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Abrasive machining is a tried-and-true technology for meeting exacting tolerances and producing superior finishes. Manufacturers continue to develop new capabilities.

Anyone who’s worked with wind turbine blades or just seen one up close can attest to the massive size of these clean-energy workhorses. Ever thought about what happens to that costly, high-tech material once the blade reaches the end of its lifespan in 20 years or so?

It’s a sad fact of practically all metal removal operations that, no matter how sharp the tool or free-machining the material, there are going to be burrs, hanging chads, ragged corners, and other edge quality issues that must be dealt with before calling the workpiece complete.

Overall, there are two overriding customer needs: reducing cycle time and machine downtime. They want higher feed rates and depth of cut for greater metal removal.

Demand for machining titanium for aerospace applications won’t abate any time soon. It is driving OEMs and the supply chain in the commercial airplane market to find ways to dramatically increase machining output. Whatever date you pick from now until 2030, there’s a sufficient backlog of commercial airliners for both structural and jet engine applications to keep spindles humming around the clock cutting titanium.

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.

For Dale Mickelson, Yasda product manager at Methods Machine Tools Inc. (Sudbury, MA) and author of several books on hard milling, tackling heat-resistant superalloys (HRSAs) requires the perfect combination of machine, workholding, tooling, tool paths and coolant.

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.

Toolholding for rotating round tools—end mills, drills, and taps—continues to evolve with innovative designs aimed at guaranteeing precision, security, and repeatability. As a result, suppliers of toolholding technology have made supporting the precision, security, and repeatability of shrink-fit, mechanical, and hydraulic toolholding the highest priority.

How do you boost productivity in a highly competitive industry segment while improving the quality of life for your workforce? That’s the story of Skills Inc. (Auburn, WA), a company that is so unique it has two bottom lines—one financial and one social.