February 2012

Iscarmetals

Improved Productivity and Less Down Time

for Mass Production Hole Making ISCAR’s SUMOCHAM drill family is the next evolution of the very successful CHAMDRILL 1.5xD 3xD 5xD 8xD 12xD P M K N S H    Double Margin ICP/ICK - 2M.

Improved Productivity and Less Down Time for Mass Production Hole Making ISCAR’s SUMOCHAM drill family is the next evolution of the very successful CHAMDRILL 1.5xD 3xD 5xD 8xD 12xD P M K N S H    Double Margin

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Yg1usa

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Cutting Tool Engineering

contents

Cutting and grinding, cover to cover cover story Main Office 40 Skokie Blvd., Suite 450, 28 Exact Replica Northbrook, IL 60062 Producing commercial aircraft replacement parts requires Publisher unwavering commitment. Don Nelson features Editorial 38 Horizontal Autopilot Improving productivity and quality with unattended.

contents February 2012 | Volume 64 | Issue 2 Visit us at www.ctemag.com Cutting and grinding, cover to cover www.ctemag.com cover story Main Office 40 Skokie Blvd., Suite 450, 28 Exact Replica Northbrook, IL 60062 (847) 498-9100; Fax: (847) 559-4444 Producing commercial aircraft replacement parts requires Publisher

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visit www.mscdirect.com/cutcosts/index.html

SAVE 20% OR MORE

ON INVENTORY COSTS NOW State-of-the-Art Industrial Vending Solutions Tailor Made for Your Business MSC Industrial Vending Solutions are customized to fit your specific business needs and are proven to reduce inventory costs by 20% or more. Scan this code or for your FREE Industrial Vending Assessment today! Westec 2012 s March 27-29 Los Angeles, CA s See us in Booth #2620.

SAVE 20% OR MORE ON INVENTORY COSTS NOW State-of-the-Art Industrial Vending Solutions Tailor Made for Your Business MSC Industrial Vending Solutions are customized to fit your specific business needs and are proven to reduce inventory costs by 20% or more. Scan this code or visit www.mscdirect.com/cutcosts/index.html

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Hornusa

HORN - THE LEADERS IN GROOVING TECHNOLOGY

FOCUS ON THE ESSENTIAL SYSTEM DR Urma licence Sensitivity instead of gross motor skills – this is the motto of the new HORN “System DR” reaming tools. Very narrow cutters, simple handling, and high repeatability when replacing inserts. A large selection of base material, coatings, and cutting geometries make the DR from HORN the perfect tool system for high precision bore machining

HORN - THE LEADERS IN GROOVING TECHNOLOGY FOCUS ON THE ESSENTIAL SYSTEM DR Urma licence Sensitivity instead of gross motor skills – this is the motto of the new HORN “System DR” reaming tools. Very narrow cutters, simple handling, and high repeatability when replacing inserts. A large selection of base material, coatings, and cutting geometries make the DR from HORN the perfect tool system for high precision bore machining. HORN – INTELLIGENT TOOL DESIGN AT WORK. HORN

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Mastercam X6 - When Second Best Won’t Cut It!

A worldwide product rollout experience!

Be a part of this exciting global event and find out how Mastercam X6 can boost your business, improve your bottom line, and deliver new opportunities

A worldwide product rollout experience! Mastercam X6 - When Second Best Won’t Cut It! Be a part of this exciting global event and find out how Mastercam X6 can boost your business, improve your bottom line, and deliver new opportunities. www.mastercam.com/X6Rollout

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United Grinding

The new benchmark

S41 for Swiss precision. scan this! 510 Earl Blvd. Miamisburg, OH 45342 phone go to i-nigma.mobi.

S41 The new benchmark for Swiss precision. scan this! United Grinding 510 Earl Blvd. Miamisburg, OH 45342 937.859.1975 To get the free app for your mobile www.grinding.com phone go to i-nigma.mobi

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Atistellram

MACHINING SOLUTIONS

FOR THE AEROSPACE 7792VX16 INDUSTRY Conquer your most daunting machining and finishing challenges s 4HE 7792VX high feed milling cutter – designed to yield the highest levels of productivity by increasing metal removal rates by as much as 90%. s 4HE 5230VS12 Chevron milling cutter – designed for high metal removal in machining.

MACHINING SOLUTIONS FOR THE AEROSPACE 7792VX16 INDUSTRY Conquer your most daunting machining and finishing challenges s 4HE 7792VX high feed milling cutter – designed to yield the highest levels of productivity by increasing metal removal rates by as much as 90%. s 4HE 5230VS12 Chevron milling cutter – designed for high metal removal in machining aerospace materials, resulting in maximum tool life and a 30% improvement in surface finish. 5230VS12 s 4HE XE Solid Carbide Endmills – an advanced geometric design that

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Brubakertool

Brands.

Four One Mission... To ensure success in all of your aerospace milling applications. For over half a century, we have been known worldwide for high performance, made-in-USA cutting tools. Our products are supported by the most skilled and experienced applications engineers in the industry. We are second to none in the manufacture.

Four Brands. One Mission... To ensure success in all of your aerospace milling applications. For over half a century, we have been known worldwide for high performance, made-in-USA cutting tools. Our products are supported by the most skilled and experienced

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To subscribe or learn more, visit www.micromanufacturing.com

THINK

SMALL The magazine for manufacturers of microparts

THINK SMALL The magazine for manufacturers of microparts. To subscribe or learn more, visit www.micromanufacturing.com

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Mdmwest

Your Gateway to the Education, Tools and

Partnerships Needed to Turn Your Big Ideas into Market-Ready Products An investment in your business, product, and you. Start the new year off strong with education, leading suppliers and resources you need to thrive in an environment that demands speed, quality, precision, and innovation. Exposition: February 14–16, 2012.

Your Gateway to the Education, Tools and Partnerships Needed to Turn Your Big Ideas into Market-Ready Products An investment in your business, product, and you. Start the new year off strong with education, leading suppliers and resources you need to thrive in an environment that demands speed, quality, precision, and innovation. Exposition: February 14–16, 2012 Conference: February 13–16, 2012 Anaheim Convention Center

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Visit tkpromo.secotools.com or scan

LET SCIENCE REDEFINE YOUR CAST IRON

TURNING APPLICATIONS TRY THIS SECO INNOVATION FOR YOURSELF. this QR code to request your free TK Grades sample insert. Seco’s new TK1001 and TK2001 Grades inserts incorporate the hard science of our DURATOMIC® coating technology to deliver a uniquely effective approach to cast iron turning. Through manipulation of aluminum and oxygen at the atomic level, the DURATOMIC process creates.

LET SCIENCE REDEFINE YOUR CAST IRON TURNING APPLICATIONS TRY THIS SECO INNOVATION FOR YOURSELF. Visit tkpromo.secotools.com or scan this QR code to request your free TK Grades sample insert. Seco’s new TK1001 and TK2001 Grades inserts incorporate the hard science of our DURATOMIC® coating technology to deliver a uniquely effective approach to cast iron turning. Through manipulation of aluminum and oxygen at the atomic level, the DURATOMIC process creates

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Visit Visit tkpromo.secotools.com or scan