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Dapra Introduces Vaper High Feed Milling

3/15/2023

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!

The Fullerton 3116 TiMill End Mill Made for Titanium

2/14/2023

by Bernard Martin

Fullerton 3116 TiMill milling titanium hi temp alloys Browne co agent regional manager

Looking for an end mill with unsurpassed performance in high-efficiency milling of Titanium? The new Fullerton 3116 TiMill end mill may be just what you need.

Titanium is half the weight of steel and twice the strength of aluminum: It's a high strength, light weight material with excellent fatigue performance, super durable in high stress environments and corrosion resistant.

As a result of titanium's material properties it's making it become evermore popular in the aerospace, defense, shipbuilding, medical adn dental industries. It's also what makes it considered a "more difficult to machine" material. Let's dig into that a bit more.

Generally, titanium grades 1 through 4 are considered commercially pure titanium with varying requirements on ultimate tensile strength while Grade 5 is what is most often seen in the machining industry. It's often alloyed with 6% aluminum and 4% vanadium. This is what is commonly known as 6Al4V or Ti 6-4. Also quite common is 4Al4V or Ti 4-4.

Why difficult? Well, first it has low Young’s modulus meaning that is more elastic than other materails: It's "gummy" which often causes spring back and chatter during machining and can readily generate long stringy chips if you don't have the correct edge prep. On top that, it's also prone to work hardening and galling super easily. You've got to keep the cutter in-the-cut: Insert cutters just aren't as good as solid endmills at doing this.

Next, titanium does not have good thermal conduction properties like aluminum. Instead of heat being evacuated in the chips or transferred to the base material, heat tends to be transferred to the cutting tool which reduces it's tool life. Heat kills. Tool life declines. The right coating helps.

The final icing on the cake is that titanium is prone to work hardening. During uniaxial loading, the initial rate of hardening is higher in compression so if you come back for another pass you need to get under the work hardened layer, that is, leave enough material for a finish pass to get under the layer or your tool life will suffer and your part finishes will decline with it. Ideally, finish to size in the final pass if you can.

The trick to machining titanium has always been to keep consistent coolant flow to evacuate the chips and maintain a consistent chip load. Again, rough to your finish size. Don't let it work harden.

That's what we've learned about titanium over the past couple of decades. There has been a ton of research on titanium's properties and that research has led to further refinement of the cutting tool geometry at Fullerton.

The design of Fullerton's 3116 TiMill is based upon over a decade of aerospace testing and development and addresses many of the machining issues that Titanium presents. It's a 6-flute tool built with a 38°helix. The increased number of flutes allows for the tools to remain "in the cut" longer and more consistently. It doesn't induce as much heat as a lower number of flutes tends to do. instead, it's consistent. The 38°helix evacuates the chip at a more optimum angle than a 35°, 37.5° or 40° helix that predecessors made by competitors have tried.

3116 TiMill End Mill Specs

End Style: Radius, Square
Number Of Flutes: 6 Flutes
Lengths: Stub, Standard
Coating: FC-13
Single/Double End: Single End
Cutting Type: Center
Spiral Direction: Right Hand
Helix Angle: 38°
Dimension Type: Imperial, Metric
Shank Tolerance: h6
Cutting Tolerance: +.0000"/-.002" | +0.00mm/-0.05mm

The 3116 TiMill also has a pretty beefy core diameter that increases the strength and stability in-cut which is ideal for a material like titanium with plastic deformation properties makes it want to spring back and push the cutting tool.

The edge prep on the 3116 TiMill is consistent and quite strong, so it naturally resists fatigue and micro-chipping. This means that you can bump up your SFM for higher speeds with longer times in-cut and the tool will produce improved surface finishes and therefore higher quality parts.

Fullerton has put their FC-13 coating on the tool. It's a nanocomposite: Nanocrystalline grains embedded into Si3N4matrix binder. It has an extremely high hardness, toughness and heat resistance which makes it ideally suited to keep the heat out of the core cutting tool in titanium applications.

The 3116 TiMill 6-flute high-performance 38°helix end mill is stocked with FC-13 coating.

Speeds and Feeds are Critical

Fullerton Speed Feed RPM SFM Titanium 6Al4V 4Al4V

* IT'S MADE FOR TITANIUM! So that means it is NOT Recommended for High Si Aluminum (>10%), Low Si Aluminum (<10%), Composites, Plastics, Brass & Copper, or Graphite. NOT Recommended!

Choose your Size

Fullerton Boeing Speed Feed RPM SFM Titanium 6Al4V 4Al4V

Create a QR Code on any Metal Component with a Nine9 Spotting Tool

1/10/2023

QR code on metal component by Nine9 spotting tool

QR codes are becoming ubiquitous. You can find them on business cards, letterhead paper, packing boxes, concert tickets, and even on metal!

QR codes are also used extensively on medical equipment, automotive parts, tool holders and clamping devices to provide operators a hand help links from their smart phone to operating instructions and other critical documentation.

As a result of laser marking being blurred or erased there has been more and more interest in a more permanent method of creating a QR code in metal and the Nine9 Spotting cutting tool has become an easy solution.

Nine9 has released a series of NC Spot Drills for general spotting-chamfer tool, a Micro Spot Drill for mini spotting, and a New ACE Spot Drill for optimized machining efficiency and stability.

Spotting tools are available in 60°, 90°, 120°, 142°, and 145° included angles.

Nine9 cooperated with Heidenhainto to demonstrate making this QR code application in the video below.

JobsOhio Reports Record Year, Advanced Air Mobility Support

12/27/2022

Successful initiatives include developing advanced air mobility (AAM) in the state.
December 23, 2022, Posted by Eric Brothers in Aerospace Manufacturing & Design

JobsOhio is Ohio's private, nonprofit economic development corporation that works outside but alongside state government to support the creation of jobs and sustainable economic growth for all Ohioans. The Q4 President's Report to the Board highlights programs that yield a return on investment and position the state as one of the world's great automotive hubs and a leader in aviation and the advanced air mobility (AAM) sector.

JobsOhio President and CEO J.P. Nauseef notes that as the No. 1 supplier state to Boeing and Airbus, Ohio is a powerhouse producer of systems and parts for the aerospace industry. Earlier in the year, Sierra Nevada Corp. announced plans to build one of the largest aircraft maintenance hangars in America in Dayton, bringing maintenance and modification of military aircraft to Ohio.

The state also plays a crucial role in developing AAM technologies with robust supply chains, test markets, partners, and enabling legislation for public and private sector entities.

From flying vehicles to air taxis to NASA AAM Mission supporters, Ohio is a leader in AAM and aeronautics research. Credit goes to Ohio lawmakers for opening the skies for unmanned aircraft systems traffic management (UTM) and urban air mobility (UAM) of the future.

In September, the Springfield-Beckley Municipal Airport hosted a groundbreaking for the National Advanced Air Mobility Center of Excellence. The NAAMCE is funded by the Department of Defense, JobsOhio, and the City of Springfield to facilitate collaborations between the Air Force Research Laboratory, NASA, the Ohio Unmanned Aircraft Systems Center, local colleges and universities, and private industry to support the development of AAM projects.

Browne & Co. Announced as Agent for Dapra Corporation

12/1/2022

CHARDON, OH - Browne & Co is excited to announce that they begin representation of Dapra Corporation products in December 2022.

Dapra specializes in the design, service, and support of American-made, high-performance indexable carbide milling tools for a broad range of operations.

Dapra Corporation is a U.S.-based, multi-generation family-owned parent company to multiple brands which provides high-quality engineered solutions for various manufacturing and industrial markets. From indexable cutting tools to permanent part marking equipment Dapra Corporation continues to develop and invest in solutions to empower the success of manufacturers across North America.

For over 65 years Dapra has provided milling, workholding, and power tool solutions to a wide array of manufacturing segments including aerospace, automotive, mold and die, and firearm. With their proven high-performance solutions combined with industry-leading application expertise and a robust distribution network Dapra has earned the trust of businesses from around the world.

From small workshops to globally diversified manufacturers, they are more than a supplier, they are a partner in yours and our success.

According to David Browne at Browne & Co., "At our core we have always had a very strong presence in CNC milling products. We're at the spindle. Dapra really matches what our company does and we're excited to launch into 2023 with Dapra's high performance milling products."

Browne & Co. is excited to work with our customers with these premiere products that include:

VAPOR™ High Feed Mill - 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
Copy / Face Milling - This family of end mills and face mills (shell mills) provides aggressive material removal so you can maximize your copy milling operations with our single- and double-sided Toroid series button cutters.
Shoulder & Edge Milling - Obtain extreme metal removal with our single-sided and EDGE² DSS double-sided 90° Square Shoulder milling tools. These high-performance end mills and face mills (shell mills) cut to a true 90 degrees, generating smoother finishes
Finishing / 3D Contour Milling - Achieve superior surface finishes with our single-sidedand EDGE² SBN double-sided Ball Nose series. Use ball nose tools for fine finishing of slopes and curves. Back draft/bull nose tools are great for finishing tapered walls and deep straight walls.

You Have Options When Choosing a Saw Arbor

11/22/2022

Edited by Bernard Martin

Often times in a shop, a saw arbor is a saw arbor is a saw arbor. That's just not the case and Martindale Gaylee offers several solutions. They have variants to saw arbors to meet your specific needs whether it be in a CNC milling machine, a CNC Lathe, a manual mill or even a Swiss Style CNC machine. This includes:

TI-LOC® Saw Arbors with integrated ER taper
Gold Star Precision Series Saw Arbors
General Purpose Series Saw Arbors
Custom Saw Arbors

Let's take a look at the differences below.

TI-LOC® Saw Arbors with integrated ER taper

Saw Arbor tiloc ER Clamping nut snapin assembly.

Twist and snap into any ER clamping nut. No special holding nuts required.

The Ti-Loc® SwissClamp System is a taper-integrated small tooling system is designed to work with virtually any collet or tool holder that employs the ER collet system (DIN6499). The Ti-Loc directly mounts into ANY ER Taper Live or Static Tool Position.

The Ti-Loc® System works with any existing tool holder and most all ER collet clamping nuts. Simply insert the Ti-Loc holder into any ER nut and twist to align the locking cam profile jus was you would for any ER collet.

The Ti-Loc® SwissClamp System can be used in any machine that has ER collet live tooling. It comes standard with ER 11, ER16 and ER20 taper arbors that serve as their own collet, eliminating need for two-piece arbor system.

This single piece design adds rigidity of set-up and improves total indicated runout (TIR). In fact, it reduces tolerance “stacking” to an incredibly low TIR of less than 0.0002". To top it off, it's less expensive & more cost effective than most comparable two-piece arbor systems.

A recommended maximum saw thickness is approximately 0.080”

Gold Star Precision Series Saw Arbors

Gold Series reach saw arbors

Gold Series reach saw arbors

Martindale Gaylee also offers a Gold Series reach arbor. These arbors are heat treated and ground to 0.0004” T.I.R. concentricity and squareness.

The Gold Series are engineered for use with carbide saws and where accuracy is a must. This VIBRA-CORE design, along with the deep low profile caps, gives extra support and less vibration.

General Purpose Series Saw Arbors

General purpose slitting slotting saw arbor

General purpose slitting slotting saw arbor

Martindale Gaylee's general purpose slitting/slotting saw arbors are all ardened all over (58/60 Rc) for added toughness on cutter locating surfaces and shanks.

The General Purpose Series Saw Arbors shanks ground to within 0.001" T.I.R. of cutter location diameter. They have an extra long, strong body with a protective black oxide finish. The super low profile on caps allows the cutter to reach areas inaccessible with conventional arbors.

Stout plug: extra support, less vibration sum up the benefits of this style. Oh, and Weldon style shanks are readily available.

Custom Saw Arbors

Custom made special saw arbors built to specification

An example of a Custom Saw Arbor

Can be made extra-long for reach beyond or inside part features

Accommodates multiple cutters for straddle or profile
Different outside diameter cutters on the arbor
ID grooving operations
Made with or without keyways

Spec your own custom made saw arbors

You can spec your own custom saw arbor

The New ARNO FAST CHANGE is a Revolution on Fast Tool Changes in Swiss CNC Machines

11/8/2022

AFC tool holders: the revolution in fast tool changes – patent applied

The ARNO FAST CHANGE system is a complete quick change solution for your Swiss machine. It consists of a through coolant gang plate that acts like a manifold, so all of the coolant is delivered behind the scenes.

It's your solution for easy tool changes despite limited space in Swiss type machines: The two-part AFC holder – even untrained staff can replace tools fast and reliably.

This is how it works: The rear part of the tool holder (AHA fixed stop) is first fixed in place.

Only the front part is removed to replace the tool.

This eliminates the need to restart and recalibrate the zero point since the length to the insert tip is always the same – whether the grooving system or the turning system is used.

When the two holder parts are plugged back together, they are immediately connected by an O-ring to prevent the tool from falling into the machine accidentally.

At the same time, the floating mount provides enough clearance to compensate for angle offset. The two parts then fit together perfectly.

Now you benefit from a high level of precisions when changing tools and a leak-proof coolant hole.

The through coolant split shank tools will reduce your tool swap time to a minute or less. This is an innovative system that is engineered and manufactured in Germany solely to keep your spindles running and dropping more finished parts per shift.

As of right now we have 51 gang plates in stock for: Citizen, STAR, Hanwha, Tsugami, KSI Swiss, DMG Mori, Nexturn and Tornos.

To learn more, click the button below:

Discover Fullerton Tool's Reamer Offering

10/27/2022

Choose from Fullerton’s selection of carbide reamers with Just-In-Time offering that includes manufacturing any size reamer within 24 hours.

Fullerton’s carbide reamers are designed for numerous reaming applications and for a variety of materials including titanium, super alloys, hardened steels, stainless steels, steels, cast iron, graphite, brass & copper, hi silicon aluminum, low silicon aluminum, composites, plastics, and wood.

Reamers are manufactured to support customers in numerous industries, including aerospace, automotive, heavy equipment, medical, and mold & die.

Ready to ship within 24 hours!

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All The Metals We Mined

10/21/2022

From: Visual Capitalist

The world produced roughly 2.8 billion tons of metal in 2021. This chart represents the metals we mined, visualized on the same scale.

This was originally posted on Elements.

“If you can’t grow it, you have to mine it” is a famous saying that encapsulates the importance of minerals and metals in the modern world.

From every building we enter to every device we use, virtually everything around us contains some amount of metal.

The above infographic visualizes all 2.8 billion tonnes of metals mined in 2021 and highlights each metal’s largest end-use using data from the United States Geological Survey (USGS).

Which Drill Point Angle Should I be Using?

10/13/2022

Technical Article written by Regal Cutting Tools

The selection of an appropriate drill point angle for your bit should be informed by questions about your application. Yes—a hole is a hole is a hole—but what is the purpose of the hole, what type of metal are you cutting into, and what are the specifications for the finished hole?

In addition to the drill point angle, factors that can affect successful drilling include:

Rigidity
Speed
Length of the Drill
Coolant Flow
Type of Drill Point

There are two main characteristics that define a drill point. First is the included angle of the point and the second is the configuration of the point. The point configuration is a key element in the choice of drill styles for a particular job.

Common Drill Angles

The most common included angles for drills are 118° and 135°. These angles are an artifact from the time when drilling was largely a manual process, and the drill bits were conventional conical shapes. Over time, tool makers learned that by grinding a conical point with a flat surface (a facet) to create a linear chisel, they could reduce the thrust required and also improve the process of cutting the metal or wood and removing the chips. If you’re drilling by hand, this is a clearly a major benefit.

Today, with advanced drilling machines, multi-faceted drill points are the norm. Not only do they require 50% less thrust, but they also generate 60% less heat than a conventional drill point. And there are a number of different configurations, each of which—when combined with a particular drill point angle—is suitable for specific jobs.

The general purpose drill points found on most jobber drills are 118° angled drills. They are typically used for cutting into soft metals such as aluminum, whereas the 135° variant is best suited for hardened materials, such as stainless steel. A 135° drill is flatter than 118°, which means that more of its cutting lips engage with the material surface sooner to begin the full metal cutting action.

Check out our guide below for what angles are optimal based on the material that is being drilled:

Efficient Drilling

Specialized Drill Point Configurations

There are a number of drill point configurations and these may be found in both 118° and 135° variants. The different configurations are selected based on the drilling application—for example:

Are you cutting into hard metal or soft?
Is self-centering possible or will a guide bushing be needed?

Conventional points with 118° point angles are used most commonly for drilling in a wide array of materials. Other drill point configurations include:

Notched Point

Notched points: were developed for drilling hard alloys and have reduced drag on the chisel edge.

Helical Drill Point

Helical points: have an S-contoured chisel that is self-centering and cuts close to actual drill diameter.

Racon Drill Point

Racon® points: have a continuously varying point angle that generates less load and less heat while cutting into the metal and have a longer usage life. However, Racon points are not self-centering and must be used with a guide bushing.

Bickford Drill Point

Bickford™ points: combine the features of the Helical and Racon points—self-centering, long life, burr-free breakthrough and higher feed capacity.Nowadays, there are few excuses for not seeking and using the right point configuration for the job. Specialist companies make drill pointing equipment and have the skill to provide many other style points for tough applications.

There’s an old proverb “A bad workman always blames his tools,” which means that success is not dependent on the tools we use, but how we use them.

In the case of drill points, that may not be 100% true. While you can drill a hole with almost any drill point, the one you use may not be the best for the whole job, whether you are drilling one hole, a hundred holes, or thousands!

By choosing the right drill point configuration and included angle, you can receive longer tool life, more precise hole geometry, cleaner breakthrough and improved job productivity.

If you have questions about the right drill point for your job, just ask us!