Articles & Columns

By recycling used metalworking fluids, shops can realize considerable savings in fluid and disposal costs. This guide takes the reader through the fundamentals of fluid recycling and management. Excerpted from a manual on the subject, the piece covers both the care and cleaning of fluids and fluid-handling equipment.

Traditional tap/drill charts recommend drill diameters for each size of tapped hole. But, according to this article, these recommendations are based on the size holes that were typically produced by less-accurate tools and processes used in the past. This article suggests guidelines for producing holes that will, in turn, produce correctly sized tapped holes.

Amorphous diamond coatings can offer performance close to that of CVD diamond film at a fraction of the cost. This article describes the amorphous diamond coating process and the coating that is produced. A comparison to CVD diamond coatings is also presented.

This article makes the argument that ball-drive quick-change tapholders, which transfer torque through hardened-steel balls fitted into mating detents, are more reliable than tang-drive units. The technology behind ball-drive tapholders and the design's benefits are explained.

Many end users would like to see carbide tool standards that would ensure consistent quality in tools from shipment to shipment or between manufacturers. Today's C and ISO designations do not provide this assurance, according to this article. The article looks at the problems that arise because of a lack of standards and the attempts being made to guarantee consistent quality in the shop.

The more sophisticated die-sinker EDMs on the market today possess enough intelligence to monitor cutting conditions and make necessary adjustments on the fly. This article describes the technology that drives these smart machines and the "fuzzy logic" they use to maintain an optimal spark.

Modern control technology makes extremely fast milling speeds possible. But the top speed can only be as fast as the slowest link in the chain between controller and machine. This article looks at some of the bottlenecks that can prevent a mill from running at full speed.

In the lab, researchers are using artificial intelligence to turn CAD and CAM programs into systems that can think and make decisions. This article looks at several of these efforts and the capabilties of the systems that have been developed.

CNCs have the power to dramatically increase productivity, yet many shops fail to make use of their controllers' full potential. This article suggests ways that a shop can fine tune its CNCs to create controllers that are optimized for the type of work being performed. The tips include many CNC features, capabilities and options that users often overlook.

CBN grinding wheels offer the promise of higher productivity and longer wheel life, but they must be carefully maintained with dressing routines that differ from routines for standard wheels. This article details the techniques and tools needed to perform CBN wheel dressing effectively and economically.

This article describes the apprenticeship program and other activities that toolmaker Komet of America is pursuing to bring new people into the metalworking industry as machinists. The company has met with some success working with the Tooling & Manufacturing Association and a local high school.

While superabrasives in grinding wheels generally perform better than conventional abrasives, the grains also possess characteristics that can lead to unwanted chemical reactions during the wheel manufacturing process or premature pullout during use. This article discusses the ways a coating applied to the grains can reduce or prevent these undesirable side effects. .

A CNC tool grinder connected to an automated loading unit can be programmed to grind tools during a shop's off hours. This article discusses the planning and preparation that are necessary to set up an unattended run.

This article discusses the various sources of machining information available, and the body of knowledge on which each type of source bases its recommendations. Emerging sources that make use of such innovative media as the Internet also are discussed.

This report details the results of a test of graphite electrodes. The test compared the performance and machinability of three graphite grades, ranging from an inexpensive coarse grade to a relatively costly ultrafine grade.

HSK toolholders were designed with high-speed machining in mind. This article explains the features of the toolholder that make it perform well in modern machining centers at high spindle rpm. It also discusses the toolholder's handling and maintenance requirements.

A toolholder that uses metal's natural thermal expansion and contraction to hold tools does not suffer from many of the drawbacks of other toolholding mechanisms, according to this article. In addition to outlining the benefits of this "shrink-fit" toolholding system, the article also explains the technology and describes how shops have benefited from it.

Dual-spindle turning centers allow shops to combine several processes into one setup. This article describes a typical dual-spindle turning center's configuration and capabilities. A common scenario is given showing how such a machine might be used to reduce cycle times.

CNC bandsaws are designed to run for long periods unattended. This is only possible if the blades used are reliable and long lasting. According to this article, bimetal blades with ground teeth fit the bill. The article describes how these blades are made and what makes them different from conventional blades with milled teeth.

Stainless steel is one of the more difficult materials to cut. This article discusses the problems that can occur when turning various types of stainless steels, the reasons for these problems and ways to avoid them. Advice is given on diagnosing problems based on tool-wear patterns. The article also suggests ways to correct problems once they are discovered.