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Streaming Video

Flexible Small Lot Production for JIT

This program provides three case studies to show how Flexible Small Lot Production for JIT is successful. See how Roll Forming Corporation realigned equipment into cells based on three primary customer types in three months. At Joy Technologies, a machining cell manufactured by Cincinnati Milacron is monitored by a Cell Controller which prioritizes jobs to be completed by due date, which reduced lead time from four weeks to one and dramatically cut inventory on hand. Then, at Lockheed Aeronautical Systems Company, a flexible machining system is used to produce quality airframe components in lot sizes of one.

Product Type: Streaming Video

Cutting Tool Materials

Because of the wide variety of machining applications, there is a need for diverse cutting tool materials. This Cutting Tool Materials program provides a broad understanding of the development of these tool materials, focusing on high speed steel tools, carbide - including its property variables, types, grades and coatings, and ceramic, cermet and superhard materials like cubic boron nitride, or CBN, and polycrystalline diamond, or PCD. The Tool Failure Modes segment focuses on edge wear & flank wear, cratering, chipping, built-up edge, deformation, thermal cracking and notching.

Product Type: Streaming Video

Metalcutting Fluids

Since metalcutting fluids are an integral part of many machining operations, they need to be applied correctly to make parts productively. When understood and used correctly, cutting fluids also optimize the production process to yield quality parts safely and at lower cost. This Metalcutting Fluids program explains how cutting fluids serve several functions during a machining operation, such as, controlling heat generation by reducing friction between the tool and material, removing chips from the work area, prolonging tool life, maintaining surface integrity of the part, and preventing corrosion. This program also gives an in-depth examination of what fluids actually do during the metalcutting process, and features segments on cutting fluid types, fluid application systems, and cutting fluid maintenance. The Cutting Fluid Types segment looks at straight/cutting oils, soluble oils, semi-synthetic/semi-chemical cutting fluids, and synthetic/chemical cutting fluids. The Fluid Application Systems segment examines cutting fluid flooding, high pressure high volume fluid coolant, spray mist, Minimum Quantity Lubrication, and Dry Machining. The Cutting Fluid Maintenance segment details the methods for maintaining fluids, titration, the refractometer, material safety data sheets, and data & information sheets.

Product Type: Streaming Video

Plating and Surface Coatings

Plating and surface coating processes are used throughout manufacturing to provide protection, durability and decoration to parts. This program explains and highlights the use of electroplating, electroless plating, conversion coating, hot dipping, and porcelain enameling.

Product Type: Streaming Video

Rapid Injection Mold Tooling

This Rapid Injection Mold Tooling program shows three different methods of producing injection molds using various rapid prototyping techniques. The first example is epoxy tooling made from a stereolithography pattern that is used to mold 15 prototype parts in actual production material. The second example used the DTM process called RapidTool to make mold inserts capable of thousands of injection cycles. These RapidTool inserts were formed using powder metal in a Sinterstation. The powder metal inserts are infiltrated with copper to give the tool strength. The last example shows how the 3D Keltool process can be used to make mold inserts capable of being used as the final production tool for an injection molded part. This program also contains a demonstration of the PROMETAL machine that can make metal tooling directly from CAD data.

Product Type: Streaming Video

Plastic Injection Molds

The injection mold is an extremely important element of any plastic injection molding operation. Molds determine the shape of the part, vent trapped air or gases during injection, act as heat exchangers to solidify the molten plastic, and eject the cooled parts. This Plastic Injection Molds program highlights the primary injection mold components, including the mold base, cavity and cores, runner system, cooling system, and ejector system. This program also features segments on injection mold types, the use of computer simulation, mold prototyping techniques, and mold maintenance & repair. The Injection Mold Types segment showcases in detail the cold-runner two-plate mold, the cold-runner three-plate mold, the hot-runner mold, and the insulated runner mold. The Plastic Injection Mold Production segment explores the use of computer simulation to develop molds, mold production methods, mold prototyping techniques, and mold maintenance & repair.

Product Type: Streaming Video

Workholding

Workholding includes any device used to grip and present a workpiece to a cutting tool on a machine tool. To provide an understanding of workholding as a fundamental issue in the machining process, this Workholding program examines the principles of workholding, milling & machining center workholding, and lathe workholding. The Principles of Workholding segment covers datums, part location, the six degrees of freedom, the 3-2-1 locational method, and issues of reclamping or rechucking workpieces. The Milling & Machining Center Workholding segment looks at small-lot, medium-lot, and mass-production workholding options while detailing the use of clamps, vises, multi-vises, cubes, columns, tombstones, indexers, rotary tables, modular fixturing, pallets, pneumatic clamping, hydraulic clamping, vacuum workholding, and application-dedicated fixtures. The Lathe Workholding segment explores the use of 3-jaw chucks, 6-jaw chucks, 4-jaw chucks, 2-jaw chucks, indexing chucks, collets, collet chucks, between centers turning, drive dogs, face drivers, steady rests, and magnetic chucks and fixtures.

Product Type: Streaming Video

Turning and the Lathe

Turning on the lathe is one of the most common metalcutting operations. Lathes are particularly suited to machining relatively long, cylindrical workpieces, yet can create a variety of parts ranging from small watch components to massive propeller shafts.

Product Type: Streaming Video

Cutting Tool Geometries

Efficient metalcutting requires using the properly shaped tool for the task. These cutting tools are all described by their angles or geometries. To better understand these angles, this Cutting Tool Geometries program examines single-point turning tool and toolholder geometries, and milling and multi-point tool geometries. The Turning & Single Point Tools segment explores the various aspects of tool/toolholder geometry, such as insert shape, angle of inclination, lead angle, tool nose radius, and the various cutting tool rake angles. Insert chipbreaker designs and chip formation are also covered. The Milling & Multi-Point Cutting Tools segment focuses on the various milling cutter/milling insert rake angles, as well as, lead angle, cutter pitch, hand of cutter, effective diameter and more.

Product Type: Streaming Video

Heat Treating

This Heat Treating program highlights the versatility of heat treating in altering the metallurgical properties of metals and alloys. This versatility is broken down into three groups of processes: through hardening processes, surface hardening processes and softening processes. The Through Hardening Processes segment utilizes animations, phase diagrams and photomicrographs to explain the hardening process and define its many variables. Quenching speed, quenching mediums and temperature control are examined, as well as the tempering, martempering, and austempering of heat treated materials. The Surface Hardening Processes segment offers detailed examples of the processes that produce surface, or case hardened parts. Included are explanations of: flame hardening, induction hardening, carburizing, nitriding and carbonitriding. The Softening Processes segment examines the use of annealing, normalizing and stress relieving within the heat treating process.

Product Type: Streaming Video

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