Articles & Columns

Numerous toolmakers provide free programs that will automatically generate G code for a specific thread milling application. The programs vary in sophistication and in whether they are online-only or downloadable, but all are useful tools. Among the suppliers of these apps are Scientific Cutting Tools Inc., Simi Valley, Calif.; Guhring Inc., Brookfield, Wis.; and Kennametal Inc., Pittsburgh.

Scrap happens. By scrap, I mean parts that are out of tolerance and, therefore, useless. Unlike other by-products of the manufacturing process, such as chips, shavings and drops, you generate scrap only through mistakes. 

So the challenge of reducing scrap comes down to preventing mistakes.

What would cause parts manufacturers not to want to extend tool life, increase speeds and feeds, enhance chip evacuation to avoid recutting, impart finer surface finishes and eliminate pecking when deep-hole drilling? Apparently, ignorance in the marketplace.

Swarf, which is the result of particles being removed when grinding hard or difficult-to-machine materials, tells a story.

Keith Jennings, who writes the Manager's Desk column for Cutting Tool Engineering, never experienced being sad and mad at the same time until recently, according to his September column. The cause? A trusted employee who wasn’t so trustworthy.

Many machinists fondly remember their early training or apprenticeships when they made 1-2-3 blocks from scratch under the watchful eye of a master toolmaker. These young machinists carefully machined the blocks oversize, heat-treated them and then ground them to size. They quickly learned that precisely holding size and geometric features to close limits is more challenging than it seems at first glance.

Metal laser melting has made possible a number of groundbreaking developments in the medical field. One example is a 3D-printed bone drill that, unlike some traditionally manufactured drills, is designed not to damage tissue during surgery.

The boost in productivity that the latest cutting tools provide enables manufacturers to reduce the amount fracking companies pay for parts.

END USER: Northeast Tool & Manufacturing, (704) 882-1187, www.northeasttool.us. SOLUTION PROVIDER: MachineMetrics, (413) 341-5747, www.machinemetrics.com. CHALLENGE: Reduce the time and manual inspection required to measure productivity. SOLUTION: A machine monitoring system.

END USER: Lowercase, (212) 510-7621, www.lowercasenyc.com. SOLUTION PROVIDERS: Axis Inc., (908) 429-0090, www.axisnewjersey.com; Robotiq, (888) 762-6847, www.robotiq.com; Universal Robots USA Inc., (844) 462-6268, www.universal-robots.com. CHALLENGE: Cost-effectively integrate automation into the production of eyewear frames. SOLUTION: A collaborative robot tooled with an easy-to-use, flexible gripper.

Until a couple of years ago, the Food and Drug Administration required a unique identifier on each distinct assembly of a medical device in human- and machine-readable forms. That rule has changed. Now, every individual component in an assembly must be marked as well. Traceability is becoming more and more prevalent, not only in the medical device sector but throughout manufacturing.

Trochoidal milling is a relatively new cutting strategy that involves the overlapping of circular toolpaths with linear movement. It is well-suited for difficult-to-machine materials and thin-walled components.

An item in the Look Ahead department of the August 2017 issue of Cutting Tool Engineering magazine features large-volume, high-accuracy robots.

Low-wattage lasers are faster, gentler and more eco-friendly than traditional parts-cleaning methods. So why aren’t they more prevalent?

Grinding is a thermally dominated process, meaning a high percentage of process heat initially enters the part before coolant quenches it. Unless the coolant is applied at the correct flow rate and pressure, and the proper input conditions are selected, this process can lead to undesirable rehardening burn, thermal softening and tensile residual stresses. 

Spindle bolts are made from difficult-to-machine, high-strength superalloys. They have very tight dimensional tolerances, which makes thread cutting a challenge. As a result of facing several thread-cutting problems during process development, we have learned important lessons at Mitsubishi.

If you’ve ever watched a bar of red-hot metal emerge from the furnace at a rolling mill, you might wonder how that scaly chunk of material became the smooth, shiny and accurate length of steel you just loaded into a lathe’s bar feeder. Machinists know it as cold-finished bar stock. It got that way thanks to a process known as bar peeling. 

The primary application for ultraprecision machining is optical-grade surfaces for injection molds, which are used to make contact lenses, LEDs for TVs and head-up displays in military aircraft and luxury cars.

Machining manifolds generates numerous burrs, and removing them is no simple task. Basin Precision Machining attempted a variety of deburring methods, including waterjet, kinetic energy and the thermal energy method (TEM).

In the August 2017 issue of Cutting Tool Engineering, Ask the Grinding Doc Columnist Jeffrey Badger, Ph.D., fields questions about spotting wheel loading, white sticking for hardened steel loading, and what causes barber pole marks during cylindrical-traverse grinding.