Articles & Columns

The author looks at some recent advancements in tool coatings: multilayer,
multielement, diamond, nanocomposite.

Author describes what he's learned about turning hardened steel. Discussed are the machine tools needed as well as PCBN and ceramic inserts.

Article discusses the disadvantages of carrying too many grades of carbide inserts. Often, using a less-than-optimal grade can save a machine shop money.

Three companies that tap millions of holes annually offer advice for improving the tapping of steel and aluminum. Discussed is coolant application, equipment for tapping and determining speeds. There's also a sidebar on thread milling.

Article defines what constitutes a high-pressure coolant-delivery system and offers advice for selecting such a system. Discussed are pumps, system prices and advantages of these systems when cutting metal.

Advanced tool grinding machines are making it possible for even small shops to regrind complicated tool geometries in-house. This article explores the cost and time factors that must be considered before a shop decides whether it will regrind tools in-house or outsource the work.

The manufacturer of the most widely used fire-hose nozzle has continually upgraded its processes and equipment to meet its customers’ needs. This article outlines the market forces and changes to its nozzle design that have driven the company to maintain a state-of-the-art shop.

A 10-question quiz tests the reader’s knowledge of gage usage and maintenance. The answers, which are provided, help correct common misperceptions about gages and gaging.

When facemilling with an indexable-insert tool, the axial and radial rake angles of the inserts can have a significant impact on performance. This article reviews the basics of rake angles and their effect on tool life, cutter effectiveness and metal-removal rates.

Vacuum chucks can be useful for holding parts that are thin, irregularly shaped, large and flat or easily marred. This article describes the components and machining required to build a vacuum chuck in-house. Accompanying Articles discuss the commercial units that are available and the use of router bits to reduce the lift on vacuum-chucked parts.

Industry professionals explain why manual machining skills are still necessary even in this age of CNCs. The article also describes the additional skills needed to program and operate computerized machine tools.

A project engineer recounts his experiences planning for, installing and setting up a new CNC vertical milling center. Among the issues he explores are the questions that must be answered before the machine arrives, selecting or designing tools and fixtures for the new machine and preparing workers for the change.

This article relates how three shops used creative ideas to solve difficult boring problems. One shop built a custom tool to bore deep holes. Another used a combination of standard tools to bore an interrupted cut. And a third achieved tight tolerances with an assortment of plastic sleeves and plugs.

Toolmakers are constantly introducing advancements to improve the metalcutting process. This article examines trends in five key areas where toolmakers are concentrating their research and development efforts.

An organized toolcrib is necessary to ensure that tools will be available when needed. This article reviews the techniques and equipment different shops have used to keep track of their tools.

Open controls allow users to integrate commercially available hardware and software with machine tool CNCs. This article reviews how different CNC makers have designed systems that incorporate or connect with PC-based products to offer this level of flexibility. Accompanying Articles describe one shop’s experience with open architecture and list the skills needed to operate these new systems.

Small-diameter drills designed for drilling circuit boards can be used as a low-cost alternative for producing holes in other materials as well. Their fragility is the only drawback. This article describes these tools and the special handling they require.

This article describes a self-contained micromachining center. The unit uses PC-based controls and a video system to machine small parts with precision, while giving the machinist a magnified view for setup and prototyping.

Spot drilling is a time-consuming process, but sometimes it is necessary to prevent drill walk. This article describes the reasons for spot drilling and the economic impact of adding the operation to a job. It also explains why a spot drill is a better choice for the operation than a center drill.

Tapping and thread milling can both produce internal threads in a variety of sizes, pitches and materials. This article discusses the factors that will dictate which process makes the most sense for a given job.