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Cutting Tool Engineering February 15, 2010

February 2010

February 2010 covers workholding and fixturing, drilling and holemaking, and milling strategy. It also looks at automation and hard-material machining.

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Vol. 62 • Issue 2

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[email protected], www.iscarmetals.com

ISCAR METALS INC. 300 Westway Place, Arlington,

TX 76018-1021 Tel+1 817 258 3200, Fax+1 817 258 3221,Tech Tel 1-877-BY-ISCAR.

ISCAR METALS INC. 300 Westway Place, Arlington, TX 76018-1021 Tel+1 817 258 3200, Fax+1 817 258 3221,Tech Tel 1-877-BY-ISCAR [email protected], www.iscarmetals.com

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visit www.micromanufacturing.com

THINK

SMALL The magazine for manufacturers of microparts. To subscribe or learn more.

THINK SMALL The magazine for manufacturers of microparts. To subscribe or learn more, visit www.micromanufacturing.com

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Hornusa

HORN - THE LEADERS IN GROOVING TECHNOLOGY

THERE IS ALWAYS A (GROOVING) SOLUTION... ...and if it doesn’t already exist, we will find it. HORN has developed the world’s most effective range of grooving technology by providing solutions to problems that others have walked away from. Many of our 9000 standard catalog items were developed as specials - but many customers had the same requirements leading to standards

HORN - THE LEADERS IN GROOVING TECHNOLOGY THERE IS ALWAYS A (GROOVING) SOLUTION... ...and if it doesn’t already exist, we will find it. HORN has developed the world’s most effective range of grooving technology by providing solutions to problems that others have walked away from. Many of our 9000 standard catalog items were developed as specials - but many customers had the same requirements leading to standards. Even though our standard catalog range is very broad, it is dwarfed by our database of over 85000 special solutions.

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IMTS.com

I ; F J  ' ) # ' . 9 > ? 9 7 = E

IS #12 M > 7J M ? B B  ? J  I F7 H A  ? D OE K 5.

I ; F J  ' ) # ' . 9 > ? 9 7 = E IS #12 M > 7J M ? B B  ? J  I F7 H A  ? D OE K 5 IMTS.com

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Lyndexnikken

trunion rotary table. Lyndex-Nikken Inc.’s

5AX-201 rotary table has an 8" faceplate trunnion work envelope, which can be incorporated in smaller BT 30 vertical machining centers. It provides a workholding space traditionally associated with larger 40-taper machines, but with a compact body design. The worm system ensures wear resistance, rigidity and the table’s.

trunion rotary table. Lyndex-Nikken Inc.’s 5AX-201 rotary table has an 8" faceplate trunnion work envelope, which can be incorporated in smaller BT 30 vertical machining centers. It provides a workholding space traditionally associated with larger 40-taper machines, but with a compact body design. The worm system ensures wear resistance, rigidity and the table’s rapid speeds, according to the company. The system uses a carbide worm and ion-nitrided worm wheel rather than a conventional bronze actuation mechanism.

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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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Nortonindustrial

“Secrets of 5-Axis Machining,” Industrial Press

Figure 1: Indexing work aids manufacturing of complex CNC Software parts, such as this lever for an industrial robot. Figure 2: Dual-rotary device mounted on a 3-axis machine. realm. A shop can purchase an affordable dual-rotary device faster and more accurately. There is no need for elaborate, mul- and bolt it on a 3-axis mill and get instant 5-axis manufactur- tiple fixtures and there is less chance of multiple-set.

“Secrets of 5-Axis Machining,” Industrial Press Figure 1: Indexing work aids manufacturing of complex CNC Software parts, such as this lever for an industrial robot. Figure 2: Dual-rotary device mounted on a 3-axis machine. realm. A shop can purchase an affordable dual-rotary device faster and more accurately. There is no need for elaborate, mul- and bolt it on a 3-axis mill and get instant 5-axis manufactur- tiple fixtures and there is less chance of multiple-setup align- ing capability (Figure 2). Some CAM software packages, such ment errors. as Mastercam, provide entry-level users with the ability to eas- 2. Simultaneous multiaxis machining. Dedicated multiaxis ily generate 3+2, 5-axis toolpaths. machines handle more than indexing work—they are also capa- This simple solution can dramatically improve efficiency. ble of synchronized, accurate and simultaneous multiaxis mo- By reducing

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Superiortoolservice

product showcase

cutoff machine. Rush Machinery workholding. Fairlane Products’ endmills. Superior Tool Service Inc.’s “Auto-Cut” CNC carbide rod cutoff Sof-Top urethane grippers, available from Inc.’s new 10-flute carbide endmills, machine automatically loads and cuts Fixtureworks, provide secure workholding featuring its Patriot Cutter design, are.

product showcase cutoff machine. Rush Machinery workholding. Fairlane Products’ endmills. Superior Tool Service Inc.’s “Auto-Cut” CNC carbide rod cutoff Sof-Top urethane grippers, available from Inc.’s new 10-flute carbide endmills, machine automatically loads and cuts Fixtureworks, provide secure workholding featuring its Patriot Cutter design, are rods from a large-capacity magazine. in assembly, machining, inspection for profiling titanium and stainless Capacity is 0.055"- to 19⁄16"-dia. rods up to or repair operations. The nonmarking, steel. The company says the additional 16" long. The machine features easy-to- nonstaining grippers feature a bubbled flutes increase longevity and allow for use controls with a touch-screen operator urethane surface, which provides a higher feed rates. Patriot Cutters have interface. Parameters can be quickly set nonslip grip. The surface allows air to

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Anca

wind, solar, bioenergy and advanced information to in-depth analysis of a a shop find work in the growing solar

batteries. Its mission is to accelerate the manufacturer’s capabilities to identify po- energy arena. “Because this industry is commercialization of alternative energy tential business opportunities and suggest growing so quickly, there is a great deal technologies, with a focus on Michigan actions required to fully exploit them. of innovation in product design and.

wind, solar, bioenergy and advanced information to in-depth analysis of a a shop find work in the growing solar batteries. Its mission is to accelerate the manufacturer’s capabilities to identify po- energy arena. “Because this industry is commercialization of alternative energy tential business opportunities and suggest growing so quickly, there is a great deal technologies, with a focus on Michigan actions required to fully exploit them. of innovation in product design and companies. NextEnergy provides the training in part- manufacturing processes.” In those cases, NextEnergy’s R&D portfolio includes nership with the Michigan Economic Soderstrom said, “It is advantageous for working with universities and govern- Development Corp., Lansing, which can companies to offer design and engineer- ment agencies to design and engineer supply grants to cover up to 70 percent ing services as well

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