Feature Article

The presence of an eta phase between a coating and the substrate is generally considered harmful to coating adhesion. However, this article argues that when the formation of the eta phase is carefully controlled, it can actually enhance adhesion. The conditions that promote the formation of beneficial eta phase are explained.

Several factors influence the effectiveness of a drilling operation. This article looks at a number of them, including coolant delivery, speeds and feeds, and tool selection.

This article warns against the dangers in recent manufacturing supply trends. According to the author, both outsourcing and integrated-supply programs can have seriously detrimental effects on productivity and innovation. In this article, he explains the reasoning behind his views.

When digital calipers that did not have to be zeroed before each measurement were introduced, they represented a significant advancement in electronic gaging. This article explains the technology behind these absolute-reading instruments and how they are used to make typical shop-floor measurements.

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.