Tag Archive for: american manufacturing

Titan USA 1K Follower Giveaway

*GIVEAWAY CLOSED – WINNER NOTIFIED*

As a thank you for reaching 1,000 followers on Instagram, we at Titan USA want to show our appreciation by giving all of our followers a chance to win a $150 Amazon gift card. With the addition of the Titan USA brand to the Harvey Performance Company family, we want to give our customers a chance to win.

How to Participate

All you need to do is follow the @titan.usa Instagram page, like the Giveaway post, and fill out the form below to gain an entry into the contest.

Entry Form

Official Contest Rules

Contest Dates:

  • The contest will run from September 12, 2022 to Semptember 19, 2022. Submit as many entries as you’d like! Entries that are submitted before or after the contest period will not be considered for the giveaway.

The Important Stuff:

  1. Follow Titan USA on Instagram
  2. Like the 1K Follower Giveaway post.
  3. Fill out the following form to make your initial entry.
  4. Additional entries will be given for:
    1. Creating an account on the Titan USA website.
    2. Leaving one comment tagging a friend on the Instagram post.
    3. Tagging @titan.usa in an Instagram post of your Titan USA tools.
    4. Leaving a review on a Titan USA product.

Prizes

All submissions and additional entries will be considered for the $150 Amazon gift card prize.

Winner of the giveaway will be chosen at random on September 22, 2022, notified on social media and be emailed the prize upon acceptance.

Full Details:

9/12/22

NO PURCHASE IS NECESSARY TO ENTER OR WIN. MAKING A PURCHASE WILL NOT INCREASE YOUR CHANCES OF WINNING. APPLICABLE ONLY IN THE UNITED STATES and CANADA. ENTRY INTO THIS SWEEPSTAKES CONSTITUTES ACCEPTANCE OF THESE OFFICIAL RULES. VOID WHERE PROHIBITED BY LAW.

By participating in the Harvey Performance Sweepstakes (the “Sweepstakes”), you agree to these official rules (the “Rules”), which are a contract, so read them carefully before participating. Without limitation, this contract includes indemnities to the Released Parties (defined below) from you and a limitation of your rights and remedies. You must follow these Rules to enter and be eligible to receive a prize in connection with the Sweepstakes.

DURATION:  Sweepstakes begins on September 12th, 2022 at 11 AM Eastern Daylight Time and ends September 19th, 2022 at 5 PM Eastern Daylight Time (“Sweepstakes Period”).  The computer clock of Harvey Performance Company, LLC (“Sponsor”) is the official time-keeping device for the Sweepstakes.

ELIGIBILITY: The Sweepstakes is open only to legal permanent residents of the United States (excluding Puerto Rico, and the U.S. Territories and Possessions) who are 21 years of age or older as of the date of entry. Employees, officers and directors of Sponsor along with its affiliates, subsidiaries, advertising, contest, fulfillment and marketing agencies, (collectively, “Promotion Parties”) their immediate families (parent, child, sibling & spouse and their respective spouses, regardless of where they reside) and persons living in the same households as such individuals (whether related or not) are not eligible to participate in the Sweepstakes. By participating, you agree to these Rules and to the decisions of the Sponsor, which are final and binding in all respects.  In addition, to be eligible to win, you must also execute and return Sponsor’s forms for you to: (i) consent to the use of your rights of publicity, (ii) assume all tax liabilities, (iii) waive all claims against Sponsor and Promotion Parties, and (iv) confirm your eligibility (collectively “Affidavits and Waivers”). This Sweepstakes is void in any jurisdiction not listed above and where prohibited by law, rule or regulation.

HOW TO ENTER: Follow the directions and complete the entry and submission form available at https://go.harveyperformance.com/l/186562/2022-07-12/2v8ly98 (the “Entry Form”), and following the Sponsor’s Instagram account.  Up to 5 additional entries can be made by providing e-mail addresses of friends that also fill out an entry form and follow Sponsor’s Instagram account.

ALTERNATIVE MEANS OF ENTRY: On a plain 3” x 5” card, legibly handprint or type your name, age, complete address, city, state, zip code, home phone number (including area code), and email address (if any). Then, mail your 3” x 5” card in a postage-affixed sealed envelope to:

428 Newburyport Turnpike, Rowley, MA 01969

If you do not provide an email address, we will call you if your name is selected. Otherwise, you will not be contacted regarding the outcome.

Mail-in entries must be postmarked by September 19th, 2022 and received by September 19th, 2022. No mechanically or programmatically reproduced entries are permitted. Each postcard is considered one (1) entry.  The information provided on such submitted 3” x 5” cards shall also be deemed part of the Entry Form.

PRIVACY POLICY:  Information collected in connection with this Sweepstakes will be used in accordance with Sponsor’s Official Privacy Policy (available at https://www.harveyperformance.com/privacy-policy/ and these Rules. In the event of any discrepancy between Sponsor’s Privacy Policy and these Rules, Sponsor’s Privacy Policy shall control and govern.

LIMITATIONS: Regardless of the method used to enter the Sweepstakes, either via the survey completion or mail-in or a combination of the two, the maximum number of entries allowed during the Sweepstakes is 6 per person.

Sponsor is not responsible for any entry that is lost, late, misdirected or undeliverable, whether due to system errors, omissions, interruption, deletions, defects, delay in operations or transmissions, theft or destruction or failures, faulty transmissions or other telecommunications malfunctions, entries not received resulting from any hardware or software failures of any kind, lost or unavailable network connections, failed, incomplete or garbled computer or telephone transmissions, typographical or system errors and failures, faulty trans-missions, technical malfunctions, or otherwise.

In the event of a dispute regarding the identity of the person submitting an entry, the entry will be deemed submitted by the authorized account holder at the time of entry. The authorized account holder is the natural person who is assigned to the account by Sponsor, the organization that is responsible for assigning accounts to customers. Potential winners may be required to show proof of being the authorized account holder.

Any attempt by an entrant to obtain more than the stated number of entries by using multiple/different email addresses, identities, registrations, logins, and/ or any other methods, including, but not limited to, automated entry, will void that entrant’s entries and that entrant may be disqualified from the Sweepstakes. Multiple participants are not permitted to share the same email address or Instagram account.

Sponsor will not verify receipt of entries for entrants. All entries submitted become the sole property of Sponsor. Sponsor reserves the right to disqualify those entries deemed to be inappropriate or in violation of this Sweepstakes (as defined solely by Sponsor).

Entries are void if they are incomplete, irregular or submitted improperly. Personal information (if any) collected through the Entry Form will be used only for purposes of (i) selecting and contacting the winners, and (ii) as identified in the Privacy Policy.

ODDS OF WINNING: The actual odds of winning will depend upon the actual number of total entries received for this Sweepstakes, regardless of the means of entry.

LIABILITY LIMITATION:  The Sponsor assumes no responsibility or liability for (a) lost, late, stolen, undelivered, inaccurate, incomplete, delayed, misdirected, damaged or garbled registrations, entries, URLs, or emails; (b) any incorrect or inaccurate entry information, or for any faulty or failed electronic data transmissions; (c) any unauthorized access to, or theft, destruction or alteration of entries or registrations at any point in the operation of this Sweepstakes; (d) any technical malfunction, failure, error, omission, interruption, deletion, defect, delay in operation or communications line failure, regardless of cause, with regard to any equipment, systems, networks, lines, cable, satellites, servers, computers or providers utilized in any aspect of the operation of the Sweepstakes; (e) inaccessibility or unavailability of the Internet or the Sponsor’s web site or any combination thereof or for computer hardware or software malfunctions, failures or difficulties, or other errors or difficulties of any kind whether human, mechanical, electronic, computer, network, typographical, printing or otherwise relating to or in connection with the Sweepstakes, including, without limitation, errors or difficulties which may occur in connection with the administration of the Sweepstakes, the processing of Entries, social networking posts, or registrations, the announcement of the prizes, or in any other Sweepstakes-related materials; or (f) any injury or damage to participants or to any other person’s computer which may be related to or resulting from any attempt to participate in the Sweepstakes. If, for any reason, the Sweepstakes (or any part thereof) is not capable of running as planned for reasons which may include, without limitation, infection by computer virus, tampering, unauthorized intervention, fraud, technical failures, or any other causes which may corrupt or affect the administration, security, fairness, integrity or proper conduct of this Sweepstakes, then the Sponsor reserve the right at their sole discretion to cancel, terminate, modify or suspend the Sweepstakes in whole or in part. If terminated, the Sponsor will award the prizes from among all non-suspect, eligible Entries received for the Sweepstakes up to the time of such action.

RELEASES: All participants, as a condition of participation in this Sweepstakes, agree to release, hold harmless and indemnify the Sponsor, its offers, directors, accountants, attorneys and agents (“Released Parties”) from and against any and all liability, claims, damages, or actions of any kind whatsoever for injuries, damages, or losses to persons or property which may be sustained, in whole or in part, directly or indirectly, in connection with (i) participation in any aspect of the Sweepstakes, (ii) the receipt, ownership or use of the prize awarded, including any travel associated with any prize, (iii) participant’s registration material on any related website, or (iv) any typographical or other error in these these Rules.

NO WARRANTIES: NEITHER SPONSOR NOR ANY OF THE RELEASED PARTIES HAVE MADE OR MAKE OR ARE RESPONSIBLE OR LIABLE FOR ANY WARRANTY, REPRESENTATION OR GUARANTEE, EXPRESS OR IMPLIED, RELATIVE TO THIS SWEEPSTAKES OR A PRIZE, INCLUDING BUT NOT LIMITED TO, ITS QUALITY OR FITNESS OR MERCHANTABILITY, AND ALL PRIZES ARE TENDERED TO ENTRANTS ON AN “AS IS” BASIS.  THERE ARE NO WARRANTIES REGARDING ANY PRIZE OR THE USE OF THE GIFT CARD WITH AMAZON.

RANDOM DRAWING: One (1) prize winner(s) will be randomly selected for the Sweepstakes to receive a $150 electronic Amazon gift card. All decisions on all matters pertaining to the Sweepstakes are final. Sponsor reserves the right to substitute a prize of equal or greater value.

WINNER NOTIFICATION: Random selection of the potential prize winner will occur during the first week that immediately follows the Sweepstakes Period from among all eligible entries received. Prize drawing will be conducted at Sponsor’s headquarters. The prize winner will be notified by e-mail or regular mail, in Sponsor’s discretion, within 30 days from the date of the winner selection.

The designated prize winner will have 14 days from notification to claim the prize and return all release and eligibility forms. Sponsor and its affiliates, subsidiaries, employees, agents, officers and directors, advertising and promotion agencies, and their respective officers, directors, employees and their respective agents, will not be liable for unsuccessful efforts to notify a winner.

The prize will be delivered via e-mail. No prize transfer, assignment or substitution by winner permitted. All federal, state and local taxes, fees and surcharges on prizes are the sole responsibility of the prize winner. If the prize winner declines the prize, fails to claim the prize, is unavailable for prize fulfillment, fails to abide by the these Rules, or is ineligible, Sponsor may select an alternate winner from all remaining eligible entries.

By entering this Sweepstakes, each entrant gives his/her express permission to be contacted by the Sponsor by telephone, e-mail and/or postal mail for Sweepstakes purposes.

The winner, by acceptance of Prize, grants to Sponsor, and each of its respective designees, the right to publicize the winner’s name, address (city and state of residence), photograph, voice, statements and/or other likeness and prize information for advertising, promotional, trade and/or any other purpose in any media or format now known or hereafter devised, throughout the world, in perpetuity, without limitation and without further compensation, consideration, permission or notification, unless prohibited by law.

Before being declared a winner, each selected entrant will be required to sign an confirmation and acceptance confirming compliance with the these Rules and acceptance of the prize as offered. The confirmation and acceptance must be returned within 7 business days of the notification date indicated on the documents, unless otherwise stated, or the selected entrant will be disqualified and the prize forfeited.

THIRD PARTY & SOCIAL MEDIA:  This Sweepstakes is in no way sponsored by, endorsed by, associated with, or administered by Facebook, Instagram, Twitter, Whatsapp, Tumblr, Google, YouTube, WeChat, or WhatsApp (collectively “Social Media Sites”).  By entering this event, you agree to hold all Social Media Sites harmless for and from any potential claims you may have related to or arising out of this Sweepstakes.

MISCELLANEOUS CONDITIONS: Sponsor reserves the right at its sole discretion to cancel, terminate, modify or suspend the Sweepstakes.

Sponsor assumes no responsibility for any error, omission, interruption, deletion, defect, or delay in operation or transmission; communications line failure; theft or destruction of or unauthorized access to Sweepstakes entries or entry forms; or alteration of entries or entry forms. Sponsor reserves the right to correct clerical or typographical errors in promotional materials or any materials related to the Sweepstakes.

WINNER NAME: To obtain the name of the winner, send a request to [email protected]

CHOICE OF LAW AND JURISDICTION: This Sweepstakes is governed by the internal substantive laws of Nevada, without regard to its conflicts of law provisions.

Hybrid Machining – Featured Customer

Featured Image Courtesy of Jeff Robinson, Hybrid Machining

Located in Holland, MI, Hybrid Machining uses machining skills combined with 3 different 3D printing technologies to manufacture complex projects. Hybrid Machining is a manufacturing company that can take the customer’s design from start to finish, allowing customers to dictate their path. Rather than focusing on a single product, Hybrid has listened to customer needs and presented solutions that, in many cases, customers didn’t know were possible. Jeff Robinson, the owner, took some time out of his day to answer some questions about Hybrid Machining.

How did you get into manufacturing?  

I started working in an architectural shop during my high school years.  I quickly realized that there was a more advanced part of the industry that I was missing out on. Therefore, I started researching CNC Routing.  I fell in love with the technology and have been studying it ever since. 

What sort of machines and materials do you use in your shop?

We currently run a Datron Neo, Fanuc Robodrill, and a CR Onsrud 5-axis Router. We work primarily with wood, plastic, and non-ferrous materials. We currently use Autodesk Fusion 360, FeatureCAM, Powermill, Vectric Aspire, and AlphaCAM for CAM.  For CAD, we run Fusion 360, Inventor, and Solidworks.

hybrid machining datron neo
Photo Courtesy of: Jeff Robinson, Hybrid Machining

When did you start using 3D printing and how has it benefitted you?

I have been 3D printing for just over a year.  It was the first technology that we initiated here at Hybrid Machining, and it has allowed us to provide the best solution to the customer no matter what the requirements are. By expanding into 3D printing, we can help the customer decide which technology will work the best for their part. Many times, we take the “Hybrid” approach and use both additive and subtractive technologies together.

How have you adapted during the Covid-19 outbreak and how has it changed your business?

We started by stopping normal production to form a non-profit called 3DC19 with other local, small business owners with the sole purpose of 3D printing and assembling plastic face shields.  Hybrid Machining became the distribution center for the efforts.  Collectively, we produced and donated 75K articles of PPE to local hospitals, nursing homes, doctor offices, and first responders.  You can learn more about the efforts at www.3DC19.com. We have also been machining a lot of acrylic face guards for customers so that we can help them to get their office staff back to work safely. 

fanuc robodrill machine
Photo Courtesy of: Jeff Robinson, Hybrid Machining

What sets Hybrid Machining apart from the rest of the manufacturing community? 

We have a serious passion for educating our youth and local businesses on the rapid changes currently happening in the manufacturing industry and preparing them for the impact that Industry 4.0 will have on our lives in the future.  We want to produce knowledgeable people just as much as we produce products, and we do this in our unique Learning Lab.  We team up with local schools, vocational schools, and community colleges to help them spread the word about manufacturing.  We also intend to do ‘Lunch and Learns’ with local businesses to help them understand what other manufacturing methods and advanced materials are available on the market today.

What is the coolest project you have had come through the shop?

Many years ago, at my previous shop, we worked on the presidential handrail that the last three presidents stood behind during the inauguration.

hybrid machining metal business card
Photo Courtesy of: Jeff Robinson, Hybrid Machining

Are you using HEM techniques to improve cycle times? 

Yes, we use a couple of the fastest and most nimble machines on the market: the Datron NEO and the Fanuc Robodrill.  We leverage the machine’s tools’ high accelerations and deceleration rates, along with HEM, to drastically reduce cycle times for our customers.  This allows us to be competitive against over-seas importers.

What do you have to lose other than cycle time? You purchased the entire tool, not just the tip, so use it!  You will be surprised how the different the machine will sound and you can get parts done faster with less tool wear.

Why is high quality tool performance important to you?

The tooling is super important to the success of a project because the tool is what is doing the work.  I like to tell people, “Why would you buy a high-end sports car with all bells and whistles and then put crappy tires on it?  All that power and handling is worthless unless you have good tires.”  The same goes for tooling.  You can have a half-million-dollar machine that is super-fast and accurate and yet still produce a terrible part with cheap tooling. 

When was a time that Harvey Tool, Helical Solutions, or Micro 100 saved the day?

Harvey Tool helped me get through some tough composite projects in the past.  Their technical support team was extremely knowledgeable on the subject matter and helped me pick the right tool and parameters to get the job done. 

machined metal part from hybrid machining
Photo Courtesy of: Jeff Robinson, Hybrid Machining

If you could give one piece of advice to a new machinist ready to take the #PlungeIntoMachining, what would it be?

NEVER STOP LEARNING.  Things may be going great at first and you think you have it all figured out, but then a new technology comes and swipes you off your feet.  Spend your spare time studying industry trends, talking to other business leaders, new and old, and preparing for the future.

 Is there anything else you would like to share with the “In The Loupe” community?

We are extremely thankful that Harvey Tool spends a lot of time developing ‘material-specific’ tooling.  We spend 90% of our time in that section of the catalog.  We recently tested out the new wood cutters and are extremely happy. We pushed these tools at speeds and feeds that are unbelievable.  We also use the Harvey Tool plastic cutters on a regular basis. 

Here at Hybrid Machining, we are blending the lines between routing and milling.  For many decades, the line had been fairly clear. There were certain types of jobs you ran on certain types of machines.  We are blurring those lines and are using the best tools for the jobs.  For instance, we use the 24K RPM spindle on the Robodrill to run it more like a router than a mill.  Therefore, we call it the “RoboRouter”.  We can produce wood and plastic parts at unbelievable speeds while achieving surface finishes that are off the charts.  This is not conventional practice, but the team at Hybrid Machining is willing to blaze the path forward for others to follow.

To check out more about Hybrid Machining go to their website or follow them on social media!

TOMI Engineering INC – Featured Customer

Featured Image Courtesy of TOMI Engineering

Since its beginning in 1977, brothers Tony and Mike Falbo have made the focal point of TOMI Engineering to deliver quality, competitively-priced parts on time. TOMI Engineering has earned a reputation through the years as being a world-class manufacturer of precision machined components and assemblies for aerospace, defense, commercial and other advanced technology industries. They are fortunate to have the highest level of engineering, quality and programming personnel on staff, and, with over 40 years in the industry, there isn’t a problem TOMI hasn’t experienced.

With all the years of experience, TOMI Engineering has a lot of knowledge to share. We had the pleasure of sitting down with Tony and Mike Falbo to ask them about their experiences, techniques, tooling and a lot more.

green machined part from Tomi Engineering INC
Photo Courtesy of: TOMI Engineering

How was TOMI Engineering INC started?

TOMI Engineering, Inc. began in 1977 when we (Tony and Mike) teamed up and got a loan from our father to purchase our first machine.  The machine was used in the garage of our parents’ home, which still resides in Tustin, California.  Forty years, 20 current machines, and countless parts later, TOMI Engineering proudly serves the defense, airline, medical and commercial industries.  We machine just about any type of product thrown our way.  Over the years, we have made wing tips for the F16 fighter jet, enclosures for GPS housings, manifolds that help transport fluids, support frames for Gulfstream, cabin brackets for Airbus, ammunition feeders for tanks, and many, many others.

At TOMI Engineering, we aim to be a one-stop shop for our customers.  Once we receive blueprints, we can program, machine, deburr, inspect, process and assemble most parts.  We utilize a mixture of 3-and-4-axis machines in order to increase efficiency, which helps us to cut down costs to our customer.  In our temperature-controlled assembly room, we can assemble bearings, bushings, rivets, nut plates, gaskets and sealants.  We also hope to add additive machining to our repertoire soon.

What machines are you currently using in your shop?

Our 21,250 square foot facility houses 20 CNC machines.  Most of our machines are Kitamura, OKK and Okuma.  The purchase dates of these machines range from 1987 to December of 2019.  With our large machine diversity, we can machine parts smaller than a penny, and as large as 30 x 60 inches. Most of the material that makes its way through our shop is aluminum.  Whether it is 6061 or aircraft grade 7000 series, we aim to have most of our parts be aluminum.  However, we do see a large amount of 6AL-4V titanium, along with 17-4 and 15-5 steel. We are currently utilizing Mastercam 2020 for most of our programming needs and are staying up to date with software upgrades and progression.

Tomi Engineering CNC mill
Photo Courtesy of: TOMI Engineering

What sets TOMI Engineering apart from the rest of the competition?

We believe our greatest asset is our experience.  Here at TOMI, we have been machining parts since 1977.  In those 40-plus years, a lot of parts have come and gone through our doors and we have helped our customers solve a large array of problems.  Most of our machinists have been with us for over 10 years, while some are approaching 20 years!  Our programmers easily boast over 60 years of experience! With so many of our employees working together for so many years, it has really helped everyone to understand what helps us quickly machine our products, while being held accountable to the high standards of AS9100. 

Where did your passion for machining start?

We grew up with machines in our garage and it wasn’t until we needed money to pay for college that our dad realized he could show us the basics of operating a milling machine, which allowed us to pay our tuition while working at home in the evenings and weekends. Machining was more of a necessity than a passion at the time. However, after nearly 40 years in the business, it has been amazing to see the strides in technology from a Bridgeport Mill to the multi-axis lights-out machining that is available today.

My favorite part of the job has always been the flexibility it has allowed me. I had the opportunity to watch my kids grow up and be a part of their lives by going to their school plays, coaching them, and being home at night to help them with anything they needed. Most importantly, I’ve had the opportunity to work with my brother, my business partner, who also shares the same ideals about being with family, so we could always cover for each while the other was gone and spending time with their family. The business would not have worked without both of us understanding the importance of each other’s input. The challenge of running a business keeps me going, and working with all of the different personalities was an added bonus.

machined part from Tomi Engineering
Photo Courtesy of: TOMI Engineering

Who is the most famous contact that you have worked on a project with? What is the most interesting product you’ve made?

At TOMI, we do not work with specific individuals, so we can’t really name drop.  However, a vast majority of our work is for Airbus, Boeing, or the military. So it’s pretty gratifying to say that we supply parts to some of the biggest companies in the world and that our work helps to defend this country.

The most interesting product we have made here at TOMI is a GPS housing for a defense contractor.  This part encompasses everything that we can do at TOMI: precision machining, complex/multi detail assemblies, gasket assembly, and pressure testing fluid transportation components. 

Why is high quality tool performance important to you?

High quality tool performance is important to us in many ways.  Purchasing high quality tools allow us to constantly achieve premium surface finishes, push our machines to the high speeds and feeds that they are capable of, and enjoy noticeably longer tool life.

Every part, day-in and day-out, is different.   Because of our vast array of products, our tools are always changing.  But when we are picking out Helical End Mills for Aluminum, we always go with their 3-flute variable helix cutters, and we have always been happy with them.

machined part from Tomi Engineering
Photo Courtesy of: TOMI Engineering

What sort of tolerances do you work in on a daily basis?

The tolerances we typically work with are ± tenths of an inch, as well as very tight true position cal louts. We can hold and achieve these close tolerance dimensions through our very experienced Mastercam programmers, as well as our superior quality department.  Our quality inspectors have over 30 years of experience in the industry and utilize two Zeiss Contura G2 coordinate measuring machines (CMMs).  While in their temperature controlled environment, the CMMs are capable of measuring close tolerance dimensions and are used to generate data for inspection reports.

Are you guys using High Efficiency Milling (HEM) techniques to improve cycle times? What advice do you have for others who want to try HEM?

Yes, we are using HEM techniques to improve cycle times while roughing to increase our MRR while increasing tool life. If you have CAM/CAD software that supports HEM, then go for it!  Machining Advisor Pro (MAP) is VERY helpful with the suggested speeds and feeds as a starting point.  Over time though, and through experience, we have learned that every single machine is a bit different and often needs a different approach with speeds and feeds.  Start with a smaller than suggested RDOC and physically go out to your machine and see how it sounds and what is going on.  Then, start increasing and find that sweet spot that your particular machine runs well on.  Many programmers in the industry will not take the time to go out and watch how their part is sounding and cutting on the machine and going out and doing that is the best way to really find out what you and the machine are capable of achieving.

If you could give one piece of advice to a new machinist ready to take the #PlungeIntoMachining, what would it be?

Ask questions!  Don’t be afraid to talk to programmers and fellow coworkers about what is trying to be achieved and WHY the programmer is holding tolerances a certain way.  Learn from them and watch what every cutter is doing during your cycles.  The more you learn, the more you can contribute to the machining process and move up in your business.  Sometimes it takes just one good suggestion about the machining approach that can change the set-up process from aggravating to very easy.  Lastly, be open minded to new ideas and approaches.  As we said earlier, there are a ton of ways to make good parts in a constantly evolving industry.

Please take the time to check out the TOMI Engineering INC website or follow them on social media!

Benefits & Drawbacks of High and Low Helix Angles

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, will wrap around the tool “faster,” while a “slower” helix angle is usually less than 40°.

When choosing a tool for a machining operation, machinists often consider the material, the tooling dimensions and the flute count. The helix angle must also be considered to contribute to efficient chip evacuation, better part finish, prolonged tool life, and reduced cycle times.

Helix Angles Rule of Thumb

One general rule of thumb is that as the helix angle increases, the length of engagement along the cutting edge will decrease. That said,
there are many benefits and drawbacks to slow and high helix angles that can impact any machining operation.

Slow Helix Tool <40°

Benefits

  • Enhanced Strength – A larger core creates a strong tool that can resist deflection, or the force that will bend a tool under pressure.
  • Reduced Lifting – A slow helix will decrease a part from lifting off of the worktable in settings that are less secure.
  • Larger Chip Evacuation – The slow helix allows the tool to create a large chip, great for hogging out material.

Drawbacks

  • Rough Finish – A slow helix end mill takes a large chip, but can sometimes struggle to evacuate the chip. This inefficiency can result in a sub-par part finish.
  • Slower Feed Rate – The increased radial force of a slow helix end mill requires running the end mill at a slower feed rate.

High Helix Tool >40°

Benefits

  • Lower Radial Force – The tool will run quieter and smoother due to better shearing action, and allow for less deflection and more stability in thin wall applications.
  • Efficient Chip Evacuation – As the helix angle increases, the length of cutting edge engagement will decrease, and the axial force will increase. This lifts chips out and away, resulting in efficient chip evacuation.
  • Improved Part Finish – With lower radial forces, high helix tools are able to cut through material much more easily with a better shearing action, leaving an improved surface finish.

Drawbacks

  • Weaker Cutting Teeth – With a higher helix, the teeth of a tool will be thinner, and therefore thinner.
  • Deflection Risk – The smaller teeth of the high helix tool will increase the risk of deflection, or the force that will bend a tool under pressure. This limits how fast you can push high helix tools.
  • Increased Risk of Tool Failure – If deflection isn’t properly managed, this can result in a poor finish quality and tool failure.

Helix Angle: An Important Decision

In summary, a machinist must consider many factors when choosing tools for each application. Among the material, the finish requirements, and acceptable run times, a machinist must also consider the helix angle of each tool being used. A slow helix end mill will allow for larger chip formation, increased tool strength and reduce lifting forces. However, it may not leave an excellent finish. A high helix end mill will allow for efficient chip evacuation and excellent part finish, but may be subject to increased deflection, which can lead to tool breakage if not properly managed.

Machining Advisor Pro Updated With New Improvements

Harvey Performance Company is excited to announce that Machining Advisor Pro, a cutting edge resource for generating custom CNC running parameters, has been updated with new features and improvements with the release of version 1.5.

Thousands of users have enjoyed the benefits of using Machining Advisor Pro (MAP) to dial in their running parameters for their Helical Solutions high-performance end mills, and with version 1.5, the Harvey Performance Company team has made customizing your speeds and feeds easier than ever. Much of the work done on MAP version 1.5 was the direct result of excellent user feedback, including some of the most innovative updates to the user experience since the launch of Machining Advisor Pro in 2018.

The new improvements to MAP include:

Improved Speed and Feed Sliders (Desktop)

The speed and feed sliders in the “Recommendations” section are now percentage-based. This allows users to more precisely adjust their running parameters while fine-tuning numbers for increased production or longer tool life. Previously, users could adjust their speed and feed values with dials, but without an exact measurement of the increase or decrease. With the new sliders, users can be more accurate, adjusting their speed and feed values by +/- 20% in one percent increments. Users can also type in percentage values to automatically adjust the sliders to their desired number.

machining advisor pro

Locking Depths of Cut

Inside of the “Parameters” section, users will now see a new button that allows them to lock their depths of cut. With this new feature, users have more control over the customization of their running parameters. In the past, the radial and axial depths of cut would adjust dynamically with each other based on the user adjustments to one of the values. Now users can lock the radial depth of cut (RDOC) and adjust the axial depth of cut (ADOC) without affecting the RDOC value, and vice versa.

Machining Advisor Pro Update

Enhanced Summary Section (Mobile)

On mobile devices, users will now see an enhanced “Summary” section at the completion of their job. The summary section will now include key metrics like material removal rate (MRR), as well as important parameters that apply to trochoidal slotting toolpaths. The summary section for chamfering toolpaths has also been updated to better reflect the necessary parameters for those tools.

Machining Advisor Pro Mobile

Smoother User Experience

In MAP version 1.5, users will be greeted with a much smoother user experience throughout the application. Due largely to user feedback, the Harvey Performance Company team has been hard at work to make sure that the major pain points within the application have been addressed. Much of the feedback centered around the “Tooling” section and the “Material” section and significant improvements have been made to each.

In the tooling section, MAP will now automatically select a tool for you if you enter a valid EDP once you navigate outside of that section. If an invalid EDP number is entered, the intrusive error message has been removed and now will display “no results found” in the drop-down menu.

In the material section, MAP requires that a material condition be selected in order to generate accurate running parameters. In the past, this was not immediately clear and could lead some users to believe that the application was malfunctioning. In version 1.5, once a user leaves the material section without selecting a condition, a message will display in the material section to alert users of the missing material condition.

Open in MAP from HelicalTool.com

On the new HelicalTool.com website, users can now import a tool into MAP from the Tool Details page. Users reach the Tool Details page by clicking on a SKU in a product table, or searching for an EDP in the search bar. Once on the Tool Details page, users can select “Open in Machining Advisor Pro” under the Resources section, and MAP will open in a new window and import the tool’s information directly into MAP.

Users will see these updates immediately upon their next log-in to the application on a desktop computer and will need to ensure their app is updated to the latest version from the App Store or Google Play to see these changes reflected on mobile.

To get started with Machining Advisor Pro, click here to create an account.

To stay up-to-date on all of the latest improvements and news on Machining Advisor Pro and the Harvey Performance Company brands, join our email list.

If you have any feedback or questions about MAP, please contact Harvey Performance Company at [email protected].

Simplify Your Cutting Tool Orders

With the launch of the new Helical Solutions website, Harvey Performance Company is proud to introduce a new way to order Helical cutting tools. Now, users of our new website are able to send a “shopping cart” of Helical tools they’re interested in directly to their distributor to place an order, or share it with a colleague. Let’s dive into the details about this functionality and learn how you can take advantage of the time savings associated with sending a “shopping cart” to your distributor for simplified ordering.

Get Started with a HelicalTool.com Account

First, you must create an account on HelicalTool.com. Having an account on the Helical website allows you to save and edit “shopping carts,” which can be sent to a distributor to place an order; choose a preferred distributor; auto-fill your information in any important forms; and to manage your shipping information.

Create Helical Account for Helical Shopping Cart

Now that you have an account, it is time to start creating your first “shopping cart.”

Creating a “Shopping Cart”

To begin creating a new shopping cart, simply click on the “My Carts” text in the top right menu. This will take you to the management portal, where you can add a new “shopping cart” by selecting “Create New Shopping Cart.”

Helical Solutions Order

Once complete, you can name your “shopping cart” anything you would like. One example might be creating a collection of tools for each of your jobs, or for different machines in the shop. In this case, we will name it “Aluminum Roughing Job.” You can create as many different “shopping carts” as you would like; they’ll never be removed from your account unless you choose to delete them, allowing you to go back to past tooling orders whenever you’d like.

Helical Solutions Website

Now that you have a “shopping cart” created, it is time to start adding tools to it!

Adding Tools to Your Helical “Shopping Cart”

There are multiple ways to add tooling to your “shopping cart,” but the easiest method is by heading to a product table. In this example, we will be adding tooling from our 3 Flute, Corner Radius – 35° Helix product line. We want to add a quantity of 5 of EDP #59033 to our “shopping cart.” To do this, simply click on the “Add To Cart” icon located in the table row next to pricing and tool descriptions. This will open up a small window where we can manage our selection. The first step will be to choose which “shopping cart” we want to add this tool to, so we will select our “Aluminum Roughing Job” collection.

Helical Online Ordering

Since this tool is offered uncoated and Zplus coated, we need to select which option we would like from the drop down menu. For this example, we will select the Zplus coated tool. Now, we simply need to update our quantity to “5”, and click “Add To Cart.” That tool will now appear in your “shopping cart” in the quantity selected.

If you need more information on a tool, you can click on an EDP number to be brought to the tool details page, where you can also add that EDP to your collection.

If you know the EDP number you need and want to check stock levels, use our Check Stock feature to check quantities on hand, and then add the tools to your “shopping cart” right from the Check Stock page.

Helical Shopping Cart checking stock

Now, it is time to send the “shopping cart” to place an order with your distributor!

Placing An Order With Your Distributor

Once you have completed adding tools to your Helical “shopping cart,” navigate back to the My Carts page to review it. From here, you can update quantities, see list pricing, and access valuable resources.

On the right side of the My Cart screen, you will see an option to “Send to Distributor.” Click on the text to expand the drop down. If you have previously added a preferred distributor from your account page and they are participating in our Shopping Cart Program, you will see their information in this area.

If you have not yet selected a preferred distributor, select “Update My Distributor.” This will bring you to a new page where you can select your state and see all participating distributors in your area. Select one distributor as your preferred distributor, and then head back to the My Cart page.

Now that you have a distributor selected, you can do a final review of the “shopping cart,” and then simply click “Send Cart.” This will send an email order directly to your distributor with all of your shipping information, your list of tools and requested quantities, and your contact information. You will also receive a copy of this email for your records.

Helical Shopping Cart Distributor

Within 1 business day, the distributor will follow up with you to confirm the order, process payment, and get the tools shipped out and on the way to your shop. No more phone calls or emails – just a single click, and your order is in the hands of our distributor partners.

To get started with this exciting new way to shop for Helical cutting tools, click here to begin creating an account on HelicalTool.com!

Axis CNC Inc. – Featured Customer

Featured Image Courtesy of Axis CNC Inc

Axis CNC Inc was founded in 2012 in Ware, Massachusetts, when Dan and Glenn Larzus, a father and son duo, decided to venture into the manufacturing industry. Axis CNC Inc has provided customers with the highest quality manufacturing, machining, and programming services since they’ve opened. They specialize in manufacturing medical equipment and have a passion for making snowmobile parts.

We sat down with Axis CNC Inc to discuss how they got started and what they have learned over there years in the manufacturing world. Watch our video below to see our full interview.

Show Us What You #MadeWithMicro100

Are you proud of the parts you #MadeWithMicro100? Show us with a video of the parts you are making, the Micro 100 Tool used, and the story behind how that part came to be, for a chance to win a $1,000 Amazon gift card grand prize!

With the recent addition of the Micro 100 brand to the Harvey Performance Company family, we want to know how you have been utilizing its expansive tooling offering. Has Micro 100’s Micro-Quik system helped you save time and money? Do you have a favorite tool that gets the job done for you every time? Has Micro 100 tooling saved you from a jam? We want to know! Send us a video on Instagram and show us what you #MadeWithMicro100!

How to Participate

Using #MadeWithMicro100 and @micro_100, tag your video of the Micro 100 tools machining your parts on Instagram or Facebook. Remember, don’t share anything that could get you in trouble! Proprietary parts and trade secrets should not be on display.

Official Contest Rules

Contest Dates:

  • The contest will run between December 5, 2019 to January 17, 2020. Submit as many entries as you’d like! Entries that are submitted before or after the contest period will not be considered for the top prizes (But we’d still like to see them!)

The Important Stuff:

  1. Take a video of your Micro 100 tool in action, clear and visible.
  2. Share your video on social media using #MadeWithMicro100 and tagging @Micro_100.
  3. Detail the story behind the project (tool number(s), operation, running parameters, etc.)

Prizes

All submissions will be considered for the $1,000 Amazon gift card grand prize. Of these entries, the most impressive (10) will be put up to popular vote. All entries put up to vote will be featured on our new customer testimonial page on our website with their name, social media account, and video displayed for everybody to see.

We’ll pick our favorites, but the final say is up to you. Public voting will begin on January 21, 2020, and a winner will be announced on January 28, 2020.

The top five entries will be sent Micro 100’s Micro-Quik tool change system with a few of our quick change tools. The top three entries will be offered a spot as a “Featured Customer” on our “In The Loupe” blog!

The Fine Print:

  • Please ensure that you have permission from both your employer and customer to post a video.
  • All entries must be the original work of the person identified in the entry.
  • No purchase necessary to enter or win. A purchase will not increase your chances of winning.
  • On January 28, 2020, the top 5 winners will be announced to the public. The Top 5 selected winners will receive a prize. The odds of being selected depend on the number of entries received. If a potential winner cannot be contacted within five (5) days after the date of first attempt, an alternative winner may be selected.
  • The potential winners will be notified via social media. Each potential winner must complete a release form granting Micro 100 full permission to publish the winner’s submitted video. If a potential winner cannot be contacted, or fails to submit the release form, the potential winner forfeits prize. Potential winners must continue to comply with all terms and conditions of these official contest rules, and winning is contingent upon fulfilling all requirements.
  • Participation in the contest constitutes entrants’ full and unconditional agreement to and acceptance of these official rules and decisions. Winning a prize is contingent upon being compliant with these official rules and fulfilling all other requirements.
  • The Micro 100 Video Contest is open to residents in US and Canada who are at least 18 years old at the time of entry.

Selecting the Right Chamfer Cutter Tip Geometry

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 aesthetics.

Due to the diversity of needs, tooling manufacturers offer many different angles and sizes of chamfer cutters, and as well as different types of chamfer cutter tip geometries. Harvey Tool, for instance, offers 21 different angles per side, ranging from 15° to 80°, flute counts of 2 to 6, and shank diameters starting at 1/8” up to 1 inch.

After finding a tool with the exact angle they’re looking for, a customer may have to choose a certain chamfer cutter tip that would best suit their operation. Common types of chamfer cutter tips include pointed, flat end, and end cutting. The following three types of chamfer cutter tip styles, offered by Harvey Tool, each serve a unique purpose.

Harvey Tool Chamfer Cutters

Pointed and Flat End Chamfer Cutters

Three Types of Harvey Tool Chamfer Cutters

Type I: Pointed

This style of chamfer cutter is the only Harvey Tool option that comes to a sharp point. The pointed tip allows the cutter to perform in smaller grooves, slots, and holes, relative to the other two types. This style also allows for easier programming and touch-offs, since the point can be easily located. It’s due to its tip that this version of the cutter has the longest length of cut (with the tool coming to a finished point), compared to the flat end of the other types of chamfer cutters. With only a 2 flute option, this is the most straightforward version of a chamfer cutter offered by Harvey Tool.

Type I Chamfer Cutter overview

Type II: Flat End, Non-End Cutting

Type II chamfer cutters are very similar to the type I style, but feature an end that’s ground down to a flat, non-cutting tip. This flat “tip” removes the pointed part of the chamfer, which is the weakest part of the tool. Due to this change in tool geometry, this tool is given an additional measurement for how much longer the tool would be if it came to a point. This measurement is known as “distance to theoretical sharp corner,” which helps with the programming of the tool. The advantage of the flat end of the cutter now allows for multiple flutes to exist on the tapered profile of the chamfer cutter. With more flutes, this chamfer has improved tool life and finish. The flat, non-end cutting tip flat does limit its use in narrow slots, but another advantage is a lower profile angle with better angular velocity at the tip.

Type II Chamfer Cutter overview

Type III: Flat End, End Cutting

Type III chamfer cutters are an improved and more advanced version of the type II style. The type III boasts a flat end tip with 2 flutes meeting at the center, creating a center cutting-capable version of the type II cutter. The center cutting geometry of this cutter makes it possible to cut with its flat tip. This cutting allows the chamfer cutter to lightly cut into the top of a part to the bottom of it, rather than leave material behind when cutting a chamfer. There are many situations where blending of a tapered wall and floor is needed, and this is where these chamfer cutters shine. The tip diameter is also held to a tight tolerance, which significantly helps with programing it.

Type III Chamfer Cutter overview

In conclusion, there could be many suitable cutters for a single job, and there are many questions you must ask prior to picking your ideal tool. Choosing the right angle comes down to making sure that the angle on the chamfer cutter matches the angle on the part. One needs to be cautious of how the angles are called out, as well. Is the angle an “included angle” or “angle per side?” Is the angle called off of the vertical or horizontal? Next, the larger the shank diameter, the stronger the chamfer and the longer the length of cut, but now, interference with walls or fixtures need to be considered. Flute count comes down to material and finish. Softer materials tend to want less flutes for better chip evacuation, while more flutes will help with finish. After addressing each of these considerations, the correct style of chamfer for your job should be abundantly clear.

How to Select a Spindle

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 comprised of a motor, a taper for holding tools, and a shaft that will hold all of the components together. Often powered by electricity, spindles rotate on an axis which receives its input from the machine’s CNC controller.

Why is Choosing the Right Spindle Important?

Choosing the right spindle to machine your workpiece with is of very high importance to a successful production run. As tooling options continue to grow, it is important to know what tooling your spindle can utilize. Large diameter tools such as large end mills or face mills typically require slower spindle speeds and take deeper cuts to remove vast amounts of material. These applications require supreme machine rigidity and require a spindle with high torque.

Contrastingly, smaller diameter tools will need a higher-speed spindle. Faster speeds and feeds deliver better surface finishes and are used in a variety of applications. A good rule of thumb is that an end mill that is a half inch or smaller will run well with lower torque.

Types of CNC Spindles

After finding out what you should look for in a spindle, it is time to learn about your different options. Spindles typically vary by the type, style of the taper, or its size. The taper is the conical portion of the tool holder that fits inside of the opening of the spindle. Every spindle is designed to mate with a certain taper style and size.

properly selecting a spindle

CAT and BT Holders

This is the most widely utilized holder for milling in the United States. Referred to as “V-flange holders,” both of these styles need a retention knob or pull stud to be secured within the machine spindle. The BT (metric style) is popular overseas.

HSK Holders

This type of holder is a German standard known as “hollow shank taper.” The tapered portion of the holder is much shorter than its counterparts. It also engages the spindle in a different way and does not require a pull stud or retention knob. The HSK holder is utilized to create repeatability and longer tool life – particularly in High Efficiency Milling (HEM) applications.

All of these holders have benefits and limitations including price, accuracy, and availability. The proper selection will depend largely on your application requirements.

Torque vs. Horsepower

Torque is defined as force perpendicular to the axis of rotation across a distance. It is important to have high torque capabilities when using an end mill larger than ½ inch, or when machining a difficult material such as Inconel. Torque will help put power behind the cutting action of the tool.

Horsepower refers to the amount of work being done. Horsepower is important for smaller diameter end mills and easy-to-machine materials like aluminum.

You can think of torque as a tractor: It can’t go very fast, but there is a lot of power behind it. Think of horsepower as a racecar: It can go very fast but cannot pull or push.

Torque-Horsepower Chart

Every machine and spindle should come with a torque horsepower chart. These charts will help you understand how to maximize your spindle for torque or horsepower, depending on what you need:

Haas spindle horsepower and torque chart
Image Source: HAAS Machine Manual

Proper Spindle Size

The size of the spindle and shank taper corresponds to the weight and length of the tools being used, as well as the material you are planning to machine. CAT40 is the most commonly used spindle in the United States. These spindles are great for utilizing tools that have a ½ inch diameter end mill or smaller in any material. If you are considering using a 1 inch end mill in a material like Inconel or Titanium, a CAT50 would be a more appropriate choice. The higher the taper angle is, the more torque the spindle is capable of.

While choosing the correct tool for your application is important, choosing a tool your spindle can utilize is paramount to machining success. Knowing the amount of torque required will help machinists save a lot of headaches.