We are very excited to announce that we are now able to offer on-site technical training to YOUR machinists at YOUR location! This is offered at no charge to customers who use any of the manufacturer's whom we represent in California and Nevada.
However, just because you don't purchase things from us, don't feel left out! We also offer on-site topic specter training on any of the following topics for $150/hour.
Each presentation lasts about 2 hours. The presentations last approximately 45-60 minutes with the remaining time for Q&A and discussion about unique applications in your facility.
Training Classes Available:
Advanced Part Manufacturing:
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.
Next Generation Tooling is excited to offer some new services coming in 2015!
Below is a very fast video of our new training series on Tapping which we can present to your manufacturing team at your site.
It's a comprehensive overview of screw thread terminology, thread forms, fundamentals of threads, classes of fit, Tap basics, types of chamfers, the tapping process,tap types, screw thread inserts, helix angles, core diameters, re an hook angles, thread reliefs, pitch tolerances, H limits, Tap substrates, Surface treatment and coatings, tapping speeds, tap drill sizes.
As the CNC manufacturing industry continues to grow we're meeting more and more new people coming into our industry. Although many experienced machinists have lots of knowledge, we're finding that the new people are asking questions about some things that may be common knowledge to the old hands. One of the questions relates to "Why the heck is the cone on the toolholder the angle that it is?" We're here to help answer that....
By now, many have undoubtedly heard that most steep taper (CAT, BT) Toolholders hold an AT3 taper tolerance or better. So what exactly is AT3?
Steep Taper, Fast Tapers & Locking Tapers
Before we get into the tolerance and specs it's important to understand that there are basically two classes of tapers:
Since Toolholders have to be automatically changed in the CNC machine you want them to be as close to a locking taper as possible (8°/side) without, well, 'locking' in place (7°/side)! This is also the reason the ER/DR style collets also are made to an 8°/side angle as well by-the-way.
What is AT3?
That brings us to the "AT" standard for steep tapers. "AT" is an ANSI/ASME (ASME B5.50-1994) and ISO Standard (ISO 1947 ) that runs from AT1 to AT11. Since the AT tolerance is essentially logarithmic, the lower the number the tighter the tolerance (and harder it is to 'hit' in manufacturing). In other words the difference between AT 3 and AT4 is NOT the same increase in tolerance as between AT3 and AT2. AT3 is harder to attain than AT4 and AT 2 is substantially harder to reach than the jump from AT 4 to AT3. Again, the lower the number, the tighter the 'self releasing' tolerance.
Most CNC Machines steep taper spindles are made to an AT2 Specification. In order to stay competitive most all toolholder manufacturers are holding an AT3 tolerance (or better). Because there are much fewer spindles made than rotary toolholders this makes manufacturing sense. The key words here to pay attention to is "or better" Just like when you make parts in your shop to a tolerance, that doesn't mean that every part is exactly the same. The parts are within a tolerance band. That's what the "AT" defines! So when a toolholder manufacturer says "AT3 or better" that can mean that some of the holders are actually holding an AT2 tolerance... and this is sometimes the cause of the tolholders 'sticking' in the spindle:Not because they are out of tolerance, but because they are actually holding a closer tolerance! (...nearer a locking taper)
By-the-way, most all steep taper toolholders are made from some derivative of 8620 steel and then case hardened.
Food for thought
So although most people think that the drive dogs on the spindle are doing the 'driving' of the rotation of the toolholder, it's actually the taper connection that is driving the rotation of the tool. If that wasn't the case, then you would see the drive dog notches in the toolholder start to show signs of wear when the spindle impacted them all the time. Afterall, the 8620 is only case hardened.
There are a couple of last things to make note of and think about:
So if you over tighten your retention knob (pull stud) it can expand the smaller part of the taper.
ER, IT’S IN THE DETAILS
The ER collet system has several advantages when using today's CNC computerized milling machines. The most significant advantage is flexibility to hold any type of round shank tool. An ER collet can be used in drilling, reaming, and tapping as well as milling applications just by exchanging the collet. Its accuracy also provides greater tool life than older style collet systems like TG or DA.
Another advantage is the flexibility of the collet for clamping a wide range of tool shanks with a small number of collets. ER 16 through ER 40 provide a collapse range of ~.039" flexibility for clamping cutting tools. This is a benefit for you because you will not have to carry as many collets in inventory for the different jobs you need to do each day.
The ER collet also provides more holding power by using two principles.
In addition to mechanical differences, the ER collet is also user friendly. It is a self-extracting collet, which eliminates the need for collet squeezers to extract the collet by any other means than screwing the nut off. This enables the operator to spend time running the machine, not extracting collets.
These basic principles allow the ER collet system to be the most widely accepted collet system in the world for holding round shank cutting tools.
ER style collet chucks should be used for the bulk of your needs. They are the most dependable, with the least runout, both in and out of the cut, are readily available (so the prices continue to drop) and will give you the best tool life out of the lot of them
We often run end mill "tests" to determine which one performs best. Obviously, our goal is to "win' the test and get more business for our manufacturer's. This is article is about one our "tricks" and it's also why represent both cutting tool manufacturers and rotary tool manufacturers. We want to insure that the products work together.
As a general rule most cutting tool & tolholder manufacturers prefer to use single angle (ER/DR style) collet chucks for general purpose cutting tool applications under 1/2" (12mm). The rules are a bit different in High Speed Machining, as there are many more things to consider, but the problems of TIR at high speeds, where you can hear and feel the chatter, are still there in general end mill cutting operations at lower RPM. It's all about runout and uneven chip load.
End Mill Holders are prone to runout problems for a couple of reasons:
Depending on the application, end mill holders can be used for holding larger insert style end mills, spade drills, etc. But somewhere between 1/2” and 3/4” there is a line that only you can determine when you need to move from a collet chuck to end mill holder. Generally we recommend using end mill holders only for very specific applications
Using small diameter end mills (1/4" and below) in end mill holders with set screws will have a adverse affect of both surface finish and tool life.
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.