September 2, 2020
Posted By pageperfect

New Tools in the Shop

Hey, Jason McCann here again from MOUNTAIN TACTICAL®. You guys really liked the last kind of making it video. So I thought I’d show you a little bit more about making it, show you some cool new tools that we have. Show them off. May help some of you guys in your manufacturing. If nothing else, it’s just kind of cool. So let’s come over and take a look at these things.

So what we have here is a new tool from AB Tooling. And what it is is it’s a Picatinny rail cutter. It cuts that entire profile at once. Now, why is this significant? Well, this is significant because this replaces four operations that use these tools. Now I got to say I love these tools, especially [00:01:00] this guy right here. This is a tool from Big Daishowa in Japan. It’s the same tool that Nightforce uses to make their Picatinny rails. Had great success with it. It just rips. I’m able to cut, I want to say 20,000 per tooth. And basically, I want to say 2900 SFM or something like that. I really like this fast spindle over here on the DMT. And it rips through the metal incredibly fast. And I’ll show you a small clip of that here in a second. 

And then we have this guy, which is a QC cutter and this cuts the undercut. So what you have to do is you have to cut the top angle with this guy, then you turn around, cut the undercut with this guy, then you got to switch tools again, cut the bottom angle with this guy and then do a cleanup pass. So multiple operations and you get a little tool that comes in from the side [00:02:00] to make sure that the side finish is really nice. I love it. It’s fast. It’s effective. But the AB Tooling guy came over and he said, “Hey, why don’t you try this? This is what a lot of guys are switching to.” And my conclusion is it’s designed for machines with low spindle RPM. They said the sweet spot is 6,000 RPM, and 1 to 2,000 per tooth. And this is a three flute cutter.

I’m running about 1200 SFM, which translates to I want to say around 10,000 RPM plus or minus a little bit. And I’m roughing at 2,000 per tooth and finishing at 1,000 per tooth. And quite honestly, I’m getting the exact same amount of or the exact same machine time as using those guys. The advantage is it’s just all done with one tool, [00:03:00] very consistent. Yesterday, I cut 150 rails with this, and it just still has an amazing shine on it. I tested it with our Renishaw probe, and it hasn’t worn down 110 thousandths of an inch yet. So we could probably push this harder, but we’d end up sacrificing a little bit of quality here. So let me show you how this guy runs. 

Okay. So we have our AB tool in the spindle. And one other advantage that I forgot to mention earlier is this tool has a very low spindle load on it. So when we’re cutting, the spindle is not working hard. The highest it goes is 8%, sometimes 9%, and then finishing it’s at 3 or 4%. 

Now, why is this important? We’re not overworking our machine. Machines or mechanical devices these spindles will wear out if you run them too hard. [00:04:00] So compared to the other tools which are faster, they have a 30 to 40% spindle load because we can drive them so hard. This does the same job in the same amount of time, less stress on the machine. 

Again, I think this tool was designed for somebody who is a Tormach user or someone who has a mini-mill or somebody whose machine maxes out at around 6,000 rpm. That’s the sweet spot for this tool. We’re able to run this tool a little harder simply because our machine is more rigid than those machines. Listen to how quiet that is. It’s just not working

[00:04:44 inaudible] 7 to 8% spindle load here. Yeah. It just spiked at 9%. So, a very low energy tool. We come in for a finishing pass. [00:05:00] And this is cutting at one [00:05:13 inaudible] on the finishing pass 1200 SFM puts us at 9550 for the RPMs just turns right along. 

So this is a really cool tool. I think we’ll definitely use it heavily in aluminum and then we’ll use the Big Daishowa tool. And it is significantly more expensive. This cutter we’re using right now runs approximately $160. I bought two, so I got a little bit of a break. That Big Daishowa doubling cutter, I want to say, I would say I bought it a little over a year ago. It was almost $800. I want to say it was like $770 [00:06:00] and each insert is $20. Take four inserts. The inserts last forever. The inserts that you saw earlier in the video, those have made roughly 1600 rails and shown no sign of wearing.

So pretty cool tools. Expensive, huge upfront cost, but this one does the same thing except significantly less expensive. That QC cutter is another expensive tool. [00:06:32 inaudible] $100 for that tool. So the combined cost of those that another tooling is roughly $1,000 where this does the same job for around $160. 

So I definitely think AB Tool has a little wearing if you’re making Picatinny rails if you’re making copper receivers, anything where you need that Picatinny profile, [00:07:00] this is going to make your life a lot easier. So we finish this up and then I’ll show you how fast that Big Daishowa cuts. And that’s another tool because I didn’t laugh because it’s just so fast. It’s still fun to watch. 

I’m going to pause this guy, clean up the window. [00:08:00] We’ll speed ahead. I’m running at 2,640 SFM. And we’re cutting 20,000 per tooth equates to a cutting speed of almost 900 [00:08:35 inaudible]. Just kind of fun.

Here’s another cool tool we just got from MariTool. And our new DM2 has Thru Spindle Coolant. And the advantage of Thru Spindle Coolant is you can buy tools that have ports in them where the coolant actually goes through the tool and [00:09:00] always has coolant flushing out chips right at the cutting surface. 

Now, I did a lot of research and there are endmills out there that do this, but this machine also has P cool and gave you special tool holders, special collets, everything else to run. For endmills, you really need a shrink-fit tool holder and the good ones are off the charts expensive. 

So while I have some roughing tools that have Thru Spindle Coolant, I went ahead and bought this drill from MariTool has Thru Spindle Coolant. And I don’t know if we can really get in there and see this, but there are two. Let’s see if I can get this to focus here. There are two tiny holes at the tip of this drill. Now, why is it so important when drilling? While drilling, you are bearing your cutting tool into the metal typically [00:10:00] multiple times the diameter of the drill and chips get caught in the flutes. They can evacuate quickly enough and you end up snapping off the drill and the part ruins the part, ruins the drill. Especially if you’re running carbide drills, they’re very expensive. Not as expensive as this guy. This guy was I want to say around $90 most expensive drill that I’ve ever purchased. But this is so flipping fast because you have coolant on the cutting surface constantly pushing up escaping through these flutes and blowing the chips out. So it really you just got to see it to believe it. I mean, this thing is just so flipping fast. I think you guys are going to really enjoy this. So let’s move over to the mill and cut some metal. 

All right. So I went ahead and paused this. And you can see the Thru Spindle Coolant drill is in the tool holder right now. I’m going to want 5% rapids to slow everything down. So you can actually see when that coolant [00:11:00] kicks in and they will kick it up to full speed. So I’m going to zoom in a little closer. Try to get this in focus. 

All right. Let’s get this going. Isn’t that fast? All right. I’m going to turn this over to zoom back out. All right. Setting on the camera. We are going to go 100% here. First time I ran this I was clenching my teeth. But now I just laugh at it. [00:12:00] You can see that cool engineering done through there. So anyways, fun stuff to show you guys. 

Well, I hope you thought that was fun. This is kind of fun. Obviously hit like. Let me know if you liked this, these types of videos, and I’ll show you more of them. And I have 650 more rails to make. So I better get to work. Have a great weekend, guys.