Feature Article

This article reviews the causes of skin irritation suffered by some shop workers, with special attention paid to skin conditions that result from poorly maintained metalcutting fluids. The article also discusses the factors that can aggravate skin problems and suggests ways that workers can protect themselves from skin irritants.

Segmented grinding wheels can help in heavy stock-removal applications with large contact areas. This guide covers where grinding segments fit and what shops should watch.

Although machinists are using cermet and ceramic cutting tools for an increasing number of applications, they have been slow to adopt them for boring. This is beginning to change, however. This article describes some of the ways a boring operation can benefit from the use of these tools.

This article traces the changes in countersink design and materials that have been made to satisfy the demands of the aerospace industry. The advantages and disadvantages of different types of modern countersinks are discussed.

When shouldered parts are held for turning with a draw-in collet, length-control problems can result. This article provides directions for making collet add-ons that allow the machinist to locate the part against the spindle face, providing a consistent length from part to part.

This article guides the reader through the many decisions that must be made when selecting and installing a hydraulic workholding system. Basic hydraulic system design principles and maintenance also are discussed.

Traditional tap/drill charts recommend drill diameters for each size of tapped hole. But, according to this article, these recommendations are based on the size holes that were typically produced by less-accurate tools and processes used in the past. This article suggests guidelines for producing holes that will, in turn, produce correctly sized tapped holes.

By recycling used metalworking fluids, shops can realize considerable savings in fluid and disposal costs. This guide takes the reader through the fundamentals of fluid recycling and management. Excerpted from a manual on the subject, the piece covers both the care and cleaning of fluids and fluid-handling equipment.

This article makes the argument that ball-drive quick-change tapholders, which transfer torque through hardened-steel balls fitted into mating detents, are more reliable than tang-drive units. The technology behind ball-drive tapholders and the design's benefits are explained.

The more sophisticated die-sinker EDMs on the market today possess enough intelligence to monitor cutting conditions and make necessary adjustments on the fly. This article describes the technology that drives these smart machines and the "fuzzy logic" they use to maintain an optimal spark.

CNCs have the power to dramatically increase productivity, yet many shops fail to make use of their controllers' full potential. This article suggests ways that a shop can fine tune its CNCs to create controllers that are optimized for the type of work being performed. The tips include many CNC features, capabilities and options that users often overlook.

Modern control technology makes extremely fast milling speeds possible. But the top speed can only be as fast as the slowest link in the chain between controller and machine. This article looks at some of the bottlenecks that can prevent a mill from running at full speed.