Machining

How do you treat your a customer who received an order and has a problem with it? Maybe you shipped the wrong part or made a part according to an old revision. How do you handle the situation and appease the customer?

Many machinists fondly remember their early training or apprenticeships when they made 1-2-3 blocks from scratch under the watchful eye of a master toolmaker. These young machinists carefully machined the blocks oversize, heat-treated them and then ground them to size.

When CNC milling machines were conceived some in the metalworking industry asked why a computer couldn't also manage tool changes. That question was the impetus behind the development of the automatic toolchanger.

To profitably machine high-quality parts, many manufacturers follow a similar path, beginning with tool selection and application and then solving any problems that arise in a reactive way. However, research suggests that manufacturers should examine the entire machining process before cutting begins, focusing on eliminating rejected parts and unforeseen downtime.

Numerous toolmakers provide free programs that will automatically generate G code for a specific thread milling application. The programs vary in sophistication and in whether they are online-only or downloadable, but all are useful tools. Among the suppliers of these apps are Scientific Cutting Tools Inc., Simi Valley, Calif.; Guhring Inc., Brookfield, Wis.; and Kennametal Inc., Pittsburgh.

Scrap happens. By scrap, I mean parts that are out of tolerance and, therefore, useless. Unlike other by-products of the manufacturing process, such as chips, shavings and drops, you generate scrap only through mistakes. nnSo the challenge of reducing scrap comes down to preventing mistakes.

Swarf, which is the result of particles being removed when grinding hard or difficult-to-machine materials, tells a story.

The boost in productivity that the latest cutting tools provide enables manufacturers to reduce the amount fracking companies pay for parts.

Pratt & Whitney's new 93,000 square-foot facility adds to an already existing GTF fan blade production line in Lansing. The company's AutoAir facility has had a tenfold ramp-up in the past 20 months, and has increased its workforce from just over 200 to almost 700.

The first day of Makino Corp.'s two-day 2017 Die/Mold Technology Expo included technology seminars, economic prognosticators, and demonstrations on more than 23 state-of-the-art machines at the company's U.S. headquarters in Auburn Hills, Mich. The company also unveiled a new vertical machining center for true 5-axis continuous processing.

In the seventh episode of The CNC Chef, Bob Warfield of the CNCCookbook outlines steps that will help you tame chatter.

The cutting of intricate profiles and odd angles is the domain of wire EDM machining processes, capable of creating ultraprecise shapes and superior finishes that are near-impossible to machine by other means. However, just because a shape is difficult to machine does not mean it should be hard to program.