by Sean McIntosh, OSG District Sales Manager
OSG’s HY-PRO® CARB VGM end mill boosts productivity and lowers cost per part in aerospace bracket application.
Founded in 1951 in Phoenix, Arizona, United States, Allied Tool & Die Co. is a family-owned precision machine and fabrication company that specializes in the manufacturing of quality parts for aerospace, medical, communications and commercial industries throughout the world.
Seventy years since its establishment, this privately owned shop has grown with multiple facilities and an estimated 32,000 square feet of manufacturing space in Phoenix, Arizona.
One of the challenges Allied Tool & Die faced recently was the machining of aerospace brackets made of Inconel 718. As is with most shops, machining Inconel 718 is time consuming. Moreover, due to the material’s special high strength and heat resistance properties, short tool life is a common obstacle.
In search for performance improvement, Allied Tool & Die CNC Process and Machining Manager Jamie Lerma reached out to his local OSG representative for new solutions. Lerma had worked with OSG previously on a 13-8 stainless steel application by utilizing OSG’s HY-PRO® CARB VGM series end mill to achieve high-efficiency milling.
OSG’s HY-PRO® CARB VGM is a high performance variable geometry end mill series. Its variable index and unique flute geometry enable the reduction of vibration and chatter, promoting smooth and stable cutting with low cutting forces.
With the addition of OSG proprietary multi-layer EXO coating, higher wear and heat resistance is achieved to prolong tool life. OSG’s VGM offering features 5-, 6- and 7-flute lineups, and is available with multiple lengths of cut, with both square end and corner radius variations. This series is suitable for carbon steels, alloy steels, die steels, stainless steels, cast iron, nickel alloy, titanium, and hardened steels up to 45 HRC.
For the 13-8 stainless steel application, the VGM end mill dominated the machining result by extending tool life from seven parts to 21 parts per tool. The parts were also completed in half the time and the tool cost is also cheaper than the competitor tool. Lerma was so impressed by the VGM end mill that he decided to apply the tool to the Inconel 718 aerospace bracket application.
Allied Tool & Die was previously using a high feed indexable milling cutter for the Inconel 718 aerospace bracket application. However, the amount of time and money spent on changing the inserts was less than desired.
The previous competitor tool was used at 150 SFM (45.7 m/min), 0.009 IPT (0.23 mm/t), 0.05 Aa (ap = 1.27 mm) and 0.75 Ar (ae = 19.05 mm).
After reprogramming to utilize OSG’s 0.5-inch diameter 5-flute VGM carbide end mill with a 0.030-inch (0.762 mm) corner radius and 1.25-inch (31.75 mm) length of cut (EDP# VGM5-0143), the cutting parameters were changed to 250 SFT (76.2 mm/min, 2,548 min-1), 0.0022 IPT (0.056 mm/t, 713 mm/min), 0.75 Aa and 0.035 Ar.
The application went from a 4-hour cycle time to just one hour and 45 minutes.
Allied Tool & Die no longer had to keep stopping the machine to rotate or change inserts, which they were doing four times per part previously.
By switching to the VGM end mill, the tool was loaded, and the job did not have to be tended to until the part was completed.
In terms of efficiency improvement, Allied Tool & Die estimated that the tool change has generated a cost savings of $6,875 USD on the Inconel 718 aerospace bracket parts. Moreover, with a lower tooling price versus the previous milling cutter, the cost of tooling also decreased by almost $100 USD per part.
With the VGM end mill, Allied Tool & Die was able to machine Inconel 718 at an astounding 250 surface feet per minute (76.2 m/min) – a speed that is only commonly seen in alloy or stainless steels, not HRSA materials.
With the recent successes, Allied Tool & Die’s CNC Programmer John Hernandez decided to apply the VGM end mill into most jobs he programs. Being such a versatile tool, the VGM can be used to machine anything from common carbon steels up to the nickel alloys required by the aerospace industry.
BMT is one of the newest technologies for Mill Turn machines and it is a more rigid solution than more traditional VDI holders. When the tool holder is mounted to the turret, four screws are used to tighten the tool holder, and is further secured with keys that are located on the turret face.
This process eliminates the need for indicating the tool holder to straighten it, which is normal with more traditional VDI tool holders.
The Operator does not need to adjust the straightness for the BMT toolholder. BMT holders are more rigid, and are often preferred for heavy duty cutting. With BMT Holders no need to adjust the straightness.
Parlec has been making BMT65 tool holders for one of the largest machine manufacturers in the world for many years. They have the know-how to produce top-quality BMT65 tooling to the most exacting standards.
Parlec BMT65 holders match Haas BMT’s in design, dimensions, and material
Ductile iron has a higher abrasion resistance due, in large part, to the high % of graphite that acts as a graphite lubricant
Adjustable coolant delivery ports are included on all Parlec BMT65 tool holders.
American-made tooling is on-the-shelf and ready to go into production – today!
Carmex has introduced two new lines of multi-functional thread mills specifically for machining hardened materials up to 62 HRc.
Engineered to meet threading challenges from ISO M1.4 x 0.3 and 0-80UN, HARDCUT thread mills deliver high performance in hardened steels, high-temperature alloys, Titanium alloys and ultra-hard formulations such as Hastelloy, Inconel, and nickel base alloys.
Thanks to their short profile, they are capable of working at high cutting speeds, thereby shortening cycle times.
The increased cutting diameter delivers better rigidity and stability, and the advanced PVD triple coating results in high wear and heat resistance and longer tool life.
The use of hard and super-hard materials in industries such as moldmaking, aviation, energy and medical implants and tools requires a new generation of thread mills capable of standing up to hard materials while, at the same time, delivering increased productivity through better performance and longer life.
The Carmex HARDCUT line meets those demands through an extensive size range that delivers the Carmex guarantee of “X-TREME results.”
Download CAD Drawings for you toolholders!
Techniks is excited to announce that they are entering into a new stage of development for their website. Over the past several weeks Techniks has compiled 2D and 3D model files for each product available on www.techniksusa.com.
That’s almost 4,800 total SKUs, 9,600 2D and 3D model drawings added for your convenience!
The addition of downloadable CAD files is just the next phase in thier continued development of their site to improve its user-friendliness. You can now find your specific drawings through directly searching for the part number in the “Drawings” section of the main menu or by navigating directly to the product page.
Simply navigate to the appropriate product table, locate the item you need, and click on the drawing file format you require. You will see a links to the 2D DWG and 3D STP files in the right-hand columns.
Can’t find what you’re looking for?
Techniks is adding more drawings every day, but if you do not find the drawings you need let them know at email@example.com and they'll
prioritize your request to get you the drawings you need, FAST!
As you begin to take advantage of their available CAD files, please don't hesitate to continue to provide feedback on your website experience to us and we can pass it along to Techniks. It’s been with your help that Techniks is able to provide the highest levels of customer service. A lot of that feedback comes form us passing along that information from you!
PLEASE NOTE: Its a direct result of this announcement we have made some navigation changes on our website to redirect Big Kaiser to BIG Daishowa which has resulted in renaming both their TOOLING page and WORKHOLDING Page URL. All of the information and articles written about Big Kaiser is still here on our website, albeit the actual URL in your bookmark may have changed. The hot links above will take you to the updated information.
Hoffman Estates, IL - BIG KAISER Precision Tooling Inc. is excited to share important news concerning the name of its company. BIG KAISER Precision Tooling Inc. will change its name to BIG DAISHOWA Inc., effective January 1, 2022.
“BIG DAISHOWA is a global leader of tooling systems, and we have been a member of the BIG DAISHOWA group of companies for many years,” said Jack Burley, President & COO. “The name change is a natural evolution in this relationship. Being known as BIG DAISHOWA in North America will strengthen our corporate presence on a global scale.
“Our customers won’t notice any change in our business day-to-day,” Burley said. “They will receive the same superior products, personal support and performance guarantee we’ve been delivering for more than 30 years.”
The name change will not impact operations, product lines, staff, distribution or licensing agreements in North America. The company will continue to offer the same high-precision tool holders, cutting and boring tools, workholding, tool measurement systems and accessories manufactured in Japan, Europe and the United States.
As a member of the BIG DAISHOWA Group (Osaka, Japan), BIG DAISHOWA Inc. has grown into a recognized global tooling provider, with manufacturing facilities in North America, Switzerland and Japan.
In addition, BIG DAISHOWA is 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.
Why dovetail workholding?
Dovetail workholding is unique and ideal for holding workpieces that require larger metal removal, and multiple machining passes and operations. The puzzle-piece connectivity provides maximum holding strength with minimum material contact.
That means that more of the part is accessible, which is even more advantageous when addressing complex components within limited machining envelopes. All that’s required are a few simple passes with minimal metal removal and your workpiece is ready to grip for a multitude of operations.
(Machining) Five Sides on Five-Axis Machining
One of the key benefits of dovetail workholding is the unique underneath grip that provides the greatest access to workpieces, making it possible for true five sides machining.
Furthermore, dovetails are a versatile solution that can hold a greater variety of parts, in effect reducing the need for custom fixtures and allowing you to standardize on a clamping method and equipment across a wide variety of workpiece types and sizes.
With Jergens Fixture Pro®, you can take the next step in productivity by adding quick-change to the equation. A new group of modular dovetail vises and adapter bases ensures secure clamping and provides Jergens repeatable quick-change solution so you can spend more time in the cut and less time in part changeover. The combination of this type of high-strength workholding with these new modular vises represents a dramatic decrease in overall setup and cycle times.
Here's how the math adds up. Part Security + Increased Accessibility + Quick-Change + Number of Parts = Next Level Productivity. Level one: For every securely fixtured workpiece, more operations can be performed without the need to index or reorientate because so much of the workpiece is unencumbered. Level two: When the workpiece needs to be repositioned or changed to the next one, it is done via one of two high-speed changeover solutions - Quick-Loc™ or QLS. Level three: In the case of QLS, several workpieces are loaded along multi-sided columns taking advantage of available vertical (or horizontal) space, filling the machining envelope with numerous parts, and all of those are quick-change as well. Workpieces stay securely clamped in the dovetail vise and adapter base during the changeover to facilitate immediate reloading and secondary operations as needed.
Of the new vises, two are engineered with Jergens Quick-Loc™ pallet system and include industry-standard patterns 52mm and 96mm. With a single drive screw, Quick-Loc™ provides fast and repeatable fixture changes for small tooling platforms. A square aluminum adapter base provides the connection to either of the two patterns. A third vise features Jergens Quick Locating System (QLS) mount, for column-mounting possibilities, and a corresponding round adapter base.
The famous Vulcan greeting from Star Trek takes on a whole new meaning when it comes to tool life. This was recently proven at Apex CNC Swiss, a machine shop specializing in high precision complex parts machined from hard materials and alloys.
According to Chuck Fluharty, co-owner of Apex,
“We were machining an electronics circuit board standoff in 303 stainless on a Star SR-20RIII machine. The part required a 0.180" (4.6 mm) deep hole threaded with a 0-80 thread. At the time, we were working with tooling from a well-known German maker that delivered 200 to 300 parts before tool failure. We did not feel that this was acceptable and, when we contacted the manufacturer’s technical support, they advised that that performance was ‘normal.’ We immediately began to look for an alternative.”
When Chuck and his team tried the Carmex mini mill-thread design, they saw production rise to more than 2,000 parts. More than that, they completed a further 500 parts in 17-4 stainless prior to failure.
Carmex performance at Apex CNC Swiss is another example of how tooling engineered for high performance and long life leads to greater prosperity for the customer. “Live Long and Prosper.”
Our NEWS blog section is written by several different people. Sometimes, it from our team here at Next Generation Tooling & at other times it's by one of the manufacturer's we represent.
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