Fabrication & Cutting

There are many good reasons a shop might choose to purchase an abrasive waterjet machine. However, as this article explains, many factors must be considered to determine if the investment makes economic sense. The article discusses how and when a shop can adopt AWJ profitably and it explores the possibility of achieving the same results more cost effectively by subcontracting the work to an AWJ specialty house.

As the use of hard-to-machine work materials grows, the need for high-performance tool coatings increases. This article discusses developments in coatings that have increased their usability. Among the coatings discussed are medium-temperature CVD coatings and multilayer PVD coatings.

Researchers tried bathing inserts in liquid nitrogen to keep them cool while cutting hard-to-machine materials. This article reports the results of this experiment. It shows how the use of cryogenic coolant can keep temperatures down and prolong tool life while machining titanium aluminum vanadium and reaction-bonded silicon nitride.

Improvements in cermet and ceramic inserts have made them a good choice for high-speed milling. This article describes how the compositions and designs of these newer inserts make them tough enough to withstand the punishment of a milling operation while maintaining the hardness that makes them wear-resistant.

This article describes the shapes and sizes of diamond particles produced through standard manufacturing processes. The uses for these different types of particles are also explained, with an emphasis on particles used in superfinishing powders and slurries.

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.

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.

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.

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.

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.

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.

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.