Ingersoll Swiss-Style & Live Tooling Cutters

Exclusive Swiss-Style & Live Tooling Cutters

Ingersoll announces exclusive integral collet tooling for their Hi-PosMicro indexable end mills and Chip-Surfer solid carbide tipped tooling lines!

Replace worn tooling with less downtime on your machine with .0005î axial and radial repeatability. Precision threads with simultaneous fit heads maximize the rigidity of your tooling application and reap the benefits of increased productivity with higher feed rates, better finishes and longer tool life.

The economy of indexability and higher feed rate capability of the Hi-PosMicro end mill tips allow you to exceed your previous throughput at lower costs. The versatility and wide range of Chip-Surfer tips complete your tooling requirements while offering premium carbide grades and coatings to be applied to the widest range of materials.

For more information be sure to contact your local Ingersoll representitive

BF Milling Cutter from Valenite

BF Milling Cutter from Valenite

No burrs - Outstanding surface finish quality!

Great for Facing:

Aluminum
Steel
Cast Iron
Bi Metal

WHAT IS THE BF MILLING CUTTER?

• Non-conventional milling cutter with a fully innovative design based on the broaching technology
• Unique axial and radial positioning of the inserts which allows each of them to remove constant chip thickness
• A single insert provides the quality of the machined surface
• Maximum optimizing of the number of teeth.

What does this mean for you?

1. Facing with no deburring
2. Full control of the quality parameters of the parts
3. Outstanding surface quality
4. No insert adjustment
5. Reduction of the cost-per-part of 30%
6. 66% reduction in set-up time
7. High-feed machining with a reduced number of teeth


If you would like to learn more about the BF Milling Cutter or looking for Valenite Carbide Inserts, Google Keyword: Valenite Carbide Inserts

Quick Tips for Face Machining

Very Cool 5 Face Machining Center

Here are three easy recommendations to help choose the right tool for high performance in face machining operations.

1. Choose the widest possible insert and tool, according to the cutting width and geometry to be machined.

2. Choose the shortest tool blade overhang, according to the maximum depth required.

3. Choose the tool range with the largest diameter depending on the initial grooving diameter required in the application.

Follow these easy steps, and you should be well on your way.

Thank you to Taegutec for providing these machining tips.

For Taegutec Inserts pricing online Google Keyword: Taegutec Carbide Inserts

Selecting Insert Width for Grooving

Video of Grooving Operation

Here are some quick tips for selecting the best insert width for your grooving applications.

1. Insert width strongly affects strength

2. For most efficient machining, select the widest possible insert.

3. Chipbreaking range depends on the insert width.

4. A narrower width means better chipbreaking at lower feed rates

5. Wider inserts and stronger blades require higher forces adn higher feeds rates to achieve a frontal clearance angle.

Use these few basis tips to give yourself the best chance at success in your machining operation.

Thank you to Taegutec for providing these machining tips.

THREADING: TAPPING TITANIUM:

Titanium and titanium alloys are most often found in aerospace applications due to its lightweight and high strength.

However, other industries are discovering the benefits of titanium as well. One of the more common alloys is Ti 6AL-4V. It is generally machined at a hardness ranging from approx. 28 to 37 Rc.

One the characteristics that makes titanium difficult to tap is its tremendous elastic memory. When tapping, the material closes tightly around the cutting tool, generating friction and heat, resulting in increased wear of the cutting edges. This material also easily work hardens.

To successfully tap titanium, a tap specifically designed with additional clearance to overcome the extreme elastic memory of the material is recommended.

Tap clearances would include extra back taper of the threads from the front to the back of the thread section, full radial clearance in the threads across the tap lands, and additional relief in the tap chamfer area.

All of these features are used to reduce friction and heat. In some cases, larger H limits might be required to overcome the shrinkage.

Premium grade materials are also used for heat and wear resistance. Obviously we offer these in our standard product lines.

Lubrication and proper pre-tapped hole size are vital to success. A compatible tapping fluid should be used that provides plenty of lubrication to reduce friction.

The drill should be selected to produce the largest hole size that is allowed by the thread class callout (2B or 3B).

Due to the additional clearances required on these tools, positive feeding of the tap is highly recommended.

Machining Titanium Tips

Inserts for Machining Titanium

Machining Aluminum

V8 Engine Block Machining From Solid Aluminum

Aluminum is Inexpensive, Lightweight and is Formable at Cold Temperatures

Aluminum is one of the most common materials used in manufacturing strong, lightweight parts. PMF manufactures parts made purely of Aluminum alloys as well as parts made from two or more materials such as Stainless Steel and Aluminum.

Common Forms of Aluminum (in various tempers)
6000's, 5000's, 1000's, 2000's, 3000's, 7000's

Benefits of Aluminum

• Inexpensive
• Lightweight
• Formable at cold temperatures

Considerations of Aluminum

• Softness can lead to tearing
• Low tensile strength (approx. 1/3 that of steel)

Applications of Aluminum

• Military munitions
• Aerospace
• Microelectronics
• Automobile parts
• Many others

Looking for inserts for machining aluminum? Find them at pgsTools.com. Your choice

PCD Inserts for Aluminum

Carbide Inserts for Aluminum

What is Induction Hardening

Definition: A widely used process for the surface hardening of steel. The components are heated by means of an alternating magnetic field to a temperature within or above the transformation range followed by immediate quenching. The core of the component remains unaffected by the treatment and its physical properties are those of the bar from which it was machined, whilst the hardness of the case can be within the range 37/58 Rc. Carbon and alloy steels with a carbon content in the range 0.40/0.45% are most suitable for this process.

What to do about Poor Thread Quality

Often taps get the blame for poor thread quality or rejected threads and it is natural to look to the tap itself as the culprit. Actually, the tap is often the victim of a badly drilled hole. You can't produce a great thread out of a bad hole! Following are some issues and possible resolutions.

1. A dull drill will create a very rough torn hole. Expect poor or incomplete threads.

2. A reground drill must be perfectly concentric. The cutting lips must be of equal length and be ground to the same angles. Failure to create a concentric point will cause the drill to cut on one side more than the other and a crooked, bent hole will result making an attempt to tap that hole very difficult. This can also produce an oval egg shaped hole.

3. Castings sometimes have a tapered hole so the part will release easily. Threading requires straight walls and tapered walls are impossible to thread correctly.

4. Undersized holes are difficult or impossible to thread.

5. Holes that have had the surface work hardened by too high a temperature in the drilling process can become too hard to thread effectively.

6. Materials that shrink or close-in after drilling are undersized for tapping.

7. Holes too near welding or flame cut areas can become hardened and difficult to thread.
Bottom line, consider good hole quality as essential in producing quality holes and if you are having difficulty, dont forget to investigate the drilling process in addition to the tap.

Selecting Thread Mill Diameters

Tips for Selecting Thread Mill Diameters

When producing internal threads, selecting the right thread mill diameter insures it will operate efficiently.

Thread mills are usually offered in several cutting diameters for a given threads per inch. Smaller diameters are used for small thread sizes, such as 3/8-16 NC.

A larger tool diameter could be used for producing a 3/4-16 NF. However, the smaller thread mill could be used to produce the larger 3/4-16 as well.

Generally, for coarser pitches (coarser than 14 TPI), selecting a cutting diameter no larger than 70% of the nominal thread size to be produced is recommended.

For finer pitches, the thread mill can be as large as 75% of the nominal diameter. Although the tool has radial clearances similar to end mills, if the tool diameter is too close to the thread diameter, the tool may rub, producing more heat that could result in excessive wear.

This rubbing may also distort the thread form affecting the thread angle.

The question is, should the largest thread mill that will fit the hole be used? The answer is, not necessarily!

For the greatest efficiency, smaller mills will remove more cubic inch of metal than a larger one, resulting in greater productivity.

There will be more clearance for the tool and more space for coolant and chips.

However, to optimize the tool, it will be rotating much faster, which may exceed the capability of the machine.

Also, the thread length on the tool may be too short for the thread depth required.

On the other hand, the larger diameter thread mill will minimize deflection, particularly on coarse thread series, but is more prone to rubbing and chip congestion.

Tips for Machining Stainless Steel

Video of Teton Creek Mfg turning Stainless Steel

Here are a list of tips for machining stainless steel:

1. Use a tool that has higher thermal-conductivity
Low thermal-conductivity of stainless steels accelerates tool wear resulting from a decline in hardness of the cutting edge of an insert, this is due to heat piling up. It is better to use a tool that has higher thermal conductivity and with enough coolant.

2. Sharper cutting edge-line
It is necessary to utilize larger rake-angles and wider chip-breaker lands to reduce cutting-load pressue and prevent build-up on the edge. This will help provide better chip control to an operator.

3. Optimal cutting condition
Inappropriate machining conditions like extremely low or high speeds or low feeds can cause poor tool life due to work hardening of work pieces.

4. Choose an appropriate tools
Tools for stainless steel should have good toughness attributes, enough strength on their edge line (cutting edge) & a higher film adhesion.

Korloy offers three grades turning stainless steel:

For high speed turning of stainless steel - NC9020

For medium to low speed turning of stainless steel - PC9030

For medium to low speed milling of stainless steel - PC9530

For Korloy carbide inserts for stainless steel, please visit pgsTools.com to order online.

Hardware for Toolholders and Boring Bars

Find Spare Parts for Tool Holders and Boring Bars

Lose a screw, lock pin, or clamp for your boring bar or toolholder? Wondering what the heck a lock pin or clamp is? Use the following guide to help you sort out what you may need in replacement parts for boring bar or tool holders. Find a definition of each component below the picture.

Here is a diagram (click on image to enlarge) of a Multi-Lock Tool Holder courtesy of Dorian Tool:


INSERT
Either conventional type or chipbreaker type may be used.

LOCK PIN
A solid locking pin for permanent locating of the insert.

SHIM SCREW
Reusable shim screw locks carbide shim into toolholder.

CARBIDE SHIM
Forms a firm seat for insert. Fastened to the shank, but easily replaceable. Protects against
damage to toolholder.

CLAMP
Maximum retention clamp is made of high alloy steel, heat treated. Broad clamp nose provides
positive clamping action. Clamp is positioned to allow for maximum insert retention, with or without chipbreaker.

CLAMP SCREW
Rugged Clamp Screw provides maximum clamping strength.

CHIPBREAKER
Solid carbide, for use when chip control is needed. Available in a range of standard chipbreaker
widths.

Most toolholders and boring bars accept generic shim seats, screws, clamps, and pins. This includes tools from Valenite, Sandvik, Kennametal, and Iscar. Check your manufacturers catalog to be sure of the replacement items part number.

PCD Tipped Carbide Boring Bars

PCD Tipped Carbide Boring Bars

PCD Tipped Brazed Boring Tool. For Bore sizes smaller than 8 mm in diameter. PCD is brazed directly to a tungsten carbide shank providing a rigid boring tool capable of remarkable surface finishies and providing a high productive alternative to internal grinding.

For Bore sizes smaller than 8 mm in diameter, it is not possible to use PCD tipped cutting tool inserts. In order to put a PCD tip into the carbide insert, material must be removed. This makes the insert weak and prone to breakage when it is clamped into the boring bar.

At the same time, clamping of small inserts into small boring bars becomes progressively more difficult as the bore size reduces.Top clamps trap swarf and, in order to fit inside the bore, become too small to exert enough clamping pressure. Screw locked inserts, while leaving space for swarf, require sufficient material under the insert for the thread of the clamping screw.

These problems are overcome by using brazed tools. The PCD tip is brazed directly to a tungsten carbide shank providing a rigid boring tool capable of remarkable surface finishes and providing a highly productive alternative to internal grinding.

Valenite Carbide Inserts for Stainless Steel

VALENITE INTRODUCES NEW TURNING GRADES FOR FINISHING, SEMI-ROUGHING STAINLESS STEELS

Valenite LLC has introduced two new tooling grades—expanding its targeted and application-specific lineup that allows users to better match machining operations and workpiece materials with tooling inserts for optimum production efficiencies, quality and economies. The new cutting technologies are the ValProTM VP8515 and VP8525 MT-CVD series of inserts. Both are being developed to augment the existing VP8535 grade and provide a complete range of turning capabilities for 304 and 316 stainless steels, Inconel and heat resistant alloys. The VP8515 is for finishing operations and the VP8525 is used for general duty semi-roughing/finishing. The existing VP8535 is for heavy metal removal tasks and roughing operations.

The VP8515 grade is set for high cutting speed (>200 m/min) at typical finishing

cut depths and has broad applicability with F5, M4, M6, M8, PM2, PM5 geometries. This grade is ideal for continuous turning of austenitic and duplex stainless steels at higher speeds providing reliable and predictable performance, with extended insert service life. Inserts using VP8515 grade have a thin yellow TiN outer coating for easy visual wear identification, an Al2O3 layer for thermal protection, a fine MT-CVD TiCN coating that helps to prevent flaking and reduces flank wear. Also incorporated in the tooling is a gradient area for added surface toughness, and a hard substrate offering greater resistance to wear and plastic deformation.

The TiCN/Al2O3/TiN coating is formulated specifically for turning of stainless steels and to resist sticking, notch wear and edge build-up, for enhanced hardness when hot.

The VP8525’s performance characteristics deliver high cutting speeds (>150 m/min) with mid- to large cutting depths...inserts have M4, M6, M8, R9, PM4, PM5 geometries to cover a myriad of cutting parameters. This grade is a basic choice for general duty M-class turning—continuous or intermittent cutting of austenitic and duplex stainless steels. These tools reduce the risk of plastic deformation and, like the VP8515, provide reliable performance and extended tool life. The VP8525 grade has similar coating technologies, layering and substrate construction as the finishing grade, including the TiCN/Al2O3/TiN coating for the efficient turning of stainless steels.

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Get carbide inserts or cutting tools for stainless steel machining at www.pgstools.com. PGS sells cutting tools and carbide inserts from Korloy, Taegutec, Valenite, Iscar and generic carbide inserts online at discount prices.

CNC Turning

To produce hubs, rods, bushes, pulleys and shafts, CNC turning is utilized where the lathe generates materials after inserting the single cutter point in to the material turning. The procedure of cutting is executed through a cutting tool which is applied either parallel or at right angle to the axis, of work piece. The tool may also be fitted at an angle relative to the work piece axis for the machining angles and tapers. The work piece may be of any cross section, but the machine surface should be straight and tapered.

There are various shapes available in CNC like pointed, simple, radius with profile added with threaded surface, curve and fillet. CNC machining is more economical than the CNC milling for producing the actual form through CNC turning. The material used for CNC turning possesses various qualities like material of work piece should be firm and can be of solid plastics. For the short running procedure of the mill, arrangements or alternative machine should be kept. CNC turning reduces the cost by minimizing the design elements.

CNC turning procedure is done through applying pressure on the work piece or the weaker material to form the flexible shapes of the material. Sometimes through CNC, the cut surface is formed by applying the helical feed as it results in rotation. The cutting procedure through which the work piece is eliminated from a material block by the help of the rotation of the tool is known as CNC milling. The work piece can rotate in perpendicular or circular way to produce different shapes and sizes. The cutting tool generally rotates in the CNC milling at an axis in a perpendicular form on the podium to generate various structures.

Variety of shapes that can be formed through CNC milling is 3D or 2D and some compound structured material. CNC milling for short procedure is also very economical. It is utilized to make different parts of engine, multifaceted mechanisms, enclosures and mold and custom tooling.

Thus, is a very effective procedure to make various machine parts of various shapes which is very significant for running the machine.

Get carbide inserts or cutting tools for your cnc machines at www.pgstools.com. PGS sells cutting tools and carbide inserts from Korloy, Taegutec, Valenite, Iscar and generic carbide inserts online at discount prices.

Author: George Ure

Article Source: http://www.articlesbase.com/sales-articles/cnc-turning-488912.html

What is a tool bit?

The term tool bit generally refers to a non-rotary cutting tool used in metal lathes, shapers, and planers. Such cutters are also often referred to by the set-phrase name of single-point cutting tool. The cutting edge is ground to suit a particular machining operation and may be resharpened or reshaped as needed. The ground tool bit is held rigidly by a tool holder while it is cutting.

Back Rake is to help control the direction of the chip, which naturally curves into the work due to the difference in length from the outer and inner parts of the cut. It also helps counteract the pressure against the tool from the work by pulling the tool into the work.

Side Rake along with back rake controls the chip flow and partly counteracts the resistance of the work to the movement of the cutter and can be optimized to suit the particular material being cut. Brass for example requires a back and side rake of 0 degrees while aluminum uses a back rake of 35 degrees and a side rake of 15 degrees.

Nose Radius makes the finish of the cut smoother as it can overlap the previous cut and eliminate the peaks and valleys that a pointed tool produces. Having a radius also strengthens the tip, a sharp point being quite fragile.

All the other angles are for clearance in order that no part of the tool besides the actual cutting edge can touch the work. The front clearance angle is usually 8 degrees while the side clearance angle is 10-15 degrees and partly depends on the rate of feed expected.

Minimum angles which do the job required are advisable because the tool gets weaker as the edge gets keener due to the lessening support behind the edge and the reduced ability to absorb heat generated by cutting.

The Rake angles on the top of the tool need not be precise in order to cut but to cut efficiently there will be an optimum angle for back and side rake.

Ref: http://en.wikipedia.org/wiki/Tool_bit

All About Cermet Inserts

Cermet inserts can't quite replace the coated carbide inserts in heavy roughing operations with interrupted cuts, but in semifinishing and finishing cermet inserts outperform carbide. They permit a higher surface speed while maintaining an acceptable surface finish with good tolerance holding property and increased tool life. Because the cermet surface is slick it presents less friction to the chip flowing over the cutting edge which decreases the possibility of build-up when machining high alloy steels and cold-formed, low-carbon steels. Cermet inserts are available from several suppliers with a wide selection of pressed-in chipbreaker configurations or ground-in chipbreakers.

The cermet inserts work at surface speeds from 100 to 1000 sfpm. On multi-spindle-automatics, positive inserts made of cermets avoid build-up encountered when running carbide inserts with low surface speeds. Also cratering is reduced due to the low heat transfer properties of the cermet material.

The recommended cutting speed for turning unalloyed steel with approximately 200 HB is 250 to 800 sfpm with 0.002" to 0.015" fpr and depth of cut of 0.004" to 0.150". Alloy steels up to hardness of 300 HB will have satisfactory tool life when machined between 200 and 600 sfpm with the depth of cut and feedrate mentioned above.

Face milling with cermet inserts can be achieved with the same cutting speeds as turning with chip loads per insert from 0.002" to 0.12". Milling is performed dry, while turning can be dry or with coolants.

Up to the present, cermets are widely used in Japan with good results in reducing machining costs. They deserve a greater consideration for material removal in the United States.

COPYRIGHT 1989 Gardner Publications, Inc.

Precision Cast Iron Machining

Whether you’re making brake discs and flywheels in grey cast iron, or crank shafts and wheel hubs in nodular cast iron, there is always a successful solution.

Over the years there have been a number of CBN grades made available for machining cast iron with CBN. Most notably are DR-80 and DR-85. These grades are made for the following applications:

For rough and semi-finish turning, milling, grooving and boring of hardened ferrous and certain softer ferrous materials:-

• Martensitic cast irons - Ni-hard - High chrome Chilled and heat treated cast irons
• Fully hardened cold-work tool steels
• Bearing steels
• High speed steels (continuous cutting only)
• Martensitic stainless steels
• Cobalt and nickel based hard facing alloys
• Fully pearlitic grey cast iron

DR-80 & DR-85 are high CBN content materials, diffusion bonded at the manufacturing stage to a tungsten carbide substrate.

DR-80 is (80% CBN) has a greater particle size than DR-85, (85% CBN). DR-80 is better for hardened steel, but DR-85 has better wear characteristics when machining cast iron with CBN, particularly when the stucture contains Ferrite.

For more information on machining with CBN Inserts
please visit David Richards Engineering UK or
David Richards Engineering US

Hard Turning with CBN

CNMA 432 Quad Edge CBN Insert Shown

Hard turning with CBN will:

• Reduce Grinding Investment
• Increase Tool Life
• Reduce Cost with Faster Cycle Times
• Lower Tool Change Down Time Costs
• Reduce Scrap Cost
• Reduce By-Product Disposal
• Extend Tool Life In High Production Hard Turn Applications
• Increase Thermal and Mechanical Shock Resistance to Handle the Most Demanding Contouring and Interrupted Cuts

Hard turning requires switching from carbide to CBN inserts. It’s easier and more economical than one would expect. The major adjustment is working with much higher surface speeds.

Earlier posts that deal with CBN Insert questions:

CBN Insert Applications

What is PCBN?

Hard Milling with Ceramic Inserts

Hard milling with ceramic inserts can help a mold shop to reduce manufacturing costs in several ways. First, a mold shop can replace several operations with one operation. Instead of machining, hardening and remachining, the use of ceramic inserts enables a shop to harden the steel first and then machine the part in the hardened form. This reduces manufacturing time and improves job tracking by reducing the number of times that you must set up and move a component through various manufacturing phases. Furthermore, roughing a hardened part with ceramic inserts also can eliminate expensive and time-consuming EDM operations, as well as the need to make one or more electrodes.

Second, ceramic inserts are capable of machining hardened steel at much higher speeds than conventional carbide cutting tools. Combine the higher operating speed with the proper feedrate and a healthy step-over and the shop can achieve some impressive metal removal rates. Another key factor in increased production rates when hard milling is the cutter density. Every additional tooth in a cutter increases the cross feedrate. Higher speed and more feed add up to lower cycle times and money saved.

Third, many times the surface finish achieved by rough milling with ceramics leaves less work for a finish milling operation, and reduces finishing and polishing time. Milling at relatively light feedrates in hardened steel with carbide usually leaves a good finish, but many times with ceramic inserts the rough finish is even better than the required finish. In some cases, additional milling, grinding and polishing can be eliminated, saving several hours of manufacturing.

Cylinder Boring with CBN or PCD Inserts

Boring out cylinders to accept oversized pistons or sleeves has long been a common practice in the engine rebuilding business. Boring allows worn blocks to be salvaged, and stock cylinder bores to be enlarged for more displacement. More recently, boring is also being used to install special cylinder liners with hard surface treatments in high performance racing engines. The hard liners almost eliminate ring and bore wear so the engine can run race after race with no increase in bore clearances blowby.

Like most other machine tools in today's shops, the equipment used to bore engines is also evolving to keep pace with changes in engine technology and the aftermarket. Small shops want equipment that is versatile and can do more than just bore holes. For this end of the market, combination boring/milling machines have become popular. At the other end of the spectrum, production engine remanufacturers (PERs) want equipment that works harder, works faster and requires less operator input. For this type of user, automated high speed boring equipment provides the needed boost in productivity and quality.

Tooling has also been improving. The latest generation of coated carbide inserts provides longer life and better cutting action. For high speed boring, polycrystaline diamond (PCD inserts) provides the longevity needed for this type of operation. The speed at which the boring bar turns has a significant impact on tooling life. High speeds just kill the bits unless you use a PCD or cubic boron nitride (CBN inserts) type of insert. The high speed boring machines that go up to 1,500 rpm need these type of inserts.