Weekly Update 04/26/2007

April 25 2007

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Tooling

New Tooling Introduced At Westec 2007 Several new cutters and insert grades were introduced at Westec 2007 that their manufacturers said deliver high performance, durability and long life for milling operations on a many materials including difficult-to-machine and hard materials. Air Power Spindles For Ultrahigh-Speed Machining New air power spindles address the challenges of micro machining at ultrahigh-speed and with precision by offering variable spindle speeds that run up to 80,000 rpm. These air-driven tools work on existing machining centers, improve surface-finish quality, extend tool life and reduce wear on high-speed spindles. Solving Spindle Problems Spindles get blamed for a lot of machining problems but, in many cases, the spindle is not the root cause of the problem. A diagnostic tool is available that uses spindle error-motion testing to determine if a spindle is the cause of machining problems, or there is another reason for unwanted spindle motion. This is especially important for attaining high accuracy, and for the production of expensive parts for which machining errors are costly. Dynamic Analysis Leads To Optimum Cuts Trying to find that elusive optimal combination of spindle speed (rpm) and axial depth-of-cut by trial and error for a given tool and material is similar to looking for the proverbial needle in a haystack. But a dynamic analysis technique is available that helps to pinpoint the optimal cutting parameters of spindle speed and depth-of-cut for a specific tool/toolholder/machine stackup to maximize metal-removal rate while avoiding chatter. The technique is used primarily for milling, boring and turning operations with aluminum, cast iron, steel and high-temperature alloys. Reducing Chip Problems Chip control is a concern because a buildup can cause hammering and chatter, and has a deleterious effect on cutting forces, surface finish and tool life. Several new inserts, chipbreakers and cutting tools now are available that help to reduce chip accumulation. Good Tool Geometries Cut Bad Vibrations Reducing vibrations in machining increases tool life, produces better machined surface finishes and prolongs the life of machine tools. In addition, smooth-cutting machines make for a quieter, more pleasing work environment. Most tools are designed for maximum metal removal rates and their designs can make them prone to developing vibrations and chatter. To cope with chatter, newer cutting-tool geometries produce chip loads that are light initially but that increase as the tool or insert bites deeper into the workpiece. This results in removing a sizeable amount of material with a cut, but these new geometries keep the cutting action smooth and progressive without producing heavy vibrations.

Featured Advertiser

JobBOSS

Exact JobBOSS is an effective and affordable software system for job shops / custom manufacturers. It provides them with the flexibility they need to respond to the day-in and day-out changes to schedule dates, quantities and part specifications. And the visibility and control they need to compete and win! Learn more about JobBOSS with one click. Or call 1-800-777-4334 to talk with one of our job shop experts.

Upcoming Webcast Series

The CNC Best Kept Secrets Series of educational webcasts from GE Fanuc and American Machinist is designed to educate manufacturers on the often overlooked ways to prevent downtime, enhance the speed of machine tools, and improve part quality.

• Best Kept Secrets to Reduce Cycle Time -- June 13, 2007 2:00 PM ET
• Best Kept Secrets to Improving Part Quality -- September 12, 2007 2:00 PM ET

Click here for more information.

Featured Advertiser

Makino

Makino— a leading manufacturer of horizontal and vertical machining centers and EDM machines — has announced a new series of online Webinars. Designed for shops of all types and sizes, the seminars are free to anyone who registers. The planned seminars are intended for shops in the automotive, aerospace, medical product and die and mold industries. In addition to metal cutting and die/mold, the seminars will cover new technologies, such as micromachining. Mark Rentschler, marketing manager, says, "Online seminars allow anyone with an Internet connection to attend without losing a day of work." The seminars concentrate on shop efficiency, lean manufacturing, asset utilization, machine tool integration and automation, machine tool technologies, and metal cutting processes. Makino's application engineers, product managers and guest speakers will give presentations. Click here for more info on upcoming seminars and registration information.

Practical Machinist Metalworking Forum

What type of 3D CAD to use? "For those of us that will only use a 3D CAD system to re-draw the parts we need to manufacture, which CAD package makes the most sense?" How to make Collets? "How hard is it to make a Collet?" Tricks of the Trade "Every Once in a while, someone showed me a great little “trick” to fix a machining problem and I’ll pass a couple along. Feel free to share your little tricks."

AMERICAN MACHINIST DIGITAL EDITION

Now you can get the latest edition of American Machinist delivered directly to your PC. Click here to learn more about the digital edition.

Welding Webcast Series

Hot topics you need to hear about

• Automation: Man vs Machine - May 16, 2007 @ 2:00 PM ET
• ERP for Gases: On the Edge of Enough - July 18, 2007 @ 2:00 PM ET
• Best Practices in Electrode Selection: Maximum Profit Starts With the Process - September 25, 2007 @ 2:00 PM ET

Click here to attend these free Webcasts.

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