The 10 Commandments of Dry High-Speed Machining

5/8/2018 The 10 commandments of dry high-speed machining
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CUTTING TOOLS
The 10 commandments of dry

Boeing, Embraer Negotiating Final
Terms for Joint Venture
APR 23, 2018
high-speed machining
EDUCATION
American Machinist Calculators Ten tips can help shops get the most out of cutting and
drilling with little or no coolant.
Patricia L. Smith | Apr 30, 1998

FEATURED
      
Global Steel Demand Forecast to
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APR 17, 2018 Ten tips can help shops get the most out of cutting and drilling with little or no coolant.
Cutting Tool Consumption Reconfirms Dry machining is making inroads onto many shop floors, as it Combining new coatings
Manufacturing Boom eliminates or greatly reduces coolant use, often cutting costs and with microfine-grain
APR 15, 2018
providing a healthier working environment. Where many shops carbide materials and
run into trouble, however, is in integrating dry machining into HSK toolholding helps
Machine Tool Orders Slipped, but their existing operations. Fortunately, the following "10 manufacturers in ultra-
Demand Still Strong
APR 09, 2018
commandments of dry high-speed machining" can serve as a high-speed machining in
guide to make the most efficient and economical use of dry dry and near-dry
FAA Orders Emergency Inspections of machining technology. conditions. Here, a high-
Jet Engines performance carbide drill
APR 21, 2018 The first commandment of dry machining concerns holemaking. from Guhring dry
Can a shop perform all operations dry, especially hole drilling? machines cast iron brake
This is important, because it would be illogical to perform most parts.
cutting operations dry, or near-dry, then use coolant to drill
holes. Guhring's new Firex
product is a multi-layer
Of course, turning or milling operations are the easiest to convert coating that combines
to dry machining. In these operations, cutting edges are exposed TiN, TiAlN, and TiCN.
and chips leave the cutting zone quickly, having little contact with The company reports
the workpiece and tool. The chips, therefore, serve as a medium that, in 8620 steel, a
to dissipate heat. On the other hand, chips are not so easily single Firex tool produced
flushed out in a drilling operation, allowing heat to build up 12,000 holes, while a TiN
quickly in the confined depths of the hole. This also applies to equivalent made just
operations involving taps, fluteless taps, and reamers. 2,500.
Companies often believe that making some operations dry will

save a bundle in waste disposal costs. However, the greatest Guhring deposits its
savings is in eliminating or simplifying coolant-management multilayer Firex coating
systems—whether they be central units supplying all machines on on cutting tools using a
a shop floor or stand-alone units system manufactured by
http://www.americanmachinist.com/cutting-tools/10-commandments-dry-high-speed-machining 1/10
a shop floor or stand alone units. system manufactured by
Platit of Switzerland.
The second commandment recommends using high-performance
carbide or diamond tools with honed cutting edges. Dry
RECENT
machining places considerable physical and thermal stress on tool cutting edges. Edge
honing is vital in increasing cutting edge strength, as non-honed edges have a tendency to
Defense Strategy crack, gall, and crumble under the stress of dry machining. However, honing does reduce
APR 30, 2018 edge sharpness, which can increase heat generation during machining. The larger the hone,
the duller the edge and greater the heat generated. By permitting both a sharper edge and a
Global Steel Production Rose 12% in smaller hone, ultra-fine grain carbide and diamond substrates deliver the edge strength and
March reduced heat generation required for optimum tool life and performance.
APR 29, 2018
The third commandment requires the use of a tool with a thermally protective hard surface
Rolls-Royce, Airbus Cooperating on New coating. Even with the sharpest tools, high temperatures build up quickly and must be
Engine Integration diverted away from the tool. Among conventional coatings, TiAlN (titanium aluminum
APR 26, 2018
nitride) has been the top choice for improved thermal insulation during dry machining. But
the adhesion characteristics of conventionally applied, single-layer TiAlN coating have not
supported optimum performance.
for $3B
APR 24, 2018
Under the dynamic stress of dry machining, single-layer TiAlN has a tendency to fissure,
Boeing, Embraer Negotiating Final crack, and flake off the tool. Multilayer TiAlN coating, whose structure inhibits surface
Terms for Joint Venture fractures from reaching the tool substrate, offers significantly improved performance. New
APR 23, 2018
coatings such as Guhring's Firex multi-layer hard coating, which is comprised of distinct,
alternating ultra-thin layers of TiN (titanium nitride) and TiAlN coating, offer even better
EDUCATION results. Firex's structure combines the good adhesion characteristics of TiN, high heat
American Machinist Calculators resistance of TiAlN, and the ability to absorb cracking of TiCN (titanium carbonitride).
One other important note: tools must be recoated after regrinding to ensure they can handle
the high heat of dry cutting. If a tool is not recoated, the heat is transferred into the tool
FEATURED
without impediment, resulting in premature failure. Even the residual coating in the flutes
Global Steel Demand Forecast to and on the tool body cannot overcome this problem.
Expand Further
APR 17, 2018
The fourth mandate of dry machining is the need for a soft, non-stick coating. Tools must
have a lubrication coat (possibly on top of a hard coat) to reduce the problem of built-up
Cutting Tool Consumption Reconfirms edge. In addition, recoating is needed after every regrind. Guhring produces such a surface
Manufacturing Boom
APR 15, 2018
treating, called Movic. This soft, glide coating essentially integrates lubricant into a tool and
creates a good sliding surface that minimizes friction between chips and tool flutes.
Machine Tool Orders Slipped, but Implanted into the tool surface, Movic remains within the surface pores during the life of
Demand Still Strong the tool, although its lubricating effect is strongly reduced after regrinding.
APR 09, 2018
The fifth commandment recommends using external mist lubrication for cost-effective,
FAA Orders Emergency Inspections of near-dry high-speed machining. Compatible with most existing machinery, this approach
Jet Engines uses a spray-jet coolant delivery system, which suspends a nanometric amount of coolant in
APR 21, 2018
a fine air-coolant mist that continuously coats the moving tool. In spray-jet, or "beam
sparkling," coolant systems, coolant and air are directed under pressure independently
through a multiple-nozzle spray head, with coolant traveling through an inner nozzle and a
faster airstream through an outer nozzle. On exit, the airstream "pulls" the coolant out of
the inner nozzle. The speed of the airstream then contains the coolant-air mixture,
preventing it from expanding or collapsing.
With mist lubrication, coolant volume drops to less than 50 ml/hour, compared to typical
flood-coolant volume exceeding 6 liter/min. Near-dry machining with external mist
lubrication is recommended when working in steel, drilling holes deeper than five times the
hole diameter, and other applications where totally dry machining is not yet commercially
viable.
The sixth commandment suggests the use of internal, or coolant-through, mist lubrication—
wherever possible. Delivering the coolant-air mist internally through the spindle and tool
and directly to the cutting edge is particularly effective and reliable, especially in extremely
deep holes, because successful application is not governed by the accuracy of the airstream
or by tool length. The only question is whether the "containing" air can transport the
coolant effectively around corners and through void areas, narrow passages, and openings
that may be found in the spindle, toolholder, or ancillary pipework. Additionally, the
rotation of the spindle subjects the airstream to centrifugal force, causing the mixture to
hurl against the bore surface.
RECENT
Fortunately, there are two commercially available solutions to these problems. The first
Airbus, Dassault Aviation Link for EU addresses the problem of the coolant-air mixing in the spindle close to the tool. A "sponge"
Defense Strategy of heavy metal within the spindle stores the coolant. When the airstream passes through,
APR 30, 2018
the spindle pulls coolant particles out of the sponge and directs them onto the cutting edge.
The second option mixes both the coolant and air before it enters the rotating spindle. Low-
March pressure air only transports a small amount of coolant through the spindle. This coolant can
APR 29, 2018 be broken down into particles smaller than 1 µm by the means of "chop-ping" devices or by
boosters.

A key limitation to internal mist lubrication is the availability of coolant-through tooling for
Engine Integration
APR 26, 2018 smaller diameter machining. Tools with diameters less than 3 mm are rarely available with
coolant ducts. As such, shops should be prepared to use both external and internal
Ryanair Orders 25 More 737 MAX Jets lubrication methods as needed.
for $3B
APR 24, 2018
The seventh commandment concerns choosing tool geometries suitable for machining dry.
Current standard tool geometries are not economical for dry machining, so shops should
select optimized tool geometries to reduce friction between the tool and the chip.
APR 23, 2018
Optimized tooling has two distinguishing characteristics. First, it reduces the amount of tool
surface that comes into direct contact with the workpiece. For example, a drill requires
EDUCATION
reducing back taper, land, and flute helix angle. Secondly, optimized tooling places
American Machinist Calculators maximum lubrication on the tool surface where built-up edges are likely to develop. This is
done by opening the lubrication duct into the flutes or between the lands.
FEATURED The eighth commandment recommends the use of suction to achieve the three-fold goals of
removing lubrication mist, fumes, and chips from the cutting region. Extended exposure to
Global Steel Demand Forecast to airborne lubrication mist and fumes presents potential health risks to machine operators,
Expand Further
while unevacuated chips can reduce tool life and threaten machining quality and accuracy.
APR 17, 2018
When dry machining on conventional machine tools, chips often remain on the workpiece,
Cutting Tool Consumption Reconfirms
Manufacturing Boom in the fixture, and on various key areas of the machine. But even with "dry machines," one
APR 15, 2018 cannot be totally sure that all the chips will quickly fall on a conveyor to be hauled away. In
such cases, automatic or manual methods of chip evacuation prove highly effective.
Machine Tool Orders Slipped, but
Demand Still Strong The ninth commandment advocates adopting new machine concepts for fast, effective hot
APR 09, 2018
chip removal. When using flood coolants, fast chip removal is rarely considered. However,
without coolant, hot chips can re-main in the cutting region, heating up the workpiece, tool,
FAA Orders Emergency Inspections of
Jet Engines and machine. Overheating risks workhardening and serious geo-metric and dimensional
APR 21, 2018 flaws in the finished part. It is essential, then, that chips are quickly removed from the
cutting region. One remedy would be to use gravity. Chips can fall on a conveyor if tools are
used vertically or diagonally upward. The diagonal method is probably the more effective
method if consideration is given to slide-way covers and machine construction.
Increasing the acceleration rates of the feed axis not only shortens machine cycle times but
also reduces the risk of "underfeeding" through slow acceleration (as with conventional
machines). The direct result of this latter feature is increased tool life.
Currently under development, but perhaps a common sight on tomorrow's factory floor, is
the ideal machine for dry machining. It will incorporate "regulating circuitry," which will
take temperature measurements at key points and, in cases of excessive heat, automatically
compensate for thermal effects by axis movement.
The final commandment asks shops to run their machines at cutting rates faster than
conventional machining to improve tool life and control heat. Initially, many thought that
removing coolant from the cutting process would require lower cutting rates to maintain
tool life. However, by increasing cutting rates, chips are forced to leave the hole quicker,
reducing heat and lengthening tool life.
Dry high-speed machining's 10 commandments
1. Dry holemaking for total success
RECENT 2. Honed cutting edges to lower cutting temperatures
Airbus, Dassault Aviation Link for EU 3. Multilayer hard coating for optimum thermal protection
Defense Strategy
APR 30, 2018 4. Integrated soft coating to fight edge buildup and increase tool life
5. External mist lubrication for machining economy and flexibility

March 6. Internal mist lubrication to maximize productivity
APR 29, 2018
7. Custom tool geometries for reducing cutting friction
Rolls-Royce, Airbus Cooperating on New 8. Suction systems to evacuate mist, fumes, and chips
Engine Integration
APR 26, 2018
9. New machine concepts for fast, effective hot chip removal
Ryanair Orders 25 More 737 MAX Jets 10. Faster, not slower cutting rates to improve tool life and control heat
for $3B
APR 24, 2018 New coating beats the heat
Properly applied, coatings increase tool hardness, toughness, and heat resistance,
permitting long tool runs at aggressive speeds and feeds. In addition, coatings can reduce
APR 23, 2018 machining friction and heat buildup, resulting in less machine wear, tool cratering, and
flute packing. Another bonus is that coatings have no chemical affinity to workpiece
materials, so they resist edge buildup and galling.
EDUCATION
American Machinist Calculators

Guhring recently introduced its multilayer Firex hard coating, developed in cooperation
with Platit of Switzerland. This coating combines layers of titanium nitride, titanium
aluminum nitride, and titanium carbonitride and features a hardness of over 90 Rc. Its
FEATURED maximum operating temperature is 1,470° F.
Global Steel Demand Forecast to The red-violet coating is deposited using physical-vapor deposition. Guhring uses a unique
Expand Further
APR 17, 2018
cathodic arc process to apply Firex, which produces a smooth outer coating layer.
Cutting Tool Consumption Reconfirms According to the company, coating quality can be severely compromised if tools are not
Manufacturing Boom properly prepared before going into the coating chamber. Therefore, Guhring cleans each
APR 15, 2018 tool in a fully automated five-stage ultrasonic cleaning system. It then sorts each job by tool
size, geometry, and material type to achieve optimum coating uniformity and thickness.
Machine Tool Orders Slipped, but Once the tools are cleaned and sorted, they are placed in the coating chamber and closely
Demand Still Strong
monitored to ensure that neither the structural integrity nor geometry of the tools is altered.
APR 09, 2018
FAA Orders Emergency Inspections of TAGS: FEATURES MACHINING / CUTTING

Jet Engines
APR 21, 2018
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Sandvik Coromant, designed
for $3B
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The insert is tilted for extra
stability, while an innovative
February demand rose to $190.12 million, up 8.7% slit design ensures the correct
Boeing, Embraer Negotiating Final clamping force. Special rails
year/year and 7.4% YTD
Terms for Joint Venture at the top, bottom and back of
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APR 23, 2018
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FEATURED

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APR 17, 2018

Manufacturing Boom
APR 15, 2018

Demand Still Strong
APR 09, 2018

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APR 21, 2018
U.S. manufacturers’ consumption of cutting tools increased again in the latest report, up
3.5% from January to $190.12 million in February, reconfirming the high volume of
domestic manufacturing production. The new total represents an 8.7% rise over the year-
RECENT
ago total for February 2017, and brings the year-to-date total for cutting tool consumption
Airbus, Dassault Aviation Link for EU to 373.73 million, signaling a 7.4% rise versus the two-month total for 2017.
Defense Strategy
APR 30, 2018
Sales of cutting tools are an indicator of current manufacturing activity, as such products
represent “a primary consumable in the manufacturing process,” according to AMT – the
Global Steel Production Rose 12% in Assn. for Manufacturing Technology and the U.S. Cutting Tool Institute, which present the
March
APR 29, 2018
monthly Cutting Tool Market Report.
USCTI/ATM

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APR 26, 2018

for $3B
APR 24, 2018

APR 23, 2018
The monthly Cutting Tool Market Report tracks the results of U.S. cutting-tool consumption, which are compared to durable-goods shipments as
an index to overall manufacturing activity.

EDUCATION
Related: Cutting Tool Demand Up Again on Manufacturing Expansion
In their release, AMT and USCTI quoted Oxford Economics director of U.S. Industry Mark
Killion, who noted, “Orders for cutting tools have benefitted in recent months from a faster
FEATURED rate of business investment spending, due to recent tax cuts and renewed strength in key
markets such as metals, mining and machinery.”
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The CTMR is based on the figures reported by participating companies, and represent the
APR 17, 2018
majority of the U.S. market for cutting tools.

Manufacturing Boom Related: Machine Tool Orders Slipped, but Demand Still Strong
APR 15, 2018
“February cutting tool sales show that business continues to grow, gaining 3.5% over
Machine Tool Orders Slipped, but January, a very solid start to 2018,” stated Philip Kurtz, president of USCTI. “Year-over-
Demand Still Strong year sales posted a 7.4 percent gain and it certainly looks like the trend will continue.
APR 09, 2018
“News of tariffs and pressure on raw-material prices could have an effect, but with strong
Jet Engines market momentum it is certainly not a given that much will change,” Kurtz forecast. “March
APR 21, 2018 may or may not bring winds of change, but it will for sure bring spring.”
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March
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APR 24, 2018 “Most of these tips would be
part of an operators’ everyday
activity, but it is always good
Boeing, Embraer Negotiating Final to remind ourselves of some
Terms for Joint Venture Follow these steps and produce better tools, increase important housekeeping
APR 23, 2018 tasks,” Richardson said.
productivity, reduce breakdowns and extend the life of a
CNC machine.
EDUCATION
American Machinist Calculators AM Sta | Apr 05, 2018
Whatever level of experience or proficiency you may have in CNC machining methods and
techniques, it’s always interesting to listen to the insights of experts on topics that interest
FEATURED
you. You may learn something new — or you may have your confidence boosted once the
Global Steel Demand Forecast to expert reaffirms your positions.
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APR 17, 2018
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Demand Still Strong
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BIG Kaiser
RECENT

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APR 30, 2018

March
APR 29, 2018
CUTTING TOOLS

Engine Integration Cutting Tool Demand Up Again
on Manufacturing Expansion
APR 26, 2018
BIG Kaiser introduced a new
modular round chamfering
too: The R-Cutter CKB3 and
Ryanair Orders 25 More 737 MAX Jets CKB5 are ultra-high-feed
for $3B January demand up 4.9% month over month, up 6.1% year front- and back-radius
APR 24, 2018 chamfering mills that feature
over year high rake angles to reduce
cutting resistance and
Boeing, Embraer Negotiating Final minimize burr generation.
Robert Brooks | Mar 18, 2018
Terms for Joint Venture The R-Cutter CKB Type offers
a novel insert geometry, for
APR 23, 2018
exceptional sharpness, and
the radius chamfering mill is
offered as a four-insert design
EDUCATION to cut in the tightest of spaces
and for higher feed rates. The
American Machinist Calculators CKB connection is equipped
with a floating drive pin that
engages on both sides into
respective pockets in the
mating part. The tapers on
FEATURED the pins and the angles on the
pockets are engineered to
permit an automatic
balancing of the two resulting
Expand Further torsional forces.
APR 17, 2018
      
Manufacturing Boom
APR 15, 2018

Demand Still Strong
APR 09, 2018

Jet Engines
APR 21, 2018
U.S. manufacturers’ cutting-tool consumption rose to $183.61 million during January, an

increase of 4.9% from December, and up 6.1% from January 2017. The results continue to
demonstrate expanding manufacturing production for machine shops and similar
RECENT
operations, as cutting tools represent “a primary consumable in the manufacturing
Airbus, Dassault Aviation Link for EU process,” according to the U.S. Cutting Tool Institute and AMT – the Assn. for
Defense Strategy Manufacturing Technology, which present the monthly Cutting Tool Market Report.
APR 30, 2018
The CTMR is based on the figures reported by participating companies, and represent the
Global Steel Production Rose 12% in majority of the U.S. market for cutting tools.
March
APR 29, 2018
AMT / USCTI

Engine Integration
APR 26, 2018

for $3B
APR 24, 2018

“The boom in domestic and global manufacturing has continued to show positive growth for the cutting-tool industry,
APR 23, 2018
Related: US Cutting Tool Consumption Rose 8.3% for 2017
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“The boom in domestic and global manufacturing has continued to show positive growth for
American Machinist Calculators the cutting-tool industry. This is causing increasing pressure on cutting-tool capacity and
raw material sourcing, but these are good problems and are welcomed by the industry,”
stated Brad Lawton, chairman of AMT’s Cutting Tool Product Group.
FEATURED
In their joint release AMT and USCTI quoted an analyst who said the January results
Global Steel Demand Forecast to “demonstrate the ongoing improvement in manufacturing activity that continued
Expand Further throughout 2017.
APR 17, 2018
Related: US Machine Tool Demand Shows Solid Expansion

Manufacturing Boom
APR 15, 2018 “Sales increased 4.9% percent month-over-month in January and rose 6.1% percent over
the same period a year ago,” stated Eli Lustgarten, president at ESL Consultants,
Machine Tool Orders Slipped, but “supporting our belief that the industrial sector will continue to strengthen as the year
Demand Still Strong progresses.”
APR 09, 2018
Lustgarten also noted that Institute for Supply Management’s February Manufacturing
Index confirmed new orders and production “remain at very strong levels, building a
Jet Engines
APR 21, 2018 backlog and pointing toward rising industrial production and higher capacity utilization as
the year progresses. With an improving global backdrop, the cutting-tool sector is headed
toward another banner year with sales gain approaching if not exceeding 10%.”
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The 10 Commandments of Dry High-Speed Machining

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5/8/2018 The 10 commandments of dry high-speed machining

Airbus, Dassault Aviation Link for EU

Global Steel Production Rose 12% in

Rolls-Royce, Airbus Cooperating on New

Ryanair Orders 25 More 737 MAX Jets