Articles & Columns

We at Cutting Tool Engineering celebrated the New Year by unveiling a major overhaul to the design and functionality of our website, ctemag.com. Sporting a bright new design with larger text and images, ctemag.com is not only easier on the eyes, it’s also easier on the fingers thanks to new navigation and search functionality. In short, finding the information visitors want will take fewer clicks than ever.

With 2015 being a year of changes and volatility in our market, the importance of strong, supportive business relationships was made even clearer. Longtime business associates became friends, and new business relationships formed with former employees who stayed in touch, neighbors, contacts made through my local chamber of commerce and even my brother’s gym-workout partners. These are people who provided helpful insights and became ambassadors of our company, because they got to know us and saw potential. 

KME CNC developed a 5-axis tombstone 8 years ago for horizontal machining centers that allows milling on five or more sides of a workpiece and on four different platters in a single setup. Recently, the company unveiled a version that requires no wires, cables or any type of connection, making it easier to move parts in and out of a machine.

The view from Jungfraujoch inspires awe. So does the railway that transports visitors to the site—a ridge located 11,332’ above sea level in the Swiss Alps. I was exposed to another example of commitment while in Switzerland, during a visit to the Mikron Group. Company vice president Markus Schnyder recounted his attempts in the early 1990s to develop a drill for a customer that used Mikron rotary transfer machines to drill holes in stainless steel watch bracelets.

Are visitors to a bearing manufacturing facility in Hoechstadt, Germany, getting an early glimpse of what Industry 4.0 looks like? That’s the hope of Schaeffler Group, which owns the facility. The plant houses a machine tool meant to show how digitalization works—not in a laboratory, but in an actual manufacturing environment.

PCD oxidizes when cutting materials such as iron, cobalt, nickel, chromium and vanadium because of the high temperatures generated while cutting. Although not as hard, PCBN possesses superior chemical inertness compared to PCD.

I typically keep my resume online at all times on the major job search engines and update it annually to keep recruiters I’ve worked with in the past abreast of what is happening with my career. The drawback is, after I update my resume, I am inundated with email from recruiters and job placement companies that want to place me in a new position. If you’ve ever posted your resume to an online job search engines, I’m sure you’re familiar with this scenario.

Metrology is evolving to allow inspection to be moved closer to the production area. Is it time to remove your inspection lab and retire your old, reliable coordinate measuring machine? Has portable metrology equipment reached a point where all your parts can be measured directly on the shop floor? The answer to both remains a resounding, “Not quite yet.”

Anyone who’s drilled a deep hole on a CNC lathe or mill knows it’s not easy. Go much deeper than 10 or 20 diameters and out-of-tolerance hole straightness, chip packing and premature tool failure become real concerns. Some machine shops turn to gundrilling houses, where specialty machines and tools make easy work of holes hundreds of diameters deep or more. Unfortunately, this means shipping the parts, incurring additional costs and increasing lead time to customers. Surely there’s a better way.

CHALLENGE: Upgrade QC to reduce the amount of time required for dimension measurements. SOLUTION: Utilize an image-dimension-measuring system that enables hundreds of features to be measured in seconds. END USER: Autocam Corp. Inc., (800) 747-6978, www.autocam.com. SOLUTION PROVIDER: Keyence Corp. of America, (888) 539-3623, www.keyence.com.

Your shop just bought its first 5-axis machining center. Now what? Not only are there new and more complex programming techniques to learn—never mind the mind-boggling variety of part processing options to contend with—there’s also the pesky problem of how to grip workpieces. With the ability to tilt, rotate and position parts in ways never before possible, machining five sides of a workpiece in a single setup is a challenging but straightforward exercise—provided clearance between the workpiece, machine table and spindle head is maintained.

The array of configurations is vast, but angle heads typically serve a common function: eliminate having to perform a separate operation to access a part feature when the
workpiece can’t be indexed.

Presented here are more tips and tricks for proper planning when CNC machining. One of the first and simplest things to look for when performing operations that involve vises is the length of the contact area between the part and the vise jaws.

The drive to reduce setup times and operator intervention has led to the proliferation of multitask machines. Multitask machines range in price and complexity from lathes capable of driving rotating tools to large machining centers that can effectively perform the turning and milling operations needed to complete complex parts in one setup.

CHALLENGE: Reduce setup and cycle times while meeting customers’ demands for high-quality parts. SOLUTION: Two horizontal machining centers. END USER: Reinhold Industries Ltd., (780) 434-8552, www.rilflo.com. SOLUTION PROVIDER: Methods Machine Tools Inc., (877) MMT-4CNC, www.methodsmachine.com.

CAD/CAM software developers are no longer competing only with each other. They are also competing with their customers’ expectations of what a satisfying user experience (UX) should be.

Productive Times challenge: Ensure there are no machining issues with a flexible manufacturing system. The solution: Machine simulation and optimization software.

Productive Times challenge: Effectively clean and cool grinding oil applied in latest-generation grinders. The solution: A filtration and chiller system that directly communicates with grinding machines.

Turbine blades are typically mounted on compressor disks and milled from a single piece of material rather than constructed blade by blade. These are known as blade-integrated disks, or blisks, and their main function is to compress air in the turbine.

To improve performance, reduce cycle times and enhance machine operation, Makino Inc. has released Hyper technologies for its full line of wire, sinker and holemaking EDMs.