As more applications require the use of super-hard alloys, manufacturers are demanding tooling that can deliver precision threads and high production in less time. To meet these challenges, Carmex Precision Tools Ltd. has engineered carbide grade HBA — an extra-fine, submicron grade with high toughness for optimized performance on hardened steel and cast iron up to 62 HRc, as well as Titanium and super alloys including Hastelloy, Inconel and Nickel base alloys.
Available for internal and external threading in both 60° and 55° partial profile, as well as ISO metric and UN, HBA delivers high wear and heat resistance and excellent edge stability. The unique combination of carbide substrate, coating type and edge conditions provide superior performance over extended tool life.
In a recent test involving an external right-hand thread: M32 x 1.5 and a length of 65 mm in hardened steel D2: 53-56 HRc, a 16 ER 1.5 ISO grade HBA insert operated at 45 m/min at 28 passes produced 36 threads per corner.
Hard machining is increasingly becoming the rule rather than the exception in complex part production. Carmex HBA was engineered to meet the challenges inherent in threading hard materials while delivering high production and longer tool life. We invite our customers and others to bring us their most challenging applications and discover the benefits of engineered carbide performance.
If you have any questions, please feel free to contact us at email@example.com and we will help you any threading application.
Have you ever wanted to upgrade your optical comparator to something newer and with more options?
Fowler Precision Tools has something to share with you that may help you take your current optical comparator from the stone age to something more digital and user friendly. Take a look at the following video's and see what Fowler has to share. You will find 3 YouTube video's below with a solution for shop's to upgrade some of their older optical comparator's.
If you have any questions, please feel free to contact us at firstname.lastname@example.org and we will help you get started in the right direction to upgrading your older equipment.
YG-1 Tool Co.'s V7PlusA series of end mills features four-flute and six-flute models.
YG-1 Tool Co. will display the V7PlusA series of end mills, which features four- and six-flute models, and the Titanox series, which offers four- and five-flute models that provide better performance in heavy cutting, trochoidal milling and fine finishing, according to the company.
The six-flute models from the V7PlusA series offer improved cutting geometry, making them more applicable to trochoidal and peel milling. For heavier cuts, the four-flute models provide variable-helix and unequal pitch design, which helps to eliminate vibration.
New Product Post - 6/26/2018. Edited by Patrick Barney, Editorial Assistant. Article in Modern Machine Shop.
Inspection Arsenal from Phillips Precision is a lean quick-swap fixture system designed to enhance the value of Fowler's new zCAT portable DCC CMM.
New for the zCAT, a custom base was designed with four locations that accept Loc-N-Load quick-swap fixture plates. Two bundled configurations are available that include 6" x 6" and 6" x 12" fixture plates, a specially designed removable qualifying ball plate and a versatile angle plate. Also included is a workholding kit versatile enough to hold most any part.
"The Loc-N-Load fixture system enhances the easy `teach and repeat' mode that sets the zCAT apart," said a company spokesperson. "Once programmed, the zCAT takes over, ensuring precise, repeatable results as many times as necessary." By fixturing on quick-swap plates, inspectors can change parts without building and breaking down set-ups. Several unique parts can be set up or multiples of the same part fixtured and programs repeated. Affordable plates can be dedicated and kept with the job box for fast, repeatable set-ups.
"These two products offer similar benefits," said the spokesperson. "They are an affordable solution for companies just starting out with automated inspection or for those wanting to complement existing CMMs. Both Inspection Arsenal and zCat help to break inspection bottlenecks with a short learning curve and by speeding inspections on the shop floor - inspections that can be conducted by anyone." Inspection Arsenal also offers companies an opportunity to standardize across all CMMs with its full line of interlocking fixture plates and non-marring workholding.
YG-1 Technical Center is located in Charlotte, North Carolina was established in 2014 with charge for the develop, produce, test and demonstrate high performance tooling for the most demanding manufacture customers in the north American market.
Contact us for more details.
NTK's industry leading line of ceramic cutting tools is expanding with new solid ceramic end mills. It's time to upgrade from carbide to this unique "SX9" SiAlON end mill which increases productivity more than 10 times over traditional end mills when machining Heat Resistant Super Alloy (HRSA) materials. NTK's durable SX9 grade can run at speeds of 2000 SFM. The line-up includes 4 and 6 flutes in inch and metric versions.
Designed for internal threading and grooving applications, the Carmex Modular Line (ML) uses a single boring bar that can be fitted with multiple adapters offering high accuracy, easy adjustment and full repeatability. Coated with abrasive-resistant nickel, the ML adapters can be used with all Carmex standard thread turning inserts sizes 16, 22 and 27 mm. The 16 mm grooving inserts fit the MLR-L 16-32 and MLR-L 16-40 adapters.
According to Jim White, National Sales Manager for Carmex USA, "The combination of high quality and flexibility in our ML not only provides high performance in internal machining, deep thread generation and grooving; it can also save appreciable costs by reducing tool inventories. The boring bars and adapters are designed for use with internal high-pressure as well as conventional coolant."
The carbide shank toolholders from Carmex Precision Tools Ltd. offer vibration resistance and longer reach. The vertical inserts are constructed of BLU-Sub-micron grade carbide with advanced PVD triple layer coating for high heat resistance, smoother cutting operation and better finish. Toolholders feature through coolant, and inserts can be quickly indexed.
Capable of threading, grooving, boring, profiling and chamfering, these units are suitable for long threads or long-reach applications, as well as small diameter, course pitch threads.
Jim White, National Sales Manager for Carmex USA, said, "The increased Swiss-style machining for complex part production has resulted in the introduction of a wide range of tools for grooving and other applications. Due to our more than 28 years of experience in thread milling applications, Carmex engineering has developed a superior and more versatile tool for multiple applications. The insert is positioned in a recessed pocket in the toolholder that provides additional support, while the carbide construction minimizes vibration even in long-reach applications. This results in a combination of improved performance and longer tool life."
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Burrs present a hazard to those who handle parts during and after the manufacturing process.
Burrs can also break off in holes, causing significant problems. Deep oil holes in crankshafts, for example, must be burr-free to prevent small caps or slivers of material from entering the fluid system.
A burr can also have a negative impact on mating parts and how the fit and finish of components and assemblies look and perform.
Customers demand that parts be smooth to the touch, aesthetically pleasing, have holes that are without burrs and, typically, have a nice looking chamfer.
When a hole is drilled, a burr is usually generated. The deburring method can have a major impact on cycle time, cost, quality and customer satisfaction.
In countries where labor costs are low and reducing cycle time is not critical, the most common way to deburr is with a manual scraping tool. These tools usually have a handle with replaceable blades. Hand scraping is time-consuming, but the tools are inexpensive.
However, repetitive use of these tools can increase the chance of long-term injuries, such as carpal tunnel syndrome. Cuts, too, are a reality, and the resulting edge consistency will not be as good, compared to an automated tool.
Out of Touch
When burrs are hard to access, such as those in the cross-holes of tubular components, there are more-efficient ways to deburr than by hand. Common methods include applying brushes, mounted points, sphere-shaped rotating tools, flexible abrasives and rotating tools with replaceable HSS or carbide blades or inserts.
Deburring tools can be used in high- and low-volume jobs and can be run on a wide range of equipment, including hand drills, drill presses, manual mills, CNC mills and lathes, and multitask machines.
Some deburring tools resemble one-piece tuning forks: a split design with two cutting “tines” that squeeze together to pass through a hole. In operation, the tool is inserted until it touches the rear of the hole, then on the retract feed it cuts the back of the burr.
The industry, however, offers a better alternative in the form of quick-change blades and inserts, which can be replaced in minutes or even seconds. These eliminate the need to remove the old-style tool and replace it or send it to the cutter grinding department for resharpening. In addition, quick-change designs are more accurate and robust. Some are even adjustable and allow the blades to be changed while the tool remains in the spindle.
When a burr is on a challenging workpiece material and hard to access, the long life and strength of a deburring tool that accepts carbide inserts can be the most cost-effective choice, especially for production applications. Inserts are available with aggressive cutting angles for difficult-to-deburr applications.
Long-reach tools and stubby lengths are readily available, too, and toolmakers can design and produce application-specific specials. For example, they can design tools with fixed pockets to accept chamfer inserts and combination tools to drill, deburr and chamfer in one pass.
Burrs and Beyond
Burrs are classified by size (as shown on page 82). These include micro-, feather- and fence-type burrs, which are referred to as levels 1, 2 and 3, respectively. These burrs can be easily and effectively removed with a single pass of a deburring tool fitted with an HSS or carbide blade. In addition, an adjustable-size chamfer can be dialed in for a great-looking result.
Level 4 is more challenging and may require more-aggressive cutting angles or coated carbide inserts for best results. This level of burr is usually beyond the capabilities of hand-scraping tools or brushes but can still be effectively removed and chamfered in one pass.
Level 5 is like a “hanging chad.” More cutting force is required to detach it, but it can elicit major customer complaints if it isn’t completely removed. It can be removed by application of the proper deburring blade, in combination with a slower feed rate, or by a secondary pass.
The last classification, level 6, is actually beyond the definition a burr. Instead, it is extruded material that is mushrooming from the hole in a way that is typical when drilling low-carbon steel and other challenging materials.
In the case of a level-6 protuberance, the deburring tool will cut the outer portion of the extrusion but generally will not be able to completely remove it. It would be better to switch to a drilling process that leaves less extruded material around the hole. The more cleanly the hole is drilled, the smaller and more manageable the burr will be.
Custom Deburring Tools Ends Hub Hubbub
Skyway Precision Inc. needed a better way to reach the back of an 80-lb. (36.3-kg) component to deburr holes. The nodular-iron component was an 11.6”-dia. (294.6mm) hub with 22 holes, 10 at 0.425” (10.795mm) in diameter and 12 at 1.093” (27.762mm) in diameter.
Plymouth, Mich.-based Skyway was removing the heavy hub and placing it on a workbench to manually deburr the rear of the holes by applying a countersinking tool in an air drill. This method was cumbersome, time-consuming and costly. Not only did the extra handling require additional man-hours to complete the part, but the countersinking tool was expensive and lasted only a day or two.
The company turned to nearby E-Z Burr Tool Co. to design and make a custom 9”-long (228.6mm) tool for the application. To accommodate Skyway’s specifications, the tool ran at a spindle speed of 550 rpm and a cutting speed of 8.8 ipm (223.5 mm/min.) when deburring the 1.093” holes. In addition, the tool gave Skyway the ability to deburr the back of the holes while the hub remained in the machine.
For the smaller holes, a standard-length tool deburred the top and bottom of the holes in one pass. It ran at 1,750 rpm and 11 ipm (279.4 mm/min.)
The E-Z Burr deburring tool saved Skyway 15 to 20 minutes per part and dramatically reduced the injury risk and additional manpower requirements. Eliminating the countersinking tool also saved money. Plus, the tool accepts E-Z Burr carbide inserts, which last a month before needing replacement. This process led to further engineered improvements, such as using a short pilot drill to start the hole and chamfer the top of the larger holes. The pilot hole eliminated the “walking” and tool breakage problems and prolonged the life of the expensive long drill.
—E-Z Burr Tool Co.
Sales Manager, E-Z Burr Tool Co.
Dan Ewing is Sales Manager for E-Z Burr Tool Co., Plymouth, Mich. For more information about the company’s deburring tools, call (800) 783-2877 or visit www.ezburr.com.
Our blog section is written by several different people. Sometimes, its from our team here at Industrial Sales Group at other times it's by one of the wonderful manufacturer's we represent.