Articles & Columns

The author discusses three recent advancements in electrical discharge machining: the use of linear motors on EDMs, wire EDMs with an automatic slug-removal capability and dielectric fluid additives that yield finer part finishes.

Metalworking companies have a "cradle-to-grave" responsibility for the fluids they use. Improper disposal can lead to costly fines. Article discusses the ramifications of improper disposal and how to develop a plan to constantly improve the condition of a shop's metalworking fluid.

Due to the exceptional strength of IN 100, INCO 718 and other nickel-based alloys, they're difficult to machine. The author, who spent 40 years endmilling these aerospace materials, discusses their unique characteristics and methods for successfully machining them.

The author provides guidelines shops can follow when selecting a PC-based CAD/CAM system. Selection guidelines include: CAD functionality, CAM functionality, NC code output, vendor evaluation and hardware selection.

The use of shrink-fit toolholders continues to grow, mainly because, compared to conventional holders, they secure tools more tightly and extend the life of cutting tools. Article includes an overview of available systems and comments from users of shrink-fit holders.

The author offers tips about making interrupted cuts while turning. He also discusses the differences between interrupted cuts in turning and milling and various types of materials.

Discussion of different types of bonds used to make superabrasive grinding wheels. Author provides tables with price comparisons, physical properties and operating parameters for various bonds.

Equipping toolchangers with nylon abrasive-filament brushes can greatly enhance process economics and the flow of parts. Case histories of in-machine deburring operations support these contentions, and the author describes how such systems should work.

Salaries earned by metalworking professionals, including machinists, production engineers, manufacturing engineers and corporate managers. Salaries are broken down by region, size of company and type of shop or manufacturing facility.

Overview of the new machine tool technologies introduced at IMTS 2000. Among them are linear motors for axes travels, ballscrew chillers, a new way to lubricate linear guideways and controlling machining processes via the Internet.

Author discusses the advantages of CVD-diamond tools compared to other types of diamond tools. He also explains how CVD-diamond tools are manufactured and gives case histories involving their usage.

Author explains the different ways to upgrade a used machine tool. He also discusses what users should expect from the company that performs the retrofit, rebuild or remanufacturing job and how long the job should take.

How to recognize the signs that lead to bandsaw breakdowns.

Author describes applications for the two basic types of ceramic turning inserts–alumina and silicon nitride–as well as the types of parts and materials users have turned with them. Specifics about speeds, feeds and DOCs are given.

Shop owners who operate multitask machines talk about the time and cost benefits of producing parts in a single chucking. They also discuss some of the problems they had when adopting the technology. Accompanying Articles focus on a multitask users group and machine that hard-turns and grinds.

Discussion of different types of toolholders for lathes, including collets, drill chucks, bushings and keyless chucks. Author discusses best holder for different applications, based on his experiences.

GE Superabrasives' silver-coated diamond crystal is designed for grinding tungsten carbide. Discussed are the benefits--reduced friction, greater crystal retention and a cooler grinding environment--and how to apply wheels made from the crystal.

The author discusses the advantages and proper application of twin-cutter boring tools. They're recommended for rough-boring applications on castings, forgings and other jobs requiring a tool that can bore a cored hole. Details are provided on the three basic types of methods for rough boring with a twin cutter: balanced, stepped and full profile.

One company instituted a comprehensive plan for reducing setup times and saw its average setup time drop from 252 minutes to 39 minutes. The plan involves everything from standardizing tooling to consolidating raw materials to creating families of parts. The author outlines a step-by-step program that readers can apply to their metalworking setup operations.

The trend toward developing finer and finer carbide grains continues. The author looks at recent developments in the production of nanosized tungsten-carbide grains, which are smaller than 0.2 microns in diameter. Though not used widely at present for the production of cutting tools, some predict that will change as the technology evolves.