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Cutting Tool Engineering August 15, 2016

August 2016

August 2016 covers milling strategy, turning, and drilling and holemaking. It also looks at digital manufacturing and tool coatings.

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Vol. 68 • Issue 8

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Fax +1 817 258 3221, [email protected]

ISCAR's Winning Edge

Grooving Innovations Jet Coolant Directed to the Cutting Edge for Better Chip Control with Superior Productivity Turning Grooving Parting ISCAR METALS INC

ISCAR's Winning Edge Grooving Innovations Jet Coolant Directed to the Cutting Edge for Better Chip Control with Superior Productivity Turning Grooving Parting ISCAR METALS INC. Tel +1 817 258 3200, Tech Tel 1-877-BY-ISCAR Fax +1 817 258 3221, [email protected] www.iscarmetals.com

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Komaprecision

NEW PRODUCTS

TBS SERIES 5 th Axis Ball Drive System RBS SERIES ROTARY TABLE S & 4th Axis Ball Drive System INDEXERS RDS SERIES Direct Drive System HIGH PRESSURE 100 Bar High Pressure Coolant HI SMART Quick Change Angle Heads ANGLE HEADS & HI FLEX LIVE TOOLS Custom Made Special Angle Heads HIGH SPEED Turboflex Spindles, Max 60,000 RPM.

NEW PRODUCTS TBS SERIES 5 th Axis Ball Drive System RBS SERIES ROTARY TABLE S & 4th Axis Ball Drive System INDEXERS RDS SERIES Direct Drive System HIGH PRESSURE 100 Bar High Pressure Coolant HI SMART

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Methodsmachine

FEATURING THE LATEST TECHNOLOGIES IN

METAL CUTTING, AUTOMATION SOLUTIONS AND ADDITIVE MANUFACTURING AT IMTS 2016 State-of-the-Art Automation Additive Machine Tools Solutions Manufacturing BOOTH S-9119 CORPORATE OFFICE TECHNICAL CENTER AND SHOWROOM TECHNICAL CENTERS FROM COAST TO COAST 65 Union Avenue, Sudbury, MA 01776 Charlotte Chicago Detroit Los Angeles Phoenix San Francisco.

FEATURING THE LATEST TECHNOLOGIES IN METAL CUTTING, AUTOMATION SOLUTIONS AND ADDITIVE MANUFACTURING AT IMTS 2016 State-of-the-Art Automation Additive Machine Tools Solutions Manufacturing BOOTH S-9119 www.methodsmachine.com CORPORATE OFFICE TECHNICAL CENTER AND SHOWROOM TECHNICAL CENTERS FROM COAST TO COAST 65 Union Avenue, Sudbury, MA 01776 Charlotte Chicago Detroit Los Angeles Phoenix San Francisco 978.443.5388 | [email protected] 704.587.0507 847.783.6800 248.624.8601 714.521.2507 602.437.2220 510.636.1430

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Heimatecinc

It's easy to say your tooling

solves problems . It's harder to prove it. We prove it every day. Stuck on a tough tooling Call us today, visit challenge? Let us help. our website or stop by our booth W-2413 Heimatec isn’t just a world leader in live tools, angle heads at IMTS 2016. and multi-spindle drill heads; we’re your source for problem solving and tooling application expertise. We'll be waiting!

It's easy to say your tooling solves problems . It's harder to prove it. We prove it every day. Stuck on a tough tooling Call us today, visit challenge? Let us help. our website or stop by our booth W-2413 Heimatec isn’t just a world leader in live tools, angle heads at IMTS 2016.

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Mini marvels deliver outstanding performance. www.hornusa.com

Mini cutting at its Peak

Small, Strong, Streamlined. Additions to the Mini Tool System achieve higher feed rates and reduced production time in steel and cast iron. Standard widths from 0.74 mm to 3 mm (.029 99 to .118 99 ) are ideal for machining bore diameters from 6 mm to 20 mm (.236 99 to .787 99 ) and cutting depths up to 8 mm (.315 99 ). New sintered geometries provide excellent chip control and greater productivity. These.

Mini cutting at its Peak Small, Strong, Streamlined. Additions to the Mini Tool System achieve higher feed rates and reduced production time in steel and cast iron. Standard widths from 0.74 mm to 3 mm (.029 99 to .118 99 ) are ideal for machining bore diameters from 6 mm to 20 mm (.236 99 to .787 99 ) and cutting depths up to 8 mm (.315 99 ). New sintered geometries provide excellent chip control and greater productivity. These www.hornusa.com Mini marvels deliver outstanding performance. www.hornusa.com H O R N – EXC EL LENCE IN TECHNOLOGY GROOVING PARTING OFF GROOVE MILLING BROACHING PROFILE MILLING REAMING

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Leistritzcorp

Visit us at IMTS 2016

Booth# N-7061 CUSTOMIZED TOOLING SOLUTIONS Many applications today require special designs – Leistritz excels n End facing at providing customized solutions that may be difficult to achieve n Profile form turning with standard tools. Our decades of experience solving machining n End milling problems is now available to manufacturers seeking greater n Step drilling.

Visit us at IMTS 2016 Booth# N-7061 CUSTOMIZED TOOLING SOLUTIONS Many applications today require special designs – Leistritz excels n End facing at providing customized solutions that may be difficult to achieve n Profile form turning with standard tools. Our decades of experience solving machining n End milling problems is now available to manufacturers seeking greater n Step drilling productivity particularly in Aerospace, Automotive and Medical Fields. n Thread milling Leistritz tools are designed to fit any spindle in any machine. n Key seating Leistritz Advanced Technologies Corp.

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Mikrontool

High performance for

stainless steel Hall West - booth 2485 cool tools DIFFICULT MATERIALS EASY MACHINING – Stainless steel – Titanium and titanium alloys – Superalloys and Cr-Co-alloys MAXIMUM PERFORMANCE IN SMALLEST DIMENSIONS – Decreased machining time – Increased tool life – High process reliability – Diameters from 0.3 mm (.0118“) drilling milling.

High performance for stainless steel Hall West - booth 2485 cool tools DIFFICULT MATERIALS EASY MACHINING – Stainless steel – Titanium and titanium alloys – Superalloys and Cr-Co-alloys MAXIMUM PERFORMANCE IN SMALLEST DIMENSIONS

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Fax+1 817 258 3221, [email protected]

ISCAR’s Winning Edge

Grooving Innovations Threading Inserts with Cutting Corners ISCAR METALS INC

ISCAR’s Winning Edge Grooving Innovations Threading Inserts with Cutting Corners ISCAR METALS INC. Tel + 1 817 258 3200, Tech Tel 1-877-BY-ISCAR, Fax+1 817 258 3221, [email protected] www.iscarmetals.com

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Schutteusa

BOOTH N-7516

CNC PRECISION 32 and 46 mm capacity 7 and 9 spindle models Low to high volume production applications Free speed selection in any position Drives, guide-ways, lubricant/coolant hoses or cables not in machining area Wide range of machining applications, including C-and Y-axis to machine second side of a component Specializing in.

BOOTH N-7516 CNC PRECISION 32 and 46 mm capacity 7 and 9 spindle models Low to high volume production applications

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Molemab

SUPER ABRASIVES FOR MECHANICAL

AND AUTOMOTIVE APPLICATIONS we shape your world NOW WITH FORTE 1D, 1B & PRO SERIES PRODUCTION IN THE USA NEW - FORTE PRO SERIES POROUS POLYGLOSS HD COME VISIT US ! BOOTH# N-6658 NEW - POLYGLOSS pHD POROUS Molemab USA Corp. 91 Carey Road, Queensbury, NY 12804 USA.

SUPER ABRASIVES FOR MECHANICAL AND AUTOMOTIVE APPLICATIONS we shape your world NOW WITH FORTE 1D, 1B & PRO SERIES PRODUCTION IN THE USA NEW - FORTE PRO SERIES POROUS POLYGLOSS HD COME VISIT US ! BOOTH# N-6658

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of EDM

Shaping the Future

Top Performing DS4 Ultra-fine Grain Leads the Industry’s Most Complete Line World's Largest Cold Isostatic Press of EDM Graphite in St. Mary's, PA Mersen is the ideal choice to handle your full range of EDM machining requirements, from roughing to DS4 Features the most demanding operation. As North America’s largest producer of specialty graphite, we’ve.

Shaping the Future of EDM Top Performing DS4 Ultra-fine Grain Leads the Industry’s Most Complete Line World's Largest Cold Isostatic Press of EDM Graphite in St. Mary's, PA Mersen is the ideal choice to handle your full range of EDM machining requirements, from roughing to DS4 Features

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Cogsdill

Benefit Benefit

DENTAL INSURANCE COMPANY VEHICLE 100% 100% 90% 90% 80% 80% 70% 70% 60% 60% 50% 50% 40% 40% 30% 30% 20% 20% 7% 10% 34% 41% 32% 17% 22% 18% 19% 41% 16% 36% 43% 10% 1% 0 0 1% 0 0 0 3% 0 33% 0% 0% MM CNC P TD TME DE PE SS ES PM CM MM CNC P TD TME DE PE SS ES PM CM PAID TRAINING PROFIT SHARING 10% 39% 49% 38% 13% 20% 18% 16% 29% 14% 22% 32% 10% 24% 30% 25% 14% 19% 12% 13% 29% 13% 26% 34%.

Benefit Benefit DENTAL INSURANCE COMPANY VEHICLE 100% 100% 90% 90% 80% 80% 70% 70% 60% 60% 50% 50% 40% 40% 30% 30%

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Makino adaptive automation combines the

JOIN US FOR EXCITING best engineering thinking with best-in-class

manufacturing technology. LUNCH & LEARN SESSIONS AT IMTS, EVERY DAY AT NOON

Makino adaptive automation combines the JOIN US FOR EXCITING best engineering thinking with best-in-class manufacturing technology. LUNCH & LEARN SESSIONS AT IMTS, EVERY DAY AT NOON. GET DETAILS AT MAKINO.COM/IMTS

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Cgctool

OPEN UP A CAN

ON HIGH COST PRODUCTION S PRODUCTION PATENT NUMBERS.

OPEN UP A CAN ON HIGH COST PRODUCTION S PRODUCTION WWW.CGCTOOL.COM | 866-888-9600 PATENT NUMBERS 7,153,067 7,367,754 Like us on Facebook for updates on all the Weapons of Mass Production at www.facebook.com/GorillaMill

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and Steve Stokey, USCTI President

CUTTING TOOL FORECAST

BREAKFAST RECEPTION AT IMTS Thursday, September 15, 2016 Please join USCTI and AMT for a breakfast reception featuring IHS Global, 7:30 - 8:30 AM West Building - W-181 discussing the cutting tool market forecast and joint statistics program. UPCOMING INSTITUTE MEETINGS 2016 Fall Meeting 2017 Spring Meeting October 15-17, 2016 May 6-8, 2017.

CUTTING TOOL FORECAST BREAKFAST RECEPTION AT IMTS Thursday, September 15, 2016 Please join USCTI and AMT for a breakfast reception featuring IHS Global, 7:30 - 8:30 AM and Steve Stokey, USCTI President West Building - W-181 discussing the cutting tool market forecast and joint statistics program. Cutting Tool Manufacturers can register by contacting the USCTI office at [email protected]. UPCOMING INSTITUTE MEETINGS

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Cutting Tool Engineering

19,851 of CTE’s 22,981 machine

shop subscribers are managers. —June 2015 BPA Brand Report Contact your CTE sales rep today about advertising. East Central East Central West Far West Scott Beller Dave Sweeney Dave Jones Ryan King Cutting Tool Engineering Buyers Guide: Where Buyers Meet Suppliers

19,851 of CTE’s 22,981 machine shop subscribers are managers. —June 2015 BPA Brand Report Contact your CTE sales rep today about advertising. East Central East Central West Far West Scott Beller Dave Sweeney Dave Jones Ryan King 847-714-0183 248-540-0300 708-442-5633 773-414-9292 [email protected] [email protected] [email protected] [email protected] www.ctemag.com Cutting Tool Engineering Buyers Guide:

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Carmexusa

thread cutting

in materials Carmex’s specially engineered combination of carbide substrates and advanced multi-layer coatings deliver higher production, improved finish and longer tool life. Carmex’s BLU, a sub-micrograin grade with PVD Carmex HBA, an extra-fine sub-micron grade, delivers triple layer coating, combines high strength and high superior performance in such tough materials as hardened.

thread cutting in materials Carmex’s specially engineered combination of carbide substrates and advanced multi-layer coatings deliver higher production, improved finish and longer tool life. Carmex’s BLU, a sub-micrograin grade with PVD Carmex HBA, an extra-fine sub-micron grade, delivers triple layer coating, combines high strength and high superior performance in such tough materials as hardened wear resistance and is an excellent choice for steel up to 62 HRc, hardened cast iron and super alloys threading stainless steel, titanium and cast iron. including Hastelloy, Inconel, and other nickel-based alloys. TEST REPORT TEST REPORT

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1-800-storloc www.storloc.com

the best tool cabinet

you’ll ever buy guaranteed for 55 years 100% made in the usa in every way! Made by aMerican.

the best tool cabinet you’ll ever buy guaranteed for 55 years 100% made in the usa in every way! Made by aMerican 1-800-786-7562 craftsMen in the Usa 1-800-storloc www.storloc.com

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Prab

INCREASE PROFITABILITY

from Your Machining Operations Turnings & Chip Dualpak™ Coolant Recycling Processing Systems Chip Briquetters Systems With Custom Built Equipment for Processing Scrap Metal and Spent Fluids OPTIMIZE IMPROVE CUT Container Loading Plant Safety New Coolant Purchases and Tool Life and Haul Away Costs Designed for you – guaranteed

INCREASE PROFITABILITY from Your Machining Operations Turnings & Chip Dualpak™ Coolant Recycling Processing Systems Chip Briquetters Systems With Custom Built Equipment for Processing Scrap Metal and Spent Fluids OPTIMIZE IMPROVE CUT Container Loading Plant Safety New Coolant Purchases and Tool Life and Haul Away Costs Designed for you – guaranteed.

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Hassay Savage

Swiss Machining’s Best Partner

Magafor USA Precision Round Tools World’s Finest Broaches GMauvaisUSA™ New 2016 3 Program Catalog MICRO Drills Now Available We Do “Small” Really Well See Us At IMTS Chicago Sept. 12-17, 2016 Booth #W2356 Hassay Savage Company 10 Industrial Blvd, Turners Falls, MA 01376-2251.

Swiss Machining’s Best Partner Magafor USA Precision Round Tools Hassay Savage World’s Finest Broaches GMauvaisUSA™ New 2016 3 Program Catalog MICRO Drills Now Available

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when whirling or milling internal threads. www.hornusa.com

Micro Circular Milling Taken to the Extreme

Produce internal features with speed and precision. Our solid carbide DC circular milling system features 3 or 4 cutting edges enable the system to generate accurate threads, grooves, radii, chamfers and rectangular cross sections in small diameters. The DC system is the cost effective solution to steel and plastics. The highly efficient system creates full or part-profile, conical as well as right and.

Micro Circular Milling Taken to the Extreme Produce internal features with speed and precision. Our solid carbide DC circular milling system features 3 or 4 cutting edges enable the system to generate accurate threads, grooves, radii, chamfers and rectangular cross sections in small diameters. The DC system is the cost effective solution to machine steels and materials used in medical technology, such as titanium, cobalt chrome, stainless www.hornusa.com steel and plastics. The highly efficient system creates full or part-profile, conical as well as right and left-handed threads of M1.6 and above. You define the runout and thread depth with utmost accuracy when whirling or milling internal threads. www.hornusa.com HO R N – E X C E L L E N CE IN T E CH N OLOGY GROOVING PARTING OFF GROOVE MILLING BROACHING PROFILE MILLING REAMING

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Visit carrlane.com to learn more.

The LOWEST clamping device

just got lower. Tiny Vise Low-Profile ® NEW Low-profile Tiny Vise® clamps from Carr Lane Manufacturing securely grip the side of a workpiece to keep the top clear for machining. Available in a wide range of sizes, from a miniature #8-32 thread size, up to a powerful 1”-8 thread size with 2500 lbs clamping force. Patented design. Made in USA

The LOWEST clamping device just got lower. Tiny Vise Low-Profile ® NEW Low-profile Tiny Vise® clamps from Carr Lane Manufacturing securely grip the side of a workpiece to keep the top clear for machining. Available in a wide range of sizes, from a miniature #8-32 thread size, up to a powerful 1”-8 thread size with 2500 lbs clamping force. Patented design. Made in USA. Visit carrlane.com to learn more. See this and our other new products at IMTS Sept. 12-17 (Booth W-1663) www.carrlane.com

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Tapmatic

High Production Tapping

on CNC Lathes has never been Faster or Greener Example: Tapping 80 M8x1.25 holes on Mori Seiki NL2500 in 6061 Aluminum. Rigid Tapping at 2500 RPM, cycle time 2 minutes 27 seconds. (33 holes per minute) Rigid Tapping at 4000 RPM, cycle time 2 minutes 16 seconds. (35 holes per minute) Tapping with ASR50 self-reversing head.

High Production Tapping on CNC Lathes has never been Faster or Greener Example: Tapping 80 M8x1.25 holes on Mori Seiki NL2500 in 6061 Aluminum. Rigid Tapping at 2500 RPM, cycle time 2 minutes 27 seconds. (33 holes per minute) Rigid Tapping at 4000 RPM, cycle time 2 minutes 16 seconds. (35 holes per minute) Tapping with ASR50 self-reversing head programmed at 2500 RPM...

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Tungaloyamerica

Ad Index

ADVERTISER NAME PAGE # CONTACT NAME CONTACT PHONE CONTACT EMAIL / WEBSITE 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 2016 by CTE Publications.

Ad Index ADVERTISER NAME PAGE # CONTACT NAME CONTACT PHONE CONTACT EMAIL / WEBSITE Tungaloy America Inc. 43 Lisa Penzick 888-554-8394 [email protected] / www.tungaloyamerica.com Tungco Inc. 171 Cliff Nance 614-214-5122 [email protected] / www.tungco.com Tungsten Toolworks 112 John Forrest 800-564-5832 [email protected] / www.tungstentoolworks.com UNISIG Deep Hole Drilling Systems 88-89 Jeff Price 262-252-3802 ext. 214 [email protected] / www.unisig.com Unison Corp. 64 Dave Swider 248-544-9500 [email protected] / www.newunison.com Unist Inc. 147 Nate Pegman 616-949-0853 [email protected] / www.unist.com UNITED GRINDING 49 Ted Neckel 937-847-1229 [email protected] / www.grinding.com USCTI 83A 216-241-7333 [email protected] / www.uscti.com

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