F&L TECHNICAL SALES INC. - News

Mate Precision demos next generation workholding system

5/17/2022

Increase your factory productivity with the next generation 52/96 workholding system of vises, bases and mounts from Mate Precision Technologies.

Mate 52/96 workholding syste

A zero-point system, Mate 52/96 workholding is compatible with similar systems, including 52mm and 96mm four post pull stud configurations from Lang, Jergens, 5th Axis, Gerardi and others.

This new line maximizes holding power and offers best-in-class accuracy and repeatability. Mate’s quick change design reduces setup time and process variability. Watch the video to see how fast you can install and remove a Mate DynoGrip™ vise to a Mate DynoLock™ base. Make the switch to more productive and efficient workholding.

Tech Tip: Glass Fiber Composite Machining

4/13/2022

Decatur Diamond CVD coated diamond tools are a perfect match for machining glass fiber composites. The very abrasive characteristics of composite materials severely limit the life of both carbide and PCD diamond tools.

GLASS FIBER COMPOSITE MACHINING

Decatur Diamond carries a large variety of high performance cutting tools optimized for machining composite materials such as carbon fiber reinforced polymer (CFRP), glass fiber reinforced polymer (GFRP), and metal matrix composites (MMC).

Tools with diamond on the surface wear longer and have a lower coefficient of friction. These characteristics provide substantial benefit to machining operations.
Because CVD diamond tools last 10-50 times longer than carbide tools, and 3-4 times PCD diamond tools they:

Improve dimensional accuracy and consistency of machined parts
Greatly reduce number of tool changes, increasing productivity
Increase machine utilization
Allow for unattended machine operations
Quickly pay for themselves

The low friction of CVD diamond tools permit using speeds higher than both carbide and PCD – again contributing to higher productivity – with no degradation of the surface quality or tool life. The consistently sharp edge and lower friction allows delicate, thin wall sections to be machined quickly and precisely. The sharp and long wearing edge also puts lower stresses on the part, fixturing, and equipment. Since CVD diamond has no cobalt binder to break down or abrade away they offer the longest possible tool life.

Glass fiber composites can be machined successfully with diamond coated endmills if resin melting and chip evacuation are carefully controlled. Observance of the following guidelines should yield tool lifetimes of approximately 10 times the equivalent carbide tool.

Resin Melting

Speeds and feeds must be adjusted to avoid melting or softening the resin in composite materials. This means that feeds must be 0.001” ipt or greater with larger diameters and speeds should be kept at 400-500 sfm for G10 or FR4 type materials.

As the depth of cut increases the cutting speeds should be reduced to below 400 to minimize heat buildup in the chips. For shallow depths of cut, feeds can be up to 0.010” ipt for 1/2” diameter tools.

Maximum feed rates are a function of the depth of cut and limited by the tool strength for a given diameter.

Chip evacuation

For slot depths exceeding more than 1/2 the diameter of the endmill the evacuations of chips from the slot becomes extremely important. Failure to adequately remove chips can cause breakage of the carbide under the diamond film on the flute edge and subsequent catastrophic failure of the tool.

The use of 2-flute tools and moderate-to-high feed rates is highly recommended to insure good chip flow. Air flow into the cut and vacuum evacuation of chips from the cutting area are also recommended.

Additional life improvements can be obtained by using a corner radius or ball end tool for the initial cut and then following up with a square end tool with a much shallower cut to achieve the final dimensions.

For side cutting applications there is also an issue with chip evacuation if the radial depth of cut exceeds 1/4 of the tool diameter for a 4-flute tool or 2/3 the diameter for a 3-flute tool.

Maximum tool life and production rates are generally achieved with 2-flute tools operated at high feed rates for most side cutting applications.

Machining Parameters: recommended parameters for sidecutting are listed in the following chart for various flute configurations. Recommendations are based on a cutting speed of 400- 500 sfm and a diameter of the tool greater than or equal to the material thickness. Larger radial depth of cuts are possible if the material is substantially thinner than the tool diameter.

Starting parameters for sidecutting glass fiber composites

Machining Parameters: recommended parameters for slotting are listed in the following chart for various flute configurations. Recommendations are based on a cutting speed of 400-500 sfm and a full width slot which does not penetrate the full thickness of the material thickness. See sidecutting chart for slots which penetrate the full material thickness.

Starting parameters for slotting glass fiber composites

Note: VDOC’s greater than 100% of the tool diameter are listed for informational purposes only and are not recommended for normal operation

Decatur Diamond carries a large variety of high performance cutting tools optimized for machining composite materials such as carbon fiber reinforced polymer (CFRP), glass fiber reinforced polymer (GFRP), and metal matrix composites (MMC).

Decatur Diamond products provide the opportunity to machine large parts while minimizing tooling changeovers and ultimately reducing your costs. They can tailor our super hard materials for the challenges at hand with coated CVD, CVD and PCD fabricated tools. Contact us with quesitons!

The 7 Most Common Deep Hole Boring Problems and Solutions

3/22/2022

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
SELECTION CRITERIA

The diameter size of the boring bar is limited from the size of the hole diameter to be bored.
The boring bar should have the largest diameter possible for maximum cutting rigidity, but small enough to clear the hole for chip evacuation.
The Boring Bar has to be held with the maximum rigidity and the shortest overhang possible to maximize cutting stability and minimize vibration.
The selection and use of the right insert grade, geometry, nose radius and rake angle will be critical for a good surface finish and close working tolerance.
The cutting parameter is to be correct for the material machined in accordance of the insert manufacturing cutting data.
The hole, while machined has to be kept clear from chips to avoid tool breakage, boring bar vibration and the walls of the work piece undamaged.

7 MOST COMMON
DEEP HOLE BORING PROBLEMS

Poor Surface Finish, Poor Machining Tolerance & Poor Insert Life are the issues that every shop faces with cutting tools. Deep hole boring is no different. Below are some rule of thumb for a quick solution. As we said above, be sure to download the Solution Tool Catalog for much more technical information and solutions.

Boring Bar Cutting Ratio: If the incorrect boring bar cutting ratio is used, the boring bar will vibrate.
Boring Bar Diameter: Too small boring bar diameter will deflect under pressure and vibrate, too large boring bar diameter, will obstruct the evacuation of the chips.
Boring Bar Holding System: When boring bar is not held properly and rigidly in the boring bar holder, vibration will develop when cutting. A split Boring Bar Holder must to be used.
Boring Overhang: When the boring bar is over extended it will vibrate (Steel bar 4 x Dia., Carbide bar 6 x Dia.,Solution Tool!™ (The NO! Vibration Re-Tunable Boring Bar) 8 - 14 x Dia.
Incorrect Insert: Incorrect insert geometry, nose radius, rake angle, chip breaker, and clearance angle will cause vibrations.
Cutting Parameter: When wrong cutting parameters are used for the specific material to be bored, and for the operation to be executed, the boring bar will not perform properly.
Chip Clogging: When chips are clogged into the work piece bore, jamming the insert, wrapping around the boring bar, and thrown against the wall, the insert will be damaged.

F&L Technical Sales adds mPOwer from Modern Industries to their workholding offering

3/2/2022

FOR IMMEDIATE RELEASE

mPower Workholding SpeedLoc ModLoc Ball Lock

NEW ENGLAND - F&L Technical Sales as been appointed manufacturing agents for Modern Industries' mPower workholding product line in the New England territory.

Modern Industries is a leading innovator of workholding and fixturing components, focusing on the development of more efficient, faster, and lower operating cost methods for a wide range of machining and manufacturing applications.

The mPower™ line of products is designed to increase productivity while reducing costs in CNC Milling Machines. These products include their SpeedLoc precision locating and mounting system, the ModLoc modular tooling columns and plates, and a line of heavy duty work supports.

As a manufacturing operation that faces global competition, they fully understand that the need work to faster, smarter and at a lower cost is the key to either success of failure in today’s competitive marketplace.

Take a look at this product overview video!

If you would like to learn more about this please get in touch with us and we can set up a demonstration!

HORN USA expands its circular milling system 304 for Small Threads

2/17/2022

Horn USA recently expanded its circular milling system 304 with new thread milling inserts to perform in diameters of 8 mm (.315”).

THREAD MILLING SYSTEM 304 for small threads from 9 mm diameter

THREAD MILLING SYSTEM 304 for small threads from 9 mm diameter.

The precision tools are available as partial and full-profile versions for the production of threads by helical interpolation. Triple-edged inserts in the 304 system already exist for groove milling, finish boring, and chamfering.

The new threading inserts spin on diameter 7.7 mm (.303”). Vibration dampening carbide shanks with integral through coolant ports make the system versatile and easy to use.

The HORN circular milling system offers users a host of process advantages. It is fast, reliable, and produces good surface finishes.

During the machining process, the tool plunges into the material either at an angle or almost horizontally and is then driven on a helical path. Threads can be manufactured at a highly reproduceable level of consistent quality.

Circular interpolation has a wide range of applications and can be more economical when strategically applied when machining steel, special steels, titanium, and alloys.

HORN’s circular milling tools are engineered for precision machining of grooves, threads, t-slots, profile milling and other circular interpolation processes.

Uncoated Import versus Techniks(Parlec) Coated Collet Nut - Put to the test

1/11/2022

edited by Bernard Martin

It’s been estimated that a tool with a run-out of 50% of the tool’s chip load will reduce its tool-life by 40%. That means that a 1/8” tool with a 0.00019” chip load per tooth will lose 40% of its tool-life with a run-out of less than 0.0001”.

Excessive and inconsistent run-out from a properly setup ER collet chuck assembly typically occurs due to friction build-up between the 30° face of the collet and the collet nut.

As the collet nut presses down and turns against the 30° face of the collet, the collet face will tend to twist with the collet nut, distorting the shape of the collet. This radial distortion negatively affects tool run-out sine the collet bore is not longer straight.

Techniks', Mike Eneix took an uncoated, imported nut and put it to the test against the PowerCOAT nut.

They took them to the limit to see which one gives you more holding power.

Check out the video test below!

Techniks Parlec Coated vs Uncoated collet nut

NEw High-Performance Coatings IG6 and SG3 INtroduced by Horn USA

1/5/2022

HORN’s new high performance coatings IG6 and SG3 are a testaments to engineering expertise in tool manufacturing.

Horn USA Carbide Grade IG6 performance machining stainless steels

Horn USA Carbide Grade IG6: More performance in the machining of steel and stainless steels.

The new coatings are less than 0.005 mm (.0002”) thick and an essential part of modern tool technology. Testing has shown that the new tool coatings extend the service life of carbide tools by over one-thousand percent.

IG6 is a copper colored aluminum-titanium-silica nitride (AlSiTiN) coating designed for use in machining materials P and M with grooving inserts type S224 and S229. In conjunction with the carbide substrate, the coating allows for faster material removal rates and significantly extended wear resistance in machining materials P and M. Standard inserts are available from stock.

Download the IG 6 Catalog

Horn USA Carbide Grade SG3 Hardened Steel machining

Horn USA Carbide Grade SG3. The choice for machining hardened steel and difficult-to-machine materials.

SG3 is designed for use in titanium and super-alloys as well as turning and grooving applications in hardened materials, up to 58 HRC. The coating can be function in temperatures up to 1,100 degrees Celsus (2,012 degrees Fahrenheit).

HORN designed this coating to deliver outstanding performance with materials that are difficult to machine. The advantage of the tool coating have been proven on selected tool systems from HORN.

The Supermini® system 105 with SG3 coating is available from stock. In both cases, the IG6 and SG3 coatings are applied in-house, allowing for reduced delivery time.

Download the SG3 Catalog

HORN has developed a high level of expertise in coating precision tools since it began in-house coating processes. From five employees in the beginning to more than fifty employees, the aim has always been to create and invest in modern coating technologies for precision cutting tools.

The HORN team was the first in the world to take delivery of HiPIMS systems from CemeCon. The opportunities to develop hard and tough coating with a homogeneous structure has provided this team the flexibility to create advancements that benefit customers who demand precision tools in demanding applications.

Swarf Talk: Blue Photon WORKHOLDING Video REVIEW IN THE UK

12/8/2021

Check out the video clip about Blue Photon using ultraviolet light to cure BlueGrip workholding adhesive on the grippers!

In this month’s Swarf Talk they deep dive into how you can reduce set-up times, increase spindle uptime, increase speeds and feeds, increase tool life longevity, improve surface finish, eliminate vibration, utilize your machine envelope and ultimately make more money by maximizing your efficiencies on your milling machines simply with workholding solutions and innovations!

Watch the full episode covering workholding on Swarf Talk HERE
Swarf and Chips is sponsored by Intoco Special Steels and Alloys.
Courtesy of MTD CNC Media and Swarf and Chips.

Practical Machinist Visits GWS Booth at Eastec 2021

11/3/2021

Ian Sandusky from Practical Machinist takes a tour of GWS Tool Group's EASTEC Trade Show booth with John Kiffner from, showcasing their line of cutting tools.

Ian dices into the monoblocks, diamond-style milling tools, GWS' ceramics and custom thread whirling inserts and last, but not least, their Hurrimill AT4 end mill tool and the Alumigator ASR5 end mill tool.

Have any questions? Drop them in the comments!

Reamer Tolerances

10/13/2021

We've been asked by one of our customers recently to post the standard reamer tolerances for Hannibal Carbide Reamers.

Here's the standard tolerances for the reamers.

Are you on our customer list yet?

Hannibal Carbide Reamer customers

Tool diameter tolerance

General Purpose & Coolant Fed Reamers

Thru 11/2” tool diameter: plus .0003”, minus .0000”
Over 11/2” tool diameter: plus .0004”, minus .0000”

Material Specific (excluding Coolant Fed Reamers)

Thru 1/2” tool diameter: plus .0002”, minus .0000”
Over 1/2” tool diameter thru 3/4”: plus .0003”, minus .0000”
Over 3/4” tool diameter: plus .0004”, minus .0000”

Shank diameter tolerance

General purpose

minus .0005”, minus .0015”

Material specific (NAS) & Coolant Fed Reamers

Thru 23/32” tool diameter: plus .0000”, minus .0010”
Over 23/32” tool diameter: plus .0000”, minus .0015”