Let Us Gear You Up for Success

By Todd Miller, Manager, Rotating Products 


Big gears are big business these days thanks to the wind turbine, energy, heavy truck and mining industries. In fact, the global gear market is worth $155 billion today, and is growing 4.7 percent annually. As a result, there’s been a lot of demand for indexable carbide cutting tool solutions.


Indexable carbide insert cutting tools for gear manufacturing have been around for decades, allowing manufacturers to increase their feeds and speeds compared to conventional high speed steel or powdered metal tools. However, modern advancements in indexable gear hobbing technology allow gear makers to achieve greater productivity, higher quality and more options than ever before. 


Ever since we introduced our first indexable carbide-insert gear hob in 2005, Seco has garnered global acclaim as a true innovator in this field because this technology has proven to generate higher productivity levels over traditional hobs.

Most recently, we have been working to build upon the success of our unique modular concept for gear hobs by exploring design variations to create an entirely new cutting solution. The result: a twin-start indexable carbide-insert gear hob that takes advantage of the increased power and speed of modern CNC gear-cutting machines to achieve increased productivity.


Featuring two half helixes on the same gear hob module, this new solution, when compared to the single module design, allows for running at feedrates that are twice as fast to reduce gear manufacturing cycle times by half — all while maintaining the highest possible quality levels. 


Testing proved the twin-start indexable carbide-insert gear hob reduced the production cycle time of a large seven-foot, module 12 gear ring from 22 to three hours for a more than 85 percent time reduction over the previously used high speed steel (HSS) hob. (For those of you who’d like to see this new gear hob for yourself, we’ll have it on display at IMTS 2012 in booth W-1564.) 


In general, carbide insert tools can produce cutting speeds between four and eight times faster than HSS tools, producing more parts in less time. Another advantage is that carbide tools can often run without coolant, which provides additional environmental benefits and cost savings.     


Keep in mind, however, that taking advantage of indexable carbide insert tools means you must have an extremely rigid machine and setup that can handle higher speeds and feeds. Therefore, you can’t expect to put our tooling on older machinery and expect it to optimally perform. 


As the gear manufacturing market continues to grow and the demand for high-performance cutting tools continues to rise, we are a total solutions provider that’s ready to assist you in any way possible. We have an extensive engineering background when it comes to the design and development of gear milling cutting tools, from v-shaped cutters to profile roughing and finishing cutters to gear hobbing cutters. We can also assist you in creating a customized configuration to achieve a specific goal.


About the Author

Todd is the manager of rotating products for NAFTA, responsible for solutions and applications involving face, square shoulder and disc milling. Todd and his team of product experts are dedicated to providing a consistent, high-level of support to Seco customers throughout the United States, Canada and Mexico. In his spare time, Todd likes to bowl and cheer on the University of Michigan football team.

Add OOMPH! to Your Power Generation Machining

By Todd Miller, Manager, Rotating Products

As global energy demand continues to multiply, manufacturers serving this industry have the means to experience growth for many years to come. However, it’s up to the cutting tool industry to continuously provide these manufacturers with new productivity-improving solutions that enable them to keep up in this booming market.

Seco, for example, has extensive experience in the power generation industry, from OEMs through all levels of the supply chain. Such industry ties enable us to help our customers within this segment achieve the highest possible levels of productivity, efficiency and profitability through new, highly innovative cutting tools.

Among our most recent developments for this arena is a new indexable carbide insert pull-broaching solution. This broaching innovation is twice as fast and significantly more productive than the traditional high-speed steel broaches typically used to machine power generation components out of steels and super alloys, including turbine discs for gas turbines. In fact, in comparison testing, we’ve found that pull broaching with our carbide inserts is the fastest way to rough slots in turbine discs.  

We produce our indexable broaches in short 12-inch long segments, which we then pin together to provide the total length necessary to complete the external form. One section of the broach may handle the form’s chamfer portion, while another tackles the root of the form. Our indexable broach employs incremental “steps” so that the height of the carbide inserts can control the feed rate. You can also adjust the height between each insert depending on what type of feature you’re looking to create.

While there is the initial investment for the broaching segments, you’ll actually gain substantial cost savings in the long run when you consider the massive productivity gains and lowered inventory costs you’ll achieve over the use of high-speed steel broaches.

After purchasing the cutter bodies, all you need to do is index the inserts. When designing the cutters, we try to incorporate standard inserts wherever possible. Depending on the form, however, some special inserts may be needed—which still keeps your overall costs lower than if you were using high-speed steel tools. Plus, with our indexable solution, you’ll never have to pay for tool regrinding again.

If you have any questions about pull broaching, feel free to send me an email or get in touch with your local Seco sales representative. We’re currently working on several exciting projects that involve pull broaching and indexable carbide inserts, and we’d be happy to discuss how this machining process can help you achieve a more lucrative power generation business.  

About the Author

Todd is the manager of rotating products for NAFTA, responsible for solutions and applications involving face, square shoulder and disc milling. Todd and his team of product experts are dedicated to providing a consistent, high-level of support to Seco customers throughout the United States, Canada and Mexico. In his spare time, Todd likes to bowl and cheer on the University of Michigan football team.   

12 Reasons to Optimize Your Tooling Stock

By Magnus Tillman, Business Solutions Manager


THINK FAST: Do you know how many cutting tools exist in your shop at this exact moment? Do you know how much disposable tooling your company uses, or even what type of insert you need to order at any given time?

If you can’t confidently answer these questions, it’s probably time to consider an advanced vending program for your operations, especially if you’re trying to manage a whole slew of part numbers.


Need some convincing? Here are the top 12 reasons—not in any particular order—as to why owning a point-of-use automated inventory control device with reporting and order management capabilities – such as our new compact SupplyPod – makes perfect business sense.

1. Inventory control devices keep things organized, allowing employees to get the items they need to do their jobs in a matter of seconds as opposed to wasting productivity time rummaging through a tooling abyss. 

2. For shops that use the “locked supply cabinet” approach, inventory control devices save supervisors valuable time because they no longer have to stop what they are doing to distribute tooling to employees. 

3. Companies can effectively manage their tooling supplies by having the ability to set dispensing limits by day, month or even shift.

4. Inventory control devices reduce overall tooling spends as well as eliminate stock-outs and UPS red shipments. 

5. If an employee dispenses a tool that typically machines up to 150 parts and he/she returns within the hour to check out the same tool, the company is privy to the fact there might be something wrong with a machining process. 

6. Inventory control devices can force tool regrinds instead of dispensing new tools, which helps play a role in reducing tooling spends. 

7. Rapid refill features ensure fast, accurate tool replenishment without any repackaging requirements, thereby improving efficiency and eliminating stock shortages. 

8. Employees are more accountable for the tools they use because inventory control devices manage item issuance and monitor tool usage with take/return, check-in/check-out and serialization functions. Essentially, this level of control allows management to know who dispensed what and for what reason. 

9. Inventory control devices help eliminate excessive or wasteful consumption because employees can no longer “hoard” tooling that could become lost or accidently discarded. 

10. Purchasing agents spend less time on tooling requisitions because inventory control devices with reordering and order management capabilities make it quick and easy to maintain adequate stock of critical tooling. 

11. Inventory control devices are simple to use and easy to implement into any work environment. The SupplyPod, for instance, only requires a power source and Internet connection for full functionality. It interfaces with modern ERP systems for continuously updating business environments. 

12. Most inventory control devices are customizable or come in a variety of configurations, which enables them to adapt to the constant changes within the manufacturing industry.

Overall, one of the easiest ways to bring more efficiencies and cost savings into your operations is by optimizing your tooling stock. Advanced inventory management systems, which includes the Seco SupplyPod, can help get you there as well as give you a competitive advantage over the other guys.


If you have questions about point-of-use automated inventory control devices, including our SupplyPod, please don’t hesitate to contact me.


About the Author

Magnus works closely with Seco customers to provide them with business solutions that increase their productivity and profitability. With a mechanical engineering degree from Wennstromska University, he began his metal cutting career as a shift supervisor for the insert quality control department at Seco Tools AB. In 2000, he joined Seco Tools U.S. as manager of production control for NAFTA insert manufacturing and took over his current role as business solutions manager in 2006. In his spare time, Magnus enjoys traveling, golfing, hockey and spending time with his family. Contact Magnus at mtillman@secotools.com.

3 Reasons to Put a Dynamic Spin on Your Hard Milling Efforts

By Gary Meyers, Product Manager - Milling

With the mold and die industry’s increased workloads these days, many shops are investing in new state-of-the-art equipment to effectively tackle hard milling applications and increase productivity. As part of this latest trend, dynamic milling techniques are becoming increasingly popular, especially when using solid carbide cutting tools. Perhaps it’s because newer machine tools provide the higher feed rates and RPMs necessary for successful dynamic milling.

For those of you who are unfamiliar with the dynamic method for milling, it’s an optimized roughing approach that combines large cutting depths with relatively small radial engagement when cutting steel. This strategy is also very effective when machining at 60 Rockwell or harder. This method, also known as peel milling, peels off small amounts of material at high speeds and feed rates.

Here are three ways dynamic milling can make a big difference when working with a wide range of steels:

1. With this technique, the tool path constantly adjusts to ensure the most efficient cut possible by maintaining constant chipload and engagement of the cutter. Furthermore, an optimized toolpath maximizes material removal rates.
2. Dynamic milling utilizes the cutting tool’s entire flute length, which helps eliminate the need for multiple depth cuts.
3. With the required CAM programming, dynamic milling can increase removal rates by up to 300 percent when compared to traditional methods.

Dynamic milling removes a lot of material at a very high feed rate, which creates pile-ups of big, long chips that can clog and damage a machine’s conveyor. Therefore implementing the right cutting tool is crucial.

Seco created the Jabro™ Solid² JS554 3C for just these situations. It’s a high-performance four-flute shoulder end mill with a long cutting edge and built-in chip splitters.

The JS554 3C uses its chip splitters to break the chips up into to a small, manageable size, resulting in improved chip evacuation from the cutting zone as well as from the machine. Furthermore, the JS554 3C’s full cutting length and chip splitters, when combined with the dynamic milling method, generate increased levels of productivity and significantly higher tool life due to a consistent load.

If you have questions about dynamic milling techniques or our new JS554 3C, please don’t hesitate to contact me.

About the Author

Gary works closely with product development, marketing and field sales to effectively launch new Seco milling products into the market as well as ensure their long-term success. Outside of work, he enjoys outdoor activities, which includes running 5k and 10k races in the summer and downhill skiing in the winter. Contact Gary at gmeyers@secotools.com.

VIDEO: Jabro™- Solid² JS554 3C

The Positives and Negatives of Cutting Tool Geometries

By Bob Winegard, Application Support and Training at Seco

In determining the most effective way to separate chips from your workpiece, several variables must be taken into consideration; however, probably the most important is selecting the right cutting tool geometry. After all, the collective angles formed by the dimensions of a cutting tool are what make a tool geometrically unique.

When it comes to your metal cutting operations, you have three general milling cutter geometries from which to choose: double positive geometry, double negative geometry and positive/negative geometry. Each of these geometries serves its own unique purpose as well as features its own set of advantages and disadvantages. Let’s see how each one might apply to you.

Double Positive Geometry

Double positive cutters hold the inserts in a way that creates a positive rake angle both axially and radially, allowing for very free cutting and clean, quiet machining. It’s an arrangement that also minimizes work hardening of the surface, achieves excellent surface finish as well as generates very little cutting force.

These geometries are good for machining non-ferrous materials, such as aluminum, copper and non-metallic materials, and even steels on smaller machines with limited power ratings. Care with the set-up is particularly important with these cutters as they are more fragile (leading to cutting edge chippage) and can lift the workpiece from the table.

Overall Advantages

Smooth cutting

Good chip removal

Good surface smoothness

Overall Disadvantages

Cutting edge strength

Unfavorable entry contact

Draws workpiece away from the machine table

Double Negative Geometry

Double negative cutters have an orientation that uses a combination of negative axial and negative radial rake angles, which direct the cutting forces further back from the edge of the insert.

This characteristic enables double negative cutters to show increased insert strength over the double positive and positive/negative cutters. However, while double negative cutters are very strong and rugged, their geometry can result in ineffective chip flow and potential issues with clogging.

While double negative geometries are ideal for cast iron, it’s imperative you have a machine with sufficient power, as well as a rigid setup for the firm mounting of your cutting tool and workpiece. Also, keep in mind that modern technology has made it possible to add chip breakers to inserts, allowing today’s negative rake cutters to machine more freely than ever before. Because of this, double negative cutters can effectively machine all materials as long as you utilize the correct chip groove profile.

Overall Advantages

Cutting edge strength

Productivity

Pushes the workpiece towards the machine table

Negative inserts double the number of cutting edges that can be used

Overall Disadvantages 

Large cutting forces

Chip obstruction

Positive/Negative Geometry

Positive/negative cutters have an orientation that uses a combination of a positive axial rake angle and a negative radial rake angle. These cutters are the most popular because they offer some of the free cutting benefits of a double positive cutter and some of the strength of a double negative cutter. 

The positive axial rake lifts the chips, while the negative radial rake directs them outward. These actions, when paired with a high lead angle, help reduce or eliminate chip flow obstructions.

Overall Advantages

Good chip removal

Favorable cutting forces

Wide range of applications

Metal cutting is not a one-size-fits-all type of process. We have literally dozens of milling cutters and hundreds of inserts from which to choose. If you have questions as to what type of insert geometry is the most effective choice for your particular application, please don’t hesitate to contact me. 


About the Author  
Bob works closely with Seco customers, helping them optimize their tool usage and find ways to increase their productivity and reduce costs. Contact Bob at bwinegard@secotools.com.

6 Questions to Ask BEFORE Running a CBN Hard Milling Test

By Chad Miller, Product Manager-Advanced Materials

Hard milling can be tricky. But if applied properly, you stand to benefit more from this machining practice than if you were using grinding, wire EDM or die-sinking EDM methods. Not only are grinding and EDM machines more costly than milling equipment, they also require a lot more set-up time. When compared to grinding, hard milling can reduce your cutting time by up to 60 percent.

To successfully hard mill a component, the right machine tool, spindle, CNC control and CAD/CAM system are critical to your operation, but even more important is choosing a high-quality cutting tool and having a clear understanding of how to effectively implement it into the machining process. When I’ve seen manufacturers fail at hard milling, it’s usually because they skimped on cutting tools. It’s common; they just don’t realize the right choice early on can help save them money in the long run.

CBN cutting tools are ideal for rough and finish machining of hard steels up to 70 Rockwell as well as abrasive materials, such as grey cast irons. CBN is harder and more abrasive resistant than the carbide and ceramic inserts that are commonly used. CBN costs nearly seven times more than carbide, but users greatly benefit from its adequate balance of strength, toughness, thermal conductivity and chemical inertness.

Here are six questions to ask yourself before making your cutting tool selection and moving forward with a CBN milling test.

1. “What material am I machining?” CBN works well in all types of hard materials, including high tensile steel, high speed steel and white cast iron; soft/abrasive material such as grey cast iron; and difficult to machine materials such as nickel-based and hard facing alloy. However, CBN does not work well in applications involving soft steels or nodular irons.
2. “Will this require rough or finish machining?” Determine whether your hard milling operation will involve rough or finish machining because knowing this helps in selecting the right insert and cutter for the job.
3. “What’s my approach angle?” Another factor that impacts cutter selection is the approach angle; therefore it’s important to decide whether square shoulder or face milling is the best choice.
4. “What is my cutter geometry and setup rigidity? Answer this to determine whether a positive or negative cutter works best in a particular application.
5. “Will I need a wiper insert?” Positioned slightly higher than other inserts, wiper inserts “wipe down” the part to create a superior surface finish. Need a porous finish? Don’t use a wiper insert.
6. “Does every pocket of my test cutter need to be loaded with CBN?” With the high upfront costs of using CBN, you should take steps to ensure you don’t lose a significant amount of money during your milling test. For example, the test cutter does not need to have every pocket loaded with CBN. An effective test can occur with only one or two inserts and an adequately adjusted feedrate. 

Hard milling know-how is vital to its successful implementation and your future productivity and profitability gains. If this is a machining practice you are really considering, but are unsure of where to begin, don’t be afraid to ask for assistance.

An OEM partner that specializes in hard milling tools, such as Seco, can assist you in selecting the best tool for your job, develop a proper cutting strategy for your application and recommend proper feeds and speeds, depths of cut and programming for your cutting material.

About the Author

Chad manages Seco's advanced materials product lines, including all CBN and PCD products. When he's not helping customers implement advanced metalcutting solutions, you can find him training for and running 5K, 10K and 1/2 marathon races and triathlons. Chad can be reached at cmiller@secotools.com.

Improving Your Process With A Process Cost Analysis

By Earl McMann, IKA – Strategic Account Manager

Over the past decade, process optimization has gone from an ideal to a necessity. Your customers need product faster, and they want it cheaper. The competition, both at home and abroad, is constantly looking for the opportunity to beat your turnaround time or price. If your operations are running at less then their full potential, you’re surrendering an advantage that can have a substantial effect on your long-term profitability.

When pursuing process improvement, one of the first considerations needs to be defining the desired outcome. The final objective is nearly always long-term maximization of profits, but companies often set short-term goals at odds with this mission. For instance, it’s common to encounter a situation where a team has been tasked with minimizing a specific cost, such as tool spend, without looking at the larger picture of overall profitability. In these cases, achieving the current goal can actually be detrimental to overall success.


As a not-entirely-hypothetical example, consider a shop that reduces its tooling cost per component by 25%, by switching to cutters that provide lower performance. On its face, this can look like a win, but there’s always a trade-off. Instead of producing 75 components per hour on a machine, output for the shop may drop to 65 components per hour. Such a loss in productivity can wreak havoc on profitability. Fixed costs, such as the machine, facility, etc., actually increase per component when efficiency suffers. The same goes for labor rates per component. Not to mention that the reduced productivity can introduce or worsen a bottleneck and limit overall capacity. In many instances, spending more on tooling, a machine or other equipment actually reduces total cost.


With the goal of total cost reduction in mind, a team or individual dedicated to process improvement must decide where to focus their efforts. If no problematic applications immediately emerge as obvious candidates, a basic analysis of workflow can help provide direction. Identifying machines or cells that are bottlenecks or consistently operating at or near full capacity will almost always offer up a good starting point.


Once an application has been targeted, the real work begins. Extensive information should be gathered and analyzed, both on the current process and on available alternatives. At this point, collaboration with your suppliers will often spell the difference between improvement and true optimization. No one will understand the machine, toolholding, cutters and other equipment in the process better than those companies that developed them. Involving representatives from these suppliers in your efforts will bring together a level of expertise that’s impossible to practically maintain in-house.


Following comprehensive analysis of options for improving a process, your team should test out the chosen solution and make sure it delivers the expected results. If it does, an implementation plan should be incorporated that includes training of your operators and other team members who will be affected by the change. This ensures your organization gets the most out of the hard work you’ve put in.


To offer assistance to our own customers’ process optimization efforts, Seco developed the PCA (Productivity and Cost Analysis). This program brings a formalized and proven approach to gathering and analyzing data, comparing and testing potential new solutions and then making a recommendation based on hard documented results.


If you have any questions pertaining to process optimization or would like additional information on Seco’s PCA, please feel free to contact me at emcmann@secotools.com.

About the Author
Earl works closely with Seco’s larger customers to find ways to improve the productivity and cost-effectiveness of their operations. When not on the clock, he enjoys spending time with his wife and kids, as well as fishing, hunting and golfing.