Machining

Grinding round HSS cutting tools can be more efficient than milling them. Being able to dress new hybrid metal/polyimide-bond wheels on the grinder adds to the efficiency.

Cutting Tool Engineering captured a brief demonstration of the FI 240 CC high-speed wire EDM machine at the GF AgieCharmille booth during the EASTEC show this spring.

Staying Sharp, Manager's Desk, Part Time, Machine Technology, Shop Operations, Get with the Program, Machinist's Corner

Reliably drilling high-quality holes in ductile cast iron requires understanding the material's structure, avoiding problems such as core shifting, keeping machining temperatures down and other considerations.

Parts manufacturers can calculate the optimal parameters when grinding with superabrasive wheels to achieve high material-removal rates and more consistent results.

Improving medium-grade PCD for high-speed milling, including interrupted milling of high-silicon aluminum.

Manufacturers use broaching to make small parts for medical and aerospace applications.

When single-point boring, parts manufacturers can break and control the long chips from low-carbon steels by taking into account setup, cutting parameters, nose radii and insert shape and sharpness.

Staying Sharp, Manager's Desk, Back to Basics, Machine Technology, Shop Operations, Part Time, Ask the Grinding Doc

Using mini and micro boring bars effectively in Swiss-style machines requires machine shops to know the types of available bars and the ways to strengthen their cutting edges, reduce pressures on the tools and position them for the most efficient cutting.

Grinding machine operators are able to listen to the processes via acoustic emission (AE) monitoring systems and use the information to shorten cycle times and minimize wheel loss from dressing. But, AE sensors need to be positioned to deal with interfering background noise.

Magnetic abrasive finishing can deburr and create highly polished, smooth surface finishes. It can also remove microcracks, recast metal, metallurgical phase changes, visible scratches and damaging residual stresses.