Articles & Columns

A project engineer recounts his experiences planning for, installing and setting up a new CNC vertical milling center. Among the issues he explores are the questions that must be answered before the machine arrives, selecting or designing tools and fixtures for the new machine and preparing workers for the change.

This article relates how three shops used creative ideas to solve difficult boring problems. One shop built a custom tool to bore deep holes. Another used a combination of standard tools to bore an interrupted cut. And a third achieved tight tolerances with an assortment of plastic sleeves and plugs.

Toolmakers are constantly introducing advancements to improve the metalcutting process. This article examines trends in five key areas where toolmakers are concentrating their research and development efforts.

An organized toolcrib is necessary to ensure that tools will be available when needed. This article reviews the techniques and equipment different shops have used to keep track of their tools.

Open controls allow users to integrate commercially available hardware and software with machine tool CNCs. This article reviews how different CNC makers have designed systems that incorporate or connect with PC-based products to offer this level of flexibility. Accompanying Articles describe one shop’s experience with open architecture and list the skills needed to operate these new systems.

Small-diameter drills designed for drilling circuit boards can be used as a low-cost alternative for producing holes in other materials as well. Their fragility is the only drawback. This article describes these tools and the special handling they require.

This article describes a self-contained micromachining center. The unit uses PC-based controls and a video system to machine small parts with precision, while giving the machinist a magnified view for setup and prototyping.

Spot drilling is a time-consuming process, but sometimes it is necessary to prevent drill walk. This article describes the reasons for spot drilling and the economic impact of adding the operation to a job. It also explains why a spot drill is a better choice for the operation than a center drill.

Tapping and thread milling can both produce internal threads in a variety of sizes, pitches and materials. This article discusses the factors that will dictate which process makes the most sense for a given job.

A machining research institute describes the testing method it developed to quantify and compare the performance of metalworking fluids. The test, which compares cutting forces generated when machining with a test fluid to a baseline fluid’s performance, is simple enough for any shop to use.

This article describes how one aerospace manufacturer boosted production capacity by partnering with a supplier, which began machining parts formerly made in-house. The article tells how the manufacturer shared its processes and manufacturing expertise with the supplier in order to ensure that quality and productivity were maintained.

The latest generation to enter the workforce comes to the shop floor with a different set of skills and experiences than their predecessors. This article explores how these differences are forcing shop owners and supervisors to rethink their management strategies.

A tool design supervisor makes a case for cautious machining. This article explains how, by extending tool life, less aggressive speeds and feeds can lead to greater economy than a shortened cycle time will yield. Tips for monitoring and recording tool data are also given.

Machinists can now find machining simulators on the Web that can tell them what the results will be for a given set of conditions as well as what set of conditions will produce the results they are looking for. This article describes these simulators and the research consortium that developed them.

This article describes reconditioning tools through hand honing, a process that can help a tool produce 20 percent more parts. In explaining the art of hand honing, the author reviews the hone materials and honing techniques to be used.

This article reviews the basics of coordinate systems and machine programming as a basis for presetting tools. The process for setting tool offsets is described with an explanation of the G-codes involved. In an accompanying article, the author tells how his company built its own presetter.

With innovations in technology, EDM has found its place as a reasonable alternative to other precision machining operations. This article reviews five recent developments: the introduction of a new electrode material, operations that replace dielectric fluid with gas, the development of electro-conductive powders, the EDMing of nonconductive materials and a method for producing complex part geometries with simple electrodes.

Insert manufacturers have devised color-coding schemes to help users select the right tool for the job. This article explores the thinking behind these schemes and the toolmakers' efforts to design tools for the specific applications defined in their selection systems.

The article looks at concerns being raised over ISO's plans to revise quality standards. An accompanying article discusses a Web site that strongly opposes the announced changes.

The steep-taper toolholder shank design remains popular, but it needs updating to keep pace with modern machining practices. This report suggests minor design changes that these researchers say might overcome steep tapers' limitations.