Feature Article

When shops purchase new machinery, a common error some make is accepting the standard live tooling package from the builder without considering other options. This is not a criticism of those packages, but end users should do as much evaluation of their processes when determining the proper tooling package as they do when evaluating machine tools. This examination can range from the simple, such as external vs. internal coolant, to the sublime, such as adjustable vs. extended tooling configurations, to the truly exotic.

There comes a time when some chipmaking shops add wire EDMing to their repertoire. This is often done to reduce costs, because bringing what were once subcontracted, secondary EDMing operations in-house often makes good financial and logistical sense.

Software for high-efficiency roughing makes moldmaking faster, more efficient.

Modular automation increases productivity and flexibility at a lower price point than custom solutions.

Small shop becomes a big aerospace manufacturer -- with a little help from its friends.

A shop I once worked at had a beautiful cast iron welding table. It was 5' wide × 12' long and had started life as a surface plate for assembling diesel engines. The owner bought it at auction for $100. With a screen in the middle, two guys could work on it at once.

When an endmill efficiently makes chips, everybody is happy: the end user, the parts buyer, and the cutting tool manufacturer and distributor. Achieving that by having the tool follow the correct toolpaths and run at productivity-boosting parameters, however, requires an endmill with optimized geometry, substrate and coating.

Efficient removal of heat from the tool/workpiece interface is the main route to high-productivity machining. Several conventional methods are available to accomplish that -- dry machining, minimum-quantity lubrication, flood coolant and high-pressure coolant -- but cryogenic machining can be added to the list.

Table-type horizontal boring mills add versatility to machine shops.

A journey of waste reduction and continuous improvement for machine shops.

A technique I call roll grinding is used to finish corners to match bend radii. Long weld seams that need to be rounded can be handled using a rolling technique with the disc grinder. It takes a little practice, but once you've mastered it, the results look just like a formed corner.

Deep holes can be difficult to define, but knowing the right tool for the job makes them easier to drill.