If you ask any DATRON application technician what their favorite cutting tool is, there’s a high probability that you’ll get this answer: The Monoblock Cutting Tool (aka. the Monoblock).
In our world of high RPM spindles, the Monoblock cutting tool is King. Co-Developed with industry leaders Big-Kaiser, the Monoblock is a 20mm, double-flute, indexable insert cutter, and is a tool of many talents.
What Sets the Monoblock Cutting Tool Apart?
1. Rigid design – The Monoblock cutting tool is different from our standard tooling in that there is no shank to clamp on – the tool and tool holder are one. By integrating the HSK-E25 taper into the tool itself, a very robust tool is provided.
2. Vibration free – Not only is it tough, but this clever design also allows for extremely minimal vibration, even at its recommended limit of 36,000 RPM! This allows for very smooth operation even under heavy load.
3. Clever cutter geometry – The cutting inserts have been engineered to provide a perfect all-around performer. A large edge radius and wiper flat provide excellent floor finish, while high radial and axial rake angles allow for lower cutting resistance for more efficient roughing.
4. Cost efficiency – The inserts for the Monoblock cutting tool come in two varieties – polished carbide for milling of plastics or non-ferrous metals, as well as specially treated inserts for milling of steel. Either way, the inserts are engineered to last, and can even be flipped 180 degrees for an entire second round of punishment. Once the inserts are depleted, simply replace them both and carry on.
What Can You Do With The Monoblock Cutting Tool?
The question should be “What can’t you do with the Monoblock?”
Face milling – Combining three excellent characteristics: edge radius, wiper flat, and vibration free operation, results in some of the smoothest possible floor finishes.
Ramp/Helix milling – While the Monoblock isn’t center cutting (no straight plunging) you can accommodate a 3-5 degree ramp angle. Pair this with the high feed/speed capabilities of the DATRON and you can make quick work of most features.
Roughing – The previously mentioned cutter geometry allows for very aggressive depths of cut at very high feed rates, as can be seen clearly in one of our well-known demonstration videos. In this instance, a very heavy stepover was utilized (80% of tool diameter) with a smaller depth of cut (around 8% of tool diameter). You can also choose to utilize the entire 10mm of cutting flute to boost efficiency as seen in my Instagram post:
3D contouring – Since the edge radius on the Monoblock cutting tool is rather sizable (0.8mm) it can serve as a bull-nose cutter for doing some large scale 3D contours – and since the tool is rock-steady, the surface finish comes out gorgeous.
So, there you have it. Now you can understand why the Monoblock cutting tool is the King in the house of DATRON.
4 Ways to Ensure Consistent Depth of Cut (even on surfaces that are anything but flat): As far as your CNC is concerned, the world is all sunshine and roses: your cutting tool never deflects or wears, your fixture is rigid and free of vibration, and the surface of your workpiece is perfectly flat. However, those of us with gray matter here in the real world, know that the truth of the situation is anything but perfect – tools wear, fixtures flex, and that surface you’re about to cut is about as flat as the good Earth itself.
The video above explains it all! Video courtesy of #rapiddtm – visit them on Facebook!
Here at the DATRON blog, we’ve talked a bit about how to wrangle in tool deflection, and we’ve shared some tips about best practices for workholding. Today, we’re going to cover a few tricks you can use to maintain a consistent depth of cut when engraving, marking or milling surfaces that aren’t exactly the poster child of flatness.
Defining Flatness: Simply put, the term “flatness” is used to describe an area between two parallel lines within which a surface must lie. This specification will often work in conjunction with other dimensional call outs on the print to describe the range of possible locations of a given surface:
As you may or may not have realized by now, no surface is perfectly flat – indeed very few surfaces even come close to perfect flatness – and when it comes to manufactured parts, flatness costs money. So, if it doesn’t have to be flat, or if the print doesn’t define it as flat, you have to assume that it really isn’t flat. Depending on what you need to do to a particular surface, it’s flatness (or lack thereof) will need to play a key role in your milling strategy.
Consistent Depth of Cut Method 1: Qualify the Surface
If you are able to do so, qualifying the surface is far and away the easiest and most sure-fire way to make sure that the surface you’re about to work on is reasonably flat and true. Qualifying a surface is just fancy machinist talk for face milling the entire surface, taking off a few thousandths at a time until the whole surface is reasonably uniform in terms of flatness. A qualification pass is often the first step you will see when watching a milling process on a shop floor or online and this is for a number of reasons, not least of which is to ensure flatness of the surface in question.
When starting with a piece of billet or raw stock, qualifying a surface is almost always an option and in general is just good machinist practice. Sometimes, however, qualifying the surface simply is not an option – such as when working with die cast material, a forging, or with otherwise completed parts that simply need marking or serialization. In these cases, a different strategy will need to be employed in order to achieve a good result.
Consistent Depth of Cut Method 2: Use of a Spring-Loaded Engraving Tool
If all you need to do is a basic engraving or part marking process, and your surface is a little “all over the map” a spring-loaded engraving tool may be just what the doctor ordered. Spring-loaded tools come in a few different varieties, with the most popular versions being a spring-loaded version of a traditional split shank engraving tool and a spring loaded “drag engraving bit”, also known as a “scribe” tool.
Spring-loaded engraving tools incorporate a compressible mechanical system between the spindle interface and the cutting tool. These tool assemblies usually have anywhere from 0.20” to 0.40” of spring travel, so they can absorb a fairly dramatic change in Z height while still keeping a consistent downward pressure on the workpiece. Spring loaded engraving bits utilize a tipped split shank engraving tool and as such can produce a variety of engraving widths and depths. Drag engraving or scribe tools literally only are dragged across a surface and are not designed to incorporate a rotational element into the process. As a result, scribe tools a truly only a good fit for very shallow part marking.
While these tools will not be of much assistance when it comes to milling or drilling applications, they perform very well for shallow to moderate depth part marking. However, there are some drawbacks to this type of tool: a common shank size for these tools is ¾”, which may be too large for some spindles. Also, since these tools are a mechanical assembly they are usually limited to 10,000 RPM max. This limitation may force you to slow your feed rate down, increasing your cycle time.
So, if you need to tool up to serialize a thousand cast aluminum parts, a spring-loaded tool will likely get the job done. However, if you are planning on completing a milling or drilling process, or if the job requires a deep, wide, or intricate/high-quality engraving, you may need to turn to other methods to get the job done.
Consistent Depth of Cut Method 3: Use of a Touch Probing System to Map an Irregular Surface
Depending on what type of milling machine you have at your disposal, use of a probing system to touch off on the workpiece a number of times to “map” the surface may be possible. Surface mapping by way of a touch probe can be one of the faster, more elegant solutions to this problem – as it uses the technology within the CNC machine to compensate for irregularities in the Z height of the workpiece. This means you can really limit the introduction of new variables in your process and just stick with your tried and true cutting tools, fixturing, and feeds/speeds.
Surface mapping via touch probing usually involves giving the machine several basic details about what you wish to probe: size of the probe area, pitch of the probing grid, and so on. From there the machine will touch off on the workpiece as many times as is necessary to probe the specified area to the desired grid pitch. Once the touch probing cycle is complete, the machine control will take the cut file that has been programmed to be cut on a flat 2D surface and modify it with the variation in Z of the workpiece that was found during the probing cycle. This way, when the cutter goes about the process of milling or engraving on the surface, it’s depth will vary automatically so you get a consistent depth of cut regardless of variation in the Z height of the surface.
Not all CNC machines offer touch probing, and surface mapping isn’t always an option when they do. But if your machine has probing and surface mapping it’s not a bad idea to get familiar with it – you never know when it might come in handy.
Consistent Depth of Cut Method 4: CMM Surface Mapping and Image Projection in CAM
When all else fails … when you can’t qualify the surface, when a spring-loaded tool won’t do what you need and your CNC machine doesn’t have touch probing, when you have a CMM laying around that’s available for use and you don’t mind doing a bunch of CAM work, there is an option of last resort.
Photo above courtesy of #rapiddtm – visit them on Facebook!
Using a CMM to map a surface in order to compensate for height irregularity is very similar to doing so on the CNC machine itself – however without the luxury of having the mapping, milling and NC integrated into one, the process becomes much more labor intensive.
This process is involved enough that an entire article could easily be written for this alone. In an effort to be concise I’ll reduce it down to a step-by-step summary:
1. Load the workpiece onto the CMM
2. Manually measure as many points as is necessary to realize the full surface variability within the working area
3. Export the resulting point cloud into your CAD software
4. Create splines linking the measured points to create a 3D surface map
5. Export 3D surface map to CAM software
6. Project artwork / milled features onto the 3D surface
7. Generate needed tool paths and post the cut file out to your CNC
8. Load workpiece onto CNC and run the part
To be clear: this process would need to be repeated 100% for each and every part run. As you can likely tell, having to use this method could easily take a job that would be done start-to-finish in about a day using touch probing in the machine, and stretch it out to take several days – simply due to the tedious nature of having to use a CMM to map the surface.
Nothing in this world is perfect – but the ability to manage imperfections to produce a good result no matter what is one of the things that separates good machinists from great ones. I hope the methods described in this post will give you an advantage next time you’re faced with a workpiece that looks more like a potato chip than a pancake.
There are few things that a machinist likes more than when they get a print and see this: +/- 0.005”. Holding five thousandths of an inch is child’s play for any good machinist – they might as well mill the part with their eyes closed. But, then there are those jobs that are a bit more demanding. Add another zero, and now you’ve got: 0.0005”. Holding five tenths of a thou is a whole different story. It’s the difference between the thickness of a human hair and a white blood cell. When it comes to holding tight tolerances, here’s a few recommendations that can keep your parts in spec.
1. Spindle Warm Up for Holding Tight Tolerances
Run a warmup routine – While this is standard procedure with most CNC machines, consider running something a bit more strenuous. A typical procedure will only warm up the spindle, which is critical for spreading grease to prevent premature bearing wear. But, you also need to allow the internal components to reach a steady operating temperature to account for thermal expansion. Now, all of this is fine if you’re only looking to hold tight tolerances in your Z axis, but if you combine the spindle warm up with machine movement in all axis, this will help even further. Allowing the machine to run for 10-20 minutes with all components moving allows for the components to reach an ideal temperature, and will help mitigate the effects of thermal expansion during milling. No matter what, at the end of your warmup, make sure to measure all your tools for absolute precision and holding tight tolerances.
2. Tool Selection for Holding Tight Tolerances
Choose your tools carefully – When you’re dealing with these unforgiving tolerances, be sure to be accommodating with your tooling. You’ll want to make sure to have specific tools for roughing and finishing, allowing the roughing tool to take the brunt of the wear, while the finishing tool is saved for only the final passes, will ensure a repeatable process for creating accurate parts.
3. Compensation for Holding Tight Tolerances
Compensate your tools – Tool manufacturers aren’t perfect, so they engineer their tools to be a little forgiving. They know that if you’re going to make something using their tools, you’ll be a lot happier if the feature it cuts comes out under-dimensioned instead of over-dimensioned. Just like a haircut: you can take more off, but you can’t put it back on. Knowing this, you’ll want to make sure the first thing you do when setting up a precise job is to dial in your actual tool diameter. You can do this several ways, but my preferred method is to mill a feature and then use accurate tools to verify the dimension – gage pins or blocks work well for this. It’s easy – if you interpolate a 0.250” hole with a 0.236” tool and only a 0.248” gage pin will fit, then your tool is undersized by 0.001” (use half of the value since it is undersized on each side). You would compensate your size to 0.235” at this point, either through your CAM software or utilizing Tool Comp commands in your cut file.
4. Temperature for Holding Tight Tolerances
Thermally Stabilize – This is one of the most important things on this list for holding tight tolerances because it can make a huge difference and you may not even notice it. Pay attention to where your machine is located. Is it near a window, if so, does the sun shine on it during parts of the day? Does the AC kick on in the afternoon and blow cold air on the machine cabin? Is your material kept a sweltering warehouse, then brought into a chilly 68° environment? These all seem innocent but can create a huge headache in your process. Thermal expansion or contraction of the milling machine or the material you cut can create large variances in your process. Put these all on lockdown – keep your machine and material in a temperature controlled climate, unaffected by sunlight, and you will reap the rewards – consistency in your process.
5. Calibration for Holding Tight Tolerances
Calibrate your equipment – When you’ve done all of the above but you need it to be just *that* much tighter, consider calling in the manufacturer. After a machine has been built, shipped, dropped off a truck, moved around, leveled, and used for thousands of hours, things will shift and settle. It’s unavoidable. Luckily, there are several pieces of equipment, be it granite squares or the Renishaw Ballbar, that can help pull the reins in on your loosened-up machine to help in holding tight tolerances. We like to perform a ballbar test and make adjustments as part of a yearly maintenance, that way you can keep a tight leash on your machine accuracy. Also, performing these annual services ensures that bearings are tight and lubricated, belts are properly tensioned, and drive motors are healthy – all important factors in having an accurate machine.
6. Linear Scales for Holding Tight Tolerances
If all else fails, scales! – If you have done everything on this list, and you still struggle, it may be time to consider getting a machine with linear scales. Your typical CNC machine will use the drive motor encoder as the primary method for keeping track of its absolute position, but this can be flawed due to imperfections in the ball screw or thermal discrepancies. Linear scales change all that – typically installed at the factory, they consist of two main components – the scale, and the read head. Put simply – the scale is like a highly accurate ruler that the machine can read, constantly comparing and adjusting for deviations. On our M10Pro, this allows for a 25% tighter positioning tolerance, a 20% improvement in repeatability, and a 85% reduction in backlash..
Hopefully, these tips will help guide you well down the long, winding, bumpy (but still rewarding!) road of high-precision machining and holding tight tolerances.
I don’t get to write Blogs too often because I’m a Purchasing Agent. But, within the CNC machine tool business, I do have some experience with regard to purchasing capital equipment and cutting tools that may help you out and save you some time. In this case, I’d like to convey a method for purchasing the perfect engraving tool that is ideally suited to your application. This may be somewhat skewed towards DATRON cutting tools and our process, but there is some good general information here about engraving tools.
What to Know When Ordering Engraving Tools
When you call in to order engraving tools here is some basic questions that you should be prepared to answer:
Your Company Name
What are you engraving? Soft Material: Aluminum Hard Material: Steel
Volume – how many do you anticipate using in a typical month?
This information gives us what we need to get back to you with pricing, turn-around time and a part number that you can reference for future orders. We will need a purchase order from you before we proceed with placing the order.
Below I have detailed the nomenclature for our engraving tools and a color-coded diagram. These help us to generate part numbers for engraving tools and may help you to understand our part numbers.
First 3 digits: Unit Prefix The unit prefix affects two parameters: shank diameter and tip diameter. 599 = metric 598 = inches When you have a 599 prefix, you’ll have metric values for shank and tip diameter.
When you have a 598 prefix, you’ll have inch values for shank and tip diameter.
The requested shank diameter is the main determining factor for unit prefix.
Digits 4 through 5: Half Angle The half angle dictates the degree of the pointed end of the engraving tool.
Be sure that you specify if you are providing a “half” or “included” angle.
For instance, if you ask for a 90-degree included angle, the half angle will be 45 degrees
This value is unaffected by the unit prefix.
Digits 6 through 7/8: Tip Diameter The tip diameter is the dimension of the flat end of the engraving tool. This value is affected by unit prefix.
If you request a tip size of 0.5mm, this value will be: 50. If you request a tip size of 0.010”, this value would be: 10. If you request a metric shank with an inch tip, we will need to convert:
For example, if you request a 6mm shank with a 0.005” tip: Since the shank diameter determines the prefix (in this case, metric, 599), we will need to convert 0.005” into metric.
This is an easy enough equation: Inch value * 25.4 = metric equivalent. In this instance: 0.005* 25.4 = 0.127mm. At this point, round to the nearest digit, and you have your number: 13. Even easier: Just Google the conversion to quickly get an answer.
If you have an exceptionally large tip on the engraving tool, exceeding 1mm or 0.100”, an additional digit (8th digit) will be required.
So a 1.5mm tip would use the number 150, or a 0.125” tip would use the number 125.
Second-to-last digit: Shank Diameter The shank diameter is the dimension of the clamped portion of the engraving tool, that is driven by the spindle.
Common metric sizes: 6mm (use value: 6), 3mm (use value: 3) Common inch sizes: 1/4 (use value: 2), 1/8 (use value: 1) Remember: This is the main determining factor in the unit prefix. If you require a metric shank, but ask for an inch tip size, you’ll need to convert the inch value to metric.
Last digit: Angle Profile The angle profile is a variety of angles applied during the grinding process to the tip and leading edge of the cutting flute. These can be adjusted to be either very sharp (good for softer materials) or very strong (good for tough materials).
There are two choices here: If you are engraving tool steels, stainless steels, or other hard materials: use letter G. If you are engraving aluminum, brass, acrylic, or other soft materials: use letter S. It is important to answer this question because if you use the wrong profiles, you’ll get poor results (decreased tool life cutting steel, burring when engraving aluminum).
Engraving Tool Diagram for Part Number Identification
So, with all that in mind here is an example:
Scenario in metric: You ask for a 6mm shank engraving tool with a 60-degree included angle, a 10 thousandths tip, so you can engrave in A2 tool steel.
Since you requested a 6mm shank, we will use the metric 599prefix.
Then, from the 60-degree included angle, we can determine that we need a 30–degree half angle
Next, convert 0.010” into metric: 0.010 * 25.4 = 0.254mm, rounded down: 25. 6mm shank = 6 in the part number.
You are cutting steel, so we use the G cutter profiles.
Since you requested a 6mm shank, we will use the metric 598prefix.
Then, from the 90-degree included angle, we can determine that we need a 45–degree half angle.
Next, take the 0.002” tip diameter and shorten it: 02. 1/8th inch shank = 1 in the part number.
You are cutting soft material, so we use the S cutter profiles. Part Number is: 59845021S.
Now fear not, in general, all you need to have prepared when you call to order engraving tools are answers to the 6 questions at the top of this Blog. We’ll walk you through the rest. But, I thought it might be helpful for you to see how all of this works, as well as the great care we take in making sure you purchase the perfect engraving tool for your application.
There is no question that electronics are getting smaller and smaller. As a result, electro-mechanical parts like Printed Circuit Boards (PCB), must be produced in smaller sizes. Therefore, the demand for step stencils (for stencil printing) is increasing, as well as the requirement for precision and accuracy in order to produce them with intricate detail. This Blog is about Step Stencil Milling and the advantages of this process over both Laser Cutting and Chemical Etching.
If you are not familiar with step stencils, they are metal sheets that help to control the volume of solder paste applied to specific components or features of a printed circuit board during the solder paste printing process. Because PCB’s are getting smaller and smaller, the components that populate the board have to be positioned closer and closer together. So, you can probably see the challenge here – smaller components and tighter spaces demand accuracy.
Milling vs. Laser for Step Stencil Production
Here’s where milling comes in … and more specifically the demand for very precise high-speed milling machines. Step stencil material such as stainless steel sheets can be milled with slots and other features to reduce the thickness in desired locations. The depth of these slots (known as “steps”) need to be very precise as does their location. This is where high-speed milling has a significant advantage over laser cutting – because laser has less accuracy as well as restrictions in depth in terms of accuracy. With laser cutting, as you go deeper in the material, the laser (an intense beam of monochromatic light) tends to bend or walk. Whereas with a high-speed milling machine very precise and even depths can be maintained. As an example, the DATRON M10 Pro <3 micron runout when using HSK-25E tool holders. If you have a need for a very large work area to produce a large step stencil or many step stencils from one sheet of material, the DATRON MLCube LS (with linear scales) delivers the same kind of accuracy and provides a 60″ x 40″ work envelope.
Milling vs. Chemical Etching for Step Stencil Production
The other process used to produce step stencils Chemical Etching. In this process, stencil material such as stainless steel is made thinner in selected areas with chemical etching. All areas that will not be made thinner (or etched) are covered with a protective film. Chemical etching is a less accurate process but is very fast. The problem is the cost and quite frankly the mess. By nature (and law), chemicals have to be managed carefully and disposed of properly, which can be very costly for the manufacturer.
High-Speed Milling Advantages for Step Stencil Production
So, getting back to the high-speed milling process, the focus should be on achieving the best production quality while saving time and obtaining a damage and residue-free stencil underside. Our customers have found that the combination of integrated probing and vacuum table workholding yield a perfectly reproducible quality, despite any material tolerances … and result in a residue-free stencil underside.
The integrated vacuum table is ideal for holding flat substrates like stainless steel sheets during the milling process. Plus, job setup is incredibly fast. The integrated probing adds to the speed of setup because the probe is used for automated part location. Additionally, the probe is used for surface scanning which records any variance in material thickness so that variance can be automatically compensated for in the milling program. This means that the depth of milled features (or steps) on the stencil will be deadly accurate!
Time Savings: faster than laser
No thermal degradation of the material structure
Absolute and constant accuracy in rapid removal of material
No costly chemicals, or chemical disposal
Download DATRON M10 Pro for Step Stencil Production Brochure
DATRON neo was specifically designed and purpose-built to provide an easy and affordable introduction to high-speed milling. It’s a Plug-and-Play system that features the new DATRON next software which gives you full control of 3-axis milling without requiring years of experience as a machinist. That said, customers ask me all the time about the CNC workflow for this machine and whether it is actually as easy to use as we say it is. Well, I’m not a machinist, I’m a salesman, but in detailing the CNC workflow below, I operated the machine myself (as evidenced by my reflection in the touchscreen). Keep in mind, that I’ve included instruction on many optional functions and features and the actual CNC workflow for DATRON neo can be as short as 4 simple steps. Anyway, here goes:
CNC Workflow for DATRON neo
Once the CAM’d part or “G” code is done, simply load onto a flash drive or send to DATRON neo if networked.
Once loaded, DATRON neo will take the operator through the steps to run the part.
After loading the “G” code into the DATRON neo, the operator can pick the saved file to run.
As the operator moves through the process, DATRON neo will check the tools already loaded vs tools the file calls for. If a is tool is missing, DATRON neo can suggest a tool that is already loaded.
Next, the operator can drag their finger across the screen and use the integrated camera system to locate the part for probing.
Once the part is visually located, the operator can simply draw on the screen to start probing with the integrated probe on the DATRON neo.
DATRON neo will automatically place probing points based on the operator’s drawing. These points can be easily moved as the operator sees fit.
Another option that the DATRON neo operator has, is to move the probe points individually and manually set the parameters to avoid any special features, all by touch.
Once the probe points are to the operators liking, they just hit go.
The next screen will bring the part into a simulation so the operator can see the tool paths they created and make sure the part is ready to run correctly.
The DATRON neo operator has options on how to view the part to ensure the correct machining file was chosen.
After the simulation, the DATRON neo is ready to execute the program.
Other options can be done on DATRON neo for quick and simple milling. Macros are pre-set on DATRON neo to run pockets, drilling, face milling, and contours. For quick prototyping, these operations can be done right on the machine without the need to CAM a part.
With DATRON neo tools can be hand loaded into the machine very easily.
After the tool is placed, the operator can simply tell DATRON neo which space and tool were used.
DATRON neo can track tools inside the tool changer, as well as tools in the shop inventory. DATRON neo also has DATRON’s full tool library installed. This makes it a breeze to load tool information.
DATRON neo can accommodate two vacuum tables and each can be operated independently. Also, DATRON can provide a sacrificial card that is air-permeable. This allows for parts to be cookie cut without milling into the table.
DATRON neo has vacuum port controls at the front of the machine to easily turn the vacuum tables on and off. This type of workholding is a great option for flat parts. When using the vacuum table, parts do not need to be perfectly aligned because you can use the probe to locate parts and their rotation will be compensated for automatically.
There are a host of other accessories available for DATRON neo including a dust extraction head and pneumatic clamping. Please let Datron know if you would like further information on these items.
In 1985, Danny Strippelhoff became a partner in the business that his grandfather established in Georgetown, KY in 1943. Now, he oversees the day-to-day operations of the Carbide Products, Inc. as President/CEO. In 1987, another of the founder’s grandsons, Paul Strippelhoff, joined the business and now oversees all manufacturing operations as Vice President.
Today, Carbide Products, Inc. owns and maintains a 15,600 sq. ft. climate-controlled facility and serves more than 200 diversified industrial customers in 26 countries each year. They employ highly-skilled personnel using the most advanced equipment to manufacture made-to-order parts, tools, and gauges, using a wide variety of materials and material combinations. This includes solid tungsten carbide, carbide tipped, silicon carbide, silicon nitride, high-speed and tool steel, stainless steel, super alloys, samarium-cobalt rare-earth, cast iron, other ferrous and non-ferrous alloys, heavy metals, PCD (polycrystalline diamond), PCBN (polycrystalline cubic boron nitride), and plastics. All of Carbide Products machining processes, as well as heat treating, brazing, assembly, inspection, and documentation, are performed in-house for total quality control.
In particular, the company is adept at producing small runs of very small parts to exacting tolerances with requirements for superior surface finishes. According to Paul Strippelhoff, “Most of our jobs are 2- to 50-piece runs and in terms of size, in many cases, you can hold a dozen parts in the palm of your hand.” Often their customers provide them with prints and the job is quoted based on that print. But, Strippelhoff explains, “Sometimes we ask the customer if we can change the print a little bit to make it easier to manufacture. We work closely with all of our customers to save them money and save us time.”
In 2016, a unique job came in that the company hadn’t seen or heard of before. An equine podiatrist asked them to manufacture special aluminum horseshoes including corrective horseshoes for horses with hoof or gait problems and horseshoes for yearlings in the thoroughbred racing industry. According to Strippelhoff, “We were getting some pretty big orders for a local equine facility, and our VMCs were just not fast enough. So, we were looking for something different, something easy to program and control, and with faster feeds and speeds in aluminum.”
During their research to find the ideal machine for this project, they came across the DATRON M8Cube, a German-engineered high-speed milling machine with a 40”x30” work area and spindle speeds up to 60,000 RPM. Strippelhoff says, “It just seemed perfect for the horseshoe job. Additionally, we had a date stamp screw job for the mold industry that we had earmarked for the M8Cube.”
A trip to IMTS in Chicago in September 2016, solidified the company’s excitement about DATRON technology, but what they saw exhibited by DATRON altered their plans just slightly. Strippelhoff explains, “They were demonstrating a smaller machine called DATRON neo and the newer touch-screen control on that machine just blew us away. Our kids these days are using their fingers on touchscreens to do everything! We decided, that we really had to get one of these in our shop and be on the front end of this technology and embrace it.”
Carbide Products purchased the DATRON neo almost as an experiment, but with their long-term goals still focused on larger DATRON machines. Strippelhoff says, “We decided to get started with the DATRON neo in hopes that the same software and touchscreen would be added to the M8Cube and M10 Pro machines so that we could replace our traditional VMCs with those. The price point on the DATRON neo was good and it doesn’t take up much floor space, so it gave us a chance to get involved with DATRON and see if we like the support that they have and the product that they have without making any huge investments.”
This “experiment” has turned out quite well according to Strippelhoff who was surprised that even the DATRON neo with its 20.5″ x 16.5″ X, Y travel has been able to supplant the company’s smaller Haas machines. He explains, “Currently, we’re making some special lightbulb parts on the DATRON neo that we were making on our Haas Super Mini Mills − and by using the vacuum chuck to hold sheet material on the neo, we’re able to batch machine these parts which has reduced cycle time by nearly 50%.” During the course of purchasing and installing the machine, Carbide Products has been able to get a feel for the American-based service that DATRON offers to support their German-made machining centers. Strippelhoff says, “Our plan to ‘get our feet wet’ with DATRON has worked out well. On a scale of 1-10, I’d give their support a 10 … it’s been really, really great. So, we’re excited now to get into that M8Cube. Everybody there has always been Johnny-on-the-spot and available.”
In terms DATRON neo’s overall ease-of-use, and the ability to quickly setup the machine and integrate it into the production flow, Strippelhoff is extremely pleased and admits, “Honestly, I haven’t personally programmed a CNC mill or written a program or anything for 22 years, and I was able to use this machine right away. The controller with the integrated probe and camera system for part location makes it incredibly easy to set up a job and operate. You don’t have to have your workpiece set up and trammed in, it does the skew alignment for you.” Although Carbide Products had never used HSMWorks before, Strippelhoff praises DATRON for strongly recommending this software, as well as how well it integrates with the DATRON neo in terms of tool libraries. He explains, “What I didn’t know upfront, but was glad to see, is that there’s a tool catalog in HSMWorks for DATRON and all we have to do is plug in a 5-digit number, drop the tool in and all the information is there which is so simple it’s crazy.”
Ultimately though, the “proof is in the pudding” as they say, and all the bells and whistles in the world amount to nothing if the machine isn’t making money for you. Strippelhoff says that is NOT the case with the DATRON neo. He explains, “I currently have 6 different 200-piece jobs running on the DATRON neo all being made with aluminum sheet material. Running multiple parts out of a sheet is completely new to us, instead of making solid-piece parts one up. What this does is gives you the ability to keep your number of tool changes down over a 200-piece order, because while your tool is in the spindle it does all of its work.” As an example, he says, “I’m getting 105 parts out of a sheet and the drill is going to drill all the holes before the machine makes a tool change – and then the machine doesn’t have to pick the drill up anymore. Reducing the number of tool changes has a huge impact on cycle time and this is a big difference between the DATRON and our VMCs.”
At the time that DATRON introduced the DATRON neo to the North American market, it was met with some skepticism on social media forums – mostly by traditional VMC operators who couldn’t imagine that this compact machine was anything but a toy. Within Carbide Products, this has not been the case. Strippelhoff says, “The other machinists in the shop walk by the DATRON neo and they kind of take a step back and are pretty impressed with what they’ve seen so far compared to running their VMCs. They can’t believe the technology that they’re seeing on this machine. Everybody in the shop is excited about it, even the people who aren’t running CNC mills – the lathe guys, guys and gals in the grinding department, everybody just loves watching that thing run.”
Innovative manufacturers logically find innovative ways to use new technologies — sometimes pushing the limits or using a machine for a process that it was not specifically designed for. That is certainly the case with Carbide Products, and they quickly found a unique use for the DATRON neo that further leverages their capital investment. In this case, they decided to replace the cutting tool with a diamond grinding wheel to use the DATRON neo like a jig grinder to grind a counter bore in solid carbide rolls. Paul says, “This was a task for our very expensive Agie Sinker EDM, but this too has changed.” Some manufacturers find it hard to think outside the box — and when they spec a machine for a job, that’s the job the machine will do until it’s at capacity, and then, they buy another machine to pick up the slack. But, Carbide Products’ methodology is to find every imaginable way to use a piece of equipment even if it means reaching capacity quicker. Strippelhoff says, “Another DATRON, probably the M8Cube, is on the horizon anyway. It has a larger bed size and that will come in handy. And if we do things right, that machine will be as busy as the DATRON neo is.”
As the example above illustrates, it is not simply the technology that drives innovation, but rather the skilled personnel who find the best ways to use it to impact efficiency, capability and ultimately the company’s bottom line. Carbide Products President/CEO, Danny Strippelhoff, says, “It takes the best of the best employees to be successful enough to have the opportunity to invest in the latest and greatest manufacturing technologies. The DATRON neo that we’ve installed is a testimony to their hard work.”
When engaged in the machine qualification process, we often ask our customer, “Who are you assigning to operate or manage the machining system?” You might ask yourself, “Why should DATRON care who operates the system?” The short answer is, to us, it’s just as important that you have the right CNC operator, as it is that you select the correct machining system.
Over the past 20 years, we have built our business on implementing high-speed machining systems that increase product efficiency and quality. Our reputation has grown on the success stories and reference companies we have accumulated over the past two decades. Truly, the DATRON milling system is only one piece of the equation for a successful implementation. The other piece is who the CNC operator is after the machine installation is complete.
Why Selection of the Right CNC Operator is Critical to Success
As a machine tool distributor, it is our responsibility to not only make sure you have the right machine configuration for your needs but also to make sure you are prepared to leverage your capital investment by assigning the right CNC operator to the DATRON machine. As expected, we go through extreme testing and scrutiny to qualify our machine tool for the given application, but sometimes, not enough scrutiny or consideration is given on which CNC operator will have the responsibility for the installed equipment. Unfortunately, there have been instances where customers have not selected the right CNC operator to run the equipment. In those cases, when the wrong CNC operator is chosen, it often leads to unsatisfactory results from the machine in terms of output – and a frustrating and costly implementation for both DATRON and the customer.
Choosing the right CNC operator or system manager varies depending on the equipment, application and production demand. I highly recommend you discuss these details with the DATRON representative who is managing your project. Clearly setting expectations such as; the learning curve, ramp-up time before you are in full production, education and experience of the CNC operator, number of days and people involved in the training, secondary processes, third-party equipment, and budgeting for advanced CNC operator training at a future date are just some of the considerations for a complete and successful implementation.
It is our goal at DATRON that every system implementation is performed on-time, quickly, efficiently, smoothly and stress-free. A successful installation is just as rewarding for us, as it is for our customers.
Bill King, President DATRON Dynamics, Inc.
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Machinists ask me all the time, “When do I go fast and when should I go slow with a single flute end mill?” Well, as you can imagine, there are a lot of variables at play regarding feed rates for single flute end mill, but let’s try to break it down.
Slow (60″/min) – Finishing – If you need an exceptional quality in the finish of a floor or wall, it helps to slow the machine down to take a fine chip and decrease cutter load/cutter deflection.
Medium Feed Rates for Single Flute End Mill
Medium (120″/min) – Slotting – Something a single flute does particularly well is slotting, which is a tool path that has 100% of the tool diameter engaged in the material. Using a proper depth cut (25% of tool diameter), you can cruise along at a decent pace without worrying about clogging up on chips.
Fast Feed Rates for Single Flute End Mill
Fast (180″/min) – Traditional Roughing – When you are using a normal milling strategy, in the range of 33-50% depth of cut (2-3mm) with a 50-70% stepover, you can be fairly safe kicking the speed up, just keep an eye on your spindle load.
Very Fast Feed Rates for Single Flute End Mill
Very Fast (240″/min) – Trochoidal Roughing – If you are using Mastercam (Dynamic milling) or Fusion 360 (Adaptive clearing) you may have heard of this strategy before. Instead of going about the traditional method, this method utilizes more of the flute to boost efficiency. For instance, we could use 100-200% depth of cut (6-12mm) with this strategy because our stepover would be decreased to 10-20%. In many cases, this prolongs the life of the tool and puts less strain on the spindle, so you can safely bump the feed rate up.
Extremely Fast Feed Rates for Single Flute End Mill
Extremely Fast (300″/min) – Shallow roughing – If you are taking off less than 10% depth of cut (0.60mm), then you should be safe cranking the feed way up. With such a shallow cut, you won’t have to worry about overloading the tool or spindle.
Question: “Should I use a drill vs. end mill?” DATRON Application Technician, Dann Demazure answers, “It depends on what you’re trying to achieve.
When to Use a Drill vs. End Mill
If you’re making a very small hole, say, less than 1.5mm in diameter, go with a drill. End mills under 1.5mm become increasingly fragile, and subsequently cannot be run as aggressively, as a drill can be.
If you need to make a very deep hole – in excess of 4x your hole diameter, choose the drill. Past this point, chip evacuation can become very difficult with an end mill, which will quickly wreck your tool and your part.
Are you making a lot of holes? Drilling is probably the way to go. In most instances, a drill will best the fastest time you can achieve with an end mill.
Need to make an extremely precise hole? While milling is typically perfectly acceptable, sometimes the tolerances require a drill and a reamer for the perfect finish.
When to Use an End Mill vs. Drill
However, there’s a lot to be said for using an end mill instead.
Need to make a big hole? Big holes need big drills and lots of horsepower, this is where helical milling shines. Use an end mill that’s 60-80% the diameter of the hole you’re making to quickly clear out while leaving plenty of room for chips to escape.
Print calls for a flat bottomed hole? Normal drills can’t do that, so you might be better off milling the feature.
Making lots of different size holes? Try to use the end mill, you’ll save time on tool changes and room in your tool changer.
Rapid prototyping? End mills will be appealing for their flexibility. Being adaptable to take on some features that may normally be drilled means you can spend less time CAMing a part and more time making chips.
With either one, there are two simple rules to remember:
Break your chip – don’t try to be a hero and blast through your hole in one go, program a quick retract to get the chip out and let the coolant in.
Turn up the coolant – unless you have through tool coolant, you’re going to want to be sure to turn up the coolant flow and decrease your air pressure. The coolant needs to be able to flow into the hole during your retract.