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Cutting Tool Engineering September 15, 2010

September 2010

September 2010 covers workholding and fixturing and aluminum machining.

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Vol. 62 • Issue 9

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Iscarmetals

60% MORE g

Deliver iinlity Prof it ab ISCAR Guara ntees Resul ts Cutting Down Production Costs with the High Productivity Tangential Parting System 3Pr oductivity Performance Profitability 30% MORE g G uaran tees R esults Turning into Lower Costs with High Productivity SUMOTURN Coated Grades 3Pr oductivity Performance Profitability.

60% MORE g Deliver iinlity Prof it ab ISCAR Guara ntees Resul ts Cutting Down Production Costs

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Widia

Victory TN5100 and TN7100 Grades

TM TM Our new WIDIA Victory TN Turning Grades provide you significant and measurable productivity gains – no matter how challenging your cut! TN5100TM Series Drastically reduce cycle times – with up to 50% higher feed/speed capability! TN7100TM Series Get exceptional tool life – with as much Unique multi-layer coating delivers.

Victory TN5100 and TN7100 Grades TM TM Our new WIDIA Victory TN Turning Grades provide you significant and measurable productivity gains – no matter how challenging your cut! TN5100TM Series Drastically reduce cycle times – with up to 50% higher feed/speed capability! TN7100TM Series Get exceptional tool life – with as much Unique multi-layer coating delivers as 50% better wear resistance! unparalleled high-speed performance!

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Walter Tools

Passion. Potential. Perfection.

TOUGHER. HARDER. SHARPER. Milling steel or cast iron? Increase output up to 75%! • Extremely stable cutting edge • Extremely smooth rake face Our passion. Your potential. • Easy wear detection thanks to Tiger·tec® Silver They drive us to create the perfect tool indicator coating for every application. The machining age is over. It’s time to Tiger

Passion. Potential. Perfection. TOUGHER. HARDER. SHARPER. Milling steel or cast iron? Increase output up to 75%! • Extremely stable cutting edge • Extremely smooth rake face Our passion. Your potential. • Easy wear detection thanks to Tiger·tec® Silver They drive us to create the perfect tool indicator coating

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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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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. IS #32 HORN

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Uncc

staying sharp

machine technology Figure 3. An array of thin pins with 0.5mm-square cross sections, approximately 75mm tall, made on a conventional 3-axis machine tool using deformation machining. for example, as a heat sink. but it is already clear that complex part States Lee College of Commercial applications for formed geometries are feasible in a range of ma- Engineering, University.

staying sharp machine technology Figure 3. An array of thin pins with 0.5mm-square cross sections, approximately 75mm tall, made on a conventional 3-axis machine tool

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Mapal

take digital pictures, but also how to do About the Author: Tom Lipton is a career calling (888) 528-

minor editing and resizing. These skills metalworker who has worked at various 7852 or visiting www. better. You can share and exchange vast and lives in Alamo, Calif. Lipton’s column By indicating the code amounts of information around the globe is adapted from information in his book CTE-2010 when ordering, using the Internet and your digital cam- “Metalworking Sink or Swim: Tips and Tricks CTE readers will receive.

take digital pictures, but also how to do About the Author: Tom Lipton is a career calling (888) 528- minor editing and resizing. These skills metalworker who has worked at various 7852 or visiting www. will only make your experience that much job shops. He has received six U.S. patents industrialpress.com. better. You can share and exchange vast and lives in Alamo, Calif. Lipton’s column By indicating the code amounts of information around the globe is adapted from information in his book CTE-2010 when ordering, using the Internet and your digital cam- “Metalworking Sink or Swim: Tips and Tricks CTE readers will receive era. You might develop a friendship with for Machinists, Welders, and Fabricators,” a 20 percent discount another inquisitive tradesperson looking published by Industrial Press Inc., New off the book’s list price of for the same answers as you from eight York. The publis

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Wolverinemachine

108" (9') long, six were about 3' long, when cutting through thicker material. Waterjet cutting consumed 80 hours,

and the rest were 6' to 7' in length. Part “Generally, we use a 0.014"-dia. orifice with each of the longer parts taking up width was roughly 3½", but some parts and a 0.040"-dia. nozzle. That seems to to 8 hours to cut. featured curves to strengthen the molded work unless you are doing something ex- Despite the challenges posed by the.

108" (9') long, six were about 3' long, when cutting through thicker material. Waterjet cutting consumed 80 hours, and the rest were 6' to 7' in length. Part “Generally, we use a 0.014"-dia. orifice with each of the longer parts taking up width was roughly 3½", but some parts and a 0.040"-dia. nozzle. That seems to to 8 hours to cut. featured curves to strengthen the molded work unless you are doing something ex- Despite the challenges posed by the carbon-fiber part. Part thickness varied treme,” he said. large workpiece, Walker said, “I like cut- from ½" to 7¼". “The majority of the Tolerances were not tight. “We put ting this thick material. It is heavier so cuts were around 5" thick,” Walker said. ±0.060" on the quote, and that’s pretty it doesn’t move around too much.” The “We needed to know how thick the pieces wide open for us,” Walker said. “They thick workpiece also required few

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Imts

Pfl_Xm\kf

Y\k_\i\ In today’s economy, it’s not the strongest who survive, but those who are most adaptable to change … at IMTS, you’ll see what’s coming … s .EW TECHNOLOGIES s )NNOVATIVE APPROACHES s "REAKTHROUGHS TO THE NEXT LEVEL More than 90,000 manufacturers, including many of your toughest competitors, will see and compare.

Pfl_Xm\kf Y\k_\i\ In today’s economy, it’s not the strongest who survive, but those who are most adaptable to change … at IMTS, you’ll see what’s coming … s .EW TECHNOLOGIES s )NNOVATIVE APPROACHES s "REAKTHROUGHS TO THE NEXT LEVEL More than 90,000 manufacturers, including many of your toughest

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Kennametal

Beyond Blast technology uses low-pressure conditions

TM to offer high-pressure performance Through-channel coolant, delivered at the cutting edge, results in twice the tool life of standard inserts Delivers superior performance on Titanium and high-temperature alloys, using either high- or low-pressure coolant systems Effective thermal management results in reduced cutting temperatures.

TM Beyond Blast technology uses low-pressure conditions to offer high-pressure performance Through-channel coolant, delivered at the cutting edge, results in twice the tool life of standard inserts Delivers superior performance on Titanium and high-temperature alloys, using either high- or low-pressure coolant systems Effective thermal management results in reduced cutting temperatures, improved lubricity, superior chip control, and longer tool life That’s Different Thinking.

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MAG IAS

Finish Titanium at 100 ipm For more information visit

w w w. m a g - i a s . c o m Machine Titanium 100 % Faster with the new MAX-FLUTE End Mill Or call one of our CYCLO specialists at ext. #7  Starting as low as $132  Ideal for Finishing Thin Walls and Floors  Make Radial Cuts of 0.035”  Proven Tool Life up to 90 minutes ,  Unique Design Allows up to 15 Regrinds  Available up to 1.250”.

Finish Titanium at 100 ipm For more information visit w w w. m a g - i a s . c o m Machine Titanium 100 % Faster with the new MAX-FLUTE End Mill Or call one of our CYCLO specialists at 800 934 0735 ext. #7  Starting as low as $132  Ideal for Finishing Thin Walls and Floors  Make Radial Cuts of 0.035”

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