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The selection of a ceramic cutting tool & grade is an important factor to consider when planning a successful metalcutting operation.  Haydale’s silicon carbide (SiC) whiskers reinforce ceramic inserts to deliver world-class hardness and fracture toughness. The inclusion of SiC provides hardness second only to diamond. Due to long range force distribution provided by the fibre, we are able to achieve this result while maintaining exceptional toughness. Ceramic cutting tools have excellent wear resistance at high cutting speeds and Haydale Ceramic Technologies (HCT), a world leading manufacturer of Silicon Carbide (SiC) ceramic materials, has the largest installed capacity for volume production across America, Europe and the APAC regions. HCT developed the world’s first whisker reinforced tools, and continues to lead in materials engineering and innovation in this category. Produced in Greer, South Carolina, their Silar® cutting tools are manufactured using the highest quality SiC products, particulate, fibers and microfibers. The inclusion of SiC whiskers provides hardness second only to diamond. Whisker-reinforced cutting tools offer both increased toughness and wear resistance, making them ideal for machining a variety of workpiece materials including Ni-based alloys, cobalt-based alloys, hardened steels, gray cast, ductile, nodular irons, and mill rolls. Cutting with reinforced or whiskered, ceramic inserts requires high surface speed and balanced feed rates. Enhanced Silicon Carbide Cutting ToolsHigh cutting forces and high heat cause the metal to plasticize while the Silar ceramic substrate remains in-tact. Whisker-reinforced cutting tools offer both increased toughness and wear resistance, making them ideal for machining a variety of workpiece materials including Ni-based alloys, cobalt-based alloys, hardened steels, ductile, and nodular irons, and mill rolls. Silar cutting tools are designed for heavy material removal in roughing and semi-finishing applications and offer the perfect solution for high-speed machining of heat resistant super alloys.
 Aerospace Cutting ToolsAs demand for lightweight materials in the aerospace industry increases, Haydale can manufacture new grades and tooling that specialise in machining hard-to-cut materials. With higher speed and feed rates, Silar cutting tools deliver consistent results and longer life in applications for:
Silar® whisker reinforced ceramic cutting tools are designed for heavy material removal in roughing and semi-finishing applications. They offer the perfect solution for high-speed machining of heat resistant super alloys (HRSA) – Inconel, Waspalloy, Haynes, Monel, Rene, Incoloy, A-286, Nimonic, Udimet, etc. The Silar® CT-25 Grade offers a comprehensive and advanced range of high-speed cutting tool solutions while Silar SBN570 is a high-content CBN grade specifically designed for finishing Heat-Resistant Super Alloys (HRSA's). The high CBN content in SBN570 ensures superior cutting performance and extended tool life when dealing with these challenging materials. It can withstand the high temperatures generated during machining, allowing for efficient and precise finishing operations. Automotive Cutting Tools It is essential for turning and milling tools in automotive applications to wear evenly with minimal maintenance in the most demanding applications. To meet the workflow and high output demands, Haydale has a range of inserts for the automotive industry using SiC whiskers that are long-lasting and deliver consistent and reliable results as well as:
Steel Mill Cutting ToolsHaydale’s steel mill inserts offer an optimal choice for milling fracking blocks and for milling flats on mill roll necks. Steel mill geometries are used to remove heavy material in the most demanding rough turning conditions. Inserts are available for:
Haydale's Silar® inserts are designed for heavy DOC material removal in cast iron, compacted graphite iron (CGI), ductile iron, nodular iron, hardened steels (transmission components), white iron, chilled iron, and powdered metals.
If you would like to determine if Silar Ceramic cutting tools are right for your application, get in contact with us!
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 OSG is pleased to announce the expansion of our PHOENIX® PDZ offering with the addition of the NEW PDZ-3D indexable flat drill.
The following list numbers are associated with the OSG PHOENIX® PDZ Series Expansion:
The PHOENIX® PDZ indexable flat drill offers the following features & benefits:
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.  Performance Micro Tool 50 μm drill shown next to ant leg. Photo courtesy of Texas A&M University 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
PMT Applications
 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 Geometry Figure 1: Chips generated at the tip of the tool flow in the direction of the blue arrow One 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. Figure 3. Exit room at end of margin 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.  Figure 4: Relationship between shank structure and coolant flow volume 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.  Figure 5: Surface of coating 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.  Figure 6: Stable and long tool life in SCM440 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.  Figure 7: Efficiency improvement in titanium alloy 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. |
NEWSOur 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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