Cutting Tool Engineering Magazine

Fallbrook Technologies’ prototype shop continues to produce one-offs for licensees of its continuously variable planetary technology while performing commercial jobs. PLUS:

• Job shop benefits from a big, 5-axis, twin-spindle machine
• Offline presetting maximizes machine availability and reduces scrap
• A combination of planning, housekeeping and the proper equipment enhances shop safety
• 5 factors shaping the ceramic tool market
• And columns covering the benefit of avoiding free worker benefits; the advantages of modular machine tools; how machine monitoring software provides data-driven manufacturing; the benefits of photo-activated adhesive workholding; an overview of broaching tools; some miscellaneous tips and tricks for machinists, and a walk on the lean side.

Tool management systems prevent mistakes and boost the bottom line. PLUS:

• A comparison of three threadmaking options: tapping, forming and milling
• Laser-assisted machining tackles hard materials
• Solid-state LED lighting in machine tools allows for increased visibility, reduced downtime and lower power consumption
• And columns covering the requirements for making difficult shop decisions; how the CNC evolution continues with Mazak's Smooth Technology; some considerations when evaluating CAM software; a Q&A about improving part inspection, and advice when applying multiple-rib grinding wheels.

Horst Engineering shifts production from Mexico to Connecticut; and INOVA Geophysical rethinks machining process, saves close to $1 million by reshoring production from China. PLUS:

• Abrasive waterjet machines become easier to use and more affordable as equipment evolves
• Bandsaws turn high-tech with advanced control and cloud-based intelligence
• And columns covering potential buried treasure in machine shops; CAD/CAM questions and answers; examples of custom workholding; the importance of preventive maintenance; some toolholder options for high-speed machining; how to straighten shafts and tubes, and the quest for cutting tool knowledge.

New aluminum alloys can pose machining challenges, but they can be mastered with sound cutting strategies. PLUS:

• How shops can help keep groundwater clean and be green in other ways
• Parting off presents challenges, but paying attention to the basics makes it a lot easier
• Manufacturing consultant leverages CAM software to help customers adopt transformative technology
• And columns covering the global machine shop; how to fixture challenging parts; the importance of inspecting parts only when needed, and the benefits of multiple-grit grinding wheels and truing cup wheels.

Move, shred or pack them—chip management doesn’t have to be hard. PLUS:

• Steelville Manufacturing Co. uses flexible manufacturing systems to enhance machine tool productivity and help continue shop growth
• New talent, experienced hands hone Peerless Precision’s capabilities
• And columns covering supplier relationships; how inertia active control cuts cycle time; the advantages of scalable CAM software; the need to train workers to sharpen their skills; coolants for challenging cuts; a conversation with a fresh "face of manufacturing"; the application of flame straightening corrections, and whether your next robot will be collaborative.

Vertical machining centers play a central role in the growth of S&S Machine Shop. PLUS:

• Software developers raise the bar with improved toolpaths, integration and simulation
• When grinding complex cutting tool profiles, attention should be paid to the software, the wheel and the tool blank for best results
• And columns covering the importance of keeping employees' personal matters separate from professional ones; some methods for minimizing chatter; boring heads that improve productivity; how quick-change tooling can boost profits; how flame hardening works, and some answers to queries about barreling and scrubber nozzles.

High-efficiency software makes roughing of molds smoother, more efficient. PLUS:

• Modular automation increases productivity and flexibility at a lower price point than custom solutions
• Small shop becomes big aerospace manufacturer with a little help from its friends
• Learn details about the numerous new products manufacturers are offering the metalworking industry
• And columns covering the need to protect a shop's digital information; correcting linear positioning errors of machine tool axes; some advice on selecting wire EDM workholders; creating process visibility with cloud computing; how to select and use the best gages; the lost art of flame straightening, and creating a plan to replace retiring workers.

Cryogenic machining systems can extend tool life and reduce cycle times. PLUS:

• Table-type horizontal boring mills add versatility to a machine shop
• A journey of waste reduction and continuous improvement for machine shops
• And columns covering how to manage requests for pricing discounts; how to keep seeing clearly through machine vision panels; the need to check the tailstock when parts go bad; finding shop apps for mobile devices; shop fundamentals, some essential elements for successful endmilling, and battling burn and other grinding issues.

Collaborative robots lend a helping hand. PLUS:

• Hybrid machining expands a part designer’s pallette and speeds the art-to-part cycle when prototyping
• Shops are deep-hole drilling on standard machine tools, but certain applications still require specialized machines
• Shops have plenty of choices when gripping small parts
• And columns covering the need to adapt to today's shop customer; measuring with capacitance sensors; the closing of the programming-to-production gap; how coordinate measuring machines benefit part manufacturers of all sizes; the use of roll grinding to finish corners, and the importance of following—and saving—instructions for new and existing jobs.

Machine tools for cutting composite materials have unique requirements. PLUS:

• The pros and cons of turning with the ‘perfect’ insert
• While many machine shops have an EDM, they still have to decide when to outsource certain jobs
• Choosing the best marking method for delicate workpieces
• And columns covering the cultivation of machining's future; an interview with an enterprising Colorado manufacturer; when to turn to a turnkey solution; more tips and tricks for parts finishing, and some methods to purposely burn workpieces.

2015 Buyers Guide issue:

• Manufacturers index
• Disributors index
• Machne Shop index.

Cloud-based CAD gains momentum. PLUS:

• Simultaneous machining on multiple spindles enhances efficiency and lowers cost per part for high-volume production
• Thermal and mechanical methods can increase part surface hardness while leaving the inside ductile
• Machine-integrated inspection systems can improve quality and profitability
• Integrating digital tool libraries into CAM software enables process improvement
• And columns covering the benefits of taking shop workers to IMTS; the advantages of preloading ball nuts; how workholder modeling slashes setup time; metrology software benefits; some significant advances in deep-hole drilling, and still more tips for effective finish work.