Machining

EDM cutting conditions change throughout the cutting process as the part thickness and the level of dielectric contamination fluctuates. This article describes an experimental setup that can monitor these fluctuations and adjust the EDM's settings to maintain an optimal spark.

EDMed surfaces have their own texture and integrity considerations. This guide explains why EDM surface condition matters for inspection, finishing, and downstream performance.

Indexable-insert drills offer several advantages for producing short holes. This article describes the drills' features, uses and benefits. Tips are provided to help select the optimal tool, insert and machine settings. A trouble-shooting chart is included.

New plunge-and-turn tools make it possible to perform several tasks, such as grooving, turning, back turning and face grooving, with the same tool. This article discusses the design and use of these tools as well as the types of cutoff tools currently on the market. Recommendations for tool selection, speeds and feeds are given for various work materials.

U.S. manufacturers are in a transition period, moving from inch to metric specifications. This article looks at the impact this change is having on the manufacturing and use of drills. The discussion also covers the advantages and disadvantages of going metric and the availability of metric drill sizes in the United States.

This article makes the argument that grinding is still a useful and necessary process despite the advancements that have made the turning of hardened workpieces possible. The article discusses the precision and finish possible with grinding, and it compares the cost of grinding to other machining processes.

Tunable tools can be adjusted to dampen vibration. However, shops must have the right equipment to tune them quickly and precisely. This article describes an instrument that can provide the necessary feedback. A system that uses a mill's vibration frequency to sense problems with the tool is also described.

When machinists plan a boring operation, they must rely on general turning data. Typically, this data is developed from OD turning operations, not boring operations. This article provides cutting data and recommendations specifically for boring that take into account such unique problems as boring bar deflection and chips trapped inside the bore.

This is the first in a series of Articles on coolants. It provides a general review of the types of fluids available, their cooling and lubricating abilities and their ease of disposal. Criteria are offered for selecting the appropriate fluid for an operation.

The EPA's ban on ozone-depleting chemicals had an impact on the formulation of metalworking fluids containing 1,1,1 trichloroethane. This article looks at the reasons for the ban and the industry's efforts to find replacement substances for the banned chemicals.

Changes in milling practices have placed new demands on the cutting tool. This article discusses the features toolmakers have added to their milling insert geometries to control chips and cutting forces. The article also reviews the milling process and the forces that act on the insert.

Thread rolling produces external threads by forming the profile instead of cutting it. This guide covers where CNC thread rolling fits, why it can outperform cutting, and what shops should watch in setup.