Welcome to the first edition of our series, “The Latest in the World of Machining.” In these blog posts, we will explore the technologies, trends, strategies, and tactics, as well as broaching, holemaking, milling, and turning products that are shaping the future of machining. Our goal is to provide you with relevant insights and actionable advice to help you stay ahead in a fast-changing industry.
Why Doing Things the Right Way Matters
Utilizing the optimal combination of machines, tooling, and program as part of an efficient machining process is crucial for achieving productivity and profitability goals. In our experience, every shop faces this fundamental question: How do we ensure we have the best combination of machine, tooling, and programming to operate most efficiently?
Many manufacturers believe that investing in new equipment automatically leads to improved efficiency, but that’s usually not the case.
One of our customers, a large manufacturer of aircraft parts, recently approached us after purchasing a new, more productive machine. They wanted to accelerate production and enhance precision. However, for a myriad of reasons, the manufacturer continued to use legacy tools and programs.
The result? Almost no measurable benefit. As one of their engineers candidly put it, “We don’t really know if we have the best setup, but we do the best we can to make sure we do, and often, we just hope it will work as planned.”
This example illustrates a universal truth in the world of machine tooling: new equipment alone doesn’t guarantee results. To realize the full potential of any machine, it must be paired with the right tooling and supported by optimal programs.
The Three Aspects of Efficiency: Machines, Tools & Programming
Your machine is only as good as its weakest link. A five-axis machining center may offer incredible capabilities, but if it’s running with the same toolpaths and feed rates as your old three-axis mill, you’re not tapping into its real value.
When it comes to tools, there are millions of tooling options along with scores of grades, coatings, and geometries. Choosing the best tool for a specific application can be overwhelming, especially with the continual pressure of production deadlines.
Today, most shops rely on manufacturers' catalogs or sales representatives to make their tooling decisions. The drawbacks to this approach are selecting the wrong tool in the absence of broader expertise and the fact that most representatives are often tied to one manufacturer and may not recommend tools outside their product line, even if better options exist. As the saying goes, “If all you have is a hammer, every problem looks like a nail.”
As for programming, toolpath strategies, cutting parameters, CAM software capabilities, and operator know-how all play a vital role. Even the best tools and machines won’t perform well with inefficient code. So, how do you optimize all three aspects of successful tooling programs? One proven way is through our Tooling Concierge service.
Just as a hotel concierge recommends the best places to eat and shop, we recommend the best precision tools for your applications in a uniquely unbiased way by connecting shops with experienced applications engineers who take the guesswork out of tooling decisions.
These engineers, with decades of real-world experience, can examine a 2D drawing or 3D model of your part, understand the capabilities of your machines, and assist you in planning your job with the optimal tooling setup and recommendations for starting feeds and speeds.
Sometimes, that means recommending tools we don’t manufacture or sell, but that’s fine with us because our goal is to help you achieve your machining goals with maximum ROI through improvements in cycle time, tool life, part quality, and cost per part.
Suppose we determine that a customer’s application requires custom tooling. In that case, we can design and manufacture the tool from scratch or quickly modify existing designs, often within a week of receiving the customer's order.
To gain a better understanding of our facilities and the activities that take place there, take a 360-degree tour.
Additionally, visit our Technology Center, which features links to our catalog, a video library with brand- and application-specific content, instruction manuals on equipment setup, and locators for national and international distributors.
Final Thoughts
To maximize the performance of your machines and tools, adopt a holistic approach that equally values tooling and programming. Don’t just hope it works—ensure it does with the right tools, team, and strategy.
Next month, look out for Installment 2 of our “The Latest in the World of Machining” series, where we’ll share another case study and explore advances in machining technology.
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