Machining Doctor

📢 CNC Programming and Tooling Layout services by The Machining Doctor 👇

🟡 Finding skilled CNC programmers can be a daunting challenge, as this expertise is among the hardest to come by. That’s why we offer access to our CNC programming experts, dedicated to meeting your programming needs.

🟡 Working with the best tool for an operation and at the optimal cutting conditions is one of the core challenges in our industry. It’s also a common area where many professionals make mistakes. One of our top areas of expertise is selecting the best tools and recommending the correct cutting conditions.

📲 Learn more and schedule a free, no-obligation Zoom/Teams meeting: https://www.machiningdoctor.com/services/

📢 I am launching a series of posts with Machining Related statistics based on REAL DATA (One post per month).

💹 The data is taken from The Machining Doctor Speeds and Feeds Calculator, aka the SpeeDoctor🧮 If you have not tried it yet, Google "speedoctor" and check it out❗

💹 Thousands of you guys use it daily to get reliable feeds and speed recommendations. I have taken the most recent 300,000 queries and compiled many insightful industry stats.

💹 The first data set I am sharing is the usage in percentage between the main 4 machining applications: Milling, Turning, Drilling, and Parting/Grooving.

💹 What do you see in your surroundings? Share your thoughts in the comments below👇

➡ Follow me if so you won't miss the next stats❗

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In most cutting tool catalogs, you will come across a "code" code🔢code that looks like "P05-P15" / "K30-K45" etc… What On Earth Does It Mean🤷‍♀️

💡 This "Code" indicates the suitable application range for a specific carbide grade👇

How should you interpret it❓
The prefix Letter indicates the target material group for the grade. Usually, It also comes with a color code.
🔵 P – Steel
🟡 M – Stainless Steel
🔴 K – Cast Iron
🟢 N- Non-ferrous
🟠 S – Superalloys
⚪ H – Hardened Steel

🔢 The numbers are between 5 and 45 in increments of 5 (05, 10, 15…45), representing the "difficulty level" of the application.

🔸 05 – for the Most Favorable overall condition: Smooth Workpieces, very well clamped, machined by a firmly clamped tool with a short overhang.
🔸 45 - For The Least favorable overall condition: Interrupted cut on poorly clamped Workpieces and machined by a Long overhanging of the tool.

📚Examples:
🔸 P05-15: A grade dedicated to machining steel in very stable conditions.
🔸 P15-30, M15-30, K15-30, S15-25: An all-around grade for machining all material types (Except non-ferous) in general conditions
🔸 S15-25: A grade dedicated to machining Superalloys in general conditions.

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The approach angle📐 (KAPR) is the angle between the cutting edge and the workpiece in the feed's direction ➡.

What's the effect ❓

🔹 You can increase the feed by 1/SIN(KAPR). Suppose you are turning at a feed of 0.2 mm/rev with a 90° approach. If you change to 45° approach, you can increase the feed by 41% to 0.28 mm/rev (And the cutting edge will "feel" the same load.
🔹 The Samre rule also applies in milling
🔹 An externe use of this formula is Feed Milling, where the approach angle gets down to 10°, allowing a feed increase of X6.
🔹 Although it's counterintuitive, a smaller approach angle causes an increase in power consumption. The formula is complex, but you can expect an increase of around 10% when changing the angle from 90° to 45°

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Bye-bye, Chicago (IMTS), Stuttgart (AMB), here I come✈️
I am at the airport now, trying to digest an incredibly productive⚒️, hectic😳, and exhausting🥱 3 days at IMTS.

My main (and positive) takeaway is that despite the digital age, the value of human interaction in business remains irreplaceable. LinkedIn, Zoom, and emails may have their place, but they do not diminish our need for personal connections 🧑‍🤝‍🧑

People who would have never reacted to a digital outreach listened, paid attention, and helped out incredibly. Fantastic😊

f you are tapping, I am sure you came across this weird comment: 📃Recommended tap drill sizes (for approx. 75% thread)📃
What is this 75%🤔❓

🔷 The distance between the crest and root is called the thread height. The thread standards define the maximum thread height as 0.5413 times the pitch (for standard metric and inch threads)

🔷 In tapping, it is customary to express the thread height (Sometimes called thread depth) as the relation in percentage between the actual depth and the maximum depth: (Hmax-H)/Hmax*100

Why does it matter❓

🔷 Thread depth is a primary factor (Next to cutting speed) that influences a tapping tool's torque and life.
Increasing the drill size makes tapping easier and extends the tool-life of the tap. However, the strength of the thread is reduced, and the minor diameter can get out of tolerance.
It's an industry standard that the default thread depth is 75%. Therefore, in most charts, the value given for the tap drill size is 75% thread height.

🔷 But what if you want another size❓ simple❗
Head over to the Machining Doctor's Calculator, where you can choose the percentage and get the required Tap Drill Size accordingly.

🔗 https://www.machiningdoctor.com/calculators/tap-drill-size/

🚀 Exciting news, everyone❗
📢 We are thrilled to announce the launch of a new series of articles on The Machining Doctor Website about GD&T📏
🔗 The first ones, already live on the website, are the general overview and perpendicularity pages. You can find these under "Learning" in the top menu🔝
🔍 Going forward, we will be diving, one by one, into all the symbols and terms that make up this essential topic, providing you with a comprehensive resource 📚
📅 Stay tuned for monthly updates and expert insights on all things GD&T 💡

Programing a thread for a lathe should not have been a challenging job. After all, we have Threading Cycles (usually G76) in our CNC controller💻 that should do the job for us.

So what's the problem🤔

1️⃣ These cycles have many parameters, and the exact function of each one of them is not always intuitive.
2️⃣ Even the slightest error in any of the parameters could lead to unsatisfactory results on the machine.
3️⃣ To make things worse, the format has many variations between the different controllers.

💡 Recently, I delved deep into the topic and added a complete technical reference🎓 to The Machining Doctor. You will not find such a comprehensive guide anywhere else👇
💡 If you don't have the time or want to spend the time learning it, I added to the guide a G-code Generator💻 that will output the code based on all the parameters for your selected controller👇

🔹 Check it out and let me know in the comments💭 what you think and what I should add to improve it. (Link in the comments below👇)

📢 Introducing the first ever Machining AI Chatbot❗ Look for the Chat Icon💬 at the bottom left corner of every page on the Machining Doctor Website and start chatting about machining😊

Question Examples:
🔷 What is the difference between Up milling and Down milling?
🔷 Calculate for me the spindle speed for a 50 mm cutter at 100 m/min?
🔷 Please explain what Chip Thinning is
🔷 How much SFM is 300 m/min?

Please🙏 check it out and come back with your feedback in the comments below👇
Remember that this is a beta version and the starting point for something BIG❗ Your feedback will help us imprrove👍