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breaking news

Modern Workholding Strategies for Swiss-type Machining

6/20/2018

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Thursday. September 13| 1:15 PM - 2:10 PM | McCormick Place Room W193-B
Matt Saccomanno, the Co-Founder of Masa Tool and inventor of the Microconic Workholding sytem will talking about process innovations in the metalcutting manufacturing industry during the International Manufacturing Technology Show, IMTS, in September at McCormick Place in Chicago, IL. 
Modern Workholding Strategies for Swiss-type Machining
Swiss-type CNC machines have gained in capability and demand as the machined components they produce are trending toward higher precision and micro-sized features. As the machines have become more sophisticated, the underlying basics of workholding remained unchanged until recently.

​This presentation is an overview of new developments as well as traditional approaches with relevance to today’s highly capable sliding headstock “Swiss-type” CNC turning centers. The goal is to summarize best-practices for optimizing use of both main and sub-spindle to maximize productivity and overall equipment effectiveness. The material presented is useful for machinists, CNC programmers, tool crib personnel, manufacturing engineers, estimators, and hands-on managers.

If you would like to reserve your spot in this technical presentation and discussion please click the below button.
Add To IMTS Show Planner

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Metal Cutting Corporation Solves 5 year Finishing Problem with Microconic

6/8/2018

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CEDAR GROVE, NJ. -  Metal Cutting Corporation is an independent metal fabricating company that specializes in the burr-free abrasive cut-off of metal parts and the related grinding, lapping, polishing, turning and EDM.  They  manufacture precision metal components for a diverse range of industries, including medical device, automotive, electronic, biotechnology, semiconductor, aerospace, fiber optic, electrical and general mechanical industries.
Recently, Rich Swift from Metal Cutting Corporation, reached out to Masa Tool on Instagram,  @Microconic, and told us:
"I recently purchased your collet system and can't tell you how happy I am with it. I have a part the has a .004 wall thickness and before your collet, no matter what I did I kept getting collet marks on my parts. Not only are the collet marks gone but it's within .0002" round. Thank you for making a superb product."
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Rich Swift's instagram comment to Masa Tool
​That comment lead to us wanting to learn more about how Metal Cutting was using our workholding! This is the very first application success story that has been shared with us on Instagram.   Rich was kind enough to send us some information about how he came to be using Masa Tool.
According to Rich, 

"The pictures with the part on the penny is the one I mentioned on Instagram. I have work on this part for the past 5 years and just when I was ready to throw in the towel I saw an adverstisment for your Microconic collet system in Production Machining Magazine.  I got in touch with Doug Brown, the Vice President of Allendale Machinery here in North Jersey,  and  he put me in touch with Masa Tool's regional manager Mark Bergonzi."
Micromachining Micoconic Citizen Swiss turning part
316L made from solid rod. Check out the .013" hole. It's only out of round by .0001". Made on a Citizen K-16.

About Metal Cutting Corporation

Metalcutting Corporation
Metal Cutting Corporation was founded in 1967 and moved to their current 52,000 square foot manufacturing facility in 1998. In 2008 they expanded their existing machine shop capabilities with Haas and subsequently Citizen turning equipment, allowing them to offer multi-axis CNC milling, lathe and automatic Swiss style machining up to 7 axes.

Their specialty has always been small diameter parts made from all metals.

"The parts can be long but are most often short, often very short."

When the company started in the late 1960's they  primarily worked with non-ferrous metals, especially tungsten and molybdenum. So much so that  in 1984 they became the exclusive North American distributor for Nippon Tungsten Co., Ltd.’s tungsten and molybdenum products. Since  the the 1980's they have been working with and machining more stainless steel and now have a developed a deep knowledge of machining the newer nickel and titanium based alloys.


Brass Medical Part Swiss machine
The part shown above has a .001" runout specification and previously run parts showed that the pickoff collet was making a tri-lobe detent on the .032" diameter. Needless to say Masa Microconic eliminated that problem.
Citizen K-16E VII Microconic Wokholding
Tiny brass contacts made on Citizen K-16E VII and held with Microconic. The head thickness is .010"/.012" and the small diameter is .030"/.033".
Mark, from Masa, and and Doug, from Allendale Machinery, visited Rich at Metal Cutting.
​
According to Rich,  "I was sold before he could get it out of his demo case."

​"Since this part is a medical part every thing had to be perfect. Ever since I purchased the Microconic system our customer has been very pleased with our parts and, believe it or not, it has less burrs than before."
Over the past several months Rich has been able to apply the Microcnic system to several other products that they make in their Citizen Machines.
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Agent Profile: Clark Manufacturer's Service

5/9/2018

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Please extend a welcome to Clark Manufacturer's Service  as the newest members our Microconic team!

OCEANSIDE, CA - Masa Tool is very pleased to announce that Clark Manufacturer's Service has joined our Masa Team in April  2018.  They will be our representative agency partner in the Northwestern US managing the states of Idaho, Oregon, Montana and Washington. 
Clark Manufacturer's Service Logo
The Clark Manufacturer's Service team represents leading industrial cutting tool and machine tool accessories manufacturers throughout the Northwestern United States.

According to Matt Clark, "We have a strong technical focus on CNC turning  tooling and workholding. The Microconic products are really going to compliment our existing product mix and provide some truly innovative new technology to our customers."

About Clark Manufacturer's Service

Clark Manufacturer's Service Seattle Skyline Spaceneedle
In March of 2015 Matt Clark started Clark Manufacturing Services in the Pacific Northwest region by working directly with existing suppliers, end-users, and assisting factory representatives. His goal was to build better brand recognition and increase product visibility of superior quality, highly-effective and versatile tooling products and systems. According to Matt, he felt that there just weren't enough technical agents in the area for the premier engineered product lines.

Matt's started in the metalcutting industry in 1996 at E.F. Bailey Co. and gained further technical experience in at Marshall Tool & Supply before starting out on his own with a select group of high performance tooling solution principles. 

Matt's father, Wylie Clark, who had been the general manger at E.F. Bailey Co. for 35 years, joined his son in November of 2015 and then relocated to Idaho to provide local support in the Idaho and Montana markets.

Matt tells us that his son recently completed an internship with Clark Manufacturing Services and there may be a third generation joining the company after college. 

Clark Manufacturer's Service Representation

  • 5th Axis Workholding Products
  • AB Tools
  • Crystallume Engineered Diamond Products
  • LMT Fette
  • NTK Cutting Tools
  • Masa Tool (NEW)
  • MD Tooling
  • Parlec
  • Precision Cutting Tools
  • RobbJack Corporation
  • SCM-Texas
  • Techniks USA

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Matt Clark
4100 25th Ave SW
Seattle, WA 98106
cell: 206.393.2653
matt@clarkmfrs.com
Wylie Clark Manufacturer Service
Wylie Clark
2151 N Main St #205
Coeur d'Alene, ID 83814
cell: 360.708.4474
wylie@clarkmfrs.com

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NEW! Masa Introduces the Microconic F201 Cartridge

4/11/2018

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OCEANSIDE, CA - Masa Tool has just released the newest product in the Microconic line of cartridges for swiss machine workholding. The NEW push type F201M10 Cartridge replaces the Tornos F20-201 collet in your CNC spindle. This enables you to use our Microconic collets to achieve concentricity guaranteed to be within 5µm (0.0002") in production use.

The F201M10 Cartridge is a micro-workholding system for use in high precision, small diameter CNC turning applications which enables you to move more work to the sub spindle operations and reduce cycle time.

​The F201M10 Cartridge  is compatible with spindles that accept F20-201 collets including  DIN 136E,  Meister Swiss 136E, Schaublin F20 (76-201),  Southwick & Meister F20-201, KEB (MasWerks) MC20-201,  Hardinge F20-201 / 4709 collets.

Masa’s Cartridge and Collet assembly is designed to vector the chucking force directly over the holding surface.  This means that the chucking force can be reduced while at the same time the holding power is increased. This opens up the possibility of moving part operations to the sub-spindle and dramatically reducing cycle time.  20% ~ 40% cycle time reduction is commonly achieved.​
F201M10 Cartridge Features
  • Solid extended nose, giving superior access for tooling and coolant, with minimal overhang.
  • The cartridge's core diameter is a single piece construction that will maintain 5 µm/.0002" concentricity at the extended nose tip.
  • Micrometer dial control of collet clamping pressure regardless of the machines hydraulic or pneumatic collet closing force with the use of our Micrograd™ Wrench. Ideally suited for small diameter part size range from .2mm/.008" to 10mm/.3934" diameter
  • 2-days shipping on all cartridges and collets​.

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How to use the Micrograd Face Dial Wrench

3/14/2018

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Set ups are quicker and more repeatable with Microconic™. You can document the micrometer-adjust collet closure in your set up plan so it's done the same every time, regardless of operator skill and without relying on "feel". ​
Our Micrograd™ Face Dial Wrench is included with the purchase of any Microconic Cartridges.

The Micrograd™ Face dial Wrench provides a method of precisely setting clamping pressure on both the Microconic collets and an Microconic overgrip collets .  

​It can be adjusted in metric increments of 0,02mm and imperial increments of .001"
Micrograd Face Dial Wrench Microconic
Top View of the 5C Cartridge with alignment arrow for use with the Micrograd collet wrench. The locking set screw to fix the position is located behind the arrow line.

How to use the Micrograd™ Face Dial Wrench

Microconic Micrograd Face Dial adjustment wrench
Side view of the F25 Cartridge with alignment line show for use with the Micrgrad collet wrench
  1. Insert a gage pin of the appropriate diameter.
  2. Tighten collet with Micrograd Collet wrench by 2 – 4 graduations to set initial clamping force. 
  3. For a firm grip on solid workpieces typically a closure of about .08mm (0.003”) is a good starting point. 
  4. Use the screwdriver allen wrench to lock the set screw on the cartridge in place.

Experience will soon teach the best settings, and they may vary significantly for different applications based on the force required, rigidity of workpiece, and machining operation being performed. 
For a complete set of instructions please see our installation procedures for more details on how to set up and replicate your clamping pressure on every machine in your shop.
micrograd wrench Microconic um10 collets
Micrograd wrench surrounded by Microconic UM-10 collets
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Revolutionary Micro Workholding System with Tighter Grip and Greater Accuracy allowing Manufacturers to Produce Micro-Precision Products on their CNC Machines

2/28/2018

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October 23, 2017CEOCFO
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Interview conducted by:
Lynn Fosse, Senior Editor, CEO CFO Magazine
Matt Saccomanno, Chief Executive Officer Masa Tool
October 23, 2017
CEOCFO:
Mr. Saccomanno, what is the idea at Masa Tool, Inc?  What is your Microconic Workholding System
Matt Saccomanno CEO Masa ToolMatt Saccomanno, CEO, Masa Tool
Mr. Saccomanno:
Masa Tool is basically formed from our life experience in the machining of micro-precision parts; primarily on Swiss-type screw machines, although the real focus is for high precision small parts manufacturing on any machine type  to better the world of micro machining. Specifically, our first major product release is the Microconic line,

as you mentioned. Microconic is a high precision, collet-type workholding system that fits in conventional machine tools of all types. It provides extremely precise, extremely rigid and also very easy to use workholding for the manufacturing of micro precision products.

CEOCFO:
What are you replacing or enhancing? What are people doing now?

Mr. Saccomanno:
We are replacing an existing collet design. A collet is a traditional workholding device. It is like a split sleeve that has a taper on it and it slides into another tapered receptacle. It clamps down on the work piece and traditionally has been the most precise and rigid way to hold small work pieces for production machining. The most widely
used collet system design was invented about a hundred years ago. It has essentially been used to this day with very little improvement until now. The Microconic system was created to resolve many of the limitations of existing legacy systems.

The neat thing about Microconic is that we fit directly into the existing legacy workholding system, so that it is an
advanced, self contained workholding unit that fits within what is already in the machine. Therefore, the costumer does not have to modify their machine or anything. They can install our product right inside their existing spindle. Then we provide improved accuracy, repeatability, adjustability, consistency, rigidity and everything in every way. There are quite a few different ways that we improved the state of the art.

CEOCFO:
Have manufacturers been looking for a better way or is it once they find Microconic they are excited?

Mr. Saccomanno:
That is a great question! There is excitement when they see what we have, but it is not an easy sell at first. That is because, as you say, it is hard to look for something that you do not know exists. That has been a big part of our marketing hurdle to get over; to distinguish ourselves from the systems that are out there. To answer your question it is both a yes and a no answer. Yes, people have been looking for something else. There are pervasive complaints
throughout the industry about the quality of existing systems and the availability and the consistency. Those are just like part of the landscape. They have been around for years.

Everyone is kind of used to dealing with it and they are always trying to find better sources to get better collets and things like that. On the flip side, because people are so used to dealing with that, they do not really anticipate the revolutionary change that you can get by all of the benefits of the Microconic system. Therefore, it takes a skilled technical person to really talk to the customers specifically about what they can do with their own applications. The cost of Microconic is not trivial, so it is important to show how the value is created by providing capabilities to significantly improve productivity over what can be done with traditional legacy collets.

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​Masa Expands Offering of Microconic Over-Grip Collets with New Long-Land T-type Series.

2/13/2018

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OCEANSIDE, CA.  Masa Tool has expanded their line of Microconic over-grip collets to include a new style called a "T-type."  The T-type over-grip collet has a longer gripping surface than the original W-type. We designed it specifically for longer parts such as bone screws with wide pitch threads.
The Microconic  over-grip collets provide more work holding and programming options than previously available. It enables you to move operations from the main spindle to the sub-spindle. This balances the work being performed between the main and sub time which can dramatically reduce cycle time.  

​The land width on the W-type over-grip collet, pictured at the right,  is approximately 1 X Diameter of the workpiece. 
Micorconic W-Type Overgrip Collet
The Microconic W-type over-grip collet can swallow up to 4mm over the held diameter
But,  in some cases, with longer parts, the land width "B" needs to be longer to support the workpiece properly.
​

Masa's new T-type collet provides the solution for longer workpieces

Typically with over-gripping applications, a shorter land length/clamping pad length/grip length is desired because of limited space available to hold the workpiece behind the enlarged head or flange that it is reaching over. That is what our original W-type collet was optimized for.

However, with longer parts, with more surface area for clamping and gripping room, a longer land length is often preferred to provide more stability to support the longer length workpiece.
​It may also be necessary with very wide-pitched threads, such as on bone screws, where a long land in the collet allows spanning several thread pitches instead of just one or two. This same spanning issue can occur with parts that have wide grooves.

The  new "T-type" over-grip collet,  has a longer gripping surface than our original W-type: Typically 2 - 3 times the diameter of the workpiece.

​For extra long parts, the T-type collet provides the opening needed for the larger head to pass through the collet, so it can be pushed through the back end of the spindle for ejection when required.
Microconic T Type Overgrip 2-3X Land width
The Microconic T-type over-grip collet provides 2 -3 times the land width "B" of the W-type over-grip collet to support longer parts.

Microconic T-Type Over-grip Collet features

  • Standard gripping land length is 2x - 3x diameter. (vs. about 1x diameter with W-type)
  • Available from Ø1.55 - 7.2mm (Ø.061" - .283"). 
  • Opens 3.5mm diameter (.138") larger than the clamping diameter. (vs. 4mm larger with W-type).
  • Every size available to ship within 2 days of order.
  • Same Microconic accuracy and rigidity.
Typical uses are generally for over-gripping of longer parts:
  • Bone screws with wide-pitch threads
  • Orthopedic surgical drills and taps
  • Long shafts with flange
  • Long, thin walled tubular parts
  • Long plastic parts
Microconic T-Type Long Land Overgrip collets
Masa Microconic Overgrip Collets: W-type (upper) & T-type (lower)
If you've tried other companies overgrip collets with poor results, Microconic over-grip collets  will allow you to do things you might have thought impossible!

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How to use the Microguide™ Sleeve

1/17/2018

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Due to the extreme opening capability of our overgrip collets , workpiece ejection must be very reliable to prevent a part from becoming stuck in the slots of the collet. ​Therefore we have developed  the Microguide™ ejection guide sleeve to prevent parts from falling inside the collet instead of ejecting into the part catcher.  ​
 Microconic over-grip collet and Microguide ejection guide sleeve blank
Microconic™over-grip collet and Microguide™ ejection guide sleeve blank
The Microconic™ over-grip collet is extremely rigid and precise. If it closes onto a part wrapped with chips the collet may be over-stressed and break.  It is critical that the workpiece be free of wrapped chips. High pressure coolant is recommended to blast away chips.

​There are many other techniques that can be applied to keep the part clear of chips, such as chipbreaker inserts, speed/feed optimization, chipbreaker G-code cycles and cutter path retracing, amongst others.

​It bears repeating that we suggest using programmed cycle stops while validating the production setup so the operator can confirm the part is clear. Once chip control is proven reliable that won't be necessary.
Each Microconic™ Over-grip collet is supplied with a brass Microguide™ ejection guide sleeve blank.  The Microguide™ sleeve  can be bored, drilled or machined to match the part profile and support the part and guide it for reliable ejection into the part catcher. 

You will need to machine the Microguide™  to fit your particular part setup.  We suggest using programmed cycle stops while validating the production setup to make sure part ejection is reliable.
Micrograd ejection guide sleeve blank Microconic over-grip collet
The Microguide™ ejection guide sleeve blank threads into the Microconic™over-grip collet after being machined to the part profile.

Microconic W style over grip collet cross section
A cross section drawing of a workpiece being held in a Microconic W style over grip collet.
Microconic W Style OverGrip Collets
Microconic W Style over grip Collets

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Microconic Workholding System Featured on Cincom L12 & L20 at EASTEC

12/6/2017

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The Microconic Workholding system was featured at the Marubeni Citizen-Cincom of New England booth at the Eastec 2017 Machine Tool Show!

Marubeni Citizen-Cincom is the exclusive New England distributor for Citizen Cincom Swiss style lathes and Miyano Multi Axis turning centers as well as ne of our premier distributors of the Micorconic Workholding system

About the CINCOM L20 Low Frequency Vibration (LFV)

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State-of-the-art LFV is a widely applicable cutting technology designed to avoid the problem of spiraling chips, entanglement of chips and built-up edges. Benefits include increased cutting tool life, reduced heat generation and reduced power consumption. 
​
The popular Citizen CINCOM L20 series sliding headstock lathes are now available with Low Frequency Vibration (LFV). 

This widely applicable cutting technology – able to handle a broad range of machining shapes and materials – is ideal for cutting difficult-to-cut materials.  The state-of-the-art LFV suppresses various risks associated with these materials, such as entanglement of chips and built-up edges.

Depending on the material being cut, a variety of problems can be caused by chips getting entangled with each other, including increased cutting resistance, scarring, changes in the texture of the machined surface, tool nose damage, and built-up edges due to cutting heat.  In LFV cutting, “air cutting” time prevents the machining temperature from rising, which both prolongs tool lives and gives relief from various problems caused by chips.

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Workholding: Success in Medical Manufacturing

11/15/2017

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Todays Medical Developments Log Masa Tool Article
This article originally appeared in the April 2017 issue of Today's Medical Developments.
​It was the cover story entitled: "Micro-Precision Machining" by Elizabeth Modic

The Microconic system benefits orthopedic bone screws, miniature precious metal components for pacemakers, and other implantables; machined surgical components made of hypodermic needle tubing; and surgical instrument components. Here’s one example – dental implants.
Material:
Titanium alloy bar stock

Machine:
Star SR20 Swiss-type CNC Automatic Lathe

Previous method:
The dental implant was machined almost entirely on the main spindle of the machine due to the need to have a powerful grip on the bar for a high-force, blind-hole, hexagon broach. Very little work was done on the pick-off spindle, so that sat idle for most of the cycle.

Cycle time reduction:
164 sec. to 98 sec. per part; 40% improvement achieved by moving all ID machining operations to the pick-off spindle, where they were performed in shaded time while the main spindle completed the OD. This was previously impossible to do with legacy collets, because the broaching force would push the part back in the collet. The 0.001" concentricity requirement of ID to OD could not be reliably achieved with legacy extended-nose collets, and they damaged the critical surface finish on the OD of the implant.
Todays Medical Developments Microconic Dental Implant workholding
Matt Saccomanno’s Microconic collet-type workholder for small part machining was inspired by his experience in a Swiss screw-machine job shop.
Cost savings:
Production rate went from 18pph to 32pph, a 44% cost savings. In addition, a hand deburring operation was eliminated due to the cut-off being on the opposite end.

ROI:
Cost of the Microconic system was recouped in 64 production hours; a $14,015 saved in direct production costs of a 10,000-piece order.

About the author: Elizabeth Modic is the editor of Today’s Medical Developments and can be reached at emodic@gie.net or 216.393.0264.
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