Emuge Corp, a leading manufacturer of high performance taps, drills, end mills and other rotary tools, announced it has established a partnership with CNC Software, Inc., developers of the manufacturing industry’s well known Mastercam® CAD/CAM software.

WEST BOYLSTON, MA U.S.A. (December 12, 2016) – Emuge Corp has introduced “circle-segment” cutters, an innovative class of end mills designed to enable substantially more material removal with fewer passes in 5-Axis machining, over 80% cycle time reductions and up to 50% smoother surface finishes. Circle-segment tools are a totally new end mill design, exclusive to Emuge.

These high-performance tools, ideal for machining turbine blades, impellers, blisks and in mold making applications, feature unique forms with large radii in the cutting area of the mills, allowing a larger axial depth of cut during pre-finishing and finishing operations.

Emuge circle-segment solid-carbide end mills are offered in four geometries: barrel-shaped, oval form, taper form and lens shape. Oval and taper form mills are ideal for curved shapes such as blades or straight-walled pockets, freely engaging more of the cutting edge. Barrel design mills provide highly effective flank milling to the sides of spiral grooves and similar applications, while lens shape mills excel in narrow channels or in lands on molds.

Specific CAM system software, such as HyperMill (Open Mind) or Mastercam® Version 2017 is required to support and compute the geometries of Emuge circle-segment end mills to achieve the performance levels the tools were designed for.

“Our all-new circle-segment end mills, only available from Emuge, provide unprecedented levels of machining performance in complex 5-axis applications, allowing precision manufacturers to attain dramatic time and cost savings, while increasing part quality,” said Mr. Bob Hellinger, President of Emuge Corp.

Emuge circle-segment end mills are offered standard, and are in stock at Emuge Corp. North American headquarters.

Emuge Corp. is a wholly owned subsidiary of the 1,500+ employee German company EMUGE-Werk Richard Glimpel GmbH & Co. KG (Lauf, Germany) that has been the product technology and performance leader in their field for nearly 100 years. The company manufactures an extensive line of taps, thread mills, drills, end mills, toolholders, clamping devices and other rotary cutting tools, over 100,000 items sold through distributors worldwide. Emuge also offers end-user technical support through a network of in-the-field engineers and in-house product specialists, all with extensive tooling and application experience.

Emuge Corp, a leading manufacturer of high performance taps, drills, end mills and other rotary tools, announced it has established a partnership with CNC Software, Inc., developers of the manufacturing industry’s well known Mastercam® CAD/CAM software.

Both companies will share technical data and best practices on machining applications and programs, participate in joint seminars and training events at each other’s technology centers, and collaborate to develop and promote advanced, high productivity machining solutions for North American manufacturing professionals.

“We are very pleased to partner with Mastercam and see the relationship as an excellent way to further enhance our metal cutting solutions for customers throughout the U.S. and Canada. Mastercam has an outstanding reputation across the industry for providing leading CAD/CAM solutions for the latest machining technology, which aligns well with our customer base and approach,” said Bob Hellinger, President of Emuge Corp.

“We are excited to establish a partnership with Emuge who, like CNC Software, has consistently provided innovative, industry-leading solutions for manufacturers. We are looking forward to working together, leveraging our extensive resources and expertise to offer the very latest technology for our customers,” said Meghan West, President of CNC Software, Inc.

Emuge and Mastercam are planning upcoming training and seminar events for 2017. Customers will be notified and information on events will also be posted on their respective websites.

Emuge Corp announced  the opening of a new technology center, located at the company’s North American headquarters in West Boylston, MA, USA.

The center, designed to be a full-service resource for manufacturers to apply cutting tool application strategies, is equipped with the latest 3 and 5-axis vertical machining centers, precision measuring devices and tool monitoring, in addition to an interactive classroom for training and seminars. The technology center will serve customers across the U.S. and Canada, enabling manufacturing professionals to test cut their applications and develop milling, drilling, and threading strategies to optimize tool life and performance and reduce cycle times.

“Our new Technology Center was conceived as a resource for manufacturers to test new machining concepts and tools without tying up their valuable machines and manufacturing time,” explained Bob Hellinger, President of Emuge Corp. “Our tooling engineers work directly with customers to replicate actual machining processes and develop new tooling and application parameters with complete documentation.”

Three major services offered at the Emuge Corp. Technology Center include Test Cuts, CNC Programming Assistance and Comprehensive Training:

For the Test Cuts Program, customers can provide Emuge sample parts and prints for evaluation by experienced Emuge tooling engineers. Once approved, test cuts are performed and documented, along with optimal recommended solutions and strategies developed by Emuge.

For CNC Programming Assistance, Emuge programmers work closely with industry leading CAD/CAM provides such as Mastercam, Open Mind and others, to help the user generate maximum machining performance and incorporate optimal tool designs. Emuge will provide customers programing assistance, a wide range of CAM tools for solving complex applications, efficient toolpaths, sub routines and optimization.

Emuge also provides Training and Development in an interactive classroom supported by CNC machining equipment for hands-on, real-time training. Training and seminars will be offered throughout the year on various topics, or custom training can be provided to meet the needs of individual companies.

Emuge has also recently introduced complete tool reconditioning services at the West Boylston, MA facility, which now also houses a state-of-the-art tool grinding/manufacturing center for refurbishing Emuge tools.

Emuge Corp. is now offering an expanded line of solid carbide thread mills in their popular THREADS-ALL Program, to include new 3XD sizes designed for maximum reach. A total of 17 new sizes have been added, from miniature to standard size tools, providing maximum versatility in a wide range of thread milling applications.

The 3XD THREADS-ALL tools, as well as the 2XD offering, enable easy machining of a variety of difficult-to-cut materials such as stainless, titanium and inconel, most often used in the demanding industries of aerospace, defense and medical.  Both 2XD and 3XD THREADS-ALL tools provide a single tool solution for through and blind holes and offer full bottom threading to within one pitch.  With THREADS-ALL, pitch diameter can be easily controlled. In addition, STI threads can be readily produced with THREADS-ALL, ideal for aerospace threading applications.

Emuge’s all new ZGF-I 3XD Thread Mills require only eight stock standard tool sizes, #10,1/4, 5/16, 3/8, 7/16,1/2, 5/8, 3/4, that allow for over 100 commonly produced screw thread designations. The  ZGF-I 3XD line also includes Miniature size thread mills, available in four sizes ranging from  2 to 8.

Emuge’s new thread mill range produces excellent thread finish and gaging to meet today’s most demanding quality standards, while helping manufacturers reduce costs and improve delivery.

“Emuge understands the challenges of today’s threading applications,” said Emuge Corp. Product Director, Mr. Mark Hatch. “The new 3XD sizes in the THREADS-ALL program will give manufacturers additional versatility, and enable them to minimize tool inventories and help increase profitability.”

Emuge Corp. is a wholly owned subsidiary of the 1,500+ employee German company EMUGE-Werk Richard Glimpel GmbH & Co. KG (Lauf, Germany) that has been the product technology and performance leader in their field for over 90 years. The company manufactures an extensive line of taps, thread mills, end mills, toolholders, clamping devices and other rotary cutting tools, over 100,000 items sold through distributors worldwide.  Emuge also offers end-user technical support through a network of in-the-field engineers and in-house product specialists, all with extensive tooling and application experience.

Emuge Corp. recently introduced a new Solid Carbide Turbine End Mills Program designed for milling turbine blades, impellers, blisks and other complex 5-Axis components. Emuge Turbine End Mills feature a variety of styles including tapered ball nose, unique barrel-shape designs and optimum tool selections from their Top-Cut, Tinox-Cut, Multi-Cut and Indexable Insert Tooling programs.

We are very pleased to offer our customers excellent solutions for milling turbines blades,” said Mr. Charles Colonair, Milling Product Manager at Emuge Corp. “OEMs and job shops in industries such as automotive, aerospace and power generation will benefit from increased productivity using these tools.”

The Emuge Turbine End Mill line includes Barrel-Shaped Oval Form End Mills, which provide manufacturers with an exceptionally efficient finishing tool for high-strength materials. The unique barrel-shaped oval form simulates the attributes of ball nose end mills having a diameter range of 150-190 mm, to provide double the axial cut vs. a standard ball nose end mill, for a superior surface finish. The Barrel-Shaped Oval Form End Mills are offered with 3 and 4 flutes with ALCR (aluminum-chromium) coating and have a form tolerance of +/- 0.01 mm (0.0004”), providing highly accurate low-vibration machining.

Torus End Mills for the semi-finishing and finishing of turbine blades feature 5 – 13 flutes with variable spacing to minimize vibrations while machining. Designs include corner radius (0.8 mm, 1 mm and 2 mm), straight and 8° taper angle versions. Internal coolant supply capability is provided. Tapered Ball Nose End Mills are offered with a 4° taper angle and feature a design with 3 flutes in the ball nose section and 6 flutes radially, a design which provides tool stability and improved surface finish of turbine blades. Torus and Tapered Ball Nose End Mills are especially well suited for milling in high-strength materials such as nickel-based alloys and titanium alloys. Both styles of end mills feature advanced multilayered TiALN coating for high heat resistance.

Emuge also offers Tapered Ball Nose End Mills in the new program that excel in the roughing, semi-finishing and finishing of impellers. These Tapered Ball Nose end mills have a 3 flute design with a 4° taper angle and also feature a design with 3 flutes in the ball nose section and 6 flutes radially. ALCR coating allows for these tools to achieve higher feed speeds, metal removal rate and extremely high performance especially in difficult- to- cut materials.

Emuge Corp. is a wholly owned subsidiary of the 1,500+ employee German company EMUGE-Werk Richard Glimpel GmbH & Co. KG (Lauf, Germany) that has been the product technology and performance leader in their field for over 90 years. The company manufactures an extensive line of taps, thread mills, end mills, toolholders, clamping devices and other rotary cutting tools, over 100,000 items sold through distributors worldwide. Emuge also offers end-user technical support through a network of in-the-field engineers and in-house product specialists, all with extensive tooling and application experience.

Over 10,000 types of cutting tools and accessories are stocked in the company’s U.S. and Canadian Headquarters located in West Boylston, MA, U.S.A. The 21,000 square foot state-of-the-art facility also serves as a technology center with a machining and tooling demonstration showroom and classroom.

In current industry scenario, the internal threading operation has become one of the most critical application as most of the time it is done during the finishing stages. While it is agreed that to avoid the rejection at this stage it has to be done with a proper threading tool, (either tap or thread milling cutter) we also need to consider the aspects of thread finish, tool life and consistency in threading. To counter this choosing an appropriate tap holder is a must.

Considering this need, EMUGE India is giving a tap holding solution for both CNC as well as conventional machines.

Softsynchro® series rigid holders are suitable for CNC machines with Synchronous tapping cycle whereas KSN series Quick change holders are for conventional machines.

The threading tool is pitch controlled by the synchronous spindle, eventually arising axial forces caused by synchronisation faults are minimised by patent-protected minimum length compensation on tension and on compression mechanism. A separate function of desired torque and axial force transmission guarantees considerable reduction axial forces which results in lesser wear on the cutting edges and hence increase in tool life.

Since it is a production tool, lot of automobile manufacturers have benefited with this holder by way of minimum 30% to 300% increase in tap life (depends on the machining conditions) and could recover the holder cost within 1 month period only.

The accuracy of the programmed thread depth/adjusted by a limit switch mechanism, is guaranteed by a patent-protected pressure point mechanism. Arising differences between spindle feed and thread pitch are compensated by length compensation feature.

A unique characteristic of Pressure Point Mechanism guarantees a safe start to the cutting process and also helps to achieve reproducible uniform thread depths. This guarantees process safety in the first cutting stage. Once it is activated, it exerts practically no force on the length compensation of the holder.

Additional front release mechanism protects the quick change holder, quick change adapter, the tap as well as the work piece against damage caused by excessive axial tension. Such tension may occur if the length compensation path is exceeded due to afterrunning of the spindle at the point of reversal or when the fast-speed function of the tool retraction movement is activated before the tool has come free from the workpiece. In these situations, the quick change adaptor is detached from the holder automatically avoiding expensive damage.

This is a very good solution provider in case of threading issues on conventional machines with a benefit of increased tool life.

Courtesy: EMUGE India