High-Feed Cutters Keep Mold Shops Competitive
Ingersoll cutting tools designed specifically for high-feed machining helped these three mold-makers improve productivity on deep cavities and hostile combinations of layered material.

Insert Geometry Doubles Hard Milling Throughput
Insert geometry can make a huge difference in throughput, as demonstrated by the gains this manufacturer realized by swapping tools in a long-reach slot-finishing application in hardened tool steel.

Ballnose End Mills Increase Repeatability
Ingersoll’s Finish-BallRush indexable, fine-milling, ballnose end mill features an stable clamping system designed to increase repeatability.

Ingersoll Breaks Ground on New Facility
Ingersoll Cutting Tools has begun construction on a new facility at its campus in Rockford, Illinois.   In addition to housing an automated product distribution center, the 50,000-square-foot facility will enable the company to open up more production space in existing buildings and speed customer deliveries.

Ballnose Cutters Increase Machining Performance
Ingersoll’s Finish-Ball Rush ballnose cutters are designed to increase machining performance.

Replaceable Tip Drills Offer Stability
The pocket design and clamping system on Ingersoll’s Gold Twist replaceable tip drills provide stable performance after multiple tip indexes.

Performance Turning with Twice the Edges
Ingersoll’s Gold-Duty family of CNMX and SNMX turning inserts with HB chipbreakers are designed to deliver low cutting forces and quality surface finishes in medium to rough machining applications.

Cutters Designed for Steel and High-Temp Alloys
The Hi-PosTrio cutting tool line of indexable end mills and face mills features cutter diameters ranging from 0.625" to 6.00" and three insert sizes.

Two-Start Indexable Carbide Insert Hob
Ingersoll says its 2-Start indexable carbide insert hob nearly doubles productivity for machining gears with large numbers of teeth compared to single-start ICI hobs.

Long-Lasting Insert Turns Around Tough Inconel Job
By changing to a hex-shaped turning insert with a 45-degree lead angle, this shop saved thousands of dollars on a difficult Inconel turning application.

Performance Grade for Turning Stainless
Ingersoll’s CVD-coated series T-TINOX grades are said to improve productivity in stainless steel turning operations.

Mini High Feed Cutter with Four Edges
The Power-Feed+Mini high feed cutter from Ingersoll Cutting Tools features a high speed geometry with a double-sided, four-edged insert.

Indexable Mills Speed Cavity Cutting
Ballnose mills are a common choice for hogging out cavities on molds and form dies. However, these three shops have realized significantly faster cavity milling by switching to Ingersoll’s Chip Surfer modular tooling system, which features a cylindrical shape that keeps more of the tool engaged in the cut.

Insert Grade for Turning Stainless
The T-TINOX series of CVD-coated insert grades are engineered for turning stainless steel.

Tool for Shallow, High-Feed Cuts Speeds Roughing
“Feed fast, cut shallow.” This strategy, in combination with a cutting tool specifically designed to take advantage of it—the Power Feed+ from Ingersoll—enabled this shop to reduce cycle time on a tough prototyping job by a factor of five and increase insert life by a factor of six.

New Tool, New Strategy Allow Five Times Faster Roughing
This shop realized a tool designed for fast feeds and shallow cutting depths could reduce the roughing cycle time of a large shipyard component from 20 to 4 minutes.

Cutters Halve Cycle Time On Custom Racing Component
Seeking to improve production time on custom-built connecting rods for racecar engines, this shop invested in a light-duty VMC with an eye toward implementing high speed machining. Retooling with cutters from Ingersoll helped make the most of this new capability.

High-Feed Cutter Features Six Edges
The Power-Feed+ high-feed cutter utilizes a trigonal-shaped insert with six cutting edges designed for performance and economy. The insert was engineered for high speed machining and features strong, heavy edge prep as well as durable, wear-resistant substrates and coatings, the company says.

Cutter Enables Hard-Part Milling On Light-Duty VMC
SPX relies on its small die shop to provide the tools needed to manufacture its service, testing and maintenance equipment for automotive and agricultural dealerships. With a limited number of machines, the die shop had no choice but to use a light-duty VMC on a process for which it is ill-suited—cutting hardened steel. To avoid jeopardizing the machine’s ceramic spindle bearings and other components, the shop implemented a face mill from Ingersoll Cutting Tools that enabled higher feeds and speeds while reducing cutting forces and spindle load.

Face Mills Offer Edge Strength, High-Feed Capability
Ingersoll’s SP6H/SP6N series of S-Max high-feed face mills is said to combine robust edge strength and high-feed capability, providing a hybrid approach to machining applications. The high-feed capability is made possible by an 80-degree lead angle for a 5x chip thinning factor. Two insert choices consist of a mult

High-Feed Face Mills

Taking The Plunge
It doesn't take sophisticated technology to perform plunge roughing effectively. In fact, if you are making due with a less effective machine, plunge roughing deserves even more serious consideration. (Includes video.)

Die/Mold Cutter Accepts Serrated, Button Insert Styles

Turning Tools Capable Of High Feed Rates, Low Cutting Forces

Realizing Large-Scale Savings On Large-Scale Parts
Converting big square bars to largely round tie bars used to require 24 hours per piece at Oak Products. The Sturgis, Michigan, company can now complete the same job in 8 hours. How did the company slash its machining times and realize substantial cost savings? Oak attributes the turnaround to process re-engineering involving aggressive mill-turning and tooling geared to stand up to the challenge.

High Feed Rate Cutting Tips

Face Mills Produce Smooth Surface Finishes

Tools For Titanium
With all of the titanium that will be required for a new aircraft, any of 1,000 spindles might benefit from the tools and techniques described here.

How To Succeed At Failure
Your cutting tool’s failure mode may be telling you what to change about the process. Not every failure mode is the same, and one mode is preferable to all the others.

Tangential Milling Helps Foundry Speed Operations While Reducing Costs
There are always exceptions to those 'hard and fast' machining rules. A tripling of edge life and a 3-to-1 reduction in cutter count on a tough-cast steel milling job at Harrison Steel Castings Company (Attica, Indiana) proves this.

Carbide Prices Bring Attention To Replaceable Tips
Small-diameter milling and drilling tools with replaceable tips not only save on carbide cost, but also save on tool management and inventory costs.

High Speed/Feed Milling In Aluminum

Shop Modernizes With Cutting Tools
Shop owners dealing with offshore competition might gain some assurance-and a few ideas-from Duane Gushee of D&G Machine Products, Inc. The company performs fabrication and machining of large parts for turbines, chemical equipment and aerospace structures. Incorporating what it refers to as "smart modernization" has allowed D&G to recapture work that had started moving to China and Romania.

Modular, Adjustable-Depth Combination Tools

The High Feed, High Reliability Process
When button cutters and high-feed mills are used properly, feed rate and confidence go hand in hand.

Top Ten Tips For Tooling Productivity
Here are 10 suggestions for improving the effectiveness of metalworking processes.

Milling Cutter With High Feed Rates

Precision Face Mills For Aluminum

Indexible Back Drafted Finishing Cutters

Start With The Right Speeds And Feeds
Running rotary milling cutters at the proper speeds and feeds is critical to obtaining long tool life and superior results, and a good place to start is with the manufacturer's recommendations. These formulas and tips provide useful guidelines.