Tech Talk
What are "Insert Tools"?
Tools for shapers, saws, tennoners, edge banders, routers, etc. have, in the past, been categorized somewhat like raw material or a tank of fuel. In other words a consumable, constantly wearing and being replaced regularily. Any consumable product has to be monitored on an on-going basis, from the perspective of both cost and efficiency. The relationship of tool life, cost of purchasing, and maintenance (re-sharpening and re-tipping) has to be examined to determine the true level of performance. Often the higher priced tool with it's higher maintenance cost is more effective and thus more economical than a lower cost solution. However, the opposite can also be true. The output requirement and the type of machine you are running could dictate using the lowest price tool.
Insert tooling demands a different mind set. You are no longer purchasing a consumable item with a foreseeable life span. High quality insert tools should have an infinite life span. I put the emphasis on high quality because it has to withstand the rigors of high production, over time. The tool has to be able to adapt easily to new machinery as they become better, faster and more versatile, because the tool could outlast the machine it was originally installed on.From a manufacturing standpoint insert tooling has a number of advantages over conventional styles, but what may not be as obvious are the advantages of one type over another and how the decision process on which to buy differs from purchase decisions involving brazed tools. In the past if someone came up with a better method of creating a profile, the tooling could be replaced when the existing ones wore out. With insert tooling the decisions made on which tool to buy become just as important as the decision process on buying machinery - not as expensive - but just as important, because the tool is permanent. And this immortality dictates a serious look at what you are getting. The cost should be a minimal factor because the variations in price will be insignificant compared to the machine cost or it's attachments and options. In other words the few dollars saved by buying the lowest cost tool might be foolish economy if it is not what you require over the long term, considering it's life span.To comfortably order the correct insert profiling tool you must, of course, be comfortable with the manufacturer as well as the distributor. They both must have the technical ability to assist you with tooling solutions, problem avoidance, and help with machinery and set up solutions as they relate to cutting production.Insert tool knives are replaced on a regular basis and you must be confident your source of supply will not be a problem down the road. This also means the raw material - the carbide blank insert - must be easily sourced and readily available. Questions such as; can the knives be re-sharpened and at what cost are quite reasonable in deciding which route to take.The head design is, naturally very important. Angles, and directions of hook and shear could be critical to performance. You should know if they have been considered and the reasons for the conclusion. The number of wings also ranks high in importance. Too few may not give you the type of cut or production required, and too many will mean unnecessary long term cost for replacement knives. This ties directly in with tool diameter, which affects peripheral speed, which affects chip load. Again, make an informed decision as to what diameter tool is most beneficial.There are basically two types of insert tools - Multi profile an Dedicated profile and they each have their advantages. Before you make a decision on insert tooling discuss both with your supplier and how each would affect your application. It goes without saying that you must be guaranteed quality of both design and construction in an insert head. Compromise in these areas will be a never ending source of aggravation.Although I don't think the tax man knows about it, the development of insert heads has changed tooling to a capitol expenditure and like any long term investment should be investigated for it's value, not just it's cost. by: Doug Reid, President, B.C. Saw
