Machining

END USER: Antron Engineering and Machine Co. Inc., (877) 225-2362, www.antroneng.com. SOLUTION PROVIDER: Eltool Corp., (877) 435-8665, www.eltool.com. CHALLENGE: Mill a long, interrupted slot in a small-diameter bore. SOLUTION: A coolant-driven angle head.

Machine tool idling, unnecessary pump rotation and continuously running peripheral equipment drive up machining costs. These energy wasters are in the crosshairs of a new suite of power-cutting control applications from Japanese machine tool builder Okuma Corp.

END USER: Greene Tool Systems Inc., (800) BUY-TOOL, www.greenetool.com. SOLUTION PROVIDER: ANCA Inc., (248) 926-4466, www.anca.com. CHALLENGE: Produce microscale cutting tools more accurately while lowering setup times. SOLUTION: Two grinding machines designed to produce tools smaller than 2mm in diameter that feature robotic arms for loading and unloading tools and wheel packs.

If you're shopping for a Swiss-style CNC lathe, the available options and machine configurations are truly staggering. Spindle speeds that compete with many machining centers, convertible spindles that turn a sliding-headstock machine into a chucker, thread whirling capabilities, laser cutting heads and enough axis letters to become the next Words With Friends champion.

Setup reduction is a common goal of every machine shop. Setup does not add value because it does not provide any measureable productivity. In short, when you are not running a machine, you are not making chips, and, therefore, you are not making money. Setup involves numerous non-value-added activities, including tool measurement, fixture alignment and setting coordinate systems, or offsets. As the term suggests, value-adding activities make a workpiece more valuable by changing its shape or physical properties. Many years in and out of machine shops and manufacturing plants have given me ample opportunities to see and establish some unique and familiar methods for reducing setup times and generating savings.

Vertical machining centers are machine shop mainstays, owing in no small part to their versatility, small footprint and relatively low cost. However, in high-volume environments, they tend to lag behind their horizontal counterparts. Fortunately, a pallet system provides a fairly simple fix.

Troubleshooting machining operations can be a daunting task, especially boring operations. This is because when machining the outside of a part, you can see what causes the tool to fail. However, when a tool is buried in a hole, as is the case when boring, you can't see what is happening to the tool.

Dear Doc: I sell grinding wheels and frequently find myself pulling my hair out when recommending wheels to customers. One customer achieved great success with a resin-bond, 400-mesh diamond wheel when grinding ¾"-dia. carbide endmills. It performed like a "superwheel." I then took that same wheel to a customer who also grinds ¾" carbide endmills on the same machine model with the same coolant and it's a disaster. Why?

I'm thankful to share that our machining business has picked up and we're running near capacity. I can't get overly optimistic just yet, but good news nonetheless. We haven't required new equipment, new employees or a second shift, but that could change if business continues at this pace or improves. While this uptick has been a nice morale booster, our energy-focused market remains unpredictable. Even so, we're getting a bit more confident with our forecasts and planning.

When it comes to highly accurate machining technology, jig boring is better. So say proponents of the century-old machining technique. In the early part of the last century, jig boring started as a better way to make holes. But the technology has since evolved into a more-versatile machining option.