Alan Richter

Numerous factors determine whether a manufacturer is profitable or not. Lately, one of those factors for a U.S. manufacturer is whether it is is focused on the domestic market or pursuing a global approach.

The technology to form, press and grind indexable carbide inserts has evolved to such a high degree that the methods to effectively clamp inserts in a cutter body have struggled to keep up, but strides are being made. Some insert shapes have advanced to the point where they have a true, 100-percent, 3D geometry with almost no flat surfaces. This requires a tool-body pocket that is dynamically shaped to accommodate the optimal geometry. For example, an insert with a wavelike feature across its back requires it be seated in a pocket with a matching shape to ensure accurate fixation with high stability.

It’s fitting that “Technology” is part of Indiana Technology and Manufacturing Cos.’s name. In addition to providing a full slate of machining and assembly services, ITAMCO created what it says is the first industrial Bluetooth transmitter (called iBlue) and continues to develop a broad range of manufacturing apps for mobile devices and Google Glass. What's more, ITAMCO has produced a virtual manufacturing showroom and developed a manufacturing forklift simulator that allows users to interact with factory equipment using the MTConnect protocol, Autodesk Factory Suite, Unity 3D game development platform, Oculus Rift virtual-reality headset and Leap motion controller.

I was saddened to hear about the passing of David A. Dornfeld, professor of mechanical engineering at the University of California, Berkeley, who died of a heart attack on March 27 at age 66. Although I never met him, I considered him to have a brilliant mind and be a great editorial source—someone who returned my phone calls and had something intelligent to say.

Early in my stint here, I called Alan Baker, founder of toolmaker A.B. Tools Inc., in connection with an article I was writing about thread milling small-diameter holes. I started the interview with a general question about available thread mills sizes for these applications and was encouraged to first gather that information from Machinery’s Handbook and then call him back. I thanked him before ending the call and turning to the appropriate section of “The Bible of the Mechanical Industries,” published by Industrial Press Inc. 

As the plans for more and more machined metal parts include numerical surface finish specifications, the need diminishes to visually qualify that a part has, for example, “a mirror finish with no burrs” or to have the machinist with the finest touch scratch the surface with his fingernail to make sure it’s “matte and rough.”

One of the most enduring issues in the metalworking world is finding and retaining skilled workers, and the 10th annual Metalworking Trends Survey from LoSasso Integrated Marketing, Chicago, showed that this challenge continues. 

To enable junior and senior high school students to follow a specific direction in the manufacturing industry, their education must be diverse. Ensuring such diversity is the goal of the Machine Technology Program at Cuyahoga Valley Career Center, Brecksville, Ohio, according to Rich Parrott, machine technology instructor. 

Virtually every established manufacturer has experienced at least one major setback during its history. For Taurus Tool & Engineering, it was losing its main tool grinding area and CNC machines to a fire in June 2014, after a 37-year run at its previous facility in Schaumburg, Ill. No injuries were reported, thankfully, and the cause of the fire is unknown. 

... in these golden years,” crooned the late David Bowie in one of his smash hits. The term “golden years” is also used in Albert B. Albrecht’s book “The American Machine Tool Industry: Its History, Growth, Restructuring & Recovery,” which he revised in 2015 for the third edition. AMT—The Association For Manufacturing Technology sponsored the book. Albrecht defines the golden years of the machine tool industry as being from 1948 to 1998. “It was during this period that the United States machine tool industry led the world in both machine tool production and consumption,” Albrecht wrote.

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. Unfortunately, the bin leaks and coolant drips on the shop floor, causing the shop’s biggest customer to slip and fall while visiting to check on his latest order. There’s got to be a better way.

Has the reshoring train left the station or not? According to the second annual U.S. Reshoring Index from global management consultants A.T. Kearney, the answer is a resounding “no.” In 2015, the index, at -115, indicates that reshoring of manufacturing activities to the U.S. has not kept up with offshoring. The index measured -30 in 2014. A positive number indicates net reshoring, while a negative value indicates net offshoring.

The array of configurations is vast, but angle heads typically serve a common function: eliminate having to perform a separate operation to access a part feature when the
workpiece can’t be indexed.

CTE Editor Alan Richter visited the Digital Manufacturing and Design Innovation Institute at Chicago’s Goose Island in September for a peek into the future of manufacturing at an event coordinated by Blaser Swisslube Inc.

Running a successful machine shop takes more than having advanced machine tools, high-performance cutting tools and machinists that boost productivity. A manufacturer of precision metal parts might also need a strategic partner that has the network, expertise and — last but not least — capital to penetrate new markets, overcome capacity constraints and make investments to help the business grow.

Milling metals hardened to 52 HRC and harder with solid-carbide cutters doesn't require a heavy-duty, high-performance machine tool when a machinist employs trochoidal milling and applies cutting tools with an appropriate substrate, coating and geometries. (With Video.)

Apply modern manufacturing methods to grow a custom motorcycle business. Automate production and improve part quality and machining efficiency with a CNC machine tool and CAM software.

Fallbrook Technologies' shop continues to produce prototypes for licensees of the company's continuously variable planetary technology while performing commercial jobs.

Minimize tool runout, extend tool life, reduce scrap and prevent fixture damage. An offline cutting tool presetter.

Time for a literature review.

Increase wire EDM capacity and cutting speed. Replace two old, technologically obsolete wire EDMs with two new ones.

Efficiently deburr machined hydraulic manifolds. A machine that deburrs via thermal energy.

World-class manufacturers expand their production space for anticipated demand rather than attempting to catch up with current needs. This effort to always be ahead of the times was on display at Horn Technology Days, which took place June 17-19 and was hosted by Hartmetall-Werkzeugfabrik Paul Horn GmbH at its headquarters in Tübingen, Germany.

An interview with Michael Nahum, Micro Encoder Inc.

Abrasive waterjet machines become easier to use and more affordable as equipment evolves.

Reduce workload on Swiss-style and mill/turn machines. A machine tool that bridges the gap between Swiss-style and multitask machines.

A laser arc method to coat engine and other parts with a diamond-like coating.

Reduce the time to rough bore bearing pockets. Twin roughing heads.

An aluminum-magnesium-scandium powder for additive manufacturing that exhibits the specific strength of titanium and the positive properties of aluminum.

A method of lubricating and cooling a machined workpiece using supercritical CO₂.

New aluminum alloys can pose machining challenges, but they can be mastered with sound cutting strategies.

Bring damaged components back into spec. A flexible cylinder hone.

A direct-drive, servomotor robotic finger.

Improve productivity for a repeat job. A multifunctional, 90° indexable-insert shoulder cutter.

Reduce cycle times when machining hydraulic components. A solid-carbide, through-coolant drill that orients the margins radially.

The Look Ahead section in the May 2015 issue of Cutting Tool Engineering magazine features an asymmetric line boring bar.

Steelville Manufacturing Co. uses flexible manufacturing systems to enhance machine tool productivity and continue growing.

Eliminate a bottleneck when inspecting parts. Work cells equipped with coordinate measuring machines and dedicated, quick-change fixtures.

The Look Ahead section in the May 2015 issue of Cutting Tool Engineering magazine also presents a sensory toolholder for wireless, in-process measurement of cutting forces.

A new process for strengthening metals while making them more resistant to corrosion.

Increase part quality and productivity when deep-cavity micromachining while achieving tight tolerances. A heat-activated, wax-based compound for holding parts.

A PCD milling cutter that combines a patented chipbreaker and direct cooling through the cutting face.

Vertical machining centers play a central role in the growth of S&S Machine Shop.

Enhance precision and shorten changeover time when machining retention knobs. Quick-change collet chucks.

Software for high-efficiency roughing makes moldmaking faster, more efficient.

Eliminate excess coolant to improve shop floor safety and cleanliness. Minimum quantity lubrication systems.

New metamaterials that 'bend' acoustic and elastic waves.

Overcome excessive tool wear and poor surface finishes when machining flats on a steel truck shaft. A milling tool that exerts all cutting forces downward and cuts freely.

The creation of superhydrophobic metals using femtosecond lasers.

Efficient removal of heat from the tool/workpiece interface is the main route to high-productivity machining. Several conventional methods are available to accomplish that -- dry machining, minimum-quantity lubrication, flood coolant and high-pressure coolant -- but cryogenic machining can be added to the list.