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Hats off to tool manufacturers! They make some of the most geometrically complex products out of the toughest materials and with the tightest tolerances. And yet cutting tools represent only 3% of the total cost of the average metalworking process.

We all know the buzzwords circulating around digital data and the factory. You have heard them—Industry 4.0, smart factories, data analytics, and artificial intelligence (AI). The question we all have is how will this impact workers in the long term? What do these terms really mean? Nevertheless, both traditional software suppliers and makers of advanced manufacturing equipment are offering digital solutions.

United Grinding North America will close its Fredericksburg, VA, office on July 1 and move those operations to its headquarters in Miamisburg, OH. “This tactical move is part of an overall strategy designed with the customer at the forefront,” said Theodore Neckel, director of corporate marketing for United Grinding North America.

Coolant is a key component to successful centerless grinding but is often overlooked. Many coolant delivery systems for centerless grinders are under engineered and are often neglected.

Cutting tool maker Shape-Master Tool Co. (Kirkland, IL) needed to expand its tool grinding capability beyond that of its conventional machines or run the risk of losing work to the competition.

In what shouldn’t be too much of a surprise, challenges for advanced grinding technology from high tech industries range from handling the most difficult-to-machine materials for aerospace jet engine turbines to series production on automotive drive train lines.

Burrs, sharp edges, and rough surfaces plague even the most precise metal-cutting or forming process. Deburring and finishing can often be treated as the step-child of a manufacturing process, but its importance is growing as tolerances get tighter and precision devices become the norm.

Many precision grinding machines on the market already offer their users near-perfect tolerances, leaving one to wonder: What’s next in grinding? But tool builders still have plenty of room to add valuable new improvements, machine shop owners say.

A recent effort by the Norton Advanced Applications Engineering Group demonstrates that for difficult-to-machine materials, grinding can be an economical alternative to other machining processes.

Until the middle of 2010, first-tier subcontract machinist, JJ Churchill, could produce turbine blades only if they had their fir-tree root-forms preground elsewhere, or if they were subsequently added by another subcontractor. No longer is this the case.