A LOOK AT WHAT’S INSIDE

Valid from 1 March to 30th April. While stocks last.

ISSUE 16 • MARCH / APRIL 2016

RESPONSIVE? YES WE ARE! In more ways than one of course - we have always been responsive to your needs but have now added a responsive website to our list. Check out the new site now.

PAGE

2HITACHI G23MR GRINDER & LEAD

INSIZE 6 PCE MEASURING TOOL SET

PAGE

6

THE TRADE MAGAZINE BY ENGINEERS FOR ENGINEERS

PAGE

4

2 Order Online at www.tradetools.co.nz We accept

I’m hanging up my tools. Stepping down. Handing over the keys. There, I said it. My time as managing director of Trade Tools is up. Simon McLeay is taking my role (read his profile below). But don’t worry, I’ll still be around, keeping an eye on things, making our reps nervous, shouting at the odd supplier, and fulfilling my continuing role as a director of Trade Tools.

Last year I asked myself: am I still the best man for this job? And the answer – my answer – was “no”. I decided to step down as managing director because it’s time for a change. Not just because I’ve worked at Trade Tools since 1981 (the last 20 years as managing director) – an entire career – or, dare I say it, because I’m getting old (though it has been a few years since I ran a sub 2h 35m marathon).

The basis of my decision is mostly about you – our customers – and how Trade Tools must operate to keep you coming back and performing at the top of your game. To do so requires a skillset quite different to mine.

Last year I sat down with my fellow Trade Tools directors to ponder the future shape of our business. While the DNA of Trade Tools remains the same: high-quality

A WORD IN YOUR EAR

brands, good advice and friendly service, aspects of our business must change if we are to stay at the top of our game.

These changes mostly relate to technology and how it will make us better to deal with, by improving the way we deliver information, services and advice, and how we support global product search and buying. No matter how you deal with Trade Tools, we’ve got to bring everything together, so you get the tools, information and services exactly how and when you need them.

During these discussions I heard fancy terms like ‘omni-channel’ and ‘end-to-end customer experience’. Giddy stuff for an old boy who cut his teeth in the Trade Tools warehouse and still rates the introduction of email right up there with landing on the moon (though I will take some credit for equipping our sales team with iPads).

It was clear to me that my time was up; the old bull had to make way for younger blood. And that’s why I am so pleased that Simon accepted our offer to take up the role of managing director at Trade Tools.

Simon’s been an integral part of Trade Tools for the past eight years, spearheading important changes to our

operating structure and, more recently, launching a successful direct-to-consumer Trade Tools offshoot that has opened our eyes to the world of online commerce and how it can complement our face-to-face customer engagement (Simon will tell you more about that, later).

So this is it, folks – my last missive as managing director of Trade Tools.

It’s been a pleasure, a life’s work, a passion.

I’ll keep putting my oar in here; keep asking tough questions – don’t you worry about that. But it’ll only be for short bursts between fishing, cycling, paddling and other things I’d prefer to keep private.

Till next time –

JM

027 243 3302 | Simon@tradetools.co.nz

Simon McLeay has been appointed managing director of Trade Tools, taking over from John McGechie, who has stepped down after 20 years in the job. Simon has worked at Trade Tools for the past eight years, holding the position of sales and marketing manager and, more recently, overseeing the development and launch of a direct-to-consumer business offshoot.

Prior to Trade Tools he was the New Zealand marketing manager for Parker Hannifin-owned hose and fitting business ENZED.

MEET THE NEW CEO

Age: 45

Base: Auckland

Origin: Born in Southland

Family: Married to Sheelagh. Two kids aged 11 and 14.

Early Career: Spent eight years in banking in London.

Most Recent Past Role: Eight years with Trade Tools, including sales and marketing manager and head of special projects.

Business Philosophy: If you’re not willing to risk the usual, you will have to settle for the ordinary.

Plans: Provide Trade Tools customers with the best of both worlds: specialist workshop products and support, and easy online access to non-specialist tools and information from around the globe.

After Work: Cycles, bites tongue while supporting kids sport, drinks Speights….

Phone in your order: 0800 4 TOOLS 3We accept All prices exclude GST

30% OFF

THE ENTIRE RANGE

THE LEADING EDGE IN BURS There are burs and then there are ATA burs. ATA Tool Company is the world’s leading bur manufacturer. No one manufactures or sells more burs than ATA...and no one else offers a more diverse line of burs and a familiarity with your challenges. ATA burs are ideal for a wide variety of applications.

Safe, effective, consistent and comfortable performance - ideal for applications from handheld to robotic.

HMD917SC Our most powerful two speed mag drill for heavy duty fabrication. Large 60mm x 76mm capacity. Our most powerful high torque motor. Two Speed gear box - 250 & 450 RPM. Pilot light - for low light or no light conditions. Two stage magnet - 30% increase in power when motor is turned on . Positive slug ejection. Integrated coolant bottle. Many accessories are available for a portable machine shop including: drill chucks, tapping, countersink, and more...Feed handles quickly change from side to side. Lift detector safety system. Rear mounted controls.Carrying case included. One year warranty.

SUTTON DRILL BIT SETS

was $2,756

$1929.002645165

50PCE 1.00MM - 5.9MM X 0.1 RISES.

41 PCE 6.0MM - 10.0MM X 0.1 RISES.HSS Blue - The blue finish reduces chip build up on the cutting edge enabling a clean cut and increased tool life when drilling ferrous materials.

KAOJEN CARBIDE TIPPED HOLE SAWSNew extended size range 14 - 200mm x 18mm cut depth & 16 - 65mm x 40mm cut depth.

30% OFF

THE ENTIRE RANGE

was $215.60

$149.002120350

was $426.80

$299.002120510

HMD505Rugged, high powered drills for fabrication and high production environments. Two speed gear box - 250 & 450RPM. Positive slug ejection. Patented quill feed arbor for smooth cuts and minimal maintenance Two stage magnet. Engages full power when motor is turned on. Feed handles quickly change from side to side. Lift detector safety system. Rear mounted controls.Coolant bottle included. Optional Pressurized coolant system available. With coolant bottle and carrying handle removed drill becomes only 15"" (381mm) high. Carrying Case included. One year warranty.

was $2415

$1690.00 2645170

HASSAY SAVAGE KEYWAY BROACHESOur US-made broaches, cut more precisely, last longer and wear better than any other on the NZ market

25% OFF

THE ENTIRE RANGE

MAGNETIC BASE DRILLS

• HMD928 Powerfeed & coolant.• Compact lightweight power feed.• Smart technology optimizes feed rate forincreased tool life and excellent hole quality.• Single handle to engage power feed system.• Selectable manual/power feed mode.• Lift detector safety system.• Positive Slug Ejection.• Side mounted controls.• Gravity fed coolant bottle included.• Many accessories are available (manual mode only).• One year warranty.

was $2,910.94

$1995.002645150

GREAT FOR HORIZONTAL, OVERHEAD, TIGHT AREAS

4 Order Online at www.tradetools.co.nz We accept

$349.00W0000573

$959.00W0000427

$998.753326910

was $231.25

$169.003326335

$199.00W0000574

HEAVY DUTY EXTENSION LEADS TESTED & TAGGED10M - 3046160 20M - 304618030M - 3046200

$24.95

$39.95

$61.95

HITACHI 18.0V ENGINEERS KIT

HITACHI3/4DR BRUSHLESS IMPACT WRENCH. High performance 620Nm tightening torque. Unique Maintenance-free Brushless motor provides significantly longer life. Stable Performance under voltage drop situations from long extension leads.Stable Performance when used with Generators.

HITACHI 10MM HIGH SPEED DRILLCompact and lightweight,10mm keyed chuck, Variable speed by trigger and dial plus reverse, Maximum no-load speed 2300rpm, Rubberised non-slip housing.

Powerful 500W motor, Recessed 10mm keyed chuck, Low profile head only 83mm, Variable speed by dial, and reverse, All controls accessed while holding drill at the rear – gives maximum reach, Drilling Capacity -Wood 22mm, Steel 10mm charger and robust 2-tool carry case.

HITACHI 125MM BARE TOOL ANGLE GRINDER

FULLY COMPATIBLE with ALL earlier models of Hitachi 'slide type' cordless tools & accessories. High cycle life* - around 1500 recharge cycles.

18V 5.0AH LI-ION BATTERY

HITACHI• Powerful 790W motor• 13mm keyed chuck• Synchronised 2-speed gearbox• Variable speed by trigger• Dial plus reverse• Safety release clutch

was $873.75

$749.003327315

was $348.75

$239.00 3325580

HEAVY DUTY ENGINEERING DRILL

COMPATIBLE WITH ALL HITACHI 18V SLIDE BATTERIES

$493.753325540

was $148.75

$118.753325520

PERFECT FOR PILOT HOLES,RIVET HOLES ETC…

HITACHI DRILL/WRENCH COMBO KITIncludes:DS18DSDL 13mm PROSeries Driver Drill, Heavy duty model – 92Nm hard torque output, Heavy duty 2-speed gearbox with metal gear transmission, variable speed and reverse, WR18DSDL PROSeries Impact Wrench, Max torque: 255Nm, 1/2"" square drive, Variable speed and reverse, Supplied with 2x 5.0Ah Energy Li-ion batteries, fan-cooled smart charger and robust 2-tool carry case.

HITACHI 230MM INDUSTRIAL ANGLE GRINDER• 2400W motor with high overload durability • Super tough alloy outer casting with double- insulated polycarbonate inner layer • Easy to operate trigger switch • 3 position anti-vibration side handle • Tool-less guard adjustment • Low profile head for access into confined areas • Auto -stop brushes and anti- dust airflow for maximum motor protection

BONUS H.D 20MTR LEAD

As they say "there can only be one winner" and that was Al from Pedersen Industries Ltd in Kawerau. Congrats Al.

BONUS 125MM GRINDER

10MM ANGLE DRILL

LIMITED STOCK!!

Includes Driver Drill, 125mm Grinder, 255Nm Impact Wrench, 2 x 6.0Ah Li-Ion Batteries, Ultra-Fast Smart Charger, Carry case. Industry Leading Charge Time – Ultra-Fast Smart Charger – 38 mins for a 6.0Ah battery – 32 mins for a 5.0Ah! Industry Leading Battery Recharge Cycles – up 1500 recharges even using the Ultra-Fast Smart Charger!

Phone in your order: 0800 4 TOOLS 5We accept All prices exclude GST

RICO INHEX SOCKET SETS

1/2dr 9pce metric impact contains 10,11,12,13,14,15,17 + 19

was $237.45

$169.003166560

was $95.65

$69.953621340

TOPTUL ADJUSTABLE WRENCHES

Chrome vanadium steel, millimeter graduation head for quick adjustment. Industrial - grade quality for maximum durability and corrosion resistance.

IDEAL FOR RACING/ROAD SERVICE, ONLY WEIGHS 25KG$433.91W0000576

9 DRAWER TOOLCHEST6 small,2 medium and 1 large drawer suitable for a variety of tools smooth ball bearing slide drawers with auto return function strong side handle and key lockincludes 1 portable tray and drawer liners.

was $626.85

$419.003810462

$644.007204550

CRC BRAKLEENFeatures & Benefits.Fast evaporation, minimises downtime.Residue free, prevents harmful build up and eliminates rinsing or wiping. Non-staining, and non-corrosive. Safely settles and removes brakes dust. Works without disassemblySuperior cleaning and degreasing properties that have many uses beyond brakes. $8.95

2850660

$199.99W0000577

ALUMINIUM AXLE STANDS2 Ton capacity , The Bahco aluminium Jack Stands comply with AS/NZS 2538:2004.100% aluminium body - lightweight yet strong!

RIVNUT TOOLTQ8205 - Heavy Duty Long Arm Nutsert Riveter, This lever style nutsert tool makes easy work of the installation of M3-M12 threaded inserts and rivet bolts/studs.Includes 7 x Cr-Mo Mandrels - M3, M4, M5, M6, M8, M10 & M12.

SUPPLIED IN BLOW MOULDED CASE

BUY 6 CANS OF CRC BRAKLEEN®AND RECEIVE A 6 PACK OF COKE FREE

MINIMISES THE RISK OF INJURY !!

12 DRAWER CHEST12 drawer chest,660w x 455d x 483h, powder coated finishing, gas struts for safety & accessibility, protective drawer liners.100% open ball bearing slides.

$19.95W0000575

SAFETY TIP AIR BLOW GUNEasily cleans and removes dust from equipment, Nylon body with trigger. Comfortable lever control and insulated handle Meets O.S.H.A requirements supplied with 1/4 bsp air fitting.

HINDIN MARQUIP STEEL RETRACTABLE AIR HOSE REELSHigh Quality Steel bodied reels

Industrial grade air hosing

Working Pressure 21Bar/300 psi

Inlet/Outlet 1/4” (F in / M out)

15M $225.008013100

20M $299.008013110

$399.00W0000580

FREE wall mount swivel bracket included

Hose specification 13mm 1/2"" rubber, working pressure 21bar/300psi inlet/outlet 3/8"" (F in / M out).

15Mbonus drawer

organisers with these toolboxes

while stocks last

3800802 WRENCH ADJ 150MM $19.00 3800804 WRENCH ADJ 200MM $24.00 3800806 WRENCH ADJ 250MM $30.003800808 WRENCH ADJ 300MM $38.00 3800810 WRENCH ADJ 375MM $69.00 3800812 WRENCH ADJ 450MM $121.00

EACH STAND WEIGHS A MERE 2.5KG

LIGHTWEIGHT ALUMINIUM TROLLEY JACK2 ton 100% aluminium body ensures a flexible and lightweight trolley jack. Quick approach to the lifting point thanks to the dual pistons which decreases the number of strokes by 50%. Dust cover that protects the pistons and spring reducing the risk of damage caused by dust and dirt. Rubber saddle included protecting all surfaces and prevents slipping. Tool tray for storing nuts, washers… Nylon wheels.Complies with AS/NZS 2615 2004.

was $95.65

$69.953621320

3/8dr 9pce metric impact, contains 4,5,6,7,8,9,10+11mm

6 Order Online at www.tradetools.co.nz We accept

5 YEAR CONDITIONAL WARRANTY!!

was $159.70

$119.00

5829430 W0000579

W0000578

COPPER RAWHIDE HAMMERSMalleable Iron head fitted with one Rawhide and one Copper cylindrical face. Used as a multi purpose soft faced hammer in engineering and automotive for assembly, repair and maintenance.

FACES ARE DESIGNED TO WEAR AND CAN BE REPLACED.

MADE IN JAPAN

3129180 1’1/2 LBS 32mm DIA $39.95 3129200 2’1/2 LBS 38mm DIA $49.95 3129220 3’1/2 LBS 44mm DIA $59.95

MITUTOYO MAG BASES & DTI'S

7011s-10 magnetic

base with fine adjustment.

2046S DIAL TEST INDICATORStandard 0.01mm graduation dial gauges having a bezel with an outside diameter of 57mm. A carbide contact point is used.The crown gear uses stainless steel that is resistant to wear and deformation.

7010S-10 Magnetic base.

was $94.37

$62.004820120

was $88.20

$56.004840340

was $85.05

$61.244820100

was $193.70

$139.464840720

513-404E DIAL INDICATOR Provides easy access to shrouded surfaces that cannot be reached with conventional dial indicators.No-clutch structure for automatic reversal of measuring direction.Resistant to water and dust thanks to the one-piece bezel and O-ring seal for the crystal. The glare-free flat crystal face has a scratch-resistant coating. High-sensitivity and quick-response due to low-friction jeweled bearings.

was $219.00

$119.954900200

NEATLY STORED IN BLOW MOULDED CASE

$108.003251780

SUPPLIED IN RECLOSABLE TIN

DIGITAL LEVEL & PROTRACTOR

Aluminum frame. Magnetic bottom with V-groove for shafts.Calibration can be made on any plain surfaces.Buttons: ON/OFF, ZERO, HOLD(keep

the reading).CR2032 battery. Automatic power off.

was $170.10

$119.954828240

6 PCE MEASURING SETIncludes:• Digital caliper, range 0-150mm/0-6"", resolution 0.01mm/0.0005"" (code 1108-150).• Outside micrometer, range 0-25mm, graduation 0.01mm (code 3202-25A)• Dial indicator, range 0-10mm, graduation 0.01mm (code 2308-10FA)• 90° beveled edge square, 100x70mm, grade 0(code 4790-1000)• Scriber (code 7230)• Steel rule, 150mm/6"" (code 7110-150)"

WELDMASTER AUTO WELDING HELMETS1/25000 sec switching time, adjustable shade 9-13, adjustable time delay from 0.3-0.6 seconds, suitable for arc & mig weldingadjustable sensitvitybattery & solar powered.

SPARE INNER & OUTER LENSES INCLUDED

OXY/ACETYLENE GAS SETBOC MasterStart Kit gets you started on general oxy-acetylene welding and cutting, contains oxygen & acetylene regulators,10mtr hose set,handpiece,cutting attachment,mixer,3 x cutting tips,1 x welding tip,bottle spanner,striker,goggles,tip cleaners ,regulator & torch mounted flashback arrestors.

$447.108303690

SURESHOT SPRAYERPressure Sprayer 946ml , Sure Shot ® sprayers are an inexpensive way to apply bulk chemicals like cleaners, degreasers, penetrating oils, solvents and lubricants. They use readily available compressed air, instead of flammable and/or dangerous propellants, and because they are reusable you don't have to worry about disposal of empty cans. They feature metal construction, brass nozzles, and corrosion resistant internal working parts. COMPATIBLE WITH ACETONE NOT SUITABLE FOR WATER BASED MEDIA.

High production ‘GOLD’ Suction gun.Fully adjustable wide spray pattern controlFluid tip 1.8mm. Air Consumption 200-260lpm.

WELLMADE SPRAYGUN

was $157.14

$117.853252900

Phone in your order: 0800 4 TOOLS 7We accept All prices exclude GST

TOPLINE XT10 EXTRA-THIN CUTTING DISCSParticularly suited to thinwall and solid stainless, high tensile and high alloy steels (optimum disc performance obtained from angle grinders over 1000w.)

30% OFF1070333 100 x 1.0 x 16mm inox1070373 115 x 1.0 x 22mm inox1070453 125 x 1.0 x 22mm inox1070573 230 x 1.9 x 22mm inox

PROLINE FT33 STEEL FREEHAND CUTTING DISCSParticularly suited to structual steels,rebar and sheetmetals over 3mm in thickness.(designed to run on lower powered angle grinders)

ALPHALINE XT70 EXTRA THIN CUTTING DISCSSuitable for stainless,structual,high tensile steels, plastic laminated metal sheeting (designed to run on lower powered angle grinders).

ALPHALINE RS28 INOX GRINDING DISCSParticulary suited to edge and surface grinding of stainless and mild steels using low powered angle grinders.

PROLINE RS38 INOX GRINDING DISCSParticularly suited to edge and surface grinding on stainless and mild steels using high powered grinders.

1071973 100 x 2.0 x 16mm steel1072013 115 x 2.0 x 22mm steel1072053 125 x 2.0 x 22mm steel1072093 180 x 2.0 x 22mm steel1072133 230 x 2.0 x 22mm steel

1071153 115 x 1.0 x 22mm inox WAS $14.85 NOW $10.39 (Pkt 10)1071193 115 x 1.5 x 22mm inox WAS $15.30 NOW $10.71 (Pkt 10)1071233 125 x 1.0 x 22mm inoxWAS $15.60 NOW $10.92 (Pkt10)1071273 125 x 1.5 x 22mm inoxWAS $15.90 NOW $11.13 (Pkt 10)

ALPHALINE KSM GRINDING DISCS Particlarly suitable for mild steel on lower powered angle grinders.

1081377 105 x 7.0 x 16mm steel1081417 115 x 7.0 x 16mm steel 1081457 125 x 7.0 x 22mm steel1081497 180 x 7.0 x 22mm steel1081537 230 x 7.0 x 22mm steel

1080907 115 x 7.0 x 22 inox1080917 125 x 7.0 x 22 inox

1080837 180 x 7.0 x 22 inox1080877 230 x 7.0 x 22 inox

more simple simply more

PROLINE SPBR HANDI ROLLS 40MM X 50MTR

30% OFF ALL ROLLS

ALUMINIUM OXIDE,CLOSED COATED J-FLEX CLOTH

ABRASIVES

SUPPLIED IN RECLOSABLE TIN

5LTR

20LTRwas $132.83

$99.62 2830310

was $37.73

$28.30 2830305

NOW ONLY

$285 4225880

EXTENDS SPINDLE LIFE AND REDUCES WEAR

Available in the following sizes:

2831295 Cimglide Slideway 5L$38.442831300 Cimglide Slideway 20L$122.852831310 Cimglide Slideway 200L $899.96

CIMGLIDE® 68 is a specially formulated MACHINE TOOL lubricant for all horizontal slideways. Meeting the Cincinnati Machine P47 Specification, it combines mineral oil and extreme pressure additives to assist in eliminating stick-slip to ensure machines run at their optimal performance. Suitable for use in the following machine tool applications:• Horizontal slideways Feed mechanisms• Tables, Gear boxes & Hydraulic systems• CIMGLIDE® 68 is designed for minimal impact on

water based metalworking fluids.

SECO TURNING25MM HOLDER 16MM INSERT External turning toolholder STGCR2525M16.

SECO BORING BARS & CARBIDE INSERTSGreat general purpose bars that take "TC" type inserts complete with through coolant for a massive range of turning applications.

PARTING KITSCIMSPIN 10CIMSPIN 10 is a spindle and hydraulic oil designed for high speed spindle bearings in precision grinders and machine tools requiring low-viscosity oils. CIMSPIN 10 is blended with premium base oils and special additive packages to exceed the needs of modern manufacturing.FEATURES AND BENEFITS:• Provides excellent lubricity to minimize wear under high load conditions including wear caused by spindle wobble from unbalanced loads.• Multi-metal compatibility - Protects ferrous and non-ferrous metals from corrosion.• Good oxidation resistance - Excellent oxidation stability to provides long service life.

TCMT16T304-F1 TP3500 4092700 $12.47A versatile chipbreaker for positive inserts. For finishing machining of steel, stainless steel and cast iron giving good surface finish. Suitable for high feed rates at small depth of cut. Machining range: f = 0,05–0,50 mm/rev, ap= 0,25–3,00 mm.

4237020 $118.15

NOW ONLY

$290 4225900

25MM CENTRE HEIGHT TOOL WITH 3MM INSERT.

20MM CENTRE HEIGHT TOOL WITH 3MM INSERT.

Includes: 1 x HSS Blade, 1 x Pkt 10 Inserts 3mm, 1 x Insert Tool

A12M – STFCR1112 x 150mm Bar, 11mm Insert pocket

$130.954228340

A16R – STFCR1116 x 200mm Bar,11mm Insert pocket

$161.354228620

TCMT 110204 TP3500 A versatile chipbreaker for positive inserts, for finishing machining of steel, stainless steel and cast iron giving good surface finish. Suitable for high feed rates at small depth of cut.

$9.834092380

www.tradetools.co.nz

DISCLAIMER: We are a fair minded company and try to exceed the requirements of fair trading legislation in NZ. All Prices exclude GST and are current at the time of publication. Stocks however may not always be available, but we can generally offer a substitute if you contact us to discuss. Errors and omissions can happen too; the images printed are sometimes generic (and may in the odd case be completely incorrect). Once again if it looks wrong or too good to be true, contact us so we can set the record straight!

Auckland PH: 09 525 8900 Palmerston North PH: 06 351 6000Hamilton PH: 07 847 9798 Christchurch PH: 03 379 8160

Vibration is a major problem factor with tool life and surface finish when machining with solid carbide cutters. This month I will talk about the problem, some causes and some ways of overcoming it. The obvious causes include workpiece stability and machining setup which can be overcome reasonably easily. High Speed Machining (HSM) has become a reality and will continue to grow because of improved machine and spindle design, improved tool designs and coatings and more rigid tool materials. High speed machining is most often limited by the onset of chatter (vibration).

VIBRATION AND SOLID CARBIDE MILLING CUTTERS

Q. What is Chatter and how does it interfere withperformance?A. Chatter is a self-excited vibration between the tool and workpiece in metal cutting which will create large cutting forces, damage tools, damage workpieces and create unacceptable surface finishes. High Speed Machining (HSM) can be compared to driving certain vehicles which at some speeds create vibration in the transmission. Speeding up or slowing down slightly usually causes the vibration to decrease. In the same way, recognizing and controlling the dynamic forces associated with HSM creates Stable Machining Zones.

Q. What are some of the causes of vibration?

A. A typical four flute end mill is completely symmetrical, with identical geometry ground onto each flute of the tool and each flute an equal distance from the next. The cutting teeth enter and exit the material at a constant angle and velocity creating a Vibration and Solid Carbide Milling Cutters natural rhythm. This rhythm creates a frequency that continues throughout the use of the tool and harmonics resulting in one of the most damaging forms of cutter wear known as chatter. Tool length is also a major cause of vibration. As the flute length is extended, the tendency for a tool to deflect and chatter is greatly increased. 20% greater length increases deflection by 50%. As an example a 6.0mm diameter tool set at 24mm length could deflect 50 percent more than the same tool set at 20mm length.

Q. How can we counter deflection on long cutter lengths?

A. Tool length and diameter are critical to the deflection and vibration effects that a cutting tool will need to contend with. You should always try to choose the shortest length possible, doubling the cutter length increases deflection eight fold. Choosing the largest diameter of tool available for your application will improve your results, doubling a diameter increases rigidity 16 times, which allows larger diameters to make smoother surface finishes. The more teeth ground on a cutter means a larger core diameter, the larger the core becomes the more rigid the tool is, but it loses effective space for chip production and material removal capabilities.

Q. How can these harmonics be overcome?

A. SGS developed a Z-Carb solid carbide cutter which was a one of a kind patented four flute end mill that incorporates two different helix angles and unequal flute spacing. This design creates a geometry that counteracts the natural harmonics created by the rhythmic pattern of a typical four flute end mill’s cutting edge engaging and disengaging into a workpiece. Variable pitch cutters are now a common way to overcome these problems.

Z-Carb end mills “tune out” chatter more efficiently than standard end mills, usually overriding recommended speed by +/- 10% is sufficient if chatter starts.

The rake angle of a cutting tool controls the size and the shape of the chip produced, the cutting tool pressure, the temperature at the shear zone, the size of the shear zone and the angle of the shear zone. In essence the rake angle of the tool plays the largest role in the material removal process and it is the one aspect SGS had not addressed with variable geometry. By incorporating the variable rake you change the flute shape thus adding an additional dimension to the variable geometry design. SGS have now introduced the Z-Carb-AP whose design now consists of multiple helix angles, variable pitch and multiple rake angles. Opposite flute geometries are equal, while adjacent flute geometries vary. Now each adjacent flute enters the material at a different distance, at a different angle and with a different flute form. The Z-Carb AP has proven to improve performance through further chatter suppression, improved surface finishes, reduced cutting tool forces and finally a reduction in tool wear.

Z-Carb Variable Pitch Geometry

Cutting Force comparison between Z-Carb and Z-Carb-AP

n n n n