More Featured Videos

• Videos Showcase SFP1 Probe

  These two videos showcase some of the technology behind the SFP1 surface finish probe option for Renishaw's Revo five-axis measuring head.

• Video: Five-Axis Machine’s Atypical Pallet Changing System

  Makino’s a61nx-5E five-axis machine features an atypical pallet changing system that brings effective ergonomics to five-axis machining.

• Video: Young People Finding High Paying Jobs in CNC Machining

  Watch video from NBC’s Today show about young people pursuing skilled work in CNC machining instead of opting for a four-year college study.

• Benefits of a Multi-CAD Viewer

  Adding the right multi-CAD viewer to your quoting process helps improve customer communication, secure new business, and save time and money.

• Core and Cavity Splitting

  Automated core & cavity construction from a solid CAD model, including shut off building using a combination of surface and solid modelling techniques.

• Video: Fifth-Axis Tombstone Workholding Solution

  Watch an HMC perform five-axis machining using a tombstone that has multiple indexers installed.

• Video: A Job Shop’s Lean Transformation

  For shops considering a move to lean manufacturing—or a recommitment to lean manufacturing—this video is a great encouragement.

• Video: Maximize Machine Tools with MTConnect

  Joel Neidig, technology manager at ITAMCO, talks about how machine monitoring and other MTConnect-enabled technologies have benefited this north central Indiana job shop.

• Check out this Family Business’ “Working Museum”

  Central Texas Tools moved to its current location back in 1937. The close-knit, three-generation shop uses the same belt-driven equipment as it did back then, too.

• How 3D Printing Methods Differ

  It was about a year ago that 3D printer makers Stratasys and Objet announced their plan to merge. This video from the now-united company shows a 3D-printed part made with both of the machine lines.

• How to Get the Most out of Your Cooling Design

  Getting the most out of a cooling design involves figuring out how to get around obstacles such as melt delivery systems (hot runners, cold runners, gates), part ejection, and mold action (slides, lifters).

• Roll-in Technique

  When using the roll-in technique, thin chips will exit the cutter from the very start of the machining process, regardless of milling cutter center line position. This eliminates the tool pressure fluctuation, and loading and unloading of the machine spindle bearings.

• CNC Machining Software Verifies Cutter Path Manipulation, Quality

  VERICUT from CGTech features a  unique algorithm that provides fast, accurate results that does not degrade with increased cuts, so it can process programs with millions of cuts and virtually any type of material removal technique.

• Workholding That Works for Jesel

  The maker of racing engine components produces parts that have many permutations within each product line. Here is how Jesel sets up work for cost-effective, responsive machining.

• Mold Design/Electrode Extraction/Plastic Flow Analysis

  Complete mold design solution based on industry specific automation taht guides the user through the mold development process.

• Video: Introduce a Girl to Engineering Day

  February 21 is “Introduce a Girl to Engineering Day.” Various companies and schools throughout the country are holding events, but the idea is a good one on any day of the year.

• Video: Blisk Milling

  The process seen here uses trochoidal tool paths and cryogenic cooling

• MMT at IMTS

  Shop Talk at IMTS 2012 - MoldMaking Technology

• CAD/CAM Advancements Increase Machine Productivity

• CAD/CAM Increases Machining Productivity

• Video: Meet a Manufacturing Engineer

  An engineer with GE Aviation describes the work she does and why she finds her field rewarding.

• On-Machine Verification Inspection Software

• Automated Work Cell for Unattended Hard Milling of Precision Mold Applications

  MGS Manufacturing Group showcases its automation provided by Makino.

• Co-Injection in Action

  Historically, co-injection workcells have been highly specialized dedicated systems with high capital cost to start with. Now there are new solutions coming on the market, which will allow molders and moldmakers to create co-injection systems at a radically different cost because they are now able to use their installed workcell base and standard molds for the solution.

• Video: Two-Spindle Inverted Vertical Turning

  See how Emag's vertical turning center reduces "nebenzeit."

• Video: Adding Strength for Additive Manufacturing

  A computer program strengthens designs before they are printed.

• Cylindrical Grinding in Moldmaking

  Mold manufacturers who take the time to educate themselves on cylindrical grinding will reap the benefits of the advantages achieved with cylindrical grinding in their mold manufacturing operations—decreased costs, superior surface finishes and high flexibility.

• Video: Collaborative Manufacturing = “Cofacturing”

  Federated Precision describes the next industrial revolution.

• Cutting Carbide with an End Mill

  A new diamond-coated end mill that "cuts" carbide

• Video: Multitasking Production at Straitline

  Straitline Components recently automated the production of its newest product using a machine that is arguably the most versatile in the shop so far—a Doosan nine-axis multitasking turning center.

• CNC Software and Complex Molds

  The right CNC Software can deliver amazing leadtime reduction results when it comes to complex mold building.

• Video: Moving Section Made in One Piece

  The cover of our latest Additive Manufacturing supplement shows an articulating section that used to require assembly of many metal links, until additive manufacturing made it possible to produce this moving section in one piece.

• CAM in Action

  CAM demonstrated via a tire mold and shoe sole mold machining application.

• Close Collaboration with Customer Results in Successful Overmolding Process

  The mold Roembke Mfg. & Design designed and built for the vial for a water test cartridge is single drop cold deck with a standard LSR valve gate design featuring side injection versus back injection for the plastic.

• Model-Based Inspection

  Using model-based inspection for real time measurements to a CAD entity.

• Laser Welding Avoids Heating Issues within the Mold

  Laser welding technology produces less of a heat-affected zone, which is important to avoid heating issues within the mold like creating carbon pockets or stressing the mold.

• The Humble Pull Stud

  I’ve said that the toolholder is the least appreciated element in many milling processes, but the pull stud (or retention knob) is perhaps the least appreciated component of the toolholder.

• Multiple Set-ups Versus Turning Capabilities

  Video demonstrating the Turn-Cut function available on a horizontal machining center.

• Cylindrical Drive Technology Adds Efficiency to EDM Operations

  New system only exposes half of the magnetic flux to the face of the coils.

• EDM video sodick

   

• EDM MC Machinery Mitsu

• Comparing Roughing Techniques

  Side-by-side comparison of traditional roughing and our new OptiRough technique.

• Eliminate Chatter and Solve Finish Problems

  Eliminating chatter is a great way to improve surface finish when performing CNC milling. Okuma's Machining Navi M-i detects chatter and automatically adjusts spindle speed to eliminate chatter, thus improving surface finish. This is a terrific tool for the mold/die industry.

• Thread Milling Explained

  Watch this short video from Sandvik Coromant to learn about the advantages of thread milling.

• Video: CT Scanning for Mold Inspection

  Injection mold maker NyproMold uses CT scanning to validate molds.

• Video: Linear Motor Machines at Die Tech

  Machines with linear motors instead of ballscrews have increased productivity for one die maker.

• Video: Perspectives on Cardinal Manufacturing

  An innovative high school vocational manufacturing program has students doing production work for paying customers.

• Linear Five-Axis at Die Tech & Engineering

  Video about using linear motor 5-axis machines at Die Tech & Engineering in Wyoming Michigan near Grand Rapids. Simultaneous five axis contour milling of hardened tool steel.

• Top Shops 2012: Premier Machining Industries

  PMI uses advanced ERP software for real-time monitoring of production flow.

• Top Shops 2012: L&H Industrial

  L&H Industrial has a wealth of advanced large-scale machining and manufacturing capabilities.

• Top Shops 2012: Southern Machine Works

  A lot of the changes this shop made were a result of integrating a CPA mindset into a contract shop environment.

• Video: Understanding Toolholders

  The toolholder is arguably the least appreciated element in a system for successful milling on a machining center. Watch a presentation for optimizing the interface between the cutting tool and the spindle.

• Top Shops 2012: L&P Machine Products

  Here are five key elements of this quality contract shop.

• Video: Time-Saving Workholding

  Erowa discusses workholding options for greater machining center efficiency.

• Time-Saving Workholding

  Erowa discusses workholding options for greater machining center efficiency.

• 3D Printing for Assembly Tooling

  Additive manufacturing offers an option for quickly creating custom tools.

• 3D Printed Mold Tooling

  XLAForm describes a process for making molds quickly by infusing a 3D printed tool.

• Video: 3D Printing for Assembly Tooling

  Additive manufacturing offers an option for quickly creating custom tools.

• Video: 3D Printed Mold Tooling

  XLAForm describes a process for making molds quickly by infusing a 3D printed tool.

• IMTS 2012 - Be There in 2012

  Reasons to attend IMTS 2012. The International Manufacturing Technology Show (IMTS) is the largest manufacturing technology show in the Western Hemisphere. IMTS 2010 drew more than 82,400 industry decision-makers over the six day show. It's the best show to get ideas and find answers to your manufacturing problems. See new solution demonstrations and choose the best for your needs. Compare technologies from around the world in one place and get the edge you need to stay competitive in your field in the future.

• Plan Your Trip with IMTS.com

  Discover the best way to plan and organize your trip to IMTS - The International Manufacturing Technology Show Sept. 10-15, 2012 at McCormick Place, Chicago, Illinois.

• IMTS 2012 - A Look Ahead with Doug Woods

  Are you ready to move ahead of your competition? IMTS - The International Manufacturing Technology Show, Sept. 10-15, 2012 at McCormick Place, Chicago, Illinois, www.IMTS.com

• Video: CT Scanning for Mold Inspection

  Moldmaker NyproMold describes its experience using computed tomography (CT) scanning to validate precise injection molds.

• Micro Inspection at Matrix Tooling

  Various inspection and measurement resources help a moldmaker produce tooling for tiny molded parts.

• Video: Reality Redesigned and Modern Machine Shop at Rapid Event

  At last week’s Rapid conference and expo in Atlanta, "The Edge Factor" producer Jeremy Bout unveiled the three winners of the reality show/design contest, “Reality Redesigned.”

• Additive Manufacturing or Low-Volume Injection Molding?

  Learn about the comparison between additive manufacturing and low-volume injection molding in this video presentation.

• Expanding Without Adding Staff

  This news story is perhaps a sign of the times. This manufacturer expanded the size and capacity of its facility, but struggled to expand its workforce.

• Video: Electron Beam Direct Manufacturing

  Lockheed Martin expects to reduce titanium part-production costs for the F-35 fighter by applying this additive manufacturing technology in place of forging.

• Video: Ultrasonic Additive Manufacturing

  This video from Fabrisonic shows ultrasonic additive manufacturing being used to produce a mold with conformal cooling channels.

• 3D Vision System Enables Robotic Bin-Picking Automation

  Position and orientation data gathered by a 3D vision system enables this robot to remove parts randomly located in a bin.

• Video: Additive Manufacturing at Morris Technologies

  A company that is advancing additive manufacturing as a production technology discusses why additive manufacturing is important right now.

• Improving Milling Accuracy

  How you use the machining center is just as important as the quality of the machine itself. This tutorial covers machining center leveling, alignment and temperature—as well as toolchange and setup procedures.

• Getting the Most out of Your Standard Spindle

  High spindle speed is not needed for high productivity. Techniques described in this tutorial video relate to plunge roughing, high feed milling and slotting.

• 3+2 Mold Machining

  Rick Hecker, Gary Schulz and Michael Nye of Eifel Mold & Engineering (Fraser, MI) describe the shop's use of 3+2 machining to mill injection molds.

• Minimizing Mistakes with Laser Scanning CMM

  Die Tech & Engineering uses its scanning CMM to avoid errors by inspecting electrodes prior to EDM.

• Reshoring!

  Harry Moser, founder of the Reshoring Initiative, talks about the total cost of ownership of manufactured goods. He also recently appeared at the amerimold expo in Novi, MI.

• Remote Monitoring of Machines

  Check out this new video from MMTOnline video contributor Todd Schuett, produced with the assistance of Jeremy Christen.

• The Value of Prototyping

  “Reality Redesigned” judge Jeremy Bout inadvertently illustrated the value of prototyping when he tried to use his 3D printed model in production.

• Five-Axis Mold Machining In Action

  This mold maker describes its use of both tilting-spindle and tilting-table five-axis machines. .

• Video: Micro Inspection at Matrix Tooling

  Various inspection and measurement resources help a moldmaker produce tooling for tiny molded parts.

• Video: Five-Axis Machining at Padgett Machine

  A job shop owner talks about five-axis machining and feature-based programming.

• Horizontal Wire EDM on the Vollmer QWD 760

  The Vollmer QWD 760 features a horizontally guided wire that rotates on an E axis. An automatic probing system verifies orientation of PCD inserts before wire cutting.

• Video: Checking Toolholder Runout

  This short video explains how to check the runout on a collet chuck toolholder.

• Video: Five-Axis Machining at Chicago Mold Engineering

  This mold maker describes its use of both tilting-spindle and tilting-table five-axis machines.

• Video: Milling Inconel 718 with Cermic Inserts

  Metal removal rate is high and the cut is dry. See other basic tips for milling with ceramics.

• Video: Submit to Reality Redesigned

  Edge Factor producer Jeremy Bout describes how design contest video entries can be submitted.

• Video: Edge Factor and Reality Redesigned

  Edge Factor producer Jeremy Bout talks about the show, the latest episode and the Reality Redesigned contest.

• Video: Manual Jog Mode within CAM

  This CAM feature allows tool paths to be defined through a process that resembles jogging the machine manually.

• Why Y?

  This toolholder takes advantage of a Swiss-type’s Y-axis motion to approach and engage the barstock from the side, which helps prevent “bird nesting.”

• Video: Reshoring Manufacturing

  An interview with Harry Moser, founder of the Reshoring Initiative.

• A Quick Way to Deburr Holes in Contoured Surfaces

  This video shows a device that enables machine tools to quickly deburr both sides of through holes in elliptical and contoured surfaces.

• High Speed Air Spindle Example 2: CNC Wood Machining

  A Fadal VMC uses an air-driven spindle to create the logo inlay pocket into the headstock of Peavey guitars.

• High Speed Air Spindle Example 1: CNC Tool Steel Machining

  In this video, a hardened tool steel tire mold is milled by an air-driven high speed spindle from Air Turbine Tools.

• High Speed Air Spindle Example 3: Robotic Deburring

  Using an air spindle, this Fanuc robot is able to deburr castings with irregular flash.

• High Speed Air Spindle Example 4: Hand Deburring

  Just a light touch is required using this device as its high speed does the cutting. Combined with low vibration and weight, this reduces the risk of stress injuries to operators.

• Top Shops 2011: Air Flow Research

  One of our 2011 Top Shops, this manufacturer of high-performance cylinder heads has a long history of applying five-axis machining to create complex internal features.

• Top Shops 2011: Altech Machining, Inc.

  Although this shop’s specialty is production CNC turning, its secondary milling, honing (or lapping) and grinding capabilities enable it to succeed in producing accurate hydraulic valve components and assemblies.

• Top Shops 2011: Bley LLC

  Bley eyes large-scale machining work.

• Top Shops 2011: Hyper-Tech

  This shop uses CNC turning, milling, gear cutting, ID and OD grinding, honing and broaching to be a done-in-one supplier of machined parts.

• Top Shops 2011: Millat Industries

  This shop invests in advanced CNC machines, CAD/CAM packages, CMM inspection systems and robotics to keep its value-added services cost effective for its customers.

• Valve Production Machine with 20-inch Turning Capability

  Mazak offers its Orbitec 20 for manufacturers of valves and similar large components.

• The Buzz about the B Axis

  The rotating milling head is a defining feature on a turn-mill machine designed for efficient production of complex parts in low volumes.

• Video: DAPRA High-Feed Cutting 316L Stainless Steel at 120 IPM

  (Sponsored Content) Dapra's 2" Mid-Feed Shell Mill video

• Video: Milling with Full Flute Length

  A shop captured this footage of the way a software feature permits deep cutting in steel.

• Dapra high feed cutting 4140ph at 300-ipm.

  (sponsored content) Video: High-Feed Cutting 4140PH at 300 IPM with RHINO-FEED Mid-Feed Shell Mill and Inserts from Dapra.

• 90-Degree Pocketing Aluminum - 0.250” DOC with Square Shoulder End Mill and XPET-ALU Inserts from Dapra

  (sponsored content) This video demonstrates Dapra's 1" Square Shoulder End Mill executing a pocketing routine in aluminum.

• Video: Maximizing Cutter Life

  A shop owner describes his simple approach to evaluating cutting tool performance and finding the best parameters.

• Video: Programmable Shopfloor Gaging System

  System provides flexible alternative to hard gaging near the machine tool.

• Drilling in White Iron

  VIDEO: A Jabro solid carbide end mill from Seco generates a tapered hole in white cast iron with a hardness of 60 Rc in preparation for internal threading operations.

• Threading in White Iron

  VIDEO: A PCBN200 insert from Seco is employed to create TR55 DIN trapezoidal internal threads to Acme 2 specification in 70-rc cast white iron.

• Video: The Edge Factor at Center Rock

  The Edge Factor’s team visits Center Rock, maker of the rock drills used to free the trapped miners in Chile.

• Video: Cryogenic Machining of Titanium

  Through-tool liquid nitrogen turns the tool into a heat sink, extending tool life.

• Video: Machining Long Parts Through a Small Machining Center

  Video from Chiron America demonstrates the company’s Multi-Profile System, which combines a machining center with in-feed and out-feed accessories so that the compact machine can mill and drill long parts.

• Video: Remote Machine Monitoring

  Two mold shops describe the ways they use remote machine monitoring via video.

• Video: Safe Shrink-Fit Has Built-in Cooling

  The cycle for heating the toolholder also includes water cooling so the toolholder finishes cool.

• Video: The Edge Factor Pilot Episode

  Quite possibly the first time a CNC job shop has figured into a major reality film production.

• Video: Hard Pocket Milling

  Relieved end mills and pre-machining of corners are two important considerations for accurate pocket machining in hard steel.

• Video: What is The Edge Factor - Teaser

  The Edge Factor is a show that will tell real stories of real CNC machining.

• Video: The Edge Factor Show Concept Trailer

  Come face to face with astounding manufacturing challenges.

• Video: In-Process Scanning of a Turned Profile—via Robot

  A robot reaching into a lathe measures along the entire part length in seconds, determining whether additional machining is needed.

• Video of a Really Cool Bar (-Fed Machining Center)

  See a five-axis, bar-fed machining center creating a complex sample part complete from barstock.

• Video: Big Boring Operations on a Marine Prop Housing

  East Texas Machine Works focuses on large-scale work. Here’s a video showing impressive boring operations on a marine component.

• New - Sandvik Coromant Machining Calculator App

  (Sponsored Content) The NEW Machining Calculator App from Sandvik Coromant is designed to help engineers and machinists optimize the performance of their turning, milling and drilling applications by calculating optimal cut settings based on job parameters.

• Video: Remote Spindle Vibration Analysis Explained

  A new remote spindle monitoring technology offers a way to predict spindle issues before they become major problems that adversely affect production.

• Video: Splitter Waterjet Machining at Michael Waltrip Racing

  A waterjet machine cuts multiple polycarbonate “splitters” used on the front facia of a Nascar race car.

• Video: Turn-Mill Probes for Accurate Camshaft Machining

  Feature-to-feature accuracy for diesel camshaft segments is possible thanks to in-process probing.

• Video: Dual-Wheel, Vertical Grinding of a Camshaft

  In this video, one of EMAG's VTC machines grinds a camshaft using two opposing grinding wheels. Opposing the wheels in such a way cancels axial forces on the camshaft.

• Video: Swiss Machining of Airbag Component

  The capability to perform multiple operations, including backworking, makes these machines attractive for complex, short parts like this airbag component.

• Does Dexter Really Need a Hard Hat?

  A Motoman SDA10D dual-arm robot (nicknamed Dexter Bot) appropriately had the honor of turning the first shovel of dirt at the groundbreaking ceremony for Motoman Robotics’ new facility in Miamisburg, Ohio.

• The Sandvik Coromant Chicago Visitor's Bureau Presents...

  (Sponsored Content) Buying a new machine at IMTS? Be sure to stop by the Sandvik Coromant Smart Hub first. Choosing the right tooling solutions from the start will help you pay off your new machine purchase up to one year faster. Meet with a yellow coat and get the tooling solutions to think smart, work smart and earn smart.

• IMTS 2010 - A Look Ahead

  You have to be there.

• Video: Palletization and Five-Axis Machining in a Mold Shop

  Die Tech & Engineering describes how palletization and five-axis machining work together to deliver efficiency.

• Video: Minimizing Mistakes with Laser Scanning CMM

  Die Tech & Engineering uses its scanning to CMM to avoid errors by inspecting electrodes prior to EDM.

• Video: What is Duplex Milling?

  This footage shows two-sided milling for fast production of square blanks.

• Video: What is Double Disc Grinding?

  This footage shows grinding of opposite surfaces at the same time.

• Video: What is Blanchard Grinding?

  This footage demonstrates rotary surface grinding of large parts.

• Video: Two-Spindle Machine Turns and Mills Turbo Housings

  This five-axis, two-spindle machining center shows how multitasking machines can be used for production applications.

• Sandvik Coromant Smart Hub

  (Sponsored Content) Coming to IMTS 2010 in Chicago? Planning on catching a Cubs game? Well forget it, they’re traveling that week. But be sure to visit the Sandvik Coromant Smart Hub at IMTS to meet with a yellow coat and get the tooling solutions to think smart, work smart and earn smart.

• Video: Pocketing Steel - 0.100” DOC

  (Sponsored Content) This video demonstrates Dapra's 1" Toroid End Mill executing a pocketing routine in steel. The material is 4140PH (30 Rc), and the machine tool used is a Fadal 4020 with a 40-taper spindle with 0.100" DOC.

• Video: Modulation Assisted Machining

  This footage shows the effect of a techology that speeds and simplifies center drilling by oscillating the drill through many pecks per second.

• Pivot™180 - the Oscillation Sensation!

  (Sponsored Content) Pivot 180 generates airflow 100 feet out, enveloping a 180 degree arc from side to side – a coverage area of an impressive 12,000 square feet. Pivot 180 installs on a column or other vertical structure proving the perfect air movement solution for areas with ceiling obstructions or tight spaces.

• Milling with Air

  ... not to mention grinding with air. Thanks to high speed spindles powered by shop air, this job shop expands the work its VMCs can do.

• The Right Fit Is In The Fixtures

  Custom engineered workholding fixtures are key to the effectiveness of an unusual Automated Production System (APS) recently installed at Kurt Manufacturing. It helps that one of this company’s specialties is custom engineered workholding fixtures.

• VIDEO: Pocketing Steel - 0.030” DOC

  (Sponsored Content) This video demonstrates Dapra's 1" Toroid End Mill executing a pocketing routine in steel. The material is 4140PH (30 Rc), and the machine tool used is a Fadal 4020 with a 40-taper spindle with .030" DOC.

• Five-Axis Head for Inspection on CMMs Increases Throughput

  Utilizing technology developed for its Revo measurement system, Renishaw says its PH20 probe head offers “head touches” for rapid touch-trigger measurement and fast, infinite, five-axis positioning for optimal feature access.

• Machining A Non-Round Part On A Turning Center

  This intricate machining cycle on a CNC Swiss-type lathe reveals how a turning center capable of X-, Y- and Z-axis motion in milling can be effective even when the part is not round. The part, a spinal hook, does not feature anything like the axial symmetry typical of a turned part. Video length: 6.0 minutes

• Sponsored Video: Helically Interpolating a Hole at 225 IPM Through a Milled Slot

  This video demonstrates Dapra's 1" Toroid End Mill executing the helical interpolation of a 1.75" diameter hole to a depth of 1.25". The material is H13, and the machine tool used is a Fadal 4020 with a 40-taper spindle.

• Video: 3+2 Mold Machining at Eifel

  A maker of injection molds for high-appearance-quality parts describes the machine tool, software and strategy this shop uses to apply 3+2 machining.

• Hard Milling Isn’t Just High Speed Machining

  Milling complex forms in hardened tool steel involves more than just fast, light cuts, says this maker of medical-related injection molds. Here are some of the ingredients of an effective hard milling process.

• Mill’s Integral Rotary Axis Allows Turning

  Video: Spanish machine tool builder Ibarmia offers a moving column machine that has an interesting table-within-a-table configuration.

• The Value Of Probing On Turn-Mills

  Part probing isn’t performed as often on turn-mills as it is on conventional machine tools. It does offer advantages for multitasking machines, though. Includes video.

• Video: Getting the Most Out of Your Standard Spindle

  High spindle speed is not needed for high productivity, particularly with the right choice of cutting tool types. Techniques described in this tutorial video relate to plunge roughing, high feed milling and slotting.

• Video: Plunge Roughing in Aluminum

  Even in aluminum, plunge roughing can be an effective way to realize high productivity.

• Video: High Feed Milling in Aluminum

  Footage shows roughing at 48 cubic inch per minute on a standard-speed machining center.

• More Efficient Turbine Blade Milling

  Video shows a multitasking machine milling a turbine blade in a cycle that few machining centers could replicate.

• Video: High Speed Milling—900 ipm

  Demonstation illustrates the kind of metal removal rate that is possible in aluminum at dynamically stable speeds.

• More In The Know

  This shop is in the early stages of integrating Internet-based training tailored specifically to the brand of Swiss-type lathes it uses. The goal is to bring prospective employees up to speed quicker while enabling existing employees to progress to more advanced roles in the shop.

• Video: Milling Inconel 718 Efficiently Without a Heavy Machine

  This video of machining Inconel at a fast metal removal rate shows the effect of constant-engagement-angle milling.

• Video: Milling Titanium 6-4 Efficiently Without a Heavy Machine

  This video of machining titanium at a fast metal removal rate shows the effect of constant-engagement-angle milling.

• Video: Getting the Most Out of Your High Speed Spindle

  Here is an introduction to machining center spindles designed for high speeds, with practical tips for using these high speed spindles effectively.

• Video: What Is High Speed Machining?

  The answer does not have to do with any particular speed. It has to do with how that speed is used.

• Video: Setting Boring Bar Offset On A Swiss-Type

  This video clip from a MasterTask Training instructional course describes how to set the X-axis geometry offset for a boring bar on a Tsugami Swiss-type lathe.

• A Significant Cell

  Manual loading of heavy housings was this manufacturer’s prime bottleneck. It had limited experience with automated cells, but decided to install a big one. A look at the manufacturer’s $13 million cell reveals an intriguing layout and blend of technologies.

• The Automation Inspiration

  Although automated manufacturing cells typically consist of standard products such as CNC machine tools, robots, pallets and cell control software, almost all of these systems rely on inventive concepts developed for the particular application. These "good ideas" often account for the outstanding productivity and flexibility of these systems. This article looks at several of the "good ideas" that characterize a cell comprised of seven wire EDM units and a robot on a rail transfer unit.

• Video: The Role of Heat in High Speed Machining

  In high speed machining of die/mold steels, the heat has a more beneficial effect than the role it plays in conventional cuts.

• Automated Cell at Big Sky EDM

• Video: Balancing Tools And Toolholders

  This video provides both the argument and methodology for performing offline balancing of tool/toolholder assemblies for high speed machining centers.

• High-Volume Alternative To Machining Centers

  Transfer machines that are flexible rather than dedicated can run large quantities without dedicating labor or floorspace. (Includes video.)

• ADVERTISEMENT: Do you need to boost productivity: Invite a yellow coat.

  Windmills are fantastic, producing energy from an endless source without waste. Their increasing importance as a power supply is welcomed. We have great solution examples for: Connecting ring, Min shaft, Hub, Ring gear and planetary carrier.

• Video: Milling For Prototypes

  Learn how Designcraft applies CNC machining for prototyping.

• Rapid Manufacturing At Morris Technologies

  VIDEO. This firm that is focused on product development has invested heavily in additive production technology such as laser sintering, as well as the “subtractive” technology of CNC machining. See how Morris uses both in this narrated tour of the company.

• Aluminum Molds In Three Weeks Or Less

  While aluminum molds are commonly used to create prototypes or to serve as stopgap bridge tooling, they are starting to receive greater attention for production work. This shop’s approach to creating aluminum molds in one day to three weeks is the same for each of these situations.

• ADVERTISEMENT: Sandvik Coromant - Thousands of new products. Millions of ideas!

  In a tough business climate, it is even more important to optimize every step; from machining processes to tooling solutions, insert and grade selections.
  
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• Straight to Sand

  Through direct CNC machining of molds and cores, this supplier of cast and machined parts skips the pattern-making step that would otherwise be fundamental to casting. The result is weeks of lead-time savings for complex parts that are needed in a hurry.

• Improving Milling Accuracy

  VIDEO. How you use the machining center is just as important as the quality of the machine itself. This tutorial covers machining center leveling, alignment and temperature—as well as toolchange and setup procedures.
  

• Turning On A Machining Center

  VIDEO. Part of Renishaw’s automated production process, this turning operation uses tools affixed to the machining center’s table while the workpiece is mounted in the spindle.

• Video: Automatic Part Verification Through Reference Comparison

  The machining center in this automated production process inspects its own work and updates its own positioning. Probing a known, traceable reference makes this possible.

• The Key Points Of Helical Holemaking

  VIDEO. Have you considered milling holes through helical ramping instead of drilling them? This brief animated video covers the high points, including tool diameter selection and the potential for savings.

• Understanding Effective Diameter

  VIDEO. On a ballnose end mill, the depth of cut determines the actual cutting diameter. This effect, along with the related concept of chip thinning, will influence the optimal choices of spindle speed and feed rate.

• Video: Grouping HMCs For Greater Efficiency

  VIDEO. In a lean machining facility, grouping horizontal machining centers close together allows a small number of operators to use the machines efficiently.

• Video: Increased Productivity With More (Not Fewer) Setups

  VIDEO. Valve maker Richards Industries took a part that used to machined at one machine tool and added an additional setup on a vertical machining center. Higher throughput was the result.
  

• Video: Three-Machine Lean Cell At Richards Industries

  VIDEO. For this valve maker, a part that might have been machined in one setup on a multitasking machine tool is instead machined with greater throughput using a series of simpler machines. Company personnel explain.
  

• Video: Form Tools On CNC Lathes

  Form tools are traditionally associated with non-CNC machines, but in certain applications they make sense on modern machines as well.

• Video Profile: Lean Machining at Vanamatic

  See how this Delphos, Ohio, screw machine shop has saved considerable time by making its process on the shop floor more lean.

• Video: What Is 5S?

  Here is a training film a job shop developed to help its employees understand 5S.

• Video: Laser Tool Probing For Productivity And Accuracy

  The ability to measure tool offsets while the tool is spinning can improve both the accuracy and performance of the process in various ways.

• Hobbing on a Turning Center

  This manufacturer’s use of live-tool lathes overcomes labor cost in various ways. One of the latest sources of savings involves bringing another operation—hobbing—into these machines. INCLUDES VIDEO.
  

• The Part Is Longer Than The Lathe

  Here is one custom machine builder’s system for producing a 40-foot part that has to be passed through the turning center and out the other side. INCLUDES VIDEO.

• Video: Retention Knob Tightening And Toolholder Deflection

  This footage illustrates how the toolholder taper is measured in a test designed to capture the retention knob’s effect on the shape of the toolholder taper.

• Video: Parts Gripper Allows Machine To Act As Its Own Robot

  This footage shows a workpiece gripper that enables a machine to load and unload workpieces on its own.

• Thread Milling On A Tiny Scale

  Machining internal threads in difficult materials is challenging, especially when hole diameters are small. Thread milling offers advantages for these applications that are important to consider.

• Video: Faster Micro-Finishes for Micromachining

   Smooth finish comes from balanced cutting parameters, as this video explains.

• Video: Drilling 0.020-Inch Holes In Stainless Steel Aerospace Part

   This footage on a small drilling machining also includes machining with full-size tools in the same cycle.

• Video: Linear Motor Micromachining Center

  Video shows the smooth, quiet, rapid motion characteristic of effective micromilling.

• 50-Micron Milled Channels

  Video captured with a microscope shows that a full-scale machining center is capable of micro-size milling work.

• Electrode Loading for Fine-Hole EDM

  The Makino EDFH1 is a fine-hole EDM machine capable of machining holes as small as 10 microns in diameter using a 6-micron-diameter electrode. One user of this machine is Hummingbird Precision Machine in Lacey, Washington. This video taken at Hummingbird shows how the electrode is loaded.

• Micro-Turned and Micro-Milled Workpiece

  Video captured with a microscope shows micromachined part.

• Threading A Horizontal Wire EDM

  A wire EDM machine designed for micromachining uses negative air pressure to thread the fine wire.

• Video: Understanding The Role Of L:D Ratio In Micromachining

  When milling with tiny tools, changing the length-to-diameter ratio can significantly change the cutting parameters it is possible to achieve.
  

• Video: Five-Axis Milling On Linear-Motor Machining Center

  Linear motors take the place of ballscrews on this machine performing high speed cutting of aluminum at a job shop near Atlanta.

• Video: Horizontal Profiler For Aerospace Machining

  An alternative to the typical profiler design, this machine saves labor by allowing chips to fall out of the way.
  

• Finishing A Pocket Floor In Titanium

  Machining animation from Boeing illustrates effective techniques for titanium workpieces. This simulation also shows finishing of the floor of the pocket.

• Finishing Walls In Titanium

  Machining animation from Boeing illustrates effective techniques for titanium workpieces. This video shows material machined out of the corners prior to finishing.

• Plunge-And-Sweep For Finishing Corners

  Machining animation from Boeing illustrates effective techniques for titanium workpieces.

• Accuracy Gain From Linear Encoders

  If the position of a machine tool’s axis is measured using a rotary encoder, then potentially the ballscrew is being asked to perform two contradictory functions. The ballscrew both drives the axis into position and indicates that position—because the ballscrew lies in between the encoder and the moving element of the machine. Control technology supplier Heidenhain calls this “semiclosed-loop” operation.

• Video: Finish-Milling Titanium With A 20-Flute End Mill

  A tool with many flutes can be effective for achieving a productive metal removal rate in titanium, where speed and chip load are constrained. See how quickly the chips accumulate in this video.

• Optimal Milling Strategy For Entering Material From The Side

  These animations show why an arc in the same direction as tool rotation is effective. The strategy is relevant for entering material from the edge, as well as for pocketing.

• Video: 56-Percent Productivity Increase By Reducing Chatter

  The video compares a milling pass that chatters to one that is stable. Because the stable speed permits greater depth of cut, productivity increases.
  

• Side Turn-Milling Of A Massive Crankshaft

  This video footage showing the machining of a massive crankshaft suggests some of the possibilities of turn-milling. Not all shops realize possibilities such as this even on their own smaller-scale turn-mill equipment.

• More Large Crankshaft Machining

  A complement to the turn-mill footage, this video clip shows a turning operation for a massive crankshaft.
  

• Video: Getting Started With Minimum Quantity Lubrication

  Minimum quantity lubrication does not require a special machine tool or special tooling. This video makes the case for MQL and describes how to apply it effectively.

• Video Tour: Bryco Machine

  Bryco Machine recently reorganized its shop floor to implement a leaner process. Here is a narrated tour through the shop.

• Waterjet Cutting a Titanium Golf Club

  Here is a different way to think about the slice in your golf game. This footage comes from a Web site exploring the lighter side of waterjet machining.

• Sawing On A Turning Center

  This part machined on a CNC Swiss-type lathe includes 0.008-inch slots machined through precision sawing. The lathe performing this work uses linear motors in place of ballscrews.

• Bone Screw Machining On A CNC Swiss-Type Lathe

  View this video to see clearly how a CNC Swiss-type lathe works. On a machine of this type, the guide bushing moves the part along the axial direction so the tool can remain close to the point of support. Thread whirling is one of the operations in this machining cycle producing a bone screw. Video Length: 3.25 minutes

• The Role Of The Subspindle In CNC Swiss-Type Machining

  This video shows a machining cycle on a CNC Swiss-type lathe that takes advantage of more sophisticated features involving the subspindle. The subspindle driving workpiece during the last machining operations reduces the length of remnant that has to be left behind.

• Video: Basics of Thin Wall Machining

  To mill thin walls in aluminum using fast light cuts, machine on alternating sides of the wall all the way down, jumping the wall with each new pass.

• Video: Trochoidal Milling

  This approach to rough milling replaces straight lines with “curlicue” moves of constant radius.

• Hole Making: Combination Tools

  This video demonstrates hole making. Hole making often involves sequential operations such as drill-then-tap. Combination tools that perform these operations simultaneously can eliminate tool changes, saving cycle time. Many combination tools call for helical interpolation. The video shows the same series of hole

• Video: Helical Interpolation Vs. Drilling

  A machining center able to maintain precise control at high feed rates makes it practical to machine holes through helical milling as an alternative to drilling.

• Video: Micromilling With a Long Tool

  This video clip illustrates micromilling at a high tool L:D ratio.

• Through-Spindle Dust Collection For Composites And Graphite

  A vacuum system for the machining center draws particulate through the center of the tool.
  

• End Mill Comparisons in CFRP, Part 1 - Carbide Tool

  Video shows the performance of coated carbide, diamond-coated, PCD and veined PCD tools in carbon fiber reinforced plastic. Part one in a four-part series.

• End Mill Comparisons in CFRP, Part 2 - Diamond-Coated Tool

  Video shows the performance of coated carbide, diamond-coated, PCD and veined PCD tools in carbon fiber reinforced plastic. Part two in a four-part series.

• End Mill Comparisons in CFRP, Part 3 - Conventional PCD Tool

  Video shows the performance of coated carbide, diamond-coated, PCD and veined PCD tools in carbon fiber reinforced plastic. Part three in a four-part series.

• End Mill Comparisons in CFRP, Part 4 - Veined PCD Tool

  Video shows the performance of coated carbide, diamond-coated, PCD and veined PCD tools in carbon fiber reinforced plastic. Part four in a four-part series.

• Cutting Out A Composite Structure

  Milling cuts out features of a composite structure, then cuts the structure itself out of the setup.

• Exit-Side Drill Penetration Without Delamination

  Slow-motion video shows the effect of a micograin tool coating in drilling CFRP.

• Five-Axis Milling And Drilling Of Composite Component

  This video from machine tool maker CMS shows high speed five-axis milling and drilling of composite component.

• Five-Axis Trimming Of Composites

  Here is video of the five-axis motion required to trim a relatively simple composite component.

• In It For The Long Haul

  Curt Reed uses advanced grinding techniques in the pursuit of short-run, sub-micron work that other shops can’t perform or won’t attempt. His shop’s commitment to its customers is reflected in the high level of equipment sophistication and applied grinding acumen.