Posts

Workshops for Warriors – Featured Customer

In 2008, Hernán Luis y Prado, a United States Navy officer, noticed his fellow service members looking for a successful path in life after service. Hernán decided he needed to make a change. He set out to make a difference for his fellow service members by starting Workshops For Warriors, a state-licensed, board governed, fully audited, nonprofit school. Its mission is to provide quality training, accredited educational programs, and opportunities for its students to earn third-party nationally recognized credentials to enable Veterans, transitioning service members, and others to be successfully trained and placed in their chosen advanced manufacturing career field.

We had the honor of speaking with Marine Veteran Scott Leoncini, an instructor at Workshops For Warriors, about the accomplishments and amazing work Workshops For Warriors does for our Veterans.

What does Workshops For Warriors offer for our Veterans?

Workshops for Warriors offers two primary tracks of training, both taught by Veterans: welding and machining, Scott explained. After choosing a track, students become a part of the 16-week accelerated program. Those with only a minimum of four months and one nationally-recognized certification can walk across the shipyards and gain employment. Workshops For Warriors remains committed to providing free training to Veterans who do not have access to living-wage jobs. U.S. Veterans often face challenges as they transition to civilian life, including significant barriers to civilian employment. In addition to the hard technical skills, our students are also learning soft skills such as attitude, communication, work ethic, teamwork, time management, problem-solving, critical thinking, and conflict resolution.

A proven path into a rewarding career can eliminate problems like unemployment, homelessness, broken families, and suicide. The problem of Veteran unemployment does not have easy, short-term solutions. Workshops For Warriors is uniquely positioned to expand proven innovative techniques to give Veterans marketable employment that will allow them to build careers and families. 

How did you find Workshops For Warriors and become an instructor?

After I left the Marines in 2009, after serving two tours in Iraq as a combat engineer, I desired an action-packed career. I thought my best option was to start a career in law enforcement. I got a job at a security company and worked there for a few years. During this time, a close friend of mine tragically passed away in a helicopter crash, leaving behind his pregnant wife. This made me reevaluate my current life with my wife and two children. I decided I didn’t need that action-packed career, and that my family comes before anything.

Another friend of mine actually told me about Workshops for Warriors and how it was giving him career skills in welding, and he talked about a machining program. When I showed up, I had no idea what was in store for me. I started learning all about CNC machines, and how to program and run these things. It was eye-opening and I was having a great time. After my first semester, I was asked to become a teacher’s assistant and I’ve been teaching here now for almost five years.

Where does your passion for teaching come from?

I love teaching Veterans and helping them transition so they don’t have to go through the same five years I did of, “What am I going to do with my life?” I’ve gone through the same situation a lot of the people coming to us are currently in.

I think that there are three fundamentals that anyone looking for a career or path can apply to their lives and be successful. You have to show up on time, you have to work hard, and you have to be willing to learn. I didn’t know anything about machinery when I first got into this field. When I went through it as a student myself, I applied those three things to my work habits, and now I’m an instructor. I had pigeonholed myself for a long time. But you have to recognize that there’s always something else, something up next and that’s what I want to help teach the Veterans who come through here.

What courses does Workshops For Warriors provide?

We offer many different courses, including CAD courses in Solidworks and CAM courses in Mastercam, and we offer welding courses for Gas Metal and Flux Cored Arc Welding. We also offer advanced training in Flowmaster Programming and Waterjet Operation, 3D Printing, and Robotics. With these courses, we offer many credentials to start a real career. The machining program is accredited by the National Institute for Metalworking Skills (NIMS). NIMS is recognized by the United States Department of Education. The welding program is accredited by the American Welding Society (AWS), which is the worldwide leader in certification programs for the welding industry.

Thanks to private donors, Veterans and transitioning service members are able to become trained and certified in our advanced manufacturing programs. Students can apply to enter one of our programs, or take specific classes that meet their needs.

What jobs have you seen Veterans acquire after Workshops For Warriors?

We have seen many success stories from Veterans once they leave Workshops For Warriors. One Veteran, in particular, visited us in search of direction in 2019. The machining program had one spot left for the semester, so he took it. He is now certified in machining and welding. He entered a job market that was struggling after his graduation. But he still had a job lined up with 5th Axis Machining in San Diego. His future plans are to own his own business to support his family.

How could people help support Workshops For Warriors?

They can donate directly to us on our website, or on our Facebook page. Or, people looking to help support us can reach out to us by email, [email protected], or by calling us at 619-550-1620, with any questions. We also accept equipment donations for each program, welding, and machining. You can also support us by following on Facebook, Instagram, Twitter, LinkedIn, YouTube, or our newsletter.

What advice would you give to anyone looking to start a career path?

After leaving the service, I fell into a depression. I kept thinking, “I’ll never be as good as I was back then.” It was hard to not have “Marine” be the primary part of my identity, so I became blinded by my obsession with still being the superhero kicking down doors. Don’t paint yourself into a corner. Be flexible and make sure to show up on time, work hard, and be willing to have an open mind and ready to learn. Test your comfort zone. When I left the service, I only knew how to be the man with the gun. Workshops For Warriors gave me a chance to be more than that – it gave me a direction in life. I now get to do what I love and help my fellow Veterans.

To learn more about Workshops For Warriors and their mission you can visit their website or follow them on Instagram, Facebook, LinkedIn or Twitter.

Heavy Duty Racing – Featured Customer

Heavy Duty Racing is a manufacturing company based in Stafford, VA, that specializes in motocross, off-road motorcycle suspension, and 2-stroke engine modification. Its owner, Pete Payne, grew up racing motorcycles. Later in life, he even taught classes on how to race. Simply, Motocross and motorcycles became Pete’s passion.

Pete always looked for ways to enhance his motorcycle’s engine, but quickly realized that no shops in his area could design what he was looking for. To get access to the parts he would need, he would have to rely upon companies from far away, and would oftentimes be forced to wait more than three weeks for them to arrive. Because of this, Pete decided he would need to take part manufacturing into his own hands. He purchased a manual lathe, allowing him to make modifications to his two-stroke engines exactly how he wanted them. Quickly thereafter, Heavy Duty Racing was born.

Pete discussed with us his love of racing, how he first got into machining, the parts his shop has designed, and tips and tricks for new machinists.

Pete Payne Heavy Duty Racing

How did you get started in machining?

Since I was a kid I have been riding motorcycles and racing motocross. I went to a tech school in the ’80s and learned diesel technologies. When I realized nobody in this area could help design the engines I wanted to make, I decided I needed to learn how to do it myself. I have a friend, George, who is a retired mold and die maker that also worked on motorcycle engines, I asked him for some advice on how to get started. George ended up teaching me all about machining and working on engines. I really learned from failures, by trying new things, and doing it every day. I started Heavy Duty Racing in 1997 and we have been modifying and designing the highest performing engines since then.

turning motorcycle part on lathe

What machines and softwares are you using in your shop?

We currently have a Thormach PCNC 1100 and a Daluth Puma CNC Lathe (we call it The Beast, it’s angry and grumpy but it gets the job done). We also have a Bridgeport Mill, Manual Lathe, and a Tiggwell. When we were choosing software to use, they had to be easy and quick to learn. We weighed our options and decided to use Autodesk Fusion 360 about 5 years ago. We mostly machine cast iron and steel since most engines are made from those materials.

What sets Heavy Duty Racing apart from the competitors?

We have a small hands-on approach and treat every part with care. We don’t have a cookie-cutter process so we are very flexible when it comes to customer needs. Since each part is different, we don’t have set prices and have custom quoting on each part. We value our customers and tailor every build to the rider, based on the weight, fuel, and skill level of the rider. We make unique components for each rider so they can have the best experience when they hop on their bike. We are just focused on letting people do what they love.

metal racing parts made by Heavy Duty Racing

What is the coolest project you have worked on?

In 2016, MX Tech Suspension in Illinois gave us the opportunity to build an engine for them to display at their event. We got to go to California to watch them demo the engine in front of thousands of people. It was very nerve-racking to watch it live but the experience was amazing. The engine was later featured on the cover of Motocross Action magazine. It was very cool to see something we dedicated so much hard time toward get that much recognition.

Why is high quality tooling important to you?

We are making really difficult machine parts so we need tools that can last. Micro 100 tooling lasts and does the job. The thread mills we use are 3-4 mm and 14 mm and they last longer than any competition out there. The thread mills do not chip like the competition and the carbide is super strong. Breaking a tool is not cheap, so to keep one tool in the machine for how long we have has really saved me in the long run. We found Micro 100 one day looking through our distributor’s catalog and decided to try some of their boring bars. After about 5 holes, we realized that these tools are the best we have ever used! Micro has had everything I’ve been looking for in stock and ready to ship, so we have yet to need to try out their custom tools.

Most engine tolerances are no more than .0005” taper. You need the tooling to hold tight tolerances, especially in engines. Just like with tooling, minimizing vibration is key to getting the engine to last longer. We need tight tolerances to maintain high quality and keep engines alive.

machined metal racing part

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

The same advice I’ve given to my son: Don’t be ashamed to start from the bottom and learn from the ground, up. Everybody wants to make cool projects, but you need to learn what is going on around you to master the craft. Learn the processes and follow the steps. It’s very easy to break a tool, ruin a part, or even hurt yourself. Don’t be scared of quality tools! Buying the cheap stuff will help you with one job, but the quality tools last and will save you in multiple situations.

Follow Heavy Duty Racing on Instagram, and go check out their website to see more about them!

Hybrid Machining – Featured Customer

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

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

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

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

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!

Harvey Performance Company Opens New 79,000-Square-Foot Manufacturing Plant in Gorham

GORHAM, ME (October 13, 2020) – Harvey Performance Company, the parent company of the Harvey Tool, Helical Solutions, and Micro 100 industrial cutting tool brands, last month opened the doors to a new, 79,000-square-foot, state-of-the-art manufacturing facility in Gorham, Maine, to support the tremendous growth and product demand its brands continue to experience.

Harvey Performance Company was quickly outgrowing its Sanford Drive facility in Gorham, Maine, where Helical Solutions products have been manufactured for more than 15 years. The new manufacturing facility, which is just 5 minutes away on Raceway Drive, will become home to Helical Solutions product manufacturing and will serve as an innovation hub for all Harvey Performance Company brands.

“We couldn’t be more excited about this new facility,” said Harvey Performance Company Senior Vice President of Sales Jerry Gleisner. “We’re quite literally opening the doors to countless opportunities for us to serve our customers in ways unmatched in the industry.”

“This new facility is an exciting step for our business, as this investment will create opportunities for us to continue to grow,” said Harvey Performance Company Vice President of Operations Steve Vatcher. “In light of the COVID-19 Pandemic, we worked closely with state and local officials to ensure that the completion of our new facility was done in a way that prioritized the health and safety of all involved. I couldn’t be more proud of how everyone came together to make this facility a reality during these unprecedented times.

“When it is safe to do so, we look forward to hosting the Gorham community, our neighbors for more than 15 years, at our new home for a ribbon cutting ceremony to share this exciting milestone with us.”

Harvey Performance Company’s New Manufacturing Plant Will:

  • Expand upon its current research and development capabilities to design, test, and manufacture innovative and high performing cutting tools.
  • Accelerate Harvey Performance Company’s new product growth while maintaining its in-stock status and same-day shipping options for all catalog standard items.
  • Host its distributor partners and customers in a state-of-the-art setting that showcases its capabilities.
  • Meet the needs of the market by scaling the size of Harvey Performance Company’s business in the future, through added machines and personnel.
  • Attract, recruit, and retain high-quality employees, engineers, and operators with a high-class work environment.

Schon DSGN – Featured Customer

In 2012, engineer Ian Schon wanted to put his skill for design to the test. He decided to challenge himself by designing a normal, everyday item: a pen. His goal was to take the pen from the design concept to manufacturing it within his own shop. Ian designed his pen how he thought a pen should be: durable, reliable, compact, leak-proof, and easy to use. Most of all, though, he wanted the pen to be of a superior quality, not something easily lost or thrown away.

With the design concept in place, Ian started his work on engineering and manufacturing his new pen. He made many prototypes, and with each discovered new features and additions to better his design. Today, Ian manufacturers his pens through local fabrications in Massachusetts, using local supplies. He makes them from 6061 Aluminum, unique in that it molds to its users’ hand, over time. His pens are designed to outlast its user and be passed on through generations.

Ian was kind enough to take time out of his busy schedule to answer some questions about his manufacturing success.

Schon DSGN silver wrist watch with black band

What sets Schon DSGN apart from competition?

I think I have a unique approach to designing and manufacturing. I design things that I like, and make them the way that I want to.  I don’t rush things out the door. I’m not thinking about scale, growth, making a big shop, etc. I just want to live a simple life where I make cool objects, sell them, and have enough time in the week to sneak out into the woods and ride my bike. This ethos takes the pressure off a lot, and that makes the workflow freer without as much stress as I had in my past career as a product development engineer.

This workflow isn’t for everyone. it’s not a winning combo for massive business success, per se, and if you audited me you would tell me I’m holding back by not scaling and hiring, but I like it. I see myself as a hybrid between artist and entrepreneur. I love doing things start to finish, blank paper to finished part on the machine. Owning that entire workflow allows for harmony of engineering, machining, tooling, finishing, R+D, marketing, etc. Further, it ensures that I don’t miss critical inflection points in the process that are ripe for process evolution and innovation, resulting in a better product in the end.

I’m sure the way I do things will change over time, but for now I’m still figuring things out and since I work largely alone (I have one amazing helper right now assisting with assembly, finishing, and shipping) I have lots of flexibility to change things and not get stuck in my ways.

Also, by working alone, I control the music. Key!

schon dsgn turning metal on lathe

Where did your passion for pens come from?

My friend Mike had a cool pen he got from a local shop and I was like “man I like that,” so I made one with some “improvements.” At the time, in my mind, they were improvements, but I have learned now that they were preferences, really. I made a crappy pen on a lathe at the MIT MITERS shop back in 2010, and that summer I bought a Clausing lathe on craigslist for $300 and some tooling and started figuring it all out. I made a bunch of pens, wrote with them, kept evolving them, and eventually people asked me to make pens for them.  I didn’t really intend to start a business or anything, I just wanted to make cool stuff and use it. Bottle openers, knives, bike frames, etc. I made lots of stuff. Pens just stuck with me and I kept pushing on it as a project for my design portfolio. Eventually it became something bigger. Turns out my pen preferences were shared with other people.

Schon dsgn gold and copper metal pens

What is the most difficult product you have had to make and why?

Making watch cases – wow. What an awful part to try and make on a desktop Taig 3 axis mill and a Hardinge lathe in my apartment! I started working on machining watch cases in 2012, and I finished my first one in my apartment in 2015 (to be fair, I was working on lots of other stuff during that time! But yeah, years…). What a journey. Taught me a lot. Biting off more than you can chew is a great way to learn something. 

What is the most interesting product you’ve made?

When I worked at Essential Design in Boston I worked on the front end of a Mass Spectrometer. The requirements on the device were wild. We had high voltage, chemical resistance, crazy tolerances, mechanism design, machining, injection molding – truly a little bit of everything! It was a fun challenge that I was fortunate to be a part of. Biomolecule nanoscale analysis device. Try saying that ten times fast.

I have something fountain pen related in the works now that I find more interesting, and very, very complex, but it’s under wraps a bit longer. Stay tuned. 

Schon dsgn gold and copper metal pens

Who is the most famous contact that you have worked on a project with?

I have made watches for some incredible customers, but I unfortunately cannot talk about who they are. Most of my watch work outside of my own parts is also under NDA which is a bummer, but hey it was great work regardless.

Same thing with the pens. I know that some of my pen are in the touring cases of a few musicians, one of which is in the rock and roll hall of fame. But I have to keep it tight!

Before leaving to work for myself, I was part of a design team at IDEO in Cambridge that designed the new Simplisafe Home Security System. As an engineer and designer, I got listed on the patents. That wasn’t machining and was more design and engineering of injection molded plastic assemblies,  but it was still cool, though! Cutting my teeth in the design industry before machining helps me a lot with the creative process in the workshop. Lots of overlap.

What capabilities does your shop have?

I utilize Citizen L series sliding headstock machines to run my company. These are Swiss Machines (though made in Japan) with twin spindles and have live tooling for milling operations. I got into this type of machining after getting advice from friends in the industry and subcontracting my work to shops with these style of machines for 7 years.

Beyond the Swiss Machines, I have a new Precision Matthews Manual Mill, a Southbend Model A, a Hardinge Cataract Lathe, and a bunch of smaller Derbyshire lathes and mills. Most of these are for maintenance related tasks – quick mods and fixtures and my watchmaking/R&D stuff. I also have a Bantam Tools Desktop CNC machine on the way, a nice machine for quick milled fixtures in aluminum and nonferrous materials. I tested this machine during their development phases and was really impressed.

What CAM/CAD software are you using?

I use Fusion 360 for quick milled stuff, but most of my parts are programmed by hand since the lathe programming for Swiss work can be done without much CAM. I’m sure I could be doing things better on the programming side, but hey, every day I learn something new. Who knows what I’ll be doing a year or two from now?

schon dsgn turning wrist watch on lathe

What is your favorite material to work with and why?

Brass and Copper. The chips aren’t stringy, it’s easy to cut quickly and the parts have this nice hefty feel to them. Since I make pens, the weight is a big piece of the feeling of a pen. The only downside is I’m constantly figuring out ways to not dent the parts as they are coming off the machines! My brass parts are like tiny brass mallets and they LOVE to get dinged up in the ejection cycles. I ended up making custom parts catchers and modifying the chutes on the machines to navigate this. I might have some conveyors in my future….yeah. Too many projects!

schon dsgn disassembled wrist watch

Why is high quality tool performance important to you?

It’s not just important, it’s SUPER important. As a solo machinist running my own machines, being able to call a tooling company and get answers on how I should run a tool, adjust its RPM, feed, DOC, or cutting strategy to get a better result is invaluable. I find that as much as I’m paying for tool performance, I’m also paying for expertise, wisdom and answers. Knowing everything is cool and all (and I know some of you out there know everything under the sun), but since I don’t know everything, it’s so nice to be able to pick up a phone and have someone in my corner. These tech support people are so crucial. Being humble and letting support guide me through my tooling challenges has helped me grow a lot. It’s like having a staff of experienced machinists working at my company, for free! Can’t beat that. Micro 100 and Helical have helped me tons with their great support.

schon dsgn multicolored fountain pens

When was a time that Harvey, Helical or Micro product really came through and helped your business?

The Helical team (shout out to Dalton) helped me nail some machining on some very wild faceted pens I was working on this month. When I switched to Helical, my finishes got crazy good. I just listened to recommendations, bought a bunch of stuff, and kept trying what Dalton told me to. Eventually, that led to a good recipe and manageable tool wear. It was great!

I also like how representatives from the Harvey/Helical/Micro family often cross reference each other and help me find the right solution, regardless of which company I’m getting it from. Nice system.

The quiet hero in my shop is my Micro 100 quick change system. It just works great. Fast to swap tools, easy to setup, cannot argue with it! Too good. 

Schon DSGN silver wrist watch with black band

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

Find a mentor who supports you and challenges you. Find a good tooling company, or good tooling companies, and make good relationships with their tech support so you can get answers. Make good relationships with service technicians who can help you fix your machines. Be a good person. Don’t let yourself become a hot head under the pressure of this industry (since it can be hard at times!), cooler heads prevail, always. Be open to seeing things from other viewpoints (in life and in machining), don’t be afraid to flip a part around and start over from square one.

To learn more about Ian and Schon DSGN, follow them @schon_dsgn and @the_schon on Instagram and check out his website. And, to learn more about how Ian got his start in the manufacturing industry, check out this video.

Rennscot LLC – Featured Customer

David Bamforth is the founder and CEO of Rennscot LLC, a manufacturing company based out of Woburn, Massachusetts, which was created to meet product design demands of both individual and commercial clients. From idea to prototype, and eventually to final product, Rennscot LLC prides itself on its ability to make part ideas come to life. David took some time to talk with us about Rennscot LLC, his company’s machining capabilities, and much more.

Assortment of end mills and tool holders at Rennscott LLC

What capabilities does your shop have?

We are mostly a mill shop with two verticals and one 5-axis machine. We also have a small bar fed lathe, a larger sub-spindle live-tooling lathe, and some design tools like a Faro Design Scan Arm. We work predominantly with aluminum, but sometimes see brass, stainless, titanium, and steel alloy jobs come through. We use Fusion 360 for everything and currently all 4 of our machines are Haas.

What sets Rennscot LLC apart from the competition?

We are a bit different from most shops because, in addition to machining services, we also offer design services. A lot of our jobs are won because we are a one-stop-shop from idea to producing the final product. Recently we have been making a lot of parts for vehicle restoration. Typically, we are just handed a part and asked to reproduce it.

David, what is your favorite part of your job?

Problem solving and learning new skills. We are a pretty young team and love being challenged by new projects. We also pride ourselves on being pretty innovative with our machining strategies to help reduce lead times and cost for our customers.

cnc machined metal part from Rennscot LLC

Where did your passion for automobiles come from?

Like many, I have always been passionate about cars. I have some great memories of going to car shows with my dad and watching any TV show with a car in it as a kid. Nowadays, I spend my personal time taking our shop development car, a Porsche Cayman, to the track.

What is the coolest product you have made?

We have had some pretty unusual characters bring us some really cool projects. Currently, we are working with a guy from Connecticut on laser scanning a model Mercedes C10 Le Mans car that we will CAD model, so a full-sized car body can be reproduced. It’s a really interesting project, trying to take a 1:43 car and blow it up to full size. Eventually, we will help design and manufacture many of the machined components on this car. Also, we once made a custom billet alternator mount in just 5 days for a 996 Porsche GT3 with a Chevy LS engine in it. We really enjoyed being part of that project and the V8 sounded amazing on track!

cnc machined metal part from Rennscot LLC

What is the most difficult product you have made?

We once worked on an enclosure for a handheld x-ray machine. The part was only about 1”x 1.25” x4” and only had .040” walls all around. The main pocket was machined with our go-to Helical ¼” reduced shank end mill. It also had #0-80 taps all along the top edge of the enclosure, making for a few broken taps! It was a pain to get dialed in but once the process was proved out it was really rewarding to get consistent good parts off the will.

Why is high quality tool performance important to you?

Once we started using high quality end mills, we immediately saw an improvement in tool life and surface finish. We also really enjoy using tools that are backed by a company that puts out so much information and resources to help its customers out.

When was a time that Harvey Tool or Helical products really came through and helped your business?

We have had several moments when we hit a wall while building a process for a new part, and Helical’s phone support helped us find the perfect tool for the process. The combination of great phone support, having such a vast array of product offerings, and all of the tools always being in stock has helped my business tremendously.

Rennscot LLC machine shop assortment of harvey tool and helical end mills

Are you guys using High Efficiency Milling (HEM) techniques to improve cycle times?

Always! All our mills are spec’ed with HSM and 12k RPM spindles, and we take full advantage of this with chip breaking roughers. Honestly, we are so young that we have only ever used HEM techniques, so I’m honestly just confused by companies that don’t use it. Not using HEM is like not driving a car on the highway because it’s too fast.

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

Machining is probably the most in demand and most satisfying industries that someone can get into now-a-days. There are a lot of companies that are in demand for green machinists who are just eager to learn. I would recommend putting together and sending out a resume to local shops that shows that you have the ability to take on projects and complete them.

If anyone is interested in learning more about what we do our manufacturing website, rennscotmfg.com is a great resource. Also, check us our on Instagram at @rennscot.

How to Optimize Results While Machining With Miniature End Mills

 The machining industry generally considers miniature end mills to be any end mill with a diameter under 1/8 of an inch. This is also often the point where tolerances must be held to a tighter window. Because the diameter of a tool is directly related to the strength of a tool, miniature end mills are considerably weaker than their larger counterparts, and therefore, lack of strength must be accounted for when machining with them. If you are using these tools in a repetitive application, then optimization of this process is key.

Key Cutting Differences between Conventional and Miniature End Mills

Runout

Runout during an operation has a much greater effect on miniature tools, as even a very small amount can have a large impact on the tool engagement and cutting forces. Runout causes the cutting forces to increase due to the uneven engagement of the flutes, prompting some flutes to wear faster than others in conventional tools, and breakage in miniature tools. Tool vibration also impacts the tool life, as the intermittent impacts can cause the tool to chip or, in the case of miniature tools, break. It is extremely important to check the runout of a setup before starting an operation. The example below demonstrates how much of a difference .001” of runout is between a .500” diameter tool and a .031” diameter tool.

chart comparing tool diameter for runout in micromachining
The runout of an operation should not exceed 2% of the tool diameter. Excess runout will lead to a poor surface finish.

Chip Thickness

The ratio between the chip thickness and the edge radius (the edge prep) is much smaller for miniature tools. This phenomena is sometimes called “the size effect” and often leads to an error in the prediction of cutting forces. When the chip thickness-to-edge radius ratio is smaller, the cutter will be more or less ploughing the material rather than shearing it. This ploughing effect is essentially due to the negative rake angle created by the edge radius when cutting a chip with a small thickness.

If this thickness is less than a certain value (this value depends of the tool being used), the material will squeeze underneath the tool. Once the tool passes and there is no chip formation, part of the plowed material recovers elastically. This elastic recovery causes there to be higher cutting forces and friction due to the increased contact area between the tool and the workpiece. These two factors ultimately lead to a greater amount of tool wear and surface roughness.

chart of edge radius in relation to chip thickness for micromachining
Figure 1: (A) Miniature tool operation where the edge radius is greater than the chip thickness (B) Conventional operation where the edge radius is small than the chip thickness

Tool Deflection

Tool deflection has a much greater impact on the formation of chips and accuracy of the operation in miniature operations, when compared to conventional operations. Cutting forces concentrated on the side of the tool cause it to bend in the direction opposite the feed. The magnitude of this deflection depends upon the rigidity of the tool and its distance extended from the spindle. Small diameter tools are inherently less stiff compared to larger diameter tools because they have much less material holding them in place during the operation. In theory, doubling the length sticking out of the holder will result in 8 times more deflection. Doubling the diameter of an end mill it will result in 16 times less deflection. If a miniature cutting tool breaks on the first pass, it is most likely due to the deflection force overcoming the strength of the carbide. Here are some ways you can minimize tool deflection.

Workpiece Homogeny

Workpiece homogeny becomes a questionable factor with decreasing tool diameter. This means that a material may not have uniform properties at an exceptionally small scale due to a number of factors, such as container surfaces, insoluble impurities, grain boundaries, and dislocations. This assumption is generally saved for tools that have a cutter diameter below .020”, as the cutting system needs to be extremely small in order for the homogeny of the microstructure of the material to be called into question.

Surface Finish

Micromachining may result in an increased amount of burrs and surface roughness when compared to conventional machining. In milling, burring increases as feed increases, and decreases as speed increases. During a machining operation, chips are created by the compression and shearing of the workpiece material along the primary shear zone. This shear zone can be seen in Figure 2 below. As stated before, the chip thickness-to-edge radius ratio is much higher in miniature applications. Therefore, plastic and elastic deformation zones are created during cutting and are located adjacent to the primary shear zone (Figure 2a). Consequently, when the cutting edge is close to the border of the workpiece, the elastic zone also reaches this border (Figure 2b). Plastic deformation spreads into this area as the cutting edge advances, and more plastic deformation forms at the border due to the connecting elastic deformation zones (Figure 2c). A permanent burr begins to form when the plastic deformation zones connect (Figure 2d) and are expanded once a chip cracks along the slip line (Figure 2e). When the chips finally break off from the edge of the workpiece, a burr is left behind (Figure 2f).

Tool Path Best Practices for Miniature End Mills

Because of the fragility of miniature tools, the tool path must be programmed in such a way as to avoid a sudden amount of cutting force, as well as permit the distribution of cutting forces along multiple axes. For these reasons, the following practices should be considered when writing a program for a miniature tool path:

Ramping Into a Part

Circular ramping is the best practice for moving down axially into a part, as it evenly distributes cutting forces along the x, y, and z planes. If you have to move into a part radially at a certain depth of cut, consider an arching tool path as this gradually loads cutting forces onto the tool instead of all at once.

Machining in Circular Paths

You should not use the same speeds and feed for a circular path as you would for a linear path. This is because of an effect called compounded angular velocity. Each tooth on a cutting tool has its own angular velocity when it is active in the spindle. When a circular tool path is used, another angular velocity component is added to the system and, therefore, the teeth on the outer portion of tool path are traveling at a substantially different speed than expected. The feed of the tool must be adjusted depending on whether it is an internal or external circular operation. To find out how to adjust your feed, check out this article on running in circles.

Slotting with a Miniature Tool

Do not approach a miniature slot the same way as you would a larger slot. With a miniature slot, you want as many flutes on the tool as possible, as this increases the rigidity of the tool through a larger core. This decreases the possibility of the tool breaking due to deflection. Because there is less room for chips to evacuate with a higher number of flutes, the axial engagement must be decreased. With larger diameter tools you may be stepping down 50% – 100% of the tool diameter. But when using miniatures with a higher flute count, only step down between 5% – 15%, depending on the size of the diameter and risk of deflection. The feed rate should be increased to compensate for the decreased axial engagement. The feed can be increased even high when using a ball nose end mill as chip thinning occurs at these light depths of cut and begins to act like a high feed mill.

Slowing Down Your Feed Around Corners

Corners of a part create an additional amount of cutting forces as more of the tool becomes engaged with the part. For this reason it is beneficial to slow down your feed when machining around corners to gradually introduce the tool to these forces.

Climb Milling vs. Conventional Milling

This is somewhat of a tricky question to answer when it comes to micromachining. Climb milling should be utilized whenever a quality surface finish is called for on the part print. This type of tool path ultimately leads to more predictable/lower cutting forces and therefore higher quality surface finish. In climb milling, the cutter engages the maximum chip thickness at the beginning of the cut, giving it a tendency to push away from the workpiece. This can potentially cause chatter issues if the setup does not have enough rigidity.  In conventional milling, as the cutter rotates back into the cut it pulls itself into the material and increases cutting forces. Conventional milling should be utilized for parts with long thin walls as well as delicate operations.

Combined Roughing and Finishing Operations

These operations should be considered when micromachining tall thin walled parts as in some cases there is not sufficient support for the part for a finishing pass.

Helpful Tips for Achieving Successful Micromachining Operations

Try to minimize runout and deflection as much as possible.This can be achieved by using a shrink-fit or press-fit tool holder. Maximize the amount of shank contact with the collet while minimizing the amount of stick-out during an operation. Double check your print and make sure that you have the largest possible end mill because bigger tools mean less deflection.

  • Choose an appropriate depth of cut so that the chip thickness to edge radius ratio is not too small as this will cause a ploughing effect.
  • If possible, test the hardness of the workpiece before machining to confirm the mechanical properties of the material advertised by the vender. This gives the operator an idea of the quality of the material.
  • Use a coated tool if possible when working in ferrous materials due to the excess amount of heat that is generated when machining these types of metals. Tool coatings can increase tool life between 30%-200% and allows for higher speeds, which is key in micro-machining.
  • Consider using a support material to control the advent of burrs during a micro milling application. The support material is deposited on the workpiece surface to provide auxiliary support force as well as increase the stiffness of the original edge of the workpiece. During the operation, the support material burrs and is plastically deformed rather than the workpiece.
  • Use flood coolant to lower cutting forces and a greater surface finish.
  • Scrutinize the tool path that is to be applied as a few adjustments can go a long way in extending the life of a miniature tool.
  • Double-check tool geometry to make sure it is appropriate for the material you are machining. When available, use variable pitch and variable helix tools as this will reduce harmonics at the exceptionally high RPMs that miniature tools are typically run at.
variable pitch versus non-variable pitch
Figure 3: Variable pitch tool (yellow) vs. a non-variable pitch tool (black)

TOMI Engineering INC – Featured Customer

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

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

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

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

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!

Titan Ring Design – Featured Customer

Officially started in 2015, Titan Ring Design is a high quality machine shop that designs rings, as well as mechanical tie clips, art based designs, and freelance custom designs. While working at a machine shop that produced top notch parts for just about every type of field you can imagine, now owner of Titan Ring Design, Trevor Hirschi, noticed that the machining industry is mostly about cranking out a mass quantity of the highest quality parts as quickly as possible. This often resulted in compromised tolerances and part finishes, something Trevor aimed to change. Quality always comes first in his projects.

Whether you are looking for a band for an upcoming wedding, looking to replace or upgrade your current wedding ring, or just want something unique and beautiful, Trevor’s designs are different than anything else. Trevor was able to take the time and answer some questions for us about his business, machining techniques, tooling, and a lot more.

machined metal ring from Titan Ring Design

How was Titan Ring Design started?

Titan Ring Designs is a part time, passion/hobby business of mine that I sort of started at the time I was ring shopping for a wedding ring back in 2013. I didn’t like what was available on the market and was inspired by a former Oakley designer to machine my own. I had been introduced to machining in High School at a technical college and had been working as a machinist since graduating in 2007, so I decided to make my own wedding ring. It sort of snowballed into my business in 2015, after finally deciding to make it official with a business license and some sales. Some further work experience in California for McWhinney Designs brought me greater motivation and encouragement to keep going and helped me get to where I am today. I now offer several different CNC Milled [wedding] rings, as well as a mechanical tie clip, some occasional art based designs, and freelance custom design and mill work. I also teach machining full time  at the same tech college I graduated from in my own education and enjoy sharing my knowledge and love for machining with those interested in the career.

machined propeller art from Titan Ring Design

What capabilities does your shop have?

Custom Design in CAD/CAM, 3axis CNC Mill work, Small Scale Lathe Work, Tumbling, Finishing, Assembling, 3D Printing/Rapid Prototyping. I cut 6-4 Titanium primarily, but also work with Stainless Steel for fasteners, Aluminum and some Steel for fixtures, and Polycarbonate for prototyping ideas. I teach machining technology full time, so I have access to SolidWorks, MasterCam, Fusion360, and NC Simul. We currently have a Haas OfficeMill 3axis, Levin High Precision Instrument Maker’s Lathe, Prusa i3 MK2S 3D Printer in the shop.

What sets Titan Ring Design apart from the competition?

There are lots of people making interesting rings today, but most are done on lathes. Anyone can make a round part on a lathe. Very few of them make rings on a mill, and I feel that gives the opportunity to be creative and allows you to think outside the box more. I try to stand out in that field by offering something that makes you think about the value of the design process more by interrupting and challenging the norm. I also like to take on work that is outside of jewelry, but still highly design related. Most other ring makers stick with just rings.

Titan Ring Design machining facility

What is your favorite part of the job and what other passions do you have?

Making cool stuff! Most machinists only end up making whatever comes through the shop, which can be cool, but most of the time you have no idea what you’re making, just some part for Customer X, Y, or Z. Being a small, design centered business, I get to come up with ideas for what to make next, and most of the time I start out making something that wasn’t ever intended to be marketed, it was simply something I wanted for myself that I found others were interested in too. I discovered machining in high school and fell in love with it when I started making parts for my dirt bikes and truck. I’ve been hooked ever since but I do have other passions. I’ve always had a big interest in LED lighting and flashlights. I’m perpetually working on different ideas for making one of my own, which will happen eventually. I’m also a bit of a health-nut and enjoy being outdoors and spending time with my family.

Who is the most famous contact that you have worked on a project with?

I made a ring for an NFL player once, but I don’t follow football and his name didn’t stick out to me so I’ve forgotten who he was. I also had the privilege of working for McWhinney Designs and made some truly remarkable products in the openable wedding ring niche market. I gained more skill in design, machining, craftsmanship, and engineering while working for Jeff McWhinney. We’re good friends and often work together to help each other when one of us gets stumped on something.

machined metal art from Titan Ring Design

What is the most difficult project you have worked on?

I was commissioned to design from the ground up and machine was a custom set of all-titanium cabinet door handle pulls for a very high end wine cabinet. Each handle was an assembly of 32 pieces, all machined from billet 6-4 Titanium. They required over 400 individual CAM toolpath operations, 35 unique machine setups, and well over 300 hours to complete, including finishing and assembly. More than anything, it was extremely time intensive in programming, set up, and machine time. The design was a fair bit challenging in my mind and initial modeling, but didn’t compete with what it took to actually produce them. I grossly underestimated and underbid the job. But in the end, I really enjoyed making a truly one of a kind, Tour-De-Force product, even if it was completely overkill for its purpose. I enjoy making that kind of stuff, and the lessons you learn from it.

What is your favorite project you have worked on?

It’s really simple and was initially designed just because I wanted it for myself, but I have a mechanical titanium tie clip that I really enjoy making. It’s quite unique in that, as far as I know, to this day, it is the only CNC machined mechanical titanium tie clip you’ll find anywhere in the world. It puts a little bling in your formal attire, for those times you have to go full suit and tie.

machined metal band from Titan Ring Design

Why is high quality tool performance important to you?

Because I cut mostly titanium, tools wear out quickly if you don’t have a rigid set up, the right coolant, proper feeds & speeds, and of course, high quality tooling. Harvey Tool makes such a wide variety of micro tooling that works so well in the industry of making small titanium parts, where I like to fit into. I’ve used a fair spread across Harvey’s offering and have always been impressed with performance and the feeds and speeds guides are top notch too. I had an application that required a .0035” internal corner radius which landed me with a .007” end mill. It’s still hard to comprehend tooling in this league. My machine actually recommends only tooling under 1/4” shank size, so I don’t get into Helical’s range too often. But I’ve used Helical 1/2” end mills extensively at other job shops and they are definitely made for eating metal. I was using another tool brand’s key cutters for some undercut hinges and would wear through them much more often than I thought was reasonable. When I finally decided to try Harvey’s key cutters, I was blown away with how much longer they have lasted me. Truly a game changer!

harvey tool end mills with Titan Ring Design machined tie clip

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

Be creative. Machining is such a rewarding career that has limitless possibilities of what you can achieve. Follow your passion and have fun with it! If you end up in a dead end shop doing something you don’t like, go somewhere else. There are so many shops that need help right now and chances are good that you can find a better shop that suits your style.

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

To those machine shops out in industry, do whatever you can to be supportive of your local trade schools that are teaching the upcoming machinist workforce. They really need your support and in turn will bring you the employees you depend on.

Please take the time to check out Titan Ring Designs website or follow them on Instagram @titanringdesigns

Chipbreaker Tooling: Not Just for Roughing

When many people think about solid carbide tools with chip breakers, they are usually tooling up for a roughing application. While the chip breaker tool is a great choice for such applications, it can be utilized in a number of other areas too. In this post, we’ll examine many other benefits of the chip breaker style of tooling.

https://www.instagram.com/p/B7JqOQKnoPu/

High Efficiency Milling (HEM)

High Efficiency Milling (HEM) uses CAM software to program advanced toolpaths that reduce cutting forces. These tool paths employ smaller end mills with a higher number of flutes (for a stronger core) running at higher speeds and feeds. This strategy includes a light radial depth of cut (RDOC), high axial depth of cut (ADOC), and a controlled angle of engagement.

Helical’s chipbreaking tools include serrated indents along the edge of flute for the entire length of cut. Because HEM utilizes heavy axial depths of cuts, these tools are able to break long chips into smaller ones. In addition to improving chip control and reducing cutting resistance, chipbreaker tools also help in decreasing heat load within the chips. This delays tool wear along the cutting edge and improves cutting performance. 

Check out this testimony from a Helical Solutions customer:

“We were able to get going with the 7 flute tools with the chipbreaker. I have to say the difference was INCREDIBLE! We can now rough the entire part with one tool. Also, the operator doesn’t have to open the door to clear chips hardly at all. We were able to rough and finish a 4.15 dia. bore 2 inches deep through the part without having to clear chips at all. Before we had to clear the chips out at least 15-20 times. Many thanks for your support.”

Slotting

When slotting, a major concern is chip control. A large buildup of chips can cause the recutting of chips, which adds a lot of heat back into the tool. Chip buildup can also cause a heavy amount of chattering. Both of these conditions are detrimental to tool life. A chip breaking tool can help reduce chip build-up when slotting which will extend tool life. Remember when slotting that 4 flute tools should be utilized in steel. For aluminum and other non- ferrous materials, a 3 flute tool is best.

Trochoidal Slotting

Trochoidal slotting is a form of slotting that uses HEM techniques to form a slot. Trochoidal milling implements a series of circular cuts to create a slot wider than the cutting tool’s cutting diameter. Using the logic listed in the earlier paragraphs of this article, a chipbreaker should be used when performing this operation.

Advantages of Trochoidal Slotting:

Decreased cutting forces

Reduced heat

Greater machining accuracy

Improved tool life

Faster cycle times

One tool for multiple slot sizes

Finishing

A little known fact about Helical’s chipbreaker style tool is that the chip breakers are offset flute to flute, which allows for a quality finish on the walls of the part. When utilizing light depths of cuts, high-quality finishes can be achieved.

https://www.instagram.com/p/B89jFAHnbfe/?utm_source=ig_web_copy_link