Feature Article

CNC lathes have evolved greatly over the past few decades. What were once simple 2-axis turning machines have become a bewildering array of extremely capable metalcutting equipment, most of which offer two spindles, multiple turrets, robust milling capabilities and can complete many parts in a single setup. In other words, they have become multitask machines.

The technology to form, press and grind indexable carbide inserts has evolved to such a high degree that the methods to effectively clamp inserts in a cutter body have struggled to keep up, but strides are being made. Some insert shapes have advanced to the point where they have a true, 100-percent, 3D geometry with almost no flat surfaces. This requires a tool-body pocket that is dynamically shaped to accommodate the optimal geometry. For example, an insert with a wavelike feature across its back requires it be seated in a pocket with a matching shape to ensure accurate fixation with high stability.

Michael Finklea believes that there isn't much reported on sawing in the manufacturing trade press because "it's kind of the redheaded stepchild in the industry—an unappreciated part of the manufacturing process. In most shops, the least-skilled person is running the saw."

It's fitting that "Technology" is part of Indiana Technology and Manufacturing Cos.'s name. In addition to providing a full slate of machining and assembly services, ITAMCO created what it says is the first industrial Bluetooth transmitter (called iBlue) and continues to develop a broad range of manufacturing apps for mobile devices and Google Glass. What's more, ITAMCO has produced a virtual manufacturing showroom and developed a manufacturing forklift simulator that allows users to interact with factory equipment using the MTConnect protocol, Autodesk Factory Suite, Unity 3D game development platform, Oculus Rift virtual-reality headset and Leap motion controller.

Value-added services shorten lead times and increase sales opportunities for parts manufacturers. The decision to bring traditionally outsourced services in-house can be an expensive and scary proposition—one with the potential to either transform a company or send it into bankruptcy. Yet that's exactly what many manufacturing companies do, and often they are pleased with the results. That proved true for the four companies profiled in the following pages.

Around for more than 100 years, air gaging is a mature technology that still has a place in modern shops.

As aerospace materials have evolved, machine shops have had to use new tools and technologies in order to process them. The June 2016 CTE cover story delves into delamination of composites and other workpiece problems that challenge aerospace parts makers.

Every parts manufacturer, regardless of size, has some sort of training program, and programs are nearly as varied as the companies themselves. Whether it's something as simple as handing out a pamphlet about company policy or as involved as an apprenticeship program, it's just a given: Where there are employees, there is training. However, while some companies regard it as a necessary evil, others have found that investing in this universal necessity yields substantial benefits—and, in the long run, actually saves money.

As the plans for more and more machined metal parts include numerical surface finish specifications, the need diminishes to visually qualify that a part has, for example, "a mirror finish with no burrs" or to have the machinist with the finest touch scratch the surface with his fingernail to make sure it's "matte and rough."

Say "EDM" and most manufacturing folks think mold, tool and die work. Yet sinker, wire and hole-popping EDMs are often employed in conjunction with, or as alternatives to, traditional part-making processes, such as milling and turning.

Lasers are good for far more than slicing sheet metal and defending against alien space invaders. Without them, many of today's high-tech products would be impossible to manufacture. Microfluidic devices, integrated circuits, medical stents and catheters, automotive fuel injector nozzles are all drilled, milled, surface-textured and ablated via laser micromachining.

Ever machined parts so small that they not only fit on a penny but can sit on old Abe's nose? Cutting parts and part features in this Tom Thumb world often comes with Titanic-sized challenges, such as unexpected cutting tool breakage, deburring parts the size of typical burrs and machine tool spindles speeds that come up short. Sometimes just handling ultrasmall parts is a gargantuan task.