Articles

Every machine tool owner can reap benefits from a good spindle maintenance program. These include reductions in costly unplanned machine downtime, longer spindle life and improved part quality. But effective spindle maintenance requires perseverance and the appropriate technology—plus a little common sense.

How often should a metalworking fluid be tested? It depends. Metalworking fluid is used in most machine shops, because it aids in evacuating chips and cooling and lubricating the tool/workpiece interface. To optimize fluid performance, it must be maintained, which is done by testing a fluid for performance and chemistry.

Careful consideration when implementing inspection processes yields efficiencies. Manufacturers continually search for ways to increase profits and reduce costs. Trying to find cost savings where chips are made makes sense and is usually where the most-significant improvements are found. However, efficiency gains can also be made in nonvalue-adding areas, like inspection.

The chip collection bin at a shop's turning center is full, so a worker grudgingly begins the mundane task of moving the bin via a forklift to the chip collection station at the opposite end of the plant.

Do you know why your last part run had a high defect rate, why parts from an outside supplier were nonconforming, and what you are going to do with those parts? If your company has a material review board, it can probably answer those questions.

Whether your shop is busy or struggling to survive a downturn, employees are your best asset. We've had to downsize over the past few months, but a good group remains. Many are handling new tasks, but a reengineering of employees' tasks can be beneficial, driving everyone to work smarter, not harder.

When CNC wire EDMs came on the market in the mid-'70s, feeding wire from a spool through a machine's elaborate series of rollers and guides was a tedious manual exercise. Luckily, electrical discharge machining was an exceedingly slow process back then, so replacing wire had to be done less frequently than on today's machines, which erode conductive metal 10 to 20 times faster than earlier models.

Multiple machine tool builders offer equipment for machining the helicopter transmission components Northstar Aerospace Inc. produces at its Bedford Park, Ill., facility, but not all are equally efficient in handling the task.

Technological advances in cutting tools, machine tools and toolholders have allowed machinists and manufacturing engineers to increase holemaking efficiency by eliminating the number of tools required to produce accurate holes. High-performance drills are the best example of these technological advances. In the past, it was common for a machinist to spot-drill, drill and then ream to achieve accurate hole geometry.

Specifications for particulate and film-residue cleanliness are a matter of course for many machined components. In addition to the parts cleaning procedure, manufacturers must consider the entire process chain when seeking to efficiently achieve and maintain the required level of cleanliness.

While it's nearly impossible to quantify the most common challenges or most important considerations when turning, experts agree that the five aspects of turning discussed below should be considered. It's important to note that each factor has the potential to impact the others.

At roughly twice the price of a vertical machining center, do horizontal machining centers make sound financial sense? Absolutely, according to Scott Baldus, product specialist at Okuma America Corp. The Charlotte, N.C., machine builder offers both VMCs and HMCs, yet, Baldus noted, HMCs provide, on average, more than three times the spindle utilization of VMCs.