Performance Micro Tool's Unprecedented Advancements in End Mills and Cutting-Edge Applications3/13/2024 Performance Micro Tool first to make the world's first 5 micron end mill. Today, Performance Micro Tool end mills are approaching diameters and tolerances thought impossible just a few years ago. Their unique manufacturing ability has led to many firsts including the world's first 5 micron end mill. PMT's in-stock and custom end mills are used in some amazing applications - from designing medical diagnostic tools for use inside the body to developing micro components for U.S. fighter jets. The PMT product line and unique quality controls assure customers of superior end mill performance and longevity. They also offer the shortest lead times in the industry! PMT Features
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OSG is pleased to announce the expansion of our HY-PRO® CARB VGM end mill series with the addition of the NEW VGM3-AL!
The HY-PRO® CARB VGM3-AL is a is a series of Variable Geometry end mills for High Speed Machining in Aluminum and Non-Ferrous Materials. The following list numbers are associated with the NEW VGM3-AL series:
The HY-PRO® CARB VGM3-AL end mill offers the following features & benefits:
Entry-level Tool Presetting and Measuring system Big Daishowa’s Speroni STP Essentia tool presetting and measuring system performs measurements next to machine tools. The SPERONI STP ESSENTIA is the entry-level Tool Presetting and Measuring system. Its robust structure and user-friendly software interface allow customers to benefit from a basic, essential unit with a tangible, long-lasting performance. The ESSENTIA enables users to measure tools offline and has user-friendly controls designed to optimize tool measurement operations. The MaxP runout function, base post processor and entry-level tool database are included in the Essentia control. Presetters measure the cutting edges of tools to ensure they match job specifications and are ready for use in the machine. Adjustments that could take up to 15 minutes can be made offline in less than one minute on a presetter, the company says, allowing the machine to continue cutting.
With the SPERONI ESSENTIA, you can efficiently measure tools, easily and independently of the operator achieving full machining productivity. Robust, space-saving, and long-lasting, ready to deliver quality results right beside your CNC machine. A leap forward in shrink-fit technology by Bernard Martin Platinum Tooling has introduced the Rineck Induktherm Rapid Shrink II VCS Machine to its repertoire, promising a paradigm shift in the way machining professionals approach shrink-fit tooling. In this article, we'll explore the key features, benefits, and applications of this cutting-edge machine that has garnered attention in the manufacturing industry.
Key Features of the Rineck Induktherm Rapid Shrink II VCS Machine: Rapid Heating Technology The Induktherm Rapid Shrink II VCS Machine is equipped with rapid heating technology, ensuring swift and efficient tool heating. This feature significantly reduces downtime and enhances overall operational efficiency. The heating time takes only between 3 – 9 seconds! Versatile Cooling System (VCS) The VCS system integrated into the machine allows for both air and water cooling, providing flexibility based on the specific requirements of different tools and materials. The cooling time varies between 15 and 50 seconds depending on the mass of the tool holder. User-Friendly Interface The machine boasts a user-friendly interface, making it easy for operators to navigate and control the heating and cooling processes. Intuitive controls contribute to a seamless user experience. Precision and Consistency The Induktherm Rapid Shrink II VCS Machine ensures precise and consistent tool clamping, critical for achieving accuracy in machining processes. This level of reliability is essential in applications where tolerances are tight. It's designed for use with HM tools with shafts of Ø 3 to Ø 32 mm and HSS tools of Ø 6 to Ø 32 mm Compact Design Despite its advanced features, the machine maintains a compact design, making it suitable for various workshop environments. Its space-saving attributes make it a versatile choice for machining facilities of different sizes. Benefits and Applications
Stable and high efficiency in small diameter deep-hole applications. by Hiroyuki Amano, OSG Corporation Applications Engineer (Drill Development Division) OSG Corporation has recently released the ADO-MICRO – the company’s first small diameter carbide drill with oil holes designed for stable and high efficiency drilling in deep-hole applications. The sense of size upon hearing the phrase “small diameter” will be understood differently among users in the manufacturing industry. The ADO-MICRO has a lineup of drill diameters from 0.7 mm up to 2 mm for drill lengths of 2xD and 5xD, and diameter 1 mm to 2 mm for drill lengths of 12xD, 20xD and 30xD. The product name ADO-MICRO may seem to be associated with the unit prefix micro (µ), but it was named to simply imply smallness in size regardless of the unit. For small diameter drilling, options such as carbide drills and HSS drills using external coolant are available. However, today’s machining needs require greater stability, higher efficiency and longer life than ever before. There is no exception in small diameter deep-hole applications, with growing needs for coolant-through small diameter drills. Tool GeometryOne of the keys for successful small diameter drilling is trouble-free chip evacuation. As illustrated in figure 1, chips generated at the tip of the tool flow in the direction of the blue arrow. However, if there is insufficient space in the flute, cutting chips cannot evacuate smoothly, which causes the drilling accuracy to deteriorate and increases the probability of tool breakage. Therefore, by providing a wider flute specification at the area where the tip of the blue arrow locates, as depicted in figure 1, cutting chips are able to be discharged without difficulty, leading to stable machining.
However, micro sludges can be easily accumulated around the outer periphery of the cutting tool, which is a key cause of abrupt tool breakage. To resolve this challenge and to achieve an overall balance, an extended flute configuration is incorporated to provide sufficient exit room as shown in figure 3. Oil HolesThe ADO-MICRO features a straight hollow shank design where coolant is injected in addition to the two spiral oil hole paths. This configuration increases coolant discharge from the tool tip. Without the hollow shank configuration, greater pressure is required in order for the coolant to pass through the thin oil hole paths. With the hollow shank feature, pressure loss is reduced, which increases the coolant flow volume. As illustrated in figure 4, with a higher coolant flow rate, cutting chips can be more effectively evacuated, thereby enabling stable machining. OSG’s Latest Coating Technology: IchAda CoatingAnother key element for achieving stable processing in small diameter deep-hole application is coating technology. The role of tool coating is to provide wear resistance and heat resistance to prolong tool life, which is particularly important to small diameter tooling. As illustrated in figure 5, the coating surface by conventional technology is not smooth, which may interfere with the performance of chip evacuation. OSG’s latest IchAda coating, on the other hand, provides excellent surface smoothness in conjunction with high wear resistance and heat resistance to enable small diameter tools to achieve long tool life by improving adhesion. Cutting DataFigure 6 demonstrates a comparison of tool life between the ADO-MICRO and two other tooling manufacturers’ products in the machining of SCM440. The competitor drills have chipped or have broken at the initial machining stage. The ADO-MICRO, on the other hand, was able to achieve long tool life stably due to its superior chip evacuation capability by breaking chips into small and manageable pieces. The ADO-MICRO demonstrates stable performance even in difficult-to-machine titanium alloy applications. As shown in figure 7, the competitor drill struggled with chip evacuation, thus requiring step processing. However, with the ADO-MICRO, step processing can be eliminated while achieving approximately five times the drilling efficiency. The ADO-MICRO was still in good shape after doubling the competitor drill’s tool life, allowing it to be used on other applications. The ADO-MICRO’s unique tool geometry and OSG’s original IchAda coating allow non-step drilling even for deep-hole applications, enabling high processing efficiency.
By eliminating common complication in small diameter deep-hole drilling, the ADO-MICRO is able to excel with stable performance in a wide range of work materials including stainless steel. In addition to standard stock items, OSG also offers customization services with tailored solutions for each and every manufacturer’s specific machining needs. Hoffman Estates, IL - BIG DAISHOWA has expanded its lineup of Smart Damper-integrated products to include 318 Large Boring Systems and the CK1, CK2 and CKB3 systems.
The new 318 Smart Damper deep boring system is for fine or rough boring of diameters from 200-320mm (7.87-12.6") and uses the CKB7 connection to adapt to almost any machine. The integration of Smart Damper shortens the distance from the damping mechanism to the cutting edge, which is the source of vibration. This produces higher damping effects to the tool assembly to minimize vibration and achieve better surface finishes and improved metal removal rates. The 318 Series low weight and secure configuration make it well suited to high-speed operations (up to 6,600 SFM). Smart Damper SW Heads offer boring efficiency six times higher, twice the cutting depth and three times the cutting conditions of other rough boring heads. Now, the new Smart Damper SW head for the CK1, CK2 and CKB3 makes the CK modular precision tool system available for the full range of SW products. This makes SW heads more versatile than ever before—and boosts the already impressive stability of CK-compatible connections. In all cases, BIG DAISHOWA’s Smart Damper technology makes boring quieter, more efficient and vibration-free. For more information about the 318 Large Boring Systems, click here. To learn more about the CK1, CK2 and CKB3 systems, click here. As a member of the BIG DAISHOWA Group (Osaka, Japan), BIG DAISHOWA Inc. is a recognized global tooling provider, with manufacturing facilities in North America, Switzerland and Japan. BIG DAISHOWA is also the North American representative of Speroni tool measuring machines, Sphinx high performance drills, mptec measuring stands, Tekusa spindle cleaners and the UNILOCK zero-point workholding system. by Kathrin Rehor, MAPAL The machine tool manufacturer bavius technologie gmbh was able to achieve impressive material removal rates of over 20 litres per minute on its new high-end model HBZ AeroCell 160 with a new generation of aluminium high-volume milling cutters from the tool manufacturer MAPAL. The result of this successful collaboration comes at the right time for the aerospace industry, which is taking off again following the downturn caused by coronavirus. The machine manufacturer, which emerged from the Handtmann Group, has been operating as an independent company under the name bavius technologie gmbh since a management buy-out in 2017 and has its headquarters in Baienfurt. Despite all the changes, the business area has remained the same for almost four decades. CNC machining centres are designed and built for the precise high-speed machining of large workpieces made of aluminium. “Over 80 percent of our work is for the aerospace industry, where our AeroCell machines are used primarily to produce large structural parts”, explains Amit Paranjape, Sales Manager at bavius. Customers are aircraft manufacturers and their first and second tier suppliers. Large volumes are required to make full use of the bavius systems. There are currently two different machine lines from Baienfurt. The PBZ profile machining centres are used, among other things, to machine seat tracks for aircraft. The HBZ horizontal machining centres are used to manufacture large structural parts from solid. “Everything long and wide is machined here”, explains Paranjape. “Users can machine all the necessary parts for the airframe of an aircraft on our machines.” The material removal rates are extreme, as one example from a bavius customer shows, who mills out finished parts weighing only 35 kilograms from blanks weighing 1.3 tonnes. Trend towards horizontal machiningThe aerospace industry is undergoing a transformation in terms of machine concepts. After decades of preferring to work on gantry machines or vertical machining centres, horizontal machines are now preferred for new investments, where the components are clamped upright and the spindle is moved horizontally. The main advantage of the horizontal design is the easier removal of the large quantity of chips, which practically fall into the chip conveyor by themselves. At bavius, it’s clear that the aerospace industry has recovered from Covid. Passenger numbers have already returned to pre-pandemic levels and are continuing to rise. As a result, new planes are needed again, which keeps machine manufacturers busy. Demand in Germany, France, Spain and other countries reveals that there is a lot of investment in Europe again. Dynamic machines with high spindle power are particularly sought after. bavius is currently expanding its high-end series HBZ AeroCell with the new AeroCell 160. With a range of mechanical changes, the manufacturer also achieves even greater dynamics with the new machine. Modifications in automation reduce non-productive times. Instead of functioning with hydraulic arms, it is now electrically powered. With the set-up station in front of the machine, a complete pallet change takes two to three minutes. If the pallet is already connected with the part, this takes less than a minute. Tool change has also been optimised with a chip-to-chip time now of 12 seconds. To the limits and beyondThe AeroCell 160 is designed for maximum material removal rates in aluminium. A powerful jet of coolant and a widened chip conveyor ensure that no chip particles can build up anywhere. “Thanks to our concept, we avoid problems that occur with gantry machines. In this way, we can optimally deploy modern tools”, explains Stefan Diem, Application Engineer at bavius. In order to test new machines and at the same time provide customers with references, bavius carries out milling tests that push them to their limits and beyond. “Lots of customers want to see evidence first before they buy a machine”, admits Diem. It is important for the machine manufacturer to use the most efficient tools currently available for the tests, which are then also available for customer demonstrations. bavius regularly tests various manufacturers’ tools. Due to the tight production deadlines, there are not many options. “To save time, it is important for us to have a good exchange with the tool manufacturer”, says Stefan Diem. “We’ve had a good relationship with MAPAL for many years and have always been very pleased with the roughing and finishing tools. I appreciate our close collaboration with MAPAL. We receive excellent advice and are in good hands.” Because milling cutters from the OptiMill-SPM series had previously been used at bavius and performed very well, MAPAL was asked again. It was perfect timing: the tool manufacturer had just finished developing a new solid carbide roughing cutter, the OptiMill-Alu-Wave, and also offered the new aluminium high-volume milling cutter NeoMill-Alu-QBig with indexable inserts for larger diameters. The milling tests are kept simple in design but put the tools through their paces. bavius mills a series of flutes in a large aluminium plate for this. Stefan Diem takes a very pragmatic approach: “if the tool can do the flute, we can also use it to mill pockets and do any other machining.” This means that the determined cutting data can be directly applied to customer parts. The tool could do even moreFor the tests with the OptiMill-Alu-Wave, bavius chose the largest diameter of this three-fluted cutter at 25 mm. At a spindle speed of 25,465 rpm and a cutting speed of 2,000 m/min, the spindle power was gradually increased. Slot number 6 delivered the best material removal rate with a record-breaking 20 dm3/min. This test run was performed with a spindle power of 175 kW, with a torque of 66 Nm, and a material removal rate of 30 mm. The machine stopped during tests at higher powers. “The tool can be fully deployed, the limiting factor is the spindle”, Diem comments on the result. “With the 25 mm OptiMill-Alu-Wave, we have achieved a new dimension in aluminium machining. The milling cutter is definitely better than anything we had previously used.” bavius used the Safe-LockTM system as pull-out protection. “In this speed range, symmetrical pull-out protection is very important in order not to create imbalance”, explains Tim Rohmer, Product Manager Solid Carbide Milling Tools at MAPAL. A Weldon flat, which is often attached to such tools as pull-out protection, is the wrong solution here. To guarantee the smooth running of the machine, there is no way around careful balancing, even with symmetrical tools. The tests in Baienfurt were also met with a great deal of satisfaction in terms of surface quality. The cord geometry of the OptiMill-Alu-Wave ensures optimum chip formation. The polished groove profile ensures seamless chip removal, which is supported by the central cooling of the tool in cooperation with the external cooling in the machine. In further tests, pockets were milled into the aluminium plate, with a material removal rate of 16 litres still being achieved with very good surfaces. For Application Engineer Thomas Jungbeck and Component Manager Alexander Follenweider, who monitored the tests for MAPAL, this is proof of the very good dynamics of the bavius machining centre: “Other machines often stop in the corners and cause high vibrations. This doesn’t occur at all with the AeroCell, which goes round corners almost unrestrained.” As an indexable insert tool, the new aluminium high-volume milling cutter NeoMill-Alu-QBig from MAPAL is an economic solution for larger diameter ranges. In the tests, the 50-mm milling cutter stood out with a high degree of stability and smooth running. It achieved a material removal rate of 18.4 dm3/min. ©bavius The tests at bavius with the new indexable insert tool NeoMill-Alu-QBig from MAPAL, for which the 50 mm diameter was selected, were also extremely positive.
The aluminium high-volume milling cutter achieved a material removal rate of 18.4 dm3/min. On the machine, the milling cutter stood out with its high level of stability, smooth running and low cutting forces. For use at spindle speeds up to 35,000 rpm, MAPAL fitted the tool body with four threaded bores for fine balancing. The high-precision peripherally ground indexable inserts achieve surface finishes of Ra 0.8 µm and Rz 4 µm during rough and fine machining. They are equipped with a polished chip guiding stage to reduce frictional resistance and heat release. Weight was also saved in order to reduce centrifugal forces. “For larger diameters, milling cutters with indexable inserts are the more economical solution”, explains Heiko Pup, Product Manager for tools with indexable inserts, contrasting the NeoMill-Alu-QBig milling cutters with solid carbide milling cutters. With a 25 mm diameter, the two systems merge. “Some of our customers always go for the more cost-efficient indexable inserts if possible, others prefer to save themselves an extra machining step and continue with the solid carbide milling cutter”, explains Stefan Diem. With different possible radii for its tools, MAPAL provides users with flexibility. With the horizontal machining centre AeroCell 160 and the aluminium high-volume tools, bavius and MAPAL provide users with a combination that takes machining structural parts to a whole new level. |
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