Each tool setting technique has merit, and it depends on where you are as a shop and the type of work you do, as cost and efficiency all come into play.

For Alpha Mold, however, the matter is cut and dried. Across the variety of mold machining jobs the shop takes on (including injection molds, blow molds and molds for glass work), the shop uses dry cutting almost exclusively. In fact, rather than listing all the merits the shop does see in forced air, it's more instructive to focus on the specific cases where the shop still insists on using liquid.

OnLogic is partnering with AI development and implementation specialists to help companies use AI-powered solutions, aiming to drive real business value.

Liquid coolant offers advantages unrelated to temperature. Forced air is the fluid of choice in this shop...but even so, conventional coolant can't be eliminated entirely.

Facing increasing competition from lower-cost imports, Suburban Tool made a move toward large-scale, in-house machining. By identifying a niche in large, precision angle plates and tombstones, the company has strengthened its ability to control quality and protect its reputation.

Custom workholding enabled Resolve Surgical Technologies to place all sizes of one trauma part onto a single machine — and cut days from the setup times.

As the demand for faster production cycles continues to grow, the ability to produce high-quality parts quickly and efficiently has become increasingly important. High-speed 3D printing has emerged as a key solution to reduce lead times and increase productivity across industries. However, like any advanced technology, it comes with its own set of challenges. In this webinar, Forward AM will explore both the opportunities and hurdles of adopting high-speed printing with a particular focus on overcoming those challenges. It’ll start by discussing the fundamentals of high-speed 3D printing and how it differs from conventional 3D printing methods. It’ll then move on to the key factors that influence successful implementation, including the impact of materials, equipment and design considerations. One of the main hurdles in high-speed 3D printing is ensuring the right balance between speed and part quality. Different materials behave differently under high-speed conditions — and not all equipment is optimized for this process. Forward AM will showcase some validated materials and equipment that are proven to perform well under these conditions. In addition, the presenters will look at real-world examples and applications where high-speed 3D printing has been successfully implemented, highlighting the collaboration between designers, engineers and manufacturers. By the end of this webinar, you'll not only have a clearer understanding of high-speed 3D printing with FFF but also the practical steps and considerations needed to make the most of this cutting-edge technology. Agenda:  Introduction The power of high-speed printing Know the process The practical side

When Puneet and Neelam Neotia moved from India to the United States several years ago, they brought with them a family background in manufacturing and CNC machining. Now the couple is working to get their startup machine shop off the ground, sourcing new customers and getting the word out about their shop in Clarksville, Indiana. The couple — proud to publicize their "Made in the USA" parts — is leveraging family connections and manufacturing capabilities back in India, but not in the way that some people assume.

The milling work of a shop like Alpha Mold is well-suited to the use of forced air in place of liquid coolant. However, in other shops that also apply high speed milling—but apply it for different purposes and different materials—the picture changes. To determine whether dry machining with forced air makes sense for a given high speed milling application, consider four main process factors:

By running a TiAlN-coated tool in the consistent high-temperature conditions this coating favors, Alpha Mold lets one insert machine away the same volume of material that used to wear out five inserts, back when a different process and a different style of cutter were used.

Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.

Pacon Mfg, Inc. has not rested on its laurels as the 2020 Top Shop Honoree for Shopfloor Practices and Performance. In the years since, it has refined its processes to continue excelling in a volatile market.

Achieve higher metal removal rates and enhanced predictability with ISCAR’s advanced high-feed milling tools — optimized for today’s competitive global market.

By contrast, Alpha's high speed milling process allows just one of the coated carbide inserts to do the same job. Even though this insert is more expensive than one of the slab mill inserts, it's not five times as expensive. By using the one insert instead of five, the shop spends only about one-third of what it formerly would have spent on tooling for this cut.

Motul announces it has acquired Chem Arrow Corp., aiming to expand the global presence and growth in lubricants for metal parts manufacturing.

Working closely with customers and making careful investments has enabled this Wisconsin machine shop to tackle difficult jobs with tight deadlines as a core part of its business.

The MFG Meeting brings together manufacturing technology industry leaders to address key business challenges and provide actionable solutions. Sessions cover a wide range of topics, including workforce, economics, supply chain, leadership, politics, and more. This unique meeting experience provides unparalleled opportunities to network with executives from companies that make, sell, service, and support MT. These peers and competitors will learn from each other, build long-lasting connections, and share insights that will benefit their business.

The VT Series of large-swing vertical turret lathes can be configured for turning, milling, boring and grinding in a single machine.

The problem is, liquid coolant has a way of cooling intermittently, and that fact creates a good reason to apply it with care. If the results of using coolant are dramatic and rapid temperature changes within the cut, then the coolant may do more harm than good. Many of today's cutting tools can stand up to high temperature so long as it's consistent, but they have little patience for change.

Essentially for all of the rest of its machining center work, Alpha Mold runs entirely dry, using forced air as the only metalworking fluid.

The Detroit Auto Show, formerly known as the North American International Auto Show (NAIAS), is located squarely at the intersection of technology and mobility. It’s a global event filled with tangible advances ready to hit the pavement today. Here, the software is as revolutionary as anything out there, and the hardware always looks better with a good polish. You won’t find any devices that will fit in your pocket, but you will discover machines that will move you in the most literal sense. You’ll also connect with thought leaders from around the world, both in and outside the automotive industry, whose collective visions for the future of mobility will shape the way we move for years to come.

No matter what your workholding application, automation always makes sense. Kurt Workholding helps you pick the right tool for the automation job — whether it be a single-vise setup or multiple vises holding large work pieces. This webinar will cover automation solutions using pneumatic, hydraulic and electronic actuation. Agenda:  Most common types of vise automation solutions How to pick the right type of automation for an application Key differences between custom workholding and off-the-shelf automation solutions

Standards for surface finishes and profiles are not static; they change as technology changes or new processes come along that need to be considered.

The Automated Shop Conference (TASC) will give shops of all sizes and production volumes key insights and practical guidance on how to implement automation.

Another case where coolant is used involves lubrication. With the move toward faster milling feed rates, the shop also has moved toward more use of ball-nose tools and other round-profile end mills in order to bring the part closer to its final form in roughing and finishing both. However, one problem with a ball-nose tool is that its shape produces vanishingly small cutting speeds ("sfm" approaching 0) near the ball's tip.

Each year Products Finishing partners with thousands of finishing operations in the U.S. to celebrate National Surface Finishing Day (NSFD) on the first Wednesday in March. NSFD is designed to celebrate and showcase the industry to trade schools, businesses, officials and media, as well as to celebrate employees and staff. The overarching goal of NSFD is to bring further awareness to the important roles plating and coating facilities play in their communities. Facilities are encouraged to host events and work with local media to build awareness about the contributions made by the surface finishing industry. For a helpful guide to reaching out to media outlets, download the NSFD toolkit here. How can you celebrate? Share your company’s story Hold an open house where the public can check out your facility –— either in person or virtual Offer student shop tours to local trade schools Invite local elected officials to visit and get to know your staff Celebrate your employees Share news about what you’re doing on social media and use the hashtag #NationalSurfaceFinishingDay or #NSFD

FANUC’s IMTS 2024 booth includes real-time demonstrations that show the abilities of its equipment, including robots, controllers and machine tools.

Moving from an aging set of five-axis mills to more advanced machines enabled Hendrick Motorsports to dramatically improve its engine production.

Custom workholding enabled Resolve Surgical Technologies to place all sizes of one trauma part onto a single machine — and cut days from the setup times.

Lee Wimmer invited us to tour his second-generation family-owned machine shop in Perkasie, PA. This video explores the production processes behind precision-machined parts for both Wimmer Custom Cycle and LS Wimmer Machine Co., and shows how ingenuity and determination are still at the heart of American manufacturing. Today, both companies are now managed by Wimmer’s three sons.

The goal of National Composites Week is to celebrate and bring attention to the myriad ways that composite materials and composites manufacturing contributes to the products and structures that shape the American manufacturing landscape today. Learn how you can participate in this year's National Composites Week on NationalCompositesWeek.com.

Job shops are implementing automation and digitalization into workflows to eliminate set up time and increase repeatability in production.

Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.

Chiron Group combines the best of both worlds at IMTS 2024, featuring live demonstrations of their Micro5 and Mill 2000 machines, alongside a cutting-edge virtual showroom. This innovative approach allows visitors to explore Chiron’s full product lineup without the logistical challenges of transporting large equipment.

Ever wonder what sets Top Shops apart from the competition? Dive into their award-winning practices and explore behind-the-scenes strategies for operational excellence.

At Mill 19, the site of the Advanced Robotics for Manufacturing Institute and Carnegie Mellon University’s Manufacturing Futures Institute, robotics data provides the foundation for AI and digital twins.

Moving from an aging set of five-axis mills to more advanced machines enabled Hendrick Motorsports to dramatically improve its engine production.

Second, the forced air is more effective than the liquid at blowing away the small chips created during high speed machining's light cuts. These chips are often harder than the workpiece surface itself. Getting them out of the way of the cutter is a paramount concern, because recutting chips causes the load on the tool to spike in a way that can reduce tool life dramatically.

Looking to automate your shop floor? The Automated Shop Conference (TASC) will connect shops with experts who can advise them through this transition.

JD Machine, 2024’s Top Shops Honoree in Human Resources, embodies its “Education for Life” core value with a robust apprenticeship program and significant continuous improvement efforts.

To cut out laborious manual processes like hand-grinding, this briquette manufacturer revamped its machining and cutting tool arsenal for faster production.

In cases where Alpha Mold does use coolant, one thing the shop does not do is apply it only on those features of the part that seem to call for coolant's use. If running with coolant makes sense for some portion of the part, the shop runs coolant all throughout the cut. To do otherwise—that is, to run both wet and dry—might result in shocking a hot tool with coolant, potentially accelerating tool failure. If for some reason a part does calls for dry machining in one region of the part followed by wet machining in another, the shop is careful to insert a delay into the process to let the tool cool down gradually before coolant is applied. In other words, just as the shop would avoid any sudden moves in the tool path, it also avoids sudden moves where temperature is concerned.

Facing increasing competition from lower-cost imports, Suburban Tool made a move toward large-scale, in-house machining. By identifying a niche in large, precision angle plates and tombstones, the company has strengthened its ability to control quality and protect its reputation.

At Carnegie Mellon University’s Manufacturing Futures Institute, researchers use a robotic test bed where AMRs deliver Lego bricks to robot arms for assembly to study AI, multirobot collaboration, assembly, safety and more.

Part of Major Tool’s 52,000 square-foot building expansion includes the installation of this new Waldrich Coburg Taurus 30 vertical machining center.

Soraluce’s wide range of machine heads and the ability to have multiple heads on a single machine (with automatic changing stations) provides flexibility and reduced setups for large-format machining.

Legacy Precision Molds takes us on a tour of their moldbuilding facility. They've recently implemented two automated 5-axis cells for metal and graphite machining that run lights out during nights and weekends.

Automation is no longer a luxury in manufacturing today – it’s a necessity. The Automated Shop Conference (TASC) will connect job shops with experts who offer advice and considerations for this process.

Deep cavity machining is one case where the shop still prefers to use coolant, Mr. Hansen says. The strong flow of liquid flushes the chips out of confined spaces where the forced air might not be able to carry them out. By the same token, the shop always uses coolant in drilling (generally delivered through the flutes of the tool). In both of these cases, coolant isn't used for any cooling value; it's used for chip evacuation.

Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.

Dry machiningprocess

In this episode of Made in the USA, several executives and senior staff at Hardinge give their first-person account of how they formulated the plan to shift the manufacturing of its milling and turning product lines from its Taiwan plant to its plant in Elmira, New York, the major challenges they encountered and the rewards that made it worth the effort.

Coordinate systems tell a CNC machine where to position the cutting tool during the program’s execution for any purpose that requires the cutting tool to move.

Even before inspection, Datanomix and Caron Engineering’s TMAC AI can extrapolate part quality from cut information. This information also helps shops push their tool life to its limits.

New U.S.-based event announced in 2021 finally debuts next year: focuses on complete additive manufacturing value chain. More at formnextchicago.com.

Achieve higher metal removal rates and enhanced predictability with ISCAR’s advanced high-feed milling tools — optimized for today’s competitive global market.

Legacy Precision Molds takes us on a tour of their moldbuilding facility. They've recently implemented two automated 5-axis cells for metal and graphite machining that run lights out during nights and weekends.

ModuleWorks and Toolpath announce a technology partnership that intends to utilize intelligent cloud-based manufacturing solutions for machining estimation and CAM automation.

Modern Machine Shop is the leading publication and media brand in North America devoted to CNC machining. MMS combines unprecedented editorial access to manufacturing facilities with decades of experience to provide long-form content that is both insightful and impactful. About Us

How does TiAlN-coated carbide reduce tooling costs? Shop mold coordinator Bob Hansen explains. The old way to rough out a typical injection mold core or cavity would involve a five-insert slab mill, he says. Each insert would be indexed halfway through the job, so both cutting edges of the insert were worn out by the time the cut was finished.

If metalworking coolant could always keep the cutting tool consistently and uniformly cool, then there would be no need for this article.

As a result, this chip-welding effect may call for coolant to be used even in cases where the coating is TiAlN. Tool life will probably suffer, but sometimes it's necessary to sacrifice tool life for the sake of a smooth finish.

In this webinar, director of manufacturing Phil Linscheid will discuss how Hamilton Company has transformed its manufacturing operations with real-time production data. Learn how Phil and his team have increased throughput five times since 2017, while simultaneously improving production efficiency. Phil will share his journey over the past few years making strategic decisions to grow the machine shop’s impact as well as how his team uses MachineMetrics to improve production visibility, automate cycle time tracking, increase machine uptime and enable accurate quoting and planning. Agenda: Enabling production visibility in Nevada’s largest machine shop Improving quoting, planning and scheduling with accurate cycle times The importance of integrating shop floor data with operational systems

When it comes to utilizing the spindle’s power, there is a lot of headroom at the upper limits, provided it’s in short bursts. Be mindful of your time at these loads so you don’t stall out.

Ceratizit USA has promoted Troy Wilt from national sales manager to managing director of Ceratizit USA, cutting tools division.

The digital landscape is evolving fast — are you ready for what’s ahead? Join SYSPRO Americas and Sam Gupta of ElevatIQ for exclusive insights into the key trends driving digital transformation in 2025. This webinar is perfect for business leaders, IT professionals and decision-makers across industries looking to prepare for the future. Whether you’re modernizing operations or staying ahead of industry disruptions, these trends will help shape your strategy for 2025 and beyond. Agenda:  AI and automation Geopolitical shifts and cybersecurity risks Collaboration and data integration Sustainability and energy efficiency

Then there are the other sources of savings dry machining can deliver. Where forced air can be used more, so liquid coolant can be used less, coolant purchase costs go down . . . and coolant disposal costs go down at the same time. In this way, reducing the use of coolant saves money coming and going.

In the latest episode of our View From My Shop series, MMS Editor-in-Chief Brent Donaldson visited the JN Shapiro Watches headquarters and production facility where Founder Joshua Shapiro—a history teacher turned watchmaker—realized his dream of "making a watch from scratch and everything in it."

Dry machiningpdf

Though most frequently used for diameter measurements, an air plug and platen can be readily configured to measure perpendicularity.

Grant funding for workforce training or the purchase of new equipment is an undervalued but complex resource for machine shops. We enlisted an expert to help navigate the process.

In the past, many shops in Alpha Mold's industry and in other metalworking sectors would have used coolant on all of their jobs as a matter of habit.

Dry machiningmachine

United Grinding has signed an agreement to acquire the GF Machining Solutions division of Georg Fischer AG, aiming to establish a global presence in ultra-precision machining.

Job shops are implementing automation and digitalization into workflows to eliminate set up time and increase repeatability in production.

Pacon Mfg, Inc. has not rested on its laurels as the 2020 Top Shop Honoree for Shopfloor Practices and Performance. In the years since, it has refined its processes to continue excelling in a volatile market.

By equipping MassRobotics with its advanced cobots, ABB aims to facilitate the creation of new and impactful solutions that address real-world challenges across various industries.

Entrepreneur Scott Colosimo found early success in China producing parts for his Cleveland-based motorcycle company in the mid-2000s. This is the story of how IP theft issues overwhelmed the business, prompting Colosimo and his team to start over from scratch — and move production back to the United States.

When revising part designs, investigate the 3D CAD, the 2D drawing and the part’s functional requirements to determine which details should be tightened up.

Learn more about the variety of technology and machinery Hwacheon Machinery America, Inc. is featuring at its IMTS 2024 booth.

The L.S. Starrett Co. has been manufacturing precision measurement tools in Athol, Massachusetts, since 1880. Attention to U.S. manufacturing often focuses on reshoring manufacturing from other countries, but Starrett never left. The facility in Athol employs hundreds and produces thousands of tools that remain vital for measurement in machining and other fields.

Dry machiningtools

To realize such long life from tools like this, the shop doesn't run liquid coolant while it cuts, but instead it replaces the coolant with 120-psi forced air. Alpha's machining centers deliver this air in much the same way they deliver coolant—by conduits that run through the spindle housing. However, a bolt-on air nozzle could accomplish much the same thing.

Heidenhain and Acu-Rite Solutions are offering several hands-on experiences at their booth this year, as well as internal components that reduce energy use.

ModuleWorks and Toolpath announce a technology partnership that intends to utilize intelligent cloud-based manufacturing solutions for machining estimation and CAM automation.

Alpha Mold (Dayton, Ohio) uses high-temperature cutting tools like these all the time. Back when the shop would mill out cores and cavities by burying a slow and heavy tool deep in the steel, flooding the job with coolant made a lot of sense. But Alpha doesn't cut that way anymore. Instead, the shop takes light cuts at high feed rates using 10,000-rpm machining centers. In place of a larger tool, the cutter of choice on these machines is often a single-insert milling tool from Millstar (Bloomfield, Connecticut), with the one insert made of carbide coated with titanium aluminum nitride (TiAlN). Cutters like this one have allowed the shop to reduce tooling costs significantly . . . but one key to realizing the savings is to run dry as much as possible.

This presentation focuses on the vital role that linear and angular encoders play in ensuring precision in machine tools. Attendees will learn about the common challenges compromising accuracy, such as thermal expansion, mechanical misalignments and vibration. Whether you're an OEM, integrator, or machine operator, this webinar will offer valuable insights into optimizing CNC performance. Agenda: Challenges to CNC machine accuracy Understanding encoder technology How encoders address accuracy challenges

So far, Made in the USA has looked into system-wide effects of broken supply chains, automation, skilled workforce issues and our perception of manufacturing jobs — examining each topic through a prism of individual experiences. For this final episode for Season 1, let’s look at one more system-wide question and bring it back to personal perspectives: Is there today a new dawn, a new moment for American manufacturing?

Stainless steel can be gummy enough that coolant may be needed as a lubricant when a ball-nose or other round-profile tool is used. That was the case with this Stavax 420 stainless steel mold core. When dry milling wasn’t producing an acceptable surface finish, the operator switched to using liquid coolant and the finish improved. Two finish-machined bands in the forward area of the part show the difference. The lower band in the inset photo is the area machined dry.

Milling without covering the job in coolant may represent a departure from the way many shops routinely expect to machine. Even so, in many applications, this will be a departure well worth making. In shops like this one where high speed machining techniques are applied to tool steel, avoiding liquid coolant extends the tool's life. There are also secondary benefits. Not only does dry machining provide the accuracy improvements the shop has observed, the dry machining process is also cleaner.

Mr. Hansen notes that there can be an interesting tradeoff here. The shop has observed that while surface finish improves with coolant, the location of the cut may shift by 3 to 5 ten-thousandths of an inch. One possible cause, he says, is that the pressure of the thin film of coolant between the tool and the workpiece is sufficient to deflect the tool by a tiny amount. Whatever the cause, the gain in surface finish sometimes comes at the cost of a small loss in dimensional accuracy.

The DG modular interchangeable head milling system optimizes the interface between the cutting head and shank for greater versatility, stability and higher changeover precision.

Determining the shape of a workpiece is required in many manufacturing processes. Keep in mind these important points to ensure that you master the process.

Q-Mark has built its metrology business by providing what customers need, when they want it. This goes for its IMTS booth, too, with free drinks alongside custom technology.

The latest episode “Made in the USA” podcast explores a company that uses collaborative robots, one of the key tools helping US machine shops and other manufacturers compete with lower cost countries by automating production.

AccuRounds has created synergy between culture and technology, driving a commitment to customer satisfaction and continuous improvement.

Pairing a shoulder mill with a five-axis machine has cut costs and cycle times for one of TTI Machine’s parts, enabling it to support a niche racing community.

This characteristic of ball-nose tools creates a danger whenever two conditions are met—(A) the cut is very light, and (B) the workpiece surface is nearly perpendicular to the axis of the tool. Under these conditions, the tip of the tool is not truly "milling" so much as being dragged across the workpiece surface. With softer steels—particularly pre-heat-treated stainless, Mr. Hansen says—this effect can visibly affect surface quality. However, the lubricating property of liquid coolant can minimize the impact of this effect, thereby protecting the part's surface quality. Accordingly, whenever the tool is a ball-nose, the finish requirement is critical, and much of the part's geometry consists of nearly flat surfaces, Alpha Mold will often use coolant.

AccuRounds has created synergy between culture and technology, driving a commitment to customer satisfaction and continuous improvement.

Coordinate systems tell a CNC machine where to position the cutting tool during the program’s execution for any purpose that requires the cutting tool to move.

In the latest episode of our View From My Shop series, MMS Editor-in-Chief Brent Donaldson visited the JN Shapiro Watches headquarters and production facility where Founder Joshua Shapiro—a history teacher turned watchmaker—realized his dream of "making a watch from scratch and everything in it."

This forced air keeps the cut consistent in two ways. First, it's less effective than the liquid at cooling the tool. This is important for the TiAlN-coated tool, which performs better in consistent high heat.

PTXPO 2025 is a comprehensive showcase of cutting-edge technologies and innovations within the plastics molding industry. Join fellow molders, moldmakers, brand owners, OEMs and their full suite of suppliers in Rosemont, IL for three days of non-stop networking, education and business development opportunities.

AI technology isn’t just a concept for the future—it’s here now, ready to transform your estimating process with the new AI BOM builder in JobBOSS². In this first-launch webinar, discover how AI can revolutionize bill of materials (BOM) entry in your shop, saving time, reducing errors and boosting efficiency. In this session, ECI will review how to use AI to build BOMs through a powerful feature that automates the extraction and input of BOM data from PDFs, Excel spreadsheets and images, all within JobBOSS². You'll have the opportunity to watch a live demonstration of the AI BOM builder in action — showcasing its ability to reduce BOM entry time from hours to mere minutes — thereby allowing you to focus on more strategic tasks. Additionally, you will learn about the real-world benefits of AI-driven BOM entry, including the minimization of manual errors, enhanced accuracy, and streamlined estimating processes — all of which can provide your shop with an immediate competitive edge. Finally, there will be a Q&A session with experts, giving you the chance to ask questions and find out how to integrate AI effectively. Agenda:  Experience AI in action in a real-world manufacturing setting Discover how the AI BOM builder can immediately impact your shop’s efficiency and productivity Get hands-on insights on implementing AI to streamline your operations

Across a range of technical presentations aimed at small and mid-sized job shops, the first-ever Automated Shop Conference (TASC) offered insights into several automated technologies, implementation strategies, shopfloor training tips, and even the untapped power of automated coolant delivery.

Pacon Mfg, Inc. has not rested on its laurels as the 2020 Top Shop Honoree for Shopfloor Practices and Performance. In the years since, it has refined its processes to continue excelling in a volatile market.

Differential gaging measures using two devices, which has advantages over standard, comparative measurements using a single sensing head. These include the ability to measure size without regard to position.

Lee Wimmer invited us to tour his second-generation family-owned machine shop in Perkasie, PA. This video explores the production processes behind precision-machined parts for both Wimmer Custom Cycle and LS Wimmer Machine Co., and shows how ingenuity and determination are still at the heart of American manufacturing. Today, both companies are now managed by Wimmer’s three sons.

Determining the shape of a workpiece is required in many manufacturing processes. Keep in mind these important points to ensure that you master the process.

But today, if a shop is using a more sophisticated process to take advantage of higher speeds, then the choice of liquid coolant versus forced air becomes one more component of the process deserving careful consideration. Both choices have their strengths. There are a variety of factors to take into account. (See sidebar entitled "Liquid Coolant Or Air? Take Four Factors Into Account" at the bottom of this article.)