Feature Article

This article describes a self-contained micromachining center. The unit uses PC-based controls and a video system to machine small parts with precision, while giving the machinist a magnified view for setup and prototyping.

A machining research institute describes the testing method it developed to quantify and compare the performance of metalworking fluids. The test, which compares cutting forces generated when machining with a test fluid to a baseline fluid's performance, is simple enough for any shop to use.nnn

Tapping and thread milling can both produce internal threads in a variety of sizes, pitches and materials. This article discusses the factors that will dictate which process makes the most sense for a given job.nn

Spot drilling is a time-consuming process, but sometimes it is necessary to prevent drill walk. This article describes the reasons for spot drilling and the economic impact of adding the operation to a job. It also explains why a spot drill is a better choice for the operation than a center drill.

This article describes how one aerospace manufacturer boosted production capacity by partnering with a supplier, which began machining parts formerly made in-house. The article tells how the manufacturer shared its processes and manufacturing expertise with the supplier in order to ensure that quality and productivity were maintained.n

The latest generation to enter the workforce comes to the shop floor with a different set of skills and experiences than their predecessors. This article explores how these differences are forcing shop owners and supervisors to rethink their management strategies.nn

This article describes reconditioning tools through hand honing, a process that can help a tool produce 20 percent more parts. In explaining the art of hand honing, the author reviews the hone materials and honing techniques to be used.

This article reviews the basics of coordinate systems and machine programming as a basis for presetting tools. The process for setting tool offsets is described with an explanation of the G-codes involved. In an accompanying article, the author tells how his company built its own presetter.

A tool design supervisor makes a case for cautious machining. This article explains how, by extending tool life, less aggressive speeds and feeds can lead to greater economy than a shortened cycle time will yield. Tips for monitoring and recording tool data are also given.

Machinists can now find machining simulators on the Web that can tell them what the results will be for a given set of conditions as well as what set of conditions will produce the results they are looking for. This article describes these simulators and the research consortium that developed them.

With close-tolerance machining, variances in the temperature of the part or gage can lead to out-of-tolerance work. This article describes the compensation systems that have been developed to measure temperatures and make the necessary adjustments to gage readings.

The steep-taper toolholder shank design remains popular, but it needs updating to keep pace with modern machining practices. This report suggests minor design changes that these researchers say might overcome steep tapers' limitations.