Articles

The presence of bacteria and fungi can seriously compromise the effectiveness of metalworking fluids. This article looks at the most harmful microbes and the conditions that allow them to flourish. Preventive measures are also discussed.

Rotary saw cutting (RSC), using a self-contained, motorized attachment that is mounted in a machine's standard cutoff position, can provide an alternative to single-point tooling for cutoff operations. This article details the ways that RSC provides results that are better than single-point tooling while advising readers on ways to optimize the operation.

This article makes the argument that an insert is really a system made up of a combination of factors. The focus of the article is on one of these factors: the top-form geometry, which has evolved from the chipbreaker designs used primarily on turning inserts. The roles these geometries play and the selection process for choosing the right geometry are explained.

The growing use of difficult-to-machine materials has driven the metalcutting industry to high-performance tools. This article reviews the trends that are behind most cutting tool research today, and it looks at the state-of-the art results of that research.

The presence of an eta phase between a coating and the substrate is generally considered harmful to coating adhesion. However, this article argues that when the formation of the eta phase is carefully controlled, it can actually enhance adhesion. The conditions that promote the formation of beneficial eta phase are explained.

Drilling with a single- or double-tube system might be the most efficient way to drill deep holes in some applications. This article, which describes the tools and the process, says tubular drilling can pay for itself in higher productivity, thriftier manufacturing and tighter tolerances.

Researchers studying the performance of diamond coatings have found a number of factors of the coating process that determine the ultimate success of the coating. This article looks at factors such as substrate preparation, stresses in the coating and substrate and the diamond coating's formation patterns.

The benefits of TiN and TiCN coatings are list in high-temperature applications such as the machining of exotic metals. TiAlN coatings, on the other hand, perform better at higher temperatures. This article describes the properties of TiAlN that make it the coating to use with high-temperature work. The article also reviews specific applications where shops have used TiAlN to increase tool life and productivity.

Several factors influence the effectiveness of a drilling operation. This article looks at a number of them, including coolant delivery, speeds and feeds, and tool selection.

Segmented grinding wheels can help in heavy stock-removal applications with large contact areas. This guide covers where grinding segments fit and what shops should watch.

This article reviews the causes of skin irritation suffered by some shop workers, with special attention paid to skin conditions that result from poorly maintained metalcutting fluids. The article also discusses the factors that can aggravate skin problems and suggests ways that workers can protect themselves from skin irritants.

When digital calipers that did not have to be zeroed before each measurement were introduced, they represented a significant advancement in electronic gaging. This article explains the technology behind these absolute-reading instruments and how they are used to make typical shop-floor measurements.