compiled and edited by Bernard Martin The choice between various materials can significantly impact performance, productivity, and cost-effectiveness in Metalcutting manufacturing. Among the materials commonly used for cutting tools, carbide-tipped tools have remained in prominence for their remarkable advantages when compared to solid carbide and high-speed steel (HSS) tools. In this article, based upon information supplied by Hannibal Carbide, we explore the distinctive benefits of carbide-tipped tools by comparing them to their solid carbide and HSS counterparts. Durability and Longevity One of the foremost advantages of carbide-tipped tools is their exceptional durability and longevity. These tools combine the best of both worlds, featuring a tough steel body with a carbide insert at the cutting edge. When compared to solid carbide tools, carbide-tipped tools often outlast them due to their ability to withstand high-impact applications. In contrast, HSS tools are more prone to wear and require frequent regrinding or replacement Versatility Carbide-tipped tools offer a remarkable level of versatility. The carbide inserts are available in various grades, each tailored to specific machining tasks. This adaptability allows users to choose the ideal carbide grade for their application, optimizing tool life and performance. In contrast, solid carbide tools, while highly capable in specific applications, lack the flexibility to adapt to various materials and machining conditions. HSS tools, though versatile, may not match the cutting speed and precision of carbide-tipped tools in demanding applications. Cutting Speed and Efficiency Carbide-tipped tools excel in cutting speed and efficiency, making them a preferred choice for high-production environments. The hardness of carbide allows for faster cutting speeds, which translates to reduced machining time and increased productivity. Solid carbide tools come close but may not always match the speed and efficiency of carbide-tipped tools, especially when it comes to demanding materials like stainless steel or hardened alloys. HSS tools, on the other hand, are often outpaced in terms of cutting speed and efficiency. Heat Resistance Heat resistance is a critical factor in machining, especially when working with materials that generate high temperatures during cutting. Carbide-tipped tools have superior heat resistance compared to HSS tools. The carbide can endure high temperatures without losing its cutting edge, ensuring consistent performance even under demanding conditions. Solid carbide tools have good heat resistance but may be prone to chipping or breakage when subjected to extreme heat, which is less of an issue for carbide-tipped tools. Cost-Effectiveness While the initial cost of carbide-tipped tools may be higher than HSS tools, their durability and longevity make them a cost-effective choice in the long run. Solid carbide tools, while durable, can be more expensive and may not justify their cost in all applications. HSS tools, although cheaper initially, may need more frequent replacements and regrinding, ultimately incurring higher costs over time. In the world of cutting tools, carbide-tipped tools stand out as a versatile, high-performance, and cost-effective solution. Their unique combination of a tough steel body with a carbide insert at the cutting edge offers durability, versatility, high cutting speeds, heat resistance, and cost savings. While solid carbide and high-speed steel tools have their merits in specific applications, carbide-tipped tools are the go-to choice for industries and machinists looking to maximize efficiency and quality across a wide range of machining tasks. Whether you're working with metals, plastics, or composites, carbide-tipped tools provide a winning edge in the world of precision cutting and machining. Advantages of Carbide Tipped |
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Advantages of CARBIDE TIPPED
VS.
SOLID CARBIDE ADVANTAGE
- Carbide grade selected for cutting characteristics - not compromised for structural strength
- Tipped tools usually cost less than solid carbide
- Often utilize specialty carbides not available in solid round forms
- Expensive carbide only used for cutting edge & chip forming surface
- More aggressive cutting edge geometries - shear, edge & rake angles
- A shattered solid carbide tool often damages the piece being machined
- Hardened tough alloy steel body provides superior structure to absorb shock loads
- Carbide cracks stopped in steel body pocket rather than shattering the entire tool
- Reduced scrap & machine downtime as even a cracked carbide tipped tool keeps cutting
- Carbide cracks stopped in steel body pocket rather than shattering the entire tool
ADVANTAGEs of CARBIDE TIPPED
VS.
CARBIDE INSERT
- Initial tooling costs far lower for carbide tipped tools
- Insert pocket interferes with chip flow
- Vibration-free brazed carbide tip permits higher feeds & speeds since inserts simply cannot be securely clamped to avoid all vibration problems
- Far better finish using carbide tipped tools
- Inserts are impractical for many operations such as reaming and most drilling
The Next Era of Performance and Versatile End Mills has arrived: Data Flute's SSI-5plus & SSI-7
2/21/2024
the SSI-5plus and SSI-7 have emerged as the performance leader in a lot of categories!
The SSI-5plus End Mill
Now, Datflute has updated the already impressive SSI-5 with a new, advanced substrate, formerly only offered in their SSI-7 series, an even higher-performance coating and field tested micro-geometry. The result is a tool that provides outstanding cutting performance and substantially greater tool life.
The SSI-5plus will appeal to machinists who demand high performance endmills, but seek to minimize tool changes, or tool inventory, over a wider range of milling operations. This offering mirrors the SSI-5 with regard to diameters, lengths of cut, overall lengths and radii offered. Dataflute is transitioning their 5 flute, variably indexed, ferrous alloy rougher/finisher from the SSI-5 to the SSI-5plus.
The tool adheres to strict tolerances, featuring a shank diameter held to h5 specifications, while the cutting diameter boasts precision within -0.001"/-0.002". The corner radius is equally refined, offering +0.001"/-0.001". Whether used for roughing or finishing, the SS-5plus from Data Flute delivers exceptional results, promising machinists a combination of accuracy, versatility, and reliability in their machining endeavors.
SSI-7 End Mill
Engineered with specific geometry tailored for titanium alloys and stainless steels, the SS-7 features seven flutes with an unequal index and a constant helix, promoting efficient chip evacuation and reduced cutting forces.
This non-center cutting tool, available in both RH-C and RH-H configurations, boasts a continuous cutting edge for seamless machining.
The SS-7 end mill sets a standard with its tight tolerances, including a shank diameter held to h5 specifications and a cutting diameter precision within -0.001"/-0.002". The corner radius further enhances precision, offering +0.001"/-0.001". Machinists can expect not only high efficiency but also superior surface finishes, making the SS-7 a standout choice for those seeking precision, longevity, and exceptional performance in ferrous alloy applications.
Tech spec overview
- Material Composition - SS-5plus and SS-7 end mills are crafted from high-quality micro-grain carbide, ensuring exceptional durability and resistance to wear.
- Geometry and Flute Design - The SS-5plus features a unique 5-flute design, providing increased stability and reduced vibrations during cutting operations. The SS-7, with its 7-flute configuration, is engineered for high-speed machining, delivering efficient chip evacuation and improved surface finish.
- Coating Technology - Both end mills come equipped with advanced coating technologies such as TiALN (Titanium Aluminum Nitride) or TiCN (Titanium CarboNitride), enhancing tool life and facilitating high-speed machining applications.
- Cutting Parameters - The SS-5plus and SS-7 are optimized for a wide range of materials, including steels, stainless steels, and exotic alloys, showcasing versatility in machining operations.
A Leap FOrward
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Maximizing Lights-on Profits
The new machine’s automation capacity enabled the shop to run many of the jobs previously on its five-axis Haas UMC 750 for longer periods, decreasing the time necessary to complete these jobs even as it left the UMC 750 idle.
Ryan Merrill, chief operating officer at Thomas/Euclid, says the search for additional work to put on the shop’s UMC 750 led the company to a customer already committed to machining EV strut housings.
Complications had arisen from the compressed timeframe to prepare for the job — the typical two-year development time for the part had been shortened to eight months — and a delay in receiving the five-axis machines the customer had been planning to use to machine the housings. Thomas/Euclid had the opportunity to act as a stopgap, delivering parts until its customer’s machines were up and running.
Another complication? Most shops that had been offered the job had already turned it down due to the nature of the part itself: a 20-inch-long, near-net aluminum casting with an odd shape and inconvenient tolerances.
While the customer would provide the casting, and all Thomas/Euclid needed to do was machine holes in it, consistently gripping the part without marring and distorting it was a massive challenge.
Getting the Green Light on Blue Photon
Properly attaching the Blue Photon grippers to the part required irregularly shaped fixtures for each of the four variants of the part (two operations, each with a left- and right-hand version). Blue Photon’s applications engineers volunteered to help, designing the fixtures for additive manufacturing and printing them through Stratasys. Thomas/Euclid then bolted the fixtures onto a quick-change base and screwed the Blue Photon grippers into the ends of the fixture.
Shining a Light on Adhesive Workholding
From here, the company was able to machine the part with no issues. Removing the part required loosening the grippers with a normal socket wrench, then using a handheld steamer to remove the residue from the Blue Photon grippers.
Hands-On At All Times
Thomas/Euclid has handed off the EV strut housing job to the original customer, but maintains its Blue Photon stock for suitable future projects.
“It was the first time our customer had ever worked with us. It was the first time we had ever worked with Blue Photon. We put a lot of trust and faith in each other that we were going to pull it off, and there were of course some road bumps along the way, but we pulled it off,” Merrill says. “It was incredibly impressive how well Blue Photon worked on this project.”
Each of these companies has had a niche place in the market as well as some product overlap over over the last few decades. In order to clarify where each brand fits under the Heritage Cutter umbrella, and to set a strategic outlook, Heritage Cutter has outlined the speciality areas that each of the brands it taking moving into the future.
Data Flute: Pioneering High-Performance Carbide Round Tools Since 1976
The mantra, "The most demanding machinists demand Data Flute!" encapsulates the brand's dedication to meeting and exceeding the expectations of machinists who demand nothing but the best. Over nearly five decades, Data Flutee has established itself as a trusted name synonymous with high-performance, application-specific carbide cutting tools.
The cornerstone of Data Flute's success lies in its state-of-the-art manufacturing facility in Pittsfield, MA. This facility serves as the epicenter of innovation, housing not only the manufacturing operations but also the brand's R&D machining test center and customer support. This consolidated setup enables Data Flute to provide a seamless experience to its customers, ensuring that design, testing, and support are all under one roof.
At Data Flute, the commitment extends beyond the production line. The brand is dedicated to high-performance machining, a philosophy reflected in its comprehensive suite of tools, factory support, and field support. The team at Data Flute is driven by a shared desire to collaborate with customers, understanding their unique challenges, and working together to maximize cutting tool productivity.
Brubaker: Brubaker Tool: A Legacy of Excellence in Taps and Threading Products Since 1881
The commitment to excellence is etched in the very fabric of Brubaker Tool. With a wealth of experience, the brand has evolved to become a leading source of American-made industrial cutting tools. Over the years, Brubaker has built upon its enduring stability, reliability, and unwavering commitment to quality, earning its status as a trusted source for distributors and manufacturers for generations.
Carrying the torch of tradition into the modern era, Brubaker Tool continues to innovate with carbide thread mills, available for special orders, showcasing the brand's adaptability to evolving industry needs.
Despite the significant changes witnessed over the last 140 years, Brubaker Tool's steadfast commitment to providing the finest taps and threading tools remains unwavering. The brand's long-standing stability, reliability, and quality have positioned it as a reliable partner in the ever-evolving landscape of industrial cutting tools.
Brubaker Tool's legacy is not just a chronicle of the past, but a testament to its enduring commitment to excellence. With a rich history and an eye on the future, Brubaker Tool remains a trusted name, embodying the values of stability, reliability, and quality that have defined it for over a century.
Weldon: Blending Tradition and Innovation in Quality Cutting Tools Since 1918
From its humble beginnings as a two-man shop in downtown Cleveland, Ohio, Weldon Tool has grown into a powerhouse, designing, manufacturing, and delivering a diverse range of cutting tools. The original dedication to craftsmanship and quality that marked its inception remains a constant thread woven into the fabric of the company.
Specialty tools such as countersinks, hole saws, and core drills further demonstrate the brand's dedication to providing a holistic solution for cutting challenges. Weldon Tool's focus on engineered to order solutions, including end mills, round tools, and other specials, positions it as a go-to partner for those seeking customized cutting tools.
For the past two decades, Weldon Tool has been co-located with Brubaker Tool in Millersburg, PA, reflecting a strategic alignment within the Heritage Cutter family. The synergy between these companies has not only provided operational efficiency but has also allowed Weldon to maintain its traditional commitment to quality while embracing the demands of modern manufacturing.
In many ways, Weldon Tool represents a harmonious blend of the old and the new. While remaining steadfast in its dedication to traditional end mills and specialty products in HSS, cobalt, and CPM, Weldon is simultaneously steering towards the future with a pronounced focus on custom tools and engineered specials. This forward-looking approach ensures that Weldon Tool continues to be a dynamic force in the cutting tool industry, adapting to the ever-changing needs of its customers and the evolving landscape of precision machining.
Decatur Diamond: Your Trusted Source for Diamond and PcBN Tools
Under the banner of "When every cut counts, count on Decatur Diamond," this brand is dedicated to delivering diamond and PcBN-based cutting tools. With a comprehensive range covering indexable milling cutters, fixed pocket brazed tools, complex monobloc solutions, and CVD diamond-coated tools.
At the forefront of Decatur Diamond's contributions is the Ultra-Mill, an early and remarkably successful indexable platform for diamond tools. This innovation underscored the brand's commitment to pushing the boundaries of what was possible in the realm of cutting materials. Similarly, the DIAbide line emerged as one of the original CVD diamond carbide round tool brands, solidifying Decatur Diamond's reputation as a trailblazer in the industry.
Decatur Diamond not only focuses on advancing technology but also places a significant emphasis on service. The brand goes beyond the design and manufacture of new tools, offering reconstruction services with an equal measure of dedication and enthusiasm. This commitment to providing comprehensive solutions showcases Decatur Diamond's holistic approach to meeting the varied demands of its customers.
Being a full-service diamond tooling company, Decatur Diamond houses all its engineering, product support, customer service, and reconstruction services in its Decatur, IN facility. This centralized hub ensures seamless collaboration between different facets of the operation, promoting efficiency and excellence in every aspect of service delivery.
Decatur Diamond's rich history and ongoing commitment to innovation make it a vital component within the Heritage Cutter family. Its legacy of pushing the boundaries of diamond-based technologies, coupled with a dedication to comprehensive service offerings, positions Decatur Diamond as a dynamic force in the cutting tool industry. As the industry continues to evolve, Decatur Diamond remains at the forefront, ready to shape the future of precision machining with its cutting-edge solutions and unwavering commitment to excellence.
As a result of precision grinding of the cutting edge, it is free from notches when magnified approximately 200 times. The tool system can be used from an inside diameter of 0.3 mm (0.012").
The sharp insert geometry enables process reliability even with very small infeed and cutting feed rates. The specially developed coating is suitable for stainless steels, non-ferrous metals and other metallic materials.
The insert of the Supermini Type 105 system requires only one tool holder for well over 1,000 insert variants. This applies equally to left-hand and right-hand versions.
The carbide inserts are available in coated and uncoated versions in different grades for every application including hard machining up to 66 HRC.
The patented droplet shape of the cross-section has a vibration-damping effect and delivers excellent repeatability when changing the insert. Internal coolant supply to the insert increases tool life, enhances cutting performance and improves chip removal.
Horn offers the tools with elements for face clamping. This allows, for example, the insert to be changed easily without having to remove the holder from the machine.
History Horn Supermini
In 1989, HORN launched the technically superior Supermini system at EMO in Hannover, Germany. After considerable technical development, it was possible to successfully manufacture precision internal grooving tools for bores down to 5 mm (0.197") in diameter.
The Supermini system was born and over time became one of Horn's most successful products. In addition, the Supermini system was the first precision tool to benefit from Horn's own in-house coatings.
The Supermini is available as a set. The set consists of a round shank holder and three different clamping elements. The latter are suitable for the three different insert heights of the Supermini system, 03, 04 and 05.
You can select the desired diameter of the round shank holder when ordering. Horn offers it in the diameters 10 mm, 12 mm, 16 mm, 20 mm, 22 mm, 25 mm and 28 mm. Inch dimensions are available in 1/2", 5/8", 3/4" and 1" diameters. All sets are available from stock.
There are some distinct advantages of Techniks Spinner Magnetic Deburring Machines over Manual and Vibratory Deburring
While manual deburring and vibratory deburring machines have been traditional go-to methods, Techniks Spinner Magnetic Deburring Machines offer a range of advantages that significantly elevate the deburring process. In this article, we're going to explore the distinct benefits of Techniks Spinner Magnetic Deburring Machines when compared to both manual deburring and vibratory deburring alternatives.
Manual deburring requires skilled labor to precisely remove burrs and imperfections from each component. However, it is a time-consuming and labor-intensive process that may result in inconsistencies from one part to another. Vibratory deburring machines, on the other hand, provide some automation but may still struggle with intricate and delicate parts.
Techniks Spinner Magnetic Deburring Machines excel in precision and consistency. They use a magnetic field to hold and precisely rotate the components while stainless steel pin media remove burrs. This ensures uniform deburring across all parts, even for complex geometries or fragile components. The result is a higher level of quality control and reduced variability in finished products.
Increased Productivity
Manual deburring is a slow process, limiting production output and often leading to bottlenecks in manufacturing. Vibratory deburring machines can handle larger quantities of parts simultaneously but may still require multiple cycles for consistent results.
Techniks Spinner Magnetic Deburring Machines are designed for efficiency and productivity. They can process multiple parts simultaneously, and their automated operation significantly reduces cycle times. This increased throughput not only improves productivity but also helps meet tight production schedules and customer demands.
Manual deburring exposes workers to potential ergonomic and safety hazards, including repetitive strain injuries and exposure to sharp edges. Vibratory deburring machines require regular monitoring and maintenance to ensure safe operation.
Techniks Spinner Magnetic Deburring Machines prioritize operator safety. By automating the deburring process, they reduce the need for workers to handle sharp-edged components manually. This minimizes the risk of accidents and workplace injuries, creating a safer working environment.
Cost-Efficiency
Manual deburring is labor-intensive and can be costly, particularly when skilled operators are required for precision work. Vibratory deburring machines, while more efficient than manual methods, consume significant amounts of energy and may require expensive abrasive media replacements.
Techniks Spinner Magnetic Deburring Machines strike a balance between precision and cost-efficiency. Their automated operation reduces labor costs, and their magnetic field eliminates the need for abrasive media, as a result of the the long life of the stainless steel media, saving on consumables. Over time, this cost-saving advantage becomes evident in reduced operational expenses.
Environmental Impact
Vibratory deburring machines often generate noise and vibration, potentially affecting the working environment and requiring soundproofing measures. Additionally, the disposal of used abrasive media can have environmental implications.
Techniks Spinner Magnetic Deburring Machines operate quietly and without vibration, creating a more comfortable and environmentally friendly workspace. They also produce less waste, as there is no need for disposable abrasive media, contributing to sustainability goals.
As manufacturing industries continue to demand high-quality components with minimal defects, the adoption of Techniks Spinner Magnetic Deburring Machines represents a significant step toward achieving these goals efficiently and effectively.
The Cutting Process
To understand the essence of carbide cutting tools, it's essential to comprehend the cutting process itself. At the heart of this process is an intense, concentrated force applied at the cutting edge, effectively separating the metal's individual crystals. This separation results in the creation of a continuous flowing chip, which eventually moves up the cutting tool face until internal stresses cause it to fracture, breaking away as a segmented or discontinuous chip.
During this process, a substantial amount of heat is generated at the cutting edge. This heat is primarily due to the friction between the tool and the workpiece as the chip is formed and flows along the cutting tool's face. Remarkably, individual carbide grains are so incredibly hard that they do not deform or flow under these intense forces and high temperatures, ensuring the tool's longevity and efficiency.
CARBIDE PRODUCTION
- Increasing % Cobalt Binder: The cobalt binder is a major factor in determining carbide's hardness and toughness. Increasing the cobalt content enhances the toughness, enabling the carbide to withstand mechanical shock or impact loads, which are typical during the cutting process.
- Decreasing Carbide Grain Size: Carbide grain size is another critical parameter. Smaller carbide grains contribute to a more wear-resistant cutting edge. It's a balance, as smaller grains can lead to decreased toughness.
Carbide Technical Specs
- Carbide Powder Creation: Metal powders, usually tungsten, and carbon, are heated to extremely high temperatures, exceeding 2800ºF. This process results in the creation of tungsten carbide powder grains that are exceptionally hard and stable at elevated temperatures.
- Powder Sorting and Mixing: The carbide powders are sorted by grain size and then recombined in appropriate ratios to achieve specific physical properties. Cobalt metal powders are mixed thoroughly with the tungsten powders.
- High-Pressure Compaction: The tungsten-carbide-cobalt mixture is forced under high pressure (30,000 psi) into molds of the desired shape and size. This forms the initial carbide blanks.
- Pre-Sintering: Carbide blanks undergo a low-temperature pre-sintering process, developing sufficient physical strength for handling.
- High-Temperature Sintering: Finally, the carbide blanks are sintered at temperatures ranging from 2500ºF to 2900ºF. This high-temperature sintering causes a dramatic shrinkage, almost 40% volume reduction, resulting in an extremely dense and hard material.
REV S.R.L., located in Northern Italy, is the manufacturer of innovative broaching solutions for CNC lathes and machining centers. The tools are ideal for machining simple keyways or internal and external profiles, both teeth and splines. Common profiles including square and hexagon are easily achieved and custom profiles are available. REV broaching tools offer excellent performance with long insert life and high surface quality.
The REV motorized broaching tool is designed for use on live tool lathes. Single machine set-up eliminates the need for secondary operation or outsourcing. REV tools are ideal for high production runs, and offer easy installation and fast processing time. These tools are designed for maximum rigidity, offer long tool life and an excellent finish.
REV static broaching tools are for use on CNC lathes with or without a Y-axis. They offer a patented eccentric bushing which eliminates alignment errors for machines without a Y-axis. The tools have a sturdy two-piece construction and are ideal for smaller runs. They are designed for use in boring bar holders on lathes and for use in collet chucks or Weldon holders on machining centers. REV tools allow for a wide variety of standard and custom profiles and sizes.
REV broaching tools are a perfect complement to the Heimatec live tools that are sold by the extensive network of Platinum Tooling manufacturers’ representatives and distributors throughout North America.
Knurling is a machining process used to create a textured pattern on the surface of a workpiece, primarily for enhancing grip, aesthetic appeal, or as a means of indexing.
Two common methods employed in knurling are knurl cutting and knurl forming. While both processes achieve similar results, they differ significantly in terms of technique, applications, and outcomes.
In this article, we will delve into the distinctions between knurl cutting and knurl forming to help you better understand when and why each method is used.
Knurl Cutting
Knurl cutting is a subtractive manufacturing process. It involves removing material from a workpiece to create the desired knurled pattern. This is typically done using a knurling tool that has sharp, hardened edges. As the tool rotates against the workpiece, it cuts into the material, forming ridges and grooves.
Tooling
Knurl cutting tools have teeth or serrations that cut into the material. These teeth come in various patterns and sizes, allowing for customization of the knurling design. The tool's sharp edges bite into the workpiece, displacing material to create the knurled texture.
Applications
Knurl cutting is ideal for materials that are harder and less malleable, such as stainless steel and hardened alloys. It is commonly employed in high-production environments where speed and efficiency are crucial.
Advantages
- Precise control over knurling depth and pattern
- Suitable for a wide range of materials
- Easily customizable for specific applications
Disadvantages
- Generates more waste material
- May require higher machining forces
- Produces more noise and vibration
The Knurl Cutting Tool is engineered to reduce the pressure exerted onto the work piece and minimize stress to the spindle of the lathe during the operation. The Cutting Style Tool is the best for knurling any material, including hard and large size work pieces as well as, for thin wall tubing.
The performance of the Dorian Tool Knurl Cutting Tool is up to 20 times faster than a conventional Knurl Forming Tool.
Knurl Forming
Knurl forming, on the other hand, is a non-cutting or deformation process. It involves pressing or rolling a knurling tool against the workpiece's surface, displacing the material to create the knurled pattern. No material is removed during this process.
Tooling
Knurl forming tools have a smooth surface with the desired knurling pattern engraved onto them. These tools apply pressure to the workpiece, causing the material to deform and create the knurled texture. They are typically used in specialized knurling machines.
Applications
Knurl forming is often used when the material being worked on is soft or easily deformable. It is suitable for materials like plastics, brass, aluminum, and mild steel. Knurl cutting is also preferred when precise control over the knurling pattern and depth is required.
Advantages
- Minimal material waste as no material is removed
- Less force and energy required
- Suitable for hard and brittle materials
Disadvantages
- Limited control over knurling depth and pattern
- Not as customizable as knurl cutting
- Specialized machinery may be required
Knurl cutting offers greater control and customization but may generate more waste material.
Knurl forming, on the other hand, is faster and more efficient, making it suitable for high-production settings, especially with harder materials.
Understanding the differences between these two methods will help manufacturers select the most appropriate technique for their specific applications, ensuring the desired knurled texture is achieved efficiently and effectively.
Consisting of Dyno Grip vises, Dyno Lock base plates and Dyno Mount tombstones, the ethos behind the range stems from Mate targeting manufacturing efficiencies within its own workshop.
Extensive trials of the previous generation zero-point systems, available from established suppliers, under real life production operations highlighted a number of limitations that have been addressed by these new products from Mate.
With Mate’s extensive knowledge of the high quality tool steels and the fine tolerances used to produce its tools for sheet metalworking, it is only logical that the same materials and processes are used for the Dyno range of fixturing. It is why the company offers a ‘zero wear out forever’ policy across the range with a 100 percent unconditional customer satisfaction guarantee.
Mate Dyno Grip self-centering vises are engineered to shorten setup time and reduce process variability. Two zero-point four-stud engagement patterns are offered, 52 mm and 96 mm, that are compatible with other systems or can be mounted directly to the machine table via toe clamps or bolted through the body.
Available in 13 sizes the vises feature quick change jaws with an innovative ‘click-lock’ system for quick setup, and a 45° angle on the top jaws to pull the workpiece down into the vise body for maximum rigidity during heavy cuts. They can also be quickly reconfigured to grip outwards with the jaws holding internal walls of the component or billet.
Production flexibility is further supported by the vices ability to hold two parts at the same time. With a fixed center jaw and the quick removal of a locking pin the vise becomes dual-station. Even dissimilar sized parts can be securely held simultaneously with absolute confidence.
With 11 size and shape variants there is a Dyno Lock base to suit any machining application. These quick-change workholding bases are the foundation of the workholding system and the key to superior productivity.
The product mounts to the machine bed, tombstone, pyramid or riser, and offers best-in-class accuracy and repeatability with a superior holding force. Mate takes the term zero-point very seriously. DynoLock has what it takes to securely hold your vise, whether you change the same vise repeatedly or exchange it for a different one. DynoLock reduces your machine setup times and keeps your spindle cutting.
For increased volume production applications and higher part loading density, Dyno Mount three- and four-sided tombstones are available for use with Mate DynoLock 52 and 96 bases. Using a chambered design for weight reduction, Mate tombstones also include a hoist ring lift connection for easy loading and unloading.
Like the rest of the Dyno range, they feature Mate’s QuickSpecs 2D bar code tag for real-time access to full product specifications, CAD files and potential integration into your business systems. Direct-to-table mounting, and custom mounting bores are also available. They are also compatible with some competitor workholding bases when used with applicable bushings and hardware.
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