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Machining Advisor Pro Updated With New Improvements

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

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

The new improvements to MAP include:

Improved Speed and Feed Sliders (Desktop)

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

machining advisor pro

Locking Depths of Cut

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

Machining Advisor Pro Update

Enhanced Summary Section (Mobile)

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

Machining Advisor Pro Mobile

Smoother User Experience

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

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

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

Open in MAP from HelicalTool.com

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

Helical Machining Advisor Pro


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

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

At face level, these new Helical end mills 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 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 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.

John Force Racing – Featured Customer

John Force Racing has been dominating the motorsports world for over 30 years, winning 20 championships and hundreds of races in the National Hot Rod Association (NHRA) drag racing series. John Force Racing features both Funny Car and Top Fuel teams, and just recently in 2017 they won both the Funny Car and Top Fuel championships in the same season.

John Force Racing invested in Force American Made to develop and create parts and components that would help drive all the teams to success and safety. The 84,000 square foot shop is located in Brownsburg, Indiana (just outside of Indianapolis) and is the heartbeat of John Force Racing. Thousands of parts are forged by Force American Made and its team of employees every season giving the team a competitive edge that has led to the team’s on-track success.

The Force American Made team has relied on Helical Solutions tooling to get the best performance and quality out of their CNC mills for years. The Harvey Performance Company team was invited out to Indiana to take a tour of Force American Made and spend some time with Tom Warga, Lead Machinist, to talk with him about his experiences with Helical Solutions tooling, his first time trying Machining Advisor Pro, the success they have had using the new Helical tool libraries for Mastercam, and the value their distributor, Dolen Tool, brings to the shop. Check out the video interview below to see the inner-workings of Force American Made and how Helical Solutions tooling has contributed to the success of this motorsports dynasty.

Okluma – Featured Customer

Okluma is a small manufacturing business located in Oklahoma City focused primarily on creating high-quality flashlights that can stand up to the most extreme conditions. The company was founded in early 2015 out of owner Jeff Sapp’s garage, and has quickly gained a solid reputation as one of the best-built and most reliable flashlights on the market today.

We were able to steal a few moments of Jeff’s time to interview him for this Featured Customer post, where he shared his thoughts on topics like the importance of customer service, the reason to use higher quality tooling, and his transition into the world of CNC machining.

To get started, how did you first get involved in manufacturing?

In high school I actually worked in a machine shop. This is where I got my first exposure to big machines and manufacturing. I worked at the shop until I graduated, doing simple things like sweeping the floor and running errands. The work wasn’t very exciting, but it did give me some really good exposure to the world of machining. Every now and then one of the machinists would let me help out with a part, but that would be rare. I did manage to save up enough money to buy a small mill and lathe, which I took with me when I went off to college.

During college and after graduation, I made a living by writing software, which I did successfully for 15 years. Eventually I got tired of writing software after I had spent more than a decade in that space, and I wanted to try something new. I had picked up small jobs and worked on personal projects over the years, so I decided to enroll in a machine shop school in Oklahoma City to learn more about manufacturing and becoming a machinist, and graduated from there with a renewed sense of what I wanted to do. Technical schools are a great way to pick up new skills and advance your career. The manufacturing technology program at the Francis Tuttle Technology Center here in Oklahoma City was great and the instructors there, Dean and Julia, are talented and very patient people.

okluma

Did your background in writing software help you transition into CNC programming?

Absolutely. It was a tremendous help to understand some very strange programming concepts that came with writing software, and it all translated very well into CNC programming. These days, CNC machinists and programmers need to be as knowledgeable about the software and programs as they do the tools and parts, so having a background in software programming or development certainly translates well to the world of CNC machines.

Where did the idea to start Okluma stem from?

After graduation from the machine shop program, I took a few weeks off and went on a long, off-road motorcycle trip 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 there was 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 4, then 20. That was 4 years ago. Now I have my own business with one employee and two dogs, and we stay very busy.

okluma

What does your current product offering look like?

For our products, I currently have two flashlights models (the DC1 and DC2) and we are working on some cool new projects for 2019. With battery and LED technology advancing like it has, there are some interesting applications, way beyond just flashlights, that haven’t been possible until recently. Stay tuned for more information on those by following us on Instagram.

What do you think separates an Okluma flashlight from the competition?

The basic values behind Okluma all stem from me simply wanting a nice tool that won’t break easily and will be supported by the manufacturer. I offer a lifetime warranty and stand firmly behind that. I want an Okluma flashlight to last forever so you will never have to buy another flashlight.

The quality and hardiness of a flashlight is important to many outdoors types, homeowners, and collectors, but we also sell lots of our flashlights to the military and police. If their light goes out in a tough situation it could be really bad, so we have to make sure our flashlights can be dependable above all else. Like they always say, you get what you pay for. Our flashlights aren’t going to be the cheapest, but we stand behind them with our warranty and pride ourselves on the quality and reliability.

okluma

What sort of machines and software do you have in the shop?

Right now I have the old standards like a Bridgeport mill and an old LeBlond lathe, as well as my CNC machines – a Daewoo Lynx 220LC CNC Lathe and a Doosan DNM 4500 CNC Mill.

For software, I use Autodesk Fusion 360 for the mill, and I write the G-code by hand for the lathe. I was more familiar with the lathe, so I had an easier time writing my own code for it. Getting Fusion 360 for my milling has been a huge help.

Have you been using the Harvey Tool and Helical Solutions tool libraries in Fusion 360?

Yes! The tool library in Fusion 360 was a huge help for me. To be able to get the right tool and not model things incorrectly probably saved me a lot of broken tools. That was a big reason why I came to Harvey Tool and Helical for support in the first place.

It was cool to come from the software community, where we collaborated on a lot of open-source projects, and see companies like Autodesk opening up their software to manufacturers like Harvey Tool and Helical for these great partnerships.

What sort of operations/parts do you create on the lathe versus the mills?

As you can imagine (being a cylindrical shaped part) most of the flashlight manufacturing is done on the lathe. For a while I had been making them all by hand, until we got the CNC lathe. While most of the work is done on the lathe, for the more intense pieces we have to drill and tap and do some different slotting operations. We also drill and tap the clip holes for all of the flashlights, so the CNC mill is huge for those operations.

As Okluma started to grow, we realized that we had a huge bottleneck doing our secondary operations by hand on the manual milling machine. We solved that problem by buying the Doosan mill to help with secondary operations, but you still have to know how to use it to make it worth the purchase!

I was completely in the dark on the CNC milling side of things at that time, as I was much more familiar with the lathe. I actually called Harvey Tool with a few questions, and the Harvey Tech team really held my hand and walked me through all of the things I needed to know, which was huge. I also used the Machining Advisor Pro application to generate speeds and feeds for my Helical end mills. MAP helped save me a lot of broken end mills and increased my production times.

okluma

You are using almost exclusively Harvey Tool and Helical for milling operations on your Doosan VMC. Why is purchasing quality tooling important to you?

I can try to do things on my own and eventually get it, but it costs me money on broken tools and it costs me my time, which is even more valuable. I could go that route with any number of different tooling manufacturers, but the fact that I can call Harvey or Helical and get an answer to my questions the first time, usually in a few minutes, and know it will work is hugely helpful. I don’t really look at the cost of the tools so much, because I just know they work and I know I will get the support I need to make my milling operations a success.

Can you remember a crucial moment when Harvey Tool or Helical technical support helped you to be more productive?

As we try to get more creative with our designs, we plan to rely heavily on Harvey and Helical to explore some of these new applications. We actually build our own tool to work on the flashlights, and we are using Harvey and Helical exclusively to machine that. At first, I was making the tools in two operations; I was doing a radius on top and then flipping the part over to create a radius on the bottom. I was having a hard time lining it up. We moved the second radius on the first operation, and used an undercutting tool and everything matched up perfect. I wasn’t really sure how to do it, but I called you guys and you figured it out with me! We have some cool projects coming up which we are planning to rely on Helical tools for, but people will have to stay tuned for that one!

okluma

What have been some of your keys to success for your growing sales?

Good customer service is key. We are one of the few companies that will offer a lifetime warranty. I know there are a lot of flashlight collectors, and we can make fun stuff for those guys, but I want people to really use our flashlights and scratch them and do ridiculous things with them. We have had people use a flashlights in crazy ways (like as a hammer) but we will still fix them under our lifetime warranty. I don’t really care what people do to our flashlights, I just want them to always work.

We can also overnight replacement flashlights for professionals who rely on them for work, so they never have to be without one. That is huge for our customers in the military or in law enforcement who rely on our flashlights as an essential tool in their day-to-day lives.

Do you have plans to expand into retailers, either online or brick and mortar stores?

We only sell direct to consumers right now through our website so that 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.

I’ve noticed that you have gathered a rather large social media following. How has social media helped shape your business?

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. We have also had a lot of success collaborating with others in the EDC (Every Day Carry) community where makers are creating knives, wallets, keychains; anything you would carry on you “every day”, hence the name. We have collaborated to make flashlights out of other people’s materials, let other shops refinish our flashlights, and things of that nature. 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.

I think social media is especially great for manufacturing because a lot of younger people don’t even know all this crazy cool stuff that is going on in the industry. I was lucky enough to see it first hand at a young age, but so many others never get the chance. It is awesome to share our work and try to inspire some of the younger generation to make their own products and participate in the world of manufacturing.

okluma


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

How to Extend the Life of Your End Mill

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

Properly Prepare Before the Tool Selection Process

The first step of any 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.

tool life

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.

 

Get to Know Machining Advisor Pro

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 MAP

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.

 

 

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.

 

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.

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 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.

 

 

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!

B&R Custom Machining- Featured Customer

B&R Custom Machining is a rapidly expanding aerospace machine shop located in Ontario, Canada, focused primarily on aerospace and military/defense manufacturing. Over the past 17 years, B&R has grown from a 5 person shop with a few manual mills and lathes, into one of Canada’s most highly respected manufacturing facilities, with nearly 40 employees and 21 precision CNC machines.

B&R focuses on quality assurance and constant improvement, mastering the intimacies of metal cutting and maintaining the highest levels of quality through their unique shop management philosophies. They seek to consistently execute on clear contracts through accurate delivery, competitive price, and high quality machined components.

We talked with Brad Jantzi, Co-Founder and Technical Manager of B&R Custom Machining, to learn about how he started in the industry, his experience with High Efficiency Milling, what he looks for most in a cutting tool, and more!

B&R Custom machining

Can you tell us a little bit about how B&R Custom Machining started, and a little background about yourself and the company?

My brother (Ryan Jantzi, CEO/Co-Founder) and I started working in manufacturing back in 2001, when we were just 20/21 years old. We had 5 employees (including ourselves), a few manual mills and lathes, and we were wrapping our parts in newspaper for shipping. We took over from a preexisting shop and assumed their sales and machines.

We bought our first CNC machine in 2003, and immediately recognized the power of CNC and the opportunities it could open up for us. Now, we have 21 CNC machines, 38 employees, and more requests for work than we can keep up with, which is a good thing for the business. We are constantly expanding our team to elevate the business and take on even more work, and are currently hiring for multiple positions if anyone in Ontario is looking for some challenging and rewarding work!

What kind of CNC machines are you guys working with?

Right now we have a lot of Okuma and Matsuura machines, many of which have 5 axis capabilities, and all of them with high RPM spindles. In fact, our “slowest” machine runs at 15k RPM, with our fastest running at 46k. One of our high production machines is our Matsuura LX160, which has the 46k RPM spindle. We use a ton of Harvey Tool and Helical product on that machine and really get to utilize the RPMs.

B&R Custom Machining

What sort of material are you cutting?

We work with Aluminum predominantly, but also with a lot of super alloys like Invar, Kovar, Inconel, Custom 455 Stainless, and lots of Titanium. Some of those super alloys are really tricky stuff to machine. Once we learn about them and study them, we keep a recorded database of information to help us dial in parameters. Our head programmer/part planner keeps track of all that information, and our staff will frequently reference old jobs for new parts.

Sounds like a great system you guys have in place. How did B&R Custom Machining get into aerospace manufacturing?

It is a bit of a funny story actually. Just about 12 years ago we were contacted by someone working at Comdev, which is close to our shop, who was looking to have some parts made. We started a business relationship with him, and made him his parts. He was happy with the work, and so we eventually got involved in his company’s switch division and started to make more and more aerospace parts.

aerospace machining

We immediately saw the potential of aerospace manufacturing, and it promoted where we wanted to go with CNC machining, so it was a natural fit. It really was a case of being in the right place at the right time and seizing the moment. If an opportunity comes up and you aren’t ready for it, you miss it. You have to be hungry enough to see an opportunity, and confident enough to grab it, while also being competent enough to handle the request. So, we took advantage of what we were given, and we grew and went from there.

Who are some of the major players who you work with?

We have great relationships with Honeywell, MDA Brampton, and MDA Quebec. We actually worked on parts for a Mars Rover with MDA that was commissioned by the Canadian Space Agency, which was really cool to be a part of.

Working with large companies like that means quality is key. Why is high quality tool performance important to you?

High quality and superior tool performance is huge. Aside from cutting conditions, there are two quick things that cause poor performance on a tool: tool life and consistency of the tool quality. One without the other means nothing. We all can measure tool life pretty readily, and there is a clear advantage that some tools have over others, but inconsistent quality can sneak up on you and cause trouble. If you have a tool manufacturer that is only producing a quality tool even 95% of the time, that might seem ok, but that means that 5% of the time you suffer something wrong on the machine. Many times, you won’t know where that trouble is coming from. This causes you to pause the machine, investigate, source the problem, and then ultimately switch the tool and create a new program. It becomes an ordeal. Sometimes it is not as simple as manually adjusting the feed knob, especially when you need to rely on it as a “proven program” the next time around.

So, say the probability of a shortcoming on a machine is “x” with one brand of tooling, but is half of that with a brand like Harvey Tool. Sure, the Harvey Tool product might be 10-20% higher in upfront cost, but that pales in comparison to buying cheaper tools and losing time and money due to machine downtime caused by tool failure. The shop rate for an average machine is right around $100/hour, so machine downtime is much more expensive than the added cost of a quality tool.

B&R Custom machining

Inconsistent tool quality can be extremely dangerous to play around with, even outside of machine downtime. We create based on a specific tool and a certain level of expected performance. If that tool cannot be consistent, we now jeopardize an expensive part. The machine never went down, but the part is no good because we programmed based on consistency in tool quality. Again, the cost of scrapped parts heavily outweighs the upfront cost of quality tooling. Tooling is a low cost of what we do here, but poor tooling can cost us thousands versus a few dollars more for quality tools. Too many people focus on the upfront cost, and don’t look downstream through the rest of the process to see how poor quality tooling can affect your business in a much bigger way. We get to see the whole picture because I am involved from cradle to grave, gaining feedback and knowledge along the way.

That’s great feedback Brad, and I think it is important for people to understand what you have laid out here. Speaking of tool performance, have you guys been using High Efficiency Milling techniques in the shop?

Absolutely. We feel that we are on the front edge of efficient milling. We are quite capable of all the latest techniques, as our programmers are well-versed and up to date. For our larger production work, we have programs dialed in that allow us to push the tools to their limits and significantly cut down our cycle times.

What advice would you have for others who are interested in High Efficiency Milling?

Make sure you are smart about using HEM. If we have one-off parts, particularly expensive ones, that do not have time restraints, we want to make sure we have a safe toolpath that will get us the result we want (in terms of quality and cutting security), rather than pushing the thresholds and taking extra time to program the HEM toolpaths. HEM makes total sense for large production runs, but make sure you know when to, and when not to use these techniques to get the most out of HEM.

B&R Custom machining

Have you been using Machining Advisor Pro in your shop when you run Helical end mills?

We have been, and it makes for a great point of reference for the Helical end mills. It has become a part of our new employee training, teaching them about speeds and feeds, how hard they can push the Helical tools, and where the safe zones are. Our more experienced guys also frequent it for new situations where they have no data. Machining Advisor Pro helps to verify what we thought we knew, or helps us get the confidence to start planning for a new job.

If you could give one piece of advice to a new machinist, or someone looking to take the #PlungeIntoMachining for the first time, what would it be?

Learn the intimacies of metal cutting. Get ultra-familiar with the results of what is actually happening with your tool, your setup, your part, and your machine. As well, don’t be limited to thinking “it sounds good,” or “it’s going good so far, so that must be acceptable.” In order to push the tools and confirm they are performing well and making money, you need to identify and understand where the threshold of failure is, and back off the right amount. This doesn’t end here though. Cutting conditions change as the tools, holders, machines, and parts change. Learning the nuances of this fluctuating environment and adapting accordingly is essential. Verify your dimensions, mitigate against risk, and control the variables.

Also, get intimate with what causes tools to succeed and fail, and keep a log of it for reference. Develop a passion for cutting; don’t just punch in and punch out each shift. Here at B&R, we are looking for continuous improvement, and employees who can add value. Don’t stand around all day with your arms folded, but keep constant logs of what’s going on and always be learning and thinking of how to understand what is happening, and improve on it. That is what makes a great machinist, and a successful shop.

B&R custom machining

University of Michigan Formula SAE Racing Team – Featured Customer

Formula SAE is a student design competition that began in 1980. The competition was founded by the SAE (Society of Automotive Engineers) branch at the University of Texas. Each year, hundreds of universities across the world spend months designing and manufacturing their best Formula style car before putting them to the test in competitions.

Alex Marshalek is the Team Captain of the University of Michigan’s Formula SAE team, MRacing. The team was originally founded in 1986, and has been very successful over the years. In the 2017 season, they finished 5th at the Formula SAE Michigan event, and took home a 1st place finish at Formula North. They are hoping to continue riding that momentum into another successful season in 2018.

Mracing

Alex reached out to Harvey Tool and Helical earlier this year, and after some conversation, the decision was made to sponsor their team’s efforts by supplying cutting tools and providing technical support. With competitions on the horizon and a new build coming over the summer, Alex was kind enough to find some time to talk with us about his experiences as a student learning the ropes in engineering, manufacturing, and design, the importance of quality tooling and maintaining a superior part finish for competition, and challenges he has faced during this process.

Hi Alex. Thanks for taking the time to talk with us today. When you were looking into college degree programs, what initially interested you in manufacturing and engineering?

I have always had an interest in Aerospace Engineering, but it was nothing more than a personal interest until I started college. My high school unfortunately did not have any machine shop or manufacturing type classes, so a lot of what I knew, I learned from my dad. My dad worked as a Mechanical Engineer at an axle manufacturing company, and he used to always be doing things around the house and showing me the basics of engineering and design.

When it came time to choose a school, I knew that Michigan had an impressive Aerospace Engineering department, and I liked the feel of the campus and community better than other schools I had toured.

How did you first get involved with the Formula SAE team?

I knew going into school that I wanted to get involved in a design team and advance my learning in that way. We have about a dozen different design teams at Michigan, but the Formula SAE team really stood out to me as a really cool project to get involved in.

I started with the team in Fall of 2016, helping out with the design and manufacturing of the vehicle’s suspension. Now, for the upcoming 2018 season, I am taking over the role of Team Captain. There will be a little bit less hands-on design and manufacturing work for me as it is more of an administrative/outreach role.

michigan racing

How does a typical FSAE season run?

So FSAE seasons are constantly running, and nearly overlapping with each other. For example, we are currently finishing up competitions from the 2018 season, but at the same time we are beginning the design of the vehicle for the 2019 season. Typically, the design work is done over the summer, and finalized in October. After that, the major manufacturing begins and lasts until about March, with spare parts and additions being added as we go. Testing begins in March, where we fine tune the vehicle and optimize the design for performance. Then, the rest of the Spring and early Summer is competition time, and the process starts all over again!

What sort of machines do you have in the shop?

Right now, we have three manual Bridgeport mills, two retro-fit CNC Bridgeport mills, 2 manual lathes, 1 retro-fit CNC lathe, and a Haas VF-2SS and Haas SL-20. For the vast majority of what we are machining, we are using the Haas. We do most of our work in Aluminum, with some parts made out of steel or titanium, and the Haas has been great for everything.

We are also using AutoDesk’s Fusion 360 software for our CAD/CAM, and we love it.

What has been the most difficult part of the build?

Time is really the biggest challenge. We are all full-time students, so time is already hard to find, but we also don’t have an overabundance of machinists so the operators can get overburdened. It all works out in the end and our machinists are great, but time management is truly the biggest challenge.

michigan formula sae

The composite materials we work with are also very challenging to machine. We constructed the vehicle’s monocoque (the structural “skin”, often seen in Formula One cars) out of carbon fiber. While we cut a lot of it on the water jet machine, we needed more precise holes than a water jet could offer, so we went to the Haas for that. We were using HSS drills and only getting 10-12 holes at a time before they wore out. However, we had Don Grandt (Harvey Performance Company Application Engineer) stop in the shop and he sent us a few Harvey Tool diamond coated drills, which should make this a much faster and more precise process!

You mentioned Don stopped in to give you guys a visit. What were some of your biggest takeaways?

Don was great. He stopped by and we gave him a tour of the facility and showed off some of the parts we were designing. We talked shop for quite a bit, and he gave us a bunch of great tips and tricks we could use to really optimize our machining. As I mentioned, he also went through the catalogs with us and helped us find exactly what we need for tooling. The Harvey Tool diamond coated drills are going to be a life saver for carbon fiber. I guess the biggest takeaway was just all of the knowledge we received from Don and how helpful that was to have someone direct from the tooling manufacturer sharing everything we knew with us.

Now that you have the Harvey and Helical tools in the shop, how have they helped you complete this project and get a leg up on your competition?

One of the most impressive things for us have been the finishing end mills we received. The Helical finishers for Aluminum are giving us some of the best finishes we have ever seen. For us, that is a point of pride. We not only want to have the fastest and most well-designed vehicle, but we also want to have the best looking parts. Subpar finishes reflect poorly on the entire build, and first impressions mean a lot in these competitions.

We have also been blown away by the Chipbreaker roughers. We absolutely love those tools and push them to the limits with great results. In fact, the first time we ran them, we used Machining Advisor Pro to dial in our speeds and feeds, and the numbers seemed insane to us. We were nervous, but we pushed the button and let it run. It was amazing to see that we could push a tool that fast without tool failure.

How has your experience been using Machining Advisor Pro?

We use Machining Advisor Pro every time we picked up the Helical end mills. MAP was actually one of the main reasons we were looking for Helical to sponsor us. We had heard a lot about MAP and your level of technical support, which was important to us as we are learning more about manufacturing and machining. Machining Advisor Pro has quickly become one of our best learning tools in the shop.

The nice thing about MAP is that is takes a look at all of the parameters. A lot of applications only give you numbers on your speeds and feeds, but MAP takes a look at the depth of cut, chip thinning, engagement angle, and all of the other parameters that are so essential to a successful run. As a result, we have been able to get very aggressive with the end mills. We are not a huge production shop, so cycle times are not as important, but we still want to get the most out of our tools in the least amount of possible time.

So, let’s break down some specs. What are you all working with on this year’s build?

Right now our car features a 4 cylinder Honda 600 CBR engine, with a Turbo and 600cc displacement. We are one of the few teams that run a turbo in competition. As we mentioned, the monocoque is completely carbon fiber, and the car features a full aero package with an undertray. The max speed is around 80 MPH, and the car weighs 420 pounds without the driver.

Once the build is complete, how does a typical competition work?

Most of the Formula SAE competitions are multi-day events, with a few static events, and then dynamic events where the car is running. For static events, we first have a Design portion. We validate and argue for our design in front of judges who are engineers in the industry. Then, we get into a Cost presentation, as one of the goals is to build the cheapest possible car with a high level of performance. That balance of cost vs. performance is a critical part of the build. The last static event is a Business presentation, where we introduce a business/manufacturing plan on how to get this design to a production level of 100 units in a year.

For the dynamic events, we have 4 different tests. First, we have the Accel Run, which is a 75 meter sprint, and the fastest cars win. From there we go to the Skip Pad event, which is centered on turning radius and the stiffness of the chassis as we do tight figure eight turns with the car.

University of Michigan FSAE

Then we have the AutoCross, a one lap race, which determines our placement in the final event; Endurance. For the Endurance event, we drive the cars around a 22km track, and the goal is to finish the race without any mechanical or design failures in the quickest time possible. Only around 50% of participants actually complete this event. If a single part falls off, or breaks, you are disqualified. Many times we see things like the suspension, powertrain, or wings falling off. It is disappointing when it happens, but it allows us to easily identify any flaws and fix them for the next event.

What is next for you after school? Any future plans or goals?

I am currently majoring in Aerospace Engineering, and would like to stay within that industry. I am leaning towards working on aircraft. Designing either aircraft structures or the aerodynamics would be very cool. I really like the size and scale of working on commercial aircraft, but I could see myself doing something more specialty like working in Defense as well.


Alex and his team had a very successful 2018 season. They recently placed 9th overall in a competition at the Michigan International Speedway. In the dynamic events, they placed 4th in Skidpad, and 7th in Autocross. The high placement in the Autocross event allowed them to race head to head against top teams in the world, and they ended up placing 4th in Endurance out of 104 cars!

The MRacing team also competed at Formula North, a competition in Ontario, Canada, where they achieved a top ranking of 2nd place overall. They passed all of the technical inspections on the first try and placed 1st in Acceleration, 2nd in Skidpad and Endurance, 3rd in Autocross, and 4th in Efficiency.

michigan fsae

Slaying Stainless Steel: Machining Guide

Stainless steel can be as common as Aluminum in many shops, especially when manufacturing parts for the aerospace and automotive industries. It is a fairly versatile material with many different alloys and grades which can accommodate a wide variety of applications. However, it is also one of the most difficult to machine. Stainless steels are notorious end mill assassins, so dialing in your speeds and feeds and selecting the proper tool is essential for machining success.

Material Properties

Stainless steels are high-alloy steels with superior corrosion resistance to carbon and low-alloy steels. This is largely due to their high chromium content, with most grades of stainless steel alloys containing at least 10% of the element.

Stainless steel can be broken out into one of five categories: Austenitic, Ferritic, Martensitic, Precipitation Hardened (PH), and Duplex. In each category, there is one basic, general purpose alloy. From there, small changes in composition are made to the base in order to create specific properties for various applications.

For reference, here are the properties of each of these groupings, as well as a few examples of the popular grades and their common uses.

Category Properties Popular Grades Common Uses
Austenitic Non-magnetic, outstanding corrosion and heat resistance. 304, 316 Food processing equipment, gutters, bolts, nuts, and other fasteners.
Ferritic Magnetic, lower corrosion and heat resistance than Austenitic. 430, 446 Automotive parts and kitchen appliances.
Martensitic Magnetic, moderate corrosion resistance – not for severe corrosion. 416, 420, 440 Knives, firearms, surgical instruments, and hand tools.
Precipitation Hardened (PH) Strongest grade, heat treatable, severe corrosion resistance. 17-4 PH, 15-5 PH Aerospace components.
Duplex Stronger mixture of both Austenitic and Ferritic. 244, 2304, 2507 Water treatment plants, pressure vessels.

Tool Selection

Choosing the correct tooling for your application is crucial when machining stainless steel. Roughing, finishing, slotting, and high efficiency milling toolpaths can all be optimized for stainless steel by choosing the correct style of end mill.

Traditional Roughing

For traditional roughing, a 4 or 5 flute end mill is recommended. 5 flute end mills will allow for higher feed rates than their 4 flute counterparts, but either style would work well for roughing applications. Below is an excellent example of traditional roughing in 17-4 Stainless Steel.

 

 

Slotting

For slotting in stainless steel, chip evacuation is going to be key. For this reason, 4 flute tools are the best choice because the lower flute count allows for more efficient chip evacuation. Tools with chipbreaker geometry also make for effective slotting in stainless steel, as the smaller chips are easier to evacuate from the cut.

stainless steel machining

Finishing

When finishing stainless steel parts, a high flute count and/or high helix is required for the best results. Finishing end mills for stainless steel will have a helix angle over 40 degrees, and a flute count of 5 or more. For more aggressive finishing toolpaths, flute count can range from 7 flutes to as high as 14. Below is a great example of a finishing run in 17-4 Stainless Steel.

 

High Efficiency Milling

High Efficiency Milling can be a very effective machining technique in stainless steels if the correct tools are selected. Chipbreaker roughers would make an excellent choice, in either 5 or 7 flute styles, while standard 5-7 flute, variable pitch end mills can also perform well in HEM toolpaths.

stainless steel

HEV-5

Helical Solutions offers the HEV-5 end mill, which is an extremely versatile tool for a variety of applications. The HEV-5 excels in finishing and HEM toolpaths, and also performs well above average in slotting and traditional roughing. Available in square, corner radius, and long reach styles, this well-rounded tool is an excellent choice to kickstart your tool crib and optimize it for stainless steel machining.

stainless steel machining

Running Parameters

While tool selection is a critical step to more effective machining, dialing in the proper running parameters is equally important. There are many factors that go into determining the running parameters for stainless steel machining, but there are some general guidelines to follow as a starting point.

Generally speaking, when machining stainless steels a SFM of between 100-350 is recommended, with a chip load ranging between .0005” for a 1/8” end mill up to .006” for a 1” end mill. A full breakdown of these general guidelines is available here.

Machining Advisor Pro

Machining Advisor Pro is a cutting edge resource designed to precisely calculate running parameters for high performance Helical Solutions end mills in materials like stainless steel, aluminum, and much more. Simply input your tool, your exact material grade, and machine setup and Machining Advisor Pro will generate fully customizable running parameters. This free resource allows you to push your tools harder, faster, and smarter to truly dominate the competition.

In Conclusion

Stainless steel machining doesn’t have to be hard. By identifying the proper material grade for each part, selecting the perfect cutting tool, and optimizing running parameters, stainless steel machining headaches can be a thing of the past.

Contouring Considerations

What is Contouring?

Contouring a part means creating a fine finish on an irregular or uneven surface. Dissimilar to finishing a flat or even part, contouring involves the finishing of a rounded, curved, or otherwise uniquely shaped part.

Contouring & 5-Axis Machining

5-axis machines are particularly suitable for contouring applications. Because contouring involves the finishing of an intricate or unique part, the multiple axes of movement in play with 5-axis Machining allow for the tool to access tough-to-reach areas, as well as follow intricate tool paths.

 Recent Contouring Advances

Advanced CAM software can now write the G-Code (the step-by-step program needed to create a finished part) for a machinists application, which has drastically simplified contouring applications. Simply, rather than spend several hours writing the code for an application, the software now handles this step. Despite these advances, most young machinists are still required to write their own G-Codes early on in their careers to gain valuable familiarity with the machines and their abilities. CAM software, for many, is a luxury earned with time.

Benefits of Advanced CAM Software

1. Increased Time Savings
Because contouring requires very specific tooling movements and rapidly changing cutting parameters, ridding machinists of the burden of writing their own complex code can save valuable prep time and reduce machining downtime.

2. Reduced Cycle Times
Generated G-Codes can cut several minutes off of a cycle time by removing redundancies within the application. Rather than contouring an area of the part that does not require it, or has been machined already, the CAM Software locates the very specific areas that require machining time and attention to maximize efficiency.

3. Improved Consistency
CAM Programs that are packaged with CAD Software such as SolidWorks are typically the best in terms of consistency and ability to handle complex designs. While the CAD Software helps a machinist generate the part, the CAM Program tells a machine how to make it.

Contouring Tips

Utilize Proper Cut Depths

Prior to running a contouring operation, an initial roughing cut is taken to remove material in steps on the Z-axis so to leave a limited amount of material for the final contouring pass. In this step, it’s pivotal to leave the right amount of material for contouring — too much material for the contouring pass can result in poor surface finish or a damaged part or tool, while too little material can lead to prolonged cycle time, decreased productivity and a sub par end result.

The contouring application should remove from .010″ to 25% of the tool’s cutter diameter. During contouring, it’s possible for the feeds to decrease while speeds increases, leading to a much smoother finish. It is also important to keep in mind that throughout the finishing cut, the amount of engagement between the tool’s cutting edge and the part will vary regularly – even within a single pass.

Use Best Suited Tooling

Ideal tool selection for contouring operations begins by choosing the proper profile of the tool. A large radius or ball profile is very often used for this operation because it does not leave as much evidence of a tool path. Rather, they effectively smooth the material along the face of the part. Undercutting End Mills, also known as lollipop cutters, have spherical ball profiles that make them excellent choices for contouring applications. Harvey Tool’s 300° Reduced Shank Undercutting End Mill, for example, features a high flute count to benefit part finish for light cut depths, while maintaining the ability to reach tough areas of the front or back side of a part.

Fact-Check G-Code

While advanced CAM Software will create the G-Code for an application, saving a machinist valuable time and money, accuracy of this code is still vitally important to the overall outcome of the final product. Machinists must look for issues such as wrong tool call out, rapids that come too close to the material, or even offsets that need correcting. Failure to look G-Code over prior to beginning machining can result in catastrophic machine failure and hundreds of thousands of dollars worth of damage.

Inserting an M01 – or a notation to the machine in the G-Code to stop and await machinist approval before moving on to the next step – can help a machinist to ensure that everything is approved with a next phase of an operation, or if any redundancy is set to occur, prior to continuation.

Contouring Summarized

Contouring is most often used in 5-axis machines as a finishing operation for uniquely shaped or intricate parts. After an initial roughing pass, the contouring operation – done most often with Undercutting End Mills or Ball End Mills, removes anywhere from .010″ to 25% of the cutter diameter in material from the part to ensure proper part specifications are met and a fine finish is achieved. During contouring, cut only at recommended depths, ensure that G-Code is correct, and use tooling best suited for this operation.