Highly abrasive materials like cast iron, polymers, glass filled polycarbonates, and some cast aluminum are called “hard” materials for a reason. They’re hard to machine, hard on tool life and hard on production cycle times.

​How do you overcome the difficulties of making parts out of challenging raw stock? By using a tool that’s even tougher. Consider a change from steel taps to carbide taps.

​We offer carbide taps in UN and Metric sizes as well as straight and NPT/F Pipe and STI Standards. A wide range of styles and features are available, including straight flute, spiral flute, spiral point, and forming taps. For increased performance and life, we can customize tools with a full line of surface coatings such as TiN, TiCN, and TiALN.

Machining with carbide does come with some “do’s and don’t”. Hand­ tapping is generally not recommended. Rigid tapping and spot­-on alignment are critical to avoid breakage. Not to worry, however. Modern CNC equipment is ideally suited for carbide applications.

Here’s some additional tips. Coolant holes through the taps are an option for flushing chips out of the holes on the most difficult materials like some of the tougher stainless steels and space-­age alloys. Carbide STI (Screw Thread Insert) tapping of these materials has become commonplace in the aeronautical and aerospace industries.

Although initially more expensive than HSS taps, significant savings can be realized, especially in long-­run jobs. Higher cutting speeds, greater tool life, and reduced down­time from fewer tooling changes translate into reduced machining costs.

An alternative to costly larger sizes is our line of Carb­I­Sert® Taps. Solid carbide cutting surfaces are bonded onto a high-speed steel body to provide the best of both worlds; durability of carbide with the “forgiveness” of a steel body and shank.

So, don’t let difficult materials give you a “hard” time. Contact us anytime and put our carbide taps to work for you.

Two of our most popular chamfer mill systems are on sale until July 31, 2021
Please contact us for your closest, authorized Everede distributor

by Steven Oszust Jr. at ​Fullerton Tool

This month we will focus on one of our most successful legacy tools, the Fullerton Tool's 3400 Harmon-i-Cut end mill. Nearly two decades ago, we recognized the advancements in machining technology demanded increasingly aggressive machining operations to enhance productivity and reduce production costs.

Advancements in spindle technology enabled greater spindle speeds while maintaining the necessary power to perform more aggressive cutting operations. With the greater acceptance and application of high-speed machining (HSM) practices in programming, spindle speeds were increased to a range which was greater than those traditionally used for an increase in material removal rates (MRR) over traditional tools.

High-speed machining is achieved by increased axial depth of cut and higher spindle speeds, combined with constant chip loads requiring new high-performance tooling design.

One limitation in achievable MRR is self-excited vibrations of the cutting tools, known as chatter. Chatter is caused by variations in the inconsistent chip thickness caused when the vibration of the tooth currently engaged in the cut is out of phase with the vibration of the previous tooth.

Specifically engineered geometries greatly reduce chatter leading to smoother running, faster feed rates. These tools are ideal for all roughing and finishing operations, offering longer tool life and improved surface finishes.

Harmon-i-cut end mills have engineered flute shape designed for maximum rigidity, variable helix, variable rake, superb chip evacuation, and excellent shearing action. Reduced load pressures and super stiff design promotes less chatter, achieving rapid Harmonic-free stock removal at rates never seen before.

By utilizing chip thinning strategies, significant increases in productivity and tool life can be achieved. These methods are also helpful when using machines with less power and stability. Even with weaker machines and less stable working conditions, very high cutting parameters can be achieved.

These strategies are particularly effective for increasing process reliability in difficult to machine materials or challenging applications.

Consider Fullerton Tool's  3400 series Harmon-i-cut a cut above the rest. With our vast inventory of sizes and configurations, we can provide a solution for your needs. Contact Browne Sales to get started

 Nine9 was recently recognized in an article  “Meet the 1000 ‘hidden champions’ behind Taiwan's electric car-making dream”. From hardware providers to software companies, Taiwanese “hidden champions” have rallied under the banner of electric vehicles. They can produce every part of the car, from top to bottom, from a small screw to whole car body, including internal combustion engine and electric system.
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The  Nine9 NC Helix Drill is used to machine multi-stepped holes in forged wheels manufacturing.  The NC Helix Drill has special insert geometry design with serrated cutting edge that makes chips small, short, and easier to evacuate. It's really good for cutting material that generates long, stringy, soft chips that are typical in the  aluminum alloy used in forged wheels.
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The NC Helix Drill is capable of helical interpolation for milling, drilling and slotting with a single tool. Take a look at the video below and you can see why it's preferred in a lights-out production floor or even a short run production machine shop: It can optimize the machining process by tool saving from 2 to 4 tools and reduce the machining time by one operation with excellent chip control!

Alpha Professional Tools has the blades and tools to make cutting porcelain pavers a breeze. Check out the video above of Alpha's contour blade for cutting a 7" circle in the middle of a 2 cm porcelain paver.

• Designed Specifically for Cutting Porcelain and Sintered Slabs
• Fits On 5" Wet & Dry Stone Cutters 
• Cuts Curved Areas Cleanly, Accurately and Safely While Allowing A Wider Kerf
• Direct Sintered Diamond Segments On Steel Core Prevents Undercutting
• Can Be Used Either Wet or Dry

We also have blades and tools for profiling and drilling and polishing as well as  restoration/maintenace solutions for all your porcelian paver needs. Please contact John for more information or to schedule a demo. Clink on button below for all of Alpha's Hardscape solutions:

We are proud to say that Browne & Company, Inc. is now a ISA SalesWerks 2.0 Independent Manufacturers Representative Agency! 

Certification means differentiation, and we are proud to be setting the standard and Leading The Channel Forward.”

One of the benefits of certification is having a defined sales process that helps IMR’s and Manufacturers work together on opportunities with a common language and greater efficiency and effectiveness for the customer!

​If you want to know more, please contact us or visit the ISA SalesWerks page.

compiled & edited by Bernard Martin

As more and more of our customers are using Martindale Gaylee Circular saws we put together this guide to the commonly asked questions such as "Is there a rule-of-thumb for the number of teeth?" or "How much side clearance should I have?" Here we cover a lot of the fundamentals of selecting the right circular saw blade configuration, some tips, tricks, and troubleshooting for when things go wrong. 

These are general cutting speed recommendations for circular saws used in metalcutting from Martindale/Gaylee. The may vary from application to application but are basically some general suggestions starting parameters when using high speed or carbide saws. 

• HSS Saws: .002”-.006”  (IPT-inch. per tooth / CLPT-chip load per tooth)
  
• Carbide Saws: .0002”-.0015”  (IPT -inch. per tooth / CLPT - chip load per tooth)

This is a conservative recommendation as a starting point for feed rates, and may vary depending on material being cut and cutting speed (SFPM).

Generally speaking, deep cuts and soft material require fewer teeth for chip clearance and stronger teeth (landed) Thin material requires more teeth, but keep-in-mind that at least 2 teeth on the blade need to be engaged in cut.

SIDE CLEARANCE (Tangential Clearance Angle)
This is also known as dish or hollow grind.  You measure down the side of the tip and the difference it is the difference between front and back.  As you cut, material it gets compressed and springs back after the cutting edge passes.

​A steep side clearance angle gives plenty of room for the material to expand and prevents thermal expansion of the base material.  Keep in mint that a very flat side clearance angle can provide a smoother cut in some materials.  For stainless steel and tenacious metals such as copper, zinc, tin or lead an increase in the side clearance is desirable as these materials tend to "spring back" (thermal expansion) on the blade. 

RAKE ANGLES
Rake angle is the term used to describe the direction of the blade’s teeth, as referenced from the rotation and central axis of a saw blade. If you imagine a line going from the exact center of the blade to each tooth, having the front of the tooth directly on that line would be a zero degree rake angle. The rake angle of the blade is described in comparison to that imaginary line.

A positive rake angle meana that the teeth are angled more towards the angle of rotation, while a negative rake angle would mean that they are angled backwards, away from the direction of rotation. Generally speaking, the preferred rake angle is:

• 5° to 10° positive for other soft materials.
• 5° negative for yellow brass
• On center for steel.

It's commonly known that when saw thickness is less than 0.125″, keyways can cause stress risers and cracks.  That is why washers are often used.  However, Breakage, Wobble and Rubbing problems are often caused by how the washers are mounted on either side of saw. 

Remember, washers drive the saw in the absence of a drive key. They must always be clean, flat and bur-free. A speck of dirt will let saws wobble and cut oversize. 

If a saw breaks, it may score the washers. Always check for scoring marks around saw hole for dirt, chips or grit.  Shiny spots, as small as a pinpoint, indicate that chips where imbedded under washers.

Circular skid marks indicate the nut was not tight.

Generally speaking:

• Thin saws should especially be supported by washers as large as possible.
• Washers must be of equal diameter or they will flex out saw dish and cause one side of saw to rub.
• The nut must be wrench-tight.

Saw Blade Teeth most often break as a result of:

• Too high a feed rate.
• Spindle bearings are worn.
• Drive belts  are loose or sheaves worn.
• Improper tightening: If saw blade pauses momentarily in its rotation while feed advances, it WILL break.
• Workpiece indexed before the saw has cleared the slot.
  
• Improper workholding - The workpiece not tight or not well supported.
• Saw is dull, even the best tools do eventually wear out.

NOTE: HSS saws will turn colors as they heat during cutting. A straw color is the limit. The saw will lose its temper when it starts turning blue.

 by Steven Oszust Jr. Product Development Manager/Lead Tool Design Engineer at Fullerton Tool Co.

At Fullerton Tool ,Our primary purpose is to provide our customers with cost-effective, high-quality, solid carbide round tool solutions at competitive prices. In the past we have discussed our consistency in our processes, and foundational approach to tool designs.

These traits can best be described as the basis for Functional Value.

In the case of our general purpose end mills, functional value involves all the core processes and systems that customers are not paying for. These processes and systems are deeply engrained in our culture.

Often development for the higher end, performance side of our offering, these systems naturally trickle down to the general purpose tools automatically in our tool strategy.

The benefits of this tool strategy can be seen in everything we do. The nearly 150 years combined experience in our production engineering team, makes Fullerton one of the most detail oriented companies in the industry. Our innovative manufacturing processes and years of experience ensure the best possible value for cost conscious metalworking consumers. 

Consider our General Purpose End Mills a cut above the rest. With our vast inventory of sizes, configurations, and coatings we can provide a solution for your needs.

Start your search for the perfect General Purpose End Mill on the Fullerton Tool Website or contact your dedicated regional managers at Browne Sales for application recommendations. 

Browne & Company is ISA SalesWerks 1.0 certified! Certification means differentiation, and we are proud to be setting the standard and Leading The Channel Forward.” One of the benefits of certification is having a defined sales process that helps IMR’s and Manufacturers work together on opportunities with a common language and greater efficiency and effectiveness for the customer! If you want to know more, please contact us or visit the ISA SalesWerks page.

Fullerton Tool's high performance 3400 Harmon-i-Cut end mill excels in difficult to machine ferrous materials like cast iron. It features a variable helix, variable index, and variable rake which maximizes tool life and removal rates by minimizing the effects of harmonics. The 3400 Harmon-i-Cut end mill allows the capacity to rough and finish with one tool and is stocked with FC-18 coating.
3400 Harmon-i-Cut High Performance End Mill Includes:

• Available in Ball, Corner Radius & Square End Types
• 4 Flutes
• FC-18 Coating
• Available in Stub, Standard, Extra Long, and Long Reach Lengths
• Center Cutting
• h6 Shank Tolerance