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.

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?

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”

Decatur Diamond has a complete line of precision cutting tools specifically designed for machining graphite. The tool geometries are optimized for such applications as electrodes, molds, and hydrogen fuel cells. These designs provide excellent cutting performance while not sacrificing tool life. Fewer changeovers and more time in the cut promote long runs and application automation for improved cost savings.

CVD coated diamond tools are a perfect match for machining the graphite moldforms for EDM. The abrasive nature of EDM graphite grades severely limit the life of carbide tools, and PCD diamond tools are not available in the configurations required for detailed moldmaking.

Tools with diamond on the surface wear longer and have a lower coefficient of friction. These characteristics provide substantial benefit to machining operations.

Because diamond tools last 10 to 50 times longer than carbide 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

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​When cutting graphite, most tool wear is caused by the abrasive nature of the graphite structure rather than by the material temperature or cutting speed. Unlike metal cutting, there is no heat generated when machining graphite, so tool speed is typically not seen as a wear factor. This distinction warrants the need for an abrasion resistant tool surface such as CVD diamond.

Because small feeds and depths of cut do not lead to increasing the amount of material chipping, tool wear will advance rapidly with light feed, but stabilize as feed is increased. Therefore, in addition to increasing the volume of material removed, increasing feed can extend tool life.

The depth of cut should not exceed one-half of an insert’s leg length or one-third of an endmill’s diameter. These parameters will minimize breakage at the exit of a cut.

Tool life is determined by the quality of the cutting edge and the thickness of the diamond layer at the cutting edge. A tool will go through a break in period that refines the cutting edge, resulting in an improved surface finish. This will be followed by a prolonged period of consistent performance and a gradual wearing of the diamond layer. End-of-life occurs when the diamond wears through, revealing the carbide substrate or when the diamond surface becomes chipped or fractured.

There is sometimes confusion over the difference between Knurl Cutting and Knurl Forming and what is the best application to use for each method.  Here's a quick synopsis of the differences and ideal application solutions. 

For a Cutting Knurl, the knurl wheel’s axis is rotated to provide a leading edge, where the sharp edge will cut the knurl pattern into the work piece. Additionally, with a Cutting Knurl, less pressure is required for the operation and higher speeds and feeds can be used (use the same cutting data of High Speed or Cobalt turning tools). When Knurl Cutting, use full faced knurl wheels with a sharp edge, to penetrate into the work piece and cut the knurl pattern.

In Forming Knurl, the knurl wheels axis is set parallel to the work piece axis, and forced against the work piece, displacing the material to form the knurl pattern. A large amount of pressure is required to displace the material that forms the knurl pattern. When Knurl Forming, use beveled edge wheels to protect the edge from chipping which will create a smooth surface finish.

Paul Horn GmbH is responding to the requirements of users with their product line expansion to the tool range for slot milling and slot cutting, .

​Horn now offers the cutter body of the M310 milling system with an internal coolant supply. This increases the service life of the indexable inserts and therefore reduces tool costs. The internal coolant supply also allows a higher level of precision when slot milling as no heat is transferred from the cutting zone into the component.

​What’s more, the flushing action of the coolant, combined with the geometry of the cutting edges, prevents chip jamming in deep grooves.

Horn offers two types of milling and slotting cutter. The screw-in milling cutter is available in diameters from 50 mm (1.969") to 63 mm (2.480") with widths from 3 mm (0.118") to 5 mm (0.197").

As an arbour milling cutter, the main bodies are available with diameters from 63 mm (2.480") to 160 mm (6.300"). The widths are also between 3 mm (0.118") and 5 mm (0.197"). The three-edged S310 carbide inserts are bolted on the left and right of the main body and therefore ensure a good distribution of the cutting forces.

In addition to further geometries for processing different materials, Horn is introducing inserts with a geometry for milling aluminium alloys.

As well as expanding the M310 system, Horn is rounding off the range of the M101 and M383 milling systems.

For the M101 tool, S101 inserts are available from stock with a width of 2.5 mm (0.098").

What’s more, new inserts with an 8-degree lead angle are available especially for slot cutting. For the 383 system, HORN is expanding the range of bodies with diameters of 125 mm (4.921") and 160 mm (6.300").

A New Era for Workholding
Leveraging nearly six decades of machining Mate’s workholding line offers an impressive selection of options: 

• Mate DynoGrip™ self-centering vises feature maximum holding power in a compact system with minimal part movement and zero-point quality engagement with a four-post pull stud pattern.
• Mate DynoLock™ quick change bases provide zero-point quality engagement with a four-post stud pattern and best-in-class center accuracy and repeatability.
• Mate DynoMount™ system includes tombstones, pyramids, risers, and dual right-angle mounts that feature zero-point quality engagement for four-point stud patterns.

The Mate 52/96 workholding system includes QuickSpecs™, Mate’s unique product identification system. QuickSpecs allows real-time access to critical user data, CAD models and potential integration into business systems. Additionally, the product supports common robotic interfaces and palletizing systems to support factory automation.

This new line is designed and manufactured with Mate’s renowned performance standards for best-in-class accuracy and repeatability. The workholding system is backed by the company’s sophisticated technical support, unsurpassed product quality, responsive customer service, and 100-percent satisfaction guarantee. Learn more online:  mate.com/products/workholding.
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The workholding announcement comes shortly after Mate changed its corporate name to Mate Precision Technologies to reflect the company's broader commitment to metalworking and using its expertise to drive innovations to shape the future of factory productivity. In describing the name change Sundquist commented, “It truly supports our mission statement, which focuses on improving our customers’ factory productivity, and we are now better positioned to extend our skills and technologies to other markets like the metal cutting and machining industry.”