Twist Drills for Success (A Dave & Davey Video)

By David Wynn

Published Issue June 2023

 

View Cribsheet

 

In today’s world it seems that all information is tailored toward carbide drills. Carbide drills are great, but how many do you really use every day? Especially in our small-to-medium quantity job shops? It is likely that we use mostly standard HSS twist drills. It is not economical to buy expensive carbide drills for shorter-to -intermediate runs. The problem is that most of the available data and recommendations are tailored toward carbide drills. It is important that we still understand the basics of twist drills. How do you know when to use what type of drill? What is the geometry you want to have? What type of flute do you want to use?

In carbide drilling it is recommended to pilot instead of spot drilling. On the other hand, with standard twist drills it is generally recommended that we spot drill. Following with
angles that are greater than or equal to the last drill point. For instance, follow a 90-degree spot with a 118-degree drill. If you drill with a 135-degree parabolic you can’t follow
with a 118-standard drill – it will walk off center. This can be especially important for parts with multiple ID dimensions, and using non-carbide drills.

When drilling in tougher materials such as stainless, high-carbon steels and most alloys, multifaceted grinds help reduce the cutting forces at the tip and help to pull the chip. This is where parabolic drills shine. Today almost all parabolic drills are made with split points allowing them to be self centering. I have found that it is better to spot drill even when using a split point drill. The parabolic drill allows chips to flow out of the hole rapidly while still allowing coolant to reach the tip.

If the hole is greater than 3 to 4 times the drill diameter, I would recommend pullouts. With HSS twist drills, pull all the way out of the hole to allow the coolant to flood the hole and remove chips. This will also allow the tip of the drill to cool before reentering the cut. On CNCs with modern G83 peck cycles, I like to pullout to .100” in front of the hole. There is a small dwell on the pullout of the peck cycle, but if you are drilling tough material it would be beneficial to increase the dwell. Write your own cycle-increasing dwell times. Also, you can get the optimum pullouts going 3.5x drill diameter first peck, 2x drill diameter on the second peck then about 1x drill diameter (1-1.5x diameter) on all pecks after the second peck. The deeper the drill goes the more difficult it is to remove chips and get coolant to the cutting tip.

It is not recommended to try to achieve tolerances less than +/-.002 without reaming or boring. Here are some recommendations for twist drills for different materials often machined in our shops. In the light metals and those having high thermal expansion, it is recommended to use standard drills because holes cut tight. See chart below.

 

Get An Edge – Paint Your Edge!

By David Wynn

Published Issue May 2023

 

https://www.productionmachining.com/articles/craftsman-cribsheet-no115-paint-your-edge-to-gain-an-edge

View Cribsheet

 

 

 

This is not a discussion of children coloring their coloring page inserts from a children’s book. I am literally asking how many of you out in the shop color your carbide inserts. If you don’t color them, then how do you know what edge is good? What edge is bad? This is a simple visual management tool to help our shop performers identify the edges that will result in trouble-free production. No matter when you go back to a holder, you always know where that insert stands. Visual management gives an immediate positive report on the status of the tool. No more guessing if the edge has been previously used. It looks good. How do we know?

It is often hard to tell when an insert is worn. The obvious ones are the chipped out or cracked in half. How about when you get a job that requires tight surface finish requirements and a worn insert is totally unnoticeable other than the resulting cut. This is where a paint marker designed to mark on oily surfaces comes in handy. The simplest solution is a one-color system. Red for a bad edge and that is it. But consider a three-colored approach to enable the most life out of your inserts:

Red for bad edge. You are not using this edge again no matter what. Used 90% of the time.

Yellow for reusable edge. You would not use a yellow edge on a part that needs some super surface finish or tight tolerance, but when you have a ± 0.015″ bushing and just need a cutoff insert, this will definitely work. Used about 7% of the time.

Green for good edge but has been used. This is reserved for only those times you go to the lathe and drill a hole in a 12L14 or 360 brass ejector. This drill is still brand new, but the color lets us know it has been used. Used less than 3% of the time.

The next time you go to a drawer and look at a load of holders and wonder which of these inserts are used, look for your colored edge so that you know. Better yet, put the inserts away instead of leaving them in the holder. Now you can go to a box of inserts and easily see how many edges you really have. How many times have you ordered a box of inserts only to find 10 holders with that insert already in it? Visual management by applying simple color codes to your tooling will save you thousands of wasted dollars in inserts of uncertain status, locked up in holders. So, add a little color the next time you go to change an insert. Add a little color and you will always have confidence in the status of your edge. Use visual management to give you an edge!

 

 

PMPA Speaking of Precision Podcast:

2023 PMPA National Technical Conference Wrap Up

Miles Free & Carli Kistler-Miller review the recent 2023 PMPA National Technical Conference in Cleveland, Ohio and the positivity it showed us about precision machining!

Published May 8, 2023

 

 

PMPA Business Trends March 2023

Our shops have had two extraordinarily strong years of sales and production. March sales return to that trend. Our Business Trends Sales Index- at 169 for the month of March- was unexpectedly high. It was the fifth highest level of sales we have ever seen for our Business Trends  Sales Index. And it was up 13.7 percent over the five year average for March. Our first quarter sales is accordingly high, just under 4 percent lower than the 2022 full year calendar year average. The demand for the precision machined components produced in our shops remains high. Sentiment for lead time for next three months tells us that backlog is solid. Precision Machined products manufacturing is thriving.

 
If you are not currently participating in PMPA’s Monthly Business Trends reporting, you are missing an excellent peer benchmark and a tool to provide you with confidence for your business decisions. Contact Veronica Durden to sign up.

 

VIEW/DOWNLOAD

 

STATE OF MANUFACTURING – Wisconsin Manufacturing

by Joe Jackson

Marketing & Events Assistant, PMPA

Published May 1, 2023

Fabricated Metal Products Manufacturing is a subsector of manufacturing that makes critical goods from metal components.

Precision Turned Products Manufacturing is a subsector of fabricated metal product manufacturing that makes the components that MAKE IT WORK!

 

WISCONSIN ECONOMIC OUTPUT

Wisconsin Manufacturing
NAICS 31-33
$64,880,000,000

Fabricated Metal Product Manufacturing
NAICS 332
$15,223,624,000

Precision Turned Product Manufacturing
NACIS 332721
$769,376,000

WISCONSIN MANUFACTURING ACCOUNTS FOR

Manufacturing Is Productivity –19% of Wisconsin’s total output (GDP)

Manufacturing Builds Businesses – 9,754 manufacturing establishments in the state of Wisconsin

Manufacturing Creates Jobs – Jobs: 17% of all Wisconsin employees are in the manufacturing sector. (475,300 employees)

Manufacturing Earns Export Dollars – Wisconsin manufactured goods exports were valued at $23.71 billion last year.

 

Manufacturing produces for WISCONSIN!

  • Manufacturing is Wisconsin’s largest industry
  • Manufacturing is Wisconsin’s largest GDP producer and the source of their largest exports.
  • Fabricated Metal Manufacturing is the 3rd largest sector in Wisconsin’s manufacturing economy.

 

Wisconsin is a great place for a career in manufacturing

  • Manufacturing jobs pay, on average, 45% more than the average job in Wisconsin with an average salary of $79,864 per year.

 

Sources: NAM.org, IndustrySelect.com, US Census, wicmp.org

Data selected to show relative values. May not be directly comparable due to differences in sampling, analysis, or date obtained.

 

Download Magazine Article

 

 

 

Author

Joe Jackson

Marketing & Events Assistant, PMPA

Email: gro.apmp@noskcajj — Website: pmpa.org.

PMPA Craftsman Cribsheet #115:
Paint Your Edge to Gain an Edge!

Kindergarten skills for the shop. Do you color your inserts?

Published May 1, 2023

By David Wynn, Technical Services Manager, PMPA

This is not a discussion of children coloring their coloring page inserts from a children’s book. I am literally asking how many of you out in the shop color your carbide inserts. If you don’t color them, then how do you know what edge is good? What edge is bad? This is a simple visual management tool to help our shop performers identify the edges that will result in trouble-free production. No matter when you go back to a holder, you always know where that insert stands. Visual management gives an immediate positive report on the status of the tool. No more guessing if the edge has been previously used. It looks good. How do we know?

It is often hard to tell when an insert is worn. The obvious ones are the chipped out or cracked in half. How about when you get a job that requires tight surface finish requirements and a worn insert is totally unnoticeable other than the resulting cut. This is where a paint marker designed to mark on oily surfaces comes in handy. The simplest solution is a one-color system. Red for a bad edge and that is it. But consider a three-colored approach to enable the most life out of your inserts:

Red for bad edge. You are not using this edge again no matter what. Used 90% of the time.

Yellow for reusable edge. You would not use a yellow edge on a part that needs some super surface finish or tight tolerance, but when you have a ± 0.015″ bushing and just need a cutoff insert, this will definitely work. Used about 7% of the time.

Green for good edge but has been used. This is reserved for only those times you go to the lathe and drill a hole in a 12L14 or 360 brass ejector. This drill is still brand new, but the color lets us know it has been used. Used less than 3% of the time.

The next time you go to a drawer and look at a load of holders and wonder which of these inserts are used, look for your colored edge so that you know. Better yet, put the inserts away instead of leaving them in the holder. Now you can go to a box of inserts and easily see how many edges you really have. How many times have you ordered a box of inserts only to find 10 holders with that insert already in it? Visual management by applying simple color codes to your tooling will save you thousands of wasted dollars in inserts of uncertain status, locked up in holders. So, add a little color the next time you go to change an insert. Add a little color and you will always have confidence in the status of your edge. Use visual management to give you an edge!

 

 

Markets Served — Who Knew?

PMPA members shared the markets they served in 2022. The top 5 may surprise you.

by Miles Free III

Director of Industry Affairs, PMPA

Published May 1, 2023

Every year, the PMPA does a survey of our membership to determine the critical topics they are seeing as we prepare
for our advocacy in Washington D.C. before Congress and working with executive branch agencies. This year’s survey
showed continued high interest in many areas of concern, particularly around expensing, depreciation and recovering research and development investments. But the surprising takeaway for me was to see how the percentage of shops serving the various market segments has changed just since last year.

Historically, the top five markets most heavily served by our North American precision machining shops have been light vehicle, aerospace, medical device and implant, industrial machinery and equipment, and agricultural equipment/off highway. One of the interesting facts is that in many years, the category “all other” is often the third or fourth largest category — our shops’ high precision, high-performance components empower many different systems in a wide variety of industries. This year, “all other” came in eighth position showing just how strongly the demand from our primary markets has been. This year’s surprise? Oil and gas customers were the second place market served with 61% of survey respondents reporting sales to that industry.

Industrial machinery and equipment came in first position, claiming shipments from 66% or two thirds of respondents.
Automotive light truck came in third position tied with medical with 55% of this year’s survey respondents producing parts for those industries. Agriculture and off road came in fourth place, tied with defense/ordnance at 53% of respondents producing for these industries. Aerospace, typically our shops number two or three industry in terms of
being served by our shops, came in fifth position, tied with heavy truck which is served by half of our survey participants.
Appliances, electronics, telecommunications, new/renewable energy (think solar, wind, hydro) and computer/business machines filled the remainder of named markets served.

Every shop is different, and even though many shops use similar machine tools, equipment and technology, each organization has its own strengths and focus as far as understanding and meeting customer requirements — both explicit and implicit. But what the shifting number of shops serving each of these different markets showed me is
that our shops also have a flexibility, an agility to meet the needs of the greater market. Yes, a shop may be a strong
provider of high-volume, low-mix critical components for autos and light trucks, but that does not mean they cannot
also be a supplier for a variety of other components in smaller quantities for other industries.

The greatest surprise to me, however, from this year’s survey results, was the strong showing of oil/gas as the market served by the second largest cohort of shops in our survey. I would never have thought that oil/gas — aka dinosaur juice, according to the pundits inside the beltway — would be the second most important market for our shops for contract parts production. And yet we are. This flies in the face of all of the policy and legislative initiatives for reducing CO2, climate change and ESG considerations in the federal government — I counted 54 separately listed entries in the Energy Information Administration’s Table 1 Included and excluded Inflation Reduction Act (IRA) provisions in the Annual Energy Outlook 2023 publication.

Despite the reports and forecasts of energy-related CO2 emissions falling 25%-38% below 2005 levels, our shops are
finding components for oil and gas to be the second largest segment of their current book of business. If we were to
add the percentage of shops also claiming renewable and new energy production orders market, the percentage of
shops serving “all energy” rises to number one position — with the largest number of our shops producing components.

Our takeaways? Despite all of the press attention on new and renewable energy, and CO2 reduction, the oil and gas market is surprisingly our industry’s second-ranked market served by percentage of shops responding. It is second to industrial machinery and equipment, ahead of automotive and light truck in third position, with medical and aerospace tying for fourth.  is ranking is quite an upset. All of these markets are human-safety critical, where requirements for safety, quality and integrity of product are of the highest importance.

For the old timers who think our industry is just about hose fittings and high volumes of commodity parts, our latest survey tells a much different story. We are the people that make things. Things that provide all of us with energy.
Energy that makes things go. Without energy there is no supply chain — nor need for one. Take the reports of the
impending death of dino juice and ICE vehicles with a healthy dose of critical thinking. While these markets are
expected to decline, our shops are currently finding plenty of opportunity to add value as they produce needed critical
components. In the long term, our parts count and book of business could shrink. But we were completely surprised
to see that the oil/gas market is, as of 2023, our second largest market served.

 

Author

Miles Free III is the PMPA Director of Industry Affairs with over 50 years of experience in the areas of manufacturing, quality and steelmaking. Miles’ podcast is at pmpa.org/podcast. Email Miles

Human Resources: Brenda Diehl and Diane Ferrera

Two women share their journeys to manufacturing and human resources, and give advice to anyone seeking a career in manufacturing.

by Carli Kistler-Miller

Director of Programs & Marketing, PMPA

Published May 1, 2023

Parts don’t get made without employees and the Human Resources (HR) Department handles recruitment, retention, compensation, benefits, training and more. The list is much longer, but, at its core, HR takes care of the employees. Brenda Diehl is the HR manager for Bracalente Manufacturing Group in Trumbauersville, Pennsylvania, and Diane Ferrera is the director of human resources for AccuRounds in Avon, Massachusetts. Both women share
their journey to manufacturing.

Brenda Diehl’s Journey
Brenda earned a bachelor’s degree in political science, then took a job as a restaurant manager. Knowing it wasn’t a good fit, she took some business classes at the local community college and provided general office help for Bracalente through a temp agency. She learned as much as she could about the business and, when the position opened, the HR manager position was ordered to her. “I like to say Ron Bracalente and I grew up together at Bracalente,” she says. Brenda continues reflecting on her 34 years in HR, “The company continues to grow and thrive every day and so do we!” Brenda loves helping people and problem-solving. She enjoys making a difference in the employees’ lives, their families and being in a position to help the company.

Diane Ferrera’s Journey
After earning her associates degree in science, Diane worked for a food distributer and retail grocery chain, and was exposed to a broad range of business processes. She worked her way up to human resource manager while earning dual bachelor’s degrees in education and psychology/sociology.
She was then hired into manufacturing in HR, which led to her current position at AccuRounds. Diane enjoys working with people and enjoys learning. “For a small company with limited resources, AccuRounds is progressive and has a forward-thinking mindset,” Diane says. “I am privileged to be entering my 18th year at AccuRounds and I have seen countless improvements made to our work environment and culture.”

Advice to Women (or Anyone) Seeking a Career in Manufacturing
Brenda’s advice to those seeking a manufacturing career is, “Do it. Manufacturing in the U.S. isn’t going anywhere, A career in manufacturing provides it all — longevity, challenge, reward, community and connection. We need the best and the brightest. Commit to being something bigger than yourself.” Diane’s advice to those seeking a manufacturing career is, “Learning is a lifelong journey. There are different career paths available, and many skills are
transferable into other fields and industries, so don’t limit yourself. Manufacturing is waiting for you.”

 

Author

Carli Kistler-Miller, MBA has over 25 years of experience with
communications, event/meeting planning, marketing, writing and
operations. Email: gro.apmp@rellimc — Website: pmpa.org.

PMPA Speaking of Precision Podcast:

Live from the PMPA PMTS Booth

 

PMPA took the podcast on the road to PMTS in Cleveland, Ohio! Listen as a wide variety of guests drop by the PMPA booth.

Published May 1, 2023