High-power laser machines—at least 5,000w—are more useful in machine shops because their power permits fast processing of thicker materials, materials more like the blocks machined by the metalcutting industry. Also, automation allows for more cost-effective laser machining.
It's not just for prototyping; additive, or rapid, manufacturing can be a cost-effective way of producing parts, especially when used for mass customization of parts and for low-volume runs of smaller, complex, net- and near net-shape parts.
Magnetic abrasive finishing can deburr and create highly polished, smooth surface finishes. It can also remove microcracks, recast metal, metallurgical phase changes, visible scratches and damaging residual stresses.
Several types of cutting tools can be protected with coatings harder than regular A1TiN coatings by combining A1TiN grains with an amorphous silicon-nitride matrix.
High-speed machining can improve productivity, but a shop will need to change its tool settings and toolpath strategies and experiment with feed rates to achieve this goal.
Grinding machine operators are able to listen to the processes via acoustic emission (AE) monitoring systems and use the information to shorten cycle times and minimize wheel loss from dressing. But, AE sensors need to be positioned to deal with interfering background noise.
Using mini and micro boring bars effectively in Swiss-style machines requires machine shops to know the types of available bars and the ways to strengthen their cutting edges, reduce pressures on the tools and position them for the most efficient cutting.
Lean manufacturing can benefit medium-size and larger companies by improving productivity and reducing quality problems and lead times. Benefits can be realized even in smaller, highly variable job shops through standardized work, balancing and flowing.
There are five tool tips for moldmakers for speeding up production and aiding in highly repeatable, precision machining. Included are deep-hole drills to avoid pecking, high-feed cutters, tools for reducing EDMing, high-precision cutters and PCBN cutting tools.
Superhard finishing tools may benefit machined parts via finer surface finishes, greater wear resistance and harder, stronger microstructures. Also, some of the tools can last longer than their conventional counterparts.
To increase productivity, the aerospace industry should consider different tool materials for faster cutting speeds, tool coatings for reduced wear, and machine tools for quicker cycle times.
Machine shops and other companies discuss the workpiece materials, machine tools and metalcutting processes needed to make the fasteners that keep aircraft and spacecraft together.
Parts manufacturers can keep chips flying and maintain part accuracy by protecting their spindles against misuse, thermal expansion, collisions and penetration by coolant and metallic dust.
With through-tool minimum-quantity lubrication, machine shops may be able to decrease coolant costs and increase productivity and part quality. But, they have to invest in equipment and tooling to achieve those results.
Companies work to interest youths in manufacturing through outreach efforts and partnerships with schools to offer courses that lead to college degrees in manufacturing.
