Why Tie Payroll Hours to Machine Tool Hours？

Widia has launched the WCE solid end milling platform, designed to offer high performance and reliability for small to medium machine shops. The initial release of the WCE platform features WCE4, a four-flute geometry that combines advanced features with a new, versatile grade.

Two key features of the tool are its asymmetrical index and variable helix. The combination of the two is said to reduce vibrations and enable heavy cuts, while the grade, WU20PE, enables versatility on steel, stainless steel and cast-iron applications. Coated Inserts These features in conjunction with with the four-flute geometry offer an end mill with reliable performance and application versatility, even in demanding operations such as full slots and heavy Deep Hole Drilling Inserts cuts.

The WCE platform includes four-flute, square-end and ball nose end mills with both straight and Weldon shanks. It is available in both metric and inch dimensions. The WCE5 five-flute geometry will be released later in 2022. 
 

The Cemented Carbide Blog: Cutting Inserts

Three Face Milling Myths & Truths

A modular tooling system for multi-spindle automatics is available, including the latest models for Davenport machines. Besides being more rigid than dovetail form tools, the modular system allows for much faster tool changes, the company says. This system consists of a modular insert holder assembly and a cross-slide holder assembly, offered in both up-cut and down-cut versions.

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The modular insert holder assembly consists of an insert, anvil and insert clamp. It mounts into mating serrations on the cross-slide holder assembly and is locked in place by a drawbar. A common wrench can turn the drawbar.

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The tools also incorporate fine-tune adjustments for taper, center line, diameter and lateral movement. These added features give operators and setup technicians more Carbide Inserts control over finish part RCMX Insert dimensions, the company says.

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The Cemented Carbide Blog: high feed milling Insert

Curved Geometry High Feed Milling Cutters

CGTech has released the Vericut Version 8.2 CNC Simulation Software. In addition to machine simulation that detects collisions and close calls, as well as over-travel errors, the focus of this edition has been to provide convenience features to improve simulation visibility, speed workflow and streamline each user’s verification process.

A WNMG Insert Right-Mouse-Button Ribbon makes functions more accessible and provides convenient access to external applications. The configurable Heads-Up Display (HUD) improves simulation monitoring and visibility by showing the NC program or machining and cutting-status information, overlaid on top of the graphical views. HUD provides constant access to important details about the machining process, while keeping simulation views as large as possible for optimal viewing. NC Program Alert symbols and colors highlight Indexable Threading Insert errors and warnings found in NC programs, making it faster and easier to identify problem sources, according to the company.

Force is a physics-based NC program-optimization module that analyzes and optimizes cutting conditions to improve chip thicknesses while managing the cutting forces and spindle power required. This version uses Force Turning to optimize lathe turning, and mill-turn operations, when combined with Force Milling.

The Cemented Carbide Blog: http://philipryan.mee.nu/

Using Small End Mills In Steel Without Breaking

Tungaloy’s DeepTri-Drill line of indexable gundrills now includes FH3135 grade guide pads. These guide pads were developed specifically to enhance thermal crack resistance when machining with water-emulsifiable oils. 

DeepTri-Drill is a line of indexable-insert gundrills designed for productivity and application security when drilling deep holes while eliminating the need for regrinding. 

The tribological conditions during gundrilling between the guide pad surfaces and the wall of the hole being drilled are far more severe than those during other applications, Tungaloy explains. While straight cutting oils have long been DNMG Insert preferred, more manufacturers are using more environmentally conscious water-emulsifiable or soluble oils over petroleum-based coolants. These oils have lower lubricity and can adversely affect the guide pad quality during gundrilling. 

The dedicated carbide substrate of the FH3135 guide pad provides enhanced resistance to fracturing and thermal cracking, reducing the risk of guide pad breakage for use with these lower-lubricity oils. In addition, the new guide pad features a double-chamfer CNC Carbide Inserts geometry on the corners of both ends, smoothing entry into the guide bushing or pilot hole to limit vibration impact and further decrease the risk of rupture.

The Cemented Carbide Blog: http://jimadelaid.insanejournal.com/

Quick Change System for Driven Toolholders

Everyone in manufacturing should easily agree that CNC programs have a big impact on productivity. U Drill Inserts Well thought-out, properly structured and user-friendly programs generate more output than ill-conceived, poorly developed and troublesome programs.

I am referring to the program that CNC setup people and operators see — the G-code program running in the CNC machine. This program may have been manually written, in which case the programmer was in total control of every aspect of how the machine runs. Alternatively, the G-code program may have been developed by a CAM system. In this case, the programmer relinquished control of how the machine will behave to the CAM system.

While CAM systems vary in their ability to appropriately generate G-code programs, nothing beats the intimacy manual programmers have with the machine when creating the G code. This advantage encompasses more than the machining DCMT Insert program that produces workpieces. There are countless G-code techniques that can be employed to help with workholding setup, cutting tool measurement and offset entry, simplification of setup and production running tasks and safety. Most CAM systems do not take advantage of these techniques — at least not automatically.

I am not advocating for a switch to manual programming; instead, I am asking that users consider the quality of the G-code programs their CAM system are producing and, if necessary, find ways to improve them. This may require a better understanding of G-code than they currently possess, so some G-code skills training may be required. And it will also require that they learn how to modify the output generated by the CAM system to minimize the number of G-code-level program edits required.

Some of these productivity-enhancing techniques involve parametric programming, which in FANUC terms is “custom macro.” Some CAM systems are incapable of generating parametric programming commands, so again, users must work at G-code level to incorporate the related techniques.

So how can CNC programs affect productivity? And what can be done to improve the G-code program? I will explore these topics in the four upcoming CNC Tech Talk columns. For now, in the spirit of a high-level view, here are four important priorities well-written CNC programs should follow in addition to defining the tool paths of the machine. I will be offering suggestions and examples in each of these four categories in the months to come:

Consistency among the programs that run on a given machine — or type of machine — will help setup people and operators become familiar with programming methods. They will be more easily able to spot mistakes if/when they notice inconsistencies. As for compatibility, there may be similar machines made by multiple machine builders that have different programming commands for similar functions. In this case, maintain nearly duplicate programs for each machine. Make programs compatible among similar machines used to produce the same components to minimize the number of required programs.

Simple tasks can always be accomplished faster than complicated tasks, so making programs more operator friendly will surely improve productivity. Not only that, task simplification reduces the potential for mistakes that lead to wasted time, scrapped workpieces and dangerous situations. Programming methods dramatically affect how easy it is to run parts. With so many newcomers entering our field, keeping things simple is a necessity.

Programming methods should never put the setup person or operator in danger, nor should they potentially damage the machine. And, of course, the programs need to make good parts. As mentioned, minimizing the potential for mistakes will enhance safety. But this is just one of many program-related functions that affects safety.

Improvements in the three productivity-affecting categories just mentioned will have a positive impact on efficiency. When programs are more understandable, easier to run and safer, they can be run more quickly. But there are additional CNC programming methods that specifically impact efficiency. Many of them cost nothing to employ and are simply related to the way the G-code program is structured.

Admittedly, it can sometimes be difficult to improve in one of these four categories without adversely affecting the others. Something that improves efficiency, for instance, may make the program more difficult to run or possibly more dangerous. Something that makes it easier to run programs may take longer. In the coming CNC Tech Talk columns, I will show techniques that improve productivity in one area without adversely affecting productivity in others.

Many of the techniques discussed have been the topics of previous columns, but I’ve never shown them in quite this context. And I will only scratch the surface of potential improvements with the examples I offer. My hope is that readers will use these considerations and examples as a starting point to consider improvements in their own CNC environment.

The Cemented Carbide Blog: WNMG Insert

Optimized Tool Paths Save Time, Boost Profits

Sandvik Coromant has Helical Milling Inserts added the CoroDrill 400 and CoroDrill 430, developed for drilling aluminum automotive parts, to its range of optimized solid round tools. Designed for machining components in medium to large volumes, the drills are said to deliver higher throughput and lower costs as well as extended tool life and enhanced process security.

The drills are supported by CoroTap 100, 200, 300 and 400, which are designed for tapping operations in ISO N materials.

Designed for drilling into solid material, the CoroDrill 400 features more flute volume for better chip evacuation. CoroDrill 430 is designed for drilling into cored material or pre-cast Carbide Milling Insert holes, featuring three flutes for increased stability. Both drills include polished flutes and precision coolant holes, with support provided for minimum quantity lubrication (MQL). The drills are available in diameters of 5, 6.8, 7, 8.5, 10.2 and 12.5 mm diameters, which correspond to M6, M8, M10, M12 and M14 thread sizes. Custom options can be designed for other applications.

While both CoroDrill 400 and CoroDrill 430 are available in the Sandvik Coromant N1BU solid carbide grade, the former is also an option in the N1DU veined polycrystalline diamond (PCD) grade. N1DU provides PCD across the entire cutting edge, promoting longer tool life. Due to PCD’s low coefficient of friction and high conductivity of heat, the tool’s cutting edges are said to be less susceptible to built-up edge (BUE).

The Cemented Carbide Blog: Carbide Drilling Inserts

VMCs Designed for Heavy, Fast Cutting

YG-1 says the coating advances and optimized designs of its i-One system of exchangeable micro-grain carbide drill inserts and premium tool steel holders with coolant channels improve tool life and changeover speed.

“Our new i-One line offers the advantage of a solid carbide drill DCMT Insert combined with the flexibility of steel bodies,” says Steve Pilger, YG-1’s Holemaking product manager. “i-One micro-grain carbide inserts combine a new, multilayered H-coating and optimized cutting angles with tool steel holders with Torx Plus clamping stability.

“With those and other advanced features, i-ONE drills last longer than competitors’ products,” he continues. “And when you finally need to change inserts, we engineered the i-ONE interface for foolproof and worry-free insert changeovers.”

i-One drill inserts feature micro-grain carbide cores to improve strength, an advanced multilayered H-coating that achieves what the company says is excellent hot hardness and minimal wear, ground negative land on the cutting edge for extended cutting Shoulder Milling Inserts life and point geometry optimized for centering and smoother cutting.

The system’s nickel-plated tool steel holder is optimized to resist corrosion and wear while ensuring body clearance. Other features include a flute shape optimized for smooth chip evacuation, a Torx Plus Screw for reliable insert seating and stability at the full range of speeds and coolant holes to assist in dissipating heat and evacuating chips from the cutting zone.

YG-1’s i-ONE drills come in various insert sizes from 0.393” to 1.328” (10 to 33.73 mm), and the tool steel holders are available at depths 3, 5 and 8 times the diameter.

The Cemented Carbide Blog: Carbide Milling Inserts

PCD Face Milling System’s Diameter Cuts Large Parts in Fewer Passes

CNC Engineering Inc. will now play a key role in the distribution, integration and support of the Meltio metal 3D additive manufacturing (AM) solutions for FANUC CNC and robotic systems in the U.S. market.

According to CNC Engineering Inc., it specializes in the integration and support of FANUC CNC machine tool retrofits, Renishaw probe and laser systems, rotary tables and additional axes, FANUC Robots and now Meltio solutions.

Meltio Carbide Milling Insert is said to take metal AM to the next level by developing high-performance, affordable and easy-to-use metal AM solutions using wire laser metal deposition (LMD) technology, which the company says is the safest, cleanest and most affordable metal feedstock in the market.

CNC Engineering and Meltio say they have collaborated to design a solution that combines the power and reliability of FANUC CNC with cutting edge AM technology. This hybrid additive and subtractive manufacturing solution is said to have several advantages, Cemented Carbide Inserts including offering one of the most affordable hybrid manufacturing solutions. It is also said to provide production savings as it offers nearly 100% material utilization. It can also generate complex geometries in a single process and combine different materials into a single part. Users can also utilize AM in their shops by taking advantage of existing machines, thereby saving floor space.

The Cemented Carbide Blog: http://philipjere.mee.nu/

New Coolant Concept Distinguishes Machine Tool Line

Tool length compensation simplifies programming and enhances trial machining and sizing during setups and production runs. It also makes it possible to assemble and measure cutting tool lengths using an offline tool length measuring device.

Though tool length compensation is a good feature, it does have some drawbacks.

1) The cutting tool must be rigid enough to machine using the programmed cutting conditions, and 2) the cutting tool must be long enough to reach the deepest machined surface without being so long that it collides with an obstruction during tool changes.

In some companies, programmers specify the components TCGT Insert for assembling cutting tools along with a range of acceptable lengths.

Many companies, however, specify only the tool name and size, leaving it to the setup person to determine how to assemble cutting tools. Setup people may not know for sure whether each tool will have adequate rigidity, or whether its length is within an acceptable range.

While they may not be able to ensure rigidity, custom macros can solve the cutting tool length range question.

The technique Cemented Carbide Inserts here is especially helpful for machines with limited Z-axis travel, like small vertical machining centers and many horizontal machining centers. We are using FANUC custom macro system variables to access offset-related data, and our example also assumes the machine has FANUC’s standard set of six fixture offsets and the user plans to set the cutting tool length as the tool length compensation offset value.

Variables in the #2200 series provide access to tool length geometry offsets. Those in the #5200 series provide access to fixture offsets. Additionally, our example “second references” the related system variable values. Our test tool length values are:

#149=4.0

#2=#[2200+#149] (Current tool length)

With common variable #149 set to 4.0, the expression 2200+#149 renders 2204. The pound sign (#) outside of the brackets makes this system variable #2204, which accesses the value of tool length geometry offset number four. Similar techniques are used for accessing the currently instated fixture offset Z-register value. We are also using system variable #4014 to access the currently instated fixture offset value (54-59).

Consider the illustration.

Input data comes from offsets, from system constants (#500 series permanent common variables) and from values specified within the program. The offsets include fixture offset Z values and tool lengths entered in the tool length compensation geometry offsets.

Users will only need to enter the following system constants one time:

#511: Clearance for making a tool change.

#512: Tool changer pullout amount (consult machine builder’s documentation).

#513: Z-axis travel (consult machine builder’s documentation).

These values match to the CNC program:

#100: Distance between Z-zero surface to highest obstruction (like a clamp).

#101: Distance between Z-zero surface and the deepest depth. This value can be specified prior to each tool change.

This technique operates from a user-defined T-code program. After setting a parameter (#6001, bit 5 for newer FANUC CNCs) to 1, any time the CNC sees a T code, it will store the T value in common variable #149 and execute program O9000.

There are two common styles of automatic tool changing systems.

With one, the T code by itself completes the tool change. With the other, the T code merely rotates the tool carousel, bringing the tool to the ready station while an M06 command changes the tools. The following example program should work nicely for both, though users may have to separate the T code and the M06 into two commands for the program to execute properly.

Here are the programs. The main program (O6001) is abbreviated to show only the related commands:

O6001 (Main program)

G54 (Select fixture offset)

#100=2.0 (Height of tallest feature/obstruction from fixture offset Z-zero surface)

#101=2.5 (Deepest depth of machining for tool 4)

(.)

(Program startup commands)

(.)

T04 (Calls program O9000, the user-defined T-code custom macro)

M06 (Tool change will occur if tool is within range)

(.)

(Machining with tool station 4)

(.)

#101=1.0 (Deepest depth of machining for tool 5)

(Tool startup commands)

(.)

T5 (Calls user-defined T-code custom macro)

M06 (Tool change will occur if tool is within range)

(Machining with tool 5)

(.)

(Balance of machining program)

(.)

M30

O9000 (Tool checking custom macro)

#1=ABS[#[5203+[#4014-53]*20]] (Current fixture offset Z value)

#2=#[2200+#149] (Current tool length)

IF[[#1-#2-#511-#512-#100]GT0]GOTO5 (Is the tool length okay?)

#3000=100(TOOL IS TOO LONG)

N5#3=#1+#101 (Deepest depth)

#4=#513+#2 (Tool reach)

IF[[#4-#3]GT0]GOTO10 (Will the tool reach deepest surface?)

#3000=101(TOOL TOO SHORT)

N10T#149 (Rotate tool to ready position)

M99

The Cemented Carbide Blog: Carbide Inserts

DN Solutions Responds to Labor Shortages, Reshoring, the Automotive Industry and More

Interconnectivity is important in establishing smart manufacturing environments Lathe Carbide Inserts in which the data shared between disparate pieces of equipment improves the speed of jobs through even simple process improvements. I learned Zoller’s philosophy while attending an open house at its U.S. center of operations in Ann Arbor, Michigan. At the event, the company invited customers into its new Industry 4.0 Technology Center to demonstrate its measuring systems and interconnected tool-storage solutions. The event included product displays and demonstrations of presetting and inspection machines as well as speeches by Zoller President Alexander Zoller and General Manager Dietmar Moll. While the speeches briefly touched on the capabilities of the measuring equipment, their main focus was on how the company’s Tool Management Solutions (TMS) Gold software facilitates data sharing across machines.

Zoller realized this interconnected approach to manufacturing by expanding on its presetting machines, which provide measurements of the length, diameter and complex cutting tool geometries. The company already had many other offerings (heat-shrinking solutions, automated inspection solutions, machines capable of complex DXF comparison and more), but it realized that the presetting machines generated data that could be useful in other applications. The presetters create “digital twins” of the tools they measure, which the company has used in secondary processes such as creating tool profiles for CAM programmers to run more accurate simulations of tool paths. In another application, the TMS software uses the digital twins to keep an accurate accounting of a shop’s tools, including their number, condition and location in the shop. Using simple inputs attached to tool-vending machines and cabinets, the shop can keep track of who has which tool, and management will have ample notice when inserts are running low.

While the company has been dedicated to metrology for decades, the development of the tool-vending and storage solutions is not a change of direction, Mr. Zoller says. “Our measuring and presetting devices were already recording most of this data for our customers,” he says. “With our vending and tool-management solutions, we are able to put this data to new use to improve our customers’ shopfloor experience.” The company simply saw that its machines were taking in useful information, and expanded its offerings to put that information to use. This is the heart of data-driven manufacturing.

Oftentimes, people hear the term “data-driven” and picture endless charts and spreadsheets filled with minute details on every metric possible to retrieve from a machine tool, but Zoller demonstrates that data-driven manufacturing is the simple act of gathering information that is truly valuable and putting it to use in your shop. Machine metrics are certainly important, but so is TCMT Insert knowing something as simple as how many carbide end mills are in stock before placing an order for more.

By using the digital twins created by its measuring devices in other applications, the company is embracing the essence of Industry 4.0: translating digital knowledge into real time savings on the shop floor. In this case, the software makes keeping track of tooling simple, and by eliminating the process of hunting down cutting tools from the workflow, the software is able to reduce the time between finishing CAM programming and starting up the machine tool to 20 minutes. Not all data in data-driven manufacturing is about the performance of the machine tool. Sometimes, the shop finds savings in improving the experience of its people.

The Cemented Carbide Blog: VCMT Insert