IN THE LOUPE- Your Source for Machining Solutions
While many factors impact the outcome of a machining operation, one often overlooked factor is the cutting tool’s helix angle. The Helix angle of a tool is measured by the angle formed between the centerline of the tool and a straight line tangent along the cutting edge. A higher helix angle, usually 40° or more, […]
Titanium is a notoriously difficult material to machine, especially in aggressive toolpaths, such as those associated with High Efficiency Milling (HEM). Helical Solutions’ new line of tooling, the HVTI-6 series of end mills, is optimized specifically for this purpose, and proven to provide 20% more tool life than a competitor’s similar tool. At face level, […]
A chamfer cutter, or a chamfer mill, can be found at any machine shop, assembly floor, or hobbyist’s garage. These cutters are simple tools that are used for chamfering or beveling any part in a wide variety of materials. There are many reasons to chamfer a part, ranging from fluid flow and safety, to part […]
When trying to develop efficient processes, many machinists and programmers turn to tool selection first. It is true that tooling can often make a big difference in machining time, and speeds and feeds, but did you know that your machine’s spindle can have an equally impactful effect? The legs of any CNC machine, spindles are […]
Boring is a turning operation that allows a machinist to make a pre-existing hole bigger through multiple iterations of internal boring. It has a number of advantages over traditional drilling methods: The ability to cost-effectively produce a hole outside standard drill sizes The creation of more precise holes, and therefore tighter tolerances A greater finish […]
“Green Manufacturing” has become a common phrase used by many in America’s largest industry. It is defined by Goodwin College as “the renewal of production processes and the establishment of environmentally friendly operations within the manufacturing field.” Taking the time to rethink dated processes can save you time, money, and help build your reputation as […]
When a machinist needs to cut material significantly deeper than wide, a Slitting Saw is an ideal choice to get the job done. A Slitting Saw is unique due to its composition and rigidity, which allows it to hold up in a variety of both straightforward and tricky to machine materials. What is a Slitting […]
Precious metals can be particularly difficult to machine due to their wide range of material properties and high cost if a part has to be scrapped. The following article will introduce these elements and their alloys as well as provide a guide on how to machine them effectively and efficiently. About the Elements Sometimes called […]
Most machinists are familiar with CNC drilling, but did you know that the common practice for holemaking is to always use a reamer? When done correctly, reaming can be a fast and highly accurate operation that results in precision holes. Critical Reamer Geometries By examining a Harvey Tool Miniature Reamer and its critical dimensions, we […]
Dovetail Cutters are cutting tools that create a trapezoidal-type shape, or a dovetail groove, in a part. Due to the form of these tools, special considerations need to be made in order to achieve long tool life and superior results. This is particularly true when machining O-ring grooves, as this operation requires the tool to […]
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 […]
Knuckle Roughers and Chipbreakers are common profiles found on roughing end mills that, while fairly similar in appearance, actually serve different functions. Chipbreakers refer to the notches along the cutting edge of a tool that work to break up chips to prevent common evacuation mishaps. Knuckle Roughers refer to the serrated cutting edge of a […]
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 […]
Do you know the key differences between a Single Form Thread Mill and a Multi-Form Thread Mill? 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 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 your tool’s life. Properly Prepare Before the Tool Selection Process The first step of any […]
While similar on the surface, Half-round Engraving Cutters and Marking Cutters are actually very different. Both tools are unique in the geometries they possess, the benefits they offer, and the specific purposes they’re used for. Below are the key differences between Engraving Cutters and Marking Cutters that all machinists must know, as the engraving on […]
Any cutting tool application will generate heat, but knowing how to counteract it will improve the life of your tool. Heat can be good and doesn’t need to totally be avoided, but controlling heat will help prolong your tool life. Sometimes, an overheating tool or workpiece is easy to spot due to smoke or deformation. […]
Machinists have a number of variables to consider when setting up workholding devices for a machining operation. When it comes to 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 […]
Few steps in the machining process are as important as selecting the best tooling option for your job. 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. […]
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 […]
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 […]
High speed machining is becoming increasingly widespread in machine shops all over the world due to the proven benefits of greater efficiency and productivity through increased spindle speeds and metal removal rates. However, at such high spindle speeds, otherwise negligible errors and imperfections can cause negative effects such as reduced tool life, poor surface finish, […]
A cutting tool’s shank is one of the more vital parts of a tool, as it’s critical to the collet-tool connection. There are several types of shanks, each with their own tolerances and suitable tool holder methods. One of the most popular and effective tool holding styles is a shrink fit tool holder, which works […]
Tolerance stacking, also known as tolerance stack-up, refers to the combination of various part dimension tolerances. After a tolerance is identified on the dimension of a part, it is important to test whether that tolerance would work with the tool’s tolerances: either the upper end or lower end. A part or assembly can be subject […]
In manufacturing large production runs, one of the biggest difficulties machinists experience is holding tooling to necessary tolerances in holes, walls, and threads. Typically, this is an iterative process that can be tedious and stressful, especially for inexperienced machinists. While each job presents a unique set of challenges, there are rules of thumb that can […]
What is Contouring? Contouring a part means creating a fine finish on an irregular or uneven surface. Dissimilar to finishing a flat or even part, contouring involves the finishing of a rounded, curved, or otherwise uniquely shaped part. Contouring & 5-Axis Machining 5-axis machines are particularly suitable for contouring applications. Because contouring involves the finishing […]
If there is one thing that all machinists and shop managers can agree on, it’s that time is money. Tool and material costs, employee wages, and keeping the lights on all add up, but most would agree that saving time is one of the best ways to make a shop more efficient. Tool changes mid-job […]
Deburring is a process in which sharp edges and burrs are removed from a part to create a more aesthetically pleasing final product. After milling, parts are typically taken off the machine and sent off to the Deburring Department. Here, the burrs and sharp points are removed, traditionally by hand. However, an operation that takes an hour […]
5 Ways Your Shop is Inefficient In today’s ultracompetitive industry, every machine shop seeks even the slightest edge to gain an advantage on their competition and boost their bottom line. However, what many machinists don’t know is that improving their shop’s efficiency might be easier than they thought. The following five ways your shop is […]
CNC Machine Growth As the manufacturing industry has developed, so too have the capabilities of machining centers. CNC Machines are constantly being improved and optimized to better handle the requirements of new applications. Perhaps the most important way these machines have improved over time is in the multiple axes of direction they can move, as […]
Coolant in purpose is widely understood – it’s used to temper high temperatures common during machining, and aid in chip evacuation. However, there are several types and styles, each with its own benefits and drawbacks. Knowing which coolant – or if any – is appropriate for your job can help to boost your shop’s profitability, capability, […]
Keyseat cutters, also called woodruff cutters, keyway cutters, and T-slot cutters, are a type of cutting tool used frequently by many machinists – some operations are impractical or even impossible without one. If you need one of these tools for your job, it pays to know when and how to pick the right one and […]
Understanding Speeds and Feed Rates NOTE: This article covers speeds and feed rates for milling tools, as opposed to turning tools. Before using a cutting tool, it is necessary to understand tool cutting speeds and feed rates, more often referred to as “speeds and feeds.” Speeds and feeds are the cutting variables used in every milling […]
Composites are a group of materials made up of at least two unique constituents that, when combined, produce mechanical and physical properties favorable for a wide array of applications. These materials usually contain a binding ingredient, known as a matrix, filled with particles or fibers called reinforcements. Composites have become increasingly popular in the Aerospace, […]
Each tool holder style has its own unique properties that must be considered prior to beginning a machining operation. A secure machine-to-tool connection will result in a more profitable shop, as a poor connection can cause tool runout, pull-out, scrapped parts, damaged tools, and exhausted shop resources. An understanding of tool holders, shank features, and […]
A chamfer mill, or a chamfer cutter, is one of the most common tools used by machinists daily. When creating a part, machining operations can oftentimes leave a sharp edge on a workpiece. A chamfer mill eliminates sharp edges, leaving a sloped surface, or a chamfer, instead. In doing so, the part will be stronger […]
The following is just one of several blog posts relevant to High Efficiency Milling. To achieve a full understanding of this popular machining method, view any of the additional HEM posts below! Introduction to High Efficiency Milling I High Speed Machining vs. HEM I How to Combat Chip Thinning I Diving into Depth of Cut […]
Undercutting end mills, also known as lollipop cutters or spherical ball end mills, are a common choice for machining undercuts. An undercut is a common part feature characterized by one part of a workpiece “hanging” over another. Undercuts are typically difficult, or even impossible, to machine with a standard end mill, especially on 3-axis machines. […]
The following is just one of several blog posts relevant to High Efficiency Milling. To achieve a full understanding of this popular machining method, view any of the additional HEM posts below! High Speed Machining vs. HEM I How to Combat Chip Thinning I Diving into Depth of Cut I How to Avoid 4 Major […]
The following is just one of several blog posts relevant to High Efficiency Milling. To achieve a full understanding of this popular machining method, view any of the additional HEM posts below! Introduction to High Efficiency Milling I How to Combat Chip Thinning I Diving into Depth of Cut I How to Avoid 4 Major […]
In today’s manufacturing industry, titanium and its alloys have become staples in aerospace, medical, automotive, and firearm applications. This popular metal is resistant to rust and chemicals, is recyclable, and is extremely strong for its weight. However, there are several challenges that must be considered when machining titanium and selecting the appropriate tools and parameters […]
Tool entry is pivotal to machining success, as it’s one of the most punishing operations for a cutter. Entering a part in a way that’s not ideal for the tool or operation could lead to a damaged part or exhausted shop resources. Below, we’ll explore the most common part entry methods, as well as tips […]
The following is just one of several blog posts relevant to High Efficiency Milling. To achieve a full understanding of this popular machining method, view any of the additional HEM posts below! Introduction to High Efficiency Milling I High Speed Machining vs. HEM I How to Combat Chip Thinning I Diving into Depth of Cut […]
Ball Nose Milling Without a Tilt Angle Ball nose end mills are ideal for machining 3-dimensional contour shapes typically found in the mold and die industry, the manufacturing of turbine blades, and fulfilling general part radius requirements. To properly employ a ball nose end mill (with no tilt angle) and gain the optimal tool life […]
A Double Angle Shank Cutter is often referred to as the “Swiss Army Knife of Machining” due to its extreme versatility. This singular tool can be used for chamfering, back chamfering, V-groove milling, deburring, and countersinking. Below, we’ll learn the nuances of each operation, and why a Double Angle Shank Cutter might is an excellent […]
The following is just one of several blog posts relevant to High Efficiency Milling. To achieve a full understanding of this popular machining method, view any of the additional HEM posts below! Introduction to High Efficiency Milling I High Speed Machining vs. HEM I How to Combat Chip Thinning I How to Avoid 4 Major Types […]
In today’s manufacturing industry, the reach necessary for many complex parts is pushing the boundaries of plausibility. Deep cavities and complex side milling operations are typical to the mold, tool, and die industry but are also quite common in many machining applications requiring angled walls. Fortunately, many long reach applications include angled walls extending into […]
A multi-start thread consists of two or more intertwined threads running parallel to one another. Intertwining threads allow the lead distance of a thread to be increased without changing its pitch. A double start thread will have a lead distance double that of a single start thread of the same pitch, a triple start thread […]
Corner Engagement During the milling process, and especially during corner engagement, tools undergo significant variations in cutting forces. One common and difficult situation is when a cutting tool experiences an “inside corner” condition. This is where the tool’s engagement angle significantly increases, potentially resulting in poor performance. Machining this difficult area with the wrong approach […]
Poor tool life and premature tool failure are concerns in every machining application. Something as simple as tool path selection – and how a tool first enters a part – can make all the difference. Tool entry has a great deal of influence on its overall success, as it’s one of the most punishing operations […]
There are two distinct ways to cut materials when milling: Conventional Milling (Up) and Climb Milling (Down). The difference between these two techniques is the relationship of the rotation of the cutter to the direction of feed. In Conventional Milling, the cutter rotates against the direction of the feed. During Climb Milling, the cutter rotates […]
While they are specialty tools, dovetail style cutters have a broad range of applications. Dovetails are typically used to cut O-ring grooves in fluid and pressure devices, industrial slides and detailed undercutting work.
Finishing cuts are used to complete a part, achieving its final dimensions within tolerance and its required surface finish. Most often an aesthetic demand and frequently a print specification, surface finish can lead to a scrapped part if requirements are not met. Meeting finish requirements in-machine has become a major point of improvement in manufacturing, as avoiding hand-finishing can significantly reduce costs and cycle times.
Harvey Tool’s Miniature High Performance Composite Drills are specifically designed with point geometry optimized for the unique properties of composite materials. Our Double Angle style is engineered to overcome common problems in layered composites and our Brad Point style is built to avoid the issues frequently experienced in fibrous composites.
When machining, proper speeds and feeds are very important to avoid breakage and maximize performance. Traditional end milling formulas use Surface Footage (SFM) and Chip Load (IPT) to calculate Speed (RPM) and Feed (IPM) rates. These formulas dictate the correct machining parameters for use in a linear path in which the end mill’s centerline is […]
Milling part features with thin wall characteristics, while also maintaining dimensional accuracy and straightness, can be difficult at best. Although multiple factors contribute, some key components are discussed below and can help to increase your thin wall milling accuracy. Use Proper Tooling Long length tooling with a long length of cut can spell trouble in […]
Deep cavity milling is a common yet demanding milling operation. In this style, the tool has a large amount of overhang – or how far a cutting tool is sticking out from its tool holder. The most common challenges of deep cavity milling include tool deflection, chip evacuation, and tool reach. Avoid Tool Deflection Excess […]
The following is just one of several blog posts relevant to High Efficiency Milling. To achieve a full understanding of this popular machining method, view any of the additional HEM posts below! Introduction to High Efficiency Milling I High Speed Machining vs. HEM I Diving into Depth of Cut I How to Avoid 4 Major […]
Drilling an ultra-precise hole can be tough. Material behavior, surface irregularities, and drill point geometry can all be factors leading to inaccurate holes. A Spot Drill, if used properly, will eliminate the chance of drill walking and will help to ensure a more accurate final product. Choosing a Spot Drill Ideally, the center of a […]
