Turning, milling, drilling, reaming, threading, measuring – all in a single integrated process. Sounds like the future, but it has long been a reality in modern manufacturing companies. Complete turning-milling machining combines high-precision machining steps into an efficient process that saves time, reduces errors and sustainably improves processes.

This is exactly what we demonstrated in our workshop. How CAM programming, tool strategy and machine concept combine to form a coherent solution. From the digital model to the finished component. With real workpieces, real machining strategies and real results.

In this article, we take you on a practical journey. You will learn how we transform complex requirements into clear solutions. And you will see why tool selection, CAM system and process thinking are now more decisive than ever for quality and competitiveness. Welcome to the world of complete turn-mill machining. Welcome to the “Drevolution“.

From past challenges to today’s precision

Anyone involved in modern turn-mill complete machining today should understand the hurdles that had to be overcome in the past. The production of complex components often began with the creation of elaborate 2D drawings. Every line, every dimension had to be interpreted precisely. This often resulted in ambiguities that developed into real problems in production.

Programming was also carried out directly on the machine. This was not only time-consuming but also blocked valuable machine running time. Any manual input error could lead to downtime. In addition, tools were often not managed centrally. Whether a suitable tool was available or even suitable at all could often only be determined during set-up. In many cases, the first part produced only served as a test piece – rejects were almost inevitable.

Digital thinking. Made efficiently.

Today, things look very different. Modern production begins with a well thought-out 3D model, for example in Step or SolidWorks format. It is no longer programmed directly on the machine, but using powerful CAM systems that also enable simulations. Even before the first cut is made, it is possible to check how the tool will behave in the installation space, whether there are any collisions and whether all the machining steps mesh properly.

Tool data, geometries and cutting values are available centrally. Customers are increasingly demanding digital twins to supplement their own systems, for example for CAM programming or collision-free assembly planning. Tool management is thus becoming an integral part of a digitized, end-to-end process.

At HAM Präzision, we live exactly what we teach in our workshops. Our goal is not only to understand processes, but to consistently optimize them. Error prevention, maximum process reliability and short production times are our daily focus. After CAM programming, we can go straight to the machine – without rejects, without time-consuming set-up, without long searches for the right tool or room for interpretation of drawings. This end-to-end process is a decisive advantage, especially in our one-off and small series production.

The advantages speak for themselves: machine downtimes are avoided, tools are centrally managed and available at all times, manual programming errors are a thing of the past. The result is an end-to-end manufacturing process that combines maximum precision with impressive efficiency. What we are experiencing is not a slow change, but a noticeable further development in machining. A new way of thinking. A real turning revolution.

What “Drehvolution” means to us

For us, “Drehvolution” describes a holistic approach that begins long before the first chip – namely, with the design of the tool. In this early phase, we lay the foundation for precise, economical and consistent production. Our goal is to design each process step in such a way that maximum precision goes hand in hand with high efficiency. This includes the consistent use of digital tool data and well thought-out process planning right from the start.

The demands on production are constantly increasing. Customers expect shorter delivery times, consistently high quality and reliable prices. At the same time, qualified personnel are becoming increasingly rare. We meet these challenges with innovative solutions that closely interlink and coordinate planning, production and tool management.

Complete machining as the key to efficiency

Modern complete turning-milling machining combines all work steps – turning, milling, drilling, threading, deburring and measuring – in a single machining center. The process runs continuously with just one reclamping, supported by automated loading and unloading systems such as bar or gantry loaders for a smooth material flow.

A look at the time involved shows the progress: whereas modeling, drawing creation, checking and programming often used to take more than 800 minutes, it now takes around 500 minutes with CAM programs and digital tool data. Manual programming and downtimes in particular are eliminated, saving several hours of time.

This efficiency is the result of high-performance CAM systems in combination with central tool management. Tools are digitally recorded and available at all times, minimizing machine downtimes and significantly reducing sources of error.

Additional challenges and solutions

In addition to technical implementation, modern manufacturing presents numerous challenges that can be specifically addressed through integrated turn-mill complete machining. In terms of economic efficiency, every minute counts today. The time from quotation to finished product must be kept as short as possible. At the same time, fewer personnel are employed, but they have to take on more responsibility and tasks.

Competitiveness is also under pressure. Delivery deadlines must be met, prices must be calculable and processes must be planned. Automated tool management provides support here, as it ensures that all operating resources are available at all times. This avoids unnecessary machine downtime due to missing tools.

Digitalization offers enormous potential, but is not yet fully exploited in many companies. Although industry four point zero is frequently mentioned, full implementation often fails due to limited financial resources, a lack of specialists or the complexity of the systems.

Added to this is the increasing time pressure in day-to-day business. Delivery times are getting shorter and customers are making changes at ever shorter notice. Sometimes adjustments even reach us during ongoing production. Without digital models and precise CAM programming, such changes would be almost impossible to implement realistically.

And finally, the focus is on quality. Optical and functional repeatability is essential today. Automated deburring ensures that every manufactured part meets the exact same requirements and remains constant in terms of form and function.

From digital model to the integrated process

The work begins on the screen long before the chips start flying. The basis for stable complete turn-mill machining is a complete 3D model of the component. This can be integrated quickly and directly into SolidWorks and forms the basis for CAM programming. This allows machining strategies to be simulated, checked and specifically adapted long before the workpiece reaches the machining center.

However, a challenge arises with models that are not designed for mid-tolerance. This is because the CAM system implements exactly what the model specifies. For example, it does not automatically recognize whether a diameter is between plus zero point one and plus zero point two. In such cases, we therefore specifically program a grinding allowance that appears to be a deviation in the simulation, but corresponds exactly to the target dimension in actual production.

For consistent and precise complete machining, all components must be coordinated with each other. The machine with its kinematics and cooling functions, the workpiece clamping, the tool holder, the CAM strategy, the selected cutting values, the type of cooling and, of course, the tools used themselves. Whether PCD or solid carbide, whether with special cutting edge geometry, coating or coordinated helix angle – every detail contributes to process reliability and repeat accuracy. A stable, reproducible production process can only be achieved when everything works together.

Turning-milling complete machining in live application

This interaction was demonstrated live during our workshop. The focus was on the complete machining of a base body for a PCD tool made of steel. From cutting, turning, milling, drilling, reaming and threading to automatic deburring and measuring, every step was carried out directly on site.

A Mazak Integrex i 100H S, equipped with the Mazatrol control system, was used. For workpiece clamping, we used gripper jaws on the main spindle and specially machined jaws on the counter spindle. Tool clamping was ensured by Capto C6 in combination with hydraulic expansion technology. Classic emulsion ensured reliable cooling.

A particular highlight was the integrated measurement during the machining process. The TC62 3D touch probe from Blum Novotest was used in this configuration for the first time. The measurement data was processed directly and fed back to the machine for correction. The result was a consistently precise component – with no manual reworking and no loss of time.

The CAM programming was implemented with SolidCAM. Among other things, powerful strategies such as iMachining were used, which enable uniform machining with optimum loading of the cutting edges. The tools we used were precisely matched to the material and the machining task. The cutting material, cutting values, geometry and surface technology interlocked perfectly.

The result was a functional, dimensionally accurate basic body – completely manufactured in a single clamping operation. Fast, safe and with maximum precision.

Watch the video to see what this process looks like in reality. Immerse yourself in the practice of modern turn-mill complete machining – precise, efficient and live.

Der Beitrag Understanding and implementing complete turning-milling machining: production without manual reclamping is this simple erschien zuerst auf HAM Präzision.

Aluminum is omnipresent. We encounter it in vehicle bodies, aircraft structures, machine components, packaging and in many industrial applications. The reasons for this are obvious: the material is light, malleable, corrosion-resistant and impresses with its excellent conductivity. However, it is precisely this diversity that poses particular challenges for manufacturers. This is because aluminum machining is anything but a matter of course.

Depending on the alloy, strength and structure, it reacts very differently to machining processes. Chip sticking, built-up edge formation and abrupt tool wear are just some of the typical side effects. The challenges often lie in the details and the path to a stable, efficient process is rarely straightforward. What makes the decisive difference only becomes apparent when you delve deeper.

From lightweight to high-performance: What makes aluminum so attractive for machining

As a material, aluminum has an exceptional combination of technical properties that make it particularly attractive for machining. Aluminum naturally forms an oxide layer that protects it from corrosion, and anodizing can further enhance this protection — a clear benefit in harsh environments or for demanding surface requirements. At the same time, aluminum conducts heat and electricity very efficiently: with around 60 percent of the thermal conductivity of copper and an electrical conductivity of around 62 percent at only a third of the weight, it is ideal for lightweight, high-performance components.

The material also offers advantages both visually and functionally. It reflects up to 90 percent of thermal radiation and 80 percent of light, making it predestined for use against light and thermal radiation in applications such as roofing and heat shields for motor vehicles. In terms of sustainability, it scores highly with its excellent recyclability. Recycling uses only a fraction of the energy while maintaining full quality and strength. Furthermore, it generally does not require any additional protective coating, as simple processes such as brushing or shot blasting are usually sufficient. However, if increased protection is required, additional surface treatments such as paints or electrochemical treatments (e.g. anodizing) can be applied.

Light, strong, versatile – ideal conditions for machining

A decisive factor for aluminum machining is the excellent ratio of weight to strength. This makes the material ideal for lightweight, robust constructions, such as in vehicles or aircraft. It also impresses with its uncomplicated processing: it can be produced in almost any desired thickness. Its easy machinability – for example through turning, milling, or grinding – and the high processing speed also make production more economical. Furthermore, it is highly formable and can be processed into fine threads or complex shapes without breakage. Despite its lower ductility compared to copper, its low density and low melting point enable the flexible production of a wide range of products such as sheets, tubes or rods..

Aluminum also shows its strengths at low temperatures: it does not become brittle, but stronger, and remains corrosion-resistant. It is also non-magnetic, which makes it ideal for shielding antennas and computer panels. Anyone who wants to machine aluminum is working with a material that is not only light and conductive, but also robust, sustainable and extremely versatile. Provided you know its characteristics and use the right precision tools, such as those developed by HAM.

Not all aluminum is the same, and that makes all the difference

Aluminum is a real lightweight with amazing strength. Compared to other materials, aluminum is in the middle range in terms of strength. However, when its density is taken into account, it clearly stands out and even surpasses steel. It is precisely this ratio that makes it so attractive for lightweight construction. Aluminum has played a key role in automotive engineering, aviation, and mechanical engineering for many years.

But as versatile as the material is, it also behaves differently when it comes to machining. Because not all aluminum is the same. In addition to pure aluminum, there are a variety of aluminum alloys with their very own properties. While pure aluminum is very soft and only has low strength, alloys usually have significantly better prerequisites for aluminum machining. A distinction is made between wrought alloys and cast alloys. Both types are basically machinable but require a differentiated approach.

In practice, aluminum alloys are divided into three classes. Class one comprises very soft materials with low strength. These often produce greasy chips during machining, which stick to the tool and lead to the formation of built-up edges. Class two describes materials with increased strength in the range of around 300 to 600 Newtons per square millimeter. These alloys are significantly more stable and lead to fewer built-up edges. Class three stands for free-cutting materials and wrought materials with chip-breaking additives such as lead. These additives ensure clean chip formation and significantly reduce the tendency for built-up edge.

The biggest challenges in machining aluminum

At first glance, aluminum seems like a dream partner for machining. Light, easy to shape and clean to process. But when you stand at the machine, you quickly realize that this material also has its peculiarities. In particular, the sticking of chips and the stubborn built-up edge make even experienced machining professionals break out in a sweat. Especially when milling aluminum, these effects can have a negative impact on dimensional accuracy, tool life and surface quality.

One key to successful aluminum machining lies in high-speed machining. Combined with a carefully selected cooling lubricant strategy, many problems can be avoided from the outset. Aluminum generates significantly lower cutting forces than steel during milling, often only about a third. This property allows high cutting speeds, but at the same time requires consistent control of the chip flow.

To ensure process stability, it’s crucial to remove chips from the cutting zone quickly and efficiently. This requires special tools for aluminum with smooth, slippery surfaces that prevent sticking and actively remove the chips. Milling cutters with a lower number of teeth than tools for steel are also characteristic. This design significantly improves the chip flow. Coordinated coating solutions, when integrated into the process, reliably control even sticky aluminum chips.

These are the factors that really matter when machining aluminum

If you want to machine aluminum reliably and precisely, you have to master the interaction of many components. It starts with the machine itself. It should not only work stably, but above all be prepared for the use of modern cooling lubricant solutions. Systems like the AerosolMaster 4000 ATS from Blum-Novotest enable highly efficient minimum quantity lubrication by precisely dosing a fine film of lubricant. At the same time, the machine must support internal and external cooling options and allow clean adaptation to dry machining, emulsion or MQL.

Another cornerstone of aluminum machining is the clamping. The tool holder and workpiece holder must grip precisely to avoid vibrations and ensure clean chip formation. In MQL machining, the cooling channel must be optimally positioned to ensure effective performance. This is the only way to ensure reliable chip removal without leaving any residue in the machining zone. When drilling, for example, a special clamping structure with a central lubricant supply via the holder can be crucial.

And let’s not forget the digital side of the process. CAM programming has a massive impact on efficiency and tool life. Those who rely on well thought-out strategies and smart adjustments to the cutting values not only save time but also ensure uniform surfaces. Those who rely on well-thought-out strategies and smart adjustments to cutting parameters not only save time but also ensure consistent surfaces. Technology such as SolidCAM‘s iMachining, in combination with optimized cutting data, enables a constant load and reduces thermal peaks at the same time.

However, the optimum machine, perfect clamping and intelligent programming only unfold their full potential in combination with the right tool. This is because the cutting material, cutting values, tool geometry and surface technology determine the cutting quality and process stability, especially with aluminum. Therefore, it’s worth taking a closer look at the specific requirements of tools for aluminum machining.

What makes our tools so special when machining aluminum

What truly makes a tool for aluminum machining outstanding isn’t just the cutting material used or a single design feature. It’s the interplay of sophisticated materials, sophisticated geometry, and state-of-the-art surface technology that makes the decisive difference.

When it comes to cutting materials, we specifically focus on two proven materials: polycrystalline diamond (PCD) and solid carbide. PCD tools are the first choice for machining abrasive aluminum alloys with a high silicon content or for very high-volume production combined with long tool life. They are characterized by exceptional wear resistance and deliver consistently high surface qualities – an advantage that is particularly in demand in sensitive sectors such as aviation or automotive engineering.

Solid carbide tools, on the other hand, score points for their versatility. They are ideal for smaller series or for processes that require a high degree of flexibility. Their advantage lies not only in their good cutting performance, but also in the fact that they are generally more cost-effective than PCD tools. They are also a particularly good choice when machining other materials in addition to aluminum, as they are suitable for a wider range of applications.

Geometry and surface technology as the key to performance

The tool geometry is decisive for the quality of machining. Our milling cutters have precisely ground cutting edges, a sharp point and defined cutting edge rounding. Internal cooling channels enable an efficient supply of cooling lubricant, while flat helix angles and uneven helix pitches minimize vibrations and improve chip breaking at the same time. The chip chambers have also been specially designed for aluminum alloys to ensure reliable chip evacuation. The strength of our tools is particularly evident when drilling: The specifically designed MQL chamfer on the cutting edges optimally supports aerosol lubrication and makes the tools particularly efficient in combination with modern MQL systems.

A decisive contribution to tool performance comes from surface technology. In order to meet the high demands placed on PCD and solid carbide tools, HAM has developed Hybrid Surface Finish, or HSF for short, a hybrid and technologically highly complex solution. This produces a defined surface finish while simultaneously homogenizing the cutting edge. In combination with a precisely coordinated grinding quality, this creates a high-performance overall system.

For tools with shank diameters up to 32 millimeters, we apply PVD hard coatings such as TiN, TiAlN, TiNAlOx, or AlOx. The HSF process ensures mirror-smooth surfaces on carbide and PCD, for diameters between 0.5 and 32 millimetres. Depending on the application, defined cutting edge preparations of 4 to 20 µm are achieved. The tool’s meticulous design comes to life only when all its properties are combined optimally, unleashing its full potential.

Machining aluminum – exploiting potential, mastering challenges

Machining aluminum is more than just a routine production step. Different alloys, complex material properties and process-specific requirements demand a high level of expertise. If you want to manufacture economically and reproducibly, you need to have the entire machining process under control – from material selection and the optimum cooling strategy to the precise coordination of machine, clamping and CAM programming. The high quality that modern applications require today can only be achieved if all factors are interlinked.

With our many years of experience in aluminum machining and our highly developed tool solutions – from polycrystalline diamond to finely tuned solid carbide – we not only offer individual components, but also sophisticated overall solutions. Technologically leading geometries, specially developed surface treatments such as HSF and perfectly coordinated coating concepts make our tools the first choice for demanding production tasks. Anyone who wants to machine aluminum efficiently and reliably benefits from our expertise down to the smallest detail.

Practical application

In our workshop “Zerspanung ALU – Best of HAMmer”, we showed how theory and practice can be optimally combined. We machined a component made from the high-strength aluminum alloy EN AW-2017A. This alloy is an age-hardenable material that develops its full strength potential after targeted heat treatment, such as solution annealing with subsequent cold ageing. It plays a key role in the aerospace and defense industry in particular due to its high mechanical strength and good machinability.

The workpiece, measuring 200 x 100 x 25 millimetres, was machined on a Hermle C12U, controlled by a Heidenhain TNC 640. We used a zero-point clamping system from LANG to ensure reliable and repeatable clamping. In combination with a precise tool holder from Diebold based on HSK-A63, a high level of stability was guaranteed.Milling was performed with targeted use of minimum quantity lubrication and classic cooling lubricant, ensuring optimal chip removal and maximizing tool life based on the machining area.

When everything works together, it shows how powerful aluminum can be in the right environment.

Der Beitrag How to achieve perfect aluminum machining: Aluminum machining live in the workshop! erschien zuerst auf HAM Präzision.

Hard machining is the machining of ferrous materials with a hardness of at least 54 HRC. Common hard machining processes include grinding, hard milling and hard turning. Hard milling has become increasingly important in recent years, particularly for components, instead of the time-consuming and costly process of grinding or eroding.

Hard machining now plays a central role in many industries. In toolmaking, precision tools are manufactured that require high hardness and wear resistance for demanding applications. In the automotive industry, it enables the machining of crankshafts, gearbox housings and other components that require not only strength but also maximum dimensional accuracy. The aerospace industry benefits from the production of critical components that have to withstand extreme loads such as high temperatures and mechanical pressure. In medical technology, it enables the precise production of surgical instruments and implants, which not only have to be precise but also biocompatible. It also plays a key role in power generation when processing components for turbines and generators, which have to withstand high loads during operation.

In all of these areas, hard machining is crucial in order to achieve the desired properties of the materials and ensure the functionality of the products.

Advantages of hard machining and hard milling

Hard machining offers numerous advantages for economical and high-quality production. It can replace time-consuming processes such as grinding or eroding and offers significantly higher productivity thanks to shorter throughput times. It also ensures a high surface quality, which noticeably improves the quality and dimensional accuracy of the components.

Hard milling in particular offers decisive advantages that make it a preferred processing method for hard materials. Thanks to its high precision, it enables the production of components with very tight tolerances and a high surface quality – a decisive factor in many applications. The high surface quality reduces the need for subsequent processing steps such as grinding or polishing. At the same time, the fast and efficient processing results in less thermal deformation of the workpiece compared to other processing methods, such as grinding. In addition, hard milling also scores highly in terms of productivity, as in many cases it can be carried out significantly faster than other machining methods.

All these advantages make hard machining an effective and efficient method for machining hard materials in various industrial applications.

From raw material to high-performance steel: Reasons why steel is hardened

The hardening of steels is an essential process to improve their mechanical properties and make them more efficient for specific applications. A key point is increasing the hardness: the hardening process increases the hardness of the steel, making it more resistant to abrasion and wear. This is particularly important for tools and machine components that experience high mechanical loads. At the same time, hardening leads to an increase in strength so that the steel can withstand higher tensile and compressive forces. It also provides increased wear resistance so that they are better protected against mechanical wear, extending their lifespan and reducing the need for frequent maintenance or replacement.

Another advantage of hardening is the improvement in dimensional stability, which ensures that components retain their original geometry even at high temperatures or under mechanical stress. The process also enables adaptation to specific applications. Through targeted hardening, steels can be optimized for special applications, e.g. for use in the automotive industry, in mechanical engineering or in the aerospace industry. Hardened steels also offer increased temperature resistance, which makes them ideal for applications in hot environments. Thus, you can apply hardening steels in various industrial applications that require high performance and reliability.

The hurdles of hard machining

A key difficulty in hard machining is tool wear, as the high hardness of the materials puts a lot of strain on the tools. This requires the use of special, high-strength cutting materials and regular tool changes. At the same time, hard milling generates a considerable amount of heat, which can have a negative impact on both the workpiece and the tool. Insufficient cooling can lead to deformation or premature destruction of the tool. Another problem can be the formation of microcracks that thermal stresses in the material cause. High heat generated during milling causes these stresses. To control them effectively, suitable cooling strategies or optimized cutting parameters are required.

Choosing the right machining parameters – including cutting speed, feed rate and cutting depth – is crucial. Incorrect parameters can lead to poor surface quality or inaccurate dimensions. In addition, machine stability plays an important role: vibrations or insufficient machine rigidity significantly reduce the processing quality. Finally, surface quality remains a key challenge, as machining hard materials often results in rough surfaces that need to be reworked.

Mastering hard milling: Strategies for precise and efficient machining

Numerous challenges arise in hard machining, but one can overcome them using various strategies and techniques. One of these approaches is the selection of the right tools. The use of high-quality carbide or cermet tools specially developed for hard milling can reduce tool wear and improve machining quality. Optimizing the machining parameters can also make a significant contribution. The careful selection of cutting speed, feed rate and cutting depth is crucial. Through tests and simulations, we can determine the optimum parameters that maximize both productivity and surface quality. Efficient cooling is also important to reduce heat generation during milling and extend tool life. In addition, targeted cooling can also prevent deformation of the workpiece.

The use of stable and precise machines is important in order to minimize vibrations. Regular maintenance and calibration of the machines contribute to stability. Sensors and monitoring systems help monitor the machining process in real time. This allows us to detect problems at an early stage and make adjustments. Furthermore, a well-trained workforce is critical to success in hard milling. Training on best practices, tool handling and machine operation can improve machining efficiency and quality. By using CAD/CAM software to simulate the machining process, potential problems can be identified in advance and machining can be optimized. By combining these strategies, we can effectively overcome the challenges of hard machining.

The tools used for hard milling are often made of coated cemented carbide, ceramic or polycrystalline cubic boron nitride (CBN). At high cutting speeds and temperatures, these materials allow for precise cuts due to their exceptional hardness and wear resistance. Manufacturers often coat the tools with special coatings that reduce friction and increase tool life. It is important to choose a carbide substrate that has high hardness and wear resistance. Typically, cobalt-bonded carbides (such as WC-Co) are used as they offer a good combination of hardness and toughness. For special applications, we can also consider other alloys or coatings to optimize performance. It is advisable to consider the specific requirements of the machining and the material to make the best choice.

Hard, harder, HAMazing: The secrets of our tools for hard machining

The right choice of carbide is a decisive factor for success in hard machining. Carbides are primarily classified according to their CO content and the tungsten carbide grain size. A higher cobalt content increases toughness but reduces hardness and wear resistance. In contrast, a lower cobalt content provides greater hardness, but at the same time increases susceptibility to fracture. HAM mainly uses carbide grades with a cobalt content of between 6 and 12 %. The microstructure and structural changes have a significant influence on the properties of carbides. The finer the grain size, the harder the carbide becomes. In order to determine the optimum carbide grades, HAM analyzed around 110 variants in its in-house laboratory.

The grain size of hard metals ranges from less than 0.2 µm in the nano range to over 6.0 µm in the extra coarse grain range. This diversity is accompanied by widely varying material properties. At HAM, we generally use a grain size range from ultra-fine to fine grain, as these meet the high requirements of many tools.It is essential to match the carbide grade carefully to the respective application. Not every grade is suitable for every tool. To ensure the selected carbides meet our high quality standards, they are extensively tested for their physical and metallographic properties in our in-house laboratory.

The geometry of the tool is also an essential component of hard machining. We do everything we can to match it perfectly to the requirements. Various factors are crucial to achieving optimal results. The negative rake angle ensures a stable cutting process even under high loads. At the same time, a reinforced core increases the robustness of the tool. Careful cutting edge rounding or preparation minimizes the risk of breakage and ensures consistent performance. Finally, mirror-smooth surfaces help to reduce friction and achieve an exceptional surface quality on the workpiece. All of these elements work together to maximize the precision and efficiency of hard machining.

To achieve a mirror-smooth surface and to meet the market’s growing demands on PCD and solid carbide tools, HAM has developed a hybrid, technologically highly complex solution – Hybrid Surface Finish (HSF). This method makes it possible to achieve a precisely defined surface quality and homogenize the cutting edges at the same time. An essential factor for the performance of the tools. A precisely coordinated grinding quality defines the basis for success before the surface treatment.

But the proper coating also gives tools decisive advantages in hard machining. This should be wear-resistant, friction-reducing thanks to a smooth coating without droplets and heat-resistant up to 1,100 °C. The most common coatings include TiAlN- / and AlTiN-based coatings. These are available as mono- or multilayers, supernitrides or nanostructures. You can use TiAlN or TiSiN coatings for applications with particularly high temperatures, such as hard machining. In the field of processing non-ferrous metals, so-called rainbow coatings (ta-C coatings) are becoming increasingly popular. However, they can only operate at a temperature up to 550 °C. A high-quality coating is only one part of success. Only the perfect interaction of all aspects makes a tool perfect.

Accept challenges, achieve precision: Our conclusion on hard machining

Hard machining is at the heart of modern manufacturing technologies. From the automotive industry to aerospace and medical technology, machining hard materials opens up a wide range of applications. These applications cover many different industries. However, it also poses considerable challenges. The extreme hardness of the materials leads to high tool wear, while the resulting heat can promote deformation and surface defects. Choosing the optimal machining parameters and efficient cooling are essential to overcoming these difficulties. HAM accepts these challenges and offers solutions that help you to machine the hardest materials with the highest accuracy. The perfect coordination of carbide grades, geometry, surface technology and coating results in tools that meet the highest demands. Let us master the challenges of hard machining together.

Live machining of a connecting rod shape (150 x 150 x 50 mm) through-hardened to 62 HRC (X155CrVMo12-1) as part of our “Hart – Härter – HAMmer” workshop on November 20, 2024

Der Beitrag Precision and efficiency for hard materials: Hard machining live at the workshop! erschien zuerst auf HAM Präzision.

Titanium – a material that is increasingly playing a key role in the modern manufacturing environment. However, due to its strength and material properties, machining it is demanding and requires specialized strategies. So how exactly can these challenges in titanium machining be mastered?

It was precisely these complex requirements that we examined in depth during our workshop. After all, a material of extremes requires equally extreme solutions. Advanced CNC technologies and special tools are required for machining. And this is exactly where our new HAM titanium program comes into play. In combination with modern cooling methods, it enables efficient and precise machining of titanium, which was impressively demonstrated during live machining.

Titanium: An overview of the light metal and its grades

Titanium, a light and resistant element, is highly sought after due to its low density and high resistance to corrosion and heat. Although the light metal is one of the ten most common elements in the earth’s crust, it is mainly found in minerals, which makes its extraction considerably energy-intensive – around four times as much as aluminum.

But not all titanium is the same! It is divided into different categories, known as “grades”, which represent either pure or alloyed titanium. Pure titanium is found in grades 1 to 4, with grade 2 being the most commonly used in medical technology with 99.7% pure titanium. It offers a good balance between strength and malleability. Alloyed titanium, on the other hand, ranges from grade 5 to 39, with grade 5 (Ti-6Al-4V) being one of the most commonly used titanium alloys in the aerospace industry, containing aluminum and vanadium and offering high strength and corrosion resistance.

The choice of grade depends on the requirements for strength, weight and corrosion resistance. Titanium outperforms aluminum, CFRP and GFRP in terms of tensile strength, but lags behind steel. However, no general statement can be made about density. Depending on the type of aluminum, the density is very close to that of titanium. However, the density of CFRP with a volume of 50% exceeds both titanium and aluminum.

The challenges of titanium machining and possible solutions

The processing of titanium poses considerable challenges for machining companies. High strength and toughness lead to higher cutting forces and temperatures and therefore to increased tool wear. The problem is exacerbated by the low thermal conductivity of titanium, as the heat generated is not effectively dissipated into the chip, but mainly into the tool. While around 80 % of the heat from steel is dissipated into the chip, only 20 % dissipates into the chip in titanium. In addition to this is the strong reactivity with oxygen, which causes increased tool wear due to diffusion at high temperatures. Heat and friction are therefore the main challenges when machining titanium.

But how can these challenges be overcome? One of the most effective ways to minimize heat and tool wear is to avoid high cutting speeds. Special solid carbide tools with sharp cutting edges ensure clean cutting and prevent breakage. Uneven tool spacing helps to minimize vibration and extend tool life by promoting even wear of the cutting edges. It also ensures better chip removal and optimized cutting forces. The correct coordination of carbide substrate and coating optimizes the heat resistance and sliding properties of the tool. The use of special coolants and optimum internal cooling of the tools are also crucial for improving process stability

Our solution: The new HAM titanium program

Our HAM standard tools are optimized for “wet” use and benefit from a flow-optimized design, which is achieved by the larger MQL shaft chamfer and a round MQL cooling channel connection. Reduced guide chamfers help to lower the temperature, while an increased taper minimizes friction as less cutting surface “rubs” against the workpiece. This is complemented by our innovative HSF (Hybrid Surface Finish) surface technology, which guarantees a smooth surface and thus further reduces friction during titanium machining.

40-3011: Our 5-cutter for trochoidal milling

The HAM 40-3011 offers maximum efficiency thanks to an internal cooling and a special coating that makes it particularly suitable for titanium machining. It has 5 teeth and is available in diameters from 6 to 20 mm.

iMachining Ø 20 | allowance 0.2mm | emulsion | roughing / finishing machining parameters

• ap / ae = 38 / 0,18-0,81 | 38 / 0,2
• n = 2.045 rpm | 1.115 rpm
• Vc = 180 m/min | 70 m/min
• fz = 0,24 mm/z | 0,06 mm/z
• Vf = 2.410 mm/min | 360 mm/min

iMachining Ø 12 | allowance 0.2mm | emulsion | roughing machining parameters

• ap / ae = 23 / 0,11-0,48
• n = 3.200 rpm
• Vc = 122 m/min
• fz = 0,12 mm/z
• Vf = 1.910 mm/min

40-3001: Our 3-cutter for full-slot milling up to 1.5xD

Our HAM 40-3001 is characterized by an internal cooling, 3 teeth and diameters from 6 to 20 mm. Thanks to a special coating, it is ideal for machining titanium and offers high wear resistance in demanding applications.

Slot 1xD Ø 10 | allowance 0.00 mm | MQL | roughing / finishing machining parameters

• ap / ae = 10 / 10 | 10 / 0,2
• n = 1.600 rpm | 2.550 rpm
• Vc = 50 m/min | 80 m/min
• fz = 0,05 mm/z | 0,08 mm/z
• Vf = 240 mm/min | 610 mm/min

Slot1.5xD Ø 10 | allowance 0.00 mm | MQL | roughing / finishing machining parameters

• ap / ae = 15 / 10 | 15 / 0,1
• n = 1.600 rpm | 2.550 rpm
• Vc = 50 m/min | 80 m/min
• fz = 0,025 mm/z | 0,08 mm/z
• Vf = 120 mm/min | 610 mm/min

HAM Titandrill: Our process-reliable 3xD deep hole drill with internal cooling

This tool combines a 30° helix angle with 2 teeth for high performance. Available in 3xD and 5xD, it is equipped with a special chip chamber geometry to ensure improved chip evacuation.

Core hole Ø 6.8 | allowance 0.00 mm | MQL | roughing / finishing machining parameters

• ap = 20
• n = 1.640 rpm
• Vc = 36 m/min
• f = 0,05 mm/U
• Vf = 164 mm/min

Core hole Friction Ø 7.8 | allowance 0.00 mm | MQL | roughing / finishing machining parameters

• ap = 20
• n = 1.500 rpm
• Vc = 36 m/min
• f = 0,05 mm/U
• Vf = 150 mm/min

Advantages of our HAM titanium program

Our innovative tool geometries with central internal cooling ensure maximum performance and efficient heat dissipation in order to achieve maximum efficiency even in demanding machining processes. Thanks to the smooth running and low-vibration machining, precise and reliable machining is achieved, which significantly improves the machining quality. With our newly developed wear protection coating for titanium and the unique Hybrid Surface Finish (HSF), not only is a defined preparation of the cutting edge achieved, but also an extremely smooth surface. The heat-resistant surface coating can withstand temperatures up to over 1000 °C. It can also be used in MQL processes (minimum quantity lubrication) under certain conditions, which further increases sustainability and process reliability.

Looking to the future of titanium in modern manufacturing

The properties of titanium – high strength, low weight and excellent corrosion resistance – make it one of the most sought-after materials in manufacturing. The aviation, automotive and medical technology industries have long recognized the potential of titanium. However, the high cost of machining has so far prevented titanium from being widely used in mass production. But with advanced machining techniques and the right choice of tooling, these hurdles could soon be overcome. It is therefore no wonder that experts expect the overall share of titanium alloys to grow by 20 percent over the next few years. Industries such as aerospace, e-mobility and electronics show strong growth potential for the use of titanium. With more efficient machining techniques and a targeted production strategy, titanium could eventually replace stainless steel and aluminum in many applications and usher in a new era in manufacturing.

Live machining of an aerospace moulded part (150 x 110 x 50 mm) in titanium grade 5 (Ti6Al4V; 3.7164) completely with minimum quantity lubrication (MQL) only as part of our workshop ‘The Swabian Titanium’ on 16.10.2024

Der Beitrag When titanium meets Swabian know-how: titanium machining live at our workshop! erschien zuerst auf HAM Präzision.

HAM Precision milling cutters for titanium: Almost as light as aluminum, but stronger than steel – these are the properties of titanium.

The machining of titanium is a complex task due to the special properties of the metal.

HAM has developed the titanium milling cutters HAM 40-3001 with teeth = 3 and HAM 40-3011 with teeth = 5 and a titanium drill for machining titanium, high-temperature alloys and stainless steels. 

Benefit from the following advantages: 

• Titanium milling cutter with central internal cooling for maximum performance
• Titanium drills with special chip flute geometry, an internal coolant and special grinding
• Very smooth running and low-vibration machining
• Special surface treatment (HSF)
• Heat-resistant surface coating up to over 1000°
• MQL-capable under certain conditions

The new HAM 40-3001 and HAM 40-3011 are available from now, the titanium drill is available on request.

Get in touch with us! We will be happy to advise you.

Der Beitrag The new HAM HSC / HPC titanium tools are convincing at the highest level erschien zuerst auf HAM Präzision.

New in the program at HAM Präzision: the new solid carbide aluminum milling cutter 40-5380 with central internal cooling

Our very successful HSC / HPC aluminium milling cutters of the 40-5350, 40-5390 and 40-5490 series have been convincing our customers worldwide for many years. The excellent performance in terms of metal removal rate, smooth running, and surface quality meets almost every requirement.

HAM milling cutters in connection with a powerful and highly dynamic machine form an invincible team.

But can first-class milling cutters still be improved?
Yes, and HAM knows HOW!

Here is the latest addition to the HSC / HPC aluminium milling family:

The new HAM 40-5380 with central internal coolant supply impresses with:

– Even better chip evacuation
– Even higher feed rate for full slot milling
– Even deeper infeed when milling full grooves
– Suitable for both roughing and finishing
– Cooling where the chip is formed
– No more chips on the workpiece
– Specifically suitable for structural components and CAD/CAM
  applications

Already available from stock!

Test it yourself and push our new HSC / HPC aluminium milling cutter 40-5380 to its limit or find our the limit of your machine!

Please note that due to the central coolant supply there is no center cutting edge, which is why the milling cutter 40-5380 is not suitable for drilling.

Do you have any questions? Feel free to contact us at any time!

Der Beitrag Performance at the highest level – the new solid carbide aluminium milling cutter 40-5380 with central internal cooling erschien zuerst auf HAM Präzision.

With the new powerful trochoidal milling cutters from HAM, users can machine workpieces even faster, with a higher quality and more reliable process. The tools with cutting lengths of 3xD and 4xD are particularly suitable for machining different types of steel, INOX and grey cast iron…

With the new milling cutters, HAM has expanded its range of trochoidal milling cutters in response to the increasing demand for longer cutting edges for shorter machining times. The HAM 40-5191 in 3xD and HAM 40-5291 in 4xD achieve very good machining results in trochoidal and high-speed milling. The tools are made of special solid carbide (VHM). They are provided with a resistant coating. HAM offers these tools with MMP TECHNOLGY, a new polishing process for mirror-smooth surfaces. Milling tools treated in this way have significantly better surfaces than conventionally polished tools. Due to the long tool life, users achieve economical machining processes. As a five-cutter, the milling cutter convinces with a very high cutting volume.

HAM has applied its extensive know-how in the development of tools and geometries to the new cutters. Important design features are the cutting edge pitch, the spiral pitch and the geometrically balanced cutting area. As a result, the milling cutters work particularly quietly, cause hardly any vibration and thus ensure reliable processes. When selecting the spiral pitch, HAM has taken care to ensure that both types have five ACPs (Axial Contact Points) each. This allows the tool to position itself optimally in relation to the component, thus enabling continuous machining.

Both tool variants have special chip breakers. This produces particularly short chips which can be easily removed. At the same time, it prevents metal parts that are too long from damaging the workpiece and disturbing or even interrupting the process. The HAM 40-5191 version is available in diameters from 6 to 20 millimeters. The HAM 40-5291 version is available in diameters from 10 to 20 millimeters. Customer-specific tool designs are possible at any time on request.

Der Beitrag Trochoid cutters from HAM erschien zuerst auf HAM Präzision.

They are the exotics among the materials: Materials such as CFRP, titanium, honeycomb or aluminium are convincing due to their high strength combined with low weight and are preferably used in the aerospace industry. However, they place high demands on machining. HAM has been dealing with this topic for years and has developed a multitude of powerful standard and special tools. They score with long tool life and achieve very good surface finishes…

High-Performance Precision Tools from HAM for CFRP, Titanium, and More

While carbon fiber-reinforced plastic (CFRP) and titanium have been in use in the aerospace industry for quite some time, such modern materials are only gradually gaining acceptance in the automotive industry. These materials are certainly very popular among designers: they are lightweight yet strong and stable. Fiber-reinforced composites such as CFRP, for example, consist of a matrix material and reinforcing fibers. This combination makes the material highly durable. Aluminum is preferred in applications where weight is a critical factor, such as in aircraft. Its low density results in significant weight savings. The honeycomb structure consists of plastics or aramid fibers coated with various cover layers. This significantly increases stability. Titanium and its alloys are characterized by low density and high strength. These materials can withstand extreme thermal loads and are corrosion-resistant.

Machinists Face a Major Challenge

What they all have in common is that they pose major challenges for machinists. The specific properties of these materials make it very difficult to achieve reliable, high-speed machining with high surface quality. For example, CFRP is highly abrasive, which leads to significant tool wear. Especially with materials that have a high resin content, chipping frequently occurs during machining. The inhomogeneity of CFRP and other composite materials places considerable stress on the tool cutting edge. The material is machined into a powdery form. Excessive heat input can lead to undesirable fusion. For reliable machining, selecting the right tool, the appropriate geometry, and determining the suitable cutting parameters are crucial.

Honeycomb, which is lightweight yet resistant to bending, is often used between the inner and outer skins of aircraft or in the blades of wind turbines to provide support and rigidity. However, the material consists of a relatively loose composite, which means it can fray easily during machining. This requires extremely sharp cutting edges. The challenge in drilling and milling lies in ensuring not only contour- and dimension-accurate machining but also high-quality cut edges and surfaces.

Significant heat build-up at Titan

Machining titanium and its alloys generates a great deal of heat. This heat is absorbed not by the material itself, but by the cutting tool. Therefore, the correct geometry and coating must be selected to prevent premature tool failure. In addition, milling and drilling titanium often produces long chips that can wrap around the workpiece or tool and interrupt the process. Machining aluminum is comparatively the least problematic, as it can be performed at high cutting speeds. However, machinability depends on the alloy’s composition. Work-hardened or hardened aluminum is easier to machine than soft aluminum.

HAM has been intensively engaged in the machining of modern materials for years and has developed tools that master the challenges posed by these exotic materials. For example, HAM’s double-edged solid carbide special contour milling cutter delivers impressive results when producing grooves of various depths in honeycomb panels with a cover layer on both sides. At a cutting speed of 376 meters per minute and 20,000 revolutions per minute, it achieved a virtually burr-free surface. There was no fraying of the films. With a tool life of 450 meters achieved in long-term tests, the milling cutter has proven its process capability for series production.

HAM Countersink Drills for Top-Quality Finishes

A common application in CFRP is drilling and countersinking rivet holes in a single operation. The key challenge is to prevent burrs at the entry and exit points of the hole. To address this, HAM has developed a solid carbide (VHM) drill and countersink. With its special geometry and optimized diamond coating, it meets the requirements for component quality and tool life. The tool achieves dimensionally accurate bore diameters and countersinks. There is no fraying between the material layers, and the surface quality is excellent. The HAM 40-7640 PCD-HPC shank-on milling cutter, for example, enables high feed rates and cutting speeds when milling CFRP. In practice, this polycrystalline diamond tool delivers high material removal rates. Efficient cooling is provided centrally through the clamping screw.

With the One-Shot Drill, HAM has developed a high-performance tool that enables the drilling and reaming of sandwich components—as well as titanium—in a single operation. The diamond-coated tool facilitates the machining of titanium. In tests conducted at a cutting speed of 25 meters per minute, the drill achieved a precise diameter and high surface finish. Minimal-quantity lubrication prevents excessive heat buildup at the cutting zone of titanium components. In addition, the tool produces short chips that are easy to dispose of. The One-Shot Drill also delivers impressive results on sandwich components made of CFRP, titanium, and aluminum. It prevents fraying in the CFRP layer, and the drill exit is virtually burr-free.

The use of modern materials will continue to grow in the future. The design advantages offered by these exotic materials are simply too tempting to ignore. Manufacturers of precision tools will continue to face challenges. HAM will continue to work closely with its customers to address this issue in depth and develop suitable tools for the efficient and cost-effective machining of CFRP, titanium, and other materials.

Der Beitrag A firm grip on the exotic erschien zuerst auf HAM Präzision.