Tag Archive for: high speed machining

TOMI Engineering INC – Featured Customer

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Featured Image Courtesy of TOMI Engineering

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

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

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

How was TOMI Engineering INC started?

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

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

What machines are you currently using in your shop?

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

Tomi Engineering CNC mill
Photo Courtesy of: TOMI Engineering

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

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

Where did your passion for machining start?

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

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

machined part from Tomi Engineering
Photo Courtesy of: TOMI Engineering

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

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

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

Why is high quality tool performance important to you?

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

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

machined part from Tomi Engineering
Photo Courtesy of: TOMI Engineering

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

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

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

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

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

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

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

Titan Ring Design – Featured Customer

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Featured Image Courtesy of Trevor Hirschi, Titan Ring Design

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
Photo Courtesy of: Trevor Hirschi, 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
Photo Courtesy of: Trevor Hirschi, 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
Photo Courtesy of: Trevor Hirschi, Titan Ring Design

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
Photo Courtesy of: Trevor Hirschi, 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
Photo Courtesy of: Trevor Hirschi, 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
Photo Courtesy of: Trevor Hirschi, Titan Ring Design

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

KAD Models – Featured Customer

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Featured Image Courtesy of KAD Models

Established in 2012, KAD Models is a small, yet steadily growing prototype machine shop, which originated in the San Francisco Bay Area and has since opened its second location in Vermont. They have been a regional leader in the advanced manufacturing space for many years, and operate in close connection with other machine shops and related businesses like turning facilities, anodizers, welders, and more. KAD Models staff is comprised of diverse occupational backgrounds (e.g. mechanic, industrial engineer, blacksmith, etc.). Further, they have invested into their local community college and technical training programs to support an expanding talent pipeline for advanced manufacturing.

Brian Kippen is the owner & founder of KAD Models & Prototypes, Inc. Before launching KAD with model maker John Dove, Brian worked as the Director of Operations at A&J Product Solutions and a machinist at Performance Structures. Brian is drawn to the challenge of making design concepts into reality, and motivated by the ever-changing landscape of machining. Brian took time to speak with us about KAD Models, his experiences, machining techniques, and so much more.

KAD Models cnc machining a custom part
Photo Courtesy of: KAD Models

Can you give us a little background on how KAD Models was started?

I worked for a few years repairing automobiles, then following high school, I attended college for about three weeks. After some strong encouragement from my mom, I moved out west. I joined the Marines, broke both of my feet, and was honorably discharged. Then, I got my broken foot in the door at a machine shop and knew what I wanted to be when I grew up. After years of working as a machinist, I went into business with one of my previous employers. After a year and a half, the partnership degraded and I made the decision to buy out my partner.

It’s been really gratifying to see the business grow and get to know different types of customers as the shop’s reputation spreads. One of the reasons I wanted to start my own shop is that I really wanted to see the industry evolve in a new way, to better meet people’s needs. It’s been really great to see that decision and the investments I’ve made in building KAD pay off.

We produce approximately $1.5M of parts for 100+ distinct clients each year.  Since its founding in 2012, KAD has continued on a steady path of growth, adding staff, equipment, and clients without marketing or advertising. We build a broad range of products such as automotive drive axles, silicone cardiovascular valves, and fully functional consumer product models. Due to the nature of prototyping, no component is outside of the realm of possibility. 

What machines are currently in your shop?

We use Haas CNC machines. At our West coast facility, we have six machines, five vertical 4 AXIS machining centers with capacities up to 26” Y AND 50” X and one 5 AXIS universal machining center. At our East coast facility, we currently have two new CNC ONE 3 AXIS and one 5 AXIS universal machining center paired with a Trinity Automation AX5 robotic cell. I decided to get a 5 axis milling machine earlier last year because I felt we should invest before the absolute necessity arose. I’m excited about the creative options it opened up and it’s been fun to put it to good use. We are currently using both Fusion 360 and Surfcam software.

What sets KAD Models apart from the competition?

Our quick turnaround time of 3-5 days with our ability to tackle very complex parts sets KAD apart from a majority of manufacturers.

I also think our willingness to really dig in with the client and get to know what they need and why. We have a really creative team here at KAD and thrive at not only building complex parts, but helping industrial designers and engineers think through manufacturing, design, and usage requirements to build the simplest, most effective product we can. I’ve created prototypes before, just from a conversation with someone – not even a CAD drawing. It’s these types of interesting challenges that made me want to be a machinist in the first place and that keeps me engaged and excited day-to-day.

end mill machining metal
Photo Courtesy of: KAD Models

KAD Models is an innovative company. Can you speak about what innovations KAD makes?

Well, KAD works with some of the most innovative companies out there, across all kinds of industries: medical devices, aerospace, automotive, and consumer electronics. We help people at the forefront of innovation bring their ideas to life, so I’d say innovation is basically our bread and butter. As far as our innovations in process, as I said before, KAD has a really creative team. Since we are well known for prototyping and since prototype manufacturing need not follow all the common work holding rules, we break them on a daily basis.

What is your favorite part of your job?

I love the challenge of taking on seemingly impossible ideas and turning them into tangible things. I’m really satisfied when I can come home after a long day and have held the things I’ve made in my hands. I’m also really proud to be a business owner. It’s incredibly rewarding to see a team you’ve taught and grown to take on and be inspired by the same types of problems as you. It’s been really cool to see what we’ve been able to accomplish for our clients. My personal passion remains automotive.  KAD has reverse-engineered many no longer available automobile components and designed parts that upgrade vintage Datsuns.

assortment of prototype parts made by Kad Models
Photo Courtesy of: KAD Models

Why is high-quality tooling important to you?

In prototyping, you often get one chance in order to make deadlines. High quality and high-performance tools allow you to get this done without question. Given 95% of our tooling is either Helical or Harvey, I would say that high-quality tooling helps us out on a daily basis. We also use High Efficiency Milling (HEM) techniques, which Helical is optimized for. We find with long cutters and with deep pockets, HEM is almost a must.  Often though, on shallow areas, it’s overkill.  As with salt, there can be too much. 

cnc machined metal wine rack
Photo Courtesy of: KAD Models

If you could give one piece of advice to a new machinist what would it be?

Fail fast and fail often. Then learn from your mistakes. 

I think the biggest thing is getting to know other machinists, learning other methods, and being open to alternative ideas. It’s important to keep your mind open because there’s always more than one way to machine something. One of the things I’ve found most rewarding about running my own shop is getting to set the tone of how we work with other shops and adjacent industries. I’m really passionate about the manufacturing community as a whole and I’m glad blogs like this exist to help draw connections amongst us.

Also, don’t be afraid to challenge the status quo. I love working with new machinists because they bring different ideas to the table. That’s really important for innovation and to keep us all moving forward.

Feel free to check them out at www.kadmodels.com or on Instagram @kadmodels or stop by their west coast shop in California or new east coast location in Vermont.

Harvey Performance Company Joins High Speed Machining Roadshow

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Updated March 30, 2020 – All In-Person Events Postponed, Join The Webinar on April 7th

Due to the current coronavirus (COVID-19) pandemic, and in an effort to maintain the safety and health of all employees and attendees, all in-person High Speed Machining events have been postponed until further notice. We hope to reschedule these events in the future.

In the meantime, we are offering the event in a virtual webinar setting on April 7th. Interested users can register here: https://micromachine.fusion360.events-autodesk.com/ 

Harvey Performance Company is excited to announce that we have partnered with Air Turbine Spindles, Autodesk, and 5th Axis Workholding on a series of nationwide events focused on high speed machining with miniature tooling from our Harvey Tool brand. This “High Speed Machining Roadshow” will be stopping at different machine tool suppliers across the US, ranging from Connecticut and Ohio to Arizona and California.

Each event will feature live high speed, micro machining demos at spindle speeds up to 65,000 RPM, and in-depth technical presentations to help unlock the mystery behind high speed machining. A free lunch will be provided for all in attendance, and there will be many opportunities to network with local CNC machinists, programmers, and engineers. Attendees will also have access to Application Engineers from all of the industry participants, including Harvey Performance Company, to help discuss difficult applications, troubleshoot current projects, and develop new, valuable relationships with local experts.

“We receive questions from our customers on a daily basis, and many are about micro machining with high RPMs,” said Jeff Rauseo, Manager of Digital Marketing, Harvey Performance Company. “We hope that by participating in these events, we can ease some of the fears that come with using miniature tooling and help enable successful micromachining projects in shops nationwide.”

A current list of dates and locations for these events can be seen here. More events and locations may be added at a later date, so stay tuned for updates from Air Turbine Spindles and Harvey Performance Company.

If you have any questions, please reach out to Tony Gunn at Air Turbine Spindles or visit their website for more information.

high speed machining

5 Things to Know About Helical’s High Feed End Mills

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Helical Solutions‘ High Feed End Mills provide many opportunities for machinists, and feature a special end profile to increase machining efficiencies. A High Feed End Mill is a High Efficiency Milling (HEM) style tool with specialized end geometry that utilizes chip thinning, allowing for drastically increased feed rates in certain applications. While standard end mills have square, corner radius, or ball profiles, this Helical tool has a specialized, very specific design that takes advantage of chip thinning, resulting in a tool that can be pushed harder than a traditional end mill.

Below are 5 things that all machinists should know about this exciting Helical Solutions product offering.

1. They excel in applications with light axial depths of cut

A High Feed End Mill is designed to take a large radial depth of cut (65% to 100% of the cutter diameter) with a small axial depth of cut (2.5% to 5% diameter) depending on the application. This makes them perfect for face milling, roughing, slotting, deep pocketing, and 3D milling. Where HEM toolpaths involve light radial depths of cut and heavy axial depths of cut, these utilize high radial depths of cut and smaller axial depths of cut.

2. This tool reduces radial cutting forces

The end profile of this tool is designed to direct cutting forces upward along the axis of the tool and into the spindle. This reduces radial cutting forces which cause deflection, allowing for longer reach tools while reducing chatter and other issues that may otherwise lead to tool failure. The reduction of radial cutting forces makes this tool excellent for use in machines with lower horsepower, and in thin wall machining applications.

3. High Feed End Mills are rigid tools

The design and short length of cut of these end mills work in tandem with the end geometry to produce a tool with a strong core, further limiting deflection and allowing for tools with greater reach lengths.

Push Harder in HEM With Helical Solutions’ High Feed End Mills

4. They can reduce cycle times

In high RDOC, low ADOC applications, these tools can be pushed significantly faster than traditional end mills, saving time and money over the life of the tool.

5. High Feed End Mills are well suited for hard materials

The rigidity and strength of High Feed End Mills make them excellent in challenging to machine materials. Helical’s High Feed End Mills come coated with Tplus coating, which offers high hardness and extended tool life in high temp alloys and ferrous materials up to 45Rc.

In summary, these tools with specialized end geometry that utilizes chip thinning and light axial depths of cut to allow for significantly increased feed rates in face milling, slotting, roughing, deep pocket milling, and 3D milling applications. The end profile of a High Feed End Mill applies cutting forces back up into the spindle, reducing radial forces that lead to deflection in long reach applications. Combining this end geometry with a stubby length of cut results in a tool that is incredibly rigid and well suited for harder, difficult to machine materials.

Machining Advisor Pro Updated With New Improvements

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

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

The new improvements to MAP include:

Improved Speed and Feed Sliders (Desktop)

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

machining advisor pro

Locking Depths of Cut

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

Machining Advisor Pro Update

Enhanced Summary Section (Mobile)

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

Machining Advisor Pro Mobile

Smoother User Experience

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

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

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

Open in MAP from HelicalTool.com

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

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

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

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

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

High Efficiency Milling for Titanium Made Easy With Helical’s New HVTI Cutter

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Titanium is a notoriously difficult material to machine, especially in aggressive toolpaths, such as those associated with High Efficiency Milling (HEM). Helical Solutions’ new line of tooling, the HVTI-6 series of end mills for titanium, is optimized specifically for this purpose, and proven to provide 20% more tool life than a competitor’s similar tool.

At face level, these new Helical end mills for titanium feature corner radius geometry, 6 flutes, and are Aplus coated for optimal tool life and increased cutting performance. But there is much more to these end mills than the typical geometry of standard 6 flute tools. The HVTI-6 was designed with a combination of a unique rake, core, and edge design that give it a leg up over standard 6 flute tools for milling titanium while cutting HEM toolpaths. Click here to watch the HVTI-6 in action!

End Mills for Titanium

The design of the HVTI-6 was the result of significant testing by the Harvey Performance Company Innovation and New Product Development teams. These teams spent many months testing tools, doing in-depth analysis on materials and tool geometry, and pushing these tools through dozens of hours in the cut at testing sites across the country.

The new HVTI-6 cutter experienced higher metal removal rates (MRR) and 20% longer tool life while performing HEM in Titanium when compared to a standard 6 flute tool offered by a Helical Solutions competitor. This type of tool life improvement will produce huge cost savings on tooling, as well as shortened cycle times and lower cost per part.

Helical HVTI Titanium

The Harvey Performance Innovation team targeted Titanium grade Ti6Al4V for their testing, which accounts for the vast majority of the Titanium being machined in North America. The test part was designed and programmed to allow for a more defined agility test of the tool, taking the tool into key geometry cutting exercises like tight corners, long straight line cuts, and rapid movement.

Many hours were spent with Lyndex-Nikken, manufacturers of high-quality rotary tables, tool holders, and machining accessories, at their Chicago headquarters. By working with the team at Lyndex-Nikken, the Harvey Performance Company team was able to test under optimal conditions with top-of-the-line tool holders, work holding, and machining centers. Lyndex was also available to provide their expert support on tool holding techniques and were an integral part of the testing process for these tools. Video of the impressive test cuts taken at the Lyndex facility can be seen below.

WATCH THE HVTI IN ACTION

In these tests, the HVTI end mills for titanium was able to run HEM toolpaths at 400 SFM and 120 IPM in Ti6Al4V, which served as the baseline for most of the testing.

While the standard 6 flute tools offered by Helical will still perform to high standards in Titanium and other hard materials (steels, exotic metals, cast iron), the HVTI-6 is a specialized, material-specific tool designed specifically for HEM toolpaths in Titanium. Advanced speeds and feeds for these new tools are already available in Machining Advisor Pro, and the complete offering is now available in the Helical CAM tool libraries for easy programming.

To learn more about the HVTI 6 Flute End Mills for Titanium, please visit the Helical Solutions website. To learn more about HEM techniques, download the HEM Guidebook for a complete guide on this advanced toolpath.

How to Extend the Life of Your End Mill

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Breaking and damaging an end mill is oftentimes an avoidable mistake that can be extremely costly for a machine shop. To save time, money, and your end mill it is important to learn some simple tips and tricks to extend tool life.

Properly Prepare Before the Tool Selection Process

The first step of any machining job is selecting the correct end mill for your material and application. However, this doesn’t mean that there should not be an adequate amount of legwork done beforehand to ensure the right decision on a tool is being made. Harvey Tool and Helical Solutions have thousands of different tools for different operations – a vast selection which, if unprepared – can easily result in selecting a tool that’s not the best for your job. To start your preparation, answer the 5 Questions to Ask Before Selecting an End Mill to help you quickly narrow down your selection and better understand the perfect tool you require.

Understand Your Tooling Requirements

It’s important to understand not only what your tool needs, but also general best practices to avoid common machining mishaps. For instance, it is important to use a tool with a length of cut only as long as needed, as the longer a tools length of cut is, the greater the chance of deflection or tool bending, which can decrease its effective life.

tool life

Another factor to consider is the coating composition on a tool. Harvey Tool and Helical Solutions offer many varieties of coatings for different materials. Some coatings increase lubricity, slowing tool wear, while others increase the hardness and abrasion resistance of the tool. Not all coatings increase your tool’s life in every material, however. Be wary of coatings that don’t perform well in your part’s material – such as the use of AlTiN coating in Aluminum (Both coating and material are aluminum-based and have a high affinity for each other, which can cause built-up edge and result in chip evacuation problems).

Consider Variable Helix & Pitch Geometry

A feature on many of our high performance end mills is variable helix or variable pitch geometry, which have differently-spaced flutes. As the tool cuts, there are different time intervals between the cutting edges contacting the workpiece, rather than simultaneously on each rotation. The varying time intervals minimizes chatter by reducing harmonics, increasing tool life and producing better results.

Ensure an Effective Tool Holding Strategy

Another factor in prolonging tool life is proper tool holding. A poor tool holding strategy can cause runout, pullout, and scrapped parts. Generally, the most secure connection has more points of contact between the tool holder and tool shank. Hydraulic and Shrink Fit Tool Holders provide increased performance over other tightening methods.

tool life

Helical also offers shank modifications to all stocked standards and special quotes, such as the ToughGRIP Shank, which provides added friction between the holder and the shank of the tool for a more secure grip; and the Haimer Safe-Lock™, which has grooves on the shank of the tool to help lock it into place in a tool holder.

helical end mill

Trust Your Running Parameters, and their Source

After selecting the correct end mill for your job, the next step is to run the tool at the proper speeds and feeds.

Run at the Correct Speed

Understanding the ideal speed to run your machine is key to prolonging tool life. If you run your tool too fast, it can cause suboptimal chip size, ineffective chip evacuation, or even total tool failure. Adversely, running your tool too slowly can result in deflection, bad finish, or decreased metal removal rates.

Push at the Best Feed Rate

Another critical parameter of speeds and feeds is finding the best possible feed rate for your job, for sake of both tool life and achieving maximum shop efficiency. Pushing your tool too aggressively can result in breakage, but being too conservative can lead to recutting chips and excess heat generation, accelerating tool wear.

Use Parameters from Your Tooling Manufacturer

A manufacturer’s speeds and feeds calculations take into account every tool dimension, even those not called out in a catalog and readily available to machinists. Because of this, it’s best to rely on running parameters from tooling manufacturers. Harvey Tool offers speeds and feeds charts for every one of its more than 21,000 tools featured in its catalog, helping machinists to confidently run their tool the first time.

Harvey Performance Company offers the Machining Advisor Pro application, a free, cutting-edge resource that generates custom running parameters for optimized machining with all of Helical’s products.

tool life

Opt for the Right Milling Strategy: Climb vs Conventional

There are two ways to cut material when milling: Climb Milling and Conventional Milling. In conventional milling, the cutter rotates against the feed. In this method, chips will start at theoretical zero and increase in size. Conventional milling is usually recommended for tools with higher toughness, or for breaking through case hardened materials.

In Climb Milling, the cutter rotates with the feed. Here, the chips start at maximum width and decrease, causing the heat generated to transfer into the chip instead of being left in the tool or work piece. Climb milling also produces a cleaner shear plane, causing less rubbing, decreasing heat, and improving tool life. When climb milling, chips will be removed behind the cutter, reducing your chances of recutting.

Utilize High Efficiency Milling

High Efficiency Milling (HEM), is a roughing technique that uses the theory of chip thinning by applying a smaller radial depth of cut (RDOC) and a larger axial depth of cut (ADOC). The parameters for HEM are similar to that of finishing, but with increased speeds and feeds, allowing for higher material removal rates (MRR). HEM utilizes the full length of cut instead of just a portion of the cutter, allowing heat to be distributed across the cutting edge, maximizing tool life and productivity. This reduces the possibility of accelerated tool wear and breakage.

Decide On Coolant Usage & Delivery

Coolant can be an extremely effective way to protect your tool from premature wear and possible tool breakage. There are many different types of coolant and methods of delivery to your tool. Coolant can come in the form of compressed air, water-based, straight oil-based, soluble oil-based, synthetic or semi-synthetic. It can be delivered as mist, flood, high pressure or minimum quantity lubricant.

Appropriate coolant type and delivery vary depending on your application and tool. For example, using a high pressure coolant with miniature tooling can lead to tool breakage due to the fragile nature of extremely small tools. In applications of materials that are soft and gummy, flood coolant washes away the long stringy chips to help avoid recutting and built-up edge, preventing extra tool wear.

Extend Your Tool’s Life

The ability to maximize tool life saves you time, money and headaches. To get the best possible outcome from your tool, you first need to be sure you’re using the best tool for your job. Once you find your tool, ensure that your speeds and feeds are accurate and are from your tooling manufacturer. Nobody knows the tools better than they do. Finally, think about how to run your tool: the rotation of your cutter, whether utilizing an HEM approach is best, and how to introduce coolant to your job.

Effective Ways to Reduce Heat Generation

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Any cutting tool application will generate heat, but knowing how to counteract it will improve the life of your tool. Heat can be good and doesn’t need to totally be avoided, but controlling heat will help prolong your tool life. Sometimes, an overheating tool or workpiece is easy to spot due to smoke or deformation. Other times, the signs are not as obvious. Taking every precaution possible to redirect heat will prolong your tool’s usable life, avoid scrapped parts, and will result in significant cost savings.

Reduce Heat Generation with HEM Tool Paths

High Efficiency Milling (HEM), is one way a machinist should explore to manage heat generation during machining. HEM is a roughing technique that uses the theory of chip thinning by applying a smaller radial depth of cut (RDOC) and a larger axial depth of cut (ADOC). HEM uses RDOC and ADOC similar to finishing operations but increases speeds and feeds, resulting in greater material removal rates (MRR). This technique is usually used for removing large amounts of material in roughing and pocketing applications. HEM utilizes the full length of cut and more effectively uses the full potential of the tool, optimizing tool life and productivity. You will need to take more radial passes on your workpiece, but using HEM will evenly spread heat across the whole cutting edge of your tool, instead of building heat along one small portion, reducing the possibility of tool failure and breakage.

heat generation in HEM

Chip Thinning Awareness

Chip thinning occurs when tool paths include varying radial depths of cut, and relates to chip thickness and feed per tooth. HEM is based off of the principal of chip thinning. However, if not properly executed, chip thinning can cause a lot of heat generation. When performing HEM, you effectively reduce your stepover and increase your speeds and feeds to run your machine at high rates. But if your machine isn’t capable of running high enough speeds and feeds, or you do not adjust accordingly to your reduced stepover, trouble will occur in the form of rubbing between the material and tool. Rubbing creates friction and mass amounts of heat which can cause your material to deform and your tool to overheat. Chip thinning can be good when used correctly in HEM, but if you fall below the line of reduced stepover without higher speeds and feeds, you will cause rubbing and tool failure. Because of this, it’s always important to be aware of your chips during machining.

heat generation in HEM

Consider Climb Milling

There are two ways to cut materials when milling: conventional milling and climb milling. The difference between the two is the relationship of the rotation of the cutter to the direction of feed. In climb milling, the cutter rotates with the feed, as opposed to conventional milling where the cutter rotates against the feed.

When conventional milling, chips start at theoretical zero and increase in size, causing rubbing and potentially work hardening. For this reason, it’s usually recommended for tools with higher toughness or for breaking through case hardened materials.

In climb milling, the chip starts at maximum width and decreases, causing the heat generated to transfer into the chip instead of the tool or workpiece. When going from max width to theoretical zero, heat will be transferred to the chip and pushed away from the workpiece, reducing the possibility of damage to the workpiece. Climb milling also produces a cleaner shear plane which will cause less tool rubbing, decreasing heat and improving tool life. When climb milling, chips are removed behind the cutter, reducing your chances of re-cutting. climb milling effectively reduces heat generated to the tool and workpiece by transferring heat into the chip, reducing rubbing and by reducing your chances of re-cutting chips.

heat generation

Utilize Proper Coolant Methods

If used properly, coolant can be an extremely effective way to keep your tool from excessive heat generation. There are many different types of coolant and different ways coolant can be delivered to your tool. Coolant can be compressed air, water-based, straight oil-based, soluble oil-based, synthetic or semi-synthetic. It can be delivered as mist, flood, high pressure or minimum quantity lubricant.

Different applications and tools require different types and delivery of coolant, as using the wrong delivery or type could lead to part or tool damage. For instance, using high pressure coolant with miniature tooling could lead to tool breakage. In materials where chip evacuation is a major pain point such as aluminum, coolant is often used to flush chips away from the workpiece, rather than for heat moderation. When cutting material that produces long, stringy chips without coolant, you run the risk of creating built-up edge from the chips evacuating improperly. Using coolant will allow those chips to slide out of your toolpath easily, avoiding the chance of re-cutting and causing tool failure. In materials like titanium that don’t transfer heat well, proper coolant usage can prevent the material from overheating. With certain materials, however, thermal shock becomes an issue. This is when coolant is delivered to a very hot material and decreases its temperature rapidly, impacting the material’s properties. Coolant can be expensive and wasteful if not necessary for the application, so it’s important to always make sure you know the proper ways to use coolant before starting a job.

Importance of Controlling Heat Generation

Heat can be a tool’s worst nightmare if you do not know how to control it. High efficiency milling will distribute heat throughout the whole tool instead of one small portion, making it less likely for your tool to overheat and fail. By keeping RDOC constant throughout your toolpath, you will decrease the chances of rubbing, a common cause of heat generation. Climb milling is the most effective way to transfer heat into the chip, as it will reduce rubbing and lessen the chance of re-chipping. This will effectively prolong tool life. Coolant is another method for keeping temperatures moderated, but should be used with caution as the type of coolant delivery and certain material properties can impact its effectiveness.

Get to Know Machining Advisor Pro

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Machining Advisor Pro (MAP) is a tool to quickly, seamlessly, and accurately deliver recommended running parameters to machinists using Helical Solutions end mills. This download-free and mobile-friendly application takes into account a user’s machine, tool path, set-up, and material to offer tailored, specific speeds and feed parameters to the tools they are using.

How to Begin With Machining Advisor Pro

This section will provide a detailed breakdown of Machining Advisor Pro, moving along step-by-step throughout the entire process of determining your tailored running parameters.

Register Quickly on Desktop or Mobile

To begin with Machining Advisor Pro, start by accessing its web page on the Harvey Performance Company website, or use the mobile version by downloading the application from the App Store or Google Play.

Whether you are using Machining Advisor Pro from the web or your mobile device, machinists must first create an account. The registration process will only need to be done once before you will be able to log into Machining Advisor Pro on both the mobile and web applications immediately.

machining advisor pro

Simply Activate Your Account

The final step in the registration process is to activate your account. To do this, simply click the activation link in the email that was sent to the email address used when registering. If you do not see the email in your inbox, we recommend checking your spam folders or company email filters. From here, you’re able to begin using MAP.

Using Machining Advisor Pro

A user’s experience will be different depending on whether they’re using the web or mobile application. For instance, after logging in, users on the web application will view a single page that contains the Tool, Material, Operation, Machine, Parameter, and Recommendation sections.

machining advisor pro

On the mobile application, however, the “Input Specs” section is immediately visible. This is a summary of the Tool, Material, Operation, and Machine sections that allow a user to review and access any section. Return to this screen at any point by clicking on the gear icon in the bottom left of the screen.

machining advisor pro

Identify Your Helical Tool

To get started generating your running parameters, specify the Helical Solutions tool that you are using. This can be done by entering the tool number into the “Tool #” input field (highlighted in red below). As you type the tool number, MAP will filter through Helical’s 4,800-plus tools to begin identifying the specific tool you are looking for.

machining advisor pro

Once the tool is selected, the “Tool Details” section will populate the information that is specific to the chosen tool. This information will include the type of tool chosen, its unit of measure, profile, and other key dimensional attributes.

Select the Material You’re Working In

Once your tool information is imported, the material you’re working in will need to be specified. To access this screen on the mobile application, either swipe your screen to the left or click on the “Material” tab seen at the bottom of the screen. You will move from screen to screen across each step in the mobile application by using the same method.

In this section, there are more than 300 specific material grades and conditions available to users. The first dropdown menu will allow you to specify the material you are working in. Then, you can choose the subgroup of that material that is most applicable to your application. In some cases, you will also need to choose a material condition. For example, you can select from “T4” or “T6” condition for 6061 Aluminum.

Machining Advisor Pro provides optimized feeds and speeds that are specific to your application, so it is important that the condition of your material is selected.

Pick an Operation

The next section of MAP allows the user to define their specific operation. In this section, you will define the tool path strategy that will be used in this application. This can be done by either selecting the tool path from the dropdown menu or clicking on “Tool Path Info” for a visual breakdown and more information on each available toolpath.

Tailor Parameters to Your Machine’s Capabilities

The final section on mobile, and the fourth web section, is the machine section. This is where a user can define the attributes of the machine that you are using. This will include the Max RPM, Max IPM, Spindle, Holder, and work holding security. Running Parameters will adjust based on your responses.

Access Machining Advisor Pro Parameters

Once the Tool, Material, Operation, and Machine sections are populated there will be enough information to generate the initial parameters, speed, and feed. To access these on the mobile app, either swipe left when on the machine tab or tap on the “Output” tab on the bottom menu.

Please note that these are only initial values. Machining Advisor Pro gives you the ability to alter the stick out, axial depth of cut, and radial depth of cut to match the specific application. These changes can either be made by entering the exact numeric value, the % of cutter diameter, or by altering the slider bars. You are now able to lock RDOC or ADOC while adjusting the other depth of cut, allowing for more customization when developing parameters.

machining advisor pro

The parameters section also offers a visual representation of the portion of the tool that will be engaged with the materials as well as the Tool Engagement Angle.

MAP’s Recommendations

At this point, you can now review the recommended feeds and speeds that Machining Advisor Pro suggests based on the information you have input. These optimized running parameters can then be further refined by altering the speed and feed percentages.

machining advisor pro recommendation

Machining Advisor Pro recommendations can be saved by clicking on the PDF button that is found in the recommendation section on both the web and mobile platforms. This will automatically generate a PDF of the recommendations, allowing you to print, email, or share with others.

Machining Advisor Pro Summarized

The final section, exclusive to the mobile application, is the “Summary” section. To access this section, first tap on the checkmark icon in the bottom menu. This will open a section that is similar to the “Input Specs” section, which will give you a summary of the total parameter outputs. If anything needs to change, you can easily jump to each output item by tapping on the section you need to adjust.

machining advisor pro mobile

This is also where you would go to reset the application to clear all of the inputs and start a new setup. On the web version, this button is found in the upper right-hand corner and looks like a “refresh” icon on a web browser.

Contact Us

For the mobile application, we have implemented an in-app messaging service. This was done to give the user a tool to easily communicate any question they have about the application from within the app. It allows the user to not only send messages, but to also include screenshots of what they are seeing! This can be accessed by clicking on the “Contact Us” option in the same hamburger menu that the Logout and Help & Tips are found.

Click this link to sign up today!