Exploring the Aggressive Efficiency of Corn Teeth End Mills in Roughing Operatio

DP Technology’s Esprit 2017 features simpler user interaction, smart toolpath technology and allows users to program faster. The company’s current CAD/CAM software showcases high speed cutting strategies called ProfitTurning and ProfitMilling, along with increased simulation speed, enhanced CAD file support, advanced tool settings and new five-axis programming features.

With accurate G code and factory-certified postprocessors, Esprit CAD/CAM software helps users increase productivity and profits in any manufacturing industry. Compatible with a range of machine tools, Esprit offers programming for two- to five-axis milling, turning, wire EDM, multitasking, Swiss-turn and high speed three- and Shoulder Milling Inserts five-axis machining. Esprit CAM High Feed Milling Insert is cloud-enabled and is part of the Industry 4.0 initiative.

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

DP Technology’s Esprit 2017 features simpler user interaction, smart toolpath technology and allows users to program faster. The company’s current CAD/CAM software showcases high speed cutting strategies called ProfitTurning and ProfitMilling, along with increased simulation speed, enhanced CAD file support, advanced tool settings and new five-axis programming features.

With accurate G code and factory-certified postprocessors, Esprit CAD/CAM software helps users increase productivity and profits in any manufacturing industry. Compatible with a range of machine tools, Esprit offers programming for two- to five-axis milling, turning, wire EDM, multitasking, Swiss-turn and high speed three- and Shoulder Milling Inserts five-axis machining. Esprit CAM High Feed Milling Insert is cloud-enabled and is part of the Industry 4.0 initiative.

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

Relations between Back Engagement, Feed, and Feed Speed and Their Calculation Fomula

Many machine shops today are machining with inserts much larger than are required. There are two trends in the machining industry today that influence the decision to consider downsizing your inserts size. The first is the raw materials (tungsten and cobalt) used to produce carbide inserts are dramatically increasing in price. The second is manufacturing technology is advancing and parts to be machined are considered “near net”. That means the unmachined part is near its net size or there is little material to be removed.  Over 75% of the turning market takes depth of cuts of 0.117" (3mm) or less. Yet many machine shops insist on using large size inserts.  The most common turning insert sold in North America today is a CNMG 432. This insert is capable of almost 0.250" (6.35mm) depth of cut. Yet as mentioned earlier over 75% of the machining industry takes cuts of less than half of that depth.  This seems wasteful.

In order to maintain the same performance, integrity and fracture resistance of the tool the smaller insert should have a thickness close to equal that of the large inserts. The insert numbering system or “nomenclature” indicates the size of the insert. The first number specifies the size of the inscribed circle of that particular insert geometry. In the case of a CNMG 432, the 4 gravity turning inserts would translate to 4/8 or ½ inch inscribed circle. The second number points to the thickness of the insert. In this case a CNMG 432 the 3 shows a 3/16 inch thick insert and the last number indicates the radius of the insert.  So if you are using a CNMG 432 insert, you can simply downsize to a CNMG 332 insert. Since the insert thickness is the same, the chip breaker and grade are the same the performance will be equal.  However the price will be 20% less.

Some shops are reluctant to change, since they consider they have an investment in the tool holder. A typical holder for a CNMG 432 would be an ACLNR 16-4 which would typically list for $85.00. A CNMG 432 insert typically has a list price of around $11.25 where as a smaller CNMG 332 would typically have a list price  20% less or around $9.00. By BTA deep hole drilling inserts downsizing your insert the break even on the tool holder would occur after only using 38 inserts. A typical tool holder is capable of lasting several hundred inserts. Of course this is only an extra cost on the first replacement as all tool holders eventually will wear out and need replacing. Of course there is no extra cost involved if the shop simply waits until the holder wears out and replaces it. However this is not recommended as the shop would be spending too much money on larger inserts.

This leads to another topic: Tool holders. Many shops tend to push the life of the tool holder without realizing the negative consequences. Tool holders are subjected to intense pressure, heat and abuse. Over time the pocket in a tool holder will “coin” or deform making the insert “fit” loose. This may cause the insert to move while in cut. This will lead to shorter tool life, slower performance and may result in catastrophic failure. It is sensible to change your holder often as it will help maintain high productivity, extend tool life and reduce the chance of catastrophic failure. Trying to save a few dollars by extending the life of the $85 tool holder generally ends up cost much more in reduced productivity, poor tool life and probable tool failure.

The Cemented Carbide Blog: deep hole drilling Inserts

Many machine shops today are machining with inserts much larger than are required. There are two trends in the machining industry today that influence the decision to consider downsizing your inserts size. The first is the raw materials (tungsten and cobalt) used to produce carbide inserts are dramatically increasing in price. The second is manufacturing technology is advancing and parts to be machined are considered “near net”. That means the unmachined part is near its net size or there is little material to be removed.  Over 75% of the turning market takes depth of cuts of 0.117" (3mm) or less. Yet many machine shops insist on using large size inserts.  The most common turning insert sold in North America today is a CNMG 432. This insert is capable of almost 0.250" (6.35mm) depth of cut. Yet as mentioned earlier over 75% of the machining industry takes cuts of less than half of that depth.  This seems wasteful.

In order to maintain the same performance, integrity and fracture resistance of the tool the smaller insert should have a thickness close to equal that of the large inserts. The insert numbering system or “nomenclature” indicates the size of the insert. The first number specifies the size of the inscribed circle of that particular insert geometry. In the case of a CNMG 432, the 4 gravity turning inserts would translate to 4/8 or ½ inch inscribed circle. The second number points to the thickness of the insert. In this case a CNMG 432 the 3 shows a 3/16 inch thick insert and the last number indicates the radius of the insert.  So if you are using a CNMG 432 insert, you can simply downsize to a CNMG 332 insert. Since the insert thickness is the same, the chip breaker and grade are the same the performance will be equal.  However the price will be 20% less.

Some shops are reluctant to change, since they consider they have an investment in the tool holder. A typical holder for a CNMG 432 would be an ACLNR 16-4 which would typically list for $85.00. A CNMG 432 insert typically has a list price of around $11.25 where as a smaller CNMG 332 would typically have a list price  20% less or around $9.00. By BTA deep hole drilling inserts downsizing your insert the break even on the tool holder would occur after only using 38 inserts. A typical tool holder is capable of lasting several hundred inserts. Of course this is only an extra cost on the first replacement as all tool holders eventually will wear out and need replacing. Of course there is no extra cost involved if the shop simply waits until the holder wears out and replaces it. However this is not recommended as the shop would be spending too much money on larger inserts.

This leads to another topic: Tool holders. Many shops tend to push the life of the tool holder without realizing the negative consequences. Tool holders are subjected to intense pressure, heat and abuse. Over time the pocket in a tool holder will “coin” or deform making the insert “fit” loose. This may cause the insert to move while in cut. This will lead to shorter tool life, slower performance and may result in catastrophic failure. It is sensible to change your holder often as it will help maintain high productivity, extend tool life and reduce the chance of catastrophic failure. Trying to save a few dollars by extending the life of the $85 tool holder generally ends up cost much more in reduced productivity, poor tool life and probable tool failure.

The Cemented Carbide Blog: deep hole drilling Inserts

U.S. Cutting Tool Consumption Down from Last Year, Reports USCTI, AMT

“First of all, aerospace material is very challenging to machine,” says Rob Caron, founder and president of Caron Engineering. He begins a rundown of the challenges a machinist confronts in hogging out an aerospace part made of, say, titanium (though when it comes to aerospace components, the material might by any number of hard, difficult-to-machine alloys including Monel, Hastelloy or Inconel).

Aircraft standards being so high, many such parts must be machined entirely from one solid block of titanium for maximum integrity when it’s helping to hold a plane aloft. This means that a milling machine might have to hog out loads of metal to get down to the net shape and ultimately to the final part.

And because the titanium is so hard, the tool is breaking down as it’s cutting: “It’s degrading right in the middle of the cut,” Mr. Caron says, “So because of the amount of material being removed and the tool degradation, getting the feed rates correct from a user standpoint is very difficult.” This doesn’t even take account of natural hardness variation through the titanium. And of course, if the next block has any property differences from the last, then those feed rates might not be repeatable.

For many aerospace machinists, the solution is a compromise. When it comes to feeds and speeds, play it safe. Operators will assume the worst potential machining conditions, and program the tool to move slower through the material. The reasons are simple, says Mr. Caron: “There are so many factors they have to consider, and the material is very expensive. So, breaking a tool can cause a very expensive part to scrap. They’ll take the conservative approach to prevent that.”

Enter Caron Engineering’s adaptive control technology.

Caron Engineering’s TMAC MP (Tool Monitoring Adaptive Control with Multi-Process monitoring) was designed to mitigate precisely the challenges described above. TMAC combines sensors and a CPU communicating with a multi-range power transducer to “learn” the optimum power load of the tool in order to adaptively control the feed rate.

The premise is pretty simple. As just described, a machinist faced with hogging out a block of hard aerospace alloy will often take the conservative route when it comes to speed and feeds. The tool moves through the metal at a slow and constant feed rate. As it passes through more and less difficult cuts, the power load of the spindle drive spikes and lowers, respectively. Besides the inefficiency, at a certain point any one of these spikes threatens catastrophic tool breakage if the user isn’t careful.

To prevent such conditions, TMAC connects to the CNC and overrides the feed rate for the whole cut. After monitoring spindle power in “learn mode” while the machine cuts a part with new tools, it establishes peak and optimal power load targets, and automatically adjusts the feed rate to maintain a constant load.

Here’s a video showing adaptive control in action.

The video shows the tool speeding up and slowing down through a cut as it moves through varying material conditions. The inset shows how it unfolds on the TMAC MP screen. Figure 1 in the slideshow at the top of this post also demonstrates what’s going on with a sample cut:

The machine learning process allows TMAC to establish beforehand the target upper limit for the power load (represented by the straight green line) as well as a bottom limit for the feed rate (orange line), below which the system knows that the tool must be so worn as to require replacement, since the cut will always require more power as the tool degrades, and since it’s tied in to the CNC, it can bring the feed rate to zero and signal an automatic tool change in such a case. This essentially prevents catastrophic tool breakage. Whereas normally a tool would continue feeding until it can’t cut anymore, adaptive control’s monitoring gradually reduces the feed rate as the dull tool requires more power, and most of the time, it will at least finish its bar peeling inserts cut.

The overall benefit of adaptive control, according to Caron Engineering, is the ability to cut hard metals like titanium more aggressively and efficiently, reducing air cutting and saving time. Cycle time savings may range anywhere from 20 to 60 percent, according to the company. Adaptive control is said to be especially useful with airplane engine component applications, such as hogging out blisks and machining integrated rotors, in which the metal around weld joints may be work-hardened.

For all these benefits, Caron observed a complication in certain situations, namely, hogging processes in which the hard aerospace material requires a large-diameter tool cutting at speeds of less than 1,000 rpm. “If you’re machining a block of aluminum, then you can go 10,000 rpm no problem, and machine as much as fast feed milling inserts you want,” Mr. Caron says. “But when you start machining titanium, the characteristics of the material don’t allow the cutter to cut that fast.”

In this case, TMAC’s sensitivity becomes problematic, since at such slow cutting speeds—sometimes as low as 200 or 300 rpm—the system actually registers the power increase generated by the resistance of each tooth entering the material. The resulting line looks like an odd-looking saw, with its many power oscillations appearing as teeth. Figure 2 shows a sample cut like this with a five-tooth shell mill, which took about 56 seconds to complete. Under traditional adaptive control, TMAC’s adjustment of the feed rate would end up mirroring each of these tiny spikes, which dampened its efficiency. 

TMAC’s latest innovation, which Mr. Caron refers to as the “sawtooth algorithm,” is an advanced form of adaptive control designed to address this issue by learning the “tooth-pass frequency” of each tool. Calculating the exact power oscillation of each tooth passing through the material and averaging the power of all the flutes for a given rotation, adaptive control can respond to the cutting action of the entire tool instead of each individual tooth. Figure 3 shows the same cut as in Figure 2, but with the sawtooth algorithm enabled. Rather than a sawtooth pattern in the feed rate (the purple line), the result is smoother, rising or falling according to the average power load of the tool moving through the cut. The new cut time is reduced to about 36 seconds.

“We’re making a low-rpm cut look like it’s a high-rpm cut,” Mr. Caron says.

The TMAC MP system is first and foremost a machine monitor. The fact that it exists on its own separate processor and uses Caron’s own sensor suite means the system can be used on legacy machines; but the limitation is with the adaptive control capability, since it needs a CNC that can enable TMAC to override the feed rate. However, the system can measure spindle motor power (the primary indicator used in adaptive control), vibration, strain, coolant pressure, coolant flow and spindle speed for monitoring tool life, work expended, bearing health, and real cut time.

Even though the product has been around for more than 30 years, the company seems to have found itself in something of a moment, as manufacturers race to connect their shop floors and gather data. As it is, Caron’s sensors collect a large amount of data for process diagnostics, system integration and advanced analytics. Like Caron’s other monitoring products, TMAC is MTConnect-compliant.

“We’ve basically been an Industrial Internet of Things product long before that term was ever used, because we’ve always had data that was available to go to anybody,” Mr. Caron says.

All the sensors can be used by TMAC to react to anomalies in normal machine operation and provide messages and alarms to the user. The biggest opportunity this opens up is unattended operation, since there doesn’t need to be a person near the machine when TMAC is automatically monitoring power, making adjustments in real time and notifying the user when a tool needs changing (or ordering an automatic tool change itself).

“We’ve had situations where a customer went from one operator per machine to maybe one operator for every seven machines just to load material,” Mr. Caron says. Obviously, adding a robot for loading and unloading to a cell enabled with TMAC and adaptive control means that a machine could work on difficult-to-machine workpieces completely unattended.

The Cemented Carbide Blog: Turning Inserts

“First of all, aerospace material is very challenging to machine,” says Rob Caron, founder and president of Caron Engineering. He begins a rundown of the challenges a machinist confronts in hogging out an aerospace part made of, say, titanium (though when it comes to aerospace components, the material might by any number of hard, difficult-to-machine alloys including Monel, Hastelloy or Inconel).

Aircraft standards being so high, many such parts must be machined entirely from one solid block of titanium for maximum integrity when it’s helping to hold a plane aloft. This means that a milling machine might have to hog out loads of metal to get down to the net shape and ultimately to the final part.

And because the titanium is so hard, the tool is breaking down as it’s cutting: “It’s degrading right in the middle of the cut,” Mr. Caron says, “So because of the amount of material being removed and the tool degradation, getting the feed rates correct from a user standpoint is very difficult.” This doesn’t even take account of natural hardness variation through the titanium. And of course, if the next block has any property differences from the last, then those feed rates might not be repeatable.

For many aerospace machinists, the solution is a compromise. When it comes to feeds and speeds, play it safe. Operators will assume the worst potential machining conditions, and program the tool to move slower through the material. The reasons are simple, says Mr. Caron: “There are so many factors they have to consider, and the material is very expensive. So, breaking a tool can cause a very expensive part to scrap. They’ll take the conservative approach to prevent that.”

Enter Caron Engineering’s adaptive control technology.

Caron Engineering’s TMAC MP (Tool Monitoring Adaptive Control with Multi-Process monitoring) was designed to mitigate precisely the challenges described above. TMAC combines sensors and a CPU communicating with a multi-range power transducer to “learn” the optimum power load of the tool in order to adaptively control the feed rate.

The premise is pretty simple. As just described, a machinist faced with hogging out a block of hard aerospace alloy will often take the conservative route when it comes to speed and feeds. The tool moves through the metal at a slow and constant feed rate. As it passes through more and less difficult cuts, the power load of the spindle drive spikes and lowers, respectively. Besides the inefficiency, at a certain point any one of these spikes threatens catastrophic tool breakage if the user isn’t careful.

To prevent such conditions, TMAC connects to the CNC and overrides the feed rate for the whole cut. After monitoring spindle power in “learn mode” while the machine cuts a part with new tools, it establishes peak and optimal power load targets, and automatically adjusts the feed rate to maintain a constant load.

Here’s a video showing adaptive control in action.

The video shows the tool speeding up and slowing down through a cut as it moves through varying material conditions. The inset shows how it unfolds on the TMAC MP screen. Figure 1 in the slideshow at the top of this post also demonstrates what’s going on with a sample cut:

The machine learning process allows TMAC to establish beforehand the target upper limit for the power load (represented by the straight green line) as well as a bottom limit for the feed rate (orange line), below which the system knows that the tool must be so worn as to require replacement, since the cut will always require more power as the tool degrades, and since it’s tied in to the CNC, it can bring the feed rate to zero and signal an automatic tool change in such a case. This essentially prevents catastrophic tool breakage. Whereas normally a tool would continue feeding until it can’t cut anymore, adaptive control’s monitoring gradually reduces the feed rate as the dull tool requires more power, and most of the time, it will at least finish its bar peeling inserts cut.

The overall benefit of adaptive control, according to Caron Engineering, is the ability to cut hard metals like titanium more aggressively and efficiently, reducing air cutting and saving time. Cycle time savings may range anywhere from 20 to 60 percent, according to the company. Adaptive control is said to be especially useful with airplane engine component applications, such as hogging out blisks and machining integrated rotors, in which the metal around weld joints may be work-hardened.

For all these benefits, Caron observed a complication in certain situations, namely, hogging processes in which the hard aerospace material requires a large-diameter tool cutting at speeds of less than 1,000 rpm. “If you’re machining a block of aluminum, then you can go 10,000 rpm no problem, and machine as much as fast feed milling inserts you want,” Mr. Caron says. “But when you start machining titanium, the characteristics of the material don’t allow the cutter to cut that fast.”

In this case, TMAC’s sensitivity becomes problematic, since at such slow cutting speeds—sometimes as low as 200 or 300 rpm—the system actually registers the power increase generated by the resistance of each tooth entering the material. The resulting line looks like an odd-looking saw, with its many power oscillations appearing as teeth. Figure 2 shows a sample cut like this with a five-tooth shell mill, which took about 56 seconds to complete. Under traditional adaptive control, TMAC’s adjustment of the feed rate would end up mirroring each of these tiny spikes, which dampened its efficiency. 

TMAC’s latest innovation, which Mr. Caron refers to as the “sawtooth algorithm,” is an advanced form of adaptive control designed to address this issue by learning the “tooth-pass frequency” of each tool. Calculating the exact power oscillation of each tooth passing through the material and averaging the power of all the flutes for a given rotation, adaptive control can respond to the cutting action of the entire tool instead of each individual tooth. Figure 3 shows the same cut as in Figure 2, but with the sawtooth algorithm enabled. Rather than a sawtooth pattern in the feed rate (the purple line), the result is smoother, rising or falling according to the average power load of the tool moving through the cut. The new cut time is reduced to about 36 seconds.

“We’re making a low-rpm cut look like it’s a high-rpm cut,” Mr. Caron says.

The TMAC MP system is first and foremost a machine monitor. The fact that it exists on its own separate processor and uses Caron’s own sensor suite means the system can be used on legacy machines; but the limitation is with the adaptive control capability, since it needs a CNC that can enable TMAC to override the feed rate. However, the system can measure spindle motor power (the primary indicator used in adaptive control), vibration, strain, coolant pressure, coolant flow and spindle speed for monitoring tool life, work expended, bearing health, and real cut time.

Even though the product has been around for more than 30 years, the company seems to have found itself in something of a moment, as manufacturers race to connect their shop floors and gather data. As it is, Caron’s sensors collect a large amount of data for process diagnostics, system integration and advanced analytics. Like Caron’s other monitoring products, TMAC is MTConnect-compliant.

“We’ve basically been an Industrial Internet of Things product long before that term was ever used, because we’ve always had data that was available to go to anybody,” Mr. Caron says.

All the sensors can be used by TMAC to react to anomalies in normal machine operation and provide messages and alarms to the user. The biggest opportunity this opens up is unattended operation, since there doesn’t need to be a person near the machine when TMAC is automatically monitoring power, making adjustments in real time and notifying the user when a tool needs changing (or ordering an automatic tool change itself).

“We’ve had situations where a customer went from one operator per machine to maybe one operator for every seven machines just to load material,” Mr. Caron says. Obviously, adding a robot for loading and unloading to a cell enabled with TMAC and adaptive control means that a machine could work on difficult-to-machine workpieces completely unattended.

The Cemented Carbide Blog: Turning Inserts

Buying a VMC： Considering Toolchanger, Coolant Delivery and Chip Removal

New research from Tungaloy suggests that over 75 percent of the turning market takes cuts of 0.117" (3 mm) depth or less. Yet, the most common turning insert sold in North America is CNMG 432, capable of nearly 0.250" (6.35 mm) depth of cut. According to John Mitchell of Tungaloy Canada, author of a white paper on this topic, this discrepancy suggests that shops may be using inserts that are larger than necessary, resulting in waste.

Tungaloy’s solution is its EcoTurn series, a “downsized” version of its conventionally sized inserts. The EcoTurn inserts have the same thickness and chipbreaker geometry as the rod peeling inserts company’s regular inserts, but in a smaller, more affordable size. View the video slot milling cutters above to learn more. 

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The Cemented Carbide Blog: steel Inserts

New research from Tungaloy suggests that over 75 percent of the turning market takes cuts of 0.117" (3 mm) depth or less. Yet, the most common turning insert sold in North America is CNMG 432, capable of nearly 0.250" (6.35 mm) depth of cut. According to John Mitchell of Tungaloy Canada, author of a white paper on this topic, this discrepancy suggests that shops may be using inserts that are larger than necessary, resulting in waste.

Tungaloy’s solution is its EcoTurn series, a “downsized” version of its conventionally sized inserts. The EcoTurn inserts have the same thickness and chipbreaker geometry as the rod peeling inserts company’s regular inserts, but in a smaller, more affordable size. View the video slot milling cutters above to learn more. 

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The Cemented Carbide Blog: steel Inserts

End Mill Comparisons in CFRP, Part 2 Diamond Coated Tool

The company says its automated tool drawer carousel can store the equivalent of 66 tool drawer cabinets in just 56 percent of the floor space, thereby allowing metalworking operations to expand internally. The carousel consists of an oval track with rotating bins containing shelves and RemStore totes that deliver stored items to the operator. Using the horizontal carousels in combination with the totes is said to provide maximum-density tool storage in a smaller space. One carousel can be used independently, or carousels can be used in groups of two or more to create a workstation pod. This pod allows an bar peeling inserts operator to pick from one active carousel while the others are pre-positioning to be picked the moment the operator is ready.?The carousels can be integrated with one of the QuickPick pick-to-light technologies to provide reduction in search time and increase accuracy, the company says. The QuickPick Position Indicator (QPi), a light bar, is mounted in front of the automated tool drawer carousel and moves vertically up and down to position itself above or below the shelf level. When a pick is ready, the indicator specifies the exact picking location by pointing directly to the tote displaying cemented carbide inserts the quantity to be picked, the part number and description. Additionally, integrating Cribmaster or FastPic inventory control software with the carousel can provide further control over tools, dies and fixtures, the company says.

The Cemented Carbide Blog: high feed milling Insert

The company says its automated tool drawer carousel can store the equivalent of 66 tool drawer cabinets in just 56 percent of the floor space, thereby allowing metalworking operations to expand internally. The carousel consists of an oval track with rotating bins containing shelves and RemStore totes that deliver stored items to the operator. Using the horizontal carousels in combination with the totes is said to provide maximum-density tool storage in a smaller space. One carousel can be used independently, or carousels can be used in groups of two or more to create a workstation pod. This pod allows an bar peeling inserts operator to pick from one active carousel while the others are pre-positioning to be picked the moment the operator is ready.?The carousels can be integrated with one of the QuickPick pick-to-light technologies to provide reduction in search time and increase accuracy, the company says. The QuickPick Position Indicator (QPi), a light bar, is mounted in front of the automated tool drawer carousel and moves vertically up and down to position itself above or below the shelf level. When a pick is ready, the indicator specifies the exact picking location by pointing directly to the tote displaying cemented carbide inserts the quantity to be picked, the part number and description. Additionally, integrating Cribmaster or FastPic inventory control software with the carousel can provide further control over tools, dies and fixtures, the company says.

The Cemented Carbide Blog: high feed milling Insert

Waterjet Cutting System Reduces Cutting Allowance

Well-known characteristics and application of thread milling

Thread milling features and applications:

With the popularity of CNC machine tools, thread milling technology is increasingly used in machinery manufacturing. Thread milling is a three-axis linkage of a CNC machine tool. The thread milling cutter is used for helical interpolation milling to form a thread. The tool moves in a circular motion every horizontal plane, and moves a pitch in a vertical plane. Thread milling has many advantages such as high machining efficiency, high thread quality, good tool versatility and good process safety. There are many types of thread milling tools currently used. This paper analyzes seven common thread milling cutters from application characteristics, tool structure and machining technology.

 

1.ordinary machine clamp thread milling cutter

Machine-clamp thread milling cutters are the most common and inexpensive tool in thread milling. They are similar in construction to conventional machine-clamping cutters and consist of reusable toolholders and easily replaceable blades. If you need to machine the taper thread, you can also use the special arbor and blade for machining the taper thread. This blade has a plurality of thread cutting teeth. The surface milling cutters tool can process a plurality of thread teeth once a week along the spiral line. A milling cutter with five 2mm thread cutting teeth can machine five thread threads with a thread depth of 10 mm by machining one cycle along the helix. In order to further improve the processing efficiency, a multi-blade machine-type thread milling cutter can be selected.

By increasing the number of cutting edges, the feed rate can be significantly increased, but the radial and axial positioning errors between each of the blades distributed over the circumference can affect the accuracy of the threading. If the thread precision of the multi-blade machine thread milling cutter is not satisfied, you can also try to install only one blade for processing. When selecting a machine-type thread milling cutter, the diameter of the cutter bar and the fast feed milling inserts appropriate blade material should be selected as much as possible according to the diameter, depth and workpiece material of the thread to be machined. The threading depth of the machine-type thread milling cutter is determined by the effective cutting depth of the toolholder. Since the length of the blade is less than the effective depth of cut of the shank, layering is required when the depth of the machined thread is greater than the length of the blade.

2.the ordinary integral thread milling cutter

Integral thread milling cutters are mostly made of solid carbide materials, and some are also coated. The integral thread milling cutter is compact and suitable for machining medium and small diameter threads. It also has an integral thread milling cutter for machining taper threads. These tools have good rigidity, especially the integral thread milling cutter with spiral groove, which can effectively reduce the cutting load and improve the processing efficiency when processing high hardness materials. The cutting edge of the integral thread milling cutter is covered with threaded teeth, and the whole thread processing can be completed by machining one thread along the spiral line. It does not need to be layered like a machine tool, so the processing efficiency is high, but the price is relatively expensive.

3.Overall thread milling cutter with chamfering function

The overall thread milling cutter with chamfering structure is similar to a conventional integral thread milling cutter, but with a special chamfering edge at the root of the cutting edge, the thread end chamfer can be machined while machining the thread. There are three ways to machine the chamfer. When the tool diameter is large enough, the chamfering blade can be used directly to chamfer the chamfer. This method is limited to machining the internal threaded hole chamfer. When the tool diameter is small, the chamfering blade can be used to machine the chamfer by circular motion. However, when chamfering is performed using the chamfering edge of the cutting edge, it should be noted that there should be a certain gap between the cutting portion of the cutter thread and the thread to avoid interference. If the thread depth of the machining is less than the effective cutting length of the tool, the tool will not be able to achieve the chamfering function, so the tool should be selected to match the effective cutting length and the thread depth.

4.thread drilling and milling cutter

The thread drilling and milling cutter is made of solid carbide and is a high-efficiency machining tool for medium and small diameter internal threads. The thread drilling cutter can complete the drilling of the bottom hole, the hole chamfering and the internal thread machining at one time, reducing the number of tools used. However, the disadvantage of this type of tool is its poor versatility and its high price. The tool consists of a drilled portion of the head, a threaded portion in the middle, and a chamfered blade at the root of the cutting edge. The diameter of the drilled part is the bottom diameter of the thread that the tool can machine. Due to the limitation of the diameter of the drilled part, a thread drilling and milling cutter can only process one thread of internal thread. When selecting a thread drilling and milling cutter, not only the threaded hole size to be machined, but also the effective machining length of the tool and the depth of the machined hole should be considered. Otherwise, the chamfering function cannot be realized.

5.thread auger milling cutter

Threaded auger milling cutters are also solid carbide tools for efficient internal threading. They can also be used to machine bottom holes and threads at one time. The tool end has a cutting edge like an end mill. Since the spiral angle of the thread is not large, when the tool makes the helical motion machining thread, the end cutting edge first cuts the workpiece material to machine the bottom hole, and then the thread is machined from the back of the tool. Some threaded auger milling cutters also have chamfered edges that allow for the chamfering of the holes at the same time. The tool has high processing efficiency and is more versatile than the thread drilling and milling cutter. The internal thread diameter of the tool can be processed from d to 2d (d is the diameter of the cutter body).

6.milling deep thread cutter

The milled deep thread cutter is a single tooth thread milling cutter. A general thread milling cutter has a plurality

of threaded teeth on the cutting edge, the tool has a large contact area with the workpiece, and the cutting force is also large, and the diameter of the tool must be smaller than the threaded aperture when machining the internal thread. Due to the limitation of the diameter of the cutter body, the rigidity of the tool is affected, and the tool is unilaterally stressed when milling the thread. When the deep thread is milled, the knife phenomenon is easy to occur and the thread machining accuracy is affected. Therefore, the effective cutting depth of the general thread milling cutter is about 2 times the diameter of the body. The use of single-toothed deep-threaded tools can better overcome the above shortcomings. Due to the reduced cutting force, the thread machining depth can be greatly increased, and the effective cutting depth of the tool can reach 3 to 4 times the diameter of the cutter body.

7．thread milling tool system

Generality and high efficiency are a prominent contradiction of thread milling cutters. Some tools with composite functions have high processing efficiency but poor versatility, while versatile tool efficiency is often not high. To solve this problem, many tool manufacturers have developed modular thread milling tool systems. The tool is generally composed of a shank, a boring chamfering edge, and a universal thread milling cutter. Different types of boring chamfering edges and thread milling cutters can be selected according to the processing requirements. This tool system has good versatility and high processing efficiency, but the tool cost is high.

The above outlines the functions and features of several common thread milling tools. Cooling is also important when milling threads, and it is

recommended to use machines and tools with internal cooling. When the tool rotates at a high speed, the external coolant is not easily introduced by the centrifugal force. In addition to the excellent cooling of the tool, the internal cooling method is more important when the blind hole thread is used to facilitate chip removal. When machining the small diameter internally threaded hole, a higher internal cooling pressure is required. Ensure that the chip removal is smooth. In addition, when selecting thread milling tools, we should also consider the specific processing requirements, such as?production batch, number of screw holes, workpiece material, thread precision, size specifications, and other factors, and comprehensive selection of tools.

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Well-known characteristics and application of thread milling

Thread milling features and applications:

With the popularity of CNC machine tools, thread milling technology is increasingly used in machinery manufacturing. Thread milling is a three-axis linkage of a CNC machine tool. The thread milling cutter is used for helical interpolation milling to form a thread. The tool moves in a circular motion every horizontal plane, and moves a pitch in a vertical plane. Thread milling has many advantages such as high machining efficiency, high thread quality, good tool versatility and good process safety. There are many types of thread milling tools currently used. This paper analyzes seven common thread milling cutters from application characteristics, tool structure and machining technology.

 

1.ordinary machine clamp thread milling cutter

Machine-clamp thread milling cutters are the most common and inexpensive tool in thread milling. They are similar in construction to conventional machine-clamping cutters and consist of reusable toolholders and easily replaceable blades. If you need to machine the taper thread, you can also use the special arbor and blade for machining the taper thread. This blade has a plurality of thread cutting teeth. The surface milling cutters tool can process a plurality of thread teeth once a week along the spiral line. A milling cutter with five 2mm thread cutting teeth can machine five thread threads with a thread depth of 10 mm by machining one cycle along the helix. In order to further improve the processing efficiency, a multi-blade machine-type thread milling cutter can be selected.

By increasing the number of cutting edges, the feed rate can be significantly increased, but the radial and axial positioning errors between each of the blades distributed over the circumference can affect the accuracy of the threading. If the thread precision of the multi-blade machine thread milling cutter is not satisfied, you can also try to install only one blade for processing. When selecting a machine-type thread milling cutter, the diameter of the cutter bar and the fast feed milling inserts appropriate blade material should be selected as much as possible according to the diameter, depth and workpiece material of the thread to be machined. The threading depth of the machine-type thread milling cutter is determined by the effective cutting depth of the toolholder. Since the length of the blade is less than the effective depth of cut of the shank, layering is required when the depth of the machined thread is greater than the length of the blade.

2.the ordinary integral thread milling cutter

Integral thread milling cutters are mostly made of solid carbide materials, and some are also coated. The integral thread milling cutter is compact and suitable for machining medium and small diameter threads. It also has an integral thread milling cutter for machining taper threads. These tools have good rigidity, especially the integral thread milling cutter with spiral groove, which can effectively reduce the cutting load and improve the processing efficiency when processing high hardness materials. The cutting edge of the integral thread milling cutter is covered with threaded teeth, and the whole thread processing can be completed by machining one thread along the spiral line. It does not need to be layered like a machine tool, so the processing efficiency is high, but the price is relatively expensive.

3.Overall thread milling cutter with chamfering function

The overall thread milling cutter with chamfering structure is similar to a conventional integral thread milling cutter, but with a special chamfering edge at the root of the cutting edge, the thread end chamfer can be machined while machining the thread. There are three ways to machine the chamfer. When the tool diameter is large enough, the chamfering blade can be used directly to chamfer the chamfer. This method is limited to machining the internal threaded hole chamfer. When the tool diameter is small, the chamfering blade can be used to machine the chamfer by circular motion. However, when chamfering is performed using the chamfering edge of the cutting edge, it should be noted that there should be a certain gap between the cutting portion of the cutter thread and the thread to avoid interference. If the thread depth of the machining is less than the effective cutting length of the tool, the tool will not be able to achieve the chamfering function, so the tool should be selected to match the effective cutting length and the thread depth.

4.thread drilling and milling cutter

The thread drilling and milling cutter is made of solid carbide and is a high-efficiency machining tool for medium and small diameter internal threads. The thread drilling cutter can complete the drilling of the bottom hole, the hole chamfering and the internal thread machining at one time, reducing the number of tools used. However, the disadvantage of this type of tool is its poor versatility and its high price. The tool consists of a drilled portion of the head, a threaded portion in the middle, and a chamfered blade at the root of the cutting edge. The diameter of the drilled part is the bottom diameter of the thread that the tool can machine. Due to the limitation of the diameter of the drilled part, a thread drilling and milling cutter can only process one thread of internal thread. When selecting a thread drilling and milling cutter, not only the threaded hole size to be machined, but also the effective machining length of the tool and the depth of the machined hole should be considered. Otherwise, the chamfering function cannot be realized.

5.thread auger milling cutter

Threaded auger milling cutters are also solid carbide tools for efficient internal threading. They can also be used to machine bottom holes and threads at one time. The tool end has a cutting edge like an end mill. Since the spiral angle of the thread is not large, when the tool makes the helical motion machining thread, the end cutting edge first cuts the workpiece material to machine the bottom hole, and then the thread is machined from the back of the tool. Some threaded auger milling cutters also have chamfered edges that allow for the chamfering of the holes at the same time. The tool has high processing efficiency and is more versatile than the thread drilling and milling cutter. The internal thread diameter of the tool can be processed from d to 2d (d is the diameter of the cutter body).

6.milling deep thread cutter

The milled deep thread cutter is a single tooth thread milling cutter. A general thread milling cutter has a plurality

of threaded teeth on the cutting edge, the tool has a large contact area with the workpiece, and the cutting force is also large, and the diameter of the tool must be smaller than the threaded aperture when machining the internal thread. Due to the limitation of the diameter of the cutter body, the rigidity of the tool is affected, and the tool is unilaterally stressed when milling the thread. When the deep thread is milled, the knife phenomenon is easy to occur and the thread machining accuracy is affected. Therefore, the effective cutting depth of the general thread milling cutter is about 2 times the diameter of the body. The use of single-toothed deep-threaded tools can better overcome the above shortcomings. Due to the reduced cutting force, the thread machining depth can be greatly increased, and the effective cutting depth of the tool can reach 3 to 4 times the diameter of the cutter body.

7．thread milling tool system

Generality and high efficiency are a prominent contradiction of thread milling cutters. Some tools with composite functions have high processing efficiency but poor versatility, while versatile tool efficiency is often not high. To solve this problem, many tool manufacturers have developed modular thread milling tool systems. The tool is generally composed of a shank, a boring chamfering edge, and a universal thread milling cutter. Different types of boring chamfering edges and thread milling cutters can be selected according to the processing requirements. This tool system has good versatility and high processing efficiency, but the tool cost is high.

The above outlines the functions and features of several common thread milling tools. Cooling is also important when milling threads, and it is

recommended to use machines and tools with internal cooling. When the tool rotates at a high speed, the external coolant is not easily introduced by the centrifugal force. In addition to the excellent cooling of the tool, the internal cooling method is more important when the blind hole thread is used to facilitate chip removal. When machining the small diameter internally threaded hole, a higher internal cooling pressure is required. Ensure that the chip removal is smooth. In addition, when selecting thread milling tools, we should also consider the specific processing requirements, such as?production batch, number of screw holes, workpiece material, thread precision, size specifications, and other factors, and comprehensive selection of tools.

The Cemented Carbide Blog: cast iron Inserts

On Machine Laser Measuring System Maintains Tool Grinding Accuracy

Rollomatic’s GrindSmart 630XW machine is designed to offer more flexibility in grinding indexable inserts and other stationary cutting tools than conventional, single-purpose grinders. With its six fully interpolated CNC axes, a six‐station wheel changer and wheel inclination ranging to 45 degrees, the machine supports simple adaptation for short and long runs of individual insert designs. Its design allows full interchangeability between inserts and round tools, according to the company. 

The clamping systems are designed to emulate the way inserts fit into their tool holders, increasing&deep hole drilling inserts nbsp;concentricity and accuracy. The clamping design supports indexable, non‐indexable and replaceable inserts; threading and form inserts; dog‐bone and grooving inserts; drilling, milling and ballnose tip inserts; and other non‐round tools. An electronic touch probe determines the exact location of the insert blank after clamping, allowing the software to grind the tool geometry according to the virtual centerline of the insert blank and achieve a run-out of 0.0001", according to Rollomatic. 

The company says the machine’s six- or 16-station wheel and nozzle changer offers flexibility for grinding a variety of inserts and other stationary cutting tools while maintaining the ability to change to round‐shank tools within minutes.

Additional features include an IC diameter range from 3.9 to 25.4 mm with automatic handling, linear motion control on CNC axes, desktop tool design software with 3D tool simulation and 3D machine animation with collision warning, chipbreaker grinding on the rake face, edge preparation grinding on the cutting edge, and a pick-and-shoulder milling cutters place robot that protects inserts from damage after grinding. Optional features include a part flipper, an in-process rotary dressing and an automatic sticking device.

The Cemented Carbide Blog: WCMT Insert

Rollomatic’s GrindSmart 630XW machine is designed to offer more flexibility in grinding indexable inserts and other stationary cutting tools than conventional, single-purpose grinders. With its six fully interpolated CNC axes, a six‐station wheel changer and wheel inclination ranging to 45 degrees, the machine supports simple adaptation for short and long runs of individual insert designs. Its design allows full interchangeability between inserts and round tools, according to the company. 

The clamping systems are designed to emulate the way inserts fit into their tool holders, increasing&deep hole drilling inserts nbsp;concentricity and accuracy. The clamping design supports indexable, non‐indexable and replaceable inserts; threading and form inserts; dog‐bone and grooving inserts; drilling, milling and ballnose tip inserts; and other non‐round tools. An electronic touch probe determines the exact location of the insert blank after clamping, allowing the software to grind the tool geometry according to the virtual centerline of the insert blank and achieve a run-out of 0.0001", according to Rollomatic. 

The company says the machine’s six- or 16-station wheel and nozzle changer offers flexibility for grinding a variety of inserts and other stationary cutting tools while maintaining the ability to change to round‐shank tools within minutes.

Additional features include an IC diameter range from 3.9 to 25.4 mm with automatic handling, linear motion control on CNC axes, desktop tool design software with 3D tool simulation and 3D machine animation with collision warning, chipbreaker grinding on the rake face, edge preparation grinding on the cutting edge, and a pick-and-shoulder milling cutters place robot that protects inserts from damage after grinding. Optional features include a part flipper, an in-process rotary dressing and an automatic sticking device.

The Cemented Carbide Blog: WCMT Insert

2D Laser Cutting Machine Features 8 kW Solid State Laser

Fullerton Tool Co., a manufacturer of solid carbide cutting tools located in Saginaw, Michigan, has announced the acquisition of Carbro Corp., a manufacturer of solid carbide rotary tools located in tube process inserts Lawndale, California. Following the acquisition, Carbro Corp. will operate as Carbro LLC.

Carbro will continue Carbide Milling Inserts to operate as its own entity, as well as partner with Fullerton to create strategic partnerships aimed at the aerospace market. This acquisition and partnership will allow Carbro to continue to provide its existing products and services.

“Carbro and Fullerton will continue to build upon their existing product lines and reputations and together will create strategic partnerships to better service specialty markets as well as our customers,” says Patrick Curry, president and co-owner of Fullerton Tool. “I am excited for the future with both of these companies and how this partnership will impact the manufacturing industry.”

The Cemented Carbide Blog: high feed milling Insert

Fullerton Tool Co., a manufacturer of solid carbide cutting tools located in Saginaw, Michigan, has announced the acquisition of Carbro Corp., a manufacturer of solid carbide rotary tools located in tube process inserts Lawndale, California. Following the acquisition, Carbro Corp. will operate as Carbro LLC.

Carbro will continue Carbide Milling Inserts to operate as its own entity, as well as partner with Fullerton to create strategic partnerships aimed at the aerospace market. This acquisition and partnership will allow Carbro to continue to provide its existing products and services.

“Carbro and Fullerton will continue to build upon their existing product lines and reputations and together will create strategic partnerships to better service specialty markets as well as our customers,” says Patrick Curry, president and co-owner of Fullerton Tool. “I am excited for the future with both of these companies and how this partnership will impact the manufacturing industry.”

The Cemented Carbide Blog: high feed milling Insert

Seamless Connectivity for Tool Presetter Data

Iscar offers a variety of inserts suitable for the machining of bearings, including its Penta series of multi-corner inserts with five cutting edges used mostly for parting-off operations, seal groove machining, raceway grooving and other applications. These inserts can also be used for trepanning, an axial operation for the separation of one thick forged ring into fast feed milling inserts two separate outer and inner rings. For such operations, the company also offers surface milling cutters its BGR and BGMR inserts for wider rings that demand deep separation operations. In addition, Iscar offers multi-parting systems designed for parting a few rings at a time. Such sets are provided with the Tang-Grip and Do-Grip insert as well as the Penta inserts.

These insert products are available in very narrow sizes that enable manufacturers to significantly reduce the width of inserts down to 0.7 and 1.0 mm for raw material savings, the company says.

The Cemented Carbide Blog: https://rockdrillbits.hatenablog.com/

Iscar offers a variety of inserts suitable for the machining of bearings, including its Penta series of multi-corner inserts with five cutting edges used mostly for parting-off operations, seal groove machining, raceway grooving and other applications. These inserts can also be used for trepanning, an axial operation for the separation of one thick forged ring into fast feed milling inserts two separate outer and inner rings. For such operations, the company also offers surface milling cutters its BGR and BGMR inserts for wider rings that demand deep separation operations. In addition, Iscar offers multi-parting systems designed for parting a few rings at a time. Such sets are provided with the Tang-Grip and Do-Grip insert as well as the Penta inserts.

These insert products are available in very narrow sizes that enable manufacturers to significantly reduce the width of inserts down to 0.7 and 1.0 mm for raw material savings, the company says.

The Cemented Carbide Blog: https://rockdrillbits.hatenablog.com/

CAM Software Delivers New Toolpath Strategies

Surfware and Swift-Carb CNC announce cutting tools built specifically to optimize TrueMill’s custom cutter path. The TrueMill Certified series of cutters is said to produce faster cycle times and extended tool life through the use of the company’s “engagement angle” or “TEA” method.

A major problem in milling is the inability to control the cutting tool’s engagement cemented carbide inserts with the material, which makes it difficult to keep the load on the tool Carbide Milling Inserts constant, forcing machines to run at longer cycle times. According to the company, the series of cutters is built to solve this problem, as the motion of the tool path is designed with consideration for the in-process material boundary along the tool path to ensure that the tool is never overengaged for any part geometry. The company adds that the series has an advantage over other cutting tools because of the substrate, geometry and coatings used on the tools.

The Cemented Carbide Blog: bta drilling

Surfware and Swift-Carb CNC announce cutting tools built specifically to optimize TrueMill’s custom cutter path. The TrueMill Certified series of cutters is said to produce faster cycle times and extended tool life through the use of the company’s “engagement angle” or “TEA” method.

A major problem in milling is the inability to control the cutting tool’s engagement cemented carbide inserts with the material, which makes it difficult to keep the load on the tool Carbide Milling Inserts constant, forcing machines to run at longer cycle times. According to the company, the series of cutters is built to solve this problem, as the motion of the tool path is designed with consideration for the in-process material boundary along the tool path to ensure that the tool is never overengaged for any part geometry. The company adds that the series has an advantage over other cutting tools because of the substrate, geometry and coatings used on the tools.

The Cemented Carbide Blog: bta drilling