Articles & Columns

As the government publishes ever-stricter regulations for metalworking fluids, more shops try dry machining. The author examines the cost benefits of machining dry and looks at the various types of tool materials designed to enhance dry-machining applications.

The author, an expert on cutting tool edge preparation, explains the importance of applying the proper edge hone to a tool. He also discusses a brush-type honing machine designed to apply a variable edge--a capability not available with other machines on the market.

Tool management software is designed to help users of cutting tools get more control of their toolcribs. The article describes the types of tool management software available, the savings possible by utilizing software and includes comments from shop owners who've installed these systems.

Dry milling and turning grow in popularity day by day, but dry drilling is
another matter. Because of the nature of drilling, it's more difficult to
perform this operation without coolant. Still, progress is being made,
thanks to research and more sophisticated coatings.

A detailed description of a combination drill that machines six different
hole diameters. Used on a dedicated drilling machine that drills cast iron
cylinder heads, it was developed over a number of years. The six-in-one tool
is made of HSS and has carbide inserts.

Most people know that using the right grade of insert can improve
productivity dramatically. Few know that the proper grade is also important
when utilizing round tools. The author examines the different types of
carbide grades available for round tools.

The CNCs on many lathes don't have drill-pecking cycles. The author
describes several ways to program CNCs to peck, including shortcuts such as
subprogramming and parametric programming.

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.