Upgrading Machine Tools During A Market Uptick

Imagine the sound of a 55-gallon drum filling to the brim in minutes flat with a steady stream of coins dropped unceremoniously CNC Carbide Inserts from high above. That is how Anthony Fettig, CEO of machine tool builder Unisig, described what it’s like to witness the company’s largest, most powerful deep-hole-drilling machines in action during a recent press event.

With more than 300 horsepower behind the tool, holes can be drilled to extreme diameters and depths (20 inches and 32 feet, respectively) in even the most difficult-to-machine materials, including Inconel and other nickel-based alloys. Automatic toolchangers can accommodate shanks as long as 24 inches on some models, and the machines’ beds can be large enough to require shipping in separate sections, each measuring as long as 25 feet, for precision assembly later.

Unisig’s line of deep-hole-drilling machines is not limited to these behemoths. On the other end of the spectrum are machines designed for holes measuring less than 1-inch deep and no broader than 0.04 inch in diameter.

The most important consideration in drilling, Mr. Fettig says, isn’t necessarily the depth or the diameter of the hole: It’s more about the ratio between the two. “We perk up and get happy,” Mr. Fettig says about being presented with depth-to-diameter ratios ranging to 300:1. “We know we can take (customers’) problems away.”

While the company is known for deep-hole drilling, the term itself does not do justice to the breadth of these machines’ capabilities, nor to the breadth of the company’s engineering expertise. With the typical application defined by more than just challenging hole-making operations, he believes “deep-hole machining” is a better descriptor.

In an era when manufacturers of all stripes seek to consolidate operations on fewer pieces of equipment, Unisig has taken the position that a gundrill does not have to be just a gundrill. Indeed, much of the builder’s equipment demonstrates a focus on external workpiece features as well as internal ones.

Although stock delivery machines are available, a significant proportion of Unisig machines are made to order from modular platforms. One example of such a platform is the USC-M line, which combines powerful hole-making with all the general machining capability of a five-axis mill. This machine is particularly useful for plastic-injection moldmakers that annot afford spending too much time drilling deep water-cooling lines. Unisig machines are designed to perform these operations in the same setup as the complex contouring required for exterior features, Mr. Fettig says. Although the machines trend large, workpieces don’t have to be, he continues, explaining that table rigidity and overall volumetric precision eliminate the need to ensure that smaller workpieces (or features of those large enough to overhang the table) are located in a specific “sweet spot.”

Five-axis capability is a function of this rotary table as well as a dedicated, 50-taper, tilting milling spindle mounted parallel to the machine’s drilling spindle. Machining is said to be just as precise—that is, volumetric accuracy is the same—regardless of the tilting spindle’s angle and position within the workzone. “Performance and accuracy aren’t compromised in seemingly less rigid headstock positions,” he says. “Compound angles are effortless.”

He attributes this precision to scale feedback and finely tuned, high-performance servo drives that facilitate precise interpolation. He also credits the company’s strategy of building machines “from the ground up” at the Milwaukee factory. Even CNC engineering is performed in house, including the defining of kinematics and other associated tasks, with components sourced directly from such manufacturers as Siemens, Heidenhain and FANUC. 

Other platforms are similarly configured for work ranging from oil and gas components to aircraft landing gear and various hydraulic systems. Each machine is made to order, with automation systems in particular differing widely from customer to customer. Beyond robot-tending and mulit-machine cells of multi-spindle drilling machines, automation systems range from pallet changers to complex conveyors, roller steadies and other systems involving in-process gaging and even extra servo-driven axes of motion dedicated to streamlining setup and unloading alike.  

Mr. Fettig emphasizes that the reason why “deep-hole drilling” is inadequate to describe what Unisig does has as much to do with what goes on inside a hole as what goes on outside of it. Beyond basic drilling, reaming, tapping and so forth, potential operations include counterboring, slotting and trepanning. Profiling is common as well, including stepped diameters, precisely curved internal radii, sculpted contours and requirements for specific levels of surface finish.

When it comes to this kind of internal machining, cutting tools literally take the initiative. “The majority of deep-hole tools and processes are based around the idea of the tool guiding itself close to the cutting edge,” he says. Standard deep-hole drilling tools come in two basic varieties: gundrills and Boring and Trepanning Association (BTA) drills.

The tools most commonly associated with extreme length-to-diameter ratios, gundrills are available with single-effective geometry. This means the cutting action is all on one side, a contrast with the double-effective geometry that characterizes most conventional drills. This construction provides the necessary clearance for chips and coolant. Typically, wear pads on the periphery help keep the tool in place and provide a burnishing action that smooths the workpiece surface. Point angle and location influence cutting thrust and radial force on the tool at a given set of parameters. The most precise hole making is achieved when tool and workpiece rotate together, he adds, and rotating the workpiece by itself typically produces better results than rotating the tool by itself.

Solid-carbide gundrills are particularly rigid. These tools offer the advantage of resharpening, but they are effective only at diameters smaller than about 300 mm. After that point, they tend to become expensive and/or and fragile, Mr. Fettig says. For larger diameters, tools are available with steel shanks and brazed carbide tips, with “V” notches rolled into the steel for chip evacuation. Alternatively, indexable-insert models eliminate the need to discard the entire tool when worn. That said, these models might not be as precise as brazed-tip tools because each insert-tool connection is subject to variance.

Whereas a gundrill is designed for internal coolant delivery and external chip exhaust, BTA drilling routines involve evacuating chips and coolant through the center of the tool itself, in the opposite direction of the feed. As a result, holes should be at least a certain size—about ½ inch—before considering this tooling, Mr. Fettig says. As is the case with gundrills, BTA tools are available with both brazed and indexable cutting edges. These tools also come in spade-tip geometries, which Mr. Fettig says are particularly useful for cross-holes (such as those typical of the water-cooling lines in the aforementioned moldmaking applications). Although he emphasizes that the gap is closing, BTA drills generally offer higher feed rates, greater rigidity and improved chip control.

Beyond these basic tool types, many Carbide Turning Inserts applications involve custom form tools for imparting more complex profiles. Generalities are difficult to draw about these widely varied offerings; suffice it to say that even familiar-looking geometries require manufacturing for a specific size bore, at the least. For example, bottle-boring tools use CNC-actuated axes to drive cutting edges away from and back into the shank as needed to create internal profiles. Without precise sizing, such action would be impossible. “Given that these tools have to guide themselves, careful planning is critical,” Mr. Fettig says. The same could be said of applications that require integrating that hole-making process with complex outside machining as well.

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Optimized Milling Strategy for Five Axis Titanium Blisk Machining

Oerlikon Fairfield Drive Systems supplies engineered gear and drive systems to off-highway and industrial equipment manufacturers from around the world. As a branch of Oerlikon, the Lafayette, Indiana-based company specializes in the design, development and manufacture of custom gear and drive assemblies for numerous industries, including construction, mining, rail, transportation and agriculture.

Fairfield vies with both foreign and domestic machine shops to stay at the forefront of the industry. To remain competitive, the 88-year-old company constantly seeks ways to streamline its production process. When Fairfield began Lathe Carbide Inserts experiencing issues with producing drive shafts for mining equipment, the company realized that finding an effective solution to its problematic production process would be vital to its success.

The problem involved a large drive shaft constructed of forged alloy steel. The company ran this application on a Carlton Radial Arm Drill with water-soluble coolant using a rotary coolant adaptor (RCA). The operation required drilling 10-inch deep, 0.787-inch diameter holes. To machine the holes, the company used a cobalt twist drill and a fixture plate with 0.787-inch bushings in a process that took 17 minutes, 33 seconds. This lengthy cycle time limited productivity and drove up costs, leading the company to search for a quicker solution.

Fairfield consulted Allied Machine & Engineering Corporation. Allied field sales engineer Carbide Turning Inserts Chad Longstreth, along with Indianapolis-based distributor Carbide, Cutting Tools, and Abrasives Inc. (CCA), brought in Allied’s GEN2 T-A drilling system to address the company’s concerns. Since this implementation, the company reports that the 0.787-inch drill insert exceeded its expectations.

Featuring a chrome helix holder, the new insert uses a bushing fixture for guidance when the tool transitions from one set of holes on the top of the part to another set of holes on the bottom.

“The bushing simply keeps the holes in line,” Mr. Longstreth explains.

Another feature designed to maintain hole straightness is the insert’s custom notch-point geometry. The insert’s design, coupled with its custom AM200 coating, increase tooling life and drill stability, the manufacturer says. In addition, the tool is designed to provide smooth breakouts in through-holes while improving chip formation.

Addressing the benefits of the GEN2 T-A tooling, Mr. Longstreth explains, “The previous process was very tedious, and tool life was minimal. Additionally, the tool required frequent re-sharpening, which detracted from machining and therefore added to production costs.”

With the capability to drill 24 holes before wear sets in, the new drill is an obvious upgrade from the previous tool, which lasted for only ten holes, the company says. The tool reduced the operation’s cycle time by nearly 64 percent to only 6 minutes and 35 seconds.

This cycle-time reduction and longer tool life has created a substantial cost savings for Fairfield. The company lowered its costs by roughly 63 percent when drilling 600 holes with the new tool, a savings that amounted to thousands of dollars.

“Having the ability to make it through an entire part without changing the drilling insert maximizes uptime and minimizes costs,” Mr. Longstreth concludes.

The Cemented Carbide Blog: central and intermediate Inserts

Insert Drill's Redesign Improves Chip Control

One year after the acquisition of SGS Tool Co. by Kyocera Corp., Kyocera SGS Precision Tools has broken ground in Danville, Virginia, beginning work on the Kyocera SGS Tech Hub. Representing a $9.5 million investment and partnership with The City of Danville and The State of Virginia, the Tech Hub is projected to create over three dozen jobs supporting next-generation engineering and manufacturing of cutting tools serving the automotive, aerospace, medical and power generation industries, among others.

The 30,000-square-foot facility will be built on 10 donated acres within an advanced manufacturing and research community known as Cyber Park. Featuring open work environments and collaborative spaces, the Tech Hub facility is designed for easy communication and idea sharing across the Cutting Tool Carbide Inserts office and manufacturing floor.

“The support and investment elected officials have made into developing a skilled workforce and engineering technology hotspot truly differentiate Danville and make it a great place to plant roots and drive innovation,” says Jason Wells, President of Kyocera SGS Tech Hub. “Excellent high school education and trade programs, world-class university engineering programs, and supporting industry research groups such as CCAM and the Institute for Advanced Learning and Research combine into a tour de force that makes Virginia an integral part of our future.”

Building construction is scheduled to last one year with a planned opening in May of 2018. Until building completion, the Tech Hub will be operating out of space provided by the Institute of Advanced Learning and Research through the assistance of the Carbide Drilling Inserts Danville Economic Development Department.

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Drill Helps Shop Balance Cycle Time, Part Quality

Pferd’s Cast Cut line of high-performance carbide burs are designed for work on cast iron, providing high stock removal rate coupled with a smooth milling action said to reduce vibration and noise. According to the company, Machining Carbide Inserts this tool achieves twice the stock removal rates of Face Milling Inserts conventional double-cut burs thanks to its tooth geometry, which is a benefit for meeting high productivity demands of automotive customers. It is available in five standard SCTI shapes with a shank diameter of ¼".

The tool is optimized for coarse stock removal on all types of black, gray and white cast iron. In addition, with a cutting speed in the 1,500- to 2,500-ft.2/min. range (rotational speed of 12,000 to 20,000 rpm), it provides aggressive cutting action resulting in large chips and good chip removal. Combined with the metal removal rates, this tool saves on energy and cutting time as well as waste.

The Cemented Carbide Blog: VCMT Insert

Groove Milling Line Eliminates Secondary Lathe Operations

I recently spent an informative day in Saline, Michigan, meeting with Peter Wiedemann, president of Liebherr Automation Systems, Cohttp://localhost:7788/Liebherr Gear Technology Inc., along with Scott Yoders, vice president of gearing sales, and Kevin Heise, vice president of automation sales. Mr. Wiedemann provided an overview of the company’s global structure and a tour of its U.S. headquarters (pictured), which offers sales and support services for its aerospace and machine tool product divisions. U.S. manufacturing operations are located at its plant in Newport Lathe Carbide Inserts News, Virginia. Parent company Liebherr Verzahntechik GmbH is based in Kempten, Germany.

While in Michigan, I learned of the upcoming Liebherr 2015 Gear Seminar, which will take place June 23-24. It will be co-hosted by Ingersoll Cutting Tools at its technical center in Rockford, Illinois. An annual event for the past 20 years, the seminar offers technical presentations on the latest developments in gear cutting and inspection technology made by experts from Liebherr Gear Technology, Liebherr Automation Systems, Ingersoll Cutting Tools, the Saacke Group and the Wenzel Group. Qualified guests will have the opportunity TNMG Insert to tour the Ingersoll shop floor and to witness a hobbing demonstration on Liebherr’s LC 500. Those interested in attending can contact Liebherr at 734-944-6369 or [e-mail]. I hope to see you there!

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Max Flute Solid Carbide End Mill

Samputensili’s SG 160 Sky Grind, available from Star SU, is said to eliminate the need for cutting oils during the grinding of gears after heat treatment. The machine features two spindles, one for skive hobbing and one for generating grinding. The two spindles are actuated by linear motors and, when combined with the use of more channels, ensure a chip-to-chip time of less than 2 sec., the supplier says.

According to Star SU, the Sky Grind removes 90 percent of the stock allowance with the first pass using a skive hobbing tool. With the second finishing pass, a grinding wheel removes the remaining stock. This process avoids heating the workpiece excessively without the use of oil-based lubricant resulting in a completely dry process.

The Thread Cutting Insert company says that the machine is faster than traditional dual-table grinding machines and has a smaller footprint and lower cost of investment for auxiliary equipment. By eliminating cutting oils, the machine is also WCMT Insert environmentally friendly.

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Covers Protect Tooling, Provide Safety For Operators

Seco Tools has introduced a cutting tool line designed for machining medical knee implants. The Jabro range of solid carbide cutters for high-speed medical machining and other aggressive milling strategies can shorten cycle times on knee implants by as much Machining Carbide Inserts as 50 percent, according to the company.

The tools’ continuous grades and coatings are said to reduce or eliminate the need for polishing or fine finishing operations. These features also promote process stability and long tool life, according to the company.&Cutting Carbide Inserts nbsp;

The product line includes nine advanced geometries and 39 tools, most of which are part of the Jabro Tornado high-speed cutting family. Each geometry is designed for particular applications in the machining of tibial tray and femoral knee implant components. Because these tools are designed to machine cobalt-chrome (CoCr) and 3D-printed Ti6Al4V ISO-S12 parts, they can also improve machine performance for other medical implant components, including hip replacements and bone plates, according to the company.

The Cemented Carbide Blog: Drilling Inserts

Efficient Aluminum Cutting PCD Milling Cutter

Any shop that aims to meet tooling needs for applications ranging from woodworking to aerospace to general machining and cutting of plastics requires versatility. Taylor Toolworks, a manufacturer and service provider of cutting tools based in Alberta, Canada, says it has found the right technology to stay at the forefront of its market with Anca’s MX7 Linear tool grinder.

Taylor Toolworks, which president Jesse Taylor runs with his sister Kristyn, uses five-axis CNC grinding and fine micro-grain carbide products to maintain Lathe Carbide Inserts the mirror finishes and exacting tolerances needed for high-performance tooling. The shop provides reconditioning services and produces end mills and custom tooling.

Taylor Tookworks’ reconditioning services consist of tool regrinding, recutting and recoating. Its end mills include super-polished flutes, special-grade carbides and performance-enhancing coatings. The custom tooling selection caters mainly to the woodworking and metal industries, with micro-grain carbide inserts, custom profile tools, step drills and other options.

When Taylor Toolworks began to move into the large-diameter carbide tooling market, focusing on tooling with diameters ranging from 1.000 to 1.500 inches, it found that it required greater manufacturing versatility. Taylor had seen Anca machines at trade shows, and initial Helical Milling Inserts conversations with Anca application specialists about the MX7 Linear tool grinder caught his attention. Anca’s swift lead times, which were much faster than the “six months to a year” timeline Taylor observed with other machine tool builders, further helped him make a decision.

The MX7 Linear’s 38-kw (51-horsepower) spindle provided the power Taylor Toolworks needed to tackle large-diameter tool manufacturing. Other features that helped the company achieve high-output, high-precision manufacturing include standard linear scales on the X and Y axes, Anca LinX linear motors for X- and Y-axis motion, an integrated wheel dresser, and automation options, which include the RoboMate or FastLoad-MX compact loader. The machine is designed to accommodate varied batch sizes with minimum setup time. Anca recommends the MX7 Linear for high-volume production of tools ranging to 25 mm (1 inch) in diameter. 

Anca’s MX7 Linear tool grinder also includes a standard six-station wheel changer that stores and changes up to six wheel packs. Taylor particularly credits this feature for helping with rapid setup and flexibility, with the versatility of six-wheel packs “essential” to machining complex geometries like step drills and porting tools with multiple grinding operations. The MX7 Linear’s cylindrical linear motor design also increases reliability to improve the quality of the surface finish.

Taylor also credits Anca’s tool simulation software in his purchasing decision. This software, part of Anca’s ToolRoom software package, allows the shop to virtually program tools on desktops or laptops before processing them on the actual machine. Taylor notes that carrying out these simulations “saves valuable machine time” that allows the shop to stay competitive. The ToolRoom software provides specific applications for each tool produced at Taylor Toolworks, such as a step tool editor and a profile tool editor.

In addition to step drills, Taylor says the shop produces through-coolant drills and form tools on the MX7 Linear. Whenever service issues arise using the MX7 Linear — or any of Taylor Toolworks’ three other Anca machines — Taylor says Anca has done well at solving them, whether through a phone call or an on-site visit.

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Reaming System Adds Four Cutting Blades, Extends Reconditioning Life

Air Turbine Tools offers its Tool Breakage Alarm System to protect work in process and cutting tools, which helps prevent scrapped parts, lost hours and machine damage.

As cutting tools follows the programed tool path, Air Turbine Tools’ tool breakage detector system monitors air flow for deviation from a sensitive baseline record of compressed air consumption.

If the cutting tool breaks, Carbide Inserts the Tool Breakage Alarm System activates to alert the operator with a light and/or a klaxon. Operators can also program the system to stop the CNC machine automatically if the CNC or robot control Tungsten Steel Inserts is connected to the Tool Breakage Alarm System’s external port — permitting unattended operation 24/7.

Compressor malfunctions are also detected by the system. If a compressor malfunctions, or if air flow is diverted to other machines, Air Turbine Tools’ Tool Breakage Alarm detects airflow cavitation and alerts the operator or stops the program, protecting work in process, tools and machines from drops in air pressure.

The Cemented Carbide Blog: Cutting Carbide Inserts

Tall AM Build Envelope Cuts Months of Aerospace Prototyping

Okuma’s Turn-Cut programming function enables turning operations on horizontal machining centers without secondary machinery. Workpieces remain stationary so that large, unbalanced parts that would be difficult to set up on a lathe can be machined. According to the company, no special-purpose machines, tooling or fixtures are VBET Insert necessary. The circular motion of the feed axis is synchronized with the spindle’s turning angle to perform cutting operations. The function is activated by a G code in the program and follows standard programing convention to describe the desired path.

The Turn-Cut option enables the horizontal machining center to create CNC Carbide Tool Insert bores and diameters with circular and/or angular features. The surfaces can be created either on the outside or inside diameter of the machined part. The function does not interfere with the performance or longevity of the machine, and may improve performance with the addition of abso-scales or Super-NURBS, the company says. The feature is available as an option on Okuma’s MA and MB series of horizontal machining centers, and can also be retrofitted to existing Okuma machining centers.

The Cemented Carbide Blog: CCMT Insert