compiled and edited by Bernard Martin
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 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.
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.
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.
Cutting Type Knurling tools create a knurling pattern by material removal. The Cutting Knurling Process is performed when the knurling tool holds the knurling wheel with a lead angle that creates a sharp cutting edge.
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, 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.
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.
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.
In summary, the choice between knurl cutting and knurl forming depends on various factors, including the material being worked on, the desired knurling pattern, and the level of precision 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.
editors note: This article covers some of the questions that have been asked as a result of of previous article we posted: KNURL CUTTING VS KNURL FORMING
One of the latest players to enter the zero-point fixturing market, Mate Precision Technologies aimed at bringing significant advantages over the competition when it launched its next generation Dyno range.
The Mate 52/96, zero point workholding system, is compatible with similar systems, including 52mm and 96mm four post pull stud configurations from Lang, Jergens, 5th Axis, Gerardi and others. The vises also accept a single pull stud configuration for compatibility with Schunk, Big Kaiser and others. By using the appropriate adapter, Mate 52/96 zero point zero point vises are easily modified to work with systems from SMW, Erowa, System 3R and others.
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.
The workholding stabilizer puck simplifies how parts are loaded, reducing scrap, enabling faster feed rates and increasing spindle uptime.
Blue Photon has designed a system using workholding grippers and insert components for use with Big Daishowa and other stabilizer systems. The system holds the workpiece without drilling and tapping into the part or with the need to clamp the part.
The unit is easily adjustable when positioning to grip the part wherever needed to stabilize the workpiece. The unit enables the transfer of loads to the machine table and base. The stabilizer puck simplifies how parts are loaded, reducing scrap, enabling faster feed rates and increasing spindle uptime.
The adhesive workholding process involves applying BlueGrip workholding adhesive to the grippers and curing through the grippers from the backside of the puck base with ultraviolet light for 60 sec. By using grippers on top of the workpiece, users can eliminate drilling and tapping into the part.
Part removal is quick and easy with a one-quarter turn twist of the gripper. Residual adhesive is simply removed by using a handheld steamer or a hot water soak and a light peeling action. Any part that is at risk of distortion from traditional clamping or poses complications in fixture design are a potential candidate for the technology.
Learn More at Workholding Fixture SystemsGrip Pallets
Paul Horn GmbH is expanding the range of carbide grades for the DAH milling system to enable its use for machining a wider range of materials. The new grades SC6A and IG6B complement the tool system for high feed milling. The expansion gives customers the opportunity to choose grades best adapted to their machining applications.
The SC6A grade is suitable for machining the ISO M material group, as well as ISO S materials as a secondary application. Horn has developed the IG6B grade for machining the ISO P group, while it is also suitable as a multi-purpose grade for other material groups.
With the DAH82 and DAH84 systems, Horn introduces a new generation of tools for high feed milling. The eight usable cutting edges of the precision-sintered insert offer a competitive price per cutting edge and hence economical and efficient machining. The positive cutting edge geometry ensures a soft and quiet cut as well as good chip flow despite the negative mounting position.
Horn offers the inserts in the substrates SA4B, SC6A and IG6B, which are suitable for universal use machining various materials. The large radius of the main cutting edge of the insert produces a soft cut, ensures an even distribution of cutting forces and thus ensures long tool life.
The maximum cutting depth is ap = 1.0 mm (DAH82) and ap = 1.5 mm (DAH84).
The DAH82 variant is available as an end mill and as a screw-in milling cutter in the following diameters (z denotes the number of inserts):
For diameters in excess of 50 mm, the larger DAH84 system is used. The variants are available only as arbour milling cutters in the following diameters:
All tool bodies receive a special surface treatment of high strength and hardness, imparting long-term protection against abrasive wear from chips. "z" denotes the number of inserts.
Platinum Tooling, the importer and master distributor of live tools, angle heads, marking tools, Swiss tools and multi-spindle tools manufactured by various global suppliers, is now the North American importer of the QUICK knurling and marking tools from Hommel & Keller.
The announcement was made by Platinum Tooling president, Preben Hansen, at headquarters in Prospect Heights, Illinois.
A longtime global leader in high-end knurling and marking tools, Hommel & Keller manufactures the QUICK line with a combination of function and innovation. Quality, precision, and stability are the key principals used to make QUICK tools successful. Furthermore, the company prides itself on a rich history of providing customized solutions for its customers.
The QUICK product spectrum offers innovative solutions for diverse knurling technology applications. For both form knurling and cut knurling, QUICK fulfills the most stringent quality standards and masters difficult tasks. Knurling tools are available for use on a wide range of workpiece diameters, including small tools for Swiss type lathes from Ø1.5mm.
QUICK marking tools make it possible to mark workpieces in seconds on a variety of surfaces and part geometries. Through single marking segments, the marking text can be individually customized. Tools are available in two diameters for interchangeable lettering, as well as custom logos.
These tools are used whenever absolute precision and first-rate surface quality are needed. Examples include medical and dental instruments, watches, fishing gear, windshield wiper shafts, barbells, screwdriver bits, fittings, connectors plus welding and cutting equipment.
To download the full catalog just click below.
Platinum Tooling, the importer of live tools, angle heads, marking tools, Swiss tools, and multiple spindle tools manufactured by various global suppliers, has been importing and stocking Henninger Speed Increasers in North America since 2019.
Henninger, located in southwest Germany is a manufacturer of specialized equipment and precision machine tool accessories. Spindle Speeders, mechanical, air, and electric motor driven, Custom Angle Heads and Live Centers are amongst their specialties.
These systems are particularly useful for small-diameter tools that require more rpms than the machine tool spindle offers. Speeders enable using small-diameter tools that require more rpms than the machine spindle can offer. An additional benefit is said to be less wear on the machine spindle because it is not required to run at maximum rpm.
These speed increasers help maximize productivity by achieving a higher spindle rpm required for certain applications in today’s marketplace.
Mechanical speeders are available with up to a 1:8 gear ratio and a maximum speed of 50,000 rpm. Air speeders can run continuously at up to 80,000 rpm and high frequency motor spindles can maintain up to 80,000 rpm with high torque, and have variable speed options.
Many of the speeders have automatic tool change capabilities and are modular in design to offer the customer greater flexibility.
Henninger also manufactures custom angle heads, live centers, face drivers, and live chucks.
Be sure to give us a call if you want to know more!
Well known throughout the United States and Canada, the Better Edge team has been providing cutting tool reconditioning services for over 25 years to metalworking end users in the Automotive & Transportation, Aerospace & Defense, Heavy Equipment, Tool Manufacturing, Medical and Energy Industries.
With state-of-the-art CNC 5-Axis grinders, sophisticated inspection equipment and in-house coating capabilities, they service a wide range of drills in a variety of tool styles, including multi-step and chipbreaker type tools. They are also experts in applying close tolerance edge preps and corner geometries on standards and blue print special drilling tools.
Better Edge will restore drill points to original specifications all top brands of solid carbide high performance drills, including Kennametal®, Widia®, Garr®, Mitsubishi®, Sumitomo®, Sandvik®, OSG®, Titex® and Hanita®.
No matter the degree of wear, Better Edge will restore like-new performance - GUARANTEED.
Get in contact with us and we'll get you started!
Horn USA has introduced its proven Supermini tool holder system with face clamping as a set, thereby responding to customer requests for different tooling system heights.
As a result of the design of the Supermini, clamping is not carried out via the lateral surface of the cutting insert but via a clamping wedge on the face. This results in a greater holding force on the insert and thus high rigidity of the entire system.
written and edited by Bernard Martin
Increase your factory productivity with the all new, next generation 52/96 zero point workholding system from Mate Precision Technologies: Mate DynoGripTM Vises, Mate DynoLockTM Bases and Mate DynoMountTM Mounts and Accessories.
Mate Precision Technologies may be a new name to some folks in the tooling and workholding industry, but Mate has decades of machining experience producing precision, high quality steel products for customers around the world.
Mate created a new standard in Rotary Toolholders decades ago when they introduced the Command Toolholder brand that set a new bar by holding an AT3 taper tolerance. Mate then moved into Punch Press Tooling, Press Brake and Laser Tooling and has become the world leader in each of those markets. Using this knowledge, Mate set out about 7 years ago to design and develop the ultimate workholding system.
The Mate 52/96 zero point workholding system maximizes holding power in a compact, quick change modular design that reduces setup time and process variability. It is ideal for 3-, 4- and 5-axis machining centers. Going beyond machining, it can be used in a variety of applications such as inspection, CMM, cleaning, washing, assembly and additive manufacturing.
Their zero point 52/96 workholding system is compatible with similar systems, including 52mm and 96mm four post pull stud configurations from Lang, Jergens, 5th Axis, Gerardi and others. The vises also accept a single pull stud configuration for compatibility with Schunk, Big Daishowa and others. By using the appropriate adapter, Mate 52/96 zero point vises are easily modified to work with systems from SMW, Erowa, System 3R and others. It is perhaps the most well thought out and versatile system on the market today.
With an eye to factory automation, the Mate 52/96 zero point workholding system includes QuickSpecsTM, a unique QR code based product identification system that provides real-time access to product information and potential integration into your business systems. The system also supports common robotic interfaces and palletizing systems.
Mate has truly taken the best-of-breed approach in the development of their DynoGrip 52/96 vises by capturing all of the state-of-the-art features offered by competitors, improved on them, and then bundled them in the most feature rich, robust system on the market today. And it's all done by machinists for machinists.
Mate's DynGRip 52/96 Vise FeatureS Overview
In the video below, Mate Latin America Regional Sales Manager Benjamin Harrison discusses the Mate 52/96 Workholding System. Ben provides a detailed look at the key product features that show how Mate Workholding is designed to be the industry's most accurate and repeatable zero point workholding systems on the market. Filmed by MTD CNC at IMTS 2022 in Chicago.
Did you miss IMTS 2022? Check out the video below recapping the Blue Photon adhesive workholding solutions that was on display.
Blue Photon’s adhesive workholding solves problems associated with current workholding devices. The technology allows the user to hold parts and most materials without clamping. It also offers fixture design and engineering for milling, turning, grinding, electrical discharge machining (ECM), electro-chemical machining (EDM), 3D printing, laser, inspection, and assembly applications, including aerospace, additive, robotics, and medical machining.
Blue Photon Grip Pallets are designed to simplify how parts are loaded, reduce scrap and increase spindle uptime.
Available in 150, 225 and 300 mm square pallets, the Grip Pallets are designed for quick change and adhesive workholding of complex and hard-to-hold parts for EDM, grinding, inspection, laser and milling operations.
The pallets can hold parts securely, providing increased machining access on five to six surfaces while using standardized fixturing systems already in place.
Blue Photon’s grippers are inserted into new external inserts, designed specifically for the Grip Pallets. The external inserts are available for use with small, medium and large grippers. The new inserts allow for simple installation of the grippers at the required height for maximum holding power.
The 150-mm square pallet is available in aluminum and steel with a 52-mm pattern for a quick change receiver that will hold up to nine grippers. The 225-mm square pallet is available in aluminum and steel with a 96-mm pattern for a quick change receiver that will hold up to 21 grippers. The 300-mm square pallet is available in aluminum with a 96-mm pattern for a quick change receiver that will hold up to 33 grippers.
Each Grip Pallet includes two handles with multiple color choices and four spacers, with a 25.4-mm standoff that allows for the recommended nominal of 1-mm joint thickness between gripper and part.
Optional clamp studs are available for both 52 mm and 96 mm patterns for 5th axis, Jergens, Lang and Mate systems. Part can be removed with a ¼ turn twist of the gripper or hot-water soak. Residual adhesive is removed by using a handheld steamer or a hot-water soak and a light peeling action.
Check out these details and more from the IMTS video below.
If you missed seeing Blue Photon at IMTS 2022, you can always schedule a customer meeting with with one of our team.
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