VIP, May 2005

VIP, May 2005

May 25, 2005
Your newsletter for tips on selecting manufacturing technology.
In this Issue...
Sponsored by Verizon Wireless and Engineering Geometry Systems (EGS)
  • Question of the month - should our elected officials lower gas taxes?
  • Tips on selecting - the right cutting tool
  • Hot products
  • Manufacturing education and training - CNC training for teachers
  • Reader's gallery of shop photos -A shop dedicated to the joys of machining

Newsletter sponsor
Verizon Wireless

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Question of the month
Should our elected officials lower gas taxes?
Tom Grasson, associate publisher and editorial director, believes our elected officials should lower gas taxes, making life easier for U.S. business and citizens. He thinks it's unfair that Americans suffer a hefty tax burden on gasoline while Iraquis can purchase it cheaply thanks to subsidies from our own government. Do you agree? Please e-mail Tom your opinion, questions, comments, or suggestions.

Be sure to check out recent issues of AMERICAM MACHINIST magazine. They feature some of the letters we have received in reply to Tom's Question of the Month.


Newsletter sponsor
Engineering Geometry Systems (EGS)
Staying competitive requires completing jobs quickly, accurately, and with minimal cost! FeatureCAM is easy to use and lets you control the amount of automation! FeatureCAM gives you cutting-edge technologies, including feature-based, knowledge-based, and automatic feature recognition! Download a FREE evaluation copy now or call 1.888.393.6455 for a FREE evaluation CD!

Tips on Selecting
The right cutting tool
With thousands of cutting tools to choose from, how do you decide which to use? Most tooling suppliers recommend working with experienced tooling specialists. They can help you through a number of steps:

1. Define the operation. Is it roughing, finishing, or a one-cut operation? Does it require through-spindle coolant, minimal-quality lubrication, or dry machining?

2. Define part geometry. Identify challenging features such as 90-degree angles or shoulders.

3. Define workpiece material. Cutting tools are now optimized for specific materials.

4. Determine workholding rigidity. Consider if parts have thin walls or demand tools with long overhang. These conditions can cause vibration, requiring rigid workholding to compensate.

5. Analyze the operation closely.

  • Milling - Because cost/cubic in. determines productivity, it's important to know how much material a tool removes, how quickly it comes off, and the cost per tool.
  • Turning - Tool performance relates to cost/piece, so select the optimum insert based on substrate and topform geometries.
  • Parting and grooving - There are many types of these applications, so differentiating factors for parting, turning, profiling, and internal, undercut, and face grooving include the use of single and double-edge inserts, chipbreaker geometries, carbide grades including PCD and CBN, and face grooving options.
  • Slotting, slitting, and cut-off tools - Look for close-pitch design with all inserts positioned in-line. Ensure inserts have strong edge-geometries that can tackle hard materials with little vibration. Pick a supplier offering a variety of coated and uncoated grades for the various operations in different materials.
  • Holemaking - Here, the cost/hole is most important. And rigidity is crucial. Use the shortest drill possible for the required hold depth.
    When deciding among solid, carbide, modular, or indexable-insert drills, tolerances are important. Solid-carbide drills typically deliver tighter tolerances than indexable-insert ones. But with larger tolerances, you can choose based on the cost or convenience of modular or indexable-insert drills instead.
    Application also influences your decision. For example, if you are drilling stacked plates use solid carbide tools. However, indexable drills are preferable if a drill enters on an angled surface greater than five degrees.
    Lastly, consider coolant flow. Deep-hole applications require through-tool delivery but for short holes (2XD), this is unnecessary and uneconomical.
  • Tapping/threading - For this, cost/part is most important. Thread-rolling tools, though expensive up-front, drive down costs in the long run. Shops having machining centers capable of 3-axis helical interpolation, through-spindle coolant (250-psi minimum), and spindle speeds of > 5,000 rpm can exploit advanced thread-milling technology like multifunction tools that drill, chamfer, and thread in one operation.

Advertisement Gradient Lens Corp.
Gradient Lens Corp. (GLC) has introduced a new line of Hawkeye Blue Flexible Borescopes. They come in 0.098425, 0.15748, and 0.23622-in. (2.5, 4, and 6-mm) diameters for looking inside castings, tube assemblies, and welded joints in bent tubes. Additional applications include automotive and diesel-parts manufacturing and maintenance and mission-critical aviation work. High-clarity fiberoptic bundles deliver resolutions up to 25,000 pixels with contrast. These borescopes reportedly provide large, bright, clear images at nearly twice the size of scopes of the same diameter.


Advertisement
American Machinist Products on Demand

Seco-Carboloy is committed to continuously improving the productivity of its customers' metal removal operations through knowledgeable application of superior carbide cutting tools and related products, systems, and services. View demonstrations of the most advanced cutting tools in Seco-Carboloy's family of drilling, milling, turning and PCBN products by clicking now on Products on Demand.


Hot Products
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Sunnen Products Company is the global leader in the manufacture and distribution of bore-sizing and finishing equipment.
Visit Sunnen's website

For serial numbering, date coding, and part numbering, Numberall Stamp & Tool Co. Inc. offers a complete line of metal-marking equipment:
For more information

Manufacturing Education and Training
CNC training for teachers
Ken Wright, CNC instructor with the Haas Technical Center located at Henry Ford Community College in Dearborn, Mich., is giving several seminars for high school and college CNC and machining-technology teachers. One will take place August 1-4, 2005, 8 a.m. - 5 p.m. Attendees will learn the latest in CNC machining and programming technology, with featured topics including G150 general pocket milling, feeds and speeds for carbide tooling for milling, thread milling, and set-up and operation of VMCs. To register, call (877)855-5252. For more information on this and other upcoming seminars, contact Ken Wright


Newsletter sponsor
Fanuc Robotics America Inc.
Fanuc Robotics America Inc., Rochester Hills, Mich. has launched an industry initiative urging North American manufacturers to use automation and robotics as an alternative to moving jobs offshore.
Learn
how automation can save U.S. jobs.

Reader's Gallery of Shop Photos
A long-time reader's website focuses on "the joy of machining" and is "dedicated to people fortunate enough to have as a hobby what they do for a living."
Check it out

Coming in June:
AMERICAN MACHINIST will focus on grinding.

To learn how to reach this newsletter's thousands of qualified readers, e-mail
Christian Webb
or call him at 216.931.9501. To subscribe send a blank email. To unsubscribe send a blank email. © 2005 Penton Media Inc., 1300 E. 9th St., Cleveland, OH 44114. Read our privacy policy.

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