Fabrication & Cutting

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.

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.

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.

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.

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.

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.

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.

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.