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Article originally published in Cutting Tool Engineering.
By, David Conigliaro  March 1, 2014 - 10:45am

The well-established concept of radial chip thinning (RCT) provides compelling productivity-enhancing benefits, but is still not widely applied. RCT occurs when the DOC is less than the radius of a round milling insert and chip thickness is less than the programmed feed per tooth.

This means a higher programmed feed rate is needed to achieve a particular chip thickness, measured in ipt. In other words, the programmed feed rate can be higher because of chip thinning.

Many programmers and machinists are afraid to increase the feed, a fear usually based on an unfortunate previous experience. However, the industry trend is to step-down significantly deeper during machining, greatly reducing step-over.

Step-overs have been typically much more than 50 percent of a tool’s width because end users tend to take shallow step-downs, whereas deep step-downs require reduced step-overs. It’s important to note RCT doesn’t comes into play when applying less than half the tool’s width.

Toolpaths programmed with Mastercam’s Dynamic Machining suite produce radial chip thinning (top), whereas a traditional toolpath (above) doesn’t enable the productivity-enhancing benefits RCT provides.
New CAM toolpaths and cutting tool designs, such as those used in Mastercam’s Dynamic Machining suite and Iscar’s High-Efficiency Machining tools, push the advantages of RCT to its practical limit.

None of this was possible until all the elements—including cutting tools, machine tools and CAM toolpaths—caught up to each other a few years ago. Therefore, now is the time to consider RCT for your operations.

Variable-pitch tools, in particular, have virtually eliminated harmonics during machining, and advances in tool coatings enable them to withstand temperatures up to 900° F (482° C). In addition, machine tools are faster and CAM toolpaths are producing movements conducive to full-depth cutting.

On the CAM side, local resellers can demonstrate how to gain efficiencies. As a result, machine shops are applying RCT to improve productivity 30 to 200 percent by reducing cycle times. They are also reducing costs via longer, more predictable tool life and less wear and tear on machine tools.

For example, one of our customers was consuming 70 minutes cutting pockets in mold bases. It was taking shallow step-downs and aggressive step-overs while running at high feed rates. We exchanged their tool with an Iscar tool made of higher-quality carbide designed for high feeds and reduced cycle time to 45 minutes.

Next, we applied the Dynamic Machining toolpath calculations—stepping all the way down—and replaced the customer’s traditional roughing operation.

Time to cut the pockets fell to 12 minutes, an improvement of nearly 500 percent.

The combination of changing the tool and its motion also reduces tool cost per part, because tools last longer. Another money-saving aspect with these advanced machining techniques is coolant isn’t usually required for heat removal when cutting most steels if the speeds and feeds are correct. Instead, chips are simply air-blasted away.

Dry machining actually extends tool life, because the heated tool is not being shocked when coolant repeatedly hits it, which breaks down the coating and causes premature tool failure.

It’s challenging for shops to try new approaches when the daily routine demands shipping high-quality work and current machining methods are achieving that. However, shops can do even better. All it requires is a conversation with your CAM reseller and tool vendor.

While the science of RCT can be confusing, the application is not. When the step-over is more than 45 percent, the productivity improvement will be modest. But the cycle-time reductions can be amazing when the step-over ranges from 10 to 35 percent.

Remember, new dynamic toolpaths ensure the machine will not shove a tool into a part corner or have it do a full-width cut. Give it a try!

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The Sowa GS multi-tasking range of vises has been specially designed for 5-axis machines. Working on 5 sides of the workpiece, it allows the best optimization of the machining cycle. Thanks to the compact design this kind of vise can be installed on all machining centers.

These vises have the highest accuracy in positioning and alignment (± 0.02mm) due to ground rack teeth on both the base and the fixed jaws.

Call or email for closest authorized Sowa distributor
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Tavares, FL February 4th, 2020 – GWS Tool Group is pleased to announce it has acquired North American Tool Corporation (NATC).  They represent the second add-on acquisition in 2020 for GWS.

With the addition of NATC, GWS further strengthens its reputation as the premier multi-disciplinary manufacturer of high-performance custom cutting tools in the marketplace today.

“NATC is an exciting add for us,” said Rick McIntyre, GWS’ CEO. “Their customer service model is one of the best in the business and their focus in taps and threadmills fits in like a perfect puzzle piece to our dynamic and holistic offering. We are very excited to be continually expanding our value proposition for our customers with highly additive acquisitions like this. ” McIntyre continued.

“North American Tool is very excited to be joining GWS Tool Group, a company that embodies the attributes that have long made us successful,” said Curt Lansbery, NATC President & CEO.

“A customer-centric approach to business rooted in a commitment to quality and quick delivery marry perfectly with our model here at North American Tool. We have no doubt that this move to join GWS will be positive for our associates and will ensure the continued growth of the legacy that we have worked to develop.”

The team at NATC will continue to operate from the Illinois facility as a manufacturing arm of GWS Tool Group, and the company expresses intent toward continued investment in the facility, machinery and equipment and human resources. Customers of NATC are said to expect continuity of the NATC offering and customer service disposition under cover of the GWS ownership.

About GWS Tool Group
GWS Tool Group is a US-based, vertically integrated manufacturer of highly engineered custom, standard, and modified standard cutting tools, primarily servicing the aerospace and defense, power generation, automotive and medical sectors. GWS Tool Group has acquired multiple businesses in the course of its growth which now serves as the respective manufacturing divisions for the Company.

For more information, please visit www.GWSToolGroup.com or contact Drew Strauchen, EVP of Marketing & Business Development for GWS Tool Group, at [email protected] or 877.497.8665.

As a leading manufacturer of high quality Rotary Tooling and Machine Vises GS Tooling is known for providing the best quality to our customers. Each GS Live Center is of the highest quality and manufactured to the industry’s tightest specifications. All this and still priced 40-50% below the leading brand names.

• Each GS Live Center uses either a 3, 4, or the incredible 5-bearing system. Each bearing system has been individually and specifically designed for the applications in which that live center is meant to be used. This specificity of design provides superior performance and tool life across the entire GS line of centers.
• An additional special coating process is applied to the lip seal contact area. This coating offers a higher sealing ability and reduces rotational friction, both contributing to longer tool life.
• If roller bearings are used at high temperatures, the hardness of the bearing steel decreases. Consequently the basic load rating, which depends on the physical properties of the material, also decreases. GS Live Centers are designed to prevent excessive heat. Live center temperatures are controlled even when rotating at maximum RPM.
• Every single center has passed at least 4 different accuracy tests to ensure our customers the highest quality available in the market today.