INSERT RESHARPENING.
R&J Tool offers a patented process for resharpening carbide and ceramic indexable inserts for milling and turning. The company sharpens the tools by selectively grinding material to produce a new cutting edge. The process does not reduce an insert’s IC or locating surfaces. According to the company, the process takes into account unique geometries, edge preps and coating combinations for specific applications.
R&J Tool
Booth: W-1846.
DAMPING SYSTEM.
The Smart Damper from BIG Kaiser Precision Tooling Inc. is a through-coolant, dynamic damping system that reportedly eliminates vibration and reduces chatter when deep-hole finish boring and extended-reach facemilling. This translates to finer surface finishes and higher metal-removal rates. Models are available for the company’s boring tools with KAB4 to KAB6 connectors and shell mills with a 1 "-dia. pilot.
BIG Kaiser Precision Tooling Inc.
Booth: W-1600.
HYDRAULIC TOOLHOLDER.
Schunk Inc.’s Tendo E compact hydraulic toolholder is suitable for milling, drilling and reaming. The toolholder can safely transfer torque up to 384 ft.-lbs. at a 20mm clamping diameter, the company reports. Runout is less than 0.0001 " at 2.5 diameters. Common spindle connections are available, including HSK A63, SK 40, BT 40, CAT 40 and CAT 50.
Schunk Inc.
Booth: W-2000.
TURNING INSERTS.
Seco Tools TK1001 and TK2001 insert grades reduce the number of grades needed when turning cast iron. TK1001 is for finishing gray cast iron up to semistable conditions, nodular cast iron under stable conditions and steels hardened to 40 to 45 HRC. TK2001 is for turning nodular and gray cast iron in difficult applications, including heavy interrupted cutting. TK-grade inserts are available in 211 new geometries.
Seco Tools
Booth: W-1564.
THIN CHUCKS.
LMC Workholding offers Chandox SE Series Super Thin chucks. The steel chucks are suitable for holding parts for gaging and metrology applications. A user directly rotates the chuck knob for gripping and loosening a part without the need for a handle. Jaws are reversible to grip various sizes more conveniently, the company reports.
LMC Workholding
Booth: W-1314.
DRILLS AND REAMERS.
Star SU LLC offers custom carbide drills and reamers, including single-pass port cavity tools, which allow complete cavity machining, reduce cycle times and hold industry tolerances for size and finish. Its Super Round tool produces extremely round holes within microns, reams holes with interrupted cuts and imparts fine finishes for spool-bore applications, according to the company.
Star SU LLC
Booths: N-6924, W-1385.
APPLICATION-SPECIFIC TAPS.
Allen Benjamin Inc.’s high-performance, color-coded taps made of HSSE premium steel are engineered for specific applications. Each of the six color rings—black, white, yellow, green, blue and red—indicate an application-specific tap geometry and design criteria based on the characteristics and hardness range of various workpiece materials. Available tap styles include spiral point, spiral flute, form and straight-flute die cast. Taps for threading cast iron are also available.
Allen Benjamin Inc.
Booth: W-2474.
VISE.
Kurt Manufacturing Co.’s Model 3400V Versatile Lock vise has a 6 " jaw opening and 0.0005 " clamping repeatability. The vise prevents parts from lifting under heavy clamping loads, and the pull-type jaw clamping design reduces deflection, the company reports. The 3400V has a one-piece vise body and stationary jaw machined from 80,000-psi ductile iron, which enhances strength and reduces vibration. It’s available in standard and reverse manual and hydraulic models.
Kurt Manufacturing Co.
Booth: W-2423.
SAWING TECHNOLOGY.
Simonds International says saws applied with its SineWave technology cut workhardening material, such as tool steel and stainless steel, 30 to 40 percent faster than traditional bandsawing. The technology uses a unique rocking motion that forces each tooth of a bimetal blade to penetrate the workpiece and impart a fine surface finish. The blade grows in width, creating a self-feeding action that improves productivity, the company reports.
Simonds International
Booth: N-6672.
DRIVEN TOOLS.
Command Tooling Systems LLC has introduced driven tools for Swiss-style machines. The tools were developed in cooperation with local medical manufacturers and Command’s parent company, EWS Tool Technologies. The tools have a labyrinth seal, which shields internal components from contaminants during machining. The housings are made of high-strength alloy steel and the solid shafts are made of tool steel. Runout is reportedly better than 2.5µm.
Command Tooling Systems LLC
Booth: W-2528.
CARBIDE SAWS.
Standard solid-carbide and carbide-tipped “Thin Saws” from Gaylee Saws are available in diameters from ¾ " to 4 ". The company produces solid-carbide saws with a tolerance of 0.0005 "/-0.0000 " on thickness and 0.005 "/-0.000 " on OD. Saws with tighter tolerances can be ordered as specials. The solid-carbide saws last 100 times longer than HSS ones, according to the company.
Gaylee Saws
Booth: W-2474.
MANUAL FIXTURES.
Advanced Machine & Engineering Co. designs and builds Amrok dedicated manual fixtures for horizontal and vertical machining centers, as well as other CNC machines. According to the company, the fixtures reduce machine setup and cycle times, improve operator safety, reduce workpiece handling and improve tolerances because a single fixture is used instead of multiple ones.
Advanced Machine & Engineering Co.
Booth: W-2405.
SPECIAL TAPS.
North American Tool Corp. produces special taps in inch and metric sizes. The taps vary from standard designs based on their shank and drive dimensions, thread form and geometry, number of pitches (threads per inch) and other variables. The taps are available in HSS, HSSE premium steel, carbide and other materials. Coated taps are available.
North American Tool Corp.
Booth: W-2474.
DIGITAL BORING HEAD.
BIG Kaiser Precision Tooling Inc.’s 310 EWD digital boring head shows absolute setting accuracy on a built-in digital display. The measurement system displays linear movement of the tool carrier in both directions during diameter adjustment of 0.00005 ". The boring heads use existing 310 EWN insert holders to allow the maximum boring range per head and are compatible with special insert holders, the company reports.
BIG Kaiser Precision Tooling Inc.
Booth: W-1600.
CUSTOM WORKHOLDERS.
Hardinge Inc. has made more than 200,000 custom workholding designs for turning, milling, grinding, welding, assembling and positioning. A custom product can increase part accuracy, eliminate secondary operations, add flexibility to a machine, enable automation integration and minimize bulky fixturing, according to the company. It can also reduce job setup, changeover time and operator handling. Users often select specials for gripping odd shapes and delicate materials and to avoid part scratching and slippage.
Hardinge Inc.
Booth: S-8148.
TURNING INSERTS.
Walter USA LLC offers an array of cutting tools, including Tiger-tec Silver inserts for turning, Titex X-treme Inox solid-carbide drills and Valenite indexable milling cutters. The inserts resist plastic deformation and crater and flank wear, and reduce machining times, according to the company. In addition to three insert grades, four geometries are available: ones for facing and light cutting, medium machining, general machining and roughing.
Walter USA LLC
Booth: W-1700.
CERAMIC FILAMENT BRUSHES.
Abtex Corp.’s ceramic filament brushes are mounted in the company’s proprietary, molded, composite material. Ceramic fiber has a hard, durable grain that exposes sharp cutting edges as it wears. The application-specific brushes cut fast to reduce cycle times and provide long tool life, the company reports. Abtex also tests parts in its lab to determine the appropriate abrasive filament product.
Abtex Corp.
Booth: N-7138.
PART LOADING DEVICE.
The Lightnin Rod from R&R Tool Inc. helps inexperienced machine operators correctly load parts. Through internal test situation analysis, operators using the device are trained quicker and are able to produce a more reliable product than those not using it, the company reports. Placing the material in the machine and watching for the Lightnin Rod’s blue light to remain lit during tightening ensures accuracy within 0.0002 ".
R&R Tool Inc.
Booth: W-1497.
TOOLHOLDERS.
Rego-Fix Tool Corp.’s dual-contact Rego Plus toolholders are compatible with all BIG Plus spindles and include a line of ER and powRgrip toolholders. According to the company, these toolholders reduce TIR, improve tool rigidity, increase surface finish quality and improve part accuracy. The holders are licensed by BIG Daishowa.
Rego-Fix Tool Corp.
Booth: W-2364.
MACHINE TOOLING.
Heimatec Inc. has introduced complete lines of tooling, each designed for specific brands of turning machines. Those include ones from Haas, Okuma, Mazak, Spinner, Miyano and Nakamura. Full-specification literature by machine brand is available.
Heimatec Inc.
Booth: W-1986.
SUPERABRASIVE WHEELS.
Saint-Gobain Abrasives Inc.’s Norton Paradigm diamond and CBN grinding wheels are for grinding the flutes of carbide and HSS tools. The wheels have a bond that provides exceptionally fast cycle times and a low cost per part, the company reports. The wheels’ high grain retention and uniform structure provide a high G ratio, up to 2.5 times longer wheel life and a 30 percent higher material-removal rate, according to Saint-Gobain.
Saint-Gobain Abrasives Inc.
Booth: N-7051.
CHIP-BREAKING TAPS.
The Rekord DZBF series taps from Emuge Corp. provide chip-breaking capabilities to eliminate the formation of long, continuous chips common when threading carbon steels, alloy steels and austenitic stainless steels. In combination, the cutting face geometry and spiral flute form affect chip flow, chip curl and chip length. This results in short, controllable chips, which eliminate flute clogging, according to the company.
Emuge Corp.
Booth: W-1536.
ER COLLETS.
Jergens Inc. has added ER collets to its Fixture Pro 5-axis, quick-change workholding system for holding rods and other round workpieces. The base of the ER collet mounts to the system’s risers and pallets. The system offers quick-change capabilities for complete part-to-part changeover in less than 60 seconds, the company reports. Collets are available for ER 11, ER 16, ER 20, ER 25 and ER 32.
Jergens Inc.
Booth: W-2312.
SIX-JAW CHUCK.
The ROTA NCR 6-jaw chuck from Schunk Inc. features a a central chuck piston, which supports three inner pendulums evenly arranged at a 120° angle. Each pendulum works in conjunction with three pairs of base jaws, resulting in six-point contact. The chuck clamps deformable rings, housings and thin-walled workpieces while providing maximum clamping force, according to the company. Diameters up to 1,200mm are available.
Schunk Inc.
Booth: W-2000.
MAGNETIC WORKHOLDER.
DocMagnet’s new permanent-electromagnetic chuck is for hard milling applications. The magnetic material, which does not contain rare-earth magnets, reportedly facilitates demagnetization, making it easier to remove hardened steel workpieces from the chuck’s steel surface. Each pole delivers more than 1,500 lbs. of clamping force. Workholders are available in any size in 4 " width or length increments.
DocMagnet
Booth: W-1092.
MILLING SPECIALS.
Lovejoy Tool Co. Inc. makes milling specials from less than 1 " to more than 55 " in diameter. The company can make custom tools for machining cast iron, heat-resistant superalloys, steel, stainless steel, aluminum and composites. The latest CAD/CAM and manufacturing technologies are used in the toolmaking process, according to the company.
Lovejoy Tool Co. Inc.
Booth: W-2214.
THREAD FORMER.
Walter USA LLC’s Prototyp Protodyn HSC solid-carbide thread former is suitable for use in all formable materials, such as steel, stainless steel and aluminum with less than 12 percent silicon. The micrograin carbide substrate, which has a multilayer TiCN coating, enhances toughness and wear resistance, the company reports. The tool’s h6 shank tolerance enables use in shrink-fit toolholders.
Walter USA LLC
Booth: W-1700.
SHOULDER MILL.
The Turbo 10 from Seco Tools is for square-shoulder milling from roughing to finishing. The cutter is also suitable for slotting, contouring, helical interpolation and ramping. Diameter range is from 0.625 " to 4 ", and the maximum cutting depth is 0.354 ". The cutter has a coated, prehardened body with two different pitch configurations for meeting tight tolerances and providing high reliability, the company reports. Mounting types include cylindrical, Weldon, arbor and Combimaster.
Seco Tools
Booth: W-1564.
MODULAR TOOLHOLDER.
The Preci-Flex from Exsys Tool Inc. is a modular toolholder system for lathe tooling changeovers. It has a single base holder and multiple tooling adapters that utilize the ER collet pocket. It allows interchanging of tooling adapters between fixed and rotary base holders. Repeatability is within 5µm.
Exsys Tool Inc.
Booth: W-1664.
LATHE CHUCK.
Lexair Inc. says its Production Dynamic Full Bore collet chuck increases the through-hole capacity of lathe spindles 25 to 30 percent by using a self-contained mechanical-grip/air-release actuation system. This allows use of a lathe’s full spindle-bore capacity. The chuck’s design eliminates the drawtube needed in hydraulic chucks, creating the additional capacity. It’s available in eight sizes for stock diameters from 0.25 " to 5.5 ".
Lexair Inc.
Booth: W-1322.
TOOL CLAMPING SYSTEM.
The Safe-Lock from Haimer USA LLC is a tool clamping system that provides integrated pullout protection for round tools. In combination with corresponding carbide drive pins in the toolholder (shrink fit, collet or hydraulic chuck), spiral-ground grooves in the tool shank prevent the tool from twisting or being pulled out of the holder during extreme machining. This enables a doubling of metal-removal rates by increasing cutting depths and feed rates, the company reports.
Haimer USA LLC
Booth: W-1464.
MANUAL WORKHOLDERS.
Fixtureworks offers manual clamps from Imao, OK-Vise and Mitee-Bite. The clamps provide quick and secure fastening of parts for repetitive machining operations and enable easy loading and unloading of workpieces, according to the company. Clamping forces range from 2 to 2,200 lbs. Configurations include swing, pull, snap, hook, toe and side. The heat-treated alloy steel clamps have a black-oxide finish.
Fixtureworks
Booth: W-1686.
THROUGH-COOLANT TOOLHOLDERS.
Techniks’ CoolBLAST toolholders have coolant paths that direct coolant to the tool tip. Benefits include faster feeds and speeds, enhanced chip evacuation and longer tool life, according to the company. Shrink-fit and endmill holders are available. In addition, facemill arbors have a CoolBLAST arbor screw that provides a coolant path when used with through-coolant facemills.
Techniks
Booth: W-1732.
MANUAL ACTUATORS.
Mitee-Bite Products’ manual actuators can be used in various workholding applications, including gripping the ID of blind-holes. The actuators can generate a pull down force of more than 4,000 lbs. and grip on bores from 0.16” to 1.39” using standard ID clamps. Mill and lathe versions are available. The mill versions can be mounted to hold a workpiece in the vertical and horizontal plane.
Mitee-Bite Products
Booth: W-1246.
POWER CHUCKS.
TMX power chucks are available from Toolmex Industrial Solutions. One suitable application is holding aluminum automotive wheels, where face clamping—an alternative to traditional axial clamping—improves concentricity and minimizes deformation of thin-wall parts during machining, according to the company. The chucks reportedly combine high clamping forces, maximum precision and minimal effort.
Toolmex Industrial Solutions
Booth: W-2275.
ABRASIVE DISC BRUSHES.
Nampower abrasive nylon disc brushes from Brush Research Manufacturing Co. Inc. contain ceramic and silicon-carbide filament to deburr parts while imparting fine surface finishes. The discs are made with a fiber-reinforced thermoplastic base that results in less vibration, according to the company. The brushes come in two styles: dot for general-purpose deburring and surface finishing, and turbine for medium and heavy deburring.
Brush Research Manufacturing Co. Inc.
Booth: N-7263.
GEAR MILLING HOB.
The CoroMill 176 from Sandvik Coromant Co. is an indexable-insert, full-profile hob for roughing, semifinishing and finishing gears. It can more than double tool life and reduce cutting time by 50 percent compared to conventional HSS hobs, according to the company. The milling tool covers gear profile sizes from module 4 to 6 and is custom made for profiles with, for example, addendum modification and protuberance.
Sandvik Coromant Co.
Booth: W-1500.
BALLNOSE ENDMILLS.
Ingersoll Cutting Tools says its Pro-Trio ballnose contour roughing endmills have three effective flutes and accept double-sided inserts. The tools are suitable for copy, channel and deep-pocket milling. Side-cutting insert stations enhance flexibility when side milling, according to the company. The dovetail clamping system ensures insert stability.
Ingersoll Cutting Tools
Booth: W-1822.
MICRODRILL HOLDERS.
Hyper-Accurate microdrill holders from Genevieve Swiss Industries Inc. are for Swiss-style machines and precision lathes. The holders have a prehardened shank and precision nut for enhanced concentricity. Collet sizes are from 0.5mm to 5.8mm.
Genevieve Swiss Industries Inc.
Booth: W-1592.
SPINDLE CONNECTION.
Kennametal Inc. says its KM4X spindle connection provides three times the bending moment-resistant capacity compared to other systems. The spindle connection’s high clamping force and controlled-interference levels result in a robust connection, high stiffness and restrained bending moment for improved performance when machining titanium, according to the company. This enables higher cutting speeds and feeds.
Kennametal Inc.
Booth: W-1522.
TOOL SELECTION SOFTWARE.
Iscar Tool Advisor software from Iscar Metals Inc. is for selecting cutting tools based on cutting conditions, machine power, metal-removal rate and cutting time. Users can enter two to six mandatory fields for quick results or complete more detailed fields, including ones specifying machine parameters, tool diameters and tool grades. The software provides the three best tool options but can display up to 25 tool recommendations per application search.
Iscar Metals Inc.
Booth: W-1800.
MICRO BORING TOOLS.
Microscope microtools from Vargus USA are for high-performance threading, boring and grooving bores as small as 1.0mm. The line includes a range of single-ended inserts and toolholders with an easy-to-use clamping system, according to the company.
Vargus USA
Booth: W-2245.
TOOL COATINGS.
Tools coated with Zenith coatings from Tool-Flo Manufacturing Inc. are effective for dry machining stainless steel, cast iron, carbon steel, titanium and high-temperature alloys hardened up to 68 HRC. The coatings have an optimal thickness and offer high adhesion and enhanced wear resistance, according to the company.
Tool-Flo Manufacturing Inc.
Booth: W-2346.
SHRINK-FIT SYSTEM.
Nexus Tool’s ShrinkMILL system uses shrink-fit technology to maximize the connection between a facemill arbor and the tool. The shrink-fit connection reduces runout and vibration, permits high feed rates, extends insert life and enables fine surface finishes, according to the company. The shrink-fit process heats the facemill, which expands the bore to receive the arbor, and the bore shrinks around the arbor as the tool cools.
Nexus Tool
Booth: W-1732.
CREEP-FEED WHEELS.
Norton Quantum X creep-feed grinding wheels from Saint-Gobain Abrasives Inc. feature the company’s pore-induced construction, Quantum ceramic abrasive and latest bond technology. The wheels reduce grinding cycle times up to 50 percent while using at least 20 percent less power, according to the company. They are available in blank stock in type-01 straight wheel in six sizes from 16 "×1 "×5 " to 20 "×5 "×8 ".
Saint-Gobain Abrasives Inc.
Booth: N-7051.
LIVE CENTERS.
Royal Products says its “standard special” live centers are standard products that accommodate about 90 percent of what were previously considered application-specific requirements. Each center incorporates the company’s Roto-Shield technology to deflect coolant, protect bearings and extend operating life up to 300 percent.
Royal Products
Booth: W-1622.
TURNING INSERTS.
Paltech PH 5000-grade turning inserts from Palbit by Toolmex Industrial Solutions incorporate a new medium-temperature CVD coating process that combines Ti(C,N) and aluminum oxide. The coating provides enhanced adhesion, toughness and wear properties through microstructural optimizations and post-coating treatments, the company reports. Five new inserts are available, which are for turning steel and cast iron.
Toolmex Industrial Solutions
Booth: W-2275.
PCD TOOL MATERIAL.
Iljin USA Inc. says its PCD provides long tool life, enhanced thermal and chemical stability, and extreme wear and abrasion resistance. Grades are available with grain sizes from less than 1µm to 40µm with diamond volumes from 40 to 95 percent. PCD tools are suitable for cutting tungsten carbide, ceramics, aluminum silicon, copper alloys and advanced composites.
Iljin USA Inc.
Booth: W-1868.
DRILL SHARPENER.
Darex LLC says its improved XPS-16 CNC drill bit sharpener sharpens any 2-flute HSS, cobalt or carbide SAE bit, and metric twist bits from 3mm to 16mm in diameter. It sharpens any angle from 118° to 150°. It stores up to 50 drill files and allows users to choose no-split, X-split, R-split and split-only operations. The new model is 20 percent faster than the previous version, according to the company.
Darex LLC
Booth: W-2180.
MILLING INSERTS.
WIDIA’s M270 and M370 series of inserts are for high-feed milling. Three M270 grades are available: TN2505 for good wear resistance when cutting materials as hard as 60 HRC, TN6540 for enhanced toughness and TN6525 for toughness and wear resistance when dry machining steel. The M370 inserts are double-sided, have six cutting edges and enhance performance and reliability when milling steel and cast iron, according to the company.
WIDIA
Booth: W-1452.
DIAMOND-COATED ENDMILLS.
UDCB diamond-coated endmills from U.S. Union Tool Inc. are for milling solid-carbide molds and parts. The tools can cut features and shapes that previously had to be ground or EDMed, according to the company. The ballnose endmills are available from 0.20mm to 6.0mm in diameter and are suitable for operations from roughing through finishing.
U.S. Union Tool Inc.
Booth: W-2108.
HIGH-PERFORMANCE ENDMILL.
M.A. Ford Manufacturing Co. Inc.’s TuffCut XT series 278 endmill is a new 5-flute version of its XR high-performance endmill. The tool has enhanced corner protection, a whisper blend between the OD and neck, and a proprietary carbide substrate coated with ALtima Blaze. The endmill provides 20 percent higher feed rates compared to competing tools and reduces harmonic vibration and imparts finer finishes, according to the company.
M.A. Ford Manufacturing Co. Inc.
Booth: W-2457.
DIAMOND FINISHING TOOLS.
Brush Research Manufacturing Co. Inc.’s Flex-Hone diamond tools are for deburring, edge blending and surface finishing hard materials, such as carbide, ceramic and aerospace-grade alloy steels. The tools’ resin-bond diamond crystals have high friability, creating self-sharpening edges. Standard sizes are from 4mm to 20mm in three different mesh sizes. Specials can be ordered.
Brush Research Manufacturing Co. Inc.
Booth: N-7263.
BORING TOOL ADJUSTER.
The SmartBore system from Rigibore Inc. is a cutting-edge adjuster with DRO for boring tools or cartridges. It enables an operator to manually make micron-level accuracy adjustments while a tool is in the machine spindle. Adjustment data is wirelessly transmitted for remote display. The minimum bore diameter is 16mm.
Rigibore Inc.
Booth: W-1280.
EXCHANGEABLE-TIP DRILL.
The CoroDrill 870 from Sandvik Coromant Co. is an exchangeable-tip drill for the intermediate hole-tolerance area of IT9 to IT10. A secure interface between the drill body and tip ensures reliability and precision, while the quick tip-change procedure helps to maximize active machining time, according to the company. Standard lengths are from 3 to 5 diameters deep. Diameter range is from 12mm to 20.99mm.
Sandvik Coromant Co.
Booth: W-1500.
CERAMIC INSERTS.
Sumitomo Electric Carbide Inc.’s SN2000K- and SN2100K-grade ceramic inserts are for rough milling and turning cast iron. SN2000K is for high-speed turning and finishing and promotes long tool life and wear resistance through its hardness and toughness. SN2100K provides high shock and impact resistance and is suitable for roughing gray cast iron, according to the company.
Sumitomo Electric Carbide Inc.
Booth: W-2422.
DRILL FOR SUPERALLOYS.
The RT100 HF drill from Guhring Inc. provides a high penetration rate when drilling nickel-base alloys. The point geometry helps dissipate heat, and the tool has a double-margin flute for enhanced stability in the cut, according to the company. It is coated with nano-Si, a silicon-based PVD coating that is 57 percent harder than TiAlN-based coatings, the company reports.
Guhring Inc.
Booth: W-2322.
TURNING INSERTS.
TT7005- and TT7015-grade Black-Rush inserts from Ingersoll Cutting Tools are for turning cast iron. The bond between the coating and substrate enhances chip resistance, the company reports. After the inserts are coated, a surface treatment is applied that reduces friction, cutting force and built-up edge. This enables stable and consistent tool life and the ability to impart fine finishes.
Ingersoll Cutting Tools
Booth: W-1822.
DEEP-HOLE DRILLS.
Precision Cutting Tools Inc. says its AXC series drills have a triple-margin design for high-penetration capability and accuracy. Designed for cutting aluminum, the tool’s 15° internal coolant design enhances chip evacuation and controls the temperature at the tool/workpiece interface, the company reports. The spiral-fluted, right-hand cutting drills are from 3.0mm to 20mm in diameter, with models for producing holes 3 to 30 diameters deep.
Precision Cutting Tools Inc.
Booth: W-2164.
EDGE CLAMPS.
Tiny Vise edge clamps from Carr Lane Manufacturing Co. grip the sides of a workpiece so the top is accessible for machining. The clamps are suitable for fixturing small parts and available from a miniature #8-32 thread to a 1 "-8 thread with 2,500 lbs. of clamping force. Force is applied by positive screw action when turning a hex wrench.
Carr Lane Manufacturing Co.
Booth: W-1663.
BORING TOOLS.
Rigibore Inc.’s Active Edge boring tools wirelessly and automatically adjust the cutting edge with micron-level accuracy. Adjustment can be performed remotely while a tool is in the machine’s spindle or carousel, eliminating operator intervention. No spindle modification is required. Up to eight cutting edges can be precisely compensated without touching the boring tool, according to the company.
Rigibore Inc.
Booth: W-1280.
MODULAR TAP.
LMT Fette’s Xchange modular tap combines a solid-carbide cutting head and steel shank. The head is screwed onto the shank and replaced when worn. The tap is for threading cast materials, such as iron, brass and high-silicon aluminum. The through-coolant taps are available in M8 to M18 sizes.
LMT Fette
Booth: W-2464.
RENTION KNOBS.
J&M Machine Inc.’s “Four Steps to Improved Tooling Performance” technology includes the use of high-torque retention knobs and machining practices that can extend tool life 30 percent. According to the company, the retention knobs prevent premature failure and decreased tool life when properly installed. The company provides installation instructions.
J&M Machine Inc.
Booth: W-2179.
WORKHOLDING CLAMPS.
Lenzkes Clamping offers Multi-Quick 60 and 106 clamps. Both have a double-stepless adjustable range and high clamping pressure via low torque. The MQ 60 clamps are for smaller machines, and the MQ 106 clamps provide extra reach and enhanced adjustability through an integrated sliding plate with a stepless, horizontally adjustable fixing set.
Lenzkes Clamping
Booth: W-1880.
CARBIDE INSERTS.
Vargus USA offers 14D carbide inserts for producing API round buttress threads. The line for the oil and gas industry includes a comprehensive variety of standard tools, the company reports. Specials can be ordered based on customer specifications for distinct applications.
Vargus USA
Booth: W-2246.
LATHE TOOLING.
Velocity Products offers a new line of tooling specifically for Okuma lathes. Also available is a patent-pending K column modular clamping and machining system for difficult-to-machine workpieces on horizontal machining centers. This through-feed, tombstone-style workholder brings bar-feed technology to all brands and sizes of HMCs, according to the company.
Velocity Products
Booth: S-9410.
BURNISHING TOOLS.
Elliott carbide roll burnishing tools from Monaghan Tooling Group can impart mirror-like finishes on ODs, IDs, faces, tapers and spherical surfaces, according to the company. The square- or cylindrical-shank tools are for use on all turning centers. They are available with four standard roll radii: 0.032 ", 0.062 ", 0.093 " and 0.125 ".
Monaghan Tooling Group
Booth: W-1286.
CERAMIC INSERTS.
NTK Cutting Tools’ SX7-grade SiAlON ceramic inserts are for machining nickel-base alloys used in the aerospace industry. The inserts provide enhanced flank- and notch-wear resistance, according to the company. The inserts can turn at speeds from 600 to 1,500 sfm and feeds from 0.008 to 0.014 ipr.
NTK Cutting Tools
Booth: W-1163.
THREAD MILLS.
Carmex Precision Tools LLC’s DMT 3-in-1 multipurpose tool drills, threads and chamfers in a single operation. The company also offers a variety of thread mills, ranging from “tiny tools” to large ID and OD thread mills, and recently introduced a series for Swiss-style machines. According to Carmex, its Helical Advantage design boosts productivity, imparts finer finishes and extends tool life.
Carmex Precision Tools LLC
Booth: W-1180.
WORKHOLDERS, TOOLS. Pioneer N.A. offers lines of chucks, collets, indexers and rotary tables, drills, reamers, tap drivers and related attachments, and tool-presetting equipment. The company, which reports it has sold more than 30,000 chucks since 1985, offers air chucks 2.5 " to 10 " in diameter that can be run at 6,000 rpm and have 0.00006 " repeatability. Its diaphragm chucks have diameters from 3 " to 6 " and a maximum operating speed of 12,000 rpm.
Pioneer N.A.
Booth: W-1192.
EQUALIZING CHUCKS.
The SJL chucks from SMW Autoblok Corp. can be switched from a 2+2+2 equalizing chuck for clamping raw materials to a 6-jaw, self-centering chuck for clamping machined diameters. In equalizing mode, the chuck clamps parts with sets of two jaws equalizing as pairs. In 6-jaw mode, the chuck is suitable for boring top jaws and clamping thin-wall workpieces that require equal wall thickness. Diameters from 220mm to 1,250mm are available.
SMW Autoblok Corp.
Booth: W-1400.
Related Glossary Terms
- abrasive
abrasive
Substance used for grinding, honing, lapping, superfinishing and polishing. Examples include garnet, emery, corundum, silicon carbide, cubic boron nitride and diamond in various grit sizes.
- alloy steels
alloy steels
Steel containing specified quantities of alloying elements (other than carbon and the commonly accepted amounts of manganese, sulfur and phosphorus) added to cause changes in the metal’s mechanical and/or physical properties. Principal alloying elements are nickel, chromium, molybdenum and silicon. Some grades of alloy steels contain one or more of these elements: vanadium, boron, lead and copper.
- alloys
alloys
Substances having metallic properties and being composed of two or more chemical elements of which at least one is a metal.
- aluminum oxide
aluminum oxide
Aluminum oxide, also known as corundum, is used in grinding wheels. The chemical formula is Al2O3. Aluminum oxide is the base for ceramics, which are used in cutting tools for high-speed machining with light chip removal. Aluminum oxide is widely used as coating material applied to carbide substrates by chemical vapor deposition. Coated carbide inserts with Al2O3 layers withstand high cutting speeds, as well as abrasive and crater wear.
- arbor
arbor
Shaft used for rotary support in machining applications. In grinding, the spindle for mounting the wheel; in milling and other cutting operations, the shaft for mounting the cutter.
- bandsawing
bandsawing
Long, endless band with many small teeth traveling over two or more wheels (one is a driven wheel, and the others are idlers) in one direction. The band, with only a portion exposed, produces a continuous and uniform cutting action with evenly distributed low, individual tooth loads. Often called band machining.
- boring
boring
Enlarging a hole that already has been drilled or cored. Generally, it is an operation of truing the previously drilled hole with a single-point, lathe-type tool. Boring is essentially internal turning, in that usually a single-point cutting tool forms the internal shape. Some tools are available with two cutting edges to balance cutting forces.
- boring head
boring head
Single- or multiple-point precision tool used to bring an existing hole within dimensional tolerance. The head attaches to a standard toolholder and a mechanism permits fine adjustments to be made to the head within a diameter range.
- built-up edge ( BUE)
built-up edge ( BUE)
1. Permanently damaging a metal by heating to cause either incipient melting or intergranular oxidation. 2. In grinding, getting the workpiece hot enough to cause discoloration or to change the microstructure by tempering or hardening.
- burnishing
burnishing
Finishing method by means of compressing or cold-working the workpiece surface with carbide rollers called burnishing rolls or burnishers.
- carbon steels
carbon steels
Known as unalloyed steels and plain carbon steels. Contains, in addition to iron and carbon, manganese, phosphorus and sulfur. Characterized as low carbon, medium carbon, high carbon and free machining.
- centers
centers
Cone-shaped pins that support a workpiece by one or two ends during machining. The centers fit into holes drilled in the workpiece ends. Centers that turn with the workpiece are called “live” centers; those that do not are called “dead” centers.
- ceramics
ceramics
Cutting tool materials based on aluminum oxide and silicon nitride. Ceramic tools can withstand higher cutting speeds than cemented carbide tools when machining hardened steels, cast irons and high-temperature alloys.
- chatter
chatter
Condition of vibration involving the machine, workpiece and cutting tool. Once this condition arises, it is often self-sustaining until the problem is corrected. Chatter can be identified when lines or grooves appear at regular intervals in the workpiece. These lines or grooves are caused by the teeth of the cutter as they vibrate in and out of the workpiece and their spacing depends on the frequency of vibration.
- chemical vapor deposition ( CVD)
chemical vapor deposition ( CVD)
High-temperature (1,000° C or higher), atmosphere-controlled process in which a chemical reaction is induced for the purpose of depositing a coating 2µm to 12µm thick on a tool’s surface. See coated tools; PVD, physical vapor deposition.
- chuck
chuck
Workholding device that affixes to a mill, lathe or drill-press spindle. It holds a tool or workpiece by one end, allowing it to be rotated. May also be fitted to the machine table to hold a workpiece. Two or more adjustable jaws actually hold the tool or part. May be actuated manually, pneumatically, hydraulically or electrically. See collet.
- collet
collet
Flexible-sided device that secures a tool or workpiece. Similar in function to a chuck, but can accommodate only a narrow size range. Typically provides greater gripping force and precision than a chuck. See chuck.
- composites
composites
Materials composed of different elements, with one element normally embedded in another, held together by a compatible binder.
- computer numerical control ( CNC)
computer numerical control ( CNC)
Microprocessor-based controller dedicated to a machine tool that permits the creation or modification of parts. Programmed numerical control activates the machine’s servos and spindle drives and controls the various machining operations. See DNC, direct numerical control; NC, numerical control.
- coolant
coolant
Fluid that reduces temperature buildup at the tool/workpiece interface during machining. Normally takes the form of a liquid such as soluble or chemical mixtures (semisynthetic, synthetic) but can be pressurized air or other gas. Because of water’s ability to absorb great quantities of heat, it is widely used as a coolant and vehicle for various cutting compounds, with the water-to-compound ratio varying with the machining task. See cutting fluid; semisynthetic cutting fluid; soluble-oil cutting fluid; synthetic cutting fluid.
- copper alloys
copper alloys
Copper containing specified quantities of alloying elements added to obtain the necessary mechanical and physical properties. The most common copper alloys are divided into six groups, and each group contains one of the following major alloying elements: brasses—major alloying element is zinc; phosphor bronzes—major alloying element is tin; aluminum bronzes—major alloying element is aluminum; silicon bronzes—major alloying element is silicon; copper-nickels and nickel-silvers—major alloying element is nickel; and dilute-copper or high-copper alloys, which contain small amounts of various elements such as beryllium, cadmium, chromium or iron.
- creep-feed grinding
creep-feed grinding
Grinding operation in which the grinding wheel is slowly fed into the workpiece at sufficient depth of cut to accomplish in one pass what otherwise would require repeated passes. See grinding.
- cubic boron nitride ( CBN)
cubic boron nitride ( CBN)
Crystal manufactured from boron nitride under high pressure and temperature. Used to cut hard-to-machine ferrous and nickel-base materials up to 70 HRC. Second hardest material after diamond. See superabrasive tools.
- cutting force
cutting force
Engagement of a tool’s cutting edge with a workpiece generates a cutting force. Such a cutting force combines tangential, feed and radial forces, which can be measured by a dynamometer. Of the three cutting force components, tangential force is the greatest. Tangential force generates torque and accounts for more than 95 percent of the machining power. See dynamometer.
- endmill
endmill
Milling cutter held by its shank that cuts on its periphery and, if so configured, on its free end. Takes a variety of shapes (single- and double-end, roughing, ballnose and cup-end) and sizes (stub, medium, long and extra-long). Also comes with differing numbers of flutes.
- facemill
facemill
Milling cutter for cutting flat surfaces.
- facemilling
facemilling
Form of milling that produces a flat surface generally at right angles to the rotating axis of a cutter having teeth or inserts both on its periphery and on its end face.
- feed
feed
Rate of change of position of the tool as a whole, relative to the workpiece while cutting.
- fixture
fixture
Device, often made in-house, that holds a specific workpiece. See jig; modular fixturing.
- flank wear
flank wear
Reduction in clearance on the tool’s flank caused by contact with the workpiece. Ultimately causes tool failure.
- flutes
flutes
Grooves and spaces in the body of a tool that permit chip removal from, and cutting-fluid application to, the point of cut.
- friability
friability
Characteristic of abrasive grains that describes their tendency to fracture or break apart when hit or placed under pressure. Highly friable abrasives cut more easily, but wear faster than other abrasives. Friable abrasives are usually used on soft, gummy materials or where heat produced by worn grits must be carefully controlled. Friability is usually related to the levels of impurities in the manufactured abrasive mineral.
- gang cutting ( milling)
gang cutting ( milling)
Machining with several cutters mounted on a single arbor, generally for simultaneous cutting.
- grinding
grinding
Machining operation in which material is removed from the workpiece by a powered abrasive wheel, stone, belt, paste, sheet, compound, slurry, etc. Takes various forms: surface grinding (creates flat and/or squared surfaces); cylindrical grinding (for external cylindrical and tapered shapes, fillets, undercuts, etc.); centerless grinding; chamfering; thread and form grinding; tool and cutter grinding; offhand grinding; lapping and polishing (grinding with extremely fine grits to create ultrasmooth surfaces); honing; and disc grinding.
- grooving
grooving
Machining grooves and shallow channels. Example: grooving ball-bearing raceways. Typically performed by tools that are capable of light cuts at high feed rates. Imparts high-quality finish.
- hardness
hardness
Hardness is a measure of the resistance of a material to surface indentation or abrasion. There is no absolute scale for hardness. In order to express hardness quantitatively, each type of test has its own scale, which defines hardness. Indentation hardness obtained through static methods is measured by Brinell, Rockwell, Vickers and Knoop tests. Hardness without indentation is measured by a dynamic method, known as the Scleroscope test.
- high-speed steels ( HSS)
high-speed steels ( HSS)
Available in two major types: tungsten high-speed steels (designated by letter T having tungsten as the principal alloying element) and molybdenum high-speed steels (designated by letter M having molybdenum as the principal alloying element). The type T high-speed steels containing cobalt have higher wear resistance and greater red (hot) hardness, withstanding cutting temperature up to 1,100º F (590º C). The type T steels are used to fabricate metalcutting tools (milling cutters, drills, reamers and taps), woodworking tools, various types of punches and dies, ball and roller bearings. The type M steels are used for cutting tools and various types of dies.
- inner diameter ( ID)
inner diameter ( ID)
Dimension that defines the inside diameter of a cavity or hole. See OD, outer diameter.
- inscribed circle ( IC)
inscribed circle ( IC)
Imaginary circle that touches all sides of an insert. Used to establish size. Measurements are in fractions of an inch and describe the diameter of the circle.
- interpolation
interpolation
Process of generating a sufficient number of positioning commands for the servomotors driving the machine tool so the path of the tool closely approximates the ideal path. See CNC, computer numerical control; NC, numerical control.
- lathe
lathe
Turning machine capable of sawing, milling, grinding, gear-cutting, drilling, reaming, boring, threading, facing, chamfering, grooving, knurling, spinning, parting, necking, taper-cutting, and cam- and eccentric-cutting, as well as step- and straight-turning. Comes in a variety of forms, ranging from manual to semiautomatic to fully automatic, with major types being engine lathes, turning and contouring lathes, turret lathes and numerical-control lathes. The engine lathe consists of a headstock and spindle, tailstock, bed, carriage (complete with apron) and cross slides. Features include gear- (speed) and feed-selector levers, toolpost, compound rest, lead screw and reversing lead screw, threading dial and rapid-traverse lever. Special lathe types include through-the-spindle, camshaft and crankshaft, brake drum and rotor, spinning and gun-barrel machines. Toolroom and bench lathes are used for precision work; the former for tool-and-die work and similar tasks, the latter for small workpieces (instruments, watches), normally without a power feed. Models are typically designated according to their “swing,” or the largest-diameter workpiece that can be rotated; bed length, or the distance between centers; and horsepower generated. See turning machine.
- metal-removal rate
metal-removal rate
Rate at which metal is removed from an unfinished part, measured in cubic inches or cubic centimeters per minute.
- metrology
metrology
Science of measurement; the principles on which precision machining, quality control and inspection are based. See precision machining, measurement.
- milling
milling
Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.
- milling machine ( mill)
milling machine ( mill)
Runs endmills and arbor-mounted milling cutters. Features include a head with a spindle that drives the cutters; a column, knee and table that provide motion in the three Cartesian axes; and a base that supports the components and houses the cutting-fluid pump and reservoir. The work is mounted on the table and fed into the rotating cutter or endmill to accomplish the milling steps; vertical milling machines also feed endmills into the work by means of a spindle-mounted quill. Models range from small manual machines to big bed-type and duplex mills. All take one of three basic forms: vertical, horizontal or convertible horizontal/vertical. Vertical machines may be knee-type (the table is mounted on a knee that can be elevated) or bed-type (the table is securely supported and only moves horizontally). In general, horizontal machines are bigger and more powerful, while vertical machines are lighter but more versatile and easier to set up and operate.
- outer diameter ( OD)
outer diameter ( OD)
Dimension that defines the exterior diameter of a cylindrical or round part. See ID, inner diameter.
- physical vapor deposition ( PVD)
physical vapor deposition ( PVD)
Tool-coating process performed at low temperature (500° C), compared to chemical vapor deposition (1,000° C). Employs electric field to generate necessary heat for depositing coating on a tool’s surface. See CVD, chemical vapor deposition.
- pitch
pitch
1. On a saw blade, the number of teeth per inch. 2. In threading, the number of threads per inch.
- plastic deformation
plastic deformation
Permanent (inelastic) distortion of metals under applied stresses that strain the material beyond its elastic limit.
- polycrystalline diamond ( PCD)
polycrystalline diamond ( PCD)
Cutting tool material consisting of natural or synthetic diamond crystals bonded together under high pressure at elevated temperatures. PCD is available as a tip brazed to a carbide insert carrier. Used for machining nonferrous alloys and nonmetallic materials at high cutting speeds.
- sawing
sawing
Machining operation in which a powered machine, usually equipped with a blade having milled or ground teeth, is used to part material (cutoff) or give it a new shape (contour bandsawing, band machining). Four basic types of sawing operations are: hacksawing (power or manual operation in which the blade moves back and forth through the work, cutting on one of the strokes); cold or circular sawing (a rotating, circular, toothed blade parts the material much as a workshop table saw or radial-arm saw cuts wood); bandsawing (a flexible, toothed blade rides on wheels under tension and is guided through the work); and abrasive sawing (abrasive points attached to a fiber or metal backing part stock, could be considered a grinding operation).
- shank
shank
Main body of a tool; the portion of a drill or similar end-held tool that fits into a collet, chuck or similar mounting device.
- slotting
slotting
Machining, normally milling, that creates slots, grooves and similar recesses in workpieces, including T-slots and dovetails.
- stainless steels
stainless steels
Stainless steels possess high strength, heat resistance, excellent workability and erosion resistance. Four general classes have been developed to cover a range of mechanical and physical properties for particular applications. The four classes are: the austenitic types of the chromium-nickel-manganese 200 series and the chromium-nickel 300 series; the martensitic types of the chromium, hardenable 400 series; the chromium, nonhardenable 400-series ferritic types; and the precipitation-hardening type of chromium-nickel alloys with additional elements that are hardenable by solution treating and aging.
- stiffness
stiffness
1. Ability of a material or part to resist elastic deflection. 2. The rate of stress with respect to strain; the greater the stress required to produce a given strain, the stiffer the material is said to be. See dynamic stiffness; static stiffness.
- superalloys
superalloys
Tough, difficult-to-machine alloys; includes Hastelloy, Inconel and Monel. Many are nickel-base metals.
- tap
tap
Cylindrical tool that cuts internal threads and has flutes to remove chips and carry tapping fluid to the point of cut. Normally used on a drill press or tapping machine but also may be operated manually. See tapping.
- threading
threading
Process of both external (e.g., thread milling) and internal (e.g., tapping, thread milling) cutting, turning and rolling of threads into particular material. Standardized specifications are available to determine the desired results of the threading process. Numerous thread-series designations are written for specific applications. Threading often is performed on a lathe. Specifications such as thread height are critical in determining the strength of the threads. The material used is taken into consideration in determining the expected results of any particular application for that threaded piece. In external threading, a calculated depth is required as well as a particular angle to the cut. To perform internal threading, the exact diameter to bore the hole is critical before threading. The threads are distinguished from one another by the amount of tolerance and/or allowance that is specified. See turning.
- through-hole
through-hole
Hole or cavity cut in a solid shape that connects with other holes or extends all the way through the workpiece.
- titanium carbonitride ( TiCN)
titanium carbonitride ( TiCN)
Often used as a tool coating. See coated tools.
- tolerance
tolerance
Minimum and maximum amount a workpiece dimension is allowed to vary from a set standard and still be acceptable.
- toolholder
toolholder
Secures a cutting tool during a machining operation. Basic types include block, cartridge, chuck, collet, fixed, modular, quick-change and rotating.
- total indicator runout ( TIR)
total indicator runout ( TIR)
Combined variations of all dimensions of a workpiece, measured with an indicator, determined by rotating the part 360°.
- tungsten carbide ( WC)
tungsten carbide ( WC)
Intermetallic compound consisting of equal parts, by atomic weight, of tungsten and carbon. Sometimes tungsten carbide is used in reference to the cemented tungsten carbide material with cobalt added and/or with titanium carbide or tantalum carbide added. Thus, the tungsten carbide may be used to refer to pure tungsten carbide as well as co-bonded tungsten carbide, which may or may not contain added titanium carbide and/or tantalum carbide.
- turning
turning
Workpiece is held in a chuck, mounted on a face plate or secured between centers and rotated while a cutting tool, normally a single-point tool, is fed into it along its periphery or across its end or face. Takes the form of straight turning (cutting along the periphery of the workpiece); taper turning (creating a taper); step turning (turning different-size diameters on the same work); chamfering (beveling an edge or shoulder); facing (cutting on an end); turning threads (usually external but can be internal); roughing (high-volume metal removal); and finishing (final light cuts). Performed on lathes, turning centers, chucking machines, automatic screw machines and similar machines.
- wear resistance
wear resistance
Ability of the tool to withstand stresses that cause it to wear during cutting; an attribute linked to alloy composition, base material, thermal conditions, type of tooling and operation and other variables.
- workhardening
workhardening
Tendency of all metals to become harder when they are machined or subjected to other stresses and strains. This trait is particularly pronounced in soft, low-carbon steel or alloys containing nickel and manganese—nonmagnetic stainless steel, high-manganese steel and the superalloys Inconel and Monel.
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