TechFront
2-56UN thread’s major diameter was 0.086" (2 mm), and the drill diameter 0.070" (1.8 mm). Repeatability was nearly im- possible on his CNC equipment, and the shop owner literally came in every Saturday to tap the holes by hand. When he started talking to Carmex, he was breaking his taps after only 20 holes—“an extraordinarily short tool life,” said Dei. By re-examining his technology, and switching to thread milling, he was able to accomplish the threading of 683 holes with a single thread-mill on his CNC equipment. Despite the number of passes, the wear factor between the first and the last holes could only be measured in tenths, and the customer was able to get the thread detail back to its original 0.150" (3.8 mm) full thread depth.
When it comes to individual tool life, three of the major factors involved are tool design or geometry, cutting tool substrate and coating. Carmex realized early on that a helical design, what Dei calls “our Helical Advantage,” eased entry of the thread-mill into the hole, reduced chatter, and created a
better finish. This reduction in stress and vibration results not only in better performance but an increased wearability and longer overall use.
“One of the most rapidly changing aspects of tooling at present involves composition, and by that, I mean both the basic carbide or other underlayment and the coating depos- ited thereon,” said Dei. “Just as we’ve seen an evolution in carbide grades, there has been a corresponding rapid devel- opment in coating materials and technology. When it comes to carbide, our engineers and designers match the grade according to a wide field of parameters, including size of the tool, the application, the material being cut, and the speeds and feeds involved.
“Coatings likewise have come a long way, and our latest PVD-BLU has met with enthusiastic acceptance in applica- tions ranging from heavy-duty threading in the energy sector, to our new line of tools for Swiss-style machines. BLU is a new harder submicron substrate with the latest nanocom-
STRAIGHT FORWARD WE ARE
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Visit
www.HexMet.us/me413 or call 800.218.7125 for more information. We are Hexagon Metrology.
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ManufacturingEngineeringMedia.com | April 2013
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