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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.

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.

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.

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.

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.

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.

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

When it comes to materials, artificial intelligence can automate the screening process, simulate the performance of different materials and identify the best option.

A manufacturing execution system is often the first step for Industry 4.0 implementation, but most are optimized to serve OEMs. Pico MES Inc. is looking out for the little guy.