Emily Probst is the associate editor for Modern Machine Shop. She joined the staff in the summer of 2006 as the editorial intern editing product releases for the International Manufacturing Technology Show (IMTS). Hired full-time in 2007 after graduating with a B.S.J. from Ohio University, she edited product releases and columns until 2012, when she moved to her current role of writing and editing case studies for both print and online media channels. In this role, she has been fortunate enough to travel the world as well as visit some interesting shops and trade shows in the United States. She also administers Modern’s blog as well as its Facebook, Twitter and YouTube accounts.
Mike Turner, operations manager at Derby Machine (Derby, Kansas) had a problem: Finding a vendor that could ID broach a blind hole in 304 stainless steel to proper size/accuracy specifications forced the company to ship its parts from Kansas to Chicago at $15 per part with a $100 setup fee, plus shipping both ways. Along with these costs, Mr. Turner says the parts were often damaged in the shipping process, so he began to ship them in ammo boxes for protection.
In search of a better solution, Mr. Turner decided to give an indexable-insert broaching tool from CNC Broach Tool (Marina Del Rey, California) a try. Though originally developed for lathes, Derby Machine would use the tool in a Haas mill. When the company received the tool and started setting up the machine, Mr. Turner says CNC Broach Tool’s John Gardner was very helpful in instructing the company on how to install the tool, as well as get the program, feeds and speeds correct.
According to Mr. Turner, the tool paid for itself several times over on the first run alone. From a single insert point, the company can broach more than 100 parts with a cycle time increase of only 2 minutes, 14 seconds. Today, the company has run more than 1,000 parts using very few inserts and has never lost the tool itself, he says.
“We never scrapped any parts because of the broach. It holds the depth and width through the whole run. I am extremely happy with the results and cost savings of this tool,” Mr. Turner says.
The digital edition of Modern Machine Shop's January 2015 issue is now available.
The digital January 2015 issue of Modern Machine Shop is now available. The cover story delves into ISO 13399, a family of standards that specify a common format for identifying and describing cutting tools. Another feature reports what trends we discovered while at JIMTOF, the Japan International Machine Tool Fair. A third story details the invisible advantage to cutting tool edge prep, while a fourth story discusses tooling up for vertical turning. Our fifth-annual Top Shops survey is now online, so be sure to check that out.
Our Rapid Traverse section highlights two technologies we saw at IMTS—a vending system that uses a carousel with adjustable slots to hold box-shaped contents, and an inspection microscope with automatic focusing capabilities that can streamline the process. This section also highlights how high-speed spindles can be powered by coolant pressure, and it looks into a new website that enables shops with excess tooling to sell it to other shops.
This month’s Better Production section includes case studies about optimizing multitasking using custom clamping, how standardized CNC improved production of power-generation equipment, and how a trunnion table helped a VMC fill a utility roll for a shop.
The Modern Equipment Review section highlights robots and automation.
I can’t help it: I’m a sucker for year-end lists. As this blog’s moderator, I like to look at the numbers to figure out what kind of content our readers appreciate so we can be sure to create more of it. (In that same vein, if you have any topics you'd like us to cover, I’d love to hear about them!)
Below is a list of our 10 most popular blog posts written in 2014. (And here’s last year’s list if you missed it.) Here’s to another great year!
The digital December issue of Modern Machine Shop is now available. The cover story details how U.S. investment in machine tools is poised to reach a remarkable level. Another feature discusses how one shop uses an atypical means to fixture thin parts that are prone to flexing when conventional workholding clamps are used. A third story details how a shop that specializes in precision thread grinding not only provides an environment in which its machinists can fully focus on challenging tasks, but also the advanced equipment needed to accurately complete them.
Our Rapid Traverse section features three short technical pieces about manufacturing titanium.
This month’s Better Production section includes case studies about how face mills kept a shop from making a large capital expenditure, how software helped race-team mechanics become CNC programmer-machinists, and how a cutting tool helped an automotive manufacturer implement a design change, and how a video measuring system ensures diamond quality for waterjets.
The Modern Equipment Review section highlights machining center equipment.
Have you heard of Workshops for Warriors? The concept of this nonprofit organization based out of San Diego, California, is that veterans could provide an answer to manufacturing’s need for skilled employees. According to the organization, there is a severe shortage of skilled labor in the welding and fabricating industries and veterans are a perfect fit for these jobs. That’s why it provides machining and welding training to recently discharged veterans and Wounded Warriors.
MMS Editor Pete Zelinski had the privilege of visiting the facility a little more than a year ago and was impressed by what he found. Training is provided at no cost to veterans, and the organization boasts a 100 percent job placement rate for graduates. This Veterans Day, learn why this organization deserves your attention and support.