Feature Article

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.

Insert manufacturers have devised color-coding schemes to help users select the right tool for the job. This article explores the thinking behind these schemes and the toolmakers' efforts to design tools for the specific applications defined in their selection systems.

With innovations in technology, EDM has found its place as a reasonable alternative to other precision machining operations. This article reviews five recent developments: the introduction of a new electrode material, operations that replace dielectric fluid with gas, the development of electro-conductive powders, the EDMing of nonconductive materials and a method for producing complex part geometries with simple electrodes.

The article looks at concerns being raised over ISO's plans to revise quality standards. An accompanying article discusses a Web site that strongly opposes the announced changes.

Routing coolant out through the tip of the tool can provide greater control of temperatures and chips. This article describes the benefits of through-coolant tools and describes the methods of retrofitting machines to accept through-coolant tools.

Computer simulations of the cutting process can help tool designers predict the effects of tool-geometry changes. This article describes how one manufacturer is using the most recent advances in computer modeling to reduce the need for producing and testing prototype inserts. An accompanying article describes a commercially available simulation program.

An increasing number of shops are purchasing saws and bringing their cutoff operations in-house. This article discusses the benefits of such a move and explains the factors that must be considered before selecting a saw. Blade selection is also discussed.