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Cutting Tool Engineering April 15, 2012

April 2012

April 2012 covers drilling and holemaking, grinding practice, and automation. It also looks at turning and surface quality.

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Vol. 64 • Issue 4

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Minimum molding
Article April 15, 2012
Minimum molding
Manufacturing molds used to produce plastic parts with features that can be too small to be seen with the naked eye or measured with standard devices is…

Advertisers in this issue

Iscarmetals

Designed for Accuracy and

High Productivity in Small Part Machining ISCAR’s new miniature inserts for face grooving and turning are available in a diameter range of 0.315” to 0.67” for a 0.216” maximum grooving depth. One toolholder carries all insert geometries. MIFR for MIFR for MITR for MIUR for MIGR for MIGR for Face Grooving Face Grooving Internal Threading Undercutting Internal Grooving Internal Grooving.

Designed for Accuracy and High Productivity in Small Part Machining ISCAR’s new miniature inserts for face grooving and turning are available in a diameter range of 0.315” to 0.67” for a 0.216” maximum grooving depth. One toolholder carries all insert geometries. MIFR for MIFR for MITR for MIUR for MIGR for MIGR for Face Grooving Face Grooving Internal Threading Undercutting Internal Grooving Internal Grooving

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Yg1usa

Expansions in product offerings

that include… STI Inch Series and Metric Series Hand Taps New manufacturing Powdered Metal Multi 1 Drill • Range: 3/32" – 1/2" Micro Carbide Dream Drill • Drilling Range: .039 – .114 facilities with additional Dream Drill for 50-70 Rc Applications • Drilling Range: .118 – .551 “STATE-OF-THE ART” equipment. Inox Dream Drill for Stainless Steel • Drilling Range: .118 – .787.

Expansions in product offerings that include… STI Inch Series and Metric Series Hand Taps New manufacturing Powdered Metal Multi 1 Drill • Range: 3/32" – 1/2" Micro Carbide Dream Drill • Drilling Range: .039 – .114 facilities with additional Dream Drill for 50-70 Rc Applications • Drilling Range: .118 – .551 “STATE-OF-THE ART” equipment.

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visit www.mscdirect.com/underpressure/index.html

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Dataflute

DIE MOLD

BALL - NOSE SERIES New Metric Offering Re-engineered Imperial Offering Data Flute is pleased to introduce our new Die Mold series of solid carbide, ball-nose end-mills for hard milling, mold applications. These material and application specific tools are designed to use the most productive, leading-edge, high-speed machining techniques. The result is superior finishes.

DIE MOLD BALL - NOSE SERIES New Metric Offering Re-engineered Imperial Offering Data Flute is pleased to introduce our new Die Mold series of solid carbide, ball-nose end-mills for hard milling, mold applications. These material and application specific tools are designed to use the most productive, leading-edge, high-speed machining techniques. The result is superior finishes, extended tool life and a work piece requiring little or no handwork. Please contact us to have one of our application specialists help you

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GOO GL

Fully integrated performance

NEW Tiger·tec® Silver ISO P Generation: By combining new grades and new geometries, Walter Valenite has created a new generation of steel turning inserts. We paired our unique Tiger·tec® Silver CVD coating with a newly developed universal geometry range for turning steel. That’s what we call pure performance – fully integrated into the.

Fully integrated performance NEW Tiger·tec® Silver ISO P Generation: By combining new grades and new geometries, Walter Valenite has created a new generation of steel turning inserts. We paired our unique Tiger·tec® Silver CVD coating with a newly developed universal geometry range for turning steel. That’s what we call pure performance – fully integrated into the

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Imcousa

/ Ê 7 Ê * " 7U,U Ê ™Ó {

IT’S LIKE THE DIFFERENCE BETWEEN LIGHT... AND LIGHTNING. E X T R E M E V E R S AT I L I T Y. SHEAR POWER. / iÊ*"7U,U Ê ™Ó{ʈÃÊ`iÈ}˜i`ÊvœÀÊ «Àœ`ÕV̈œ˜]Ê«ÕÀiÊ>˜`Êȓ«i°Ê"«Ìˆ“ˆâi`ÊÀ>ŽiÊ >˜`ÊÀiˆivÊ>˜}iðÊ,iˆ˜vœÀVi`ÊVÕÌ̈˜}Êi`}iÃÊ >ÃÌʏœ˜}iÀʈ˜Ê`i“>˜`ˆ˜}Ê>««ˆV>̈œ˜Ã°Ê*ÕÃ]Ê  "½Ãʏ À 8Êi˜}ˆ˜iiÀi`ÊVœ>̈˜}Ê >ÃÊ Lii˜Êà œÜ˜Ê̜ʈ“«ÀœÛiÊ̜œÊˆviÊiÝ«œ˜i˜Ìˆ>Þ°.

/ Ê 7 Ê * " 7U,U Ê ™Ó { IT’S LIKE THE DIFFERENCE BETWEEN LIGHT... AND LIGHTNING. E X T R E M E V E R S AT I L I T Y. SHEAR POWER. / iÊ*"7U,U Ê ™Ó{ʈÃÊ`iÈ}˜i`ÊvœÀÊ «Àœ`ÕV̈œ˜]Ê«ÕÀiÊ>˜`Êȓ«i°Ê"«Ìˆ“ˆâi`ÊÀ>ŽiÊ

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United Grinding

The new benchmark

S41 for Swiss precision. 510 Earl Blvd. Miamisburg, OH 45342.

S41 The new benchmark for Swiss precision. United Grinding 510 Earl Blvd. Miamisburg, OH 45342 937.859.1975 Booth #1709 www.grinding.com

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Cutting Tool Engineering

finer surface finishes than standard machining. “When using

MLS, you have to consider the size of the grain and the size of the laser burst and what is the resolution,” he said. “With all of your additive processes, it’s a function of the bonding method that determines how smooth a surface you get. “For good resolution, you need submicron powders and highly focused lasers with high energy bursts,” Kinder contin-.

finer surface finishes than standard machining. “When using MLS, you have to consider the size of the grain and the size of the laser burst and what is the resolution,” he said. “With all of your additive processes, it’s a function of the bonding method that determines how smooth a surface you get. “For good resolution, you need submicron powders and highly focused lasers with high energy bursts,” Kinder contin- ued. “Some machining centers offer 0.2μm resolution. With a machine tool—if you can create the geometry in the cores and cavities—you can produce better resolution than just about

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tools and over 100,000 application solutions. www.hornusa.com

Always Milling

The Ultimate in Precision Milling, as needed. Horn has many innovative tool solutions that are effi- cient, economical, and precise and can be individually customized for your advanced milling processes. Horn offers the most comprehensive standard tool program worldwide, specializes in creating application specific tooling.

Always Milling The Ultimate in Precision Milling, as needed. Horn has many innovative tool solutions that are effi- cient, economical, and precise and can be individually customized for your advanced milling processes. Horn offers the most comprehensive standard tool program worldwide, specializes in creating application specific tooling and provides complete project planning. As the technology leader, our stan- dards are others specials. We have more than 18,000 standard precision tools and over 100,000 application solutions. www.hornusa.com HORN – LEADERS IN GROOVING TECHNOLOGY

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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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See the latest technology www.dmgmoriseikiusa.com

DMU 125 P/FD duoBLOCK®

When it comes to complex machining, there’s a difference between surviving and thriving. Machines from DMG / Mori Seiki USA handle complex geometries, tough-to-machine materials and intricate details with speed and accuracy—offering productivity you may not have even believed possible. So you can have your part and profit, too

DMU 125 P/FD duoBLOCK® When it comes to complex machining, there’s a difference between surviving and thriving. Machines from DMG / Mori Seiki USA handle complex geometries, tough-to-machine materials and intricate details with speed and accuracy—offering productivity you may not have even believed possible. So you can have your part and profit, too. Machining is believing. MAY 8-10 See the latest technology www.dmgmoriseikiusa.com and advanced techniques.

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800.521.9520 | mscmetalworking.com

Available exclusively at MSC Industrial Supply Co.®

Available exclusively at MSC Industrial Supply Co.® 800.521.9520 | mscmetalworking.com

Available exclusively at MSC Industrial Supply Co.® 800.521.9520 | mscmetalworking.com

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Compass Automation

productive times

Universal Grinding Corporation Looking for Mr. Goodpart Grinding Services: O Blanchard Diversification helps minimize the risk END USER: Mitchel & Scott O Centerless Bar & Tube that a downturn at one customer or one Machine Co. O Double Disk industry will negatively impact a parts O Gun Grinding manufacturer’s business. For more than www.mitchelgroup

productive times Universal Grinding Corporation Looking for Mr. Goodpart Grinding Services: O Blanchard Diversification helps minimize the risk END USER: Mitchel & Scott O Centerless Bar & Tube that a downturn at one customer or one Machine Co. O Double Disk industry will negatively impact a parts (317) 684-8247

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Imts

I will succeed every time I compete against you.

I’ve directed my team to see and compare the world’s newest manufacturing technology solutions in person. They have the budget and the power to buy. They’ll meet with the best minds in the business. Educational sessions will enhance their knowledge. Decisions will be made. Orders will be placed. We will begin taking deliveries. You will be hard-pressed to keep up

I will succeed every time I compete against you. I’ve directed my team to see and compare the world’s newest manufacturing technology solutions in person. They have the budget and the power to buy. They’ll meet with the best minds in the business. Educational sessions will enhance their knowledge. Decisions will be made. Orders will be placed. We will begin taking deliveries. You will be hard-pressed to keep up. Some call this continuous improvement. We call it survival of the fittest. Dominate the competition.

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MDMEast.com

The Education, Innovative Solutions, and Strategic Business

Partnerships Needed to Bring Your Device to Market For nearly 30 years, MD&M East has been the industry’s trusted resource for every aspect of medical device development. This annual event puts you face-to-face with the industry’s best and brightest who have the expertise and engineering know-how you require to thrive in an environment that demands speed, quality, precision, and innovation

The Education, Innovative Solutions, and Strategic Business Partnerships Needed to Bring Your Device to Market For nearly 30 years, MD&M East has been the industry’s trusted resource for every aspect of medical device development. This annual event puts you face-to-face with the industry’s best and brightest who have the expertise and engineering know-how you require to thrive in an environment that demands speed, quality, precision, and innovation. Exposition: May 22–24, 2012 | Conference: May 21–24, 2012 Pennsylvania Convention Center | Philadelphia, PA Complete event details and registration at: MDMEast.com

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Cutting Tool Engineering

CUTTING TOOL ENGINEERING reaches more

machine shop managers than any other magazine in the metal, metalworking and machinery market.* › 15,551 machine shop managers subscribe to CTE March Vol. 64 www.c Issue temag.c om –December 2011 BPA Circulation Statement up pa rts pr oduc tion June Editorial Focuses: Making Medical Parts; Drilling; Quality Control; heats.

CUTTING TOOL ENGINEERING reaches more machine shop managers than any other magazine in the metal, metalworking and machinery market.* › 15,551 machine shop managers subscribe to CTE March Vol. 64 www.c Issue temag.c om

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