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. 
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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!

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by Bernard Martin

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.

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.

Guest Blog by Mark Donze at Fullerton Tool 

First, let's discuss general purpose end mills. General Purpose (GP) End Mills are standard single, 2, 3, or 4 flute geometry end mills made for use in a wide variety of materials.

​Benefits of General Purpose End Mills:

• Lower prices
• Very versatile - they work in a variety of materials and applications
• Typically easier to resharpen - general-purpose end mills can usually be resharpened by the user or by a local regrind shop, whereas a high-performance end mill typically will need to be sent back to the OEM for resharpening

Next, High-Performance (HP) End Mills contain specialized geometries for a specific material being cut.

Benefits of High-Performance End Mills:

• Material and/or application-specific - This does not mean that an HP cutter will not work in more than the listed materials or applications. For example, our Fury end mill is recommended for a wide range of materials and applications and will cut almost anything and any tool path. So don't be afraid to experiment.
• Better tool life, especially in difficult-to-machine Materials - HP cutters typically require less frequent tool changes and fewer offsets.
• More adapted to high-speed machining or other advanced milling techniques.
• Better surface finishes on your parts.
• Usually have premium coatings that target a specific range of materials.
• Typically have edge preps like hones or polishes that target a specific range of materials

With this information in mind, if you are a company that does small runs in a wide variety of materials you may prefer GP end mills. Whereas, if you are making high-volume parts where cycle-time and up-time are king, you may prefer an HP end mill for your use. Remember, there are no hard lines drawn. Each application is different and preference is ultimately up to you, the end-user. 

If you aren't sure, you can contact your Fullerton authorized distributor to help make this decision. We will work with you to get the end results you desire with a wide variety of both GP and HP end mills available.

We even have some tooling where we apply HP coatings to GP tools to help you get the most out of your cutting tool investments. We have a huge selection of inventory items and of course, if you need a special tailored tool to your specific needs, we have engineering and application knowledge to get the most out of your cutting tool budget.

We also have resources on our website to help you navigate which tool is the best for your needs. Discover what end mills are recommended for your material and application by using the Fullerton Tool End Mill Selection Guide 

You can also explore and search for tooling by material, application, or tool specs as well as 
 recommended speeds and feeds by series which you can access at the search button below.

"Ergo" is a new trademark of Nine9 for ER type indexable cutter. The cutter is assembly kit by the 3 parts including Ergo nut, high strength Ergo pin and Integrated ER taper. Patented design mechanism to produce high clamping Forces and high runout accurancy.

It's perfectly suitable for driven tools and spindles with ER interface of CNC turning centers and swiss type automatic lathes such as Star, Citizen, Tsugami, Doosan, Tornos, INDEX, EMAG and so on.

​The Ergo provides types ER11, ER16, ER20, ER25 taper-shank cutter. The ergo tooling include milling cutter, spot drill, chamfering tool, corner rounding, engraving tool, deburring tool, center drill and boring tool.

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

 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. 

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 

Fullerton Tool Company now supplies, stocks, and supports InovaTools' products!

Their strategic partnership with InovaTools allows Fullterton to expand thier product offering by selling, stocking, and supporting Inovatools' coolant fed, deep hole drills, micro drills, modular tools, diamond coated end mills, and die & mold end mills.

Fullerton is Now Offering InovaTools:

• Coolant Fed Drills
• Deep Hole Drills
• Micro Drills
• Modular Tools
• Diamond Coated End Mills
• Die and Mold End Mills

Download our InovaTools Catalog for a full offering of available products sold by Fullerton or download the Tooling Portfolio for an overview of available InovaTools products

Did you know that you can quote custom end mills instantly with Fullerton Tool's new and improved FAST Quotes - Specials system? It's true - you can generate pricing and lead times for your custom end mill in a matter of minutes. 

New & Improved FAST Quotes - Specials Includes:

• Pricing for Expedited & Standard Production Times
• Notifications when Tooling Specs Match a Preexisting Standard EDP
• Pre-Population of Tool Features (like coating) by Series
• Expanded Series Offering (now includes 3116-TiMill, 3600-Force, and 3845-Falcon Finisher)
• Addition of Chipbreakers
• Improved User Experience

Interested in creating your first quote? Our FAST Quotes system can only be accessed by registered users. To get started, create your account via the button below

Have questions? Contact our Customer Service by email: sales@fullertontool.com, by phone: 800.248.8315, or by Live Chat at the bottom right corner of our website