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
As seen at IMTS 2022. Dorian Tool’s Jet-StreamTM Thru Coolant Cutting Tools use a patented thru-coolant locking clamp which is precisely aimed to direct high pressure, high velocity coolant exactly onto the cutting edge of the carbide insert, from a short distance of 1⁄4”.
This controlled Jet-Stream coolant, directed onto the insert chip interface (right under the chip and over the insert cutting edge) will dissipate the generated heat very effectively as well as lubricate the cutting edge of the insert, causing the chips to hydroplane over the insert surface instead of adhering to it. As a result, the insert will operate at a constant low temperature, with a clean and undamaged cutting edge, changing the way metal is cut.
Higher speeds and feeds can be achieved, with a better surface finish, tolerance control and machining performance.
The insert life is extended up to 200%.
It's that time of year for IMTS!
Here's a preview of some of the products that are going to be featured during the International Manufacturing Technology Show September 12-17. You can see all of these new products and talk to the manufacturers in the Tooling & Workholding Systems Pavilion in the West Building Level 3.
Blue Photon Workholding
Horn USA, Inc.
Supermini Set. Horn USA is featuring the Supermini tool holder system with face clamping as a set, in response to customer requests for different tooling system heights. With this holder variant, 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. This increases repeatability when changing the insert and provides better utilization of the available space. This is a big time saver on Swiss-type lathes, as the user can change the cutting insert without removing the tool holder.
New carbide grades for system DAH8 - Horn USA is expanding its range of carbide grades for its 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 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 multipurpose grade for other material groups.
Techniks Tool Group
If you would like to learn more about any of these products or to see a demonstration, get in contact with us and we'll set up some time with you to visit your shop!
Dorian Tool has some very detailed technical information in their Solution Tool catalog to address deep hole boring. First we're going to list the fundamental rules of selecting the correct boring bar and then take a deeper dive into the fundamentals of troubleshooting.
If you want more information, technical specifications and much more detailed information on troubleshooting you can download the Solution Tool catalog below.
DEEP HOLE BORING
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