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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:
Extra Length, Tanged, Bright Finish (Catl No 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 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 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.
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. 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 ChipCast 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.
Type 2: Continuous ChipMedium 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.”
Type 3: Sheared ChipsLow 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.
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.
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.
Grade SelectionDapra 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.
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.
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).
Geometry SelectionDapra offers three different cutting edges for the Square Shoulder milling line:
General RecommendationsMaterial 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.
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. 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. 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 NecessityAndreas 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 ComplexBack 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 CenterA 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 EnvironmentHAIMER 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 BalancingJust 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.” 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.
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." 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 TapsRoll 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:
When Not to Use Roll TapsWhile an excellent choice for most applications, there are a few situations that do not lend themselves to roll tapping including:
Types of Roll TapsRoll 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. 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 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.
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.
Speeds and Feeds are Critical* 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 SizeQR 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. |
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