## How Boring Bar Geometries Impact Cutting Operations

Boring is a turning operation that allows a machinist to make a pre-existing hole bigger through multiple iterations of internal boring. It has a number of advantages over traditional drilling methods:

• The ability to cost-effectively produce a hole outside standard drill sizes
• The creation of more precise holes, and therefore tighter tolerances
• A greater finish quality
• The opportunity to create multiple dimensions within the bore itself

Solid carbide boring bars, such as those offered by Micro 100,  have a few standard dimensions that give the tool basic functionality in removing material from an internal bore. These include:

Minimum Bore Diameter (D1): The minimum diameter of a hole for the cutting end of the tool to completely fit inside without making contact at opposing sides

Maximum Bore Depth (L2): Maximum depth that the tool can reach inside a hole without contact from the shank portion

Shank Diameter (D2): Diameter of the portion of the tool in contact with the tool holder

Overall Length (L1): Total length of the tool

Centerline Offset (F): The distance between a tool’s tip and the shank’s centerline axis

## Tool Selection

In order to minimize tool deflection and therefore risk of tool failure, it is important to choose a tool with a max bore depth that is only slightly larger than the length it is intended to cut. It is also beneficial to maximize the boring bar and shank diameter as this will increase the rigidity of the tool. This must be balanced with leaving enough room for chips to evacuate. This balance ultimately comes down to the material being bored. A harder material with a lower feed rate and depths of cut may not need as much space for chips to evacuate, but may require a larger and more rigid tool. Conversely, a softer material with more aggressive running parameters will need more room for chip evacuation, but may not require as rigid of a tool.

## Geometries

In addition, they have a number of different geometric features in order to adequately handle the three types of forces acting upon the tool during this machining process. During a standard boring operation, the greatest of these forces is tangential, followed by feed (sometimes called axial), and finally radial. Tangential force acts perpendicular to the rake surface and pushes the tool away from the centerline. Feed force does not cause deflection, but pushes back on the tool and acts parallel to the centerline. Radial force pushes the tool towards the center of the bore.

### Defining the Geometric Features of Boring Bars:

Nose Radius: the roundness of a tool’s cutting point

Side Clearance (Radial Clearance): The angle measuring the tilt of the nose relative to the axis parallel to the centerline of the tool

End Clearance (Axial Clearance): The angle measuring the tilt of the end face relative to the axis running perpendicular to the centerline of the tool

Side Rake Angle: The angle measuring the sideways tilt of the side face of the tool

Back Rake Angle: The angle measuring the degree to which the back face is tilted in relation to the centerline of the workpiece

Side Relief Angle: The angle measuring how far the bottom face is tilted away from the workpiece

End Relief Angle: The angle measuring the tilt of the end face relative to the line running perpendicular to the center axis of the tool

### Effects of Geometric Features on Cutting Operations:

Nose Radius: A large nose radius makes more contact with the workpiece, extending the life of the tool and the cutting edge as well as leaving a better finish. However, too large of a radius will lead to chatter as the tool is more exposed to tangential and radial cutting forces.

Another way this feature affects the cutting action is in determining how much of the cutting edge is struck by tangential force. The magnitude of this effect is largely dependent on the feed and depth of cut. Different combinations of depth of cuts and nose angles will result in either shorter or longer lengths of the cutting edge being exposed to the tangential force. The overall effect being the degree of edge wear. If only a small portion of the cutting edge is exposed to a large force it would be worn down faster than if a longer portion of the edge is succumb to the same force. This phenomenon also occurs with the increase and decrease of the end cutting edge angle.

End Cutting Edge Angle: The main purpose of the end cutting angle is for clearance when cutting in the positive Z direction (moving into the hole). This clearance allows the nose radius to be the main point of contact between the tool and the workpiece. Increasing the end cutting edge angle in the positive direction decreases the strength of the tip, but also decreases feed force. This is another situation where balance of tip strength and cutting force reduction must be found. It is also important to note that the angle may need to be changed depending on the type of boring one is performing.

Side Rake Angle: The nose angle is one geometric dimension that determines how much of the cutting edge is hit by tangential force but the side rake angle determines how much that force is redistributed into radial force. A positive rake angle means a lower tangential cutting force as allows for a greater amount of shearing action. However, this angle cannot be too great as it compromises cutting edge integrity by leaving less material for the nose angle and side relief angle.

Back Rake Angle: Sometimes called the top rake angle, the back rake angle for solid carbide boring bars is ground to help control the flow of chips cut on the end portion of the tool. This feature cannot have too sharp of a positive angle as it decreases the tools strength.

Side and End Relief Angles: Like the end cutting edge angle, the main purpose of the side and end relief angles are to provide clearance so that the tools non-cutting portion doesn’t rub against the workpiece. If the angles are too small then there is a risk of abrasion between the tool and the workpiece. This friction leads to increased tool wear, vibration and poor surface finish. The angle measurements will generally be between 0° and 20°.

## Boring Bar Geometries Summarized

Boring bars have a few overall dimensions that allow for the boring of a hole without running the tool holder into the workpiece, or breaking the tool instantly upon contact. Solid carbide boring bars have a variety of angles that are combined differently to distribute the 3 types of cutting forces in order to take full advantage of the tool. Maximizing tool performance requires the combination of choosing the right tool along with the appropriate feed rate, depth of cut and RPM. These factors are dependent on the size of the hole, amount of material that needs to be removed, and mechanical properties of the workpiece.

## The Geometries and Purposes of a Slitting Saw

When a machinist needs to cut material significantly deeper than wide, a Slitting Saw is an ideal choice to get the job done. A Slitting Saw is unique due to its composition and rigidity, which allows it to hold up in a variety of both straightforward and tricky to machine materials.

## What is a Slitting Saw?

A Slitting Saw is a flat (with or without a dish), circular-shaped saw that has a hole in the middle and teeth on the outer diameter. Used in conjunction with an arbor, a Slitting Saw is intended for machining purposes that require a large amount of material to be removed within a small diameter, such as slotting or cutoff applications.

Other names for Slitting Saws include (but are not limited to) Slitting Cutters, Slotting Cutters, Jewelers Saws, and Slitting Knives. Both Jewelers Saws and Slitting Knives are particular types of Slitting Saws. Jewelers Saws have a high tooth count enabling them to cut tiny, precise features, and Slitting Knives are Slitting Saws with no teeth at all. On Jewelers Saws, the tooth counts are generally much higher than other types of saws in order to make the cuts as accurate as possible.

## Why Use a Slitting Saw?

These saws are designed for cutting into both ferrous and non-ferrous materials, and by utilizing their unique shape and geometries, they can cut thin slot type features on parts more efficiently than any other machining tool.

### Common Applications:

1. Separating Two Pieces of Material
1. If an application calls for cutting a piece of material, such as a rod, in half, then a slitting saw will work well to cut the pieces apart while increasing efficiency.
2. Undercutting Applications
1. Saws can perform undercutting applications if mounted correctly, which can eliminate the need to remount the workpiece completely.
3. Slotting into Material
1. Capable of creating thin slots with a significant depth of cut, Slitting Saws can be just the right tool for the job!

## When Not to Use a Slitting Saw

While it may look similar to a stainless steel circular saw blade from a hardware store, a Slitting Saw should never be used with construction tools such as a table or circular saw.  Brittle saw blades such as slitting saws will shatter when used on manual machines, and can cause injury when not used on the proper set up.

## In Conclusion

Slitting Saws can be beneficial to a wide variety of machining processes, and it is vital to understand their geometries and purpose before attempting to utilize them in the shop. They are a great tool to have in the shop and can assist with getting jobs done as quickly and efficiently as possible.

## How to Advance Your Machining Career: 8 Tips from Machining Pros

Since we began shining a light on Harvey Performance Company brand customers via “In the Loupe’s,” Featured Customer posts, more than 20 machinists have been asked to share insight relevant to how they’ve achieved success. Each Featured Customer post includes interesting and useful information on a variety of machining-related subjects, including prototyping ideas, expanding a business, getting into machining, advantages and disadvantages of utilizing different milling machine types, and more. This post compiles 8 useful tips from our Featured Customers on ways to advance your machining career.

## Tip 1: Be Persistent – Getting Your Foot in the Door is Half the Battle

With machining technology advancing at the amazing rate that it is, there is no better time to become a machinist. It is a trade that is constantly improving, and offers so many opportunities for young people. Eddie Casanueva of Nueva Precision first got into machining when he was in college, taking a job at an on-campus research center for manufacturing systems to support himself.

“The research center had all the workings of a machine shop,” Eddie said. “There were CNC mills, lathes, injection molding machines, and more. It just looked awesome. I managed to get hired for a job at minimum wage sweeping the shop floor and helping out where I could.

As a curious student, I would ask a million questions… John – an expert machinist – took me under his wing and taught me lots of stuff about machining. I started buying tools and building out my toolbox with him for a while, absorbing everything that I could.”

One of the best things about becoming a machinist is that there is a fairly low entry barrier. Many machinists start working right out of high school, with 12-18 months of on-the-job training or a one to two year apprenticeship. Nearly 70% of the machinist workforce is over the age of 45. The Bureau of Labor Statistics is predicting a 10% increase in the machinist workforce with opportunities for 29,000 additional skilled machinists by 2024, so it is certainly a great time to get your foot in the door.

## Tip 2: Keep an Open Mind – If You Can Think of It, You Can Machine It

Being open-minded is crucial to becoming the best machinist you can be. By keeping an open mind, Oklahoma City-based company Okluma’s owner Jeff Sapp has quickly earned a reputation for his product as one of the best built and most reliable flashlights on the market today. Jeff’s idea for Okluma came to him while riding his motorcycle across the country.

“I had purchased what I thought was a nice flashlight for \$50 to carry with me on the trip. However, two days in to the trip the flashlight broke. Of course, it was dark and I was in the middle of nowhere trying to work on my bike. I’m happy to pay for good tools, but that wasn’t what happened. Not only was there no warranty for replacement, there was no way to fix it. It was just made to be thrown away. That whole attitude makes me angry. When I got home, I decided I was going to put my new skills to work and design and build my own flashlight, with the goal of never running into an issue like I had on my trip ever again. I started by making one for myself, then four, then twenty. That was four years ago. Now I have my own business with one employee and two dogs, and we stay very busy.”

An awesome side benefit to working as a machinist is that you have all the resources to create anything you can dream of, like Jeff did with Okluma.

Image courtesy of Okluma.

## Tip 3: Be Patient – Take Time to Ensure Your Job is Setup Correctly before Beginning

The setup process is a huge part of machining, but is often overlooked. Alex Madsen, co- owner of M5 Micro in Minnesota, has been working in manufacturing for more than 11 years. Alex is also a part owner of World Fabrication, and owns his own job shop called Madsen Machine and Design. Alex has spent countless hours perfecting his setup to improve his part times.

“It is certainly challenging to use little tools, but the key is to not get discouraged. You should plan on lots of trial and error; breaking tools is just a part of the game. You may buy ten end mills and break six, but once you dial one in it will last the rest of the job.

You should also make sure to put extra time and effort into understanding your machine when working on micromachining jobs. You need to know where there is any backlash or issues with the machine because with a tiny tool, even an extra .0003” cut can mean the end of your tool. When a difference of one tenth can make or break your job, you need to take your time and be extra careful with your machine, tool inspection, and programming before you hit run.”

## Tip 4: Effort Pays Off – Long Hours Result in Shop Growth

Success isn’t earned overnight. That is especially true in the machining world. Becoming a good machinist takes a great deal of sacrifice, says Josh from Fleet Machine Co. in Gloucester, MA.

“Opening your own shop involves more than learning how to program and machine. You also need to be willing to sacrifice some of your free time by working long hours to build your business from the ground up. Being a great machinist is important, but you also need to understand the basics of business, and you need to be able to sell your service and maintain a certain level of quality to keep your customers coming back.”

Working hard is a common theme we hear from our featured customers. Brothers Geordan and Nace Roberts of Master Machine Manufacturing have similar advice.

“We often need to work odd hours of the day to maintain the business, but we do it in a way that makes sure we have our family time. There are many times where we will go home, have dinner and hang out with the family, and wait until they are all sleeping to go back to work until two or three a.m. We will get back home later that morning to sleep a little and have breakfast with the family and send them on their way before heading back into the shop.” Starting and growing a business takes time. Every machinist starts from the beginning and through hard work and determination, grows their business.

Image courtesy of Liberty Machine Inc.

## Tip 5: Utilize Tooling from Quality Manufacturers – All Tooling Isn’t Created Equal

When it comes down to it, tooling is singlehandedly the biggest choice you will make as a machinist. Grant Hughson, manufacturing engineer at Weiss Watch Company who works as a manufacturing instructor in his spare time, reflected on the importance of tooling.

“Tool to tool accuracy and performance is vital in this business, especially with our extremely tight tolerances. High quality tools make sure that we get the same performance time after time without needing to scrap parts. This saves us valuable time and money.”

While opting for cheaper tooling can appear to be beneficial when just starting out, before long, machinists are losing time and money because of unpredictability. Jonathan from TL Technologies echoed this point, saying:

“We feel that if we invested so much in these high-end machining centers, it would be criminal to put insufficient tooling and holders into them. We found that by selecting the proper tool with the appropriate sciences behind it we have been able to create products with a cost per cut that is not only competitive, but required to stay current. By keeping the quality as high as possible on the part making side of things, we’ve insured as much ease and reliability into our downstream process as we could. Quality tooling also provides predictability and added safety into the workflow. High-quality carbide tooling is the lifeblood of the business.”

#### Don’t Cheap Out

• “The additional cost is always worth the payoff in the end knowing that you have a tool that will produce quality parts and shave valuable minutes off your cycle times. The slightly higher cost of the Harvey/Helical product is small change compared to the long term cost savings associated with their performance” – Seth, Liberty Machine

#### Consistency is Key

• “We know the performance we are going to get from the tools is consistent, and we can always rely on getting immaculate finishes. While using the Harvey Tool and Helical product, we can confidently walk away from the machine and come back to a quality finished part every time.” – Bennett, RIT Baja SAE

#### Superior Specialty Tools

• “One of the greatest things that I’ve experienced over the past year and a half is flexibility. We’ve asked for some specific tools to be made typically, the lead times that we found were beyond what we needed. We went through the Helical specials division and had them built within a couple of weeks. That was a game changer for us.” – Tom, John Force Racing

“Having high quality tooling like Helical is essential. Helical tools help us maintain a much higher machining efficiency because of the outstanding tool life, while also achieving more aggressive run times. In addition, we are able to consistently keep high tolerances, resulting in a better final product.” – Cameron, Koenig Knives

## Tip 6: Get With the Times – Join the Social Media Community

Social media is a valuable tool for machinists. With ever-increasing popularity in networks such as Facebook, LinkedIn, Twitter, and Instagram, there will always be an audience to showcase new and unique products to. We asked a few of our featured customers how they incorporated social media into their machining and the benefits that come along with it.

“A lot of our sales come through Instagram or Facebook, so I would recommend those platforms to anyone who is trying to start a business,” Jeff from Okluma said. “We have also had a lot of success collaborating with others in the community. Typically it is something we couldn’t do ourselves, or they couldn’t do themselves, so we share the labor and collaborate on some really cool items.”

## Tip 7: Value Your Customers – Always Put Them First

“In the Loupe’s” featured customers repeatedly emphasized the importance of putting customers first. It’s a simple concept to master, and pays off immensely. Repeat customers tell you that you are doing something right, said Brian Ross, owner of Form Factory.

“We have kept our customers happy and consistently deliver parts on time, so we get a lot of repeat business. Word definitely gets around on how you treat people so we try to treat everyone with respect and honesty which is key to running a good business.” Jeff from Okluma takes great pride in his customer service, saying “we only sell direct to consumers through our website so we can control our lifetime warranty. It has worked really well for us so far, so we have no plans to change that right now. I care more about our customers than any retailer is able to.”

Image courtesy of MedTorque.

## Tip 8: Never Stop Learning – Ask Questions Whenever You Can

Hopefully some of these tips from our featured customers stuck with you. To leave you with a quote from of Seth Madore, owner of Liberty Machine, “Don’t stop learning. Keep your ears open and your mouth shut,” “That old guy in the shop has likely forgotten more than you will ever learn. The amount of tools in your Kennedy box doesn’t mean you’re a good machinist. Some of the best toolmakers I knew had small boxes with only the common tools. Learn how to excel with limited resources. Ask questions, and own up to your mistakes.”

## Harvey Performance Company Partners with SolidCAM

April 4, 2019 (Rowley, MA) – Harvey Performance Company is proud to announce a new partnership with SolidCAM, the industry leaders in integrated CAM software. SolidCAM software runs directly inside the popular SOLIDWORKS and Autodesk Inventor CAD programs, with seamless integration and full tool path associativity.

As a result of this new partnership, SolidCAM users can expect to see updated Helical Solutions tool libraries, new Harvey Tool and Micro 100 tool libraries, and more engaging technical content in the coming months. Users will see the immediate benefits of this new partnership during the upcoming Live Machining Webinar titled “The Science of Cutting” hosted by SolidCAM on April 10. This webinar will feature live machining with Helical Solutions tooling, utilizing SolidCAM’s iMachining technology. Interested viewers can register for this event here.

Key SolidCAM and Harvey Performance Company Customer Benefits:

• Harvey Performance Company tool libraries optimized for SolidCAM users
• New educational and technical content for machinists and programmers
• The opportunity for CAM and tooling companies to learn from each other, bettering the overall customer experience from tool selection to programming.

“SolidCAM and Harvey Performance Company are a great fit as partners,” said Jeff Rauseo, Senior Marketing Specialist – Strategic Partnerships & Applications, Harvey Performance Company. “We are especially excited to work with them on their iMachining technology, which utilizes many of the same High Efficiency Milling techniques and benefits that we share with our customers regularly.”

“SolidCAM is honored to embark on this partnership with Harvey Performance Company,” said Ken Merritt, Director of Partner Projects & Senior Applications Engineer, SolidCAM. “The Harvey Performance Company tooling brands are a great fit with iMachining, providing high performance chip removal that does not limit the performance of SolidCAM’s revolutionary iMachining tool path.”

SolidCAM provides a powerful, easy-to-use, integrated CAD/CAM solution that supports the complete range of major manufacturing applications, including iMachining 2D and 3D, 2.5D Milling, High Speed Surface Machining, 3D Milling/High-Speed Machining, Multi-sided Indexial 4/5 axis Milling, Simultaneous 5 axes Milling, Turning, advanced Mill-Turn including Swiss-Type CNCs and WireEDM. SolidCAM’s patented, unique revolutionary iMachining technology saves 70% in CNC machining time and more and extends tool life dramatically. The iMachining Technology Wizard provides a reliable partner in automatically determining speeds and feeds and other machining parameters. iMachining provides unbelievable savings and increased efficiency in CNC milling operations, translating into profits and success. All SolidCAM customers worldwide, who bought iMachining, are enjoying immense savings! For more information visit www.solidcam.com.

Harvey Performance Company strives to offer unique and innovative products to solve industries’ most challenging machining requirements. Its distinct brands, Harvey Tool, Helical Solutions, and Micro 100, serve specialty needs and markets with a shared commitment to delivering high quality friendly service, providing comprehensive product support, and treating customers, suppliers, and shareholders in a way that builds strategic, strong, products and superior service. The brands offer a broad range of products and services that help support machinists, engineers, and CNC programmers while giving their shops a competitive advantage. Harvey Performance has a proud history of doing business the right way – offering fast and enduring relationships. For more information visit www.harveyperformance.com.

## Harvey Performance Company Announces Partnership with Mastercam

ROWLEY, MA (November 30, 2018) – Harvey Performance Company is proud to announce a new partnership with CNC Software Inc., the developers of Mastercam software. Mastercam is a CAD/CAM software for 2-through-5-axis routing, milling and turning, 2-and-4-axis wire EDM, 2D and 3D design, surface and solid modeling, and Swiss machining

This new partnership between Harvey Performance Company’s leading cutting tool brands, Harvey Tool and Helical Solutions, and Mastercam will allow both companies to work together to share ideas that shape the future of manufacturing from both a tooling and CAM perspective. A great example of this collaboration is the new Deburring toolpath available in Mastercam 2019. Harvey Tool has many deburring tools which have been used in various tests of this new toolpath. These opportunities have given the Harvey Performance Company team additional insight into the performance of the tooling and allowed the Mastercam team to optimize this new toolpath for their users.

“I think the major benefit from both partners is bringing CAM software and cutting tool innovation closer together to generate a better user experience from the moment you start programming until the time you hit the Cycle Start button and start making chips,” says Jeff Rauseo, Senior Marketing Specialist – Strategic Partnerships & Applications, Harvey Performance Company.

Thread milling can present a machinist many challenges. While thread mills are capable of producing threads with relative ease, there are a lot of considerations that machinists must make prior to beginning the job in order to gain consistent results. To conceptualize these features and choose the right tool, machinists must first understand basic thread milling applications.

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The primary function of a thread is to form a coupling between two different mechanisms. Think of the cap on your water bottle. The cap couples with the top of the bottle in order to create a water tight seal. This coupling can transmit motion and help to obtain mechanical advantages.  Below are some important terms to know in order to understand threads.

Root – That surface of the thread which joins the flanks of adjacent thread forms and is immediately adjacent to the cylinder or cone from which the thread projects.

Flank – The flank of a thread is either surface connecting the crest with the root. The flank surface intersection with an axial plane is theoretically a straight line.

Crest – This is that surface of a thread which joins the flanks of the thread and is farthest from the cylinder or cone from which the thread projects.

Pitch – The pitch of a thread having uniform spacing is the distance measured parallelwith its axis between corresponding points on adjacent thread forms in the same axial plane and on the same side of the axis. Pitch is equal to the lead divided by the number of thread starts.

Major Diameter – On a straight thread the major diameter is that of the major cylinder.On a taper thread the major diameter at a given position on the thread axis is that of the major cone at that position.

Minor Diameter – On a straight thread the minor diameter is that of the minor cylinder. On a taper thread the minor diameter at a given position on the thread axis is that of the minor cone at that position.

Helix Angle – On a straight thread, the helix angle is the angle made by the helix of the thread and its relation to the thread axis. On a taper thread, the helix angle at a given axial position is the angle made by the conical spiral of the thread with the axis of the thread. The helix angle is the complement of the lead angle.

Depth of Thread Engagement – The depth (or height) of thread engagement between two coaxially assembled mating threads is the radial distance by which their thread forms overlap each other.

External Thread – A thread on a cylindrical or conical external surface.

Internal Thread – A thread on a cylindrical or conical internal surface.

Class of Thread – The class of a thread is an alphanumerical designation to indicate the standard grade of tolerance and allowance specified for a thread.

Source: Machinery’s Handbook 29th Edition

## Types of Threads & Their Common Applications:

ISO Metric, American UN: This thread type is used for general purposes, including for screws. Features a 60° thread form.

British Standard, Whitworth: This thread form includes a 55° thread form and is often used when a water tight seal is needed.

NPT: Meaning National Pipe Tapered, this thread, like the Whitworth Thread Form, is also internal. See the above video for an example of an NPT thread.

UNJ, MJ: This type of thread is often used in the Aerospace industry and features a radius at the root of the thread.

ACME, Trapezoidal: ACME threads are screw thread profiles that feature a trapezoidal outline, and are most commonly used for power screws.

Buttress Threads: Designed for applications that involve particularly high stresses along the thread axis in one direction. The thread angle on these threads is 45° with a perpendicular flat on the front or “load resisting face.”

Threads must hold certain tolerances, known as thread designations, in order to join together properly. International standards have been developed for threads. Below are examples of Metric, UN, and Acme Thread Designations. It is important to note that not all designations will be uniform, as some tolerances will include diameter tolerances while others will include class of fit.

M12 x 1.75 – 4h – LH

In this scenario, “M” designates a Metric Thread Designation, 12 refers to the Nominal Diameter, 1.75 is the pitch, 4h is the “Class of Fit,” and “LH” means “Left-Hand.”

¾ 10 UNC 2A LH

For this UN Thread Designation, ¾ refers to the thread’s major diameter, where 10 references the number of threads per inch. UNC stands for the thread series; and 2A means the class of thread. The “A” is used to designate external threads, while “B” is for internal threads. For these style threads, there are 6 other classes of fit; 1B, 2B, and 3B for internal threads; and 1A, 2A, and 3A for external threads.

A 1 025 20-X

For this ACME Thread Designation, A refers to “Acme,” while 1 is the number of thread starts. The basic major diameter is called out by 025 (Meaning 1/4”) while 20 is the callout for number of threads per inch. X is a placeholder for a number designating the purpose of the thread. A number 1 means it’s for a screw, while 2 means it’s for a nut, and 3 refers to a flange.

Threads are measured using go and no-go gauges. These gauges are inspection tools used to ensure the that the thread is the right size and has the correct pitch. The go gauge ensures the pitch diameter falls below the maximum requirement, while the no-go gauge verifies that the pitch diameter is above the minimum requirement. These gauges must be used carefully to ensure that the threads are not damaged.

Thread milling is the interpolation of a thread mill around or inside a workpiece to create a desired thread form on a workpiece. Multiple radial passes during milling offer good chip control. Remember, though, that thread milling needs to be performed on machines capable of moving on the X, Y, and Z axis simultaneously.

## 5 Tips for Successful Thread Milling Operations:

### 1.  Opt for a Quality Tooling Manufacturer

There is no substitute for adequate tooling. To avoid tool failure and machining mishaps, opt for a quality manufacturer for High Performance Drills for your starter holes, as well as for your thread milling solutions. Harvey Tool fully stocks several types of threadmills, including Single Form, Tri-Form, and Multi-Form Thread Milling Cutters. In addition, the 60° Double Angle Shank Cutter can be used for thread milling.

### 2. Select a Proper Cutter Diameter

Choose only a cutter diameter as large as you need. A smaller cutter diameter will help achieve higher quality threads.

### 3. Ensure You’re Comfortable with Your Tool Path

Your chosen tool path will determine left hand or right hand threads.

Right-hand internal thread milling is where cutters move counterclockwise in an upwards direction to ensure that climb milling is achieved.

Left-hand internal thread milling a left-hand thread follows in the opposite direction, from top to bottom, also in a counterclockwise path to ensure that climb milling is achieved.

### 4. Assess Number of Radial Passes Needed

In difficult applications, using more passes may be necessary to achieve desired quality. Separating the thread milling operation into several radial passes achieves a finer quality of thread and improves security against tool breakage in difficult materials. In addition, thread milling with several radial passes also improves thread tolerance due to reduced tool deflection. This gives greater security in long overhangs and unstable conditions.

### 5. Review Chip Evacuation Strategy

Are you taking the necessary steps to avoid chip recutting due to inefficient chip evacuation? If not, your thread may fall out of tolerance. Opt for a strategy that includes coolant, lubricant, and tool retractions.

## In Summary

Just looking at a threading tool can be confusing – it is sometimes hard to conceptualize how these tools are able to get the job done. But with proper understanding of call, methods, and best practices, machinists can feel confident when beginning their operation.

## Harvey Tool: Behind The Scenes

Many of our end users have had great questions about our manufacturing process, how we keep all of our tools in stock, and more. Now for the first time, we decided to open our doors and show you how we manufacture and fulfill the Harvey Tool product. We partnered with John Saunders from NYC CNC to create a “Factory Tour” video, covering topics like our CNC grinding machines and setups, tool manufacturing, and our warehouse organization and fulfillment procedures.

In the video below, we first toured our Rowley, MA warehouse and fulfillment center with Fulfillment Manager Megan Townsley. After that, we head up to Maine to check out how the Harvey Tool product is manufactured and inspected with VP of Operations Brian McKahan.

## 7 Facts Revealed in Our Factory Tour (Plus 3 More That Didn’t Make the Cut)

We know you’re busy making amazing parts, and might not have time for the entire video. To save you time, here are some of the highlights and facts you should know about Harvey Tool.

### When We Say Miniature, We Mean Miniature

Our miniature end mills are in stock in diameters down to .001″. In fact, our Stub and Standard end mills cover every diameter from .001″ to .120″, meaning we will always have you covered when it comes to micro-machining. Although it is hard to see with the naked eye, you can get an up-close look at the famed .001″ end mill by jumping to the 35 minute mark in the tour video.

### Micro-Tools Require Precision Grinding

We utilize advanced CNC grinding technology to manufacture our miniature tools at our plant in Maine. Brian MacKahan, VP of Operations, does an excellent job of breaking down our manufacturing process beginning at the 21 minute mark of the tour video. If you just want to see some miniature CNC grinding in action, jump ahead to the 26 minute mark.

### Our Inspection Process is Rigourous

All of our tools are sent through an extensive inspection process, both at our plant in Maine and at our headquarters in Massachusetts. To check out the Massachusetts inspection room, head to the 19 minute mark of the video. If you want to see some more in-depth inspection at our facility in Maine, you can jump to the 35 minute mark.

### Yes, We Have It In Stock

If you need it, we have it. All 20,000+ tools from our catalog are kept stocked and ready to ship to you the same day. If you need more proof, jump to 15:30 in the tour video, where you will see John Saunders choose a randomly selected Undercutting End Mill from our catalog and find it in our warehouse, in stock and ready to head out to a shop.

### We Maintain a 99.8% Order Accuracy Rate

Our fulfillment team handles all of your orders with precision and accuracy. We maintain a 99.8% order accuracy rate, with fulfillment team members checking every order multiple times to ensure you receive exactly what you need. You can learn more about our order fulfillment process and accuracy rates by moving to the 5 minute mark in the video.

### We Sell More Than Miniature

Miniature end mills have always been our bread and butter, but did you know that we have many larger diameter tools in stock as well? At the 9 minute mark in the video, you can see John pull out a 3/4″ Long Reach Ball Nose End Mill from our shelves. If you are interested in larger diameter specialty tooling, jump to 12:15 in the video to check out one of our large diameter Corner Rounding End Mills.

### When You Call, You’ll Always Talk to An Experienced Tech Expert

Though we didn’t catch it on tape, John Saunders was blown away by our tech team during his visit. He got a chance to pick their brains about a problem he was having and a few minutes later, he received a recommendation for the right compression cutter to tackle his unique operation. This tool was later showcased in one of his “Widget Wednesday” videos.

When you choose Harvey Tool, you will never get an automated system or countless steps before you are able to talk to a real person about your applications. Our industry-leading technical support team is available over the phones or via email every Monday-Friday from 8 AM EST to 7 PM EST. You can reach them by calling 800-645-5609, or by sending an email to [email protected].

### We Value Our Distributor Network

We value our large distributor network, and we ask that all orders are placed with your local dealer. To find the closest distributor to you, use the “Find a Distributor” tool on our website.

### We’re Hiring!

We are currently hiring for many different positions, including open CNC Machinists positions for all shifts at our manufacturing plant. If you want to be a part of the Harvey Performance Company team, check out our Opportunities page for more information.

## 5 Ways Your Shop is Inefficient

In today’s ultracompetitive industry, every machine shop seeks even the slightest edge to gain an advantage on their competition and boost their bottom line. However, what many machinists don’t know is that improving their shop’s efficiency might be easier than they thought. The following five ways your shop is inefficient will provide a clear starting point of where to look for machinists desperate to earn a competitive edge.

### 1. Premature Tool Decay / Tool Failure

If you’re finding that your tools are failing or breaking at an unacceptable rate, don’t mistake it for commonplace. It doesn’t have to be. Prolonging the life of your tooling starts with finding not just the right tool, but the best one; as well as running it in a way to get its optimal performance. Many machinists mistake premature tool failure with running parameters that were too aggressive. In fact, not pushing the tool to its full potential can actually cause it to decay at an accelerated rate in certain situations.

Tool failure can occur in many different ways: Abrasive Wear, Chipping, Thermal Cracking or Tool Fracture, just to name a few. Understanding each type and its causes can help you to quickly boost your shop’s efficiency by minimizing downtime and saving on replacement tool costs.

An example of a tool with excessive wear

For more information on tool wear, view Avoiding 4 Major Types of Tool Wear.

### 2. Subpar Part Finish

Your shop spends money to employ machinists, run machines, and buy cutting tools. Get your money’s worth, lead the industry, and ensure that you’re providing your customers with the highest quality product. Not only will this help to keep your buyer-seller relationship strong, but it will allow you the flexibility to increase your prices in the future, and will attract prospective customers.

Many factors influence part finish, including the material and its hardness, the speeds and feeds you’re running your tool at, tool deflection, and the tool-to-workpiece orientation.

### 3. Inefficient Coolant Usage

One often forgotten expense of a machine shop is coolant – and it can be pricey. A 55-gallon drum of coolant can run more than \$1,500. What’s worse is that coolant is often applied in excess of what’s required for the job. In fact, some machines even feature a Minimum Quantity Lubricant (MQL) functionality, which applies coolant as an extremely fine mist or aerosol, providing just enough coolant to perform a given operation effectively. While drowning a workpiece in coolant, known as a “Flood Coolant,” is sometimes needed, it is oftentimes utilized on jobs that would suffice with much less.

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### 4. Not Taking Advantage of Tool Versatility

Did you know that several CNC cutting tools can perform multiple operations? For example, a Chamfer Mill can chamfer, bevel, deburr, and countersink. Some Chamfer Mills can even be used as a Spotting Drill. Of course, the complexity of the job will dictate your ability to reap the benefits of a tool’s versatility. For instance, a Spotting Drill is obviously the best option for spotting a hole. If performing a simple operation, though, don’t go out of your way to buy additional tooling when what’s already in your carousel can handle it.

To learn more about versatile tools that can perform multiple applications, check out Multi-Functional Tools Every Shop Should Have.

### 5. High Machine Downtime

What use is a machine that’s not running? Minimizing machine downtime is a key way to ensure that your shop is reaching its efficiency pinnacle. This can be accomplished a variety of ways, including keeping like-parts together. This allows for a simple swap-in, swap-out of material to be machined by the same cutting tool. This saves valuable time swapping out tooling, and lets your machine to do its job for more time per workday. Production planning is a key factor to running an efficient machine shop.

## Aspex CNC – Featured Customer

Aspex CNC is a CNC machine shop based out of Poway, California. They offer prototype turning and milling, as well as production level machining. Their quick turnaround times and premium quality have garnered them some serious recognition in the manufacturing industry. Aspex CNC is just one of the four businesses that Gary Colle Jr. currently owns, but they are an essential part of his business ecosystem, creating parts for the other three product-based companies while also offering machining services to outside customers.

We talked to Gary about his unique experiences in the industry, his thoughts on 5 axis machining, his advice for trying High Efficiency Milling, and more!

## Tell us a bit about how you got started in machining, your businesses, and how Aspex CNC was formed.

It is a bit of an interesting story. I got started in manufacturing because my father designed, developed, and manufactured one of the first lines of Wheelchair Accessible Vehicle lifts, which allow people in wheelchairs to easily get in and out of their vehicles. The company was called GoldenBoy Mobility and is still one of the four business I currently own and operate today.

At a young age, I was working in my father’s shop, answering phones and doing odd jobs as young as the age of 10. When I got to high school, I worked after school and during the summers in a more hands-on position, welding parts, cutting up cars, and helping on the shop floor. This really inspired my love for metalworking at a young age.

My dad used to let me mess around in the shop at night, so I started welding my own parts and trying to learn as much as I could. One day, someone came in and asked if I could create a “tuna tower” (an accessory for wakeboarding/water skiing) for their boat. I relented at first, but eventually gave in and welded all the parts together for him. After I made that one, word got around that I could create these at night. I started to advertise a little bit locally, and people started ordering more and more. That summer, I ended up making 50 of these towers and got noticed by a couple of big distributors. Scaling up like that made it necessary to outsource some of our parts to local machine shops, which is where I discovered machining. I had very little prior knowledge of machining, but once I stepped into my first machine shop, I was blown away.

As that business grew even larger (now known as DBG Concepts), I needed more parts and needed them faster. We outgrew the local shops and purchased our first machine, a Fadal 4020 CNC Mill, from a local machine salesman, who also helped teach me the ropes. I learned a lot in those first 6 months about machining.

Business kept ramping up, and my father eventually retired and I took over GoldenBoy Mobility. With all the extra parts we needed, we kept machining things in-house, and buying more mills. Eventually, machining became an even larger part of the business than either DBG Concepts or GoldenBoy Mobility, so we formed Aspex CNC to move our machining out of the product line and more into prototype work and production machining for other business. We still machine most of the parts for DBG and GoldenBoy in-house, but we are doing much more for outside sources than we used to.

## What sort of machines do you use in your shop?

Right now, we are a Haas-only shop. We currently have eight Haas machines in our shop. Our lineup consists of a couple of lathes (ST10 and ST30), a Super Mini Mill, and five CNC Mills (VF2SS, VF2SSYT, VF4SS, VF5SS, and UMC750SS), with another UMC750 on the way!

## Which materials do you most often work with in your shop?

We work with a lot of the common materials, 6061/7075 Aluminum, 1018/1045 Steel, 303/304/17-4ph Stainless, as well as plastics like Acetal, UHMW, HDPE, and PVC.

## How has your experience been with 5 axis machining?

If you don’t keep up with technology, you won’t be able to keep up with business, so learning multi-axis machining was a no-brainer for us. We first started with a Haas HRT210 4th axis rotary, and began to play with that. Over the next two years, we learned everything we could about multi-axis machining and made the decision to upgrade to a 5 axis machine. We actually went to IMTS that year to talk to manufacturers and find the perfect machine for us and ended up sticking with Haas because of their support platform and educational resources.

5 axis can be hard, but there are a lot of tools out there (HSM Works from Autodesk being one) that can help you learn. It does require a little more upfront work and discipline, but it eliminates a lot of setup time, creates new opportunities for our shop, and has been really good for us from a business standpoint. A big part of our business is machining one-off parts, so the 5 axis machine allows for a faster turnaround time for those odd shapes and sizes we come across.

Honestly, even though it can become a bit of a distraction at times, using social media to share our work and partner up with companies like Harvey Tool and Helical has been a lot of fun. We are still young in the social media space, so we haven’t seen a massive impact yet, but the best is yet to come. We have received a few bites here and there which has led to work, but as with everything, it takes some time. We expect a lot of growth this year as we work on more really neat projects and continue to get our name out there. As we grow, the opportunities are going to come.

## What are some of the coolest projects you have ever worked on?

Unfortunately, we can’t talk about most of the work we do, due to customer confidentiality, but we did just do a project for the State of California building a training vehicle for their driver’s education program. We designed and built a dual steering system that gave the driver’s trainer a second steering wheel on the passenger side of the car to be used during training. Another job we just finished up was some parts for the new Raiders football stadium in Las Vegas. They contacted us in a pinch and needed them in two days, and we made it happen. It is pretty cool to know you played a part in a huge project like that.

Aspex CNC also does a lot of work with racing/off-road vehicle companies, often machining parts for the chassis and suspension components. We have worked on projects for companies like Scarbo Performance, ID Designs, TSCO Racing and a whole list of others.

## You can only use one machine for the rest of your life. Do you go with a CNC Milling machine or the Lathe?

I would hate to have to choose between them, but it is 100% the CNC Mill. I love ripping around with end mills and working with the 5 axis machines. It is mind blowing what these things are capable of.

## Why is manufacturing products in America important to you?

Growing up in the industry which I did while working under my father (building wheelchair accessible vehicles), we had a lot of customers who were veterans coming back from Vietnam or Desert Storm who had been injured overseas and needed extra accommodations, which we could provide for them. The veterans I have worked with made me so patriotic with their stories and courage. We also get to work on a lot of projects with the US Department of Veteran’s Affairs, which is putting money back into the American economy by supporting companies like ours and contracting us to make these vehicles. It only makes sense that we employ more people here and avoid sending things overseas to support those who have supported us.

## Do you utilize High Efficiency Milling (HEM) techniques in your shop? What advice do you have for those who are getting started with HEM?

Absolutely, all the time!

The biggest thing is listening to your tool manufacturer for recommendations and then cut those in half to start. From there, work your way up until you are comfortable. Just because the tool can handle it doesn’t necessarily mean your machine, work holding and or set up can, so I would advise people to walk before you run when it comes to HEM.

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

Be conservative and establish good habits from the start. You can get more aggressive as your career starts to take off, but don’t run out and try to run the biggest and baddest machines on day one and try to cut corners. You need to learn what is behind machining; you can get easily lost in all the technology that is available, but you need to understand the core science behind it first. Take it slow, because if you go too fast, you might miss something important along the way.

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

The best thing is building relationships with companies like Haas, Harvey Tool, and Helical. Not only do they provide great service and support for you, but it quickly becomes a mutually beneficial relationship. As we give feedback to the tool and machine manufacturers, and even our metal supplier, it helps them improve their products, which in turn allows our shop to increase our production and efficiency.

Also, having a good team with good people makes all the difference. No matter how many machines you have and how automated you get, you still need good people on your side. I would put my guys up against any other machine shop out there in terms of skill, and it is a big part of what has made our business so successful.

Would you like to be considered for a future “Featured Customer” blog? Click here to submit your information.

## Optimize Roughing With Chipbreaker Tooling

Chipbreaker End Mills feature unique notch profiles, creating a serrated cutting edge. These dividers break otherwise long, stringy chips into small, easily-managed swarf that can be cleanly evacuated from the part. But why is a chipbreaker necessary for some jobs, and not others? How does the geometry of this unique tool impact its proper running parameters? In this post, we’ll answer these questions and others to discover the very real benefits of this unique cutting geometry.

## How Chipbreaker Tooling Works

As a tool rotates and its cutting edge impacts a workpiece, material is sheared off from a part, creating chips. When that cutting process is interrupted, as is the case with breaks in the cutting portion of the tool, chips become smaller in length and are thus easier to evacuate. Because the chipbreakers are offset flute-to-flute, a proper, flat surface finish is achieved as each flute cleans up any excess material left behind from previously passed flutes.

## Benefits of Chipbreaker Tooling

### Machining Efficiency

When chips are removed from the part, they begin to pile in the machine. For extensive operations, where a great deal of material is hogged out, chip accumulation can very rapidly get in the way of the spindle or part. With larger chips, accumulation occurs much faster, leaving machinists to stop their machine regularly to remove the waste. As any machinist knows, a stopped machine equates to lost money.

### Prolonged Tool Life

Inefficient chip evacuation can lead to chip recutting, or when the the tool impacts and cuts chips left behind during the machining process. This adds stresses on the tool and accelerates rate of wear on the cutting edge. Chipbreaker tooling creates small chips that are easily evacuated from a part, thus minimizing the risk of recutting.

### Accelerated Running Parameters

A Harvey Performance Company Application Engineer recently observed the power of a chipbreaker tool firsthand while visiting a customer’s shop in Minnesota. The customer was roughing a great amount of 4340 Steel. Running at the parameters below, the tool was able to run uninterrupted for two hours!

 Helical Part No. 33737 Material 4340 Steel ADOC 2.545″ RDOC .125″ Speed 2,800 RPM Feed 78 IPM Material Removal Rate 24.8 Cubic In/Min

## Chipbreaker Product Offering

Chipbreaker geometry is well suited for materials that leave a long chip. Materials that produce a powdery chip, such as graphite, should not be machined with a chipbreaker tool, as chip evacuation would not be a concern. Helical Solutions’ line of chipbreaker tooling includes a 3-flute option for aluminum and non-ferrous materials, and its reduced neck counterpart. Additionally, Helical offers a 4-flute rougher with chipbreaker geometry for high-temp alloys and titanium. Harvey Tool’s expansive product offering includes a composite cutting end mill with chipbreaker geometry.

## In Summary

Chipbreaker geometry, or grooves within the cutting face of the tool, break down chips into small, manageable pieces during the machining process. This geometry can boost shop efficiency by minimizing machine downtime to clear large chips from the machining center, improve tool life by minimizing cutting forces exerted on the tool during machining, and allow for more accelerated running parameters.