SHAPER DUO

For socket hole machining｜ Swiss CNC lathes

Highly productive socket hole machining

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Hexagon, square, and hexalobular sockets machined without special equipment and at significant cost savings

Utilize the tool stations on the backside of the Swiss lathe

Features

Large insert selection to machine a range of socket sizes in Hexagon, Square, and Hexalobular (6-lobe) shapes
Low cutting forces make this tooling ideal for machining small diameter workpieces
Each insert size is spec’d to machine a range of socket hole sizes

Tooling application

Swiss CNC lathe socket feature machining

Product video

For medical parts (Abutment screws) Hexagon socket : AF 1.0mm .0393” – 1.4mm .0551”

Work Materials
Titanium / Stainless steel / PEEK / TEFLON

Socket hole type

Hexagon & Square socket process comparison

- - - Scroll the table - - -

	Tool pressure	Cycle time	Flexibility	Tool cost
Shaper Duo	◎	△ * Can be off-set by overlapping operation	○	◎	Less tool pressure, especially good for small diameter parts. One insert can machine a range of socket sizes
Broach	△	○	╳	△	You need a tool for each socket size

Hexalobular (6-lobe) socket process comparison

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	Tool pressure	Cycle Time	Tool Cost	High speed spindle	Program
Shaper Duo	◎	◎	◎	Not necessary	Simple	No need for a high speed spindle Short cycle time
Milling	○	╳	△	Necessary	Complicated	Requires high speed spindle Time consuming process

Shaper programming code examples

Shaper Duo Set-up Instructions (hexagon example)

① Insert Installation

Confirm that D-cut surface of sleeve holder is parallel to the side of the insert bar. Minimize the overhang of the insert

② Make sure the sleeve is set parallel

Set the sleeve into the tool post and make sure the sleeve is set parallel.
Minimize sleeve overhang.

③ Confirmation of height

Machine one feature larger than the pilot hole without chamfering
*If the insert chips with large depth of cut, then increase the number of machining passes with smaller depths of cut.
(Recommend: 0.025mm .039” x 5 passes) No chamfering is required.
Measure the length of both [a] and [b] with a comparator or magnifier.
Adjust centerline height by rotating the sleeve until you get the same length for [a] and [b]. (the difference should be less than 0.02mm .0008” )
* If a step is still seen even after increased passes, please restart the setup process.
Make sure both the insert and the holder are set up correctly.

④ Visual of step by step machining of hexagon socket

Hexalobular (6-lobe) machining Basically same as hexagon machining

Shaper Duo process chart (Hex example)

[ Recommended cutting contitions ]
Feed 1000 to 4000 mm/min 39.3 to 157.5 IPM DOC: Roughing 0.025mm and Finishing 0.005mm .0010” and Finishing .0002” (1 to 2 times)

Case study

Hexagon hole machining
Material : SUS303 303SS
Feed : 2,000 m/min 78.7 IPM
DOC : Roughing 0.025 mm .0010 inch
DOC : Finishing 0.005 mm .0002 inch
Coolant : WET
TM4 SSP030N1940H	10,000 pcs / corner
Competitor’s carbide inserts	300 pcs / corner

Competitor’s product dulled very quickly resulting in short tool life.
NTK’s hexagon shaper insert achieved longer tool life by maintaining insert edge sharpness and shape.
Improved cycle time and excellent surface finishes.

Related News

For more information about this product, visit our online e-catalog, or download the catalog/product report

NTK Cutting Tools

SHAPER DUO

Hexagon, square, and hexalobular sockets machined without special equipment and at significant cost savings

Features

Tooling application

Product video

For medical parts (Abutment screws) Hexagon socket : AF 1.0mm .0393” – 1.4mm .0551”

Socket hole type

Hexagon & Square socket process comparison

Shaper Duo

Hexalobular (6-lobe) socket process comparison

Shaper Duo

Shaper programming code examples

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