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Unveiling the Precision Brand Tool Black® Products: Enhancing Metal Tool Performance

11/14/2023

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written, compiled & edited by ​Bernard Martin
​
Precision Brand, a renowned name in the world of tool maintenance and enhancement, offers a line of cutting-edge products designed to cater to the needs of professionals and hobbyists alike.

Among these, the Tool Black product range stands out for its ability to enhance, protect, and maintain metal tools and surfaces.

​In this article, we'll take a closer look at three key Tool Black products: Tool Black Gel, Tool Black Metal Polisher/Cleanser, and Tool Black Prevent. We will also compare Tool Black Gel with some competitive products to highlight its unique features and advantages.
Precison Brand Tool Black Gel, Metal Polisher cleanser Rust PREVENTative
Precison Brand's Tool Black®Gel, Tool Black®Metal Polisher/Cleanser and Tool Black®PREVENT is the combination of products that should be on -the-shelf in every shop.

Tool Black® Gel

Precision Brand's Tool Black® Gel is a revolutionary product that provides a quick and efficient solution for enhancing metal tools and surfaces. Whether you're looking to touch up your metalworking tools or restore the shine to your household items, Tool Black Gel is a versatile option.

Fast, inexpensive alternative to black oxide. Imparts a tough, dull black protective finish to ferrous metal parts. Ideal for prototypes, repair parts, and general machine work. The Gel formula is best for larger areas or fixed vertical spaces
Precision Brand Tool Black Gel

Tool Black® Gel should be used at room temperature as a cold application. One pint of Tool Black® Gel covers 20 square feet, however coverage varies with application technique. 

  • Easy Application: Tool Black Gel is user-friendly and can be easily applied with a brush or a cloth. Its gel-like consistency ensures that it adheres well to the surface, allowing for precise application.
  • Quick Drying: Unlike some competitive products that may require lengthy drying times, Tool Black Gel dries quickly, reducing downtime and increasing productivity.
  • Long-Lasting: Tool Black Gel provides a durable, long-lasting black finish that resists wear and tear. It helps protect metal surfaces from corrosion and oxidation.
  • Versatile: This product can be used on a wide range of metal surfaces, including tools, machinery, automotive parts, and more.

Tool Black®​ METAL POLISH/CLEANSER

For those seeking an effective solution to restore and maintain the shine of metal surfaces, Precision Brand offers the Tool Black Metal Polisher/Cleanser. This product is designed to remove tarnish, oxidation, and stains, leaving metal surfaces looking brand new.
​
Precision Brand Metal Polish Cleanser
Tool Black Metal A safe, fast-acting, effective cleaner for all metals. Removes grease, oil, alkali, silicone, cutting fluids, etc. without harm to metal. Can be sprayed or applied with brush or coarse rag. 

  • Gentle yet Effective: Tool Black Metal Polisher/Cleanser is tough on stains and tarnish but gentle on the underlying metal. It won't scratch or damage the surface.
  • Restores Shine: It restores the original shine to metal surfaces, enhancing their aesthetic appeal.
  • Multi-Purpose: This product can be used on a variety of metal items, from kitchenware to jewelry to automotive parts.

Tool Black®​ PREVENT rust

To ensure that your metal tools and surfaces remain protected from corrosion and rust, Tool Black Prevent is a valuable addition to your maintenance toolkit.
Precision Brand Tool Black Prevent rust preventative
Tool Black®​ PREVENT is a low odor, spray-on sealer and rust preventative that can be applied to wet or dry surfaces. This product displaces water from the part. It dries to a thin, soft, waxy protective film that resists draining off parts in storage or wicking off into packaging material. Ideal for use on parts which go into storage or overseas shipment. 
  • Anti-Corrosion: Tool Black Prevent creates a protective barrier on metal surfaces, preventing the onset of corrosion, rust, and oxidation.
  • Long-Lasting: It provides long-lasting protection, reducing the need for frequent re-application.
  • Versatile Use: Tool Black Prevent is suitable for use on all types of metal surfaces, including hand tools, machinery, and outdoor equipment.

Comparison with Competitive Products

While there are several competitive products on the market for tool and metal surface maintenance, Tool Black Gel from Precision Brand offers distinct advantages:
  • Ease of Application: Tool Black Gel's gel-like consistency and easy application process set it apart from some competitors that may have more complicated or messy application methods.
  • Quick Drying: Unlike some alternatives that require extended drying times, Tool Black Gel dries rapidly, allowing for faster return to work.
  • Long-Lasting: The durability of Tool Black Gel's finish means that you won't need to reapply it as frequently as some other products.
  • Versatility: Tool Black Gel can be used on a wide range of metal surfaces, making it a versatile choice for professionals and DIY enthusiasts.
Precision Brand's Tool Black®​ products, including Tool Black Gel, Tool Black Metal Polisher/Cleanser, and Tool Black Prevent, are valuable additions to any toolkit.

​Whether you're looking to enhance the appearance of your metal tools, maintain their performance, or protect them from corrosion, Precision Brand's Tool Black®​ range offers effective solutions. When compared to competitive products, Tool Black Gel stands out for its ease of application, quick drying, long-lasting finish, and versatility. It's a reliable choice for those seeking to elevate the performance and appearance of their metal tools and surfaces.
Please note: ​Tool Black® products cannot be shipped via air transportation.
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What is "Class of Fit" for a Cutting Tap?

10/17/2023

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written, compiled and edited by Bernard Martin
What does Class of Fit for a Cutting Tap mean
The basic profile of all UTS threads is the same as that of all ISO metric screw threads. Only the commonly used values for Dmaj and P differ between the two standards.
Class of fit for a cutting tap refers to the specific tolerance or fit that is desired between the threads of the tap and the threads of the hole it is being used to create. In other words, it defines how tightly or loosely the threads should mesh together.

The class of fit is typically expressed using a combination of letters and numbers. The most commonly used standards for class of fit are the Unified Thread Standard (UTS) and the ISO metric thread standard. In the UTS, the class of fit is denoted by a combination of a letter and a number, such as 2B, 3A, etc. In the ISO metric thread standard, it is represented by a combination of a letter and a number, such as 6g, 4h, etc.

For cutting taps, the class of fit is usually specified based on the intended application and the level of precision required. The class of fit can affect factors like the ease of assembly, the strength of the threaded connection, and the ability to engage the threads smoothly during tapping.

A classification system exists for ease of manufacture and interchangeability of fabricated threaded items. Most, but certainly not all, threaded items are made to a UTS classification standard. This system is analogous to the fits used with assembled parts.
  • Class 1 threads are loose fit, intended for ease of assembly or use in a dirty environment.
  • Class 2 threads are free fit, and the most common. They are designed to maximize strength considering typical machine shop capability and machine practice.
  • Class 3 threads are medium fit, still quite common and used for closer tolerances on high quality work.
  • Class 4 threads previously designated a close fit for even tighter tolerances, but this classification is now obsolete.
  • Class 5 fit is an interference thread, requiring the use of a wrench for turning. These can be seen in applications like spring shackles on an automobile.

The letter suffix "A" or "B" denotes whether the threads are external or internal, respectively. Classes 1A, 2A, 3A apply to external threads; Classes 1B, 2B, 3B apply to internal threads

Here are some common classes of fit for cutting taps:
  1. Class 2B (UTS) or 6H (ISO metric): This is a standard fit for most general-purpose applications. It provides a balance between ease of assembly and thread engagement.
  2. Class 3B (UTS) or 6HX (ISO metric): This is a tighter fit than Class 2B or 6H and is used when a higher level of thread precision and engagement is required.
  3. Class 2A (UTS) or 6g (ISO metric): This is a loose fit that is often used for applications where ease of assembly and disassembly are important, such as with interchangeable parts.
  4. Class 3A (UTS) or 6HX (ISO metric): This is a tighter fit than Class 2A or 6g and is used in applications where a higher level of precision is required.
The choice of class of fit should be made based on the specific requirements of the project, taking into consideration factors like material type, thread size, intended use, and the desired level of thread engagement. It's important to consult relevant standards and guidelines to ensure that the chosen class of fit is appropriate for the application.
​
The standard designation for a UTS thread is a number indicating the nominal (major) diameter of the thread, followed by the pitch measured in threads per inch. For diameters smaller than 1⁄4 inch, the diameter is indicated by an integer number defined in the standard; for all other diameters, the inch figure is given.

This number pair is optionally followed by the letters UNC, UNF or UNEF (Unified) if the diameter-pitch combination is from the coarse, fine, or extra fineseries, and may also be followed by a tolerance class.
Example: #6-32 UNC 2B (major diameter: 0.1380 inch, pitch: 32 tpi)
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Visit The Haimer Booth At EMO 2023

10/11/2023

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If you would like to learn more about any of Haimer's World Class products, please reach out to a member of our team in the Ohio, Western PA, or Kentucky areas with a click of the button below.
Contact Our Team
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Besly Parabolic Flute Turboflute Drills offer Unique Advantages to Improve Performance

9/18/2023

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Besly Turboflute Drill setsBesly Turboflute Drill sets T-715-TF
Besly Turboflute Drills have heavy duty parabolic profiled flutes for easy chip flow.

​Designed for automotive, aerospace, and other high volume metalworking industries, they give longer life and better drilled hole quality while allowing increased feed rates. The split point design seats itself and holds centers. 

​These heavier web drills are ideal for use in stringy, low and medium strength steels below 120,000 psi ultimate tensile strength, and for use in exotic and difficult-to-machine materials, ferrous and nonferrous.

Parabolic flute drills, also known as parabolic flute twist drills, offer several advantages compared to standard twist drills with straight flutes. These advantages make them a popular choice in various drilling applications. Here are some of the key advantages of using parabolic flute drills:
  1. Improved chip evacuation: Parabolic flute drills have a curved or spiral flute design that helps facilitate better chip removal. As the drill bit advances into the material, it creates chips that move up and out of the hole more efficiently. This reduces the risk of chip clogging and ensures smoother drilling operations.
  2. Reduced friction and heat generation: The curved flute geometry of parabolic flute drills allows for a larger volume of coolant or cutting fluid to reach the cutting edges and the workpiece, helping to dissipate heat effectively. This minimizes heat buildup and reduces the risk of workpiece overheating or material deformation during drilling.
  3. Increased drilling speed: Parabolic flute drills are designed to cut more efficiently, thanks to their improved chip evacuation and reduced friction. This often translates to faster drilling speeds and shorter cycle times, making them ideal for applications where productivity is crucial.
  4. Enhanced tool life: The combination of better chip evacuation, reduced heat generation, and increased drilling speed can extend the life of the drill bit. Parabolic flute drills tend to experience less wear and damage compared to standard twist drills, leading to longer tool life and cost savings.
  5. Versatility: Parabolic flute drills can be used on a wide range of materials, including metals, plastics, and composites. Their ability to handle various materials makes them versatile tools suitable for different machining applications.
  6. Improved hole quality: Due to their efficient cutting action and reduced vibration, parabolic flute drills often produce cleaner and more precise holes. This is particularly important in applications where hole quality is critical.
  7. Lower power consumption: Because parabolic flute drills require less force to cut through materials, they can lead to reduced power consumption in drilling machines, which can result in energy savings over time.
It's worth noting that the specific advantages of using parabolic flute drills may vary depending on factors such as the material being drilled, the drill bit's size and geometry, and the machining conditions. However, in many cases, these drills offer improved performance, longer tool life, and a more efficient drilling process compared to standard twist drills.

Extra Length, Tanged, Bright Finish (Catl No T-218-TF)

Besly Turboflute Drill Extra Length Tanged Bright Finish T-218-TF
Besly Turboflute Drill Extra Length Tanged Bright Finish T-218-TF
Besly Turboflute drills handle hole depths of up to 12 times their own diameter in a single pass. The unique flute design produces short chips, that pass out of the hole with no clogging or woodpeckering. These drills are designed for drilling materials such as steels below 120,000 psi ultimate tensile strength and iron castings. 

Jobbers Length, Bright Finish (Catl No T-755-TF)

Besly Turboflute Drill Jobbers Length Bright Finish T-755-TF
Besly Turboflute Drill Jobbers Length Bright Finish T-755-TF
Besly Turboflute Drills have heavy duty parabolic profiled flutes for easy chip flow. Designed for automotive, aerospace, and other high volume metalworking industries, they give longer life and better drilled hole quality while allowing increased feed rates.

​The split point design seats itself and holds centers. Bright finish drills, Catl No. T-755-TF, are for use in aluminum and other nonferrous materials. 

Jobbers Length, Surface Treated (Catl No T-705-TF)

Besly Turboflute Drill Jobbers Length Surface Treated T-705-TF
Besly Turboflute Drill Jobbers Length Surface Treated T-705-TF

Besly Turboflute Drills have heavy duty parabolic profiled flutes for easy chip flow. Designed for automotive, aerospace, and other high volume metalworking industries, they give longer life and better drilled hole quality while allowing increased feed rates.

​The split point design seats itself and holds centers. Surface treated drills, Catl No. T-705-TF are intended for drilling stringy, low and medium strength steels below 120,000 psi ultimate tensile strength.  Also available in sets (Catl No. T-715-TF). 

Jobbers Length Sets, Surface Treated (Catl No T-715-TF)

Besly Turboflute Drill sets, Catalog No. T-715-TF. have heavy duty parabolic profiled flutes for easy chip flow. Designed for automotive, aerospace, and other high volume metalworking industries, they give longer life and better drilled hole quality while allowing increased feed rates. The split point design seats itself and holds centers. 
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Chip Formation: You're Not Cutting Chips, You're Separating Metal from Itself

8/14/2023

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by Bernard Martin
Contrary to popular terminology, metal is not “cut” as much as it is a “forced separation from itself.” To understand this, think of how molecules bond together.  Molecules resemble our solar system with the nucleus represented by our Sun (or a carbon atom in the image) and the electrons represent by the various planets. 

When one molecule “bonds” with another it is as if two solar systems’ planets became intertwined into each others orbits with both solar systems sharing certain planets and making the whole larger than the sum if it’s parts. ​

When we use a cutting tool we are inducing these bonds to break apart. ​​

The “machinability” of a particular metal partially defines how easily the material separates from itself.  ​

Picture
The basic mechanics of forming a chip are the same regardless of the base material. As the cutting tool engages the workpiece, the material directly ahead of the tool is sheared and deformed under tremendous pressure. The deformed material then seeks to relieve its stressed condition by fracturing and flowing into the space above the tool in the form of a chip. 

The important difference is how the chip typically forms in various materials.
 
Regardless of the tool being used or the metal being cut, the chip forming process occurs by a mechanism called plastic deformation. This deformation can be visualized as shearing. That is when a metal is subjected to a load exceeding its elastic limit.

​The crystals of the metal elongate through an action of slipping or shearing, which takes place within the crystals and between adjacent crystals.

Type 1: Discontinuous Chip

Cast Iron, Hard Brass and other materials that produce a Powdery chip.
 
“Discontinuous Chip - Discontinuous or segmented chips are produced when brittle metal such as cast iron and hard bronze are cut or when some ductile metals are cut under poor cutting conditions.
discontinuous-chip
As the point of the cutting tool contacts the metal, some compression occurs, and the chip begins flowing along the chip-tool interface. As more stress is applied to brittle metal by the cutting action, the metal compresses until it reaches a point where rupture occurs and the chip separates from the unmachined portion. 

This cycle is repeated indefinitely during the cutting operation, with the rupture of each segment occurring on the shear angle or plane. Generally, as a result of these successive ruptures, a poor surface is produced on the workpiece.”  

Notice how the chips deform and begin to break up at a considerable distance in front of the cutting edge. Chip control is usually not a problem when machining these materials. Harder, more heat and wear resistant Carbide Grades can be used in these applications. Edge strength becomes less of a factor vs. machining Steel or Stainless or other materials that make long chips.  

Type 1 Discontinuous Chipping materials are where most of our competitors have focused their attention.

Type 2: Continuous Chip

Medium to High carbon and alloy Steels – Long Chipping Materials
 
“Continuous Chip - Continuous chips are a continuous ribbon produced when the flow of metal next to the tool face is not greatly restricted by a built-up edge or friction at the chip tool interface. The continuous ribbon chip is considered ideal for efficient cutting action because it results in better finishes. Unlike the Type 1 chip, fractures or ruptures do not occur here, because of the ductile nature of the metal.”
discontinuous-chip
Carbon and Alloy Steels such as 1030, 1035, 1045, 1144, 4130, 4140, 4340 contain at least .3% carbon that allows them to be hardened by heating and quenching. They produce long continuous chips.
 
When machining these metals with Carbide Inserts the material in front of the cutting edge deforms resulting in high temperatures which softens the metal and consequently lowers it's strength and hardness making it easier to machine.

The chips weaken and begin to break in front the cutting edge; the tool acts much in the same way that a wedge does when splitting wood. In some cases, air, oil or coolant quenches the hot chips, hardening them and making them brittle and easier to break.

The chips produced when cutting these metals contact the face of the tool behind the cutting edge creating a zone of high heat that can result in cratering. Coatings usually eliminate this problem. 

Type 2: Continuous chip materials are the other area where many of our competitors have focused their attention.

Type 3: Sheared Chips

Low carbon Steels, Stainless Steels, Nickel Alloys, Titanium, Copper, Aluminum and other soft, “gummy’ Materials.
 
Sheared Chips or as some refer to it “Continuous Chip with a Built-up Edge (BUE). The metal ahead of the cutting tool is compressed and forms a chip which begins to flow along the chip-tool interface.
sheared Chip
As a result of the high temperature, the high pressure, and the high frictional resistance against the flow of the chip along the chip-tool interface, small particles of metal begin adhering to the edge of the cutting tool while the chip shears away.

As the cutting process continues, more particles adhere to the cutting tool and a larger build-up results, which affects the cutting action. The built-up edge increases in size and becomes more unstable. Eventually a point is reached where fragments are torn off. Portions of these fragments break off and stick to both the chip and the workpiece.

The build-up and breakdown of the built-up edge occur rapidly during a cutting action and cover the machined surface with a multitude of built-up fragments. These fragments adhere to and score the machined surface, resulting in a poor surface finish.
These metals readily deform in front of the cutting edge and have to be "sheared" by the tool. What the above paragraph doesn’t tell you is that these materials require tools with sharper cutting edges than those used for machining cast Iron or higher carbon content Steels. The chips tend to compress onto the face of the tool which can result in built-up edge. 

The chips formed when cutting these metals are thicker than those produced by Medium Carbon or Alloy Steels at the same Feed Rates and Depths of Cut. These thicker chips are stronger and harder to break. Destiny Tool, through a combination of rake face geometry, carbide substrate and concentricity tolerance is able to enable the chip to more readily "separate from itself" which not only improves MRR, but also reduced heat into the end mill and thereby extends tool life as the feed rate increases.

​High strength metals such as Stainless Steel, Nickel Alloys and Titanium generate high heat and high cutting pressures in the area of the cutting edge. This results in reduced tool life compared to easier to machine materials. 
  • This article was originally written in 2001
  • Portions of this have been edited from http://www.manufacturingcenter.com/tooling/archives/0101/0101bk.asp
  • Plastic Deformation image by Jutka Czirok, Design Technology and ICT Teacher
  • Special thanks to Charles Colerich, who created these drawings for me in 1994.
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Choosing the Right Insert Dapra Grade & Geometry for Your Application

7/12/2023

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Choosing the right insert geometry and grade for an application can easily make or break a job. Making the right choice requires educating yourself on what types of cutting edge and carbide grades are best suited to the machining conditions present.
​
Typical considerations include:
  • Material being machined
  • Workholding rigidity
  • Machine tool rigidity (40 or 50 taper, box or linear ways
  • Tool holder used
  • Tool length / diameter ratio
  • Coolant vs. dry machining
  • Machining parameters (DOC, WOC, speed & feed)
​Other factors can come into play, but those listed above are almost always the important issues when determining what geometry and grade to select. Following are some brief suggestions for geometry and grade selection, according to the variables above.

Keep in mind that these are typical scenarios and this selection process will in most cases result in the correct choice. However, combinations of the above factors can create unique situations that call for unusual grade/geometry selections. The best course of action is to contact your Dapra Applications Specialist for technical support. We are here to help!
Picture

Grade Selection

Dapra uses an easy-to-understand system that separates grades by toughness/hardness. The same coatings are available for each carbide substrate, so choosing the grade begins with the toughness of the substrate desired and ends with the coating of choice.

For abusive applications, use of the toughest grade is recommended. These would be identified as the following: interrupted cuts; long tool lengths; poor chip evacuation; stainless steels; high-temperature alloys; poor workpiece or machine rigidity; coolant use or very heavy cut depths.
​
These abusive applications require a cutting tool with high shock resistance and toughness to reduce the chance of insert chipping. Use of these grades will provide excellent toughness at the cost of some wear resistance properties.

Dapra's toughest (most shock-resistant) Square Shoulder insert grades are:
  • DMP35 (uncoated substrate)
  • DMP353 (low-to-medium temperatures)
  • DMP35-HP (low-to-medium temperatures – premium)
  • DMP357 (high temperatures)
  • DMP35-GLH (high temperatures – premium)
Dapra End and Face Mills
For stable, steel and ductile iron applications, Dapra recommends our medium toughness/hardness carbide. Examples of some good applications include: uninterrupted steel cuts; good workholding / machine rigidity; short tool / diameter ratios; lighter depths of cut; good chip evacuation; alloys; low and high carbon steels; ductile (long-chipping) irons; and dry machining.
​
Dapra's mid grade provides high performance and increased tool life over the toughest grade, due to increased hardness of the carbide substrate. This allows higher speed and improved wear resistance, but at a slightly higher risk of insert chipping.


​Available grades include:
  • DMP30 (uncoated substrate)
  • DMP303 (low-to-medium temperatures)
  • DMP30-HP (low-to-medium temperatures – premium)
  • DMP307 (high temperatures)
  • DMP30-GLH (high temperatures – premium)
Dapra Insert Face Mill End Mill heavy
For very stable, high-wear applications in cast iron and nonferrous materials, as well as hard milling of heat-treated materials, Dapra recommends the use of our hardest grades. Application examples include: gray cast irons; aluminum and copper alloys; plastics; light, smooth cuts in any material; and heat-treated steels (typically over 48 Rc).

Dapra's hardest grades provide optimum wear resistance, with the longest tool life possible. However, insert chipping is a more common occurrence when shock is encountered.

​
Dapra's hardest grades are:
  • DMK25 (uncoated substrate)
  • DMK253 (low-to-medium temperatures)
  • DMK25-HP (low-to-medium temperatures – premium)
  • DMK257 (high temperatures)
  • DMK25-GLH (high temperatures – premium)
Dapra Copy Milling-

Geometry Selection

Dapra offers three different cutting edges for the Square Shoulder milling line:
  • APET – Strong reinforced cutting edge for optimum wear and chip resistance. This geometry will provide the strongest edge, but at increased spindle load and usually higher decibel levels.
  • XPET – Sharper edge for cutting gummier materials such as low carbon steel, stainless steel and high-temperature alloys. Light hone provides some reinforcement and reduces cutting forces and noise. More susceptible to edge chipping.
  • XPET-ALU – Sharpest edge. Ideal for aluminums and plastics where high-shear cutting is needed. Creates the lowest spindle load and least noise, but most susceptible to edge chipping.

General Recommendations

Material Being Machined
Use stronger, T-land cutting edges for steels and cast irons. Use sharper honed edges for stainless steels and high-temperature alloys. For aluminum and plastics, use sharp, un-honed cutting edges.

Workholding / Machine Tool Rigidity
Use the recommended grades and geometries for rigid setups and machines. In cases where rigidity is lacking (light-duty machine, poor workholding, etc.), use tougher grades and stronger geometries. The exception to this rule is when the use of the sharper geometry (XPET) actually stops or reduces the vibration created by the poor rigidity. These situations typically present a "trial and error” scenario.
​
Material
Geometry Recommendation
Low carbon steels
XPET
Medium carbon, alloy steels
APET
Hardened steels
APET
Stainless steels
XPET
Cast irons
APET
Aluminums
XPET-ALU
Copper alloys
XPET
High-temperature alloys
XPET
Titanium
XPET
Plastics
XPET-ALU
Long Toolholder / Length to Diameter Ratio 
This situation closely resembles the previous rigidity issue. Long tool lengths (including longer tool holders) decrease tool rigidity, creating the potential for chatter and vibration. This can typically be combated with stronger cutting edges, but can also sometimes be corrected with a sharper, free cutting edge. Use the APET unless the results prohibit the use of such a strong edge. The XPET may reduce vibration enough to quiet the operation. Again, use of the toughest grades is typically recommended in long reach applications where chatter or vibration is present.

Coolant vs. Dry Machining
Most applications using Dapra cutting tools are best performed using dry air blast. Exceptions to this rule include: high-temperature alloys, aluminum and some exceptionally tough stainless steels. When dry machining, use the grades and geometries suggested previously. When using coolants, Dapra recommends using the tougher grades, but with sharper cutting edges (XPET). This allows the heat generated in the cutting zone to be minimized, delaying the effects of thermal shock.

Machining Parameters 
For heavier cuts, tougher substrates should be used, due to the increased pressure and potential vibration created. In lighter cuts, the harder grades provide better performance (speed) and longer tool life.

The minimum FPT (feed per tooth) for the APET geometry should be .006". This is to get the chip thickness past the T-land edge preparation, allowing the insert to cut, not rub. The minimum FPT for the XPET insert should be .003". Consequently, lighter cuts (FPT) should not be taken with the APET unless other conditions exist that necessitate the use of the stronger edge.
​
The selection procedure described here will require your careful consideration of several application conditions and insert characteristics. This may take some time, but the cutting results will be well worth your effort.
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Automation and Digitization for Maximum Quality and Sustainable Success at Haimer

6/13/2023

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HAIMER, an innovative global player in tool management for machine tools, is convinced that production engineering will be determined by automation and digitization in the future.

​This development is an established part of the company's own production and has accordingly also found its way into the product range from i4.0-capable machines to the HAIMER Automation Cube robot cell, which can be scaled according tocustomer’s request and is suitable for automated shrinking, presetting and balancing.
​
HAIMER Plant Manager Production Manager, Manfred Mayr
HAIMER Plant and Production Manager, Manfred Mayr: “Only with optimal tool presetting can the machines run rather than the employee.”
Efficient machining demands powerful machines and tools “as well as high-precision tool holding technology which ensures that the precision of the spindle is transferred to the cutting edge,” says Andreas Haimer.

This is the sort of statement you would expect from the Managing Director of Haimer GmbH and President of the HAIMER Group, the worldwide leading manufacturer in the field of tool holding. But it is not simply a marketing slogan – there are many years of experience behind it. HAIMER started off 45 years ago as a machine shop for the aerospace industry and soon started to develop high-precision toolholders for their own use.
​
HAIMER also has many years of experience in automation. The Bavarian family company made the decision to equip their first machine tools with robots for loading and unloading over 20 years ago. Since then, automation at HAIMER has advanced swiftly, as evidenced by their manufacturing facilities at their headquarters in Igenhausen or in Motzenhofen, just 3 miles away. The Motzenhofen production plant in particular, which has been operating since 2018, has been equipped from the beginning with numerous automated machining centers in recent years.

Automation is a Necessity

Andreas Haimer stresses: “If, like us, you depend on a very high level of in-house production completely ‘made in Germany’, there is no way you can avoid extensive digitization and automation. Otherwise we would not be able to keep up economically with our global competition.”
​
Soft machining of the tool holders is carried out in Motzenhofen alongside all precision components for shrink fit and balancing machines including accessories. Up to 4,000 rotating tool holders can be turned and milled there per day before heat treatment, followed by µm-precise grinding at the headquarters in Igenhausen. Fine balancing is also carried out in Igenhausen – using systems that have been developed in-house and are fully automated.

Not Every Automation is Complex

Back to Motzenhofen: Amongst others, HAIMER operates a fully automated manufacturing cell with several five-axis DMG MORI MILLTAP 700 machines. 


These highly dynamic vertical machining centers, which were installed at the beginning of 2019, are perfect for boring and milling components such as the BT30 or the SK30 steep taper tool holders. Manfred Mayr, who completed his apprenticeship at HAIMER over 40 years ago and is now responsible for around 100 machine tools as the plant and production manager, explains:

“Here we use a simple plug & play complete solution, which includes a fully automated loading and unloading system using a KUKA robot. Blanks and the machined parts are placed in three drawers, each of which has around 78 positions. This ensures that unmanned production is possible for a minimum of eight hours up to 20 hours.”

The automation of four identical DMG MORI NHX4000 machining centers, which are equipped with a pallet pool FMS system, is considerably more demanding, as Manfred Mayr describes:

“There are twelve pallets, each with 400 places, ready to process various components. This provides us with ideal flexibility, also when it comes to smaller batch sizes and short-notice changes in the production flow.”

​The machines generally work highly productively and trouble-free in a 3-shift operation, supervised by just one employee. In order to operate the machines as autonomously as possible with a large variety of products, HAIMER had the machines equipped with a tool magazine with 183 tool pots. 

Manfred Mayr considers the fact that all tools for these machines are equipped with an RFID chip on the tool holder to be a key factor of success. They are read in at a dedicated station when they are changed into the magazine. This means the control receives the correct tool data digitally from the HAIMER Microset VIO linear presetter. This completely eliminates any input errors or mix-ups.

Digital Data Flow Between the Tool Room and the Machining Center

A key basic requirement for economic operation of the NHX and all other machine tools – according to the plant manager – is a perfectly operating and well organized tool room:

This technology represents a central component of our expertise. Of course we use our own products here – from shrink fit, balancing and presetting machines to tool holders and cutting tools. This enables end-to-end digitization all the way to the machine, which is an essential component for automated, economic manufacturing operations.” 

This means that all tools for milling and turning machines are centrally prepared and managed in the tool room. They are mounted, shrunk, measured, and balanced – and all data is digitally recorded. This either takes place on the aforementioned RFID chips, by means of digital interfaces, such as post processors, or via a QR code. Only then they are packed onto special tool wagons as required, where the machine operator can pick them up for their machine. This eliminates extra walking throughout the shop.

​“Only with optimal tool presetting room, the machines run and not the employee,” is Plant Manager Mayr’s credo.

The Tool MUST Fit into the Digital Production Environment

HAIMER – Your system provider around the machine tool
HAIMER evolved to become a complete system provider for tool management centered around the machine tool. HAIMER Microset tool presetting technology complements the existing HAIMER portfolio, which consists of an extensive tool holding program, shrinking and balancing technology, tool management logistics as well as 3D measuring devices and solid carbide cutting tools.
The digitization of the production processes represents a key factor for success not only for HAIMER but for every company. “As the tool with its specific data is a central component of the process chain for machining, it needs to fit into the digital production environment,” explains Andreas Haimer. This includes the consistent implementation of all digital options – from the tool itself, the tool holder including the clamping process, the balancing to the tool presetting, and the use on the machine.

Especially when making new investments, the user should ensure that every element in the tool environment is Industry 4.0 capable and can be incorporated into the digital workflow, advises Andreas Haimer:

“Our products are fully prepared for digital production. We have even developed our own tool management software, the HAIMER Data Analyzer and Controller (DAC), which establishes and manages the exchange between the actual and target values along with other tool data between the individual stations in the tool room and the company network. Our equipment in the Industry 4.0 series are prepared for automation with modern digital features and interfaces. Moreover, they have been designed to be robust with a long service life, which is a guarantee of the highest process reliability – a decisive factor for successful automation.”

HAIMER supports a wide range of automation models with its products. The range starts with individual machines which combine several work steps, such as the presetter HAIMER Microset VIO linear toolshrink.

​It is capable of shrinking tools with a length adjustment on the μm scale and at the same time measuring the tool. Amongst other things, it is ideal for sister tools, which always need to be shrunk to the same dimensions. Their use in series production or in multi-spindle machines promises to increase process reliability and minimize setup times.

One Robot Cell for Shrinking, Presetting and Balancing

Just last year at the EMO Milano, HAIMER presented a much more far-reaching solution: the HAIMER Shrink Automation Cube. This automated shrink station contains a cobot, that supports shrinking and unshrinking of tools with highly accurate length repeatability.

The cell is scalable according to the customer’s requirements. This means the cube is controlled by the HAIMER DAC Tool Management and HAIMER presetting and balancing technology can be integrated in the Automation Cube. A scanner for reading out unique tool combinations and a conveyor belt that is variable in lengths are also available.

Such equipment allows the following procedure to be carried out, for example: The operator places the worn complete tool assembly (consisting of tool holder and cutting tool) on the conveyor belt and provides a new cutting tool. The cobot picks up the complete tool holder assembly and identifies it via its unique data matrix code (optionally via RFID).

It then picks up the new cutting tool and measures the cutting edge. In the meantime, the coil moves onto the worn complete tool holder assembly, unshrinks the old cutting tool and then shrinks in the new one to the required projection length. After air cooling, the new complete tool is ready for use. The old cutting tool is disposed of.

Andreas Haimer is convinced:  “This automation solution is suitable for companies that perform a very large number of shrink operations every day.”

Especially if there is only limited automation expertise in the company, a complete solution like this from a single source is a good idea. Andreas Haimer also points out that HAIMER components can be integrated into almost any existing automation environment: “We are also happy to partner on larger automation projects.”
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The ACE Spot Drill - 60° 90° 120° for Spotting, Countersink & Chamfering

5/17/2023

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ACE Spot Drill 60° 90° 120° spotting, countersink chamfering
Picture
Spotting tools produce a shallow hole to enable a drill to get a more accurate hole position. This enables you to produce more accurate machined parts. Spot Drills hep insure geometrically uniform holes and improve hole location accuracy.

Ideally, the proper spotting angle should have larger point angle than that of your drill, so the center of a drill shall be the first point to contact workpiece to prevent the drill from "walking".

The Nine9 ACE spotting tool is not only produce better hole position but also extends the tool life of the drill and improves production efficiency.  . Nowadays, to cope with market demands, we supply various point angles.
Nine 9 Ace Spot Drill 2-flutes edged
The ACE Spot Drill design assures precise positioning of the insert as a result of the dual clamping screwed design. This results in vibration free while cutting.

​The symmetric 2-flute edge design reduced the lateral forces and enhances the rigidity enabling to you to run higher feed rates.

Additionally, the double point angles make the insert tip stronger and prolong the service life of the tool. Optimal internal coolant design brings better balancing to run at high speed. 
The ACE Set Drill Design enables a very precise positioning of the inserts a result of the dual clamping screwed design.

​This also ensures vibration free while cutting.

The internal coolant design enhances the balance so you can run at higher speeds.

2-flutes edged is symmetric, it reduces the lateral force.
  •  Cylindrical shank.
  • • Made of hardened high alloy steel, 58 HRC.
  •  • Internal coolant.
Nine 9 Ace Spot Drill 2-flutes edged
According to customer feedback : "The surface finish on the holes is very nice and the chips fall away very easily. I am very impressed with how well the tip is holding up. That has been my biggest issue with using carbide spotting tools in the past, as the tips are too fragile. The Nine9 ACE Spot Drill features a dual point angle design that ensures strength at the center to prevent fracturing."
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Detailed Guide to Roll Taps

4/18/2023

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Technical article courtesy of  Regal Cutting Tools
​
Most craftspeople will agree that whenever an internal thread can be made with a roll form tap, this is the tool that should be used for the job. Roll taps, also known as form taps, hold distinct advantages over cut taps. Roll tap advantages are inherent in the way they create the threads.

As the names suggest, these taps form the threads by rolling and deforming the material inside the hole. They push the metal out of the way to create the thread roots and base. Cut taps, also true to their name, carve metal away from inside the hole, ejecting chips as they go.

Reasons to Use Roll Form Taps

Roll taps are a great option when considering workmanship and price point. First, roll taps are chipless. Because they do not remove material from the hole, form taps generate no chips that must be removed. This carries several advantages:

  • Tool Life – Cut taps have flutes cut into them through which chips migrate up and out of the hole during threading. Flutes take away the taps’ bulk and rigidity, weakening them and making them more susceptible to wear and breakage.

  • Efficiency – Flushing chips from a blind hole and disposing of them takes time. Roll taps eliminate this wasted time so machinists can thread more holes in the same amount of time. Roll taps’ strength also permits their use at higher feeds and speeds, increasing their efficiency even more.

  • Thread Quality – Forming threads rather than cutting them creates more precise pitch diameters and surface finishes. Just as important, rolled threads are stronger than cut threads because the metal grains are deformed along the thread contours.

  • Speed – Roll form taps should be run at 1-1/2 to 2 times the speed of a cut thread tap for a given material. The forming action creates heat and can “work harden” the material being formed. It is a good practice to form the thread and reverse out of the hole as quickly as possible.
Regal Roll Form MetFlo Taps
Regal MetFlo Taps

When Not to Use Roll Taps

While an excellent choice for most applications, there are a few situations that do not lend themselves to roll tapping including:
  • Threading a through-hole – Form taps may deform the exit hole, which will necessitate a second, time-consuming step to repair. Spiral-point cut taps are the best option for such a job. They push chips ahead of the cutting edges, keeping flutes clean. The chips fall harmlessly out the exit hole as the tap breaks through.

  • You’re threading a big hole – Thread-cutting taps require less horsepower than thread-forming taps. Cutting large holes with a form tap requires twice or three times as much torque as with cut taps, which can take its toll when threading large internal surfaces.
​
  • The workpiece is hard –Form taps are suitable only for soft and malleable metals such as soft steel, some stainless steels, aluminum, copper, brass, and lead. Typically, the material to be formed should be less than 32Rc in hardness.
​

Types of Roll Taps

Roll taps are engineered and manufactured in two main styles to match the type of hole and fastener to be used. Bottoming roll taps feature little to no taper on their end threads. This allows full thread production to the very bottom of the hole.

The bottom 3 to 5 threads on a plug tap are tapered to allow the tap to gradually begin deforming the hole material, creating less stress on the tool and giving the full threading edges a base from which to work.
 
Regal Cutting Tools has built a reputation for high quality taps and other metalworking tools and an uncompromising commitment to customer service. Regal manufactures a full line of roll taps to suit any application. Regal can even engineer custom taps quickly and affordably. To learn more about Regal’s taps and learn which products are best suited for your workflow, contact our team today.
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Dapra Introduces Vaper High Feed Milling

3/15/2023

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VAPOR™ is a high feed indexable mill that maximizes metal removal rates.
​Utilizing light depth of cut (DOC) combined with extreme feed per tooth (FPT) to increase productivity.

Dapra Vaper High Feed Milling
Dapra Corporation has announced the DAPRA Next Technology - High Feed Indexable Milling Platform - "VAPOR™ powered by TRI-X2".

VAPOR™ is ideal for extreme machining. The VAPOR™ platform has unique elements in body design and TRI-X2 insert geometry for higher metal removal rates and extended tool life. 
​
The design is created for lighter, faster cutting and versatility through positive cutting geometry and excellent ramping capability. It's designed with a new double-sided insert series for lower cost per usable cutting edge. Inserts are installed with a large insert screw for longevity and easy indexing. This makes the advanced design highly shock resistant through-hardened steel.
  • Available in both endmill and shell mill configurations
  • A diameter range of 0.500” - 2.00”, with up to 7 flutes
  • Through coolant holes for maximum control and chip evacuation
  • Initial offering is a double-sided 6mm insert series
  • Additional product series coming soon!
​
Picture
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Browne & Co., Inc.
9605 Tanager Drive
Chardon, Ohio 44024
Phone 440.285.8655
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dmb@brownesales.com
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