Increase your factory productivity with the next generation 52/96 workholding system of vises, bases and mounts from Mate Precision Technologies.
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.
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.
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:
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.
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.
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.
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.
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!
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
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!
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.
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.
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.
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.
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!
Here's the standard tolerances for the reamers.
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Tool diameter tolerance
- Thru 11/2” tool diameter: plus .0003”, minus .0000”
- Over 11/2” tool diameter: plus .0004”, minus .0000”
- 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
- minus .0005”, minus .0015”
- Thru 23/32” tool diameter: plus .0000”, minus .0010”
- Over 23/32” tool diameter: plus .0000”, minus .0015”
This is where we publish technical articles, applications stories, tip and tricks, new product announcements and press releases.
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High Speed Whirling
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