As machine shops seek precision, tool life, and versatility in a wide variety of materials, the SS-5plus and SS-7 emerge as compelling choices to be the leader.
written and edited by Bernard Martin
Data Flute, the renowned end mill manufacturer who pioneered the adoption of the 3 and 5 flute end mills for stainless steel and exotic alloys nearly 30 years ago, has recently introduced two new groundbreaking end mills— the SS-5plus and SS-7. These cutting-edge tools are designed to set the standard for versatility and performance in (P)steel, (H)hardened steels, (M)stainless steels, (S)super alloys and even (K)cast iron.
The SS-5plus End Mill
For many years the SSI-5 has been the mainstay of Datflute's variably indexed, ferrous alloy rougher/finisher. It's truly the all-terrain vehicle of their ferrous alloy series.
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 SS-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 SS-5plus.
With five flutes featuring an unequal index and a variable helix, this end mill is designed to optimize chip evacuation and reduce cutting forces, ensuring efficiency in a variety of machining scenarios. The SS-5plus is a non-center cutting tool available in both RH-C and RH-H configurations, with a continuous cutting edge for seamless performance.
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
Data Flute unveils the SS-7 end mill, a cutting-edge solution designed for high-efficiency machining in ferrous alloys. This finisher showcases a new carbide substrate, ensuring superior durability and outstanding tool life, even in demanding applications.
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
A Leap FOrward
Data Flute's SS-5plus and SS-7 end mills signify a significant leap forward in cutting tool technology. With their meticulous design, superior materials, and advanced coating technologies, these end mills are poised to meet the diverse needs of modern machining processes. As machinists seek precision, tool life, and versatility in materials, the SS-5plus and SS-7 emerge as compelling choices, ready to cut their place in the new era of cutting tools.
BY Evan Doran | Associate Editor, Modern Machine Shop
When a casting proved too malleable for traditional gripping, Thomas/Euclid Industries adopted — and succeeded with — Blue Photon adhesive workholding.
As metals go, aluminum is soft and quick to bend — factors which make it easy to work with for most machining applications but make workholding to tolerances of 0.0005 inch unfeasible with traditional grippers. The force required to perform workholding could send the part out of tolerance, requiring rework or scrap. For Thomas/Euclid Industries, this difficulty became the push it needed to experiment with alternative forms of workholding, utilizing Blue Photon’s adhesive grippers to perform contactless gripping on an EV strut housing made from an aluminum casting.
Maximizing Lights-on Profits
Thomas/Euclid is primarily an aerospace manufacturer — EV automotive parts are not the norm for the company. In this case, the job came about not long after the shop installed a MatsuuraMX 330 five-axis machine.
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.
The combination of a quick-change base and adhesive workholding enabled the shop to manually change over setups and fixture parts in about seven to 10 minutes while achieving a repeatability that other workholding methods could not match.
Getting the Green Light on Blue Photon
Adhesive workholding offered a path forward, but not one Thomas/Euclid had used before. While the company had looked at Blue Photon’s adhesive grippers for several applications, the shop had always decided against using them due to the technology’s startup costs. With the EV strut job requiring a contactless workholding setup, however, Thomas/Euclid’s programmers and engineers were quick to point out that adhesive workholding was the most viable method for handling the job.
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
After applying dime-sized dollops of the BlueGrip adhesive to the grippers, Thomas/Euclid’s machinists set the workpiece on the fixture and slid an ultraviolet light up from underneath. This light is connected to a magnetic rod, which snaps into place at the back of the gripper. After about a minute, the adhesive locks the part into place.
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
Due to the short run of the part, the shop was not able to automate this last step and therefore manually fixtured parts and changed over setups. Still, the combination of a quick-change base and adhesive workholding enabled the shop to perform these changeovers in about seven to 10 minutes while achieving a repeatability that other workholding methods could not match.
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.”
Heritage Cutter is the parent company to the iconic metalcutting industry names Brubaker, Data Flute, Decatur Diamond and Weldon Tool each with their own specialization in cutting tools
Written & edited by Bernard Martin
Heritage Cutter is the parent company to the iconic metalcutting industry names Brubaker, Data Flute, Decatur Diamond and Weldon Tool. Each of these companies names reflect their longstanding reliability, quality and commitment to industry has made them a trusted source to distributors and manufacturers for generations.
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
Data Flute, a distinguished brand under the Heritage Cutter umbrella, has been a stalwart leader since its inception in 1976. Known for its unwavering commitment to excellence, Data Flute has carved a niche as a premier designer and manufacturer of both standard and special high-performance solid carbide cutting tools.
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.
Data Flute's product portfolio is a testament to its expertise, offering a comprehensive range of carbide round tools meticulously crafted to cater to diverse machining needs. From end mills tailored for aluminum and non-ferrous alloys to those designed for steel and ferrous alloys, Data Flute's offerings span roughing, semi-finishing, and finishing applications.The brand goes even further with its CVD Diamond Coated Tools, encompassing routers, end mills, and drills, showcasing its commitment to cutting-edge technologies. Additionally, Data Flute provides specialty tools and miniature end mills, catering to intricate and specialized machining requirements.
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
For over 140 years, Brubaker Tool, a distinguished member of the Heritage Cutter family, has been a cornerstone in the industry, proudly serving with high-performance, special, and standard taps & threading tools. Established in 1881 in Millersburg, PA, Brubaker Tool began its journey by supplying taps to the burgeoning railroad industry, laying the foundation for a legacy that has endured for over a century.
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.
Brubaker Tool's extensive product offerings include an array of high-performance taps, showcasing versatility and precision. From spiral flute, spiral point, straight flute, forming, to carbide taps, Brubaker Tool caters to the diverse needs of the industry. The brand also specializes in pipe taps, covering NPT, NPS, interrupted thread, and short projection variations. General-purpose taps, including spiral flute, spiral point, straight flute, forming, and STI, further demonstrate Brubaker's dedication to meeting the threading requirements of various applications.
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
In the specialized tapestry of Heritage Cutter's family of companies, Weldon Tool stands as a beacon of craftsmanship, quality, and a commitment to customer service that has endured since its founding in 1918. Rooted in a legacy that spans over a century, Weldon Tool has evolved into a trusted source for quality high-speed steel (HSS), cobalt, and carbide round tools, with a distinct emphasis on engineered specials.
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.
Weldon Tool's product offerings reflect a comprehensive understanding of the diverse needs of the industry. The range includes HSS, cobalt, and CPM end mills for both roughing and finishing applications, underscoring the brand's commitment to versatility. Carbide end mills designed for ferrous and non-ferrous materials showcase Weldon's expertise in adapting to evolving machining requirements.
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
Nestled within the Heritage Cutter family of companies, Decatur Diamond is the home of innovation and expertise in diamond-based cutting tools. The brand's lineage is intricately tied to some of the earliest adoptions of diamond-based technologies in the cutting tool industry, showcasing a history marked by success and innovation.
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.
As the landscape of cutting tools evolved, so did Decatur Diamond's portfolio. The addition of fixed-pocket brazed tools and complex monobloc solutions further expanded the brand's capabilities, offering a comprehensive suite of options to meet the diverse needs of precision machining.
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.
Heritage Cutter's strategic approach to housing these specialized brands showcases its unwavering dedication to providing cutting-edge solutions to an array of industries. With a legacy spanning over a century, Heritage Cutter continues to lead the way in the ever-evolving landscape of cutting tool technologies.
At EMO 2023 in Hannover Germany, Horn presented an innovative extension for the Supermini system in the field of ultra-fine machining.
Horn has added a variant with a precision-ground rake face to the Supermini system especially for ultra-fine machining of bores.
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.
compiled and edited by Bernard Martin
There are some distinct advantages of Techniks Spinner Magnetic Deburring Machines over Manual and Vibratory Deburring
Deburring is a critical step in manufacturing and machining processes, as it ensures that metal components are free from sharp edges, burrs, and imperfections that could compromise product quality and safety.
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.
Precision and Consistency
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.
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.
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.
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.
Techniks Spinner Magnetic Deburring Machines have revolutionized the deburring process by offering precision, consistency, increased productivity, operator safety, cost-efficiency, and a reduced environmental impact. When compared to manual deburring and vibratory deburring methods, they outshine their counterparts in terms of overall performance and long-term cost savings.
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.
Carbide cutting tools have long been at the forefront of machining technology, revolutionizing various industries through their remarkable hardness, heat resistance, and longevity. In this article, we delve into the technical aspects of carbide, exploring the intricacies of the cutting process and the production of these extraordinary tools.
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 Technical Specs
The production of carbide tools involves a series of precise steps to achieve the desired physical properties and performance characteristics:
Carbide cutting tools have revolutionized various industries with their exceptional hardness, heat resistance, and longevity. Understanding the intricate details of the cutting process and the meticulous production of carbide tools sheds light on their unmatched performance in the world of machining. Whether it's the intense forces at the cutting edge or the precise control of cobalt binder content and carbide grain size, carbide tools continue to shape the future of manufacturing and engineering.
Platinum Tooling, the importer and master distributor of live tools, angle heads, speed increasers, Swiss machine products, knurling and marking tools, and shrink fit tool holders manufactured by various international suppliers, will now carry REV broaching tools in North America.
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.
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.
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