Cutting Tool Engineering Magazine

Manufacturers large and small develop strategies to quickly redesign and machine new parts for military customers. PLUS:

• Tools and techniques for engraving 2-D data matrix bar codes on machined metal parts
• Fine finishing with wire EDM is eliminating the need for secondary operations
• How microscopes and vision systems are used in machine shops for noncontact inspection and measurement
• Statistical analysis of metalcutting data can help shops select the right indexable insert geometry.

‘Lightweighting’ vehicles through the use of magnesium parts can improve vehicle mileage and impact resistance, among other benefits. PLUS:

• Tapping medical parts requires unique considerations not needed in general-purpose tapping
• Special glasses are not required, but multiple other considerations apply in 3-D abrasive waterjet machining
• High-density workholding squeezes more productivity from machining centers
• Wisconsin-based Pointe Precision creates business opportunities with new machines and skilled employees
• With technology, experience and attitude, M&S Centerless Grinding is breeding grinding success—on a very small scale.

Examining the development and evolution of drill/tap-style machines; horizontal boring mills are behemoth in size and flexibility. PLUS:

• When applying finishes to parts, shops have a key choice: outsource or DIY
• Grooving hardened steel parts with PCBN cutting tools
• Controlling foam when applying high-pressure coolant requires trade-offs to achieve effective machining
• New imX event offers education ranging from one-on-one instruction to panel discussions on the future of manufacturing.

Improved holemaking efficiency drives powertrain machining throughput; a qualified approach to machining complex, deep holes. PLUS:

• Improving productivity when changing cutting tools
• Advances in machine tool technology, tooling and software facilitate high-productivity milling strategies
• Advanced machine technology requires advanced training options
• “Do-it-yourself” route appealing to more dentists who install prostheses.

The use of plastic medical parts is growing, and in certain applications machining them is advantageous and even essential. PLUS:

• Machining fiber-reinforced composite materials with fiber and other types of lasers can be an effective option
• Some part makers are bringing inspection technology to the shop floor for quality control—with good results
• Reamers are an effective option for hole finishing, but choosing the right one for the job depends on hole type, diameter and depth, among other factors
• Equipment and media options for cleaning automotive parts
• A novel approach to micromachining involves mounting the workpiece in the machine spindle and machining it with a stationary cutting tool mounted on the table.

Superabrasive wheels add science to the art of polishing; developments in superabrasive grinding wheels for producing ceramic balls; and various edge preparations are available for PCBN inserts when hard turning, but not all are equal. PLUS:

• 5-axis machining on a vertical machining center doesn’t have to be complicated
• Adjustable finish boring heads allow for a range of diameters to be machined with one tool
• Cold forming is a fast, chipless way to make parts.

Cavalier Tool uses a palletized machining center to reduce setup and benching times and bring outsourced hard milling work in-house. PLUS:

• Mass finishing parts at the machining center offers economic advantages
• Shop takes ‘systems’ approach to holding microparts
• Tactics and tools for Swiss-style machining
• Technical advances enable ceramic inserts to tackle difficult machining applications. 

Parts manufacturers are gearing up to serve the nuclear power industry, which is growing globally and expected to expand in the U.S. as well; Hunting Energy Services not only machines oil and gas drilling components—it assembles and repairs the tools that do the work. PLUS:

• Technology opens up new applications for small horizontal machining centers
• Using countersinking to increase part functionality
• Comparison between calculating cutting time when facing at a constant cutting speed vs. a constant rpm.

When it comes to milling aerospace parts made from Ti5553, difficulty is in the eye of the beholder. PLUS:

• Turning a lathe vertical can be a productivity turn for the better—for large and small parts
• CAM and simulation software packages enable productive programming of multitasking machines—particularly as they become ‘ultratasking’ machines
• Strategies for grinding HVOF-coated aerospace parts
• Learn details about the many new products manufacturers off er the metalworking industry.

Drilling stacked materials, which have alternating layers of composites and metals, requires a careful strategy and the right tools. PLUS:

• Simplified application of 5 machining axes produces big cost savings in routine part making
• With a structured cutting tool repair program, significant cost savings are realized while tool quality remains intact
• Boosting milling productivity requires an understanding of the process
• Tips and techniques that can turn a standard milling job into a work of art.

With the right tools, thread milling large bore diameters doesn’t have to be daunting; tapping isn’t easy and one of the toughest challenges is preventing oversized threads. New tools can help. PLUS:

• More flexible grinding machines allow part manufacturers to fine-tune their production processes
• Toolmakers combine technologies to meet growing demand for PCD tools
• Connectivity converts presetters into shopwide productivity boosters
• An out-of-level grinding machine can cause major operating and part quality problems—the good news is the solution is simple
• The metalworking industry trended up in 2010
• Learn about companies’ specialties as suppliers to the metalcutting industry.

New materials and improved part manufacturing help maintain and upgrade aging military aircraft. PLUS:

• Nanotechnology opens up new coating possibilities, performance
• Better technology boosts use of EDMs for production applications
• A look at portable measurement technologies and their applications
• It’s never been easier to recycle cutting tools, which produces both cost savings and environmental benefits
• Learn details about the many new products manufacturers offer the metalworking industry.