Milling

Round-up of five recently introduced indexable tools: stub drill, universal nmilling cutter, center-cutting endmill, dovetail cutter and insert clamp.n

When facemilling with an indexable-insert tool, the axial and radial rake angles of the inserts can have a significant impact on performance. This article reviews the basics of rake angles and their effect on tool life, cutter effectiveness and metal-removal rates.

A project engineer recounts his experiences planning for, installing and setting up a new CNC vertical milling center. Among the issues he explores are the questions that must be answered before the machine arrives, selecting or designing tools and fixtures for the new machine and preparing workers for the change.

A machining research institute describes the testing method it developed to quantify and compare the performance of metalworking fluids. The test, which compares cutting forces generated when machining with a test fluid to a baseline fluid's performance, is simple enough for any shop to use.nnn

Machinists can now find machining simulators on the Web that can tell them what the results will be for a given set of conditions as well as what set of conditions will produce the results they are looking for. This article describes these simulators and the research consortium that developed them.

The PVD and CVD processes produce coatings with specific strengths and weaknesses. This article compares the processes and attempts to correct some common misconceptions about CVD coatings. The findings of a survey on tool coaters' use of coating materials and methods are also reported.

Researchers using computer simulation and refined probing techniques attempted to mill a pocket as accurately as possible. This report tells how the researchers used their high-tech tools and how close to perfection they came.

The benefits of TiN and TiCN coatings are list in high-temperature applications such as the machining of exotic metals. TiAlN coatings, on the other hand, perform better at higher temperatures. This article describes the properties of TiAlN that make it the coating to use with high-temperature work. The article also reviews specific applications where shops have used TiAlN to increase tool life and productivity.

Modern control technology makes extremely fast milling speeds possible. But the top speed can only be as fast as the slowest link in the chain between controller and machine. This article looks at some of the bottlenecks that can prevent a mill from running at full speed.

When shops crank up the speed, they have to be prepared for the consequences, even if they're milling "easy-to-machine" aluminum.

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.