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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.

US machine shops are potentially underutilizing the machinability of brass by as much as 85 percent in their part processing operations, reports a recent study from the Copper Development Association Inc. (McLean, VA).

Many industries have been making parts with micron dimensions for some time, but in the last few years, the market for miniaturization has expanded. The demand is not only for small parts, but also for small complex features on larger parts. This is due chiefly to the switch to modules in which the functions of several parts or subsystems are not handled by a single complex unit.

Turning to software over paper reports does more than just save trees. Chris Mahar, Associate Editor of Manufacturing Engineering, talks with David McPhail, President and CEO of Memex Inc., about how manufacturers can utilize technology to improve efficiency, reduce downtime and boost productivity and profits across their business.

Simulation tools are making it much easier for manufacturers to optimize their processes, visualizing the entire path of production from NC metalcutting simulations through 3D design and factory-floor imaging.

Additive manufacturing is both growing and coping with growing pains. Companies “have to find ways to streamline” polishing and other finishing processes of 3D printed parts, industry consultant Terry Wohlers said today during a speech at RAPID + TCT.

When first introduced in the late 1970s, cutting tool coatings—especially titanium nitride (TiN)—were embraced by tool manufacturers for their ability to extend tool life. As workforce materials have expanded from conventional ferrous and nonferrous metals to exotic alloys, composites, ceramics, and others, coatings have likewise progressed and, thanks to new formulations and deposition methods, are extending cutting tool capabilities as well as tool life.

Manufacturing Engineering asked thought leaders at five companies for their views on challenges and trends facing the metalworking industry.

Tool life, geometry, and stability largely depend on proper edge preparation. Tool Flo, located in Houston, TX, is a manufacturer of carbide cutting tools such as inserts for threading, turning, and milling. The company uses optical 3D measurement systems from Alicona Corp. (Bartlett, IL) in the quality assurance of inserts.

When you’re managing a global manufacturing enterprise, there’s no choice but to go big. Large manufacturers, and even mid-sized builders, need the latest and best available technology in fast, real-time enterprise resource planning (ERP) software to handle the rapidly changing situations on the shop floor, often at multiple manufacturing sites located anywhere in the world.