Cleveland OH – Jergens introduces its new Washdown Tool, a clever device that provides 360 degrees of spray using coolant flow to wash away chips from exposed surfaces.

The in-between-processes tool is programmed inline (as with any standard tool) after a predetermined number of machining cycles. The Washdown tool provides thorough chip removal from the many exposed surfaces inside the machining area. In turn, this saves time for operators by reducing the time spent cleaning chips from a machine interior, workpiece, or workholding setup.

The unit uses multiple spray nozzles on its circumference, providing a steady and pressurized stream. Each nozzle can be plugged or opened to create customized spray patterns. Added spindle rotation ensures that coolant reaches virtually everywhere inside the machine.

​Residing in the tool changer, and programmed just as any other, the Jergens Washdown Tool is deployed periodically at scheduled intervals. This automation shortens cleaning time and supports long machining cycles, even lights out manufacturing periods when no operator is present.

“Any aspect of the machining process, even something as simple as cleaning chips, that can be made more systematic and repeatable will allow for greater productivity and reduced scrap”, said Mike Antos, Jergens Workholding Product Manager. “The washdown tool is another way of helping them (customers) achieve that”, continued Antos.

​JMI CNC Tooling & Automation is proud to announce the participation of our esteemed principals at IMTS 2024 in Chicago.

​This premier manufacturing technology show, which runs from September 9-14, 2024, will feature innovations and products from leading companies represented by JMI, including Achteck, BRM Brush Research, Blue Photon Workholding, GMN Spindles, Jergens Workholding, MAQ Devibe Tooling, Pratt Burnerd America, and Widen Cutting Tools.

These industry leaders will showcase their latest advancements and solutions, highlighting their commitment to excellence and innovation in the CNC tooling and automation sectors.

Achteck is one of the world's fast growing manufacturers of carbide cutting tools, friction materials, wear resistant items, and civil engineering products.

Brush Research Manufacturing is a leading American manufacturer of premium quality power brushes, twisted-in-wire brushes, and the BRM Flex-Hone Tool. Focused on creating solutions for metal surface finishing, deburring, cleaning and polishing, Brush Research sells products domestically as well as exports products to a global network of distributors.

Blue Photon’s patented workholding products are a manufacturer’s solution to hold parts for tight-tolerance machining and inspection. Blue Photon designs and manufacturers grip technology for complex-shaped, and hard-to-hold parts. Blue Photon grippers are easily installed into fixtures to grip and support the part without the use of mechanical clamps.

GMN USA is the North American Spindle Sales and Service Center for GMN Paul Mueller Industries, a world-wide supplier of high-speed machine tool spindles, high precision bearings, clutches and seals

Jergens Inc is a global manufacturing leader of CNC machining custom workholding products. Today, you'll find their vises, clamps & fixturing systems, tooling components, at work in just about every segment of the metalcutting industry on every continent. And our innovative engineered solutions like the patented Ball Lock®️ Mounting System and Fixture-Pro®️ 5-axis workholding have changed the way manufacturers worldwide think about metalworking productivity.

Pratt Burnerd America is in the business of supplying quality workholding products for CNC Lathes and turning machines throughout North America. They have one of the largest varieties of rotary workholding products in the world, with Power Chucks, Manual Chucks, Collet Chucks, Collets, Special Chucks, Rotating Cylinders, and Workholding Accessories. 

by Bernard Martin

The International Manufacturing Technology Show (IMTS) 2024 is just around the corner, and JMI CNC Tooling & Automation is excited to highlight the exceptional innovations our represented companies will showcase at the event.

Taking place from September 9-14 in Chicago, IMTS is the premier platform for exploring the latest advancements in manufacturing technology. As you plan your visit, make sure to stop by the booths of the following JMI-represented companies.

Here's a sneak peek at what you can expect to learn about in each to these booths!

At Achteck America Inc.'s booth you can learn about their broad range range of cutting tools.

Achteck offers both indexable and solid carbide tools designed for turning, milling, drilling, and grooving across materials such as steel, stainless steel, heat-resistant alloys, and more.

With an extensive inventory maintained in Michigan, Achteck stands out for their competitive pricing and ability to meet the needs of both general-purpose and specialized machining tasks, including Swiss tool, heavy-duty turning, and railway wheel turning. Their innovative grooving inserts, milling cutters, and solid carbide drills are perfect for those looking to enhance their productivity and precision in manufacturing operations.

• West Building, Level 3 — 431258 — Tooling & Workholding

At AB Tools booth at IMTS 2024 you can learn about top-quality, USA-made cutting tools that have been trusted by professionals since 1977.

As the home of the renowned Shear Hog®, AB Tools specializes in a range of innovative solutions including indexable dovetails, O-ring grooving tools, keyseat cutters, and precision firearms tooling. With an impressive turnaround time of just 5-6 workdays for custom specials, AB Tools ensures you get exactly what you need, when you need it.

• West Building, Level 3 — 432264 — Tooling & Workholding

Visit Blue Photon’s booth at IMTS 2024 to learn about their unique adhesive workholding solutions, designed to hold parts securely without the distortion that comes from traditional clamping.

Whether you're working with hard-to-hold, easily distorted, or brittle parts, Blue Photon’s technology is the perfect fit, especially for applications in milling, turning, grinding, and more. Their system is ideal for a wide range of industries, including aerospace, medical machining, and optics. Plus, with the ability to integrate zero-point systems, you can automate your workholding processes with unmatched precision.

• West Building, Level 3 — 431446 — Tooling & Workholding

At BRM - Brush Research Manufacturing Co., Inc. at IMTS 2024 to explore their industry-leading solutions for improving surface finishes and deburring.

Known for their Flex-Hone Tools and abrasive brushes, BRM's products are essential for achieving superior surface quality in a wide range of applications. Whether you're working with metals, composites, or other materials, BRM offers tools that enhance performance and extend the life of your components

• North Building, Level 3 — 237148 — Abrasive Machining/Sawing/Finishing

Be sure to visit GMN USA’s booth at IMTS 2024 to learn about their high-performance spindle technology firsthand. Known for their precision and reliability, GMN spindles are designed to meet the demands of high-speed machining across various industries.

Whether you’re involved in aerospace, automotive, or any other field requiring top-notch machining capabilities, GMN’s products can enhance your production efficiency and quality.

• North Building, Level 3 — 237065 — Abrasive Machining/Sawing/Finishing

Visit Jergens' booth at IMTS 2024 to check out their 5 axis machining workholding solutions designed to boost productivity and precision in your machining operations. Jergens will be showcasing their 5CV 130mm self-centering vise, perfect for high-accuracy clamping and ideal for various machining applications.
Additionally, check out their Tooling Columns, which provide robust and flexible workholding options to maximize machine output. Don’t miss the opportunity to get a demo on the Jergens Ball Lock® Mounting System, a quick-change solution that drastically reduces setup times, allowing for fast and repeatable fixture changes.

• West Building, Level 3 — 432154 — Tooling & Workholding

Visit MASA Tool's booth at IMTS 2024 to discover the innovative Microconic™ system, specifically designed for precision workholding in CNC Swiss machining.

This cutting-edge system is ideal for holding workpieces ranging from Ø0.15mm to 10mm (Ø0.006" to 0.390") in any machine with a collet-type chuck.

The Microconic™ system consists of two major components: the Microconic™ cartridge, which replaces standard collets such as 5C, TF15, TF16, TF20, TF25, or TF37 in your CNC machine spindle, and the Microconic™ collet, which fits seamlessly into the Microconic™ cartridge. This setup ensures micron-level accuracy and repeatability, making it perfect for industries that require extreme precision, such as medical devices, aerospace, and watchmaking.

• West Building, Level 3 — 432163 — Tooling & Workholding

Visit Pratt Burnerd America's booth at IMTS 2024 to explore their high-quality lathe chucks, known for delivering unmatched precision and durability. As a trusted name in workholding solutions, Pratt Burnerd offers a wide range of products, including manual, power, and special application chucks that are designed to enhance the performance of your CNC machines. Whether you’re looking for innovative rotary workholding solutions for standard or custom applications, Pratt Burnerd has the expertise and products to meet your needs.

• West Building, Level 3 — 431384 — Tooling & Workholding

Visit Tapmatic’s booth at IMTS 2024 to explore their extensive range of innovative tapping solutions and toolholders designed to optimize your machining processes.

Tapmatic is best known for their high-performance tapping heads, which are engineered to reduce cycle times, enhance thread quality, and significantly extend tool life. But that's not all—Tapmatic also offers cutting-edge tools like the Scribewriter for precise marking, the DeBurr-Z tool for efficient deburring, and the TapWriter Dot Peen Marking tool for robust and permanent part marking. Whether you're in need of tapping solutions or advanced marking and deburring tools, Tapmatic has the expertise and products to elevate your production capabilities.

• West Building, Level 3 — 431246 — Tooling & Workholding

Five-axis machining has built its reputation in the metal manufacturing world through the many advanced machining strategies that are impossible without the additional rotational axes that set it apart.

​However, many manufacturers have found great benefits in 3+2-axis manufacturing techniques, using the rotational axes to reduce setup time. This approach can provide a firm foundation for highly automated machine cells such as the ones I found at Clippard Manufacturing, a Cincinnati-based valve manufacturer and machine shop.
​

Clippard began in the 1930s as a manufacturer of radio parts. Its early claim to fame came during World War II, when it manufactured coils for the Allies’ radio-based proximity fuse — one of the most successful weapon technologies developed for the war. Over subsequent decades, the company pivoted to pneumatic valves for various industries, especially the medical industry. More recently, the company has also begun working as a contract manufacturer of medical parts, putting its experience meeting the exacting standards of the medical industry to further use.

The company’s first foray into heavy automation was in its fleet of 20 Swiss-type lathes, which found success working lights-out. Using this success, Manufacturing Engineer Alex Werdman convinced the company to invest in a five-axis Haas UMC 500 SS with a 16-station pallet changer to perform work that had been done on three-axis mills. The company made this investment with the intention of developing lights-out processes for the machine cell, but getting to that point meant investing in more than just the machine tool.

One of the major draws of a five-axis machine was the ability to dramatically reduce setup time by machining multiple faces of parts in a single setup. According to Werdman, the move to the five-axis Haas made the jump to high-mix medical work much easier. “Being able to reach more faces of the part reduced the setup time for secondary operations by a lot,” he says. “Jobs that took 45 minutes per part on a three-axis were down to 27 minutes.” CNC Programmer Kyle Shearer agrees, saying, “I might touch a part 17 times before and only four times now.” However, this strategy relied on workholding that provided the cutting tool as much access to the part’s faces as possible.

At first, Clippard considered using dovetails, but after a conversation with Jergens representatives and distributors, the company opted for vises with modular jaws. “We thought we would have to use dovetails,” Werdman says, “but the vise has enough grip force and clearance to meet our needs.”
​

​And did this work pay off? “The Haas proved that five-axis machines were worth it,” Werdman says. “We could get 50 hours a month on the three-axis mills, and with fiveaxis we get 200-300 hours.”

The success of the Haas spurred Clippard to invest further in five-axis machining with a Matsuura MAM72-35V, intended to both increase the volume of parts the company could produce lights-out and improve the precision of its fiveaxis machining.

The Matsuura came standard with a 32-station pallet changer in a condensed footprint, dramatically increasing the capacity for lights-out machining. Like the Haas, it regularly puts in over 200 hours of machining time, mostly performing 3+2-axis machining. It can also pursue more aggressive machining strategies while maintaining the finish needed, as it can maintain a tolerance of ±0.0005 inches.
​
Despite being one of the major benefits of five-axis machining, this kind of dramatic increase in capacity and production speed is often overlooked by machine shops. Not all fiveaxis machines produce near-net shapes or large contours, and shops like Clippard have found great success thanks to careful consideration of the machine cell as a whole.

​“The people in charge needed convincing,” Shearer says, “but once they saw how much more we could get done and how quickly we could do it, they were on board.”

Join Jones Marketing at SOUTHTEC 2023 - October 24-26, 2023! 

​We're a premier Manufacturers' Representative Agency will be featuring innovative metal cutting technologies from a distinctive group of high performance tooling & workholding suppliers. Some with no known competitors!

The Southeast is experiencing exceptional growth in areas critical to the economy, such as aerospace, automotive, advanced materials and workforce development – making the region a hotbed for advanced manufacturing.

SOUTHTEC is designed to give manufacturers the means to discover and acquire the tools needed to drive the next evolution of their industry.

SOUTHTEC creates a greater opportunity to engage first-hand with world-class suppliers and identify solutions needed – from development to final production.

Save the date for SOUTHTEC 2023 - October 24-26, 2023.  ​

And don't forget to visit our other partners while you're at the show!
​You can click the links below to add them to your show planner:

• Blue Photon Technology & Workholding Systems LLC  - booth 1934
• GMN USA  - booth 1936
• Jergens -  booth 1928
• ​Tapmatic Corporation & OMG North America - booth 1931

Jack Rushlander from Jergens workholding talks about how advancements in 5 Axis CNC machining technology has changed dramatically in the past 20 years. Dynamic Work Offsets and other capabilities have made workholding easier but also given shops even more opportunities to to improve process and reduce cycle time.

5-axis machining is a game-changer in modern manufacturing, allowing for the creation of complex, precise parts with unparalleled efficiency. By enabling simultaneous movement along five axes, this technology significantly reduces the need for multiple setups, resulting in improved accuracy and faster production cycles. However, while its benefits are transformative, the challenges and considerations associated with 5-axis machining are equally significant.
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One of the most striking advantages of 5-axis machining is its ability to streamline operations. Complex geometries that would traditionally require multiple setups can now be completed in a single run, reducing production time and minimizing the chance of errors. This capability not only enhances precision but also eliminates the need for extensive fixturing and repositioning, leading to higher-quality finishes.

Despite these advantages, adopting 5-axis machining is not without its hurdles. The machines are more complex and expensive than their 3-axis counterparts, requiring substantial investment in both equipment and training. Programming 5-axis operations is also more intricate, demanding advanced software and experienced operators who understand the nuances of tool paths and machine kinematics.

Success in 5-axis machining begins with thorough preparation. Selecting the right tools, understanding the machine's capabilities, and ensuring proper workholding are all critical. Matching the machine’s specifications—such as spindle speed, torque, and material handling capabilities—to the project requirements is equally essential.

Accurate part drawings and the right choice of raw materials lay the foundation for a successful operation. Clear, detailed drawings provide machinists with a reliable guide, while high-quality materials ensure both machining efficiency and final product performance. Tools like dovetail fixtures are particularly valuable for securing workpieces during machining, especially for intricate parts requiring multiple angles.

To maximize efficiency, leveraging tools like SolidWorks to define the machine's work envelope can help visualize part orientation and motion. This approach allows operators to identify potential collisions and optimize tool paths before production begins, saving time and resources.

Collaboration plays a crucial role in 5-axis machining. Consulting with machinists during the planning and programming phases can reveal practical insights and preempt potential issues. Troubleshooting is another vital aspect, addressing challenges such as tool deflection, chatter, and thermal expansion to maintain quality. Engaging additional perspectives—whether from colleagues or external experts—can also lead to valuable refinements in the process.

Lastly, clear and comprehensive communication with CNC programmers ensures that tool paths and machining strategies align with the project's goals. Providing detailed specifications, including geometry, materials, and tooling requirements, is essential for effective programming.

In conclusion, while this article covers key points about 5-axis machining, there’s so much more to learn about the process and its practical applications. For a detailed exploration of this technology, watch the full video below and see how Galactic Widget Company tackles the workholding of a Thingamajig and discover insights that can take your machining expertise to the next level.

• 00:00 - 01:35 Introduction
• 01:35 - 03:50 The Pros of 5-Axis
• 03:50 - 06:20 The Cons of 5-Axis
• 06:30 - 09:36 Process Essentials
• 09:39 - 11:53 The Machine
• 11:55 - 15:40 Part Drawing & Raw Material
• 15:50 - 19:45 When to Use a Dovetail
• 19:46 - 21:35 Start to Finish Operation in Drawings
• 21:36 - 30:38 Work Envelope in Solidworks
• 31:24 - 33:58 Analyze With Your Machinists
• 35:30 - 37:08 Troubleshooting
• 37:18 - 37:56 Getting Other Eyes on Your Project
• 38:00 - 39:40 The Process of Sending Project to Your Programmer
• 39:45 - 49:36 Questions

Jergens Inc. offers fixture plate machining kits and receiver bushing plugs for its line of Ball Lock quick-change mounting systems.
EDITED BY JEDD COLE  Production Editor, Modern Machine Shop​

The machining kits consist of one fixture plate, four extra-long Ball Lock shanks and four spacers that provide clearance between the fixture plate and subplate below. This open space allows cutting tools to “break through” the fixture plate without damaging the subplate, making it possible to machine fixture plates while mounted to the same subplates they will be used with during production, the company says.

The plugs are designed to prevent chips and coolant from accumulating inside receiver bushings that are not in use during certain operations. This saves time by eliminating the need to clean out the bushings between setups. The receiver plugs are made of blue anodized aluminum, providing durability for better resistance to hot chips when compared to plastic plugs.

The flush mount design means the plugs do not protrude above the subplate surface, making it easier to clean and avoiding interference during machining. These plugs are available in standard sizes to accommodate different hole openings and come with an O ring and tapped hole for easy installation.