Non-ferrous and non-metallic materials are not usually considered difficult to machine, and therefore, machinists often overlook the use of tool coatings. But while these materials may not present the same machining difficulties as hardened steels and other ferrous materials, a coating can still vastly improve performance in non-ferrous applications. For instance, materials such as aluminum and graphite can cause machinists headaches because of the difficulty they often create from abrasion. To alleviate these issues in non-ferrous machining applications, a popular coating choice is Helical Solution’s Zplus coating.
What is Helical Solutions’ Zplus Coating?
Helical’s Zplus is a Zirconium Nitride-based coating, applied by a Physical Vapor Deposition (PVD) process. This method of coating takes place in a vacuum and forms layers only microns thick onto the properly prepared tool. Zirconium Nitride does not chemically react to a variety of non-ferrous metals, increasing the lubricity of the tool and aiding in chip evacuation.
When Should a Machinist Use Helical Solution’s Zplus?
Working with Abrasive Materials
While Zpluswas created initially for working in aluminum, its hardness level and maximum working temperature of 1,110°F enables it to work well in abrasive forms of other non-ferrous materials, as well. This coating decreases the coefficient of friction between the tool and the part, allowing it to move easier through more abrasive materials. This abrasion resistance decreases the rate of tool wear, prolonging tool life.
Concerns with Efficient Chip Evacuation
One of the primary functions of this coating is to increase the smoothness of the flutes of the tool, which allows for more efficient chip removal. By decreasing the amount of friction between the tool and the material, chips will not stick to the tool, helping to prevent chip packing. The increased lubricity and smoothness provided by the coating allows for a higher level of performance from the cutting tool. Zplus is also recommended for use in softer, gummy alloys, as the smooth surface encourages maximum lubricity within the material – this decreases the likelihood of those gummier chips sticking to the tool while machining.
Large Production Runs
Uncoated tools can work well in many forms of non-ferrous applications. However, to get a genuinely cost-effective tool for your job, the proper coating is highly recommended. Large production runs are known for putting a lot of wear and tear on tools due to their increased use, and by utilizing an appropriate coating, there can be a significant improvement in the tools working life.
When is Zplus Coating Not Beneficial to My Application?
Finishing Applications
When your parts finish is vital to its final application, a machinist may want to consider going with an uncoated tool. As with any coating, ZrN will leave a very minor rounded edge on the tip of the cutting edge. The best finish often requires an extremely sharp tool, and an uncoated tool will have a sharper cutting edge than its coated version.
https://www.harveyperformance.com/wp-content/uploads/2019/04/Feature-Image-Zplus-Coatings-IMG.jpg5251400Harvey Performance Companyhttp://www.harveyperformance.com/wp-content/uploads/2018/08/Logo_HarveyPerformanceCompany-4.pngHarvey Performance Company2019-04-01 03:17:542023-10-24 10:53:44What to Know About Helical Solution’s Zplus Coating
Aluminum and magnesium alloys are common materials found in machine shops worldwide, and are known as an “easier” material to machine. However, machinists can still experience hiccups while machining this material if they are not prepared with the proper tooling.. When working with aluminum and magnesium alloys, it is important to choose a coating that will work to extend your tool’s life and aid in the removal of chips. A popular choice for this material bucket is Harvey Tool’s TiB2 coating.
Harvey Tool’s TiB2 coating is a Titanium Diboride, ceramic-based coating that provides superb erosion resistance during machining. TiB2 is added to a tool by a method called Physical Vapor Deposition (PVD), which is conducted in a vacuum where particles are vaporized and applied onto a surface, forming thin layers of material onto the properly-prepped tool. This method enables the coating to be corrosion and tarnish resistant.
TiB2 is identified in Harvey Tool’s product catalog with a “-C8” following the sku number. It can be found offered in Harvey Tool’s lines of Variable Helix End Mills for Aluminum Alloys and Miniature High Performance Drills for Aluminum Alloys.
When Should a Machinist Use TiB2 Coating?
Chip Evacuation Concerns
TiB2 has an extremely low affinity to aluminum, which helps with the chip evacuation process. Simply, chips of a material are able to evacuate through chip valleys easier if they don’t have a high affinity to the coating being used. TiB2 coating does not chemically react with aluminum and magnesium, which allows for smoother chip evacuation, as the chips do not stick to the coating and create issues such as chip packing. This is a common machining mishap that can cause both part and tool damage, quickly derailing a machining operation. By using a coating that increases the lubricity of the tool, chips will not have a surface to stick to and will more smoothly evacuate from the flutes of the tool.
Large Production Runs
While an uncoated tool may work fine in some applications, not all applications can succeed without a tool coating. When working with large production runs where the tools need to hold up through the process of machining large numbers of parts, using a coating is always recommended because they extend the life of your tool.
When is TiB2 Coating Not Beneficial to My Application?
Extremely Abrasive Materials
During the PVD coating process, tools can reach a temperature in excess of 500° F, which can cause the toughness of the carbide to drop slightly. This process does not normally compromise the performance of the tool due to the coating being placed over the carbide. The coating then protects the slightly weakened edge and increases tool performance in recommended materials. Micro-fractures only start appearing when the tool is being run incredibly fast through highly abrasive materials, leading to a decrease in the life of the tool.
Extremely Soft Materials
The coating, while only a few microns thick at most, still provides an ever-so-slight rounded edge to the cutting edge of the tools it is placed on. It is important to take this into consideration, as using the sharpest tools possible when working with materials such as soft plastics is recommended. The sharpest edge possible decreases the likelihood of any “pushing” that might occur on the material and increases the likelihood of proper “shearing” when machining.
When Finish Is Vital
If your part’s finish is imperative to the final product, an uncoated tool may work better for your application. A coating, like stated above, creates a microscopic rounded surface to the cutting edge of the tool. When running tools at finishing speeds and feeds in materials like aluminum, a sharp edge can create the difference between a finished part that does – or does not – pass final inspection.
https://www.harveyperformance.com/wp-content/uploads/2019/03/Feature-Image-TiB2-Coatings-IMG-1.jpg5251400Harvey Performance Companyhttp://www.harveyperformance.com/wp-content/uploads/2018/08/Logo_HarveyPerformanceCompany-4.pngHarvey Performance Company2019-03-08 09:14:352023-10-24 10:54:05What to Know About Harvey Tool’s TiB2 Coating
A machinist is faced with many questions while selecting the proper tool for their job. One key decision that must be made is whether a material specific tool is appropriate and necessary for the application that’s going to be performed – whether the benefits of using this type of tool outweigh the higher price tag than that of a tool designed for use in a variety of materials. There are four main categories to consider when deciding whether a material specific tool is your best bet: internal tool geometry, coatings, material removal rates (MRR), and cost.
When to Utilize Material Specific Tooling
Are you a machinist in a shop that deals primarily with one type of material? Or, do you generally change materials frequently throughout the day? Further, how many parts do you make at a time? These are questions you must ask yourself prior to making a tooling decision.
Material Specific Tooling is best utilized where several parts are being machined of the same material. For instance, if your shop is machining 1,000 plastic parts, it would be in your best interest to opt for a tool designed for this material as your tooling would not only last longer but perform better. If machining flexibility is paramount for your shop, if you’re only machining a few parts, or if part finish is not of high importance, a regular end mill may suffice.
Pros and Cons of Material Specific Tooling
There are pros and cons to purchasing a Material Specific Tool.
Pros:
Tool geometry designed for the material you’re working in to achieve the best results.
Coating optimized for the material you’re cutting.
More aggressive speeds and feeds, and boosted MRR as a result.
Increased tool life.
Cons:
Higher upfront cost, though long term savings are possible if used in proper situations.
Less opportunity for flexibility. While most end mills may be suitable for use in many jobs and many machines, Material Specific End Mills are engineered for use in specific materials
For instance, a machinist may be faced with a dilemma while preparing to machine a plastic part. While an end mill found in Harvey Tool’s Miniature End Mill section could certainly machine this material, Harvey Tool’s end mill offering designed to machine plastics feature a high rake, high relief design. This is ideal for plastics because you want to effectively cut and form chips while the strength of the tool is less of a concern. The high rake and high relief creates a sharp cutting edge that would quickly break down in metals. However, in plastics, this effectively shears the material and transfers the heat into the chip to produce a great finish in your part.
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Specific Coatings & Substrates for Optimal Performance
One key benefit of opting for a material specific tool is the ability to utilize the best coating option available for that material. Tool coatings serve many functions, including improved lubricity, increased tool life, and a higher-quality part finish. In addition, coated tools can typically be run around 10% faster than uncoated tools.
While many manufacturers will specially coat a standard end mill at your request, this takes added time and cost. In its Material Specific catalog sections, Harvey Tool offers coated tools stocked and ready to ship. For instance, their Hardened Steels and Exotic Alloys categories utilize AlTiN Nano coating. This is a unique nanocomposite coating that has a max working temperature of 2,100° F and shows improved performance in materials such as Hardened Steels, Titantium Alloys, and Inconel, among others.
Increased Material Removal Rates
Because Material Specific Tooling features optimal tool geometry for a job, running parameters are generally able to be more aggressive. Any machinist knows that Material Removal Rates (MRR), is the metric that’s most closely related to shop efficiency, as the more material removed from a part in a given period of time, the faster parts are made and the higher the shop output.
The following example compares running parameters of end mills from Harvey Tool’s Miniature End Mill and Material Specific End Mill Sections. You can notice that while key geometries between the two tools are identical, and are in use in the same material with the same operation, the chip load (+25%), linear feed rate (+33%), and depth of cut (+43%) are boosted. This allows for more material to be removed in a shorter period of time.
Description: 3 Flute 1/8 inch diameter 3x LOC Square Variable Helix for Aluminum Alloys
Material: 6061 Aluminum
Application: Slotting
Speed: 10,000 RPM
Chip Load: .00165 IPT
Linear Feed: 49.5 IPM
DOC: .0625
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Extensive Cost Savings
The following chart displays a cost analysis breakdown between a tool found in the Miniature End Mill section, item 993893-C3; and a tool found in the Material Specific End Mill section, item 933293-C6. When compared for the machining of 1,000 parts, the overall savings is nearly $2,500.
Material Specific Tooling Summarized
In conclusion, Material Specific End Mills have many benefits, but are best utilized in certain situations. While the initial cost of these tools are higher, they can work to save your shop time and money in the long run by lasting longer and producing more parts over a given period of time.
https://www.harveyperformance.com/wp-content/uploads/2019/02/Feature-Image-Material-Specific-Tooling-IMG.jpg5251400Harvey Performance Companyhttp://www.harveyperformance.com/wp-content/uploads/2018/08/Logo_HarveyPerformanceCompany-4.pngHarvey Performance Company2019-02-01 08:43:172023-10-24 10:55:30How Material Specific Tooling Pays Off
Do you know the key differences between a Single Form Thread Mill and a Multi-Form version? Do you know which tooling option is best for your job? This blog post examines how several factors, including the tool’s form and max depth of thread, are important to ultimately making the appropriate Harvey Tool decision.
Thread Mill Product Offering
Single Form
The single form thread mill is the most versatile threading solution Harvey Tool offers. These tools are ground to a sharp point and are capable of milling 60° thread styles, such as UN, metric, and NPT threads. With over 14 UN and 10 Metric sized tools, Harvey Tool’s single form selections allow machinists the opportunity to machine many different types of threads.
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Single Form Thread Mills for Hardened Steels
Similar to the standard single form, Harvey Tool’s thread mills for hardened steels offer machinists a quality option when dealing with hardened steels from 46-68 Rc. The following unique geometries helps this tool machine tough alloys:
Ground Flat – Instead of a sharp point these tools have a ground flat to help ensure long tool life.
Eccentric Relief – Gives the cutting edges extra strength for the high feeds at relatively low RPMs required for harder materials.
AlTiN Nano Coating – Allows for superior heat resistance.
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A key difference between the standard Single Form and the Single Form for Hardened Steels is that the tools for hardened steels are actually only capable of milling 83% of the actual thread depth. At first, this may seem detrimental to your operation. However, according to the Machinery’s Handbook 29th Edition, “Tests have shown that any increase in the percentage of full thread over 60% does not significantly increase the strength of the thread. Often, a 55% to 60% thread is satisfactory, although 75% threads are commonly used to provide an extra margin of safety.” With the ability to preserve tool life and effectively perform thread components, Harvey Tool’s single form thread mills for hardened steels are a natural choice when tackling a hardened material.
Tri-Form
Tri-Forms are designed for difficult-to-machine materials. The tri-form design reduces tool pressure and deflection, which results in more accurate threading. Its left-hand cut, left-hand spiral design allows it to climb mill from the top of the thread to the bottom.
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Multi-Form
Our multi-form thread mills are offered in styles such as UN, NPT, and Metric. Multi-Form tools are optimized to produce a full thread in single helical interpolation. Additionally, they allow a machinist to quickly turn around production-style jobs.
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Coolant-Through Multi Form Thread Mills
Coolant-Through Multi Form Thread Mills are the perfect tool for when a job calls for thread milling in a blind hole. The coolant through ability of the tool produces superior chip evacuation. These tools also improve coolant flow to the workpiece – delivering it directly from the tip of the tool – for decreased friction and high cutting speeds.
Harvey Performance Company, LLC.
Long Flute
These tools are great when a job calls for a deep thread, due to their long flute. Long Flutes also have a large cutter diameter and core, which provides the tool with improved tool strength and stability.
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N.P.T. Multi-Form
While it may seem obvious, N.P.T. Multi-Form Thread Mills are perfect for milling NPT threads. NPT threads are great for when a part requires a full seal, different from traditional threads that hold pieces together without the water-tight seal.
Harvey Performance Company, LLC.
https://www.harveyperformance.com/wp-content/uploads/2019/01/Feature-Image-Selecting-Thread-Mill-IMG.jpg5251400Ben Holmhttp://www.harveyperformance.com/wp-content/uploads/2018/08/Logo_HarveyPerformanceCompany-4.pngBen Holm2019-01-10 01:44:532023-10-24 10:57:32Confidently Select Your Next Thread Mill
Breaking and damaging an end mill is oftentimes an avoidable mistake that can be extremely costly for a machine shop. To save time, money, and your end mill it is important to learn some simple tips and tricks to extend tool life.
Properly Prepare Before the Tool Selection Process
The first step of any machining job is selecting the correct end mill for your material and application. However, this doesn’t mean that there should not be an adequate amount of legwork done beforehand to ensure the right decision on a tool is being made. Harvey Tool, Helical Solutions, Titan USA, and Corehog have thousands of different tools for different operations – a vast selection which, if unprepared – can easily result in selecting a tool that’s not the best for your job. To start your preparation, answer the 5 Questions to Ask Before Selecting an End Mill to help you quickly narrow down your selection and better understand the perfect tool you require.
Understand Your Tooling Requirements
It’s important to understand not only what your tool needs, but also general best practices to avoid common machining mishaps. For instance, it is important to use a tool with a length of cut only as long as needed, as the longer a tools length of cut is, the greater the chance of deflection or tool bending, which can decrease its effective life.
Another factor to consider is the coating composition on a tool. Harvey Tool and Helical Solutions offer many varieties of tool coatings for different materials. Some coatings increase lubricity, slowing tool wear, while others increase the hardness and abrasion resistance of the tool. Not all coatings increase your tool’s life in every material, however. Be wary of coatings that don’t perform well in your part’s material – such as the use of AlTiN coating in Aluminum (Both coating and material are aluminum-based and have a high affinity for each other, which can cause built-up edge and result in chip evacuation problems).
Consider Variable Helix & Pitch Geometry
A feature on many of our high performance end mills is variable helix or variable pitch geometry, which have differently-spaced flutes. As the tool cuts, there are different time intervals between the cutting edges contacting the workpiece, rather than simultaneously on each rotation. The varying time intervals minimizes chatter by reducing harmonics, increasing tool life and producing better results.
Ensure an Effective Tool Holding Strategy
Another factor in prolonging tool life is proper tool holding. A poor tool holding strategy can cause runout, pullout, and scrapped parts. Generally, the most secure connection has more points of contact between the tool holder and tool shank. Hydraulic and Shrink Fit Tool Holders provide increased performance over other tightening methods.
Helical also offers shank modifications to all stocked standards and special quotes, such as the ToughGRIP Shank, which provides added friction between the holder and the shank of the tool for a more secure grip; and the Haimer Safe-Lock™, which has grooves on the shank of the tool to help lock it into place in a tool holder.
Trust Your Running Parameters, and their Source
After selecting the correct end mill for your job, the next step is to run the tool at the proper speeds and feeds.
Run at the Correct Speed
Understanding the ideal speed to run your machine is key to prolonging tool life. If you run your tool too fast, it can cause suboptimal chip size, ineffective chip evacuation, or even total tool failure. Adversely, running your tool too slowly can result in deflection, bad finish, or decreased metal removal rates.
Push at the Best Feed Rate
Another critical parameter of speeds and feeds is finding the best possible feed rate for your job, for sake of both tool life and achieving maximum shop efficiency. Pushing your tool too aggressively can result in breakage, but being too conservative can lead to recutting chips and excess heat generation, accelerating tool wear.
Use Parameters from Your Tooling Manufacturer
A manufacturer’s speeds and feeds calculations take into account every tool dimension, even those not called out in a catalog and readily available to machinists. Because of this, it’s best to rely on running parameters from tooling manufacturers. Harvey Tool offers speeds and feeds charts for every one of its more than 21,000 tools featured in its catalog, helping machinists to confidently run their tool the first time.
Harvey Performance Company offers the Machining Advisor Pro application, a free, cutting-edge resource that generates custom running parameters for optimized machining with all of Helical Solutions’ and Harvey Tool’s products.
Opt for the Right Milling Strategy: Climb vs Conventional
There are two ways to cut material when milling: Climb Milling and Conventional Milling. In conventional milling, the cutter rotates against the feed. In this method, chips will start at theoretical zero and increase in size. Conventional milling is usually recommended for tools with higher toughness, or for breaking through case hardened materials.
In Climb Milling, the cutter rotates with the feed. Here, the chips start at maximum width and decrease, causing the heat generated to transfer into the chip instead of being left in the tool or work piece. Climb milling also produces a cleaner shear plane, causing less rubbing, decreasing heat, and improving tool life. When climb milling, chips will be removed behind the cutter, reducing your chances of recutting.
Utilize High Efficiency Milling
High Efficiency Milling (HEM), is a roughing technique that uses the theory of chip thinning by applying a smaller radial depth of cut (RDOC) and a larger axial depth of cut (ADOC). The parameters for HEM are similar to that of finishing, but with increased speeds and feeds, allowing for higher material removal rates (MRR). HEM utilizes the full length of cut instead of just a portion of the cutter, allowing heat to be distributed across the cutting edge, maximizing tool life and productivity. This reduces the possibility of accelerated tool wear and breakage.
Decide On Coolant Usage & Delivery
Coolant can be an extremely effective way to protect your tool from premature wear and possible tool breakage. There are many different types of coolant and methods of delivery to your tool. Coolant can come in the form of compressed air, water-based, straight oil-based, soluble oil-based, synthetic or semi-synthetic. It can be delivered as mist, flood, high pressure or minimum quantity lubricant.
Appropriate coolant type and delivery vary depending on your application and tool. For example, using a high pressure coolant with miniature tooling can lead to tool breakage due to the fragile nature of extremely small tools. In applications of materials that are soft and gummy, flood coolant washes away the long stringy chips to help avoid recutting and built-up edge, preventing extra tool wear.
Extend Your Tool’s Life
The ability to maximize tool life saves you time, money and headaches. To get the best possible outcome from your tool, you first need to be sure you’re using the best tool for your job. Once you find your tool, ensure that your speeds and feeds are accurate and are from your tooling manufacturer. Nobody knows the tools better than they do. Finally, think about how to run your tool: the rotation of your cutter, whether utilizing an HEM approach is best, and how to introduce coolant to your job.
https://www.harveyperformance.com/wp-content/uploads/2018/12/Featured-Image-Life-of-End-Mill-IMG.jpg5251400Harvey Performance Companyhttp://www.harveyperformance.com/wp-content/uploads/2018/08/Logo_HarveyPerformanceCompany-4.pngHarvey Performance Company2018-12-05 11:28:212023-10-24 09:56:33How to Extend the Life of Your End Mill
Machinists have a number of variables to consider when setting up devices for a machining operation. When it comes to cnc workholding, there are some major differences between holding a loosely toleranced duplicate part with a 10-minute cycle time and holding a tightly toleranced specialized part with a 10-hour cycle time. Determining which method works best for your machining job is essential to maintaining an efficient operation.
CNC Workholding Devices
Ideal workholding devices have easily repeatable setups. For this reason, some machines have standard workholding devices. Vises are generally used with milling machines while chucks or collets are used when running a lathe machine. Sometimes, a part may need a customized cnc workholding setup in order to secure the piece properly during machining. Fixtures and jigs are examples of customized devices.
Fixtures and Jigs
A jig is a work holding device that holds, supports and locates a workpiece and guides the cutting tool into a specific operation (usually through the use of one or more bushings). A fixture is essentially the same type of device, but the main difference is that it does not guide the cutting tool into a specified operation. Fixtures are typically used in milling operations while jigs are generally used in drilling, reaming, tapping and boring. Jigs and fixtures are more precise relative to standard cnc workholding devices, which leads to tighter tolerances. They can also be indexable, allowing them to control the cutting tool movement as well as workpiece movement. Both jigs and fixtures are made up of the same basic components: fixture bodies, locators, supports, and clamps.
The 4 Fixture Bodies
There are 4 basic types of fixture bodies: faceplates, baseplates, angle plates, and tombstones.
Faceplates: Typically used in lathe operations, where components are secured to the faceplate and then mounted onto the spindle.
Baseplates: Common in milling and drilling operations and are mounted to the worktable.
Angle plates: Two plates perpendicular to each other but some are adjustable or customized to change the angle of the workpiece.
Tombstones: Large vertically oriented rectangular fixtures that orients a workpiece perpendicular to the worktable. Tombstones also have two sides to accommodate multiple parts.
Locators
Locators are characterized by four criteria: assembled, integral, fixed, and adjustable. Assembled locators, can be attached and removed from the fixture, which is contrary to integral locators that are built into the fixture. Fixed locators allow for no moving components, while adjustable locators permit movement through the use of threads and/or springs, and can adjust to a workpiece’s size. These can be combined to provide the appropriate rigidity-assembly convenience ratio. For example, a V-locator fixture is the combination of assembled and fixed locators. It can be secured to a fixture but has no moving components.
Supports
Supports do exactly what their name suggests, they support the workpiece during the machining process to avoid workpiece deformation. These components can double as locators and also come fixed, adjustable and integral, or assembled. Generally, supports are placed under the workpiece during manufacturing but this also depends on the geometry of the workpiece, the machine being operated and where the cutting tool will make contact. Supports can come in different shapes and sizes. For example, rest buttons are smaller support components used in series either from underneath the workpiece or from the sides. Concurrently, parallel supports are placed on either side of the part to provide general support.
Clamps
Clamps are devices used for strengthening or holding things together, and come in different shapes, sizes and strengths. Vises and chucks have movable jaws and are considered standard clamps. One atypical example is the toggle clamp, which has a pivot pin that acts as a fulcrum for a lever system. One of the more convenient types is a power clamping system. There are two type of power clamping methods: hydraulic and pneumatic.
Example of a standard fixture setup.
Hydraulic Workholding Systems
Hydraulic Systems create a gripping force by attaining power from compressing a liquid. This type of power clamp is generally used with larger workpieces as it usually takes up less space relative to pneumatic clamps.
Pneumatic clamps
Pneumatic clamps attain their gripping force from the power created by a compressed gas (usually air). These systems are generally bulkier and are used for smaller workpieces that require less room on the worktable. Power clamping offers a few advantages over conventional clamping. First, these systems can be activated and deactivated quickly to save on changeover time. Second, they place uniform pressure on the part, which help prevent errors and deformation. A significant disadvantage they pose is the cost of a system but this can be quickly offset by production time saved.
Key Guidelines to Follow
Lastly, there are a few guidelines to follow when choosing the appropriate CNC workholding fixture or jig setup.
Ensure Proper Tolerancing
The tolerances of the workholding device being used should be 20%-50% tighter than those of the workpiece.
Utilize Acceptable Locating & Supporting Pieces
Locating and supporting pieces should be made of a hardened material to prevent wear and allow for several uses without the workpieces they support falling out of tolerance. Supports and locators should also be standardized so that they can be easily replaced.
Place Workholding Clamps in Correct Locations
Clamps should be placed above the locations of supports to allow the force of the clamp to pass into the support without deforming the workpiece. Clamps, locators and supports should also be placed to distribute cutting forces as evenly as possible throughout the part. The setup should allow for easy clamping and not require much change over time
Maximize Machining Flexibility
The design of the fixture or jigs should maximize the amount of operations that can be performed in one orientation. During the machining operation, the setup should be rigid and stable.
Bottom Line
Workholding can be accomplished in a number of different ways and accomplish the same task of successfully gripping a part during a machining operation with the end result being in tolerance. The quality of this workholding may differ greatly as some setups will be more efficient than others. For example, there is no reason to create an elaborate jig for creating a small slot down the center of a rectangular brick of aluminum; a vise grip would work just fine. Maximizing the efficiency and effectiveness of an operators’ cnc workholding setup will boost productivity by saving on changeover, time as well as cost of scrapped, out of tolerance parts.
Few steps in the machining process are as important as proper end mill selection. Complicating the process is the fact that each individual tool has its own unique geometries, each pivotal to the eventual outcome of your part. We recommend asking yourself 5 key questions before beginning the tool selection process. In doing so, you can ensure that you are doing your due diligence in selecting the best tool for your application. Taking the extra time to ensure that you’re selecting the optimal tool will reduce cycle time, increase tool life, and produce a higher quality product.
Question 1: What Material Am I Cutting?
Knowing the material you are working with and its properties will help narrow down your end mill selection considerably. Each material has a distinct set of mechanical properties that give it unique characteristics when machining. For instance, plastic materials require a different machining strategy – and different tooling geometries – than steels do. Choosing a tool with geometries tailored towards those unique characteristics will help to improve tool performance and longevity.
Helical Solutions also provides a diverse product offering tailored to specific materials, including Aluminum Alloys & Non-Ferrous Materials; and Steels, High-Temp Alloys, & Titanium. Each section includes a wide variety of flute counts – from 2 flute end mills to Multi-Flute Finishers, and with many different profiles, coating options, and geometries.
Question 2: Which Operations Will I Be Performing?
An application can require one or many operations. Common machining operations include:
Traditional Roughing
Slotting
Finishing
Contouring
Plunging
High Efficiency Milling
By understanding the operations(s) needed for a job, a machinist will have a better understanding of the tooling that will be needed. For instance, if the job includes traditional roughing and slotting, selecting a Helical Solutions Chipbreaker Rougher to hog out a greater deal of material would be a better choice than a Finisher with many flutes.
Question 3: How Many Flutes Do I Need?
One of the most significant considerations during end mill selection is determining proper flute count. Both the material and application play an important role in this decision.
Material:
When working in Non-Ferrous Materials, the most common options are the 2 or 3-flute tools. Traditionally, the 2-flute option has been the desired choice because it allows for excellent chip clearance. However, the 3-flute option has proven success in finishing and High Efficiency Milling applications, because the higher flute count will have more contact points with the material.
Ferrous Materials can be machined using anywhere from 3 to 14-flutes, depending on the operation being performed.
Application:
Traditional Roughing: When roughing, a large amount of material must pass through the tool’s flute valleys en route to being evacuated. Because of this, a low number of flutes – and larger flute valleys – are recommend. Tools with 3, 4, or 5 flutes are commonly used for traditional roughing.
Slotting: A 4-flute option is the best choice, as the lower flute count results in larger flute valleys and more efficient chip evacuation.
Finishing: When finishing in a ferrous material, a high flute count is recommended for best results. Finishing End Mills include anywhere from 5-to-14 flutes. The proper tool depends on how much material remains to be removed from a part.
High Efficiency Milling: HEM is a style of roughing that can be very effective and result in significant time savings for machine shops. When machining an HEM toolpath, opt for 5 to 7-flutes.
Question 4: What Specific Tool Dimensions are Needed?
After specifying the material you are working in, the operation(s) that are going to be performed, and the number of flutes required, the next step is making sure that your end mill selection has the correct dimensions for the job. Examples of key considerations include cutter diameter, length of cut, reach, and profile.
Cutter Diameter
The cutter diameter is the dimension that will define the width of a slot, formed by the cutting edges of the tool as it rotates. Selecting a cutter diameter that is the wrong size – either too large or small – can lead to the job not being completed successfully or a final part not being to specifications. For example, smaller cutter diameters offer more clearance within tight pockets, while larger tools provide increased rigidity in high volume jobs.
Length of Cut & Reach
The length of cut needed for any end mill should be dictated by the longest contact length during an operation. This should be only as long as needed, and no longer. Selecting the shortest tool possible will result in minimized overhang, a more rigid setup, and reduced chatter. As a rule of thumb, if an application calls for cutting at a depth greater than 5x the tool diameter, it may be optimal to explore necked reach options as a substitute to a long length of cut.
Tool Profile
The most common profile styles for end mills are square, corner radius, and ball. The square profile on an end mill has flutes with sharp corners that are squared off at 90°. A corner radius profile replaces the fragile sharp corner with a radius, adding strength and helping to prevent chipping while prolonging tool life. Finally, a ball profile features flutes with no flat bottom, and is rounded off at the end creating a “ball nose” at the tip of the tool. This is the strongest end mill style. A fully rounded cutting edge has no corner, removing the mostly likely failure point from the tool, contrary to a sharp edge on a square profile end mill. An end mill profile is often chosen by part requirements, such as square corners within a pocket, requiring a square end mill. When possible, opt for a tool with the largest corner radius allowable by your part requirements. We recommend a corner radii whenever your application allows for it. If square corners are absolutely required, consider roughing with a corner radius tool and finishing with the square profile tool.
Question 5: Should I Use a Coated Tool?
When used in the correct application, a coated tool will help to boost performance by providing the following benefits:
More Aggressive Running Parameters
Prolonged Tool life
Improved Chip Evacuation
Harvey Tool and Helical Solutions offer many different coatings, each with their own set of benefits. Coatings for ferrous materials, such as AlTiN Nano or TPlus, typically have a high max working temperature, making them suitable for materials with a low thermal conductivity. Coatings for non-ferrous applications, such as TiB2 or ZPlus, have a low coefficient of friction, allowing for easier machining operations. Other coatings, such as Amorphous Diamond or CVD Diamond Coatings, are best used in abrasive materials because of their high hardness rating.
Ready to Decide on an End Mill
There are many factors that should be considered while looking for the optimal tooling for the job, but asking the aforementioned five key question during the process will help you to make the right decision. As always, The Harvey Performance Company Technical Service Department is always available to provide recommendations and walk you through the tool selection process, if need be.
https://www.harveyperformance.com/wp-content/uploads/2018/10/Feature-Image-5-Questions-IMG-2.jpg5251400Harvey Performance Companyhttp://www.harveyperformance.com/wp-content/uploads/2018/08/Logo_HarveyPerformanceCompany-4.pngHarvey Performance Company2018-10-16 09:00:242023-10-24 10:42:255 Questions to Ask Before Selecting an End Mill
Thread milling can present a machinist many challenges. While thread mills are capable of producing threads with relative ease, there are a lot of considerations that machinists must make prior to beginning the job in order to gain consistent results. To conceptualize these features and choose the right tool, machinists must first understand basic thread milling applications.
What is a Thread?
The primary function of a thread is to form a coupling between two different mechanisms. Think of the cap on your water bottle. The cap couples with the top of the bottle in order to create a water tight seal. This coupling can transmit motion and help to obtain mechanical advantages. Below are some important terms to know in order to understand threads.
Root – That surface of the thread which joins the flanks of adjacent thread forms and is immediately adjacent to the cylinder or cone from which the thread projects.
Flank – The flank of a thread is either surface connecting the crest with the root. The flank surface intersection with an axial plane is theoretically a straight line.
Crest – This is that surface of a thread which joins the flanks of the thread and is farthest from the cylinder or cone from which the thread projects.
Pitch – The pitch of a thread having uniform spacing is the distance measured parallelwith its axis between corresponding points on adjacent thread forms in the same axial plane and on the same side of the axis. Pitch is equal to the lead divided by the number of thread starts.
Major Diameter – On a straight thread the major diameter is that of the major cylinder.On a taper thread the major diameter at a given position on the thread axis is that of the major cone at that position.
Minor Diameter – On a straight thread the minor diameter is that of the minor cylinder. On a taper thread the minor diameter at a given position on the thread axis is that of the minor cone at that position.
Helix Angle – On a straight thread, the helix angle is the angle made by the helix of the thread and its relation to the thread axis. On a taper thread, the helix angle at a given axial position is the angle made by the conical spiral of the thread with the axis of the thread. The helix angle is the complement of the lead angle.
Depth of Thread Engagement – The depth (or height) of thread engagement between two coaxially assembled mating threads is the radial distance by which their thread forms overlap each other.
External Thread – A thread on a cylindrical or conical external surface.
Internal Thread – A thread on a cylindrical or conical internal surface.
Class of Thread – The class of a thread is an alphanumerical designation to indicate the standard grade of tolerance and allowance specified for a thread.
Source: Machinery’s Handbook 29th Edition
Types of Threads & Their Common Applications:
ISO Metric, American UN: This thread type is used for general purposes, including for screws. Features a 60° thread form.
British Standard, Whitworth: This thread form includes a 55° thread form and is often used when a water tight seal is needed.
NPT: Meaning National Pipe Tapered, this thread, like the Whitworth Thread Form, is also internal. See the above video for an example of an NPT thread.
UNJ, MJ: This type of thread is often used in the Aerospace industry and features a radius at the root of the thread.
ACME, Trapezoidal: ACME threads are screw thread profiles that feature a trapezoidal outline, and are most commonly used for power screws.
Buttress Threads: Designed for applications that involve particularly high stresses along the thread axis in one direction. The thread angle on these threads is 45° with a perpendicular flat on the front or “load resisting face.”
Thread Designations
Threads must hold certain tolerances, known as thread designations, in order to join together properly. International standards have been developed for threads. Below are examples of Metric, UN, and Acme Thread Designations. It is important to note that not all designations will be uniform, as some tolerances will include diameter tolerances while others will include class of fit.
Metric Thread Designations
M12 x 1.75 – 4h – LH
In this scenario, “M” designates a Metric Thread Designation, 12 refers to the Nominal Diameter, 1.75 is the pitch, 4h is the “Class of Fit,” and “LH” means “Left-Hand.”
UN Thread Designations
¾ 10 UNC 2A LH
For this UN Thread Designation, ¾ refers to the thread’s major diameter, where 10 references the number of threads per inch. UNC stands for the thread series; and 2A means the class of thread. The “A” is used to designate external threads, while “B” is for internal threads. For these style threads, there are 6 other classes of fit; 1B, 2B, and 3B for internal threads; and 1A, 2A, and 3A for external threads.
ACME Thread Designations
A 1 025 20-X
For this ACME Thread Designation, A refers to “Acme,” while 1 is the number of thread starts. The basic major diameter is called out by 025 (Meaning 1/4”) while 20 is the callout for number of threads per inch. X is a placeholder for a number designating the purpose of the thread. A number 1 means it’s for a screw, while 2 means it’s for a nut, and 3 refers to a flange.
How Are Threads Measured?
Threads are measured using go and no-go gauges. These gauges are inspection tools used to ensure the that the thread is the right size and has the correct pitch. The go gauge ensures the pitch diameter falls below the maximum requirement, while the no-go gauge verifies that the pitch diameter is above the minimum requirement. These gauges must be used carefully to ensure that the threads are not damaged.
Thread Milling Considerations
Thread milling is the interpolation of a thread mill around or inside a workpiece to create a desired thread form on a workpiece. Multiple radial passes during milling offer good chip control. Remember, though, that thread milling needs to be performed on machines capable of moving on the X, Y, and Z axis simultaneously.
Choose only a cutter diameter as large as you need. A smaller cutter diameter will help achieve higher quality threads.
3. Ensure You’re Comfortable With Your Tool Path
Your chosen tool path will determine left hand or right hand threads.
Right-hand internal thread milling is where cutters move counterclockwise in an upwards direction to ensure that climb milling is achieved.
Left-hand internal thread milling a left-hand thread follows in the opposite direction, from top to bottom, also in a counterclockwise path to ensure that climb milling is achieved.
4. Assess Number of Radial Passes Needed
In difficult applications, using more passes may be necessary to achieve desired quality. Separating the thread milling operation into several radial passes achieves a finer quality of thread and improves security against tool breakage in difficult materials. In addition, thread milling with several radial passes also improves thread tolerance due to reduced tool deflection. This gives greater security in long overhangs and unstable conditions.
5. Review Chip Evacuation Strategy
Are you taking the necessary steps to avoid chip recutting due to inefficient chip evacuation? If not, your thread may fall out of tolerance. Opt for a strategy that includes coolant, lubricant, and tool retractions.
Titan USA Threadmill
In Summary
Just looking at a thread milling tool can be confusing – it is sometimes hard to conceptualize how these tools are able to get the job done. But with proper understanding of call, methods, and best practices, machinists can feel confident when beginning their operation.
Keyseat Cutters, also known as Woodruff Cutters, Keyway Cutters, and T-Slot Cutters, are commonly used in machine shops. Many machinists opt to use this tool to put a slot on the side of a part in an efficient manner, rather than rotating the workpiece and using a traditional end mill. A Staggered Tooth Keyseat Cutter has alternating right-hand and left hand shear flutes and is right-hand cut, whereas a traditional keyseat cutter has all straight flutes and is right-hand cut. Simply, the unique geometry of a Staggered Tooth Keyseat Cutter gives the tool its own set of advantages including the ability to index within the slot, increase feed rates, and achieve better part finish.
Three Key Benefits
Indexing
The alternating right-and-left-hand flutes of a Harvey Tool Staggered Tooth Keyseat Cutters are relieved on both sides of its head, meaning that it allows for both end cutting and back cutting. This adds to the versatility of the staggered tooth keyseat cutter, where one singular tool can be indexed axially within a slot to expand the slot to a specific uncommon dimension. This can save space in a machinist’s magazine and reduce machine time by eliminating the need to swap to a new tool.
Increased Feed Rates
Due to the unique geometry of a Staggered Tooth Keyseat Cutter, chips evacuate efficiently and at a faster rate than that of a Straight Flute Keyseat Cutter. The unique flutes of Staggered Tooth Keyseat Cutters are a combination of right-and-left-hand shear flutes, but both types are right-hand cutting. This results in the tool’s teeth alternating between upcut and downcut. Chip packing and chip recutting is less of a concern with running this tool, and results in increased chip loads compared to that of a standard keyseat with the same number of flutes. Because of this, the tool can account for chiploads of about 10% higher than the norm, resulting in heightened feed rates and shorter cycle times overall.
Better Part Finish
Staggered Tooth Keyseat Cutters have “teeth”, or flutes, that are ground at an angle creating a shear flute geometry. This geometry minimizes chip recutting, chip dragging and reduces the force needed to cut into the material. Chip recutting and dragging are minimized because chips are evacuated out of the top and bottom of the head on the side of the cutter that is not engaged in the material. Shear flutes also reduce vibrations that can lead to chatter and poor finish. By minimizing cutting forces, vibration, and chatter, a machinist can expect a better part finish.
Image courtesy of @edc_machining
Staggered Tooth Keyseat Cutter Diverse Product Offering
On top of the higher performance one will experience when using the Stagger Tooth Keyseats, there are also multiple options available with various combinations to suit multiple machining needs. This style is offered in a square, square reduced shank and corner radius profile which helps if a fillet or sharp corner is needed. The square and corner radius tools are offered in diameters ranging from 1/8” to 5/8”, and the square reduced shank tool is offered in diameteres ranging from 3/4″ to 1-1/2″. The increased diameter comes with an increase of radial depth of cut, allowing deeper slots to be achievable. Within the most popular cutter diameters, ¼”, 3/8”, and ½” there are also deep slotting options with even greater radial depth of cuts for increased slot depths. On top of the diameters and radii, there are also multiple cutter widths to choose from to create different slots in one go. Finally, an uncoated and AlTiN coatings are available to further increase tool life and performance depending on the material that is being cut.
Opt for a Smoother Operation
A Staggered Tooth Keyseat Cutter adds versatility to a tool magazine. It can be indexed axially to expand slots to make multiple widths, allowing machinists to progress operations in a more efficient manner where tool changes are not required. Further, this tool will help to reduce harmonics and chatter, as well as minimize recutting. This works to create a smoother operation with less force on the cutter, resulting in a better finish compared to a Standard Keyseat Cutter.
Machining Advisor Pro (MAP) is a tool to quickly, seamlessly, and accurately deliver recommended running parameters to machinists using Helical Solutions end mills. This download-free and mobile-friendly application takes into account a user’s machine, tool path, set-up, and material to offer tailored, specific speeds and feed parameters to the tools they are using.
How to Begin With Machining Advisor Pro
This section will provide a detailed breakdown of Machining Advisor Pro, moving along step-by-step throughout the entire process of determining your tailored running parameters.
Whether you are using Machining Advisor Pro from the web or your mobile device, machinists must first create an account. The registration process will only need to be done once before you will be able to log into Machining Advisor Pro on both the mobile and web applications immediately.
Simply Activate Your Account
The final step in the registration process is to activate your account. To do this, simply click the activation link in the email that was sent to the email address used when registering. If you do not see the email in your inbox, we recommend checking your spam folders or company email filters. From here, you’re able to begin using MAP.
Using Machining Advisor Pro
A user’s experience will be different depending on whether they’re using the web or mobile application. For instance, after logging in, users on the web application will view a single page that contains the Tool, Material, Operation, Machine, Parameter, and Recommendation sections.
On the mobile application, however, the “Input Specs” section is immediately visible. This is a summary of the Tool, Material, Operation, and Machine sections that allow a user to review and access any section. Return to this screen at any point by clicking on the gear icon in the bottom left of the screen.
Identify Your Helical Tool
To get started generating your running parameters, specify the Helical Solutions tool that you are using. This can be done by entering the tool number into the “Tool #” input field (highlighted in red below). As you type the tool number, MAP will filter through Helical’s 4,800-plus tools to begin identifying the specific tool you are looking for.
Once the tool is selected, the “Tool Details” section will populate the information that is specific to the chosen tool. This information will include the type of tool chosen, its unit of measure, profile, and other key dimensional attributes.
Select the Material You’re Working In
Once your tool information is imported, the material you’re working in will need to be specified. To access this screen on the mobile application, either swipe your screen to the left or click on the “Material” tab seen at the bottom of the screen. You will move from screen to screen across each step in the mobile application by using the same method.
In this section, there are more than 300 specific material grades and conditions available to users. The first dropdown menu will allow you to specify the material you are working in. Then, you can choose the subgroup of that material that is most applicable to your application. In some cases, you will also need to choose a material condition. For example, you can select from “T4” or “T6” condition for 6061 Aluminum.
Machining Advisor Pro provides optimized feeds and speeds that are specific to your application, so it is important that the condition of your material is selected.
Pick an Operation
The next section of MAP allows the user to define their specific operation. In this section, you will define the tool path strategy that will be used in this application. This can be done by either selecting the tool path from the dropdown menu or clicking on “Tool Path Info” for a visual breakdown and more information on each available toolpath.
Tailor Parameters to Your Machine’s Capabilities
The final section on mobile, and the fourth web section, is the machine section. This is where a user can define the attributes of the machine that you are using. This will include the Max RPM, Max IPM, Spindle, Holder, and work holding security. Running Parameters will adjust based on your responses.
Access Machining Advisor Pro Parameters
Once the Tool, Material, Operation, and Machine sections are populated there will be enough information to generate the initial parameters, speed, and feed. To access these on the mobile app, either swipe left when on the machine tab or tap on the “Output” tab on the bottom menu.
Please note that these are only initial values. Machining Advisor Pro gives you the ability to alter the stick out, axial depth of cut, and radial depth of cut to match the specific application. These changes can either be made by entering the exact numeric value, the % of cutter diameter, or by altering the slider bars. You are now able to lock RDOC or ADOC while adjusting the other depth of cut, allowing for more customization when developing parameters.
The parameters section also offers a visual representation of the portion of the tool that will be engaged with the materials as well as the Tool Engagement Angle.
MAP’s Recommendations
At this point, you can now review the recommended feeds and speeds that Machining Advisor Pro suggests based on the information you have input. These optimized running parameters can then be further refined by altering the speed and feed percentages.
Machining Advisor Pro recommendations can be saved by clicking on the PDF button that is found in the recommendation section on both the web and mobile platforms. This will automatically generate a PDF of the recommendations, allowing you to print, email, or share with others.
Machining Advisor Pro Summarized
The final section, exclusive to the mobile application, is the “Summary” section. To access this section, first tap on the checkmark icon in the bottom menu. This will open a section that is similar to the “Input Specs” section, which will give you a summary of the total parameter outputs. If anything needs to change, you can easily jump to each output item by tapping on the section you need to adjust.
This is also where you would go to reset the application to clear all of the inputs and start a new setup. On the web version, this button is found in the upper right-hand corner and looks like a “refresh” icon on a web browser.
Contact Us
For the mobile application, we have implemented an in-app messaging service. This was done to give the user a tool to easily communicate any question they have about the application from within the app. It allows the user to not only send messages, but to also include screenshots of what they are seeing! This can be accessed by clicking on the “Contact Us” option in the same hamburger menu that the Logout and Help & Tips are found.
https://www.harveyperformance.com/wp-content/uploads/2018/09/machiningadvisorpro.jpg6001599David Pichettehttp://www.harveyperformance.com/wp-content/uploads/2018/08/Logo_HarveyPerformanceCompany-4.pngDavid Pichette2018-09-13 14:20:202021-09-21 08:23:11Get to Know Machining Advisor Pro
