Articles

As CNC machining gets more complicated, the chance of programmer and operator errors increases. These errors can cause collisions involving machine components and workpieces during the cutting process, resulting in downtime and part, tool and machine damage. Costly crashes aren't inevitable, however, thanks to technologies aimed at preventing collisions and minimizing their impact.

When a good customer requests a meeting at his place, I go. That happened recently, when our shop's account manager accompanied me on a 20-minute trek to a customer's new corporate headquarters for a meeting to review our contract and extend it a few years. The customer happens to be a large corporation, and our shop has a contract to exclusively manufacture certain products.

Contrary to the history lessons from middle school about "the" Industrial Revolution, it is a widely held belief that the modern world has experienced three industrial revolutions. In the first, industry harnessed the power of steam and water. Mass production, reliable electrical power and division of labor drove the second revolution. Electronics and the computer defined the third.

Deep-hole drilling is virtually an art unto itself, with a host of complexities and considerations inherent to the process. Greg Forman, technical director of toolmaker Precision Cutting Tools Inc. (PCT), Santa Fe Springs, Calif., answered questions to provide some insight into drilling holes greater than 5 diameters deep.

It's not the most glamorous piece of equipment by any means, but the ball bar is a diagnostic tool used, in some form, to benchmark the performance of virtually every machine tool sold, according to Harold Schoch, vice president of technology and sales for Konecranes, Erlanger, Ky.

Components used in the manufacture of combustion hardware for a Mitsubishi gas turbine begin life as sheet or plate stock. Because our components come from large sheets, we start every manufacturing process by cutting the desired shape or profile.

CNC lathes have evolved greatly over the past few decades. What were once simple 2-axis turning machines have become a bewildering array of extremely capable metalcutting equipment, most of which offer two spindles, multiple turrets, robust milling capabilities and can complete many parts in a single setup. In other words, they have become multitask machines.

The technology to form, press and grind indexable carbide inserts has evolved to such a high degree that the methods to effectively clamp inserts in a cutter body have struggled to keep up, but strides are being made. Some insert shapes have advanced to the point where they have a true, 100-percent, 3D geometry with almost no flat surfaces. This requires a tool-body pocket that is dynamically shaped to accommodate the optimal geometry. For example, an insert with a wavelike feature across its back requires it be seated in a pocket with a matching shape to ensure accurate fixation with high stability.

Michael Finklea believes that there isn't much reported on sawing in the manufacturing trade press because "it's kind of the redheaded stepchild in the industry—an unappreciated part of the manufacturing process. In most shops, the least-skilled person is running the saw."

END USER: RDC Control Ltd., (800) 363-2264, www.rdccontrol.com. SOLUTION PROVIDER: Rösler Metal Finishing USA LLC, (269) 441-3000, www.rosler.us. CHALLENGE: Reduce the cost and time to finish end plates for hydraulic cylinders. SOLUTION: A shot-blasting machine to perform the process in-house.

END USER: Kluba Machine LLC, (636) 390-4088. SOLUTION PROVIDER: CNC Software Inc., (800) 228-2877, www.mastercam.com. CHALLENGE: Improve cycle times and spindle uptime while maintaining part quality. SOLUTION: CAD/CAM software.

I was saddened to hear about the passing of David A. Dornfeld, professor of mechanical engineering at the University of California, Berkeley, who died of a heart attack on March 27 at age 66. Although I never met him, I considered him to have a brilliant mind and be a great editorial source—someone who returned my phone calls and had something intelligent to say.