Articles & Columns

It is widely acknowledged within the manufacturing industry that PCD tools deliver excellent results when reaming nonferrous metals and abrasive plastics. Reaming with a PCD tool allows the user to ream holes faster, to tighter tolerances and produce cleaner-edge holes than is possible with carbide or HSS tooling. 

Cutting Tool Engineering magazine's 2016 Salary Survey reveals the paychecks metalworking professionals receive are not packing as much punch.

Within the last decade, multiple endmilling developments have occurred. These include bold, new cutter designs, extremely tough but wear-resistant carbide grades and toolpaths that reduce mechanical shock to machine tool and cutter alike while reducing cycle times by 50 percent or more and extending tool life. 

Talk about composites in most machine shops usually refers to carbon-fiber material, though “composites” may refer to a variety of mixed materials going back to the mud-and-straw structures made in ancient times. The latest example: A new metal nanocomposite composed of magnesium infused with a dense and even dispersal of ceramic-silicon-carbide nanoparticles. It’s a superstrong-yet-lightweight structural metal with record levels of specific strength and specific modulus, or stiffness-to-weight ratio, and was created by a team led by researchers from UCLA. The material also showed superior stability at high temperatures. It could be used to build lighter aerospace and automotive vehicles, helping to improve fuel efficiency, and for mobile electronics and biomedical devices, according to the researchers.

Autodesk CAM software developer Delcam Ltd., working with toolmaker Technicut Ltd., has created a software and cutting tool combination for machining blisks that reportedly reduces machining time and costs about 50 percent compared to traditional methods. 

CNC machining takes a blend of computer skills and machining skills. Some competent machinists, especially old-timers, lack the computer skills needed to go from print to part using CNC machines. I previously lacked the computer skills, but couldn’t tolerate not having complete control of the jobs I was running. Therefore, I taught myself the computer side of CNC machining so I could create my own programs. 

You might think laser pulse lengths measured in nanoseconds—that is, billionths of a second—are short. But they’re long compared to those of picosecond (a trillionth of a second) and femtosecond (a quadrillionth of a second) lasers, which are known as ultrashort-pulse lasers. Once confined mainly to laboratories and medical facilities, USPLs have become increasingly popular machining options over the last decade, thanks to lower prices and more-rugged designs intended for industrial settings.

This issue of CTE includes our IMTS 2016 Show Preview, featuring show highlights, information about the various pavilions, a guide to Chicago attractions and an extensive array of announcements about what exhibitors plan to showcase. The latter includes machine tools, software, workholders, automation equipment and cutting tools. 

Our supplier in Asia is grinding hardened-steel parts and sending them to us for final processing. Some of them are cracking, so we’re going to visit the supplier. What should we be looking for?

If you’re considering implementing a real-time machine monitoring system and looking for solid reasons to make the investment, you’re in for a pleasant surprise. Real-time machine monitoring and overall equipment effectiveness software can help address many issues, whether they’re obvious or not. There are a number of warning signs indicating that it might be time to investigate acquiring OEE software.

This summer has been hectic, both professionally and personally. The business side has been a roller coaster, requiring intense management. Personally, I had the pleasure of seeing my third of four kids graduate from high school and begin developing an interest in our family business.

The National Center for Manufacturing Sciences is helping industry develop lightweight automotive parts from nontraditional materials.

END USER: Wagner Machine Co., (217) 384-0072, www.wagner-machine.com. SOLUTION PROVIDER: 5th Axis Inc., (858) 505-0432, www.fifthaxis.com. CHALLENGE: Reliably and cost-effectively grip parts during 5-axis machining. SOLUTION: A compact, dovetail-style, 5-axis clamping system.

Four major players involved in industrial automation are collaborating on the development of a platform that connects CNC machines, robots, peripheral devices and sensors. The purpose of the system is to deliver analytics that optimize manufacturing production.

Numerous factors determine whether a manufacturer is profitable or not. Lately, one of those factors for a U.S. manufacturer is whether it is is focused on the domestic market or pursuing a global approach.

It’s not the most glamorous piece of equipment by any means, but the ball bar is a diagnostic tool used, in some form, to benchmark the performance of virtually every machine tool sold, according to Harold Schoch, vice president of technology and sales for Konecranes, Erlanger, Ky.

When a good customer requests a meeting at his place, I go. That happened recently, when our shop’s account manager accompanied me on a 20-minute trek to a customer’s new corporate headquarters for a meeting to review our contract and extend it a few years. The customer happens to be a large corporation, and our shop has a contract to exclusively manufacture certain products.

A team of engineers from several California colleges has developed and tested a type of steel with a record-breaking ability to withstand impacts without permanent deformation. The new alloy, named SAM2X5-630, could be used in applications from drills to body armor to meteor-resistant casings for satellites. The material is an amorphous steel alloy, a subclass of steel alloys made of arrangements of atoms that deviate from steel’s classical crystal-like structure, where iron atoms occupy specific locations.

END USER: Special Quality Alloys Inc., (281) 548-1277, www.sqainc.net. SOLUTION PROVIDERS: Industrial Diamond Products Co. Inc., (713) 991-1600, www.idp-tx.com; Simonds Saw, (800) 343-1616, www.simondsint.com. CHALLENGE: Extend bandsaw blade life while reducing cycle times. SOLUTION: Back-edge ramping technology to accelerate the sawing rate.

The technology to form, press and grind indexable carbide inserts has evolved to such a high degree that the methods to effectively clamp inserts in a cutter body have struggled to keep up, but strides are being made. Some insert shapes have advanced to the point where they have a true, 100-percent, 3D geometry with almost no flat surfaces. This requires a tool-body pocket that is dynamically shaped to accommodate the optimal geometry. For example, an insert with a wavelike feature across its back requires it be seated in a pocket with a matching shape to ensure accurate fixation with high stability.