General Shop Equipment & Supplies

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

Thinking about and managing the risks of operating a job shop and machining parts is a straightforward process when using tools such as risk matrices and Failure Mode and Effects Analysis.

It's not just for prototyping; additive, or rapid, manufacturing can be a cost-effective way of producing parts, especially when used for mass customization of parts and for low-volume runs of smaller, complex, net- and near net-shape parts.

High-power laser machines—at least 5,000w—are more useful in machine shops because their power permits fast processing of thicker materials, materials more like the blocks machined by the metalcutting industry. Also, automation allows for more cost-effective laser machining.

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.

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Acoustic emission (AE) sensors detect ultrasonic sound waves emitted when the grinding wheel contacts a part or the dressing wheel and send that information to a process control unit. Monitoring the sound waves and comparing them with reference values allows operators to control the grinding and dressing processes. Variations in acoustic emissions indicate changes in cutting forces, which can then be modified. Some AE sensors are stationary while others rotate with the wheels.n

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.

There are five tool tips for moldmakers for speeding up production and aiding in highly repeatable, precision machining. Included are deep-hole drills to avoid pecking, high-feed cutters, tools for reducing EDMing, high-precision cutters and PCBN cutting tools.

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.

Lean manufacturing can benefit medium-size and larger companies by improving productivity and reducing quality problems and lead times. Benefits can be realized even in smaller, highly variable job shops through standardized work, balancing and flowing.