Fabrication & Cutting

Articles • March 1, 1996 • Louis Caldarera Jr.

Stress Management

High-performance aluminum-alloy workpieces are prone to residual stresses that can lead to part distortion. This article reviews the milling tools and practices that affect these stresses. Some tools and practices alleviate the stress, while others allow the machinist to mill the part without adding more stress.

Articles • March 1, 1996 • Ann Marie Rooke

Saw Change

Blades for contour bandsawing vary in their materials, their tooth set and selection, their width and the way they are welded. This article discusses how each of these variables contributes to the blades' ability to cut intricate shapes without seizing or wearing prematurely. Blade lubrication is also covered.

Articles • March 1, 1996 • Ronald Biagiotti

The Time is Right for Cermets

Cermet inserts have evolved into cutting tools capable of finish-turning steel reliably at high speeds. This article traces the developments that have led to modern cermets and describes the properties that enhance the performance of these tools. The development of coatings for cermets is also covered.

Articles • February 1, 1996 • John Olsen

A Bend in the Stream

Programming a cut with an abrasive waterjet is complicated by the fact that the stream of water deflects as it passes through the workpiece. This article describes newer controller technology that can adjust the traverse speed to minimize deflection at corners and curves.

Articles • February 1, 1996 • Wolfried Mielert

Coating for Speed

To meet their customers' demands, mold and die shops are milling hardened steels at high speeds. This article discusses the use of coated carbide inserts to handle the heat generated by these operations. Specifically, the article talks about recently developed aluminum-titanium-nitride coatings, which reportedly are much more stable at elevated temperatures than other coatings.

Articles • February 1, 1996 • Andrew Johnson

CVD Diamond Inserts Stick

The development of the CVD thick-film diamond process has made it possible to produce tools that can machine abrasive work materials without losing their cutting edge. In this article, the technology for producing the diamond film and the brazing of these thick-film chips onto inserts is described.

Articles • June 1, 1995 • Richard Thalmann

Cracking the Code

This article reviews the nomenclature that toolmakers use to identify inserts. Both ANSI and ISO codes are described character by character. A chart lists all of the possible choices for each position in the code and what each code letter or number signifies.

Articles • March 1, 1995 • Stanley Biernat Jr.

Carbide Coatability

A clear and intact substrate surface is important to the success of a coating deposited on a carbide insert. This article looks at the surface problems and contamination, introduced by the insert manufacturing process, that the coating company or insert user must correct before the insert is ready to be coated.

Articles • March 1, 1995 • Mike Sasnett

Squared Straight

Three different problems can cause a laser to make beveled cuts. As these problems interact, they create distinct patterns of bevel angles that require sophisticated mathematical analysis to sort out. This article discusses an experiment using Fourier analysis to determine which combination of problems caused the cyclical variation that was observed in the measurements of a laser's cutting angle.

Articles • March 1, 1995 • Ann Marie Rooke

Saving Saw Bucks

Advancements in bandsawing are allowing shops to closely control the cost and precision of the operation. This article looks at such innovations as informational computer programs that provide advice on workpiece positioning and machine settings. Improvements in blade design and the applicability of these new blade geometries is also covered.

Articles • March 1, 1995 • Roy Gat

CVD Diamond for Everyone

It took years to perfect, but manufacturers finally found a way to economically coat carbide inserts with a diamond film. This article describes the coating process and looks at that companies that are offering diamond-coated tools, the companies that are coating tools for other manufacturers and the companies that are supplying coating equipment. Thick-film diamond is also discussed.

Articles • February 1, 1995 • James Treglio

Eye on Ions

Ion implantation bombards a tool's surface with accelerated metal ions. According to this article, the process increases tool life and the performance of tool coatings. Two theories explaining why the process works are also discussed.