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Cutting Tool Engineering December 15, 2011

December 2011

December 2011 covers tool presetting, EDM, and grinding practice. It also looks at drilling and holemaking and workforce development.

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Vol. 63 • Issue 12

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For more information, view this interactive ad at www.iscar.com

T490 LNMT

Tangential Geometry with 4 Cutting Edges for Fast Metal Removal Cutting Down Production Costs by Increasing Cutting Conditions ITA recommends the optimal tool based on application parameters and your machine power. 3 tool options, 25 alternatives, cutting data, power consumption, cutting time, metal removal rates, engineering support and more.

T490 LNMT Tangential Geometry with 4 Cutting Edges for Fast Metal Removal Cutting Down Production Costs by Increasing Cutting Conditions For more information, view this interactive ad at www.iscar.com ITA recommends the optimal tool based on application parameters and your machine power. 3 tool options, 25 alternatives, cutting data, power consumption, cutting time, metal removal rates, engineering support and more

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Iscarmetals

Endmills and Face Mills with 45º Endmills and Face Mills

Tangentially Clamped Inserts in with Double-Sided Inserts in a a Diameter Range of 8-80 mm Diameter Range of 25-200 mm H490 - A New Family of New HELIDO-FEEDMILL Double-Sided Inserts with Combination Inserts with 4 Helical Cutting Edges 6 Cutting Edges Powerful Inserts with Endmills and Facemills with Tangential Geometry for Tangentially Clamped Inserts in.

Endmills and Face Mills with 45º Endmills and Face Mills Tangentially Clamped Inserts in with Double-Sided Inserts in a a Diameter Range of 8-80 mm Diameter Range of 25-200 mm H490 - A New Family of New HELIDO-FEEDMILL Double-Sided Inserts with Combination Inserts with 4 Helical Cutting Edges 6 Cutting Edges Powerful Inserts with Endmills and Facemills with Tangential Geometry for Tangentially Clamped Inserts in Fast Metal Removal a Diameter Range of 25-50 mm IS #70

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Hornusa

HORN - THE LEADERS IN GROOVING TECHNOLOGY

FOCUS ON THE ESSENTIAL SYSTEM DR Urma licence Sensitivity instead of gross motor skills – this is the motto of the new HORN “System DR” reaming tools. Very narrow cutters, simple handling, and high repeatability when replacing inserts. A large selection of base material, coatings, and cutting geometries make the DR from HORN the perfect tool system for high precision bore machining

HORN - THE LEADERS IN GROOVING TECHNOLOGY FOCUS ON THE ESSENTIAL SYSTEM DR Urma licence Sensitivity instead of gross motor skills – this is the motto of the new HORN “System DR” reaming tools. Very narrow cutters, simple handling, and high repeatability when replacing inserts. A large selection of base material, coatings, and cutting geometries make the DR from HORN the perfect tool system for high precision bore machining. HORN – INTELLIGENT TOOL DESIGN AT WORK. HORN

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Tungaloyamerica

IS #51

Find us on the web.

IS #51 Find us on the web www.tungaloyamerica.com 3726 N. Ventura Dr. Arlington Heights, IL 60004 ph: 888-554-8394 fax: 888 -554-8392

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Time to think about grinding in-house.

How would you sharpen these tools?

We send them out O.K.…But how much time do you spend? for resharpening Lost production while waiting for tools? Manual tool grinder How do you keep up? Quality? Training? Maybe it’s time to think about a WALTER CNC? WALTER POWER That’s what most people check – over 7,000 shipped! Super fast for short cycle times. Fastest setup – On the.

How would you sharpen these tools? We send them out O.K.…But how much time do you spend? for resharpening Lost production while waiting for tools? Time to think about grinding in-house. Manual tool grinder How do you keep up? Quality? Training? Maybe it’s time to think about a WALTER CNC? WALTER POWER That’s what most people check – over 7,000 shipped! Super fast for short cycle times. Fastest setup – On the machine or off-line so machine stays productive. Most versatile. Simplest and most reliable autoloaders –

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Toolflo

Carbide • Cermet • CBN

• Ballnose • Flat Bottom ENDMILLS TBXR • Back Draft For maximum metal removal TBNR FC Series CUT OFF SYSTEM For finishing SAVE MONEY! Our unique anvil and clamp system allows for various cutting widths using the same All holders and inserts come with... tool holder. RIGID LOCK the best locking system in the market! Inch: Holders:.

Carbide • Cermet • CBN • Ballnose • Flat Bottom ENDMILLS TBXR • Back Draft For maximum metal removal TBNR FC Series CUT OFF SYSTEM

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800.521.9520 | mscmetalworking.com

MILLING • HOLEMAKING

THREADING • INDEXABLE For over 60 years, Hertel has been providing the metalworking industry with unsurpassed value. Hertel cutting tools are ideal for general machining applications and come in a wide variety of styles and sizes. Available exclusively at MSC Industrial Supply Co.® IS #59.

MILLING • HOLEMAKING THREADING • INDEXABLE For over 60 years, Hertel has been providing the metalworking industry with unsurpassed value. Hertel cutting tools are ideal for general machining applications and come in a wide variety of styles and sizes. Available exclusively at MSC Industrial Supply Co.® 800.521.9520 | mscmetalworking.com

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Schutteusa

Another class of errors is rotational. indicates the machine moved too little. to account for the error.

Because guide ways are not flat, as For a given machine position, the value Economic feasibility determines how each axis moves, the carriage may tip of each error function at that position can accurately a machine is built. To achieve forward or backward in the direction be mathematically combined to give the the required part accuracy, remaining.

Another class of errors is rotational. indicates the machine moved too little. to account for the error. Because guide ways are not flat, as For a given machine position, the value Economic feasibility determines how each axis moves, the carriage may tip of each error function at that position can accurately a machine is built. To achieve forward or backward in the direction be mathematically combined to give the the required part accuracy, remaining of travel (pitch), turn right or left from geometric error of the machine. The com- geometric errors are corrected through the direction of travel (yaw) or rotate manded machine position can be altered software. CTE clockwise or counterclockwise around the axis of travel (roll). The roll errors are denoted εx(X), εy(Y) and εz(Z), where ε indicates an angular error, the subscript

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Rollomaticusa

smart

machine grinding The GrindSmart®628XW - Increased Autonomy and Flexibility with Rollomatic’s NEW SmartChanger U 6 position wheel changer with integrated coolant distributor simultaneously changed with the wheel pack UÊ Simultaneous changing of the wheel packs during the tool loading/unloading cycle UÊ Accurate and repetitive wheel pack change within 0.002 mm runnout accuracy.

smart machine grinding The GrindSmart®628XW - Increased Autonomy and Flexibility with Rollomatic’s NEW SmartChanger U 6 position wheel changer with integrated coolant distributor simultaneously changed with the wheel pack UÊ Simultaneous changing of the wheel packs during the tool loading/unloading cycle UÊ Accurate and repetitive wheel pack change within 0.002 mm runnout accuracy UÊ New synchronous spindle motor offering 14kW of power and 23Nm of torque UÊ The latest Fanuc control, type 30iMB

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Tungaloyamerica

productive times

No more blowups END USER: Marquardt Engineering Inc. New and improved is in the eye of the mild, tool and stainless steels. Jobs range www.marquardt-eng. beholder. After using a style of indexable- from screw machine parts to ones 26" in com insert drill for nearly 20 years, Marquardt diameter and volumes range from one a CHALLENGE: Eliminate chatter to.

productive times No more blowups END USER: Marquardt Engineering Inc. (847) 669-0690 New and improved is in the eye of the mild, tool and stainless steels. Jobs range www.marquardt-eng. beholder. After using a style of indexable- from screw machine parts to ones 26" in com insert drill for nearly 20 years, Marquardt diameter and volumes range from one a CHALLENGE: Eliminate chatter to Engineering Inc. experienced problems year to 10,000 monthly. prevent indexable when the toolmaker replaced it, accord- The parts manufacturer initially tried inserts from blowing ing to Brian Mueller, president of the to make the new drill work by reduc- up and causing

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3M

ad index

I.S. # ADVERTISER NAME PAGE # CONTACT NAME CONTACT PHONE CONTACT E-MAIL / WEB SITE The Advertisers Index is provided as a courtesy to advertisers. Every effort is made to avoid errors, but should one occur, CTE is not responsible. Reviewed by the Engineering Index. Cutting Tool Engineering® (ISSN:0011-4189) is published monthly. Copyright 2011 by CTE Publications Inc., 40 Skokie Blvd., Suite 450, Northbrook, IL 60062

ad index I.S. # ADVERTISER NAME PAGE # CONTACT NAME CONTACT PHONE CONTACT E-MAIL / WEB SITE 1 3M Abrasive Systems Div. 37 Customer Contact Center 866-279-1288 ext. 1687 [email protected] / www.3m.com/abrasives 2 Advent Tool & Mfg. Inc. 71 Jim Hartford 800-THREAD-4 [email protected] / www.advent-threadmill.com 45 Allied Machine and Eng. Corp. 5 Heather Kaiser 800-321-5537 [email protected] / www.alliedmachine.com 3 AMAMCO Tool 41 Andrew Gilpin 800-833-2239 [email protected] / www.amamcotool.com 4 Arno Rouse USA LLC 67 Bruce Welz 800-943-4426 [email protected] / www.arno-rouse.com 5 Bal-Tec 34 Patricia Johnson 800-322-5832 [email protected] / www.precisionballs.com 6 BIG Kaiser Precision Tooling Inc. 43 Tim Stapula 888-TOOL-PRO [email protected] / www.bigkaiser.com 7 Briney Tooling Systems 54 Donna Strozeski 800-752-8035 [email protected] / www.b

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