Feature Article

As the government publishes ever-stricter regulations for metalworking fluids, more shops try dry machining. The author examines the cost benefits of machining dry and looks at the various types of tool materials designed to enhance dry-machining applications.

The author, an expert on cutting tool edge preparation, explains the importance of applying the proper edge hone to a tool. He also discusses a brush-type honing machine designed to apply a variable edge--a capability not available with other machines on the market.

Creep-feed grinding is not as popular a process as it was predicted to become in the late 1980s. But a machine shop that specializes in CF grinding has found great success by using the process. The shop's owner and other CF-grinding experts contend that as workpiece tolerances become tighter and manufacturers begin using more exotic workpiece materials, CF grinding will grow in popularity.

The author looks at some recent advancements in tool coatings: multilayer, nmultielement, diamond, nanocomposite.n

Most people know that using the right grade of insert can improve nproductivity dramatically. Few know that the proper grade is also important nwhen utilizing round tools. The author examines the different types of ncarbide grades available for round tools.n

A detailed description of a combination drill that machines six different nhole diameters. Used on a dedicated drilling machine that drills cast iron ncylinder heads, it was developed over a number of years. The six-in-one tool nis made of HSS and has carbide inserts.n

Dry milling and turning grow in popularity day by day, but dry drilling is nanother matter. Because of the nature of drilling, it's more difficult to nperform this operation without coolant. Still, progress is being made, nthanks to research and more sophisticated coatings.n

The CNCs on many lathes don't have drill-pecking cycles. The author ndescribes several ways to program CNCs to peck, including shortcuts such as nsubprogramming and parametric programming.n

Article discusses the disadvantages of carrying too many grades of carbide inserts. Often, using a less-than-optimal grade can save a machine shop money.

Article defines what constitutes a high-pressure coolant-delivery system and offers advice for selecting such a system. Discussed are pumps, system prices and advantages of these systems when cutting metal.

Author describes what he's learned about turning hardened steel. Discussed are the machine tools needed as well as PCBN and ceramic inserts.

Three companies that tap millions of holes annually offer advice for improving the tapping of steel and aluminum. Discussed is coolant application, equipment for tapping and determining speeds. There's also a sidebar on thread milling.