Quality’s Hidden Costs
An examination of deburring and the cost of poor quality.
Operation / Process
Surface Finishing & Coating
Under Development
Examined are four recent developments in cutting tool coatings: "smooth" diamond coatings, which incorporates that are nanometer-sized; a process that deposits diamond on carbide substrates via a laser; highly lubricious coatings for dry-machining operations; and a patented system for "locking" conventional coatings together.
Sizing Up Nickel
Due to the exceptional strength of IN 100, INCO 718 and other nickel-based alloys, they're difficult to machine. The author, who spent 40 years endmilling these aerospace materials, discusses their unique characteristics and methods for successfully machining them.
Clean Sweep
Equipping toolchangers with nylon abrasive-filament brushes can greatly enhance process economics and the flow of parts. Case histories of in-machine deburring operations support these contentions, and the author describes how such systems should work.
Size Matters
The trend toward developing finer and finer carbide grains continues. The author looks at recent developments in the production of nanosized tungsten-carbide grains, which are smaller than 0.2 microns in diameter. Though not used widely at present for the production of cutting tools, some predict that will change as the technology evolves.
Getting a Better Edge
The author, an expert on cutting tool edge preparation, explains the importance of applying the proper edge hone to a tool. He also discusses a brush-type honing machine designed to apply a variable edge--a capability not available with other machines on the market.
The Coating Edge
The author looks at some recent advancements in tool coatings: multilayer, nmultielement, diamond, nanocomposite.n
Lowering Your Grades
Article discusses the disadvantages of carrying too many grades of carbide inserts. Often, using a less-than-optimal grade can save a machine shop money.
Under Pressure
Article defines what constitutes a high-pressure coolant-delivery system and offers advice for selecting such a system. Discussed are pumps, system prices and advantages of these systems when cutting metal.
Hone Improvement
This article describes reconditioning tools through hand honing, a process that can help a tool produce 20 percent more parts. In explaining the art of hand honing, the author reviews the hone materials and honing techniques to be used.
Inserts Show Their True Colors
Insert manufacturers have devised color-coding schemes to help users select the right tool for the job. This article explores the thinking behind these schemes and the toolmakers' efforts to design tools for the specific applications defined in their selection systems.
PVD Coatings for Turning
Researchers report on their study of coating performance. Their tests of TiN, TiCN and TiAlN coatings involved turning Inconel 718, medium-carbon steel and ductile cast iron. The wear rates and failure mechanisms of the coated tools are compared.