Feature Article

Say your machine shop just received an order for 316 stainless fuel-injector nozzles requiring angled holes to be drilled on the workpiece face. Or perhaps your best medical customer needs miniature blood-pump impellers with complex 3-D blade geometries like those on a jet-engine turbine. How are you going to make them?

Manufacturing molds used to produce plastic parts with features that can be too small to be seen with the naked eye or measured with standard devices is challenging. That's why moldmakers that perform this work are specialists in the nuances of designing and building micromolds.

When choosing among coated-abrasive flap discs to remove metal and finish parts, grit size is just the beginning.

Bar feeders, once known as slow and inefficient 'rattle tubes,' are now high-speed, automated units.

Significant progress in metalworking productivity most often results from the combined efforts of toolmakers, machine tool builders and software developers. Plunge, or Z-axis, milling is a good example.

As the U.S. strives to become less dependent on foreign energy sources, energy producers are increasingly employing hydraulic fracturing, or "fracking," to drill shale deposits and extract natural gas and some oil. That booming market requires a range of parts from shops around the country.

Where there are drilled holes, there are burrs. The only question is how large the burrs will be, according to Dave Lopes, vice president of sales and marketing for Cogsdill Tool Products Inc., Camden, S.C.

Dynomax Inc. is taking self sufficiency to a new level. For example, while machine tool builders often use their machines to produce parts for making other machines, Dynomax stands out by building machines for its own contract part manufacturing operation.

Part Time: While some shops shy away from difficult projects, others welcome them. According to Bob Perkins, president of PDS (Precision Defense Services) Industries, Irwin, Pa., the company has built its business on doing things others can't do.

When turning 2mm-dia. and smaller parts on a Swiss-style machine, it only makes sense that the radius on the tool should be equally tiny. After all, you can't cut a 0.5mm bone screw with a TNMG-431 insert—the tool's nose radius is nearly as big as the part.

Nickel-base superalloys can withstand hot and tough conditions, but are difficult to machine. With the right approach, machinists can keep their cool when cutting them.

Swiss Automation's success is based on machining complex parts quickly, accurately and consistently.