Articles & Columns

Dear Doc: I grind fine threads into hardened stainless steel with a fine-mesh aluminum-oxide wheel. The threads are 0.8mm deep in a 5mm-dia. ID. There are three threads per part. This operation just chews through the wheel, and I get only one part before I have to dress a 0.2mm depth in my 4mm-dia. wheel. What am I doing wrong? 

The moving elements of a machine tool have mass. Forces from the actuators cause the masses to move and accelerate. As the speed of the machine tool motion increases, the ability of the actuators to cause acceleration becomes more important.

Lightweight and easy-to-program robotic arms.

END USER: 1-866-Dial-EDM, (866) DIAL-EDM, 1866dialedm.com. CHALLENGE: Produce a high volume of 0.006"-dia., 1/16"-deep blind-holes in an exotic material. SOLUTION: An EDM drill. SOLUTION PROVIDERS: Britton Machinery Sales Inc., (585) 241-3267; GF AgieCharmilles, (800) 282-1336, www.us.gfac.com

END USER: David Buchberger, (585) 208-7382, www.hispeedcorp.com. CHALLENGE: Efficiently machine lightweight components for an “extreme” racecar. SOLUTION: High-performance cutting tools, including a drill and endmill. SOLUTION PROVIDER: WIDIA Products Group and Services, (724) 539-5000, www.widia.com

END USER: Continental Motors Inc., (800) 718-3411, www.genuinecontinental.aero. CHALLENGE: Boost productivity when rough and finish milling cast aluminum crankcases. SOLUTION: PCD-tipped, cartridge-type facemills. SOLUTION PROVIDER: Ingersoll Cutting Tools, (866) 690-1859, www.ingersoll-imc.com

The combination of rigid machine tool and strong spindle connection is ideal for cutting titanium.

Similar to a multitask machine, a machine tool that combines ID and OD grinding enables producing a part in one chucking.

In my August column, I described several common applications for workholding when turning, where the cutting tool is static and the workpiece spins. There are several standard workholders for turning, which were illustrated.

Manufacturing faces more uncertainty than usual in 2013, but the year ahead could be a good one.

A machine shop can become a messy place if you don’t stay on top of it. If you’ve visited other shops, you’ve probably observed what I’ve seen over the years—a few that are spotless and well-maintained, and others that look like a cave, with little thought or care given to the work environment. Most shops are somewhere in between. We maintain a decent shop, which consists of machining and fabrication departments in separate areas, but it takes constant effort to keep it that way.

The pros and cons of marking parts with laser, micropercussion and scribing technologies.

In my October column, I explained how the design of manual milling machines could be improved. This month, I share some tips for enhancing the operation of a manual mill.

Holding a few tenths tolerance on a piece of 60-HRC steel was once the domain of expensive grinding equipment. Today, it's no big deal.

Many reasons are given, including the bad image of manufacturing, lack of training in high schools and competition from other economic sectors. All of these reasons seem plausible. But now comes a study by The Boston Consulting Group, a management consulting firm, that seems to throw cold water on the idea of a serious skills gap. According to the authors, the skills gap in U.S. manufacturing is more limited than many believe. The study is part of BCG’s ongoing “Made in America, Again” study, which examines the changing economics of manufacturing.

A second item in the Look Ahead section of the October 2012 issue of Cutting Tool Engineering magazine covers an automatic, scalable component-testing system that combines acoustic and functional testing.

The October 2012 Get With The Program column focuses on improving 5-axis machining by combining post-processors and verification software.

How many times does a project break down just from trying achieve perfection? Machinist's Corner columnist Michael Deren urges readers not to let perfect trump better.

Effectively reaming nickel-base alloys requires a slow and steady approach.

This Look Ahead item features a CNC gear honing machine that uses a honing wheel with external teeth and reduces the number of process stages.