compiled & edited by Bernard Martin

The Weldon flat quickly gained popularity and became a standard feature in many milling tools. Machinists embraced it for its reliability and the tangible improvement it brought to the overall machining process. Its success was emblematic of how a seemingly simple yet ingenious design modification could elevate the efficiency and accuracy of machining operations.

However, with the continuous evolution of the machining industry, especially with the rise of CNC machining and the increasing demand for higher precision, the prevalence of the Weldon flat began to diminish. Two primary factors contribute to the decline in the use of Weldon flats: Tool Balance and Runout (TIR).

​Tool balancing, or the lack thereof, poses a significant challenge. Many high-end machine tool manufacturers stipulate the use of only "balanced tooling," underscoring the critical need for proper balancing of Weldon Flat Toolholders before utilization. The removal of material from the tool shank introduces inherent imbalance, leading to potential harmonic distortions in part finish, particularly in high-speed machining environments.

Additionally, TIR presents a challenge in today's high-tolerance machining landscape. The design of Weldon-style endmill holders inherently displaces the cutter off-center, inducing runout (TIR) that can significantly reduce tool life and compromise the surface finish of the machined part.

That said, it's important to note that Weldon flat holders can still prove advantageous, especially in scenarios involving rough machining and the removal of substantial material. This is particularly relevant in the Aerospace sector, where machining critical components like expensive wing spars carries the risk of tool pullout—an occurrence that can be financially and structurally detrimental. When dealing with challenging materials like Titanium, characterized by high torque forces during machining, Weldon Flat holders remain well-suited for applications that demand an aggressive depth of cut at relatively slow spindle speeds.

While the Weldon flat remains a valuable feature in many machining applications, its decreasing prevalence in certain advanced CNC machining requirements reflects the dynamic nature of the industry. New technologies and methodologies have emerged, emphasizing the need for even greater precision and stability within cutting tools to meet the demands of contemporary machining practices.

​The innovation of the Weldon flat marked a significant chapter in the history of machining, revolutionizing tool retention and setting new standards for reliability and precision. Its popularity soared in its heyday, but the ever-evolving requirements of modern CNC machining have reshaped the landscape, emphasizing the continuous quest for higher levels of accuracy and performance in the field of metal cutting.

written by ​Bernard Martin

Rocky Mountain Twist Drill's introduction of Blue nACo coating is a truly revolutionary surface treatment to enter the market in the drilling segment.

​Blue nACo was developed by PLATIT, an independent, family-owned company headquartered in Selzach, Switzerland.  PLATIT is a manufacturer of high-tech PVD and PECVD hard coating equipment for tools and machine components.

Blue nACo is an AlTiSi-based nanocomposite coating and performs best in the field of milling and drilling C-steels and outstanding performance in superalloys, hard material machining, and high heat applications. The use of nACo provides excellent adhesion and good performance even for more unusual applications such as milling with coated ceramic tools and CBN tools.

This treatment has been shown to improve drilling operations with its exceptional lubricity, unmatched hardness, and impressive heat resistance. An AITiSi-based nanocomposite coating,

The culmination of over 20 years field testing, Blue nACo coating has demonstrated an elevated the performance of Rocky Mountain Twist Drill's products. This coating is a testament to the commitment to pushing boundaries and delivering solutions that meet the evolving demands of the metalcutting sector.

What do you need in a drill coating particularly for superalloys, hard material machining, and high heat applications?  Typically the goal is a super thin coating layer that compliments the drill geometry and grind finish, a high hardness for wear resistance and a high level of lubricity so that the chips can slide up and out of the flutes.

Keep in mind also that there's a tremendous amount of heat generated in the cutting tool process so the coating needs to be able to not only withstand that heat but also be "slippery" e.g. have a low coefficient of friction, aka lubricity, to evacuate the chip quickly. Blue nACo coating has pushed the boundaries of that desired balance in each of those categories.

Lubricity, as measured by the coefficient of friction receives a significant boost with the Blue nACo coating. The incorporation of nanocomposite technology reduces adhesion between cutting edge of the and workpiece. This ensures reduced friction and enhanced wear resistance, resulting in smoother drilling operations. It translates to improved chip evacuation, reduced tool wear, and increased tool life – a trifecta that directly impacts productivity and cost-effectiveness.

As an indicator of the material's ability against deformation, hardness has been studied for more than a century. Adding a coatings provides an extra layer of protection to the drill, ensuring longevity and durability with this additional hard wearing layer.  

​The Nano-hardness of the Blue nACo coating is 39-41 GPa (which roughly converts to Micorhardness ~3977 ~ 4181Hv) which is in the higher hardness range when compared to many other common coatings used on drills. In  Rocky Mountain Twist Drill users can expect consistent performance even in the face of challenging materials, making the Blue (nACo) coating an invaluable asset for demanding drilling applications.

Heat resistance is a critical factor in drilling operations, where elevated temperatures can compromise tool integrity and precision. According to Platit, the maximum service temperature for the coating is 1200°C or about 2192°F. which is substantially higher that the most common coatings used on drills such at TiN, TiCN, TiAlN and AlTiN. 

The Blue nACo coating advanced thermal stability ensures that the drill maintains peak performance even in high-temperature environments, reducing the risk of premature tool failure and minimizing downtime.

Behind the scenes, Platit Coating Chambers has played a pivotal role in bringing the Blue (nACo) coating to fruition at Rocky Mountain Twist Drill. Operating around the clock, their state-of-the-art facilities have been dedicated to applying this surface treatment, to their very deep drilling product offering.

The Blue nACo coating represents a leap forward in drill surface treatment technology. Rocky Mountain Twist Drill's dedication to providing its customers with tools that embody precision, durability, and efficiency is exemplified in this cutting-edge coating. As the metalcutting industry continues to advance, the Blue nACo coating stands poised to make a lasting impact, setting a new bar for performance and reliability in drilling operations.

A groundbreaking collaboration in the medical industry is reshaping how implants are produced. Through the ZykloMed project, funded by the Federal Ministry of Education and Research (BMBF), industry leaders INDEX, Paul Horn GmbH, Beutter Präzisions-Komponenten GmbH, and the wbk Institute for Production Engineering at the Karlsruhe Institute of Technology (KIT) have joined forces to develop innovative machining processes for creating advanced medical implants.

At the heart of this collaboration are cutting-edge methods that enable the efficient production of implants with complex, bionic designs. Using techniques like eccentric turning, polygon turning, and turn whirl milling, the team has successfully overcome the economic challenges of manufacturing implants with intricate geometries. These methods promise to revolutionize the production of orthopaedic, trauma, and dental implants.

The New Standard for Medical Implants
Modern implants are designed to meet stringent standards for strength, biocompatibility, and patient comfort. Their shapes, optimized to mimic natural bone structures, allow for better integration with the body, less invasive procedures, and easier attachment. However, these new designs have traditionally come with a steep price tag—due to their non-circular, curved surfaces and functional elements that require several manufacturing steps on different machines.

The ZykloMed project partners sought to simplify this complex process, reducing costs and increasing efficiency while maintaining the precision and quality required for medical applications. Their focus was on developing synchronized manufacturing techniques that can handle these bionic, non-round shapes without the need for constant repositioning and multiple machines.

The novel processes developed—eccentric turning, polygon turning, and turn whirl milling—all rely on synchronized rotating axes, making it possible to create non-circular and curved shapes efficiently. Each method brings unique capabilities to the table:

From Lab to Real-World Application
After rigorous testing in both laboratory and near-production environments, the ZykloMed team demonstrated that these synchronized machining processes can economically produce complex, multifunctional implants. These advancements not only make the production of new, bionically designed implants more cost-effective but also hold potential for optimizing the production of existing implant designs.

Beyond the medical industry, the processes developed through the ZykloMed project could have applications in other sectors where complex geometries and high precision are required.

A Step Forward in Medical Manufacturing
The success of the ZykloMed project marks a significant step forward in medical manufacturing. By combining cutting-edge research with practical industry applications, the project partners have paved the way for more efficient, economical production of advanced implants that meet the needs of modern healthcare. Their efforts are set to improve patient outcomes and push the boundaries of what is possible in implant design and production.

The International Manufacturing Technology Show (IMTS) is just around the corner, and it's shaping up to be a can't-miss event for anyone in the manufacturing industry. F&L Technical Sales is excited to announce that several of our principals will be showcasing their cutting-edge products. Below is a sneak peek at what you can expect!

When it comes to precision and stability in boring operations, Dorian Tool stands out with their Solution Tool Anti-Vibration Boring Bars. These tools are engineered to reduce chatter and vibration, resulting in superior surface finishes and extended tool life. Don't miss the opportunity to see these high-performance tools in action at the Dorian Tool booth.

Horn USA will be introducing their new grade IG35 as well at IMTS. This latest innovation is designed to deliver exceptional performance in a wide range of materials, offering outstanding wear resistance and extended tool life. The new grade offers improved thermal properties so it really boosts productivity in stainless steel and heat resistant alloys. It allows improved edge adhesion on sharp edge geometries.

And don't forget to check out the new new Supermini type 105 sintered chip breaking geometry we talked about last month!

Mate Precision Technologies is set to unveil their advanced 52/96 workholding system, designed to provide unmatched precision and stability for your machining operations. These systems are tailored to improve setup times and ensure consistent, high-quality results, making them a must-see at IMTS.

by Bernard Martin

With the new Supermini type 105, Horn has succeeded in developing a universal boring tool with sintered chip breaking geometry.  The cutting edge geometry extends far into the corner radius of the insert. This ensures chip control even with small in-feed settings. The geometry can be used universally for different material groups and is suitable for internal, face, copy and back turning.

Innovation is key to maintaining a competitive edge. Horn has raised the bar with the introduction of a sintered chip breaking geometry for their Supermini tool system. This latest development, which became available for shipping on June 12, 2024, is the next milestone in the history of the Supermini, a product that has been a cornerstone of Horn’s portfolio since its inception in 1989.

A Legacy of Innovation
The Horn Supermini system, launched 35 years ago, has undergone continuous development, addressing a wide array of machining challenges globally. "This will revolutionize boring," thought Paul Horn when he first examined the prototype of what would become one of the company's most successful products. Since then, the Supermini has evolved through numerous stages, each improving its versatility and performance.

The Supermini tool system is designed for a variety of machining operations, including boring, profile turning, internal grooving, threading, chamfering, face grooving, drilling, and slot broaching. It is adaptable to a range of diameters from 0.2mm to 10mm, thanks to solid carbide inserts shaped in a unique teardrop form. This innovative design ensures large, precise contact surfaces in the tool holder, enhancing the system's overall rigidity and minimizing deflection and vibration during use.

Addressing the Chipping Challenge
One of the most persistent issues in internal machining is managing long chips, which can lead to tool breakage and operational inefficiencies. Traditionally, chip breaking geometries were either lasered or ground, processes that increased production costs. The new sintered chip breaking geometry in the Supermini type 105 changes the game, offering high process reliability with superior chip control.

Markus Horn, Managing Director of Paul Horn GmbH, stated, "With a lot of hard work, we have managed to solve economically the problems of long chips when internally machining small bore diameters." The new geometry ensures effective chip control even with small in-feed settings and can be used across various material groups and machining operations, including internal, face, copy, and back turning.

Enhanced Features for Greater Performance
In addition to the advanced chip breaking geometry, Horn has optimized the carbide blanks to provide greater rigidity and a more stable cutting edge. The coolant supply system has also been improved to enhance performance. The new inserts are compatible with a wide range of type 105 tool holders, available in lengths of 15.0mm, 20.0mm, and 25.0mm, and in carbide grades TH35 and IG35. With a corner radius of 0.2mm, these tools are suitable for bores starting from a diameter of 6 mm.

The extensive Supermini portfolio includes approximately 2,500 standard variants, supplemented by countless custom solutions to meet specific user needs. Horn also offers a variety of tool holder options, including round shank, square shank, interface, and adjustable holders, with multiple clamping solutions to suit different applications and space constraints.

A Commitment to Excellence
The latest advancement in the Supermini series underscores Horn’s commitment to innovation and excellence in the field of machining technology. By addressing critical issues like chip management with cost-effective solutions, Horn continues to provide tools that enhance productivity and reliability for machinists around the world.

As the machining industry evolves, the introduction of the sintered chip breaking geometry in the Supermini type 105 reaffirms Horn's position as a pioneer in tool technology, dedicated to solving the challenges faced by its customers and setting new standards in the industry.

For more information or to test some of these new inserts contact the F&L Technical Sales team!

by Bernard Martin

Unlock the full potential of your composite machining with Decatur Diamond's high-performance cutting tools! From carbon fiber and glass fiber reinforced polymers to metal matrix composites, their extensive range includes versatile routers, honeycomb routers, compression routers, diamond cut routers, and drilling products.

Engineered for precision, durability, and efficiency, their tools minimize delamination and fiber pullout while ensuring clean, precise cuts and extended tool life. Discover why Decatur Diamond is the industry leader in advanced tooling solutions for composite materials.

Diamond Coated End Mills
Decatur Diamond 's Diamond Coated End Mills are designed for high-performance machining of non-ferrous materials. With potentially the best diamond adhesion in the coated tool industry, these tools offer coating thickness and crystal size options to meet various application requirements. Available in square, corner rounding, ball, and profiling geometries, these end mills ensure superior performance and tool life. Sizes start from 0.015” (1mm) and can be customized for special applications.

• ​All standard grade D25 endmills are produced to +0.000/-0.001 on diameter, -0.0001/-0.0003 on the shank, 0.001 runout,+0.060/-0.000 on flute length and +/-0.060 on OAL.
• All standard grade D27 endmills are produced to +0.001/-0.001 on diameter, -0.0000/-0.0003 on the shank, 0.002 runout, +0.060/-0.000 on flute length and +/-0.060 on OAL.
• All Ultra Premium grade D25 endmills are produced to +0.000/-0.0005 on diameter, -0.0001/-0.0003 on the shank, 0.001 runout, +0.060/-0.000 on flute length and +/-0.060 on OAL.
  

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Decatur Diamond’s commitment to innovation and quality makes our tools the preferred choice for machining composite materials. With tailored solutions and a focus on reducing operational costs, our high-performance tools help you achieve superior results in your machining processes.

Here at F&L Technical Sales, we're excited to introduce an advanced lineup of Tecnicrafts High Precision Collets and Guide Bushings, specifically engineered for Swiss Type CNC Automatic Lathes. This comprehensive range offers unparalleled precision, versatility, and durability to meet the demanding needs of modern manufacturing environments. Tecnicrafts is one of the premiere brands brought to us by Platinum Tooling.

Carbide Lined Guide Bushings: Precision Meets Versatility
Tecnicrafts Carbide Lined Guide Bushings are designed for exceptional performance, available in round, hex, square, or custom profiles to suit diverse machining needs. With Max Land Extended Carbide options available up to 75 mm and special features like Ultra Precision, Extended Nose, and U-line options, these bushings set new standards in machining accuracy and flexibility.

Steel Collets: Unmatched Reliability for Main & Sub Spindles
Tecnicrafts' Steel Collets are crafted to enhance your lathe's efficiency, compatible with both main and sub spindles. Choose from round, hex, square, or custom profiles, with smooth or grooved bores to match your project requirements. Our Steel Collets also come with special options, including Ultra Precision and Extended Nose, in the V-line series, offering superior clamping and precision.

Bar Feeder Collets: Uniform Tension for Optimal Feeding
Designed for seamless integration with bar feeders, Tecnicrafts Bar Feeder Collets are available with external & internal threads or in a pin type style, ensuring uniform tension for consistent feeding and machining accuracy.

ER Collet Chucks: Precision and Durability
​Tecnicrafts ER Collet Chucks, available in both single and double-ended styles, these chucks are distinguished by their exceptional runout tolerance, maintained within a maximum of .005 mm. They conform rigorously to h6 shaft standards, ensuring that each component delivers superior accuracy and extends tool life. Offered in a wide variety of shank types. Customers can choose from round shanks, round shanks with flats, in both single and double ends, available in an extensive range of both metric and inch sizes. Shanks can also be equipped with a back-up screw, providing additional customization options to meet specific operational requirements.

Guide Bush with Extended Carbide Insert: For Long, Accurate Components
The "Max Land" Guide Bushing with an Extended Carbide Insert offers a guiding surface length of up to 70mm and bore diameters ranging from 4 mm to 42 mm. This solution is ideal for components requiring extensive drawing back, such as long thread chasing, ensuring high concentricity and preventing slippage with its extended carbide insert.

Guide Bush - Drawn (Adjustable) Type: Custom Precision for Swiss Type CNC Lathes
Tailored for Swiss type CNC automatic lathes, ​Tecnicrafts Drawn (Adjustable) Type Guide Bushes ensure an excellent bore finish with a surface finish Ra value of 0.4 micron. With standard bore chamfer and customizable solutions, these guide bushes are engineered for optimal flexibility and precision.

Guide Bush with Brass Guide: Enhanced Component Guidance 
Upon request, all ​Tecnicrafts Guide Bushes can be equipped with a Brass Guide, providing superior guidance and support for the job, ensuring smoother operations and enhanced product quality.

Tecnicrafts, is committed to pushing the boundaries of precision machining. Their collets are not just tools; they are the building blocks for achieving peak performance and excellence in your machining processes. Dive into the future of manufacturing with Tecnicrafts' precision solutions—because when it comes to precision, we settle for nothing but the best.

Ready for Precision? Explore the transformative impact of Tecnicrafts High Precision Collets and Guide Bushings on your Swiss Type CNC Automatic Lathes.

​Contact us at F&L Technical Sales Inc. to discover more about how our products can elevate your machining projects to new heights of precision and efficiency.

Russell, MA – F&L Technical Sales, a leading provider of industrial solutions, is excited to announce its recent appointment as the exclusive agent for Hirt-Line, the pioneering manufacturer of "The Original Coolant Hose System" for CNC machine tools. F&L Technical Sales becomes the first agent in North America  to begin development of the supply chain of this product line.

This strategic partnership marks a significant step forward in F&L Technical Sales' commitment to delivering top-tier industrial products and solutions in New England.

Hirt-Line, known for its high-quality, stainless steel, high-pressure coolant lines that withstand machine vibration and pressures up to 1500 psi, has chosen F&L Technical Sales to represent its interests due to their outstanding reputation and deep market penetration in the metalcutting sector. This collaboration is set to bring Hirt-Line’s innovative and highly customizable coolant hose systems closer to a broader audience while enhancing CNC machine tool performance.

"The partnership with Hirt-Line aligns perfectly with our mission to offer only the best in class solutions to our clients," said Howie Freedman, of F&L Technical Sales. "Hirt-Line’s dedication to innovation and quality in high pressure coolant system delvierey will complement our range of cutting tool products and services, providing our customer with high pressure coolant delivery for optimizing their machining processes."

Hirt-Line’s coolant hose systems are renowned for their flexibility, durability, and precision. They are designed to be easily adjustable and are capable of handling a variety of machining applications including milling, turning, and grinding. The systems are available in multiple configurations, ensuring that every CNC machinery's cooling needs can be met with precision.

Hirt-Line offers four distinct coolant hose systems, each designed to meet specific machining needs. The Type 0 system (1/8") is ideal for precise adjustments and includes a range of nozzles suitable for detailed work. Type 1 (1/4") supports a broader range of applications with its extensive nozzle options and adapters, handling flow rates up to 170 liters per minute. Type 2 (1/2") enhances machine processes by optimizing flow and stability with a variety of nozzles for different machining tasks. Lastly, Type 3 (3/4") is the most robust, supporting the highest flow rates and offering nozzles and adapters that ensure maximum stability and efficiency in demanding environments. Each system is tailored to deliver exceptional performance and adaptability in coolant management across various CNC machining operations. Most importantly, all 4 system sizes that are mutually compatible!

"We are excited to partner with F&L Technical Sales and confident that their expertise and network will increase our presence in the New England market," stated Tim Young, at Altitude SI LLC, the exclusive North American distributor of Hirt-Line. "Through this partnership, we aim to enhance the operational capabilities of CNC machines, ultimately contributing to greater productivity. longer tool life, redcued cycle time and better surface finishes for our customers."

The partnership is effective immediately, with F&L Technical Sales set to handle inquiries, sales, and support for the entire range of Hirt-Line products.

In a significant development that is set to redefine machining standards, Horn USA has announced the launch of its new carbide grades, IG3 and IG6. These introductions signal a major breakthrough in extending tool life in the machining of materials such as stainless steels, titanium alloys, and superalloys, offering unmatched performance and longevity thanks to their unique coating thicknesses and substrate materials.

The IG3 grade is distinguished by its 3-micron coating thickness, a feature denoted by the "3" in its name. Meanwhile, the IG35 insert, which falls under the IG3 grade, designates carbide substrate 5, a MG12 10% cobalt micrograin that Horn designed to be an optimal balance of hardness and toughness for enhanced durability. For more demanding applications, the IG6 grade steps up with a thicker, 6-micron coating, ensuring even greater efficiency and performance longevity.

A pivotal aspect of these new grades is the application of High Power Impulse Magnetron Sputtering (HIPIMS) coating technology. This advanced coating method ensures that the AlTiSiN coating adheres exceptionally well to the tool surface without necessitating hones or edge preparation. The coating adhesion remains consistent even on upsharp inserts.

This breakthrough not only extends tool life significantly but also contributes to a tougher tool capable of withstanding temperatures up to 1100 degrees Celsius and maintaining a Vickers hardness of 1820 (HV10). The AlTiSiN coating, applied using HIPIMS technology, facilitates a lower coefficient of friction and ensures that the heat generated during machining is directed to the chip instead of being absorbed by the insert substrate. This innovative approach allows for higher machining temperatures without compromising the tool's performance.

The enhancements brought by the IG35 variant are particularly noteworthy. Turning tools coated with IG35 have shown a remarkable increase in tool life compared to those using the previous TH3 grade, as evidenced by extensive testing. Although the IG3 grade matches the performance of the TH3 in milling applications in terms of tool life, the introduction of the IG6 grade with its thicker coating has significantly improved tool life in milling operations, without sacrificing the quality of the finish.

These improvements have been achieved while running the surface feet per minute (SFM) of the older TH3 grade, highlighting the substantial advancements in tool life and efficiency.  In some milling applications it was found to increase tool life beyond twice that of TH3, making it a good choice as a drop-in replacement in established processes.  Most engineers seems to feel that higher SFM rates should be able to be attained with the IG6 while still getting great tool life and finish.

The applications for the IG3 and IG6 grades are extensive, covering a wide array of machining tasks from grooving, both internal and external, to more specialized operations such as chamfering, face grooving, and thread machining. This versatility ensures that Horn USA's new carbide grades can meet the diverse needs of the machining industry, setting new benchmarks in performance, efficiency, and tool longevity.

Horn USA's commitment to pushing the boundaries of innovation is evident in the launch of the IG3 and IG6 grades. These new offerings not only cater to the evolving demands of the machining sector but also underscore Horn USA's dedication to enhancing manufacturing efficiency and tool performance.

Operating from Nashville, Tennessee, Horn USA, a subsidiary of the globally renowned Horn Group, continues to lead the way in delivering high-performance cutting tools and solutions. With a steadfast focus on innovation, quality, and customer service, Horn USA is poised to drive the machining industry forward, helping customers achieve unparalleled manufacturing success.

For more details on the IG3 and IG6 grades and other products from Horn USA, interested parties are encouraged contact F&L Technical Sales Inc. today.

The , stainless steel pin media, can be added to a single or multiple tubs along with liquid solution, cutting fluid or even water. The parts that require deburring are added to the container and the desired cycle time and other parameters are dialed in to the controller.  

When it's time to separate the demurred parts from the media, simply pour everything through a strainer that sits in a second container.  Place the strainer and the container back in the tub of the sPINner unit, momentarily turn it on and all of the magnetic pins are sucked through the colander/strainer.  And you're ready for your next batch of deburring parts to be added.
​
Here are a few usage tips to operate the Magnetic Deburring Machine:

• When working with hard materials that require more power, choose media with a diameter of 0.5mm or larger.
• For softer materials, use media with a diameter of 0.5mm or smaller.
• When dealing with parts that have small holes and crevices, opt for 3mm length media.
• Always make sure that the diameter of the media is smaller than the holes present in your parts.

By following the recommended operation procedure and usage tips, you can effortlessly achieve optimal results, ensuring your parts undergo a thorough and efficient deburring process.