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Tapping Tip – Finding the Perfect Tap

Warning, the blog your about to read has more information than many of you may want and can be confusing, but it’s what we do in designing a tap.

The actual pitch diameter of a ground thread tap is designated in many ways. It’s dependent on, if it is inch or metric, the amount that it is different than the basic pitch diameter, and the direction of that difference (larger or smaller).

Ground thread taps are designed with “Back Taper”, a decrease in its thread form, including the pitch diameter. The back taper starts at the front of the tap and decreases towards the back. The designated Pitch Diameter size of the tap is located at the first full thread after the chamfer. It’s this thread, that is the last tooth to cut, bringing the thread form including the pitch diameter of the threaded hole to size.

 

 

Basic Pitch Diameter
Before we can discuss the tap pitch diameter limit, we need to understand what the basic or nominal pitch diameter of the thread designation is.
The pitch diameter of a basic thread is located where the width of the tooth and the width of the space between them is equal. It is calculated by subtracting the basic height for the given size of thread, from the basic OD of the thread. The value for the height of thread is dependent on the pitch (P) of the thread. On a 60 Degree thread, the formula for the basic height of thread is 0.64952P.

Example, the basic pitch diameter
1/4-20 UNC
OD = 0.2500
P = 1”/20TPI = 0.0500
Basic Height of Thread = 0.64952 x .0500 = 0.032476
Basic Pitch Diameter = 0.2500 – 0.032476 = 0.2175

M6X1
OD = 6.000mm
P = 1.00mm (the 1 in the size designation is the pitch not a TPI)
Basic Height of Thread = 0.64952 x 1.00mm = 0.64952mm
Basic Pitch Diameter = 6.000mm – 0.64952 = 5.350mm

H or L Limits (inch taps)
H and L limits are used for inch size ground thread taps. H (high) represents a pitch diameter that is larger than the basic pitch diameter, and L (low) represents a pitch diameter that is smaller. The number after the H or L, indicates the amount it is different than the basic pitch diameter. Each number after the H or L is equal to 0.0005, so an H3 or L3 is equal to 0.0005 x 3 or 0.0015. The H (high) limit is the maximum pitch diameter of the tap, whereas an L (low) limit is the minimum pitch diameter of the tap. The minimum value for the H limit, and the maximum limit of an L limit, are derived by applying the tolerances from the tap standards. I should mention that H and L limits are also expressed as GH or GL, with the G being that tap has a ground thread, either designation, with or without the G, will work.

Example,
Maximum tap pitch diameter for H limit
1/4-20 UNC GH5
= Basic PD + GH5 amount
= 0.2175 + (5 x 0.0005)
= 0.2175 + 0.0025
= 0.2200

Minimum tap pitch diameter for L limit
1/4-20 UNC GL3
= Basic PD – GL3 amount
= 0.2175 – (3 x 0.0005)
= 0.2175 – 0.0015
= 0.2160

D or DU Limits (metric taps)
D and DU limits are used for metric size ground thread taps. D represents a pitch diameter that is larger than the basic pitch diameter, and DU represents a pitch diameter that is smaller. The number after the D or DU, indicates the amount it is different than the basic pitch diameter. Each number after the D or DU is equal to 0.013mm, so an D3 or DU3 is equal to 0.013mm x 3 or 0.039mm. The D limit is the maximum pitch diameter of the tap, whereas an DU limit is the minimum pitch diameter. The minimum value for the D limit, and the maximum limit of an DU limit, are derived by applying the tolerances from the tap standards.

Example,
Maximum tap pitch diameter for D limit
M6 X 1 D5
= Basic PD + D5 amount
= 5.530mm + (5 x 0.013mm)
= 5.530mm + 0.065mm
= 5.595mm

Minimum tap pitch diameter for DU limit
M6 X 1 DU3
= Basic PD – DU3 amount
= 5.530mm – (3 x 0.013mm)
= 5.530mm – 0.039mm
= 5.491mm

Plus (oversize), Minus (undersize) Limits (whether inch or a metric)
When the specified amount, that the desired tap pitch diameter is to be over or under the basic pitch diameter, it is used to calculate the minimum limit, then the tolerance is applied plus to obtain the maximum limit.
If this maximum pitch diameter is an even multiple of, 0.0005 for inch sizes or 0.013mm for metric sizes, then the applicable G, GL D or DU can be determined. As an example, a 1/4-20 UNC +0.005 is not a GH10 (0.005/0.0005) , when adding the amount over size of 0.005 to the basic pitch diameter, it equals the minimum pitch diameter, then adding the tolerance, the maximum pitch diameter is now 0.0055 over the basic pitch diameter. 0.0055 / 0.0005 = GH11.
When the amount is not an even multiple of, 0.0005 for inch sizes or 0.013mm for metric sizes, it is used to calculate the minimum limit, and the maximum limit is established by adding a tolerance from the tap standard. In this case the tap is marked with “+” or “-“ followed by the amount, example 1/4 – 20 UNC + 0.0017, 1/4 – 20 UNC – 0.0017, M6 X 1 + 0.035 or M6 X 1 – 0.035.

G(S) Special Tap Pitch Diameter
When a tap does not fit H, L, D, DU, +, or – as described above and a maximum and minimum tap pitch diameter is provided, than the tap is marked with a G(S) followed by the maximum and minimum pitch diameter. Example, 1/4-20 UNC G(S) PD 0.2203-0.2198.

The information above as well as the tap pitch diameter tolerances, can be found in one of the two industry standards that govern the general dimension of taps in the United States.
ASME (American Society of Manufacturing Engineers), B94.9
USCTI (United States Cutting Tool Institute), Taps, Ground Thread

As you can see, determining the proper designation for the required tap limit can be quite confusing. The information is merely a way for you to determine what the pitch diameter limits are for a tap you may either have in your possession, called out on a print, etc. The selection of the proper tap pitch diameter is dependent on your application requirements. This blog did not discuss various application and how to determine the correct tap pitch diameter designation, we can cover that in a future blog. But until then, you can contact us with your application information, and we can work together to ensure your success.

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Are You Using the Right Thread Mill Design for Exotic Materials?

If you deal with exotic alloys like Inconel, titanium, Hastelloy, etc., this blog post is written especially for you. Wise operators always select the correct tool for the job, avoiding the problems others face when they try to apply a general-purpose tool to a unique situation. In this article, we give you the information you need to select the proper tools for machining exotics. It will make your shop stand out from the competition since you will produce better results at a reduced cost.

The Hard Stuff
Exotic alloys are specifically designed for high-temperature applications (think aerospace), performance in corrosive environments (think underground), or to have the highest available strength to weight ratios (think earth-moving applications). The machinability of these materials is NOT the first consideration. As much as it would be nice from the machinist’s viewpoint to have an aluminum firewall in a helicopter, as the pilot or passenger you want a material that is strong and heat retardant.

Unique Challenges
When you’re working with exotics, it’s not just another day at the shop. On the positive side, their unique elemental compositions make them suitable for applications where traditional materials like alloyed steels or aluminum, would fail. On the other hand, some of these materials exhibit undesirable (to say the least) behaviors like igniting spontaneously when machined and exposed to the atmosphere. Also, these alloys are typically more expensive than traditional steels machined in most shops, so scrapped pieces are going to cost you big time.

The Answer
One day a new job order comes in and you are faced with machining (more specifically threading) these kinds of alloys. What’s an operator to do? Fortunately for you, we manufacture application-specific thread mills right here in the USA. These tools are made from solid carbide and have been specially designed with exotic materials in mind. The results are longer more consistent tool life and the elimination of scrap due to tap failures in your parts.

Uniquely Crafted
Our thread mills for exotic alloys are designed with only three teeth. This places less stress on the tool than a conventional thread mill with six, eight, or ten teeth engaged in the workpiece at the same time. Carbide thread mills nickel-based alloys are also made with left-hand helix and left hand-cut, which permit an operator to run from the top of the hole to the bottom and climb mill the threads. This will create a right-hand thread on the part. The threads are milled, rather than cut, typically producing a better quality thread in the part.The thread mills are coated with AlCrN to give them greater heat and wear resistance in the high heat, higher abrasive applications that typically confront an operator when machining exotic alloys.

Exotic Material Experts
As well as thread mills, we are the industry leader in designing and manufacturing special taps for exotic materials as well. Thread mills are a good alternative tool to the special taps we design every day provided of course, you have a 3-axis CNC capable of the interpolation tool path needed for thread mills.

 

If you are working with exotic materials and need a thread mill or special tap, please contact us for a quote. We’d be happy to help.

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GWS Value – A Review of Our Latest Capability & Upgrades

 

GWS Tool Group is constantly in motion. In fact, we are such a dynamic company that you might not be aware of all the products and services we offer. This article is designed to provide a complete and updated overview of our capabilities. We think you will come away with a better understanding of who we are, our wide range of product and service offerings, the quality of those products, and why we are so easy to work with.

Our Profile
We are a US-based, vertically integrated, manufacturer of highly engineered custom, standard, and modified standard cutting tools. Through our Preferred Partner Program, we reserve most of our capacity and capabilities for our Key Distributors and the Core End Users that they serve with our products.

Our slogan, “Custom Comes Standard”, represents our goal to make purpose-built custom solutions as readily available as our standard products. In fact, over 80% of the products we sell are custom-designed for specific customer applications. The remainder stems from our full range of off-the-shelf product offerings featured in our cutting tool solutions catalog.

While we service all industries, we have particular expertise in the aerospace, medical, armament, and automotive sectors.

World Leading Capacity, But Nimble as the Guy Next Door
Through a series of acquisitions and subsequent integration, we have formed a dynamic team of highly skilled cutting tool experts spread across six manufacturing facilities in the USA. Companies are added to the mix when they offer particular expertise that fills a strategic and customer product need.

We employ over 400 employees and operate 200 plus CNC machines. Ten percent of our annual net revenue is reinvested in capital equipment. This number may seem high, but it is our philosophy to maintain excess capacity to meet customer demands, maintain ultra-fast turnaround times and seize opportunities when our customers present them to us. We would rather have idle machines than make a customer wait unnecessarily for the next open spot in the schedule. We feel this responsiveness is a major differentiator between us and our competitors.

Typical Turnaround Times:

  • Simple modification: within 24-48 hours
  • Thread whirling inserts: within 72 hours for first piece
  • Custom end mills & drills on standard blanks – 2 weeks
  • Custom taps – 24-48 hours
  • Total complex custom form tools: within 6 weeks

Tool Capacities
Specialty cutting tools come in a variety of shapes and sizes; every application is different and we engineer and build tools specific to those needs. These can range in size from a 5¼” root form cutter down to a 0.040” micro tool.

Our Complete Tool product offerings include:

Round Tools:

  • End Mills
  • Form tools
  • Step drills
  • Thread mills
  • Keyway cutters
  • PCD drills
  • Threaded shank tools
  • Reamers
  • Taps
  • Round dies
  • Thread gages

Inserts:

  • Top Notch inserts
  • Grooving inserts
  • CBN & PCD-tipped inserts
  • Ceramic & Whiskered Ceramic inserts
  • Thread Whirling inserts
  • Carbide inserts

Custom Comes Standard
The custom tools we design are purpose-built, by industry and application. For example, for aerospace, where composites make up 50% or more of modern commercial aircraft, we produce an assortment of custom drills and reamers with brazed threaded adaptors. These are designed to accommodate the manual air-driven tools used to perform the majority of holemaking in the fuselage and wings. On the engine side of aerospace, we developed tools like our AlloyCatTM whisker-reinforced ceramic insert for turning nickel and cobalt-based super alloys at metal removal rates 5-10 times higher than carbide.

Chamber reamer machining for gun applications is almost always going to require custom tools, and recent designs from our holemaking division are averaging 3-5X tool life versus the competition. For medical applications, we designed the “Zombie” thread whirler insert, so-called because you just can’t kill them, and their win rate is over 95%. These are just a few examples. Talk to your local distributor and give us a challenge, the more difficult the better. We’ll work with you to make the tooling that fits your particular needs.

GWS Engineering Support
How does custom tooling happen? The process begins with a customer need that can’t be met by an off-the-shelf product (such as the examples above). The first thing our engineering team does is sit down with the customer to understand the requirements. They can work from prints, a sample part or even napkin drawings. Our Inside Sales and Engineering Departments will put together a concept of a tool and how it can be applied. A quote is submitted and an order processed. Approval prints are created, proofed, and signed off on. (Communication is a key element.) We manufacture the tool, coat it in-house (if the coating is deemed necessary), and ship it to you. The entire process takes a fraction of the time you would expect.

Tool Reconditioning
Even after we supply you with the perfect tooling for your application, we still have something more to offer. The GWS Reconditioning Program can give new life to your drills, step tools, PCD & CBN inserts, form tools, end mills, and ceramic inserts. Our Custom Regrind Portal lets you follow the status of the process every step of the way. All brands of tools are accepted. We’ll even hold your reconditioned parts in inventory and send them to you JIT through our Preferred Distributor partners.

That concludes our snapshot of GWS Tool Group. Keep in touch for new developments (click here to subscribe to our monthly newsletter) because we’re always on the lookout for better ways to serve you. Contact us for more information. We’d be happy to answer any questions you might have.

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Production Control Manager Kelli Harris is a Cutting Tool Veteran

Kelli Harris

Meet Kelli Harris, the Production Control Manager at our Northern Illinois facility, formerly known as North American Tool. In this position, Kelli manages the oversight of manufacturing practices, inventory control, and strategic manufacturing planning.

Depth of Knowledge

During her 15-year career, Kelli has been involved in a number of key areas, serving as Sales & Marketing Assistant and Purchasing Manager. At the time of the acquisition, she held the position of Production Supervisor. “My years of experience in diverse roles have given me the opportunity to learn about the many facets of manufacturing and the business structure”, she said. “Both of those arenas are helpful for balancing the interests of the organization with knowledge of the manufacturing floor needs as well.”

Helping Others Grow

Kelli has a reputation among her fellow workers for being a generous mentor who is always willing to take time to pass along suggestions and provide guidance. “I enjoy having the ability to provide strategic data to others about projects and performance,” she said. “It improves productivity in our operations as well as providing opportunities for individual growth.”

Kelli’s impact on her peers is undeniable and many have expressed their gratitude to her for taking the time to help with their professional development.

Always Learning

While her career has given her a wealth of practical knowledge on the manufacturing process, Kelli continues in her efforts for personal advancement. She is rightfully proud of the fact that she returned to college as an adult and earned a Bachelor’s degree in Business Management Studies.

Leisure Time Activities

Kelli is an avid Chicago Cubs and Bears fan and enjoys going to as many baseball games as possible. Her favorite Cubs player is Wilson Contreras.

Kelli Harris

As for vacation travel spots, Las Vegas is Kelli’s first choice, but she finds that exploring any new and different location is always a fun experience. Hawaii and Alaska are definitely high on her bucket list.

Kelli is also an enthusiastic golfer and takes every opportunity to hit the driving range or get in a few holes at local courses, or at scenic links when she travels.

Interested in a Career at GWS Tool Group?

If you enjoy working with dedicated people like Kelli, consider applying to GWS Tool Group. We are always looking for talented and driven individuals to work at our facilities in Florida, Indiana, Illinois, Arizona, Michigan and Massachusetts. Browse open jobs here.

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Tapping Tip – Don’t Let % of Thread Derail Your Part

taps

As any experienced machinist will tell you, you usually gain some experience drilling and milling, before you learn about tapping a hole (the operation in which internal threads are produced). Why? Because a higher level of precision is required for this operation and tapping the hole is the last operation to occur in completing the part. If an error is made, all the earlier efforts (time and materials) will be wasted.

The first thing a novice learns about tapping is that the hole you drill will be smaller than the diameter of the bolt that will go into the hole. This is because you have to leave enough material in place to cut the threads into. The threads tapped will increase the diameter enough to engage the bolt.

But how do you determine the proper size hole to drill for a pre-determined size of bolt and the correct size tap to add the threads?`

A Rule of Thumb

When considering the hole size for 60-degree threads, the percentage of the thread relative to the complete hole should be 75%. This is a good rule of thumb for anyone machining to satisfy 2B or 3B classes of fit. A little bit higher is okay for softer materials and a little bit lower for harder materials.

taps

Hole Size Risk Factors

There are many factors that go into this range:

  1. As the percentage of thread rises, so do the stress factors on the tap. This can lead to an increased likelihood of tap breakage due to increased torque during tapping which can lead to disastrous failures that leave the tap and thread in pieces. Such failures can often not be salvaged, leading to a scrapped part.
  2. A lower percentage of the thread also has its own challenges. While the larger hole size reduces torque and, thus ease of tapping, it can lead to lower thread engagement or even cross-threading issues. If tapping less than 3X diameter, we recommend no less than 65% of thread to ensure the internal thread exceeds the strength of the mating bolt.
  3. When the application consists of higher tensile steels, a larger hole size (with less percentage of thread) may work better to reduce the tapping torque. Consider an oversized chamfer point diameter with plug chamfer style when using a larger hole diameter. This will provide more cutting edges while also ensuring they are all actually engaged. This will spread the “work” out of each effective cutting edge and optimize tap performance.

taps

Picking the Perfect Tap

When all is said and done, taps are made to very exacting tolerances. At the first sign of trouble, it’s the tap that gets the blame. But before jumping to conclusions, look at the hole size (and percentage of thread) to ensure your calculations are correct. As with many things, tapping success begins with the proper prep work.

taps

While many companies manufacture taps that “could” work, there are many variables that go into a tap selection. A tap that is designed for a specific application will always give the best results. The easiest way to ensure you have the right tool for the job is to contact us anytime for all your tapping needs.

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Coating Tech Jose R. Enjoys Being Part of GWS Success Story

Jose R. Mass

Meet Jose R., who started out as a material handler in our plant at GWS Massachusetts in 2011. Since then, he has mastered a variety of jobs, each one adding to his knowledge of the business and allowing him to advance to positions of increasing responsibility.

In his time with us, Jose has learned about shipping & receiving, packaging, laser marking, inspection and grinding. He previously worked for over eight years as a machinist at a major packaging company, so he brought a lot of practical knowledge about CNC machines and tooling to our operation.

The Science of Coating

Now Jose is one of our Coating Technicians. We depend on him to make sure the machines are running properly and that they’re always clean and ready for the next job. He also performs hardness and thickness inspections to make sure the coating is uniform across the entire tool. “I find coating to be an interesting process,” he said. “Something about seeing it all come together and helping make a great tool even better appeals to me.”

Best Parts of the Job

Naturally, he knows our tools are unique in the marketplace and appreciates being one part of the daily sales, manufacturing and delivery process that is the heartbeat of the company. “Seeing our sales grow day by day is a big accomplishment and I’m happy I can contribute to it,” he said. Jose also enjoys the comfortable, friendly workplace and the fact the company is so busy that the days seem to fly by.

He appreciates the faith we have in him and being given the opportunity to travel to our other facilities to learn new processes and techniques that he can immediately put to use on the job.

Burning Up the Quarter Mile

Jose is very mechanically minded and loves working on cars in his free time. His current project is getting his drag racer to achieve 1,000+ horsepower with a 4-cylinder engine!

Jose R. Mass

Interested in a Career at GWS Tool Group?

If you think Jose has sweet gig and want in on the action, we are always looking for talented and driven individuals to work at our facilities in Florida, Indiana, Michigan and Massachusetts. Browse open jobs here.

 

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If You Haven’t Tried GWS Form Tools, You Might Be Missing Out

form tools

Let’s say you have to machine a part with a unique profile or feature. Would you rather use several off-the-shelf tools, each machining a different section of the contour, or just one tool that could do it all in one setup? Form tools, which are precision ground to machine a particular profile or contour on the workpiece surface, are designed to do exactly that. This type of custom tooling (solid milling tools or turning inserts) can be beneficial for almost any industry that has complex part shapes being produced in mass.

The Case for Form Tools

Buying three or four tools to do the same job as one form tool can be costly. Besides the initial cost per unit, there is the time spent in ordering and managing the inventory. Each tool has to be set up and programmed individually, taking more time and operator involvement. Additional downtime is spent trying to dial in tight tolerances and blend the multiple surface finishes from different tools.

A tool that is custom made for a specific application will always provide optimum performance over just using “what’s in stock,” even if your machinist has the skill and experience to make it work. Often the cobbled together, multi-tool process will fill up the clock with excess cycle time, or even the scrap bin, with a lot of trial and error mistakes. That can be especially stressful on everyone involved if you are on a tight delivery schedule with even tighter profit margins.

Rethinking the Status Quo

Despite all the advantages, there are still a lot of shops that could benefit from form tools that haven’t given them a try. Some just never thought about it. Others were simply used to the process of opening a catalog and making do with what was available “off the shelf.”

But what happens when your “go to” guy, the one that could always make the “off the shelf” tools work, suddenly leaves? Finding a replacement with the kind of skill, knowledge and experience to orchestrate a satisfactory multi-tool result is going to be difficult, if not impossible.

Another group that gives form tools a pass are shops that have tried them in the past and have been burned by long delivery times, poor quality, high costs or tooling that just couldn’t do the job.

A Custom Mindset

We are the first to agree that not every cutting tool company can make a high-quality form tool. They’ll give it a try, but if they are not used to thinking outside the “standard” box, they won’t often produce good results. At GWS, we think “custom” every day. Even the majority of our catalog tools started out their careers as made-to-order items. More often than not, each time the phone rings, it is a customer that has a problem requiring a unique solution. Our job is to provide it ASAP. Nothing extraordinary. It’s just another day at the plant. This custom mindset gives us a tremendous advantage.

form tools

 

form tools

 

Knowledge is Power

When you do something for a long time, you collect a lot of information. We have put that data in a digital format for all our design engineers to access; a design library with tens of thousands of tools, searchable by tool attributes. We can put that data to use by looking up what has been done before and tweaking it to perfectly match a new application. Did a certain design element to increase reach work well for a jet engine impeller? We can apply that to a diesel turbo impeller, where reach is also an issue, while incorporating the cutting geometry from a second previous design that was successful with the same work material. Geometry, relief, rake angles, substrates, coatings – it’s all in there. Sometimes one of our high-performance standard tools is a good foundation for a new custom version. We’ll look at those, too.

form tools

A Proven Process

Even if we don’t find the answer in our library, every entry in it has gone through the same design process perfected over years. Our engineers can work from prints, a sample part or even napkin designs to come up with the answer to your machining needs. Our Inside Sales and Engineering Departments will put together a concept of a tool and what it should look like. A quote is submitted and an order processed. Approval prints are created, proofed and signed off on. (Communication is a key element.) We manufacture the tool, coat it (in our own plant) and ship it to you. The entire process takes a lot less time than you would expect. (For an example, read this testimonial from Medtronic.)

What Does Quality Look Like?

Custom is even in the DNA of our quality control professionals. Because we manufacture something new and different every day, a deeper understanding of how geometry works is needed to properly inspect custom tools. Checking several independent features, without understanding how they relate to other features and performance, is not good enough at GWS. Our quality experts work with the engineers during the design process so they can not only tell you if something is wrong during inspection, but can also help tell you why and even how to fix it! The result is complex tools, delivered fast, that work the first time.

So you see, from start to finish, there’s a big difference between form tools and GWS form tools. Please contact us or upload a part print to start speaking with one of our engineers today on making Custom a Standard for you.

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Ti-Feed: A Titan Among High Feed Endmills for Titanium

Not to brag, but one of our specialties is looking at a machining problem and coming up with ways to make your job a bit easier and more lucrative. Our Ti-Feed Series of high feed endmills is a great example of this. The series came about because popular multi-flute tools and iMachining tool paths are not practical when milling turbines for aerospace or automotive applications in a 5-axis machining environment. Z-level machining tool paths are needed to accommodate part shape and fixturing rigidity.

Traditional High Feed Mills Don’t Cut It

High feed mills and z-level processing are nothing new, Mold makers have been using this technology for years to machine hardened steels. The trouble is that the high feed mills they use are specifically designed for those materials. Neutral cutting geometry, combined with slow helix angles and ultra-hard nano coatings, are great for hardened D2 or H13, but not so much for Ti-6Al4V. So, at GWS, we have taken the principles of radial chip thinning and high feed mills and applied them to our new Ti-Feed Series for ultimate machining performance in titanium alloys.

Titanium Troubles

The problem is titanium has a tendency to generate excessive heat at the contact area during the machining process. With titanium’s low thermal conductivity characteristics, that heat gets transferred mainly to the cutting tool. This results in long continuous chips that can weld on to the tool edge, giving you a poor finish, or worse yet, out of tolerance parts. Sharper cutting geometries with fine precision honing and heat resistant coatings are needed to better attack the machineability challenges of titanium alloy and other gummy materials such as stainless steel successfully.

high feed mills

How We Did It

The cutting geometry of the Ti-Feed Series is designed specifically for titanium machining. It features a high positive cutting geometry with precision ground hone and 30-degree helix to ensure a high degree of shear action during cutting. A non-center cutting design increases core strength (and consequently rigidity) during machining. Flute count ranges from 5 to 7 flutes, based on diameter, to provide the maximum number of cutting edges for optimum MRR and thermal management. Longer overall lengths, combined with longer tapered neck bolster reach and rigidity and make the tool ideal for long-reach z-level machining operations. Lastly, our multi-layered HX coating provides heat and wear resistance for longer tool life when machining high-temperature alloys, while our optional coolant-through series provides maximum performance for those with coolant-fed spindles.

Depending on your need, tools in the Ti-Feed Series are available from stock in solid (2052 Series) & coolant- through (2053 Series) versions.

Special Promotion

To make your decision even easier, from May 15 to June 30 if you buy three of our Ti-Feed Series high feed endmills, we’lll give you another one absolutely FREE. That’s right: four titanium chomping endmills for the price of three! Use Promo Code: TIFEED20.

 

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Autocam Medical Fights COVID-19 with a Little Help from Their Friends

Ventilator parts

Autocam Medical, with headquarters in Kentwood, Michigan, is a global contract manufacturer of orthopedic implants, spinal implants, precision instruments and orthopedic cutting tools. Like all of us, they have watched the coronavirus crisis unfold over the past few months. But unlike most of us, they were provided with an opportunity to make a life-saving difference. The company was asked to take on a challenge that could double the capacity of vitally needed ventilators.

Ventilating Multiple Individuals

Dr. Kyle VanKoevering of MakeMedical, LLC, approached Autocam Medical with a drawing of a “splitter” device that could enable one ventilator to assist two patients at the same time. Dr. VanKoevering is a Clinical Assistant Professor at the University of Michigan Medical School. He has broad experience in the application of 3D Printing for diagnostic and surgical applications, having played a key role in several groundbreaking and novel uses of additive manufacturing in medicine. His work continues in this field while he continues to provide excellent care and leadership at the University of Michigan.

The “splitter” device is called VentMI™ (Ventilate Multiple Individuals) and its purpose is to help provide mechanical ventilation to two patients from a single ventilator. “We know that Individualized pressure control and the addition of other components is the key to effective ventilation,” said Dr. VanKoevering. “Combining custom pressure regulators and one-way valves, this system has been tested in simulated lung and animal environments, and has Emergency Use Authorization (EUA) from FDA.”

When asked if Autocam Medical could use their manufacturing skills and experience to rapidly develop prototypes of several components for the piece, the answer was a resounding, “Yes!”

Ventilator parts

Although ventilator parts are not in their current product line, Autocam Medical is fully certified to manufacture medical components. Their knowledge and experience in the medical industry, combined with their manufacturing expertise, made them a perfect choice for the assignment.

Tooling Turnaround

When the engineers at Autocam Medical studied the prints provided by Dr. VanKoevering, they realized that special tooling, specifically end mills and chamfer mills, would be needed to machine the components. Luckily, GWS Tool Group was right around the corner (quite literally). Justin Pickerd, Manufacturing Quality Engineer, had worked with Fred Edmonson, General Manager at GWS-MI, before and had always received excellent turnaround times. Justin said the company hadn’t had time to set up a purchase order and explained what the tooling was for. Fred just replied “What do you need and when do you want it?” Tool design and manufacturing prints were put into motion immediately, without an order, and within 24 hours Autocam Medical had the 6 different custom tools they needed from GWS.

Ventilator parts

Making It Happen

With the proper tooling in place, Autocam Medical proceeded to do what they do best, but in record time. It can take months to develop a prototype like this. Autocam Medical had the parts ready for assembly within days. Meanwhile, a sister facility in Tennessee was tapped to manufacture other components for the splitter device, which were then shipped to Michigan. The assembled parts were presented to MakeMedical, LLC within the week.

Granted, Autocam Medical’s specialty is medical components, but, even so, the turnaround on this project was amazing. From a doctor’s innovative idea to the power of a professional manufacturer to our own commitment to provide the tooling, this team cut months off the usual delivery timeframe! It sounds like a story out of World War II, when America was known as the “Arsenal of Democracy.” This story shows that a “Can Do” attitude is alive and well within the latest generation of manufacturing companies like Autocam Medical. We are proud to have been part of the process.

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Manufacturers Shift Gears to Medical Machining for COVID-19 Support

GWS helps deliver in 48 hours

Over the past weeks, while lives have changed for nearly everyone due to the COVID-19 pandemic, we have witnessed the manufacturing industry rise to the occasion and respond with phenomenal dedication. Almost overnight, our partners have shifted their production lines from their usual products to producing medical parts for COVID-19 support.

At GWS Tool Group, we are committed to assisting our customers in their battle against the Coronavirus by delivering custom tools to them as quickly as possible.

A Few Highlights:

A manufacturer of air-conditioning parts on the East Coast converted their operations to make vital components for badly needed ventilators. Their engineering and design processes were quickly adapted to this new sector of machining. They were able to utilize our custom end mills already in their inventory, but the components also needed a special diameter drill. After some information sharing with our engineering team, the tools were produced and on their way within 24 hours.

A heavy-duty seat manufacturer in the Midwest turned directions completely to counter the COVID-19 threat to medical workers. They switched over to manufacturing respirators and face shields that will be supplied to the Federal Emergency Management Agency (FEMA) and hospitals. GWS worked in the background and supplied several tools on short notice.

Most recently, a longstanding partner in the medical field rapidly responded to the Coronavirus crisis by supporting the efforts to develop an innovative solution to the ventilator shortage. They used their vast knowledge of medical manufacturing to machine the new precision components required. Our small part was developing and producing a custom cutting tool within 24 hours for the new parts. We were happy to part of a team that will ultimately get critical ventilation units to where they are needed most.

Working together during this time of crisis is vital to our industry and our country. We are thankful to work with such dedicated and selfless U.S. manufacturers who are willing to do anything to support the greater good of people across the nation. We are grateful that we have been able to contribute in our small way by providing our partners with the tooling they need in their essential manufacturing response to this virus.

If you’re adapting your production to fight against Coronavirus, we are waiving ALL expedite fees to get custom tools to you in as little as 24 hours. If you need a tool fast, please contact us, we are open and ready to assist.

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GWS Solves What Others Could Not

custom pin hole drill

The Opportunity

A global small engine manufacturer was dealing with an unacceptable scrap rate (3.03%) when drilling piston ring pin holes into pistons for the two-cycle engines that make up a large part of their product line. The parts are made out of high silicon aluminum castings. Upon placement of the pins, pistons were cracking due to excessive force. The root cause was identified as inconsistent diameters and surface finish of the cross pin drill hole. The target was 1.520mm (+/- 2 µm) using a rotary transfer machine. Without holding this tolerance, too much force was required to insert the pin, which resulted in the breakage of the finished part. The problem was aggravated by poor surface finish which made measuring and controlling such a small hole an additional challenge. After consulting with over a dozen well respected brands, they pursued what appeared to be a more costly solution from GWS.

GWS Action Plan

As with any application, the process with GWS started with our application specialists studying the operation and listening carefully as the customer outlined their problem and experiences with their test results. Taking these data points into consideration, GWS engineers were committed to finding a solution.

Their first conclusion was that an off-the-shelf drill just would not be able to deliver the solution needed. Tighter tolerances were required, as well as better finishes. Thus, the design team set out to create a drill design that would address the problems outlined by the customer, while delivering better tool life. Key design elements included a 2-micron diameter tolerance, a double margin for improved finish and custom cutting edge geometry suited for the abrasiveness of high silicon aluminum. The rest of the tool profile took shape as follows:

  • Construction: Solid
  • Material: Ultra-fine grain Carbide
  • Coating: Uncoated, high polished flutes
  • Geometry: 30 Degree Helix
  • Tip: High-Performance S Type

custom pin hole drill

As the prototype came together, it became obvious why the customer was having so much trouble finding the right tool for this job. Putting all of these features together in a double margin drill so small is beyond the capabilities of most cutting tool companies (see photo for proper scale). The final element in its successful production was the knowledge and skills of our manufacturing hole making division.

custom pin hole drill

The Results

The customer’s manufacturing engineer stated that “The consistent diameter and phenomenal surface finish on the drilled hole now made it easy to consistently push the pin in with minimal force.”

The custom Micro Piston Pin Hole Drill from GWS:

  • Dropped the scrap rate from 3.03% to .4% (including additional process improvements)
  • Increased drill life from 10,000 to 22,000 parts per drill
  • Created an estimated total cost savings well into 6 figures

custom pin hole drill

Custom Comes Standard

Pennies still count, even when you’re a global manufacturing giant. But, as many of our other customers have discovered, paying a little more for a well designed and manufactured custom cutting tool can pay back big dividends in performance. The manufacturing engineer responsible for implementation noted that, while the cost savings from tool life alone justified the tool, the more significant savings was by far and away the elimination of the breakage problem. “Throwing away all of the costly machining work done prior to that drilling operation represented our biggest problem on that part, and GWS solved it.”

If you’re wasting time and money trying to find the right cutting tool for your application, contact us and put our expertise to work for you.

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GWS Coatings 101: End Mills Beat the Heat With nACo®

Welcome back to our series on the different types of coatings we offer to make your cutting tools provide better performance. Cutting tool coatings are designed to improve wear properties via higher hardness, increased thermal stability and reduced coefficients of friction. In our first two posts, we discussed the properties and uses of AlTiN and ALCRO-MAX.

AlTiN is a general-purpose coating with high aluminum content. Applied to the tool with a coating thickness between 1-4 microns, it provides excellent heat and oxidation resistance for application in a broad range of materials.

ALCRO-MAX is a super-strong coating has been engineered to give an optimum balance between the toughness of the core layer and the abrasion resistance of the top nano-layer. An upgrade from AlTiN for materials like stainless steel and Titanium.

If you do a lot of hard milling or machining of Nickel Alloys, you’re going to be very interested in what our next coating can do for you. Meet nACo.

Tough. Heat Resistant. Long Lasting.

A nanocomposite coating based of Titanium and silicon, nACo coating is ideal for increasing performance and extending tool life (up to 30%) versus more standard coatings like AlTiN. This super-hard coating can be found in any industry that needs an end mill that has a tough core with extreme wear and high heat resistance for milling hard materials. Examples include die mold (D2, A2 tool steels), aerospace (Inconel®), and military (4140 hardened alloy steels).

Offered standard on our Hurrimill 1030 Series of high-performance end mills in 4, 5 or 7 flutes, nACo is one of many in-house coating technologies GWS applies to both standard and custom tools.

cutting tool coatings: nACo

Why It Works So Well

With a coating thickness of 1-4 µm, nACo offers maximum protection against heat and tool wear. It resists heat up to 2,192°F before it starts to oxidize and break down. It’s also harder than ALTiN or AlCrN – the top layer has an extremely high nanohardness number (41).

Efficiency is also enhanced by a low coefficient of friction for less resistance.

nACo is applied to our tools using the Platit® high performance physical vapor deposition (PVD) units in our coating facility. Keeping the process in-house gives us total control on quality control and turnaround time. In fact, demand is so strong for our coating services, we have expanded our operations by recently opening a new state-of-the-art coating facility in our Springfield, Massachusetts location.

Contact us to see if nACo or any of our other coating options will help you maximize performance. Remember, if you don’t see what you need in the catalog, we specialize in custom engineering the right tool for your application.

nACo is a registered trademark of Platit, Inc. 
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Custom Tool Spotlight: 10-Flute Form Tool for Defense

Welcome to our Custom Tool Spotlight, a series that takes GWS cutting tools and gives them mini biographies. Today, we’re talking about a custom 10-flute form tool to be coated with AlTiN for defense.

What’s it for?

This tool is specifically made for one our large tier defense/armament manufacturers. This tool will be used to machine a AR15 Bolt Carrier Group component.

What’s cool about it?

The 10-flute design on this custom tool permits higher feed rates for optimum production while simultaneously providing rigid construction that minimizes chatter. It also features a reduced neck, which provides an abundance of clearance. This tool will also be finished with a multi-layered AlTiN coating, which is ideal for alloyed steels.

custom form tool defense

Why Custom?

With most form tools, there is a precise profile or contour needed to be milled. What often would require multiple tools and milling sub-routines now requires just one tool with simple linear tool paths. In this case, not only are cutting passes and tools reduced, but form tolerances of the part itself are held within 0.0005”.

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Carbide Taps: A Practical User’s Guide to When, What, How and Why

Highly abrasive materials like cast iron, polymers, glass filled polycarbonates, and some cast aluminum are called “hard” materials for a reason. They’re hard to machine, hard on tool life and hard on production cycle times. How do you overcome the difficulties of making parts out of challenging raw stock? By using a tool that’s even tougher. Consider a change from steel taps to carbide taps.

When to Use Carbide Taps

While high speed steel (HSS) taps have a practical top limit of around 35-­40 HRC before tool life becomes severely limited, carbide is often used in materials with hardness up to 65 HRC (the ones that chew up HSS in no time). With the appropriate style for the application, tool life of carbide can be 5­20 times that of HSS, with the added bonus of superior accuracy.

Array of custom High-Speed Steel taps available

What Carbide Taps to Use

That’s easy. Our carbide taps are American made from high-quality C2 micro-grain carbide by highly skilled machinists on state-­of-­the-art equipment, and are backed by decades of experience from our support staff.

We offer carbide taps in UN and Metric sizes as well as straight and NPT/F Pipe and STI Standards. A wide range of styles and features are available, including straight flute, spiral flute, spiral point, and forming taps. For increased performance and life, we can customize tools with a full line of surface coatings such as TiN, TiCN, and TiALN.

How to Use Carbide Taps

Machining with carbide does come with some “do’s and don’t”. Hand­ tapping is generally not recommended. Rigid tapping and spot­-on alignment are critical to avoid breakage. Not to worry, however. Modern CNC equipment is ideally suited for carbide applications.

Here’s some additional tips. Coolant holes through the taps are an option for flushing chips out of the holes on the most difficult materials like some of the tougher stainless steels and space-­age alloys. Carbide STI (Screw Thread Insert) tapping of these materials has become commonplace in the aeronautical and aerospace industries.

Array of custom High-Speed Steel taps available

The Why of Carbide Taps

Although initially more expensive than HSS taps, significant savings can be realized, especially in long-­run jobs. Higher cutting speeds, greater tool life, and reduced down­time from fewer tooling changes translate into reduced machining costs.

An alternative to costly larger sizes is our line of Carb­I­Sert® Taps. Solid carbide cutting surfaces are bonded onto a high-speed steel body to provide the best of both worlds; durability of carbide with the “forgiveness” of a steel body and shank.

So, don’t let difficult materials give you a “hard” time. Contact us anytime and put our carbide taps to work for you.

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Coating Technician Danny Cinnamon Knows How to Spice Up the Day

Danny Cinnamon

Meet Danny Cinnamon, a long-tenured employee at GWS-Florida, who helps make work there much more fun for everyone.

Since 2011, Danny has tackled nearly every production job there is on the GWS shop floor. That includes everything from laser etching and cleaning tools to assisting the team with our CNC machines. If it needed to be done (even if it was cleaning the bathrooms), Danny made up his mind to do it, and do it well.

He remembers when we had a solo gig as GW Schultz, and has experienced every acquisition and expansion since! “Think where we’ll be in another 15 years or so,” he said. “And we got in on the ground floor. That’s pretty cool.”

Know your Coating Tech

Now Danny is our Coating Technician at GWS Headquarters in Florida. He is responsible for the application of a multitude of GWS coatings, including AlTiN, NaCo, NaCro and ZrN, to name just a few. And with a brand new PVD coating vessel hitting the floor this March, this list will be growing even larger!

When you ask Danny what he likes most about his job, he just says with a smile, “Everything.” You can’t find a more positive outlook from anyone in the shop and that’s what helps GWS maintain our high level of success. He says “The best way to have a good day is to make a co-worker smile.”

When you ask his supervisors about him, they say that Danny is one of the most dedicated workers here, “He even has a GWS sticker on his truck,” one of them commented.

We couldn’t be prouder to have someone like Danny on our team!

Work Hard. Play Hard. 

When he’s not doting on his love for GWS, Danny loves spending time with Pepper, his wonderful wife of 21 years. They rush off whenever they can to spend time at one of their favorite spots, Rocky Top, Tennessee. Danny and Pepper enjoy going up to the mountains, staying in cabins and even hiking on the trails up in the Smoky Mountains. (Danny says to go to Cade’s Cove, if you’re visiting!) The outdoor life in Tennessee is only one of their passions. If there is a Tennessee Volunteers football game on, you can bet Danny and Pepper will be leading the cheers (Go Vols!)

When they aren’t in Tennessee, you can find them relaxing at home watching The Walking Dead, anything on the ID Discovery channel or indulging in a good Hallmark Movie with their 3 Dachshunds – Penny, Lillo Peep and Ladybug.

Interested in a Career at GWS Tool Group?

If you think Danny has a good thing going and want in on the action, we are always looking for talented and driven individuals to work at one of our 6 manufacturing locations. Browse open jobs here.

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GWS Tools Up for Aerospace with a Line of PCD Holemaking Products

PCD holemaking tools

As a major provider of ​highly engineered custom, standard, and modified standard cutting tools ​to the aerospace sector, we have expanded our capacity in this area with a special emphasis on brazed PCD drills, reamers and countersinks with or without brazed threaded shank adapters. PCD (polycrystalline diamond) is made by fusing diamond grit with metal under high temperatures and pressure. The result is a substrate that is extremely resistant to wear, lasting as much as 25X that of carbide.

PCD and Aerospace

Tools made with PCD are in demand for machining abrasive non-ferrous materials, such as aluminum, fiberglass, or composites, which are prevalent in the aerospace industry. A composite material is defined as two or more different materials which are combined to create characteristics different from the individual materials themselves. Plywood is a perfect everyday example. Composite materials like Carbon Fiber Reinforced Plastic (CFRP) are used for making aircraft components that include wings, wingboxes, vertical tail sections, and fuselages, as well as a number of smaller parts. CFRP achieves significantly better stiffness to weight ratios versus traditional aerospace materials, making the planes significantly lighter and hence more fuel efficient.

Why PCD is Better

Since it is harder than carbide (6500 Vickers vs. 2000 Vickers), cutting tools made with PCD hold their edge much longer and provide a better finish. This is vital since dull edges can fail to cut the soft fibers in composites, or cause the combined components to delaminate (pull apart) due to excessive cutting forces or heat, destroying the integrity of the piece. Be it composites or Aluminum, cost savings are realized because tools made of PCD can run faster and last longer, reducing cycle times tool changes and overall tooling costs.

Our PCD Lineup

The new line of PCD holemaking tools covers a wide range of applications so we can offer a complete range of solutions to our aerospace customers. For each tool, the PCD is brazed to a carbide or steel body, depending on the application. CNC applications typically incorporate carbide bodies, while those for use in hand tools, such as pneumatic drills, are brazed to high speed steel for greater forgiveness in less rigid holding environments. Be it carbide or HSS, our holemaking tools can be made with or without a threaded adaptor on the back for screw-in type hand tools.

Other structural aerospace tools in our new lineup include:

  •  8 facet PCD Drills for CFRP
  •  Carbide & HSS Drill countersinks
  •  Carbide Drill/Reamers
  •  Carbide Dagger Drills
  •  Carbide Routers
  •  Brazed PCD Countersinks w/Threaded Adapter
  •  PCD Tipped Inserted Countersinks

Solid PCD versus Veined Technology 

“Solid PCD can outlast Veined, or grown, diamond by 2-3 times in specific applications. It tends to be much more wear resistant, thus offering more holes per drill and less money per hole. In addition, Solid PCD drills with solid carbide bodies can be resharpened several times and reconditioned many times. With the advancements in laser cutting and erosion equipment, it has given GWS the necessary ability to create complex point geometry that is needed to leave behind a superior hole, surface finish and delam free.

While the structure of composites is continually improving, solid PCD drilling is the wave of the future and GWS is the future of the wave.”

– Rich Rogers, Director of Manufacturing GWS-AZ

If you are an airline manufacturer or OEM that could benefit from our new line of PCD products,​ ​call us​ ​for a consultation and get a quote today.

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Custom Tool Spotlight: Ball Nose End Mill for Titanium

Custom End Mill Aerospace
An army of GWS Custom Ball Nose End Mills

Welcome to our Custom Tool Spotlight, a series that takes GWS cutting tools and gives them mini biographies. Today, we’re talking about a custom tapered ball nose end mill for Ti-6Al4V.

This is a ⅛” 3FL .75 LOC 6.00 OAL ⅜ Shank 3° Taper per side. While this ball nose endmill isn’t coated now, it will be finished in a TiCN coating. 

Custom End Mill Aerospace

What’s it for?

This tool is specifically made for one of our aerospace customers. It is used for finish milling operations of Titanium turbine blades.

What’s cool about it?

The long OAL combined with the 3-degree taper and short length of cut make these tools ideal for reaching deep areas between the blades. The blade shape in combination with a 5-axis machining center toolpath present obvious interference issues when it comes to toolpath. The tapered tool configuration designed below eliminates the alternative solution of longer tools and slow machining speeds. These tools, per request from the customer, will receive Titanium Carbon Nitride (TiCN) coating as a final operation prior to inspection and shipping.

Custom End Mill Aerospace

Why custom?

Our customer needed over 2,500 of these tools and they needed them fast. GWS was able to come in and help produce this project in 4 weeks, with partial shipments going out the door in a matter of days. Custom Comes Standard around here, but that’s not simply something we say. It’s something we deliver.

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Aluminum Machining Goes from Awful to Awesome with GWS Tooling

aluminum machining - Alumigator

Breiner Machine is a family-owned-and-operated manufacturing facility located in Brooksville, Florida. Their 11,000 square foot facility offers a wide range of services such as product development, precision CNC milling and turning, welding, and CNC sheet metal fabrication.

The company produces components for a variety of manufacturing industries, including the Food and Beverage Industry, Aerospace, Aviation, Marine and aftermarket automotive industry. All of these industries call for the use of various materials. A good portion of their aftermarket Automotive parts are made from various grades of aluminum.

Old Dog. New Trick.

The cuts made on these work pieces involve perimeter ramping, and helical ramping into the material and then deep pocketing. The trick to doing that with aluminum is the need to remove chips effectively and maximize tool life while still maintaining acceptable cycle times. Acceptable cycle times mean not only machining fast, but also entering the part equally as fast without reducing feed rates or altering toolpath to compensate for end mills incapable of aggressive part entry.

About 15 years ago, the company was working with a competitor’s brand endmill for their aluminum applications on a vertical machining center. They ran those tools as fast and hard as they could while maintaining finish and tolerances. A GWS sales engineer paid a visit and left behind a standard off-the-shelf-tool for them to try. That’s when the company’s programmer found out that a good quality tool can increase productivity and finishes dramatically. Finishes were much better with the very first run. Cycle times were reduced by close to 20%.

Chip. Chip. Hurray.

Today, Breiner Machine uses the latest version aluminum cutting tool in the GWS lineup, the Alumigator. One of the things that Jason Breiner, President of Breiner Machine, has found unique on the Alumigator line is their outstanding center cut gash design. “The ramping is insane, I’ve never seen anything so aggressive,” he said. “The chips eject with no problem even when ramping at extremely steep angles.” Jason says in his experience, that usually packs up any other endmill. The best I can usually ramp in at is 10 degrees with other brands. I can more than double the ramp angle with the Alumigator. The ramp angles achieved with this tool exceed the capabilities of any other endmill he has tried.

With their old tool, Breiner Machine was only capable of 250 IPM when pocketing in aluminum via ramping high-speed machining for turbo mounts for diesel engines. With the 1025 Alumigator Series they were able to achieve 450 IPM. “Few tools can plunge and ramp like the Alumigator can,” Jason said.

The reasons for this outstanding chip flow can be attributed to the design of the tool. The tapered core of the endmill adds stability and a carefully designed gash at the tip maximizes chip clearance while still maintaining rigidity during machining.

Tooling Along

Breiner Machine recently acquired a brand-new Kitamura vertical machining center. This only gave the shop more reason to take the GWS tooling they’ve been using and push it harder, to test not only the tool’s capability, but the machines. They recently tried a 1010 Alumigator to make airboat propeller hubs, and they’ve far exceeded the initial recommended feeds/speeds which were 300 IPM and 10,000 RPM. The roughing operation consists of a 30-degree ramp angle going 1.5″ deep with no speed reduction. The spindle load meter on the machine has yet to register.

The impact to the bottom line has been huge. Aside from the performance of the GWS tool, profitability is way up. While cycle times are dropping, yield is good. Tool changes have been eliminated by using the same tool for roughing and finishing operations; tool life has been maximized; and the scrap rate has dropped since parts are no longer messed up by chip-packed tools. Those are just a few of the advantages Breiner Machine has seen so far with tooling from GWS.

Exceptional Value. High Performance.

Jason is known to experiment. So, he’s familiar with many of the “top tier” brands in the market and what their competitive tool offers. But GWS has proven to have great cost performance (good price point). “It doesn’t make sense to use a tool at double the price if it doesn’t yield comparable results,” Jason said.

What’s next for Breiner Machine? Jason has only been using standard off-the-shelf items and has reached milestones he’s never thought possible. Just imagine if he decided to tap into GWS’s custom capabilities (something they are known for)? The sky is the limit.

So, if you’re machining aluminum, take deep cuts in the parts, not your profits. Contact us anytime. We’ll be glad to put an Alumigator or any of our fine tools to work for you.

And be on the lookout for the newest addition to our aluminum offerings, our the GWS KA5. Watch it work

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The Graduate: How Derek Haller Makes GWS Better

GWS has some impressive employees, and Derek Haller is one of them. Derek is one of our talented CNC operators and programmers at our Michigan facility. He has been with us since 2012, going all-in on the custom cutting tool world.

Derek discovered a love of metalworking when he was a freshman in high school. He started taking courses featuring milling machines and lathes, and he never looked back.

Beyond the Books

In December 2019, Derek graduated with his Bachelors of Science in Manufacturing Engineering from Ferris State University. He’s drawn to the ever-changing technology shifts in the metalworking industry while also focusing on problem-solving even the smallest of customer woes. Derek loves the constant challenges that come with creating custom cutting tools. “There is something fulfilling about starting a project with a paper design and ending with a tangible product,” he said.

Derek prides himself on implementing our new Strausak machining in our Michigan facility. He worked closely with this line of machines to add a new layer of technology-forward capabilities to our lineup.

His formal training in Manufacturing Engineering, paired with his hands-on experience with programming and operations, helps deliver unmatched efficiency to our production. A deeper understanding of customer needs helps him deliver the right tool in the shortest amount of time.

Derek’s education won’t stop with his degree. He embraces the opportunity to learn something new every day and help customers meet their goals. We are lucky to have Derek as a part of the GWS Team, and we congratulate him for attaining his bachelor’s degree!

Gone Fishin’

When he’s not working, Derek enjoys doing anything outdoors. Whether it be hunting whitetail deer, fishing, kayaking or hiking with his chocolate lab puppy, Goose, you’ll always be able to find Derek outside. He is pretty modest when he says he likes to fish as a hobby. Derek has been part of the Ferris State University Fishing Club and loves to enter bass fishing tournaments all summer long. He doesn’t quit there; he also spends his winters out on Lake Erie, ice fishing whenever he can.

Derek Haller

Interested in a Career at GWS Tool Group?

We are always looking for talented and driven individuals at our facilities in Florida, Indiana, Michigan and Massachusetts. Browse open jobs here.

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Team Effort Speeds Production of Intricate Titanium Aerospace Parts

Titanium Aerospace Parts

Superalloy Manufacturing Solutions Corporation offers turnkey components for aircraft engines and other mechanized systems in the commercial and military sectors. As you can well imagine, their customers are very particular about quality and delivery time. When an order came in for a titanium pylon part for aircraft landing gear, Marcia DeVeny, Superalloy Senior CNC Programmer, was tasked with programming the part, and started exploring the best way to get it done.

The project was for 8 sets for a total of 16 components, which would be machined on the company’s new DMG Mori Horizontal Machining Center. The finished part has several deep cavities in it that are within thin walls, a demanding application that requires the right tool, right machine and the right toolpath strategy.

Teaming Up

Titanium is expensive, and planning for a machining project like this can resemble the preparations for a moon landing. Marcia did her homework to make sure the ideal cutting tools and toolpaths were in place before hitting the “cycle start.” She decided to consult with Mark Scott, a GWS Application Specialist with over 20 years of industry experience.

After reviewing the prints and specs, Mark looped in Mike Littlejohn, GWS’s Senior Applications Specialist. Mike is GWS’s programming guru, and he recommended adaptive milling: a technique available on NX 12 CAM software that uses a large axial depth and a small radial depth of cut for high-speed cutting. Mike demonstrated the technique to Marcia on a shared screen. “Seeing it in operation was a big help,” she said. He also showed her how to approach the pockets, and Marcia purchased the adaptive milling license from Siemens.

Marcia DeVeny and Mike Littlejohn
Marcia DeVeny and Mark Scott

While Mike was helping online, Mark worked with Marcia onsite to help dial in the application. The team proved out the process in a steel set-up part first. When satisfied, they adjusted Speeds & Feeds for Titanium. A lot of fine tuning was needed to pin down the process. “Mark was in here almost daily to help us get this running,” Marcia commented. “As we worked through the application, he would bring in trial tools to improve the process. The turnaround time on those was incredible.”

The Right Tool

Mike has a lot of experience helping customers machine titanium (see “Milling Titanium is a Lot Easier with Specialty Tools from GWS”). He outlined the problem with the material. “Titanium has a tendency to generate excessive heat during the machining process. It has low thermal conductivity characteristics so the heat mainly gets transferred to the cutting tool. This results in long continuous chips that can weld on to the tool edge, giving you a poor finish, or worse yet, out of tolerance parts. Feeds and Speeds need to be dialed in carefully if you want to mill it successfully.”

Titanium Aerospace Parts

To counter these problems, he suggested the PYSTL 538 series which has a dedicated geometry and Alcro-Max coating that are ideal for titanium. The team used a range of sizes to get the best result, deciding on 1” and ½” tools. “The 1” tool did 90% of the job (pocket milling and all the OD work),” Marcia recalled. “The cornering work was done with the ½” tool.” As expected, the PYSTL did a great job breaking up chips.

The Results

Superalloy ran the parts in less than ½ the time of a test program, also running pocket milling, but using older cutting techniques. They finally reduced the cycle time to 8.5 hours per set, going to the full depth of the floor of the part, almost 2.5”. Using adaptive milling, they achieved 7% engagement on the cutting tool, and a much higher metal removal rate of 5.78 in 3/min than the test program.

Each part only used three 1” diameter tools to complete. “GWS initially recommended a cutting time of approximately 100 minutes per tool,” Marcia said. “But when I looked at it after 90 minutes and saw minimal visible wear, we decided to keep going. The tools lasted up to 180 minutes after finding the sweet spot of Speeds & Feeds and optimized MRR.”

Customer Support Plus

Now that the project is complete, Marcia said, “The assistance of Mike and Mark on this project went way beyond the cutting tool on this application. They never hesitated while providing two levels of support: Mike provided remote advanced programming help and Mark gave us onsite application support.”

This was a smaller production run, but Marcia indicated that there are many opportunities beyond this initial application in the same product family. “What we learned here will pay benefits to Superalloy and our customers for years to come.”

If you have a complicated machining situation and could use some advice from guys like Mike and Mark, contact us anytime. We’ll be glad to help.

 

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Custom Tool Insert Professional: Anne Cooper – Master of Design

Anne Cooper

Meet Anne Cooper, a 27-year veteran of the custom cutting tools industry. Anne is the Lead Design Engineer for GWS Tool Groups’ insert division and started her career with humble origins as a machine operator in the Edge Prep Department. From there, she has continued to perfect her craft and expand her responsibilities, making her position one of the company’s most vital roles.

Uniquely enough, Anne’s path to becoming an integral part of the GWS family started as she was celebrating her 25-year anniversary in the industry. It happened to be the same day it was announced that CGI Tool would be joining the GWS Tool Group Family.

A Design Dynamo

Using solid model CAD/CAM software and years worth of experience, Anne designs custom cutting tool inserts that machine parts as diverse as medical implants to parts for heavy machinery. It is not uncommon for customers and sales representatives to ask Anne to work from basic 2D part prints or reverse engineer a sample to design custom inserts to fit their special needs

In addition to her design work, on a typical day you can find Anne taking an active role in researching & developing new techniques “to improve the features of an insert for a customer’s unique application, while working to keep costs down at the same time.”

Mindful Mechanics

While Anne is modest about her natural abilities, she has a strong mathematical and mechanical background, citing the fact that “her father was a self-taught inventor and her grandfather was an architect.” Combined with degrees in Manufacturing Technology and Design Technology, she uses her strong background to help “visualize the whole process and imagine the proper tool” for the customer’s requirements.

Anne Cooper

The GWS “Edge”

As an expert in her field, Anne takes pride in knowing that GWS never hesitates to invest in new technology that will make a better product for their customers. “Working with the most advanced equipment on the market helps us provide a much faster turnaround than the competition,” she said. “Plus, it’s a lot of fun having new toys to play with.”

Beyond Design

Thanks to her diverse background, Anne is very knowledgeable in all aspects of the business and truly knows it inside and out. She enjoys the different challenges that every day brings and has the confidence that her years of experience, along with utilization of state-of-the-art machinery, will enable her to handle any task.

Beside custom cutting tools, she has a strong knowledge of CNC machines and is a tremendous asset when it comes to troubleshooting and fixing a downed machine to prevent costly downtime and expensive service calls.

Off the Clock

Anne Cooper

In her free time, Anne enjoys spending time with her kids and contributing to the community. She is vice president of the local chapter of Optimist International, a worldwide volunteer organization whose members work each day to make the future brighter by bringing out the best in children and their communities. Anne’s group helps to promote childhood health & wellness, organizes programs for summer youth camps and offers scholarship opportunities to assist local high school students.

 

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GWS Coatings 101 – ALCRO-MAX

ALCRO-MAX

In our last post in this series, we introduced you to AlTiN, a great general purpose coating with a high aluminum content, which is used for machining steel, titanium alloys, Inconel, stainless, and cast iron in both wet and dry environments. In this article, we’re going to kick it up a notch with a coating that has all the advantages of AlTiN, but performs at an even higher level. Meet ALCRO-MAX.

Strong. Stable. Long Lasting.

ALCRO-MAX is a Triple Platit® Coating based on AlCrN (aluminum, chromium, nitride) combined with titanium. Triple Coatings are deposited with 3 sections freely programmed in one batch. ALCRO-MAX is applied to our tools using the Platit high performance physical vapor deposition (PVD) unit right on our shop floor. Keeping the process in-house give us total control on quality and turnaround.

This super-strong coating has been engineered to give an optimum balance between the toughness of the core layer and the abrasion resistance of the top nano-layer. The addition of titanium reduces adhesive wear and chipping compared to conventional AlCrN coatings. It increases the micro-hardness up to 3500Hv and stops the crack propagation through the coating.

When to Use It

ALCRO-MAX is highly suited to machining tool steels; 303, 304 and 316L stainless steel; and Ti-6Al4V or other titanium alloys. These materials have a tendency to generate excessive heat at the contact area. This results in long continuous chips that can weld on to the tool edge, giving you a poor finish and scrapped parts. And you can just imagine what that kind of heat does to tool life. All materials that fall into the “gummy” category require a coating like ALCRO-MAX for increased thermal resistance and extended tool utilization. Our customers use it for wet and MQL (minimum quantity lubrication) application to achieve longer tool life and increased thermal stability. And because it is does not rely on heat to activate the coating, like AlTiN, its performance in wet milling applications noticeably better.

ALCRO-MAX

The ability of the cutting edge to shear the work material with as little residual friction as possible after initial contact is critical in producing an end mill that will satisfy the tool life and metal removal demands of today’s manufacturers. That’s why ALCRO-MAX coatings are available on all of our PYSTL series end mills. Of course, we can always add ALCRO-MAX to a custom tool designed specifically to your needs.

Contact us to see if ALCRO-MAX or any of our other coating options will help you achieve better results. Remember, if you can’t find what you need off the shelf, we specialize in custom engineering the right tool for your application.

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GWS Coatings 101 – AlTiN

Machining metal generates heat, and coatings are all about providing resistance to that heat while also providing some other tangible benefits as well. The make-up of the coating depends on the cutting application and the coating machine itself. Variables like work material, cutting fluid, cutting tool type and even part tolerances can all play roles in coating selection.

Cutting tool coatings are designed to improve wear properties via higher hardness, increased thermal stability and reduced coefficients of friction. In a new series of posts, we’ll review the different types of coatings we offer to make your cutting tools provide better performance. First up: AlTiN.

AlTiN. For when things heat up.

This chemical compound is named for the three elements that make up its composition: Aluminum, Titanium, and Nitride. It, along with most coatings we will discuss in this series, is applied to tools using the PVD (physical vapor deposition) method. While TiAIN is made up of the same basic components, the percentages of aluminum and titanium differ. Based upon the application, one may work slightly better than the other, but for our purposes here we will place them both in the same category.

See Boost Productivity with the Right Cutting Tool Coating

Once deemed a new innovation, AlTiN is now considered a general purpose coating with high aluminum content. Applied to the tool with a coating thickness between 2-4 microns, it provides excellent heat and oxidation resistance. This is partly due to its nano hardness of 36 gpa (gigapascal – a unit of pressure). AlTiN remains stable at operating temperatures up to 1,292F°. Uncoated tools get into trouble at around 572°F.

One note about AlTiN is its application in wet machining environments (which, obviously, is most of them). Simply put, AlTiN performs best in applications where temperatures are both elevated and stable, as consistently high temperatures essentially activate the aluminum in the coating, improving performance. When run wet, temperatures fluctuate up and down, somewhat reducing the coating’s maximum performance capabilities.

AlTiN Cutting Tool Coating
Convex Radius Cutter

What does all this mean for you? Higher feeds and speeds when machining ferrous materials, for starters. Better tool life, too. AlTiN is a good coating for dry machining and machining titanium alloys, Inconel, stainless alloys, and cast iron.

AlTiN coatings are available on the following GWS tool groups:

• 210 Series – 335 | 3FL | Radius
• 215 Series – 335BN | 3FL | Ball Nose
• 220 Series – 545 | 5FL | Square & Radius
• 240 Series – S94 | 2FL | Chamfer Mill
• 241 Series – S94 | 4FL | Chamfer Mill
• 243 Series – CM2 | 2FL | 90 deg. | Chamfer + End Mill
• 4005 Series – ECO | 2FL | 5xD | Solid | Inch & Metric

And of course, we can always add AlTiN to a custom tool designed specifically to your needs.

Contact us to see if AlTiN or any of our other coating options will help you achieve better results. But whatever you do, don’t run a bare tool. Put a coat on it!

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5 Signs You Need Custom Cutting Tools for a Better Bottom Line

Cutting tool catalogs are full of very good off-the-shelf options for a lot of machining applications. But not every situation has a standard answer. Is it possible that you may save time and even more money by going to a tool tailor-made to your needs? Here are 5 signs that you might be better off going with a customized product.

One: Unsatisfactory Performance

The most obvious sign that a custom tool may serve you better is when you pull a part out of the CNC machine and are not happy with the results. For example, if you feel your surface finish could have been better, or you’re routinely sending pieces off to another operation for polishing or deburring, you could be wasting time and money. Likewise, if you are getting the quality you want, but wish you got more tool life, custom may be the way to go. Constantly stopping the run to replace tools that break prematurely is also an obvious red flag.

Custom Carbide Twist Step Drill
Custom Carbide Twist Step Drill

Two: Bottlenecks in Production

Simple logic tells us that when you can make a part faster, you reduce the cost per unit and generate more revenue. Along with this, when big rush orders come through the door (and they always do), having the ability to increase throughput makes customers happy in the form of on-time deliveries. If you’re cutting profiles on a part that require multiple tools to complete, especially on turning centers where tool storage is limited, it might be worth investigating whether a custom form tool will do it in one operation. The custom tool, combined with a little tool path reprogramming support from GWS, has the potential to reduce hours into minutes and minutes down to seconds. And as we all know, in manufacturing, every second counts!

Three: Room for Improvement

The best tool out of the catalog may not be the best option for the application. How much in terms of operational performance is it leaving on the table? You probably experimented with different makes and models before you selected the standard tool you are using now. Why not keep that thought process going and really dial in the geometry, coating and substrate to wring out every ounce of performance possible? Custom could open up a whole new world for you.

Custom Top Notch Insert
Custom Top Notch Insert

Four: Slow or Late Delivery

Just because a part is in a catalog doesn’t mean it’s actually on the shelf. Lead time on out of stock tools can stretch from a few days to a few months, depending on the manufacturer and their production backlog. A custom tool means it’s unique to you with no one else to deplete inventory and leave you stranded. With over 150 grinding centers organized in cells to accommodate highly customized work with rapid turnaround times, GWS can fill large volume orders quickly, consistently and with the highest degree of quality. To ensure consistent and on-time-delivery, we even work with our distributors to keep inventory on their shelves dedicated exclusively to individual customers.

Five: Spending Too Much $$$

It may seem counterintuitive that custom tools can save you money. But if you’re a high-production manufacturer using hundreds or even thousands of tools over the course of the year, you could be ordering a hundred or two hundred tools at a time. However, the catalog price is the catalog price. You won’t get a concession for volume because the price has already been set. Custom tool pricing is based on quantity breaks, and as a consequence, often yield cost savings versus pre-defined “stocked standards.”

Getting out of the “stock” mindset and seeking optimum performance for your cutting tool dollar by going “custom” makes sense in today’s manufacturing environment. If you have noticed any of these signs in your operations, contact us and put our expertise to work for you.

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Cut Cost, Not Quality, with Reconditioned Inserts from GWS

 

If you’re a high-volume production type facility, getting as much value as possible out of your cutting tool inserts on long runs is essential.  So, what if you could find a source of high-quality cutting tool inserts at half the price?  That’s exactly what happens when you take advantage of our Tool Reconditioning services.  Beyond the initial cost savings of being able to use the inserts 2 to 3, or even more times, our regrinding operation offers value-added benefits you won’t find anywhere else. Reduced lead times, inventory management and cloud-based tracking are other ways to benefit from our regrinding process.  Most importantly, the service you get will be tailor-made to your needs.  Let’s take a closer look at how it all comes together.

Quality

Let’s set the record straight right up front.  Reconditioning inserts does not mean taking a step down in quality.  Quite the contrary.  The GWS Tool Recondition program regrinds your worn out, chipped and used inserts back to newly manufactured tool quality.  When you put one of the reconditioned inserts into your CNC, you can machine with confidence.

Reconditioning Tips

A PCD or CBN tipped insert can generally be re-sharpened 2 to 3 times.  After that the substrate (body) of the insert may start to be degraded from the heating and cooling cycle during the brazing process.  The most common styles that we recondition are ISO standard as well as most standard and special milling inserts, both carbide and steel bodied.  We can do multi-cornered inserts, but usually these are only for CBN inserts, and PCD inserts are normally only single tipped.

Choose a Process

Depending on your needs and the applications, there are three ways to add new life to your old inserts.  The first is to shim and regrind. With this method, the PCD/CBN tip is removed and then placed back into the original body with shim stock placed behind the tip.

reconditioned inserts - PCD-Tipped Carbide Inserts
PCD-Tipped Carbide Inserts
 

This will “push” the tip out from the body and the overhanging (damaged from use) material will be ground away, to re-establish  a new cutting edge by utilizing the un-used material for a brand new cutting edge that will be ground to the original dimensions of the new insert.

Another approach is to re-tip the inserts, by replacing the worn tip with a brand new PCD or CBN tip. This will allow the edge length of the tip to be the exact length of the original insert.  In some applications, the edge length is critical and must be maintained.  This is one of the reasons that a re-tipped insert may be needed as opposed to the Shim and Regrind. The re-tipping process is slightly more expensive due to the new material which is being introduced, but is still roughly 30% less expensive than a brand new insert.

If you use a variety of insert sizes in sequence in your shop, a succession technique may work for you.  This is most often used in conjunction with ceramic inserts, usually whisker-reinforced and other types of ceramic.  This can be used with PCD or CBN inserts that are solid or “full top” configurations.  With the succession, we start with the larger size (or feeder) insert and then will be ground to the next standard size.  For example, RNG-45 ground to a 4V to 3V to 2V.  If you do not utilize all the standard sizes, we can skip steps if needed, i.e. RNG-45 to a 3V, or 4V to a 2V and so on. These examples are for round inserts, but they can be utilized with grooving and some ISO standard inserts as well. Depending on the mix of inserts that you use, you may never have to buy a new smaller sized insert.  You can buy the large (feeder) insert, and use all down-sized/reground inserts for all of your smaller insert applications.

With each process, new coating and edge preparations (T-lands, or hones) are added as required. Whatever method works best for, our turnaround for reconditioned inserts is significantly less than for new tool manufacture.

Hidden Value

Besides seeing insert costs go down by half or more, our Tool Reconditioning program offers additional benefits that reduce inventory handling and carrying costs.

Our Tool Tracking System gives you a customized communication experience. We provide live to-the-minute information on your tool regrind process and keep everything accessible through the cloud. The GWS Portal, customized to your needs, allows you to track your current regrinds in real time and stay on top of your tool inventory.

Personalized service comes standard in the reconditioning process as our technicians have the expertise to visually analyze each of your unique inserts and decide which can be shimmed and reground, which can be re-tipped and which should “fallout” (be scrapped). They can accurately predict the number of times your tool can be reground, which reduces the need for new tool purchases and helps you avoid rush charges.

We also provide custom laser etching/labeling on your reconditioned inserts for traceability and inventory management programs provided certain minimums are met.

As you can see by this article, we are offering not only an insert reconditioning service, but a whole new way to administer the tool consumption process. To discover all the ways we can help you save money and time managing your tool insert program, please contact us for a consultation.

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New AlloyCat™ Whiskered Ceramic Inserts Ideal for Super Alloys

It’s a fact. Carbide inserts aren’t your best bet for finishing and roughing nickel and cobalt-based super alloys. By the time the temperature “sweet spot” is reached, the carbide is in meltdown (literally). Even traditional ceramics have a tough time due to the heat and stress generated during the machining process.

What’s the answer? By adding silicon-carbide crystals (whiskers) to a hard ceramic matrix, we can now offer inserts that provide excellent wear and shock resistance at high surface speeds. Our new AlloyCat premium whiskered ceramic inserts are also tougher and stronger than carbide (and even traditional ceramics) thanks to the interlaced fibers within the ceramic material. For example, our brand-new CG-88 grade is ideal for machining nickel and cobalt-based super alloys at metal removal rates 5-10 times higher than carbide.

Right Shape. Right Edge. Right Ceramic.

Our new AlloyCat line features a variety of shapes so it’s easy to find just the right insert for your application. These include round, round V-bottom, dog bone full nose and dog bone flat nose. And if there is a shape we are missing or a custom configuration you are looking for, our team can produce nearly any shape in as short as a few days. Whatever your choice, any number of standard or specialized edge preps are available to perfectly match your machining needs. Upgrades to the ceramic matrix, such as Silicone Nitride, Alumina TIC and Al203, are available upon request.

Whiskered Ceramic Inserts

Insert Reconditioning

The GWS Tool Group Reconditioning program adds even more value to the AlloyCat line. Be it our own inserts or a competitor’s, we offer a comprehensive downsizing program to maximize savings for our customers. Our regrinds aren’t just made to be as good as your brand-new tools; they’re reground to such exacting specifications that they are often better. Whether it’s improved edge preparation or coating enhancements, GWS can downsize your used ceramic inserts so they can be put back to work.

Our AS-9100 certification and vast knowledge of ceramic inserts ensures that you will get quality reground inserts every time. All of this comes with exceptional turnaround times.

A GWS regrind provides cost savings in material, manufacturing process time, volume shipping and inventory reduction. These cost savings are data-driven, not anecdotal. Our Regrind Portal tracks and provides real-time comparisons between regrinds and the purchase of new tools.

Whiskered Ceramic Inserts

Tool-Tracker

Tired of managing your inventory? We can do it for you. We take your worn-out tools, regrind them and release them to you as needed. Our Tool Tracking System gives you a customized communication experience. We provide live to-the-minute information on your tool’s regrind process and keep everything accessible through the cloud.

To discover all the AlloyCat configurations available, please contact us for a consultation.

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Milling Titanium is a Lot Easier with Specialty Tools from GWS

milling titanium

Here’s a true story for you. A Tier One supplier was fulfilling a defense contract for titanium components using conventional 40 taper vertical machining centers. The part had a simple turning operation and then was put into the VMC and machined to its final stage. Total cycle time: 5.5 hours.

Enter Mike Littlejohn, Senior Applications Specialist for GWS. Long story short – supplier reduces cycle time to 29 minutes and drops one whole setup. Owner’s jaw drops. He turns to the GM and says, “We’ve been doing this wrong the whole time!”

Just Another Day on the Shop Floor

These are the sort of things GWS specialists, like Mike, do every day. With their background in process analysis and cycle time reduction, they have the ability to re-approach a particular manufacturing process and achieve great results through the use of our custom tooling. When running production quantities, even a quarter of a second cycle time savings on a part could save hours annually and dramatically affect your bottom line. The experience and expertise of our specialists have led customers to hours and hours of cycle time reduction.

The Trouble with Titanium

milling Titanium

Titanium is used extensively in the aerospace and medical segments. The problem is it has a tendency to generate excessive heat at the contact area during the machining process. With titanium’s low thermal conductivity characteristics, that heat gets transferred mainly to the cutting tool. This results in long continuous chips that can weld on to the tool edge, giving you a poor finish, or worse yet, out of tolerance parts. And you can just imagine what that kind of heat does to tool life. Feeds and speeds need to be dialed in carefully in order to get any decent tool life at all. All of these characteristics must be taken into account if you want to mill titanium successfully.

Hold Up on Desperate Measures

To solve titanium issues, aerospace companies might be ready to invest in new machinery that costs hundreds of thousands of dollars. Here’s a tip. Consult with one of our specialists on the appropriate tooling on your current machine before breaking the budget for new capital assets.

To serve industries where titanium and other alloys are widely used, GWS has developed a standard cutting tool line that was created with these materials in mind. The PYSTL series comes in different multiple flute variations and coatings. Even more styles are currently in development.

Tailor-Made for Your Application

milling TitaniumWhen you need more than standard tooling, GWS can develop a custom design from a part print or reverse engineer a tool from a part sample. We can design a custom tool that potentially can machine more than one feature at a time.

To us, building a custom tool is like putting together a new recipe. In addition to geometry, we research combinations of substrates and coatings. Because we specialize in custom tools, our specialists have this process down cold. That’s why we’re known for our fast turnarounds for tailor-made products.

If titanium and other space-aged alloys are giving your operators fits and causing a dip in your bottom line, contact us and see if a standard or custom cutting tool from GWS will help give your jaw-dropping results.

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Custom Holemaking Tools Available from GWS Tool Group

To answer an increasing demand from customers, GWS has added a new line of precision tools to its existing lineup of holemaking products. Initial models include the 4005 Series ECO Premium High Performance Carbide Drills, the 4050 Series PAC Premium High Performance Carbide Reamers, and the 4105 Series ECO Premium High Performance Carbide Drills with coolant through.

These offerings are ideal for many applications right off the shelf. But that’s only part of the story. In addition to our standard items, we now offer quick turnaround on custom holemaking solutions like step drills, deep hole drills and step reamers. This is especially important to our customers in fast moving industries like automotive, aerospace and medical, where new special applications are routine occurrences.

Times Have Changed

holemaking

Responsibility for the new holemaking line falls to John Kiiffner, our Product Manager of Drills, Reamers and Micro-Drills. John’s background in tooling beganin 1988, and he’s been with GWS since 1997. During his career, John has seen cutting tools go from simple to complex. He says the level of sophistication seen in the GWS catalog has grown to match the advances in jet engines, medical implants and electric vehicles. “The geometries and options were pretty simple back when I started,” he said. “Not to mention there was a smaller range of raw materials. Now we have so many different grades of aluminum and steel, exotic metals like titanium and cobalt chrome, not to mention high temp, chemical resistant plastics that are machined for medical implants.”

There’s been a lot of changes on the tool side of manufacturing as well. “We have more variables to work with for our custom line, including new carbide substrates, drill point designs and custom coatings.” Innovations in offline programing and simulation software also play a huge part.

“We can leverage these advances to provide high levels of precision along with cost savings that come from long tool life and minimization of cycle times,” John remarked. “This is extremely vital in high volume production environments.”

Finding Out the Need

holemaking

As a Product Manager, John’s job is to analyze the customer’s application and give direction to the type of custom tooling needed for the job. His work requires a lot of road time to maintain relationships with his customer base, which is more high-volume production than your typical job shop. Quantities of parts produced in an automotive, aerospace or medical facility can easily reach 40-50K per day.

Along with volume, precision is extremely vital in custom applications. Automotive parts related to fuel injection such as diesel fuel rails, lifter bodies, etc. have holes that can be as small as 1 to 1.5mm in diameter. Some of our custom finishing reamers are within 5 microns tolerance in diameter and 10 microns in length. We have proven ourselves to be very successful with major automotive parts corporations and their 1st and 2nd tier suppliers due to our ability to make tools that are accurate to specifications like these time after time.

How It Comes Together

holemaking

Staying in front of the customer’s machine on a regular basis allows John to get the feedback necessary to continually improve the process. “We may start with nothing more than a standard CAD drawing or even a sample of the component to be machined,” he said. John then coordinates with our designers to reverse engineer the right combination of elements to make the perfect tool for the application.

“Not that we always hit the mark on the first try,” John remarked. “It may take 3 to 4 variations of a tool over a span of time, sending the customer anywhere from 6 to 12 pieces of each variation to test.

“But, as our long-term customers know, we are totally committed to the process. We never raise the success flag until the part is in production.”

Regrind for a Second (or More) Life

Adding to this value is our ability to regrind drills and reamers in-house. Some straight drills can be reground 3 to 4X depending on the wear condition. We take regrinding seriously because the customer has to get the same result in the hole regardless of whether it’s a new or a reground tool. In fact, we have gotten so good we are the preferred regrind source of many customers for their non-GWS drills.

If you have a unique holemaking application, contact us for a consultation. We think you’ll be please with the results.

 

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How GWS Cutting Tools Go from Custom to Standard

Many of the tailor-made cutting tools we engineer for customers are so innovative they are easily adaptable to a wider range of applications than originally anticipated. This doesn’t happen by accident. Our organization is full of highly experienced and talented people who have a knack for both listening to customer feedback and seeing the future potential for each tool they design. Because of this, every custom project we undertake has the potential to develop a new standard tool for our catalog, expanding and strengthening our overall product mix.

Tool Design 101

How does a custom tool become a standard? It’s not rocket science (actually, sometimes it is), but a careful thought process consisting of equal parts of experience, knowledge and communication.

custom cutting tool

For example, here’s a quick overview of the design process for an end mill. The first step is to marry the tool to the cutting material. There is still a lot of machining in nonferrous aluminum material, especially in the aerospace/aircraft sector. Machine tool builders are busy making machines for that area, which are usually outfitted with high rpm spindles (30k rpm and up) and can feed as fast as 1,000 IPM. It’s up to us to develop the right kind of cutting tool that works in these high-volume removal applications.

This involves calculating the chip load based on the tool diameter to get good chip thickness and generate the proper cutting angle to attain the preferred shearing action.

Communication with the end user during the development process is vital to improve the original design. We stand right by the machine, listen to the customer’s feedback and fine-tune the geometries of the tool until its performance and longevity match our high expectations.

When we have success with a particular design in a certain application, we document it in our master database. The library acts as a starting point when the next request arrives for a similar material and application. Having examples to work from puts us ahead of the game and speeds up delivery times for a new tool.

Rapid Prototyping

This is truly where GWS stands apart from the competition. We do not impose limits on ourselves simply because we already have an outstanding standard product portfolio. If a custom tool is required, we pride ourselves on delivering the very best design without prolonged wait times for the end customer.

A critical component of our “custom comes standard” model is our ability to pull resources, develop completely new tooling (be it custom inserts, a complex form tool or redesigned high-performance end mill) and deliver it to the customer in days. With other suppliers, the wait could be weeks or even months. Our capacity also allows us to deliver these tools with scale (a few hundred to a few thousand pieces), to support the largest of demands.

Constant Learning. Practical Applications.

The entire process is actually a little more sophisticated than our simple outline would suggest. Tooling design has gone beyond the typical 4 flute design that used to be the benchmark. Variations today include indexable tooling options, variable helix from flute to flute that eliminate vibration and chatter, eccentric reliefs ground in for better edge support, and edge preparation for better tool life.

The evolution of the best tool is always a moving target. Developments are always on the horizon, from manufacturing and inspection technologies to new carbide substrate compositions and advances in the area of PVD and CVD coatings. To keep pace, our own education process needs to be continuous.

Even understanding the varieties of software customers are using in their process is a must in developing the right cutting tool. A tool for light, high speed Z-level machining will be designed very differently from one for heavy, high-volume milling applications. Understanding the capabilities of a customer’s software enables us to not only design the right tool, but also helps our programmers determine if applying a more efficient toolpath for the customer is possible.

Whether you use a model right out of our catalog or need a custom approach, contact us for a consultation. Either way, we’ll always deliver the cutting tool you need.

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GWS Custom Inserts Last Longer by a Wide Margin

CBN custom inserts
Continually changing worn out cutting tools can be a real profit breaker. If you’re machining automotive and aerospace components made out of hardened steel or nickel-based alloys, you really know what we mean. How do you avoid the costly downtime and excessive tooling costs typically associated with these super-hard materials? Find yourself a tougher tool. We offer a full array of standard and custom turning inserts tipped with the hardest substances on Earth.

Cubic Boron Nitride

CBN comes in right behind diamonds on the hardness scale. Unlike other types of boron nitride, it exists as a cubic crystal lattice, like the crystalline structure of diamond. It’s the perfect choice for applications that require extreme wear resistance and toughness like hard turning, grooving and milling hardened steel and nickel alloys or roughing gray cast iron at high cutting speeds.

CBN custom inserts

We were once called in to consult with a large automotive manufacturer that was having difficulty machining clutch plates made out of powdered metal. The part was very intricate, with a lot of internal and external diameters that needed to be turned, with some grooving and interrupted cuts. Inserts from their current supplier lasted only 20 parts before they had to be replaced. Initial tests with our CBN product immediately bumped this up to 215 parts per insert.

Polycrystalline Diamond

Polycrystalline diamond (PCD) is diamond grit that has been bonded onto a carbide substrate under high-pressure, high-temperature conditions.

PCD custom inserts

It works best for abrasive non-ferrous composite material applications. Our PCD- tipped inserts (including intricate form tools), come in several extremely wear-resistant grades (so you don’t have to buy more PCD than you actually need.)

Expect a dramatic change in tool life when you switch to PCD. In our experience, the first tool life can yield savings of up to 30-50% when compared to carbide inserts.
Believe it or not, the savings don’t stop there. Frankly, PCD inserts are costly compared to their carbide relatives, so we purposefully design each of our tips so they can be brought back to life multiple times by re-grinding. This gives you hours more cutting time for your initial investment.

How the Inserts Are Made

After receiving the raw material from a supplier (usually in the form of a 63mm to 75mm diameter disc), we cut out the desired tip and shape it using an electrical discharge machine (EDM). Features and edges are ground into the tip, which is then braised onto a carbide insert body. Using this process, we can take any standard turning insert and make it the top of the line for hardness.

Edge Preparation

Edge preparation is a big part of the performance of a CBN insert. A T-Land (or chamfer)is a common edge preparation we use for CBN inserts. Prior to edge preparation, a too typically has a 90 degree corner. Edge preparation removes this sharp angle which gives the insert a beveled edge.

For example, a 20 degree chamfer results in a “strong negative” cutting angle, with a rake of 70 degrees. The advantage of a chamfered tool is that the tool lasts significantly longer than a tool with a square or “positive” edge. Most companies offer standard angles of 20, 25 and 30 degrees. If 25 isn’t right, you have to make the leap to 30. This jump would probably not give you the ideal balance between strength and accuracy required for your application. At GWS, we have proprietary equipment that allows us to go from 10-45 degree angles and everywhere in between. We are the only company that has the ability (and the will) to give our customers this level of optimal customization.

Just the Right Composition

There are only a handful of companies that sell raw CBN and PCD. While our competitors usually work with only one, we order from a group of suppliers. The reason for this is that each source has a slightly different formula that may be a better match for any one of our customers. This “pick and choose” approach gives us more flexibility to provide a superior product for different applications. If your cutting tool inserts wear out too fast, contact us for a consultation and see the difference custom can make. When it comes to our customers, we don’t make do, we make better.
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GWS Increases Tool Life 4000% for Semiconductor Parts Maker

Manufacturing valves, manifolds and fittings used for the delivery of ultra high purity gas for semiconductor production is a demanding job. Part of the problem is that the components are primarily made with heat resistant super alloys and stainless steel. One manufacturer came to us with a situation that is not unusual in the industry. They were experiencing poor tool life with one particular semiconductor part family. The bulk of the work was being done on either 3-axis vertical or 4-axis horizontal machining centers. Only 6-8 parts could be completed before their end mills failed or needed to be replaced. This was unacceptable.

High Standards vs. Tough Materials

The majority of projects in the semiconductor industry involve HASTELLOY® C-22® alloy (UNS N06022) and 316L stainless steel, along with some aluminum components. The problem-causing semiconductor application mentioned above involved HASTELLOY material.

This material is a well-known nickel-chromium-molybdenum blend, the chief attributes of which are resistance to both oxidizing and non-oxidizing chemicals, and protection from pitting, crevice attack, and stress corrosion cracking. Like other nickel alloys, HASTELLOY C-22 alloy is very ductile, exhibits excellent weldability, and is easily fabricated into industrial components.

On the down side, HASTELLOY C-22 alloy is generally very abrasive. It is also gummy and generates a lot of heat when machining. Ideal for semiconductor components, but not so ideal for cutting tools trying to machine it.

Setting the Bar

The situation was frustrating for a company that has a solid reputation for delivering the highest standards of quality and using the latest manufacturing technologies in order to meet strict demands for on-time delivery and value. It’s no surprise that they set about to find a partner who would meet their goal of increasing tool life.

It had already been decided to switch from a sharp corner tool to a radius corner to reduce corner edge break down. But the specifications called for a very small radius.

The search for an off-the-shelf tool that would provide longer tool life when machining their test piece led nowhere. No one seemed able to help. Then Kevin Corrigan, a representative of Deco Tool (a local distributor) suggested they bring GWS in for a consultation on a custom end mill. GWS’s ability to produce high performance purpose-built tooling quickly made getting the exact tool needed easy and virtually delay-free.

Tweaking a Standard

Semi-Conductor Board

Our engineers took a close look at the customer’s application and realized just a few subtle enhancements to one of our standard tools would make it an excellent fit for their requirements. The tool was a 1/2″ diameter, 8-flute carbide end mill that was originally intended for titanium. But since the material was HASTELLOY C-22, we adjusted the dish angle on the tool to add rigidity and went from a non-center to a center cutting tool for improved performance in plunging operations needed to machine the “elbow.” As specified, it has a 0.0015 corner radius, which provides better tool life when compared to a sharp corner tool which was more prone to chipping. We finished off the tool with a different hone on the cutting edge for optimum cutting in HASTELLOY C-22.

Unbelievable Test Results

The customer ran two different batch tests with the new GWS tool. The first test produced 384 parts with one end mill. The second test delivered 324 parts. That accounts for the huge % increase in our headline. It was estimated that the new tool will save them $30,000 per year based on tool life alone and an estimated cost per part savings of $5.83 per part.

Aside from increasing tool life dramatically, a productivity improvement was also realized. They went from 9.6 ipm (inches per minute) to 12.9 ipm, an increase of 33%.

Similar success in their stainless steel parts yielded an additional annual savings of $20,000 not including productivity gains via higher metal removal rates in these parts as well.

Customer Satisfaction

The lesson to be learned from this case study is to never give up until you find a solution that will give your customers the finest parts available. Because that’s what they deserve. We work hard to be the best provider of customized cutting tools on the market. Because that’s what you deserve.

If you have a cutting tool problem that no one else can solve, contact us. We’ll find a way to save you time and money as well as increased performance.

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Capital Expenditures: An Investment in Our Customers

Capital expenditures are often thought of in a negative light. After all, no organization likes to spend down their profits. But, in reality, the company that does not take the opportunity to enhance capability, create more throughput and/or to address an efficiency issue is not going to be in business for long.

One way to look at the CAPEX situation is like priming the pump. You pour money into the business to make more money in the end. To a certain extent, that is true. But at GWS, we are always on the lookout for ways to provide additional value to our customers. The purchasing of the latest manufacturing technologies is one way we accomplish this goal.

Whether it’s the purchase of a new machine tool to produce our cutting tools, or the acquisition of a whole company that is advanced in a competency we don’t currently have, all of our expenditures are executed with the intent to stay true to our “Custom Comes Standard” mission.

Scaling
We focus our CAPEX planning on scaling the organization to match the needs of our customers. “Scaling” is the important word in that sentence. Creating scale within our industry is not always a seamless exercise. Like many other skilled trades, there exists a shortage of skilled labor. That means there’s not always a clear equation that says 1 person + 2 machines = $X of growth

You can generally estimate what a machining center is capable of producing within a prescribed window of time, but the spindle utilization rate achieved plays a critical role in whether or not that potential is realized.

Utilization rate is driven by presence of skilled labor, but the ability to spread the talent you have across the production floor is only possible if you work to achieve machine standardization.

Standardization
Commonality of CNC equipment (both in construction and programming language), allows operators to be familiar with all the machines on the floor, not the just the ones they attend. The result is faster operations, from setup and programming, as well as maintenance and troubleshooting. This consistency allows for a flow of expertise across the workforce. The shared knowledge increases the quality of our custom-engineered tools and facilitates fast deliveries.

Inspection of our cutting tools is done the same way. Standardized inspection processes and equipment across multiple facilities gives each product the same quality signature from one shop to the next. You can be sure that the end mill you receive from Florida, the drills and reamers you get from Michigan and catalog products from Massachusetts all meet our high standards for quality.

FANUC LR Mate 200iD

The Automation Advantage
If you want to maximize utilization of your work force, investing in automation is essential. Let’s look at this concept in action, using cutting tool grinders as an example. First of all, automation is key in quality control and JIT deliveries. And of course, it’s impossible to run 24/7 without loading/unloading robots. Automated probing tools check measurements like diameter and flute depth and make adjustments on the fly to save time and keep tools within tolerance.It also decreases downtime via manual inspection processes and limits the use of physical contact gauges, like mircometers, which can damage cutting edges.

 

Tool Changer

Automatic grinding wheel changers house redundant or special tools so that a grinder can continue to run without additional setup time. This versatility, created by some judicious spending, gives us the flexibility to quickly change orders on the floor.

Meanwhile, while automation keeps the line moving, our master toolmakers can utilize their expertise in other areas more critical to our customers, like new tool design and turnkey application support.

 

Specialization
The exception to the standardization rule would be when we are tooling up for a new customer, or a new advanced technology.

GWS will always consider the purchase of special purpose machinery and equipment to fulfill a customer’s need, (after a thoughtful and thorough cost analysis process, of course). This could be a CNC machine tool that maintains a super high tolerance or a new coating vessel to apply a special treatment. The evaluation of specialized equipment is done carefully by our engineers so that they are able to choose equipment that meets the standards of GWS and ultimately those of the customer.

When the demand for the new application grows to a certain point, we purchase more machines of the same model to invoke the standardization rule once again.

Return on Our Investment
Careful investment in capital assets ensures that we put the finest technology available to work for our customers. That, in turn, means even faster turnarounds and higher levels of quality at a fair price.

But mechanics aside, our biggest investment is always in our relationship with you, our customers. We consider that to be priceless.

Contact us if you have a cutting tool problem that no one else can solve. We’ve invested in the people, hardware and software to come up with the answers.

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Cutting Tool Breakage: The 3 Most Common Mistakes

Cutting tool breakage is a fact of life in this business. But you should be able to get your money’s worth out of them before it happens. There’s nothing like premature cutting tool breakage to get a machinist steamed. Not only is it slowing the operator down, it’s costing money. The problem is, there are a ton of variables that could be in play when a tool bites the dust before its time.

What’s to blame? Was it a bad tool? It’s not really like the old days when you could get a bad batch of carbide. It’s all reasonably good stuff today. So outside of that, what other reasons could be at fault for cutting tool breakage, chipping and inadequate performance? Let’s look at 3 of the more common mistakes.

ONE: Improper Tool Holder Assembly
In order to make good parts, run out and balance are fundamental. This leads to a discussion about whether you’ve chosen the correct type of toolholder for the application (collet chuck, end mill, hydraulic, milling and heat shrink types) the correct profile of the toolholder in regards to reach, and how far your tool is hanging out. The goal of course is to minimize runout and unbalance while gripping the tool adequately with maximum rigidity in the setup. These attributes become more or less significant depending on the application. For example, balance is more critical for high speed machining operations, while gripping torque is more crucial in roughing operations where pullout is more likely.

Stopping premature cutting tool breakage.
The GWS “Alumigator” End Mill

Correct Tool Holder: As a rule of thumb, we lean towards hydraulic chucks for hole making and maybe some light milling work; mill chucks for low speed milling and roughing. For high speed machining and/or high precision work, shrink fit tool holding.

Correct Length: More times than you might think, the selection of the toolholder is an afterthought. While many operators look to achieve short stick out lengths with the cutting tool, they often overlook the gage line of the holder itself. Marrying both the correct holder type with proper cutting tool stick out are both fundamental to optimum tool performance. Save the excessively long holders for only those applications that require the reach.

Stick Out Tip– For carbide tools, look to maintain an LDR (Length to Diameter Ratio) of 6:1 or less for optimum performance. When the applications require longer, you will need to reduce cutting parameters (speeds, feeds, depths of cut) to compensate for the increased tool deflection.

Correct Profile: The shape of the tool holder and construction has a lot to do with its inherent ability to provide rigidity or reach or balance in a given application over a long period of time. For example, mill chucks generally have greater centers of mass, that when coupled with internal needle bearings, create an extremely rigid holder that dampens vibration while achieving a high degree of gripping torque. However, the balance properties of these holders are often inconsistent, making them less ideal for long reach or finish operations. Slimmer profiles, like that of shrink fit holders, enable significantly more reach (hence shorter tool LDR) while possessing ideal balance and runout properties.

TWO: The Wrong Tool/Speed for the Material
When you call us with a tool life problem, probably the first things our technicians will ask is what material you are cutting followed by the speed, feed rate, radial and axial depth of cut.

Stopping premature cutting tool breakage.
Protip: Run your Alumigator at higher speeds for optimal performance.

If you’re running 303, 304 and 316L stainless steel, or Ti-6Al4V and other titanium alloys, you need a tool that can handle the excess heat generated at the contact edge. (See GWS Takes Aim at Gummy Materials for information about our PYSTL Series End Mills.)

A note about speed.What’s the first thing an operator does when a job doesn’t sound or look right? They turn the dial left and slow the machine down, right? It may seem counter-intuitive, but many of our tools are actually designed to run faster, not slower. This can be uncomfortable for operators who aren’t used to running at high speeds, especially if it’s a tool they are not familiar with. So, when we ask if you’re running at the right speed, we may mean you are not going fast enough to take advantage of the tool running in its sweet spot.

Machine tool and cutting tool technology have been leap-frogging for decades. A lot of operator habits developed back when cutting tools couldn’t match the total speed output of the CNC machine. Today, the learning curve has shifted back towards carbide tooling, where they are now fully capable of handling the speed and actually perform better at higher revs.

THREE: A Flawed Tool Path
Five to ten flute tools (and sometimes more) can be incredibly productive when properly applied. After all, more flutes equal greater feed rates. However, you have to marry it with the right type of tool path. While more flutes translate to higher feed rates, they also translate to less chip pocket space.  Therefore, to be successful with these tools requires a specific tool path that keeps percentage of total tool engagement (relative to its diameter) limited, so as not to bury it and cause breakage. The amount of tool engagement varies, but generally the more flutes you have, the more careful you need to be to ensure its not overloaded (put into a slot or sharp corner). With the right tool path, techniques like full radial trochoidal milling tool paths can be used to shred cycle times!

We have had great success with our 7-flute tool cutting titanium, but we’ve also had people break it right away because it’s very dependent on the amount of engagement (as previously stated). It’s got to be consistently light. Slotting or heavy pocketing with a 7-flute tool is not going to work. It just doesn’t have enough chip clearance within each flute. With the right tool path that keeps cutter tool engagement at around 20 percent, the tool is going to run smoothly and permit optimum metal removal rates.

If tool engagement cannot be adjusted, using 4 or 5-flute end mills may be the optimum solution, as the large chip pockets provide more forgiveness in potentially unforgiving scenarios like pockets or deep slots.

A Lot to Think About
Of course, the simplest way to avoid premature cutting tool breakage is to call in the pros. Contact Us and we’ll be happy to conduct a thorough investigation of your particular application and help you optimize your process.

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Max Out 5-Axis Value with the Right Cutting Tools

Demand for faster cycles times in industries such as aerospace, die and mold, automotive and medical continue to drive OEM’s and their manufacturing suppliers to find ways of reducing production costs. This has given rise to a parallel popularity in 5-axis machining. That’s why there are more and more machine builders offering 5-axis machine platforms in today’s market.

         C62U 5-axis machine courtesy of Hermle USA

Why 5?
Simple. 5-axis machines are the price of admission to the game. You might be able to get highly creative with the machines you currently have and use a combination of 3 and 4 axis machines to produce a given part. But this would involve multiple setups – cutting certain features on one machine, then switching machines to cut another feature to make the complete part.

Don’t forget the added setup time whenever you move the part or the challenge of maintaining tight tolerances between machines. And what if there is a bottleneck on one of the machining centers? You could wait half a day or more just for it to free up pending other work in your pipeline. With this scenario, it is highly doubtful you could win the bid, deliver on time and make money.

But all this hassle and delay is preventable (in many cases) thanks to 5-axis machines.

The Joys of 5

Convex Radius Cutter

The beauty of 5-axis machines lies in the simple fact that you can do more with less…more machining in one setup. Less downtime, fewer touch points and ultimately more money in your bank account and smiles on the faces of your customers for faces via improved deliveries.

This formula: [fewer setups + increased metal removal rate = reduced overall cycle time = more profit] is the reason many shops are going to 5-axis machines when they replace old equipment (or even sooner if they want to bid on new parts more competitively).

Issues with 5
Great. End of problem? Not exactly. With a couple more axes added to the typical XYZ, a couple more variables are often encountered. First, programming with 5 axes does become more complex, and will require some additional training and learning with programmers used to only 3-axis machines.  Another issue is the physical reach constraint that is often created where none was present in a 3-axis machining plane.  Entirely new tool holding and cutting tools are often needed to avoid collisions.

Something else to consider is that the work materials often machined in the industries most frequently using 5-axis machines tend to be more exotic and expensive by nature. From stainless steel and Titanium to Inconel and Cobalt-Chrome, these materials have higher price tags and consume more tooling.

Solution: The Right Tool
Not to worry. GWS can help you maximize the 5-axis positives by creating custom tooling that fits your specific application. GWS has the designs and capability to build tools that will maximize the enhanced capability of 5-axis machines.  Tools that include

Toroidal Cutter Before Coating

  • Barrel endmills
  • Tapered endmills
  • Spherical endmills
  • Bullnose high-feed endmills.

And remember that increased metal removal rate we mentioned? It won’t happen if you’re using a standard ball nose tool. There’s just not enough cutting edge surface area. These spherical type endmills, can take a greater length of cut with each pass as compared to tradition ball end mills. Pivoting the tool and workpiece (which the 5-axis makes possible) brings more of the cutting edge in contact with the part. Longer cutting edge engagement means a dramatic increase in metal removal rates.

Custom Carries the Day
With the variety of contours that 5-axis parts require, for example, turbine blades, you really need a custom tool that you can marry to the shape. Off the shelf won’t cut it (literally). We can deliver custom tools specifically designed for your application with the right length, taper, diameter, radius, geometry, substrate and coatings – to address the issues of reach, collision and tool life.

When you look to 5-axis, look to GWS for the optimum tools for your application. Contact Us today to see what we can do for you.

 

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Boost Productivity with the Right Cutting Tool Coating

Do your cutting tools head south much sooner than you would like? Are you going through them by the gross? Is their performance less than satisfactory? If you answer yes to any (or all) of these questions, you might want to take a look at what kind of coating is protecting your tool. Cutting tool coatings are designed to improve wear properties via higher hardness, increased thermal stability and reduced coefficients of friction. The right coating can vastly improve overall performance and increase productivity, and new coating technologies are hitting the market every day.

GWS Chrome-based AlcroMax Coating

The Right Coating
Matching the proper coating to an application is key for maximum performance. There are a lot of variables including the application, geometry, profile, substrate and machining environment (wet or dry). For example, Aluminum-based PVD coatings typically perform best in stable high temperature environments. Therefore, when used in a wet machining environment, a stable machining temperature is impossible to realize due to the natural hot/cold cycle that accompanies wet machining. In contrast, Chrome-based coatings don’t require a reaction between Al and the heat to extract the coatings potential. They perform just as well wet as they do dry. We won’t go into it further here because the variations are endless.

Our in-house coating facility provides fast turnaround on coated tools, with a wide range of standard PVD coatings. If you don’t see the one you’re looking for, we can even start with your particular application and formulate a custom coating for you via our in-house resources or with one of our many coating partners.

The Mechanics of Coating
If you’re not familiar with the process, coating a cutting tool is a bit more complex than many realize. Physical Vapor Deposition (PVD) is a vacuum coating process of vaporizing a solid metal to a plasma of atoms under high temperatures, that are subsequently deposited on tools to create a high performance coating. Coating properties such as hardness, structure, heat resistance and adhesion can all be precisely controlled. The coating centers, or vessels, can hold are large amount of tools (the smaller the tool the more it can fit) and uses a rotating pillar system internally to hold the tools during processing to ensure even coating adhesion (think of the inside of a watch). While there are multiple methods for PVD coating, like arc evaporation or sputtering, all utilize targets composed of the base materials the coating itself is composed of (Titanium, Aluminum, Etc.). These targets are hit with high levels of energy to atomize the material, and in combination with reactive gases like Nitrogen, are deposited on the tool substrate. Primary components to any PVD process are heat, pressure and time. And like any good recipe, the best results are typically a combination of both the cook, his recipe and his oven.

ZrN (Zironium Nitride)

Coating Resources
As you can imagine, these coating vessels are not inexpensive. We’ve invested in them so we can control quality and cost while still being able to deliver quickly when our customers need it.

However, we also work with a wide range of coating manufacturers, who obviously have vessels of their own. We do this because our core belief is predicated on providing the absolute best tool for any given specific application. If this means a coating we have internally isn’t the best fit, we look externally to our partners for the right one to produce the best results for our customer.

For example, our machines can typically coat to a thickness of 1.5 to 3.0 microns, but if the application demands a thinner coating (micro tools for example), some of our suppliers can go down to one micron for such applications. We work with companies both big and small in order to keep current with all the latest evolutions in coating technology on the market. We can pass on the benefits of this research and networking to you. The important thing to us is what works best for your unique application.

Rebirth of a Tool
If you regrind your tools, obviously the coating will need to be reapplied. We can help with the grinding and the coating – even if it’s not one of our tools. In fact, by using our geometry and coating resources, we frequently give customers reground tools that yield better performance that of the original tool. Thanks to our relationships and buying power, the variety of coatings we can offer is virtually unlimited. Combine this with our experience in grinding cutting tools, from drills and mills to PCD inserts and forming tools, we have an extensive library of programs that can be applied within the area of regrinds to enhance nearly anyone’s tool.

At GWS, we like to say that we have all the flexibilities of the little guys, but with all of the production capacity of the big guys. Let us put that combination to work for you. Contact Us today.

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South-Tec 2017

It’s almost here! Join us tomorrow at South-Tec 2017

We’ll be at booth 2837.

We’re ready to give you an inside look on our high-performance cutting tools.

This year we’re also partnering up with Carbide Grinding. Check them out here! GW Schultz and Carbide Grinding will be showcasing tools and inserts and engineers will be standing by to field questions.

The HGW is a high-performance end mill designed for cutting hard alloys and tool steels. With unequal indexing and variable helix, the HGW lasts up to 30% longer than the competition.

See the HGW Series


The Alumigator, the next generation of high performance end mills that cuts through aluminum with ease, faster, stronger and longer lasting than other aluminum end mills. Customers have proven time and again that “you can’t outrun the Alumigator.”

See the Alumigator Series


The GWS Regrind program reconditions worn out, chipped and used tools back to new manufactured tool quality. Quick turnaround, inventory management and incredible quality can yield cost savings as high as 60% over the cost of new tools.

Learn More


Don’t have time to stop by? Contact us and we’ll give you the run-down on all of our tools and services.

Looking for digital copies of our catalogs? Get yours here.


October 24-26, 2017 at
South-Tec, Booth 2837
TD Convention Center, Greenville, South Carolina

Plan Your Visit