recently adopted Rego-Fix’s reCool through-coolant system for ER collets, reducing the cycle times on a nickel alloy job by 70%.
Facing increasing competition from lower-cost imports, Suburban Tool made a move toward large-scale, in-house machining. By identifying a niche in large, precision angle plates and tombstones, the company has strengthened its ability to control quality and protect its reputation.
Xcelicut is a startup shop that has grown thanks to the right machines, cutting tools, grants and other resources.
Custom workholding enabled Resolve Surgical Technologies to place all sizes of one trauma part onto a single machine — and cut days from the setup times.
How can shops can make informed decisions using data-driven feedback to improve shopfloor efficiency and profitability? And how will these technologies differ between high- and low-volume production?
Pacon Mfg, Inc. has not rested on its laurels as the 2020 Top Shop Honoree for Shopfloor Practices and Performance. In the years since, it has refined its processes to continue excelling in a volatile market.
OnLogic is partnering with AI development and implementation specialists to help companies use AI-powered solutions, aiming to drive real business value.
Even before inspection, Datanomix and Caron Engineering’s TMAC AI can extrapolate part quality from cut information. This information also helps shops push their tool life to its limits.
ModuleWorks and Toolpath announce a technology partnership that intends to utilize intelligent cloud-based manufacturing solutions for machining estimation and CAM automation.
Coordinate systems tell a CNC machine where to position the cutting tool during the program’s execution for any purpose that requires the cutting tool to move.
As production tolerances become ever tighter and the error margin for measurement results shrinks, manufacturers must consider thermal fluctuations in their inspection processes.
Not only can Gelsight’s tactile sensor detect and evaluate defects, but it can also measure part features, surface roughness and even contamination.
Determining the shape of a workpiece is required in many manufacturing processes. Keep in mind these important points to ensure that you master the process.
Differential gaging measures using two devices, which has advantages over standard, comparative measurements using a single sensing head. These include the ability to measure size without regard to position.
Heidenhain and Acu-Rite Solutions are offering several hands-on experiences at their booth this year, as well as internal components that reduce energy use.
Q-Mark has built its metrology business by providing what customers need, when they want it. This goes for its IMTS booth, too, with free drinks alongside custom technology.
Adding pallet systems brought Mach Machine success and additional productivity. The shop has since furthered its automation goals while adding new capabilities.
How can shops can make informed decisions using data-driven feedback to improve shopfloor efficiency and profitability? And how will these technologies differ between high- and low-volume production?
In this episode of the AM Radio podcast, Robots & Autonomy Editor Julia Hider joins Additive Manufacturing’s Executive Editor Stephanie Hendrixson and Editor-in-Chief Peter Zelinski to discuss how robots and 3D printing enable each other.
Pacon Mfg, Inc. has not rested on its laurels as the 2020 Top Shop Honoree for Shopfloor Practices and Performance. In the years since, it has refined its processes to continue excelling in a volatile market.
By equipping MassRobotics with its advanced cobots, ABB aims to facilitate the creation of new and impactful solutions that address real-world challenges across various industries.
At Carnegie Mellon University’s Manufacturing Futures Institute, researchers use a robotic test bed where AMRs deliver Lego bricks to robot arms for assembly to study AI, multirobot collaboration, assembly, safety and more.
The Modern Machine Shop editorial team highlights their takeaways from IMTS 2024 in a video recap.
IMTS only happens every two years. Here’s how to make the most of your time at the 2024 show.
Across a range of technical presentations aimed at small and mid-sized job shops, the first-ever Automated Shop Conference (TASC) offered insights into several automated technologies, implementation strategies, shopfloor training tips, and even the untapped power of automated coolant delivery.
Automation is no longer a luxury in manufacturing today – it’s a necessity. The Automated Shop Conference (TASC) will connect job shops with experts who offer advice and considerations for this process.
The Automated Shop Conference (TASC) will give shops of all sizes and production volumes key insights and practical guidance on how to implement automation.
Looking to automate your shop floor? The Automated Shop Conference (TASC) will connect shops with experts who can advise them through this transition.
New tech center is serving as a cutting-edge showroom and a technological hub for advanced machining applications.
New U.S.-based event announced in 2021 finally debuts next year: focuses on complete additive manufacturing value chain. More at formnextchicago.com.
Chiron Group combines the best of both worlds at IMTS 2024, featuring live demonstrations of their Micro5 and Mill 2000 machines, alongside a cutting-edge virtual showroom. This innovative approach allows visitors to explore Chiron’s full product lineup without the logistical challenges of transporting large equipment.
Half of the 16 machines in the company’s booth are world or North American debuts.
Learn more about the variety of technology and machinery Hwacheon Machinery America, Inc. is featuring at its IMTS 2024 booth.
FANUC’s IMTS 2024 booth includes real-time demonstrations that show the abilities of its equipment, including robots, controllers and machine tools.
As production tolerances become ever tighter and the error margin for measurement results shrinks, manufacturers must consider thermal fluctuations in their inspection processes.
Determining whether to use high-density fixtures or to simplify workholding requires a deeper look into the details of your parts and processes.
How can shops can make informed decisions using data-driven feedback to improve shopfloor efficiency and profitability? And how will these technologies differ between high- and low-volume production?
Knowing how scales will influence machine accuracy will help you decide if they’re worth the extra investment.
Coolant care can be simply managed if you know where to pay attention and which hazards to look out for.
A little ingenuity goes a long way toward improving machine utilization.
Take a tour of Machineosaurus, a Massachusetts machine shop where every CNC machine is named after a dinosaur!
Lee Wimmer invited us to tour his second-generation family-owned machine shop in Perkasie, PA. This video explores the production processes behind precision-machined parts for both Wimmer Custom Cycle and LS Wimmer Machine Co., and shows how ingenuity and determination are still at the heart of American manufacturing. Today, both companies are now managed by Wimmer’s three sons.
AccuRounds has created synergy between culture and technology, driving a commitment to customer satisfaction and continuous improvement.
In the latest episode of our View From My Shop series, MMS Editor-in-Chief Brent Donaldson visited the JN Shapiro Watches headquarters and production facility where Founder Joshua Shapiro—a history teacher turned watchmaker—realized his dream of "making a watch from scratch and everything in it."
Legacy Precision Molds takes us on a tour of their moldbuilding facility. They've recently implemented two automated 5-axis cells for metal and graphite machining that run lights out during nights and weekends.
Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.
In this episode of Made in the USA, several executives and senior staff at Hardinge give their first-person account of how they formulated the plan to shift the manufacturing of its milling and turning product lines from its Taiwan plant to its plant in Elmira, New York, the major challenges they encountered and the rewards that made it worth the effort.
The L.S. Starrett Co. has been manufacturing precision measurement tools in Athol, Massachusetts, since 1880. Attention to U.S. manufacturing often focuses on reshoring manufacturing from other countries, but Starrett never left. The facility in Athol employs hundreds and produces thousands of tools that remain vital for measurement in machining and other fields.
The latest episode “Made in the USA” podcast explores a company that uses collaborative robots, one of the key tools helping US machine shops and other manufacturers compete with lower cost countries by automating production.
When Puneet and Neelam Neotia moved from India to the United States several years ago, they brought with them a family background in manufacturing and CNC machining. Now the couple is working to get their startup machine shop off the ground, sourcing new customers and getting the word out about their shop in Clarksville, Indiana. The couple — proud to publicize their "Made in the USA" parts — is leveraging family connections and manufacturing capabilities back in India, but not in the way that some people assume.
Entrepreneur Scott Colosimo found early success in China producing parts for his Cleveland-based motorcycle company in the mid-2000s. This is the story of how IP theft issues overwhelmed the business, prompting Colosimo and his team to start over from scratch — and move production back to the United States.
So far, Made in the USA has looked into system-wide effects of broken supply chains, automation, skilled workforce issues and our perception of manufacturing jobs — examining each topic through a prism of individual experiences. For this final episode for Season 1, let’s look at one more system-wide question and bring it back to personal perspectives: Is there today a new dawn, a new moment for American manufacturing?
Working closely with customers and making careful investments has enabled this Wisconsin machine shop to tackle difficult jobs with tight deadlines as a core part of its business.
Part of Major Tool’s 52,000 square-foot building expansion includes the installation of this new Waldrich Coburg Taurus 30 vertical machining center.
JD Machine, 2024’s Top Shops Honoree in Human Resources, embodies its “Education for Life” core value with a robust apprenticeship program and significant continuous improvement efforts.
Ever wonder what sets Top Shops apart from the competition? Dive into their award-winning practices and explore behind-the-scenes strategies for operational excellence.
SSP’s commitment to adopting the latest machining technology benefits not only the business, but its employees as well.
Job shops are implementing automation and digitalization into workflows to eliminate set up time and increase repeatability in production.
Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.
Take a tour of Machineosaurus, a Massachusetts machine shop where every CNC machine is named after a dinosaur!
Lee Wimmer invited us to tour his second-generation family-owned machine shop in Perkasie, PA. This video explores the production processes behind precision-machined parts for both Wimmer Custom Cycle and LS Wimmer Machine Co., and shows how ingenuity and determination are still at the heart of American manufacturing. Today, both companies are now managed by Wimmer’s three sons.
AccuRounds has created synergy between culture and technology, driving a commitment to customer satisfaction and continuous improvement.
In the latest episode of our View From My Shop series, MMS Editor-in-Chief Brent Donaldson visited the JN Shapiro Watches headquarters and production facility where Founder Joshua Shapiro—a history teacher turned watchmaker—realized his dream of "making a watch from scratch and everything in it."
Legacy Precision Molds takes us on a tour of their moldbuilding facility. They've recently implemented two automated 5-axis cells for metal and graphite machining that run lights out during nights and weekends.
Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.
Tungaloy-NTK America Inc. introduces the STV type insert for its TungShortCut internal grooving tool line, enhancing internal profiling and machining of complex shapes or narrow areas.
Mazak’s facility in Florence, Kentucky, currently produces more than 70 machining solutions with a local workforce that exceeds 600 employees.
Sandvik Coromant’s QS Micro quick-change holding system combines simple tool changes with modularity, ideal for small part machining operations.
Flex Machine Tools’ Open House event will take place Thursday, December 5 at the company’s headquarters in Wapakoneta, Ohio. It will feature a facility tour and live machining demonstrations.
Siemens’ Sirius 3RC7 intelligent link module combines IT and OT for complete industrial automation data transparency.
Fixtureworks’ CP170 five-axis clamping vises provide stable workholding during five-axis machining.
In this webinar, director of manufacturing Phil Linscheid will discuss how Hamilton Company has transformed its manufacturing operations with real-time production data. Learn how Phil and his team have increased throughput five times since 2017, while simultaneously improving production efficiency. Phil will share his journey over the past few years making strategic decisions to grow the machine shop’s impact as well as how his team uses MachineMetrics to improve production visibility, automate cycle time tracking, increase machine uptime and enable accurate quoting and planning. Agenda: Enabling production visibility in Nevada’s largest machine shop Improving quoting, planning and scheduling with accurate cycle times The importance of integrating shop floor data with operational systems
No matter what your workholding application, automation always makes sense. Kurt Workholding helps you pick the right tool for the automation job — whether it be a single-vise setup or multiple vises holding large work pieces. This webinar will cover automation solutions using pneumatic, hydraulic and electronic actuation. Agenda: Most common types of vise automation solutions How to pick the right type of automation for an application Key differences between custom workholding and off-the-shelf automation solutions
AI technology isn’t just a concept for the future—it’s here now, ready to transform your estimating process with the new AI BOM builder in JobBOSS². In this first-launch webinar, discover how AI can revolutionize bill of materials (BOM) entry in your shop, saving time, reducing errors and boosting efficiency. In this session, ECI will review how to use AI to build BOMs through a powerful feature that automates the extraction and input of BOM data from PDFs, Excel spreadsheets and images, all within JobBOSS². You'll have the opportunity to watch a live demonstration of the AI BOM builder in action — showcasing its ability to reduce BOM entry time from hours to mere minutes — thereby allowing you to focus on more strategic tasks. Additionally, you will learn about the real-world benefits of AI-driven BOM entry, including the minimization of manual errors, enhanced accuracy, and streamlined estimating processes — all of which can provide your shop with an immediate competitive edge. Finally, there will be a Q&A session with experts, giving you the chance to ask questions and find out how to integrate AI effectively. Agenda: Experience AI in action in a real-world manufacturing setting Discover how the AI BOM builder can immediately impact your shop’s efficiency and productivity Get hands-on insights on implementing AI to streamline your operations
The tool crib is the backbone of any machine shop — without the right tools, nothing moves forward. While most ERP systems overlook the tool crib, ProShop integrates it seamlessly with CNC programming, job planning, scheduling and more. Join this webinar for an exclusive look at how Roush Yates Manufacturing Solutions leverages ProShop to document tool requirements, sync tool demand from CAM software and efficiently manage the tool crib and work instructions. Discover how ProShop transforms the tooling workflow to maximize efficiency and precision.
As the demand for faster production cycles continues to grow, the ability to produce high-quality parts quickly and efficiently has become increasingly important. High-speed 3D printing has emerged as a key solution to reduce lead times and increase productivity across industries. However, like any advanced technology, it comes with its own set of challenges. In this webinar, Forward AM will explore both the opportunities and hurdles of adopting high-speed printing with a particular focus on overcoming those challenges. It’ll start by discussing the fundamentals of high-speed 3D printing and how it differs from conventional 3D printing methods. It’ll then move on to the key factors that influence successful implementation, including the impact of materials, equipment and design considerations. One of the main hurdles in high-speed 3D printing is ensuring the right balance between speed and part quality. Different materials behave differently under high-speed conditions — and not all equipment is optimized for this process. Forward AM will showcase some validated materials and equipment that are proven to perform well under these conditions. In addition, the presenters will look at real-world examples and applications where high-speed 3D printing has been successfully implemented, highlighting the collaboration between designers, engineers and manufacturers. By the end of this webinar, you'll not only have a clearer understanding of high-speed 3D printing with FFF but also the practical steps and considerations needed to make the most of this cutting-edge technology. Agenda: Introduction The power of high-speed printing Know the process The practical side
This presentation focuses on the vital role that linear and angular encoders play in ensuring precision in machine tools. Attendees will learn about the common challenges compromising accuracy, such as thermal expansion, mechanical misalignments and vibration. Whether you're an OEM, integrator, or machine operator, this webinar will offer valuable insights into optimizing CNC performance. Agenda: Challenges to CNC machine accuracy Understanding encoder technology How encoders address accuracy challenges
The Detroit Auto Show, formerly known as the North American International Auto Show (NAIAS), is located squarely at the intersection of technology and mobility. It’s a global event filled with tangible advances ready to hit the pavement today. Here, the software is as revolutionary as anything out there, and the hardware always looks better with a good polish. You won’t find any devices that will fit in your pocket, but you will discover machines that will move you in the most literal sense. You’ll also connect with thought leaders from around the world, both in and outside the automotive industry, whose collective visions for the future of mobility will shape the way we move for years to come.
The MFG Meeting brings together manufacturing technology industry leaders to address key business challenges and provide actionable solutions. Sessions cover a wide range of topics, including workforce, economics, supply chain, leadership, politics, and more. This unique meeting experience provides unparalleled opportunities to network with executives from companies that make, sell, service, and support MT. These peers and competitors will learn from each other, build long-lasting connections, and share insights that will benefit their business.
Each year Products Finishing partners with thousands of finishing operations in the U.S. to celebrate National Surface Finishing Day (NSFD) on the first Wednesday in March. NSFD is designed to celebrate and showcase the industry to trade schools, businesses, officials and media, as well as to celebrate employees and staff. The overarching goal of NSFD is to bring further awareness to the important roles plating and coating facilities play in their communities. Facilities are encouraged to host events and work with local media to build awareness about the contributions made by the surface finishing industry. For a helpful guide to reaching out to media outlets, download the NSFD toolkit here. How can you celebrate? Share your company’s story Hold an open house where the public can check out your facility –— either in person or virtual Offer student shop tours to local trade schools Invite local elected officials to visit and get to know your staff Celebrate your employees Share news about what you’re doing on social media and use the hashtag #NationalSurfaceFinishingDay or #NSFD
CCAI is offering a comprehensive Industrial Finishing Safety Seminar developed by industry experts well-versed in safety for finishing operations. This day-and-a-half seminar focuses on NFPA 33, the Standard for Spray Application Using Flammable or Combustible Materials and will deliver important and critical information on how to safely operate an industrial finishing line. Topics Covered: An introduction to safety Overview and definitions General requirements and electrostatic spray equipment Ventilation Storage handling and distribution Fire protection Operations, maintenance and training Drying and curing Liquid and powder coatings Authority Having Jurisdiction panel discussion Who Should Attend? Manufacturing, staff and environmental engineers (industrial health & safety) Lead painters Maintenance leads and personnel Finishing equipment designers System controls and project engineers Facility managers Finishing industry distributors Date: Tuesday, March 11 and Wednesday, March 12 Time: Tuesday - 9:00 AM - 4:00 PM and Wednesday 8:00 AM - Noon Location: Sames 45001 5 Mile Road Plymouth, MI 48170 Registration Fee: CCAI Members: $599 / Non-Members: $750 Registration Fee Includes: Classroom instruction; lunch on day one; a certificate of completion; and a printed copy of the NFPA 33 Standard for Spray Application Using Flammable or Combustible Materials. Registration: CLICK HERE to register. Space is limited.
PTXPO 2025 is a comprehensive showcase of cutting-edge technologies and innovations within the plastics molding industry. Join fellow molders, moldmakers, brand owners, OEMs and their full suite of suppliers in Rosemont, IL for three days of non-stop networking, education and business development opportunities.
Founded in 2001, PMTS reconvenes in April 2025 to celebrate its 13th biennial event for precision machining pros. Mark your calendar now and plan to join the precision machined parts community when we once again gather in person to share challenges and insights, see new technology solutions and learn about process innovations you can take back and immediately put into use in your own shop. The Precision Machining Technology Show is centered at the intersection of the industry's newest and most advanced product technologies, process innovations, business development prospects and personal career growth opportunities.
Determining whether to use high-density fixtures or to simplify workholding requires a deeper look into the details of your parts and processes.
Knowing how scales will influence machine accuracy will help you decide if they’re worth the extra investment.
Coolant care can be simply managed if you know where to pay attention and which hazards to look out for.
Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.
When it comes to utilizing the spindle’s power, there is a lot of headroom at the upper limits, provided it’s in short bursts. Be mindful of your time at these loads so you don’t stall out.
Each tool setting technique has merit, and it depends on where you are as a shop and the type of work you do, as cost and efficiency all come into play.
When the right cutting tool, toolholder, cutter paths and machining parameters are applied intelligently, a shop may have more capability to mill titanium effectively than it recognizes.
Machining this titanium workpiece, which could fit inside a cigar box, is a manageable job for today’s generation of machining centers. Details about the process are under the second heading, Really Cool Tool Paths.
Using a smaller tool reduces the contact between the cutting edges and the workpiece surface. As a result, less heat is absorbed by the tool. This strategy requires a programmed tool path and the proper speeds and feeds that enable this smaller tool to remove material efficiently.
Programming techniques that control the angle of engagement between the cutter and the workpiece can keep cutting conditions constant. Although the resulting tool path (shown on the left) makes more motion for the cutter than traditional paths, it enables the programmer to choose small stepovers and a high spindle speed that are right for machining titanium.
Red markers point to contrasting forms of relief applied to cutting edges on these end mills. The eccentric relief on the left provides better support and protection for cutting edges when machining titanium than does the standard relief shown on the right.
The three smaller end mills shown above have four, five and six flutes. When programming a cutter for an operation that requires more engagement between cutter and workpiece (as in traditional roughing), choose the smaller number of flutes. Where less engagement is appropriate (as in constant-angle roughing, semi-finishing and finishing), choose a higher number. Machines designed for titanium machining can use a larger-diameter end mill like the eight-fluted one on the far right, although this rule about the best number of flutes still applies.
Machine tools designed for milling titanium are generally characterized as having heavy, rigid structures with spindles designed for high torque at low spindle speed. Large spindle tapers and high-pressure coolant are also typical. For multi-axis work, a beefy trunnion and rotary table may be provided as well.
However, a shop with a 40-taper vertical machining center in sound condition should not rule out this manufacturing resource for effectively and profitably milling titanium. Mike MacArthur, VP of engineering and a titanium expert at cutting tool manufacturer RobbJack, has been promoting this point for a while now. Importantly, he does not take a purely cutting-tool-centric view of this proposition, although cutting tool considerations naturally become a focal point, simply because a systematic approach to milling titanium revolves around managing the conditions that enable an end mill to remove this tough material efficiently.
“Regardless of the type of machine tool a shop has for milling titanium, the principles of milling titanium are the same. What have changed in recent years are the options available for controlling variables that these principles are based on,” Mr. MacArthur says. These options create choices that are appropriate for milling this metal on many existing machining centers, he goes on to say.
For example, toolpath algorithms that ensure constant engagement of the cutter in the workpiece material are especially effective—and necessary—in titanium. Super-accurate toolholders with highly concentric, rigid gripping force address another requirement for titanium machining. A high-pressure coolant delivery system on a machine is advantageous. Of course, the range of end mills designed for various machining operations in titanium are now well developed and available from many cutting tool manufacturers.
“In fact, there are so many choices, it can be a bit confusing or intimidating for planners and programmers,” Mr. MacArthur admits. “The simple guidelines presented here can keep the cutting tool selection process very manageable, though.”
The background to any discussion of titanium milling has to cover the issue of heat. “It is a primary consideration in crafting a strategy for milling titanium on any machine, but especially so for general-purpose machining centers,” Mr. MacArthur says. Excessive heat can quickly damage the cutting edges of an end mill and thus undermine the “support structure” built into the rest of cutting strategy. Titanium needs a strong, sharp cutting edge, because a clean, shearing action enables this material to form chips that leave a superior workpiece surface, absorb heat and flow up the flutes smoothly.
“Cutting tool manufacturers have the right designs to do this, but it is up to the shop to put in place the means that protect this cutting edge,” Mr. MacArthur says.
Perhaps the most important way to protect the cutter when machining titanium is to provide tool paths that avoid conditions that overheat the tool and degrade the cutting edges. For milling pockets and wide slots, this can be accomplished by using toolpath algorithms that maintain a constant angle of engagement between the cutter and the workpiece. Today, most of the CAM software developers offer such algorithms, under a variety of names. All of them create a tool path that restricts how much of the tool radius can be in contact with the workpiece at any time. In a slot, such a tool path will usually follow a regular trochoidal pattern. The tool moves in a series of uniform curves from side to side as it forms the slot. The uniform arcing of these moves is rather easy to see, Mr. MacArthur asserts.
When applied to an irregularly shaped pocket, the toolpath algorithms create a pattern that may be much harder to discern because it does not seem to reflect the shape of the pocket’s sidewalls at first. In fact, that tool path is designed to avoid burying the cutter in corners or during sudden changes in direction by removing material with a progressive series of circular and arcing moves. Although the offerings from different CAM developers may vary in terms of significant nuances or speed of processing, they all provide a similar benefit when machining titanium—the ability to use a smaller-diameter cutter at smaller stepovers and at higher tool rotations per minute.
This approach achieves an adequate metal- removal rate with lighter cuts. The lighter cuts, in turn, keep the individual flutes of the cutter in contact with the workpiece for a shorter period of time, so less heat can be absorbed. “And that’s how this strategy wards off the excessive heat buildup that damages cutting edges,” Mr. MacArthur concludes.
To put some representative numbers to this concept, he describes the following sample test part. A block of 6Al4V titanium (6 by 4 by 1.5 inches) was machined (roughing and finishing) with a ½-inch-diameter cutter with six flutes. The feed rate was 75 ipm and 400 sfpm. Radial depth of cut was 0.05 inch—10 percent of cutter diameter. Axial depth was 1 inch (two times cutter diameter). In this example, approximately 22 cubic inches of material was removed in slightly less than 15 minutes. To give perspective to the metal removal potential indicated here, Mr. MacArthur adds that, in a strictly roughing operation using this approach, a 1/2-inch-diameter cutter is capable of removing more than 65 cubic inches of 6Al4V titanium in 15 minutes.
What is significant here is that the rigidity and torque requirements for machining with these parameters do not demand the capability of a large “titanium machine,” but are achievable with many vertical machines produced within the last five or six years. “The latest generation of 40-taper machining centers are more rigid and capable then preceding models, because builders are applying finite element analysis and other advanced design tools,” Mr. MacArthur explains. Thus, a well-maintained, newer machine is a candidate for titanium machining.
Of course, strong, sharp edges are not the only design characteristic that cutting tool manufacturers give to end mills for titanium. Common design principles include uneven flute spacing to break up harmonics that can induce chatter; helix angles that vary from flute to flute for chip flow; and a coating that is smooth, slick and slow-wearing to reduce frictional heat. Eccentric relief along the cutting edges is also typical, because it supports and strengthens the cutting edges, which are ground and polished for sharpness.
“This is not to say that all titanium end mills are created equal,” Mr. MacArthur cautions. RobbJack, for example, applies its own proprietary concepts and innovations to end mill design. The differences may be subtle as well as significant, so shops should look closely at a supplier’s offerings, he advises.
Regardless of the supplier, end mills suitable for machining titanium may have four (or fewer) flutes and as many as 10 (or more). “Many shops get stuck when deciding the best number of flutes for titanium work on a general-purpose machining center,” Mr. MacArthur says. “Advice from a supplier on this choice can seem a bit mysterious, especially if the shop is new to titanium machining.”
Choosing the number of flutes is best understood as it relates to the strategy of managing how much contact each flute has on the surface of the workpiece. In situations where the flutes are more likely to be in contact with the surface, a smaller number of flutes is preferred. In situations where the flutes are less likely to be in contact, a larger number is preferred.
Because end mills with a diameter of ½ inch or smaller are the best fit for the power and rigidity profiles of a 40-taper machine, four-flute end mills are a good choice for heavier cuts and for pockets with many tight corners. Settings that generate 125 to 200 sfpm at a 15-ipm feed rate are average for a four-flute end mill. Stepovers in X and Y that are as much as 25 percent of the tool diameter are acceptable here.
Where permissible, however, using a six- or eight-flute end mill of a comparable diameter is a good choice for open, rectangular pockets, because applicable speeds and feeds typically reach 400 sfpm. This makes this tool very productive. The corresponding feed rates of 45 to 75 ipm are indicative of this potential. Six-and eight-flute end mills perform especially well when constant-engagement tool paths can be applied. Stepovers in X and Y will range from 2 to 10 percent of diameter in this case. High-speed finishing cuts that leave a smooth surface are also an ideal operation for this type of tool.
Super-accurate, high-quality toolholders are a must for milling titanium. The quality of the toolholder influences a machining operation in several ways. Secure clamping in the machine tool spindle enhances rigidity of the entire cutting tool assembly. The accuracy of the toolholder minimizes runout and contributes to consistent conditions when the tool is in the cut. Well-balanced toolholders reduce stress on the machine spindle and on the cutting tool, while also reducing causes of vibration. Super-accurate toolholders provide higher gripping force on the cutting tool, too. Because milling titanium creates higher cutting forces than milling softer, freer cutting materials, the gripping power of the toolholder is critical.
“There’s a wrinkle in this scenario that is often overlooked or misunderstood,” Mr. MacArthur warns. “It’s the roundness of the tool shank.” A tool shank manufactured to a very high level of roundness complements and enhances the benefits of super-accurate, high-quality toolholders. This roundness directly affects its degree of contact with the clamping surface of the toolholder. The roundness of the tool shank and the quality of the toolholder go hand-in-hand, but most discussions of toolholder requirements neglect the importance of using tools with exceptional roundness. (According to Mr. MacArthur, the tool shank on a RobbJack end mill for titanium is produced to a roundness of 0.000025 of an inch.)
Roundness of the tool shank is especially important with small-diameter cutting tools, because the area of contact between the cutting tool and holder is proportionately smaller. Any loss of contact reduces gripping force significantly.
The Pressure’s On
Metalworking coolant has three functions: It provides cooling, lubricity and chip control. All three functions are valuable when milling titanium. Most of today’s machining centers have coolant delivery options that benefit titanium milling. Having a high-pressure, through-the-spindle capability is best, because it is the most effective for promoting chip evacuation. Additional coolant ports and “showerheads” are also recommended.
Mr. MacArthur notes that three coolant considerations are critical to machining titanium: high pressure, adequate volume and consistent flow on the cutting zone.
End mills for titanium usually have thick cores to resist deflection, so the channels between the flutes are not especially commodious. However, they are adequate when light cuts produce thin chips that can be flushed up and out. This is true even for six- and eight-flute styles in which space for chip flow is especially tight. In short, copious amounts of coolant at high pressure (as high as 1,000 psi) greatly reduce opportunities for chips to become trapped between flutes.
This article suggests that a practical approach to milling titanium enables shops to consider the capability of existing machining resources such as a newer VMC. The approach is practical because suitable choices in cutting tools, toolholders, CAM software and so on are readily available.
However, this approach could also have been called a thoughtful one, because it calls for users to learn about titanium, understand its characteristics and apply basic principles knowledgeably. And any serious effort to master the machining of titanium must follow this call earnestly.
Once it had a bird’s eye view of various data points across its shops, this aerospace manufacturer raised its utilization by 27% in nine months.
Succeeding in aerospace manufacturing requires high-performing processes paired with high-performance machine tools. IMTS can help you find both.
All five Solar Atmospheres facilities are now an option for customers with Northrop Grumman requirements for vacuum heat treating.
You’re attending IMTS to advance your business. Regardless of your role in the manufacturing process, considering how your parts will be finished is crucial. This article can help you understand trends in surface finishing and better communicate with your finishing partners.
The new space includes a showroom, office spaces and an auditorium that will enhance its work with its technical partners.
Achieve higher metal removal rates and enhanced predictability with ISCAR’s advanced high-feed milling tools — optimized for today’s competitive global market.
Use these tips to carefully plan your machine tool purchases and to avoid regretting your decision later.
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