Engineering Manager & Product Manager
Proper clamping techniques will ensure the proper operation of all mechanical milling chucks.
Since the introduction of the XT Series 4 flute, 5 flute and the new 279 series 4 flute ball nose end mills they have proven to be a huge success in the machining of Titanium and stainless steels. These tools have already made their impact in the machining of many other areas such as all steels and super alloys.
MA Ford's spotlight focus is on some other materials that are widely used in the market. 17-4 PH stainless many feel is somewhat difficult to machine and performance may vary depending on the material hardness. That is not the case with the new XT series end mills. These tools do not seem to care what hardness is presented to them! 28-42 RC is primary range for this series of stainless steel.
Example: A customer had a very difficult 17-4 PH medical component with lots of contouring both roughing and finishing. A 1/2" 279 Series was used for roughing the profile at 600 SFM with a depth of .015 and .025 step over at 80 IPM. The customer had to double the speeds and feeds as well as increase the step over to get the desired finish required!
The 277 Series 4 flute can full slot up to 1X dia. depth at speeds as high as 260 to 340 SFM. The chip loads will be lighter than profile milling dependent on the tool diameter and fixture set up. The slotting depth can be increased even beyond 1X depth (which generally requires a reduction in speeds and feeds).
The 278 Series 5 flute can slot up to 1X depth effectively but slotting is more suited for the 4 flute 277 Series if a lot of slotting is to be done. The speeds and feeds are the same as the 277, but calculations must be made for the additional cutting edge. It is not recommended to slot over 1X the tool diameter with this 5 flute tools as it is best suited for profile milling both conventional and high speed machining.
The new 279 Series 4 flute ball nose end mill is an excellent choice for both conventional and high speed machining of stainless steels. With the added radial relief and a thicker cross section in the center of the tools it can withstand extreme speeds and feeds both roughing and contouring.
NTK's industry leading line of ceramic cutting tools recently expanded with new solid CERAMIC end mills! You can see our product announcement here: NTK now offers SX9 Ceramic End Mills for Cutting Exotic Alloys which contains the various features. Below is the technical info on how to run the NTK Ceramic End mills and a troubleshooting guide.
NTK's SX9 cermaic end mill grade can run at speeds of 2000 SFM. The line-up includes 4 and 6 flutes in inch and metric versions. Again, you can learn more about on our Blog Post.
Solid ceramic end mills are made with SX9 SiAlON grade substrate which features a balance of toughness and wear resistance. It's suitable for even the most demanding applications.
Gernarel Recomendations for machining heat resistant alloys & PH stainless steel
As with any other techncial questions please get in touch with us on our CONTACTS page and we can provide both over-the-phone troubleshooting or schedule at time for on-site techncial training.
The concept of using guide pins to load large fixtures has been around for a long time, and it even applies when incorporating Unilock zero-point clamping systems in your fixturing.
The main Unilock clamping knob is very robust, i.e.: very hard, and as such it can cause damage to a Unilock chuck if a fixture is very heavy or large.
Guide pins are set up on the base, and their corresponding holes or notches located on the edge of the fixture pre-position the fixture so, that as it is being lowered, the knobs do not impact the critical location faces of the clamping chuck.
This also has the added benefit of keeping operators in a safe location not having to use their hands & fingers to fine-adjust a slightly out-of-place fixture being lowered.
An end mill is a type of milling cutter. It is distinguished from the drill in its application, geometry, and manufacture.
...and here's the segment from "How It's Made" that covers the more general principles of making a HSS end mill. You can see that OSG has a more advanced process for their carbide end mills.
Matt Saccomanno, the inventor of the Microconic Workholding system discussed how it works at IMTS 2016.
Masa Tool has developed the Microconic™ system specifically for holding workpieces from Ø0.15mm to 10mm (Ø0.006" to 0.390") in any machine that has a collet-type chuck.
The system consists of two major components: The Microconic™ cartridge, which fits into your CNC machine spindle replacing the standard 5C, TF20 or TF25 collets, and the Microconic™ collet, which fits in the Microconic™ cartridge.
The Microconic™ system has unsurpassed concentricity: Our manufacturing tolerance is 3µm (.0001") and we guarantee our cartridges to be within 5µm (0.0002") in production use in your machine.
The Microconic™ system works with either draw-type or push-type standard collet systems that are in any machine.
The Over-grip collet capabilities of Masa Microconic™ System, introduces a whole new world of time saving opportunities awaiting. Our Overgrip Collets open up to 4mm (0.157") diameter larger than the clamping diameter.
In case you missed the episode of 5th Axis vises on How Its Made, you can re-watch it right here.
This may be useful in explaining what you do in your job.... even though there's a lot of talk about "carving", "shaping" and "Sculpting"
Smart Damper products are designed for deep-hole boring with BIG KAISER’s CKB modular boring system, and also for extended reach milling with both inch- and metric-pilot shell mills and face mills.
The original rollout of the Smart Damper for finish boring included an integral BCV50, BBT50 and HSK-A100 tool holder with a CKB modular connection at the business end. A BCV50 integral 1” shell mill holder was also available.
This new design for boring 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 the chatter or vibration – thus achieving better surface finishes and improved metal removal rates.
The EWD Smart Damper damps vibrations and reduces chatter in deep-hole finish boring and extended-reach face milling applications – thus achieving better surface finishes and improved metal removal rates.
For precision machining of deep bores, it has previously been necessary to choose low cutting data in order to prevent vibrations, which massively increases processing time. The EWD Smart Damper overcomes this problem, and enables high cutting parameters to be used. This means that extremely short turnaround times can be achieved, which improves productivity by up to a factor of ten.
Technical Support Blog
At Next Generation Tool we often run into many of the same technical questions from different customers. This section should answer many of your most common questions.
We set up this special blog for the most commonly asked questions and machinist data tables for your easy reference.
If you've got a question that's not answered here, then just send us a quick note via email or reach one of us on our CONTACTS page here on the website
Our technical section is written by several different people. Sometimes, it's from our team here at Next Generation Tooling & at other times it's by one of the innovative manufacturer's we represent in California and Nevada.