Before a NASA space shuttle crew takes off into outer space, a series of "goes" contained in a check list must be configured to minimize catastrophic failures, and to maximize the success of the mission and its safe return. In the world of Wire EDM professionals, the mission is very similar to NASA's, in minimizing scrap rate and in maximizing quality (i.e. meeting customer specifications). That is the challenge to each Wire EDM operator and tool designer. Before the Wire EDM operator gives it a "go" (starts his machine cycle), there is a responsible and lengthy check list of concerns, which if not checked off could result in scrapping the work at hand. Some of these concerns are: workpiece perpendicularity, workpiece home coordinate reference, workpiece type (material conductivity factor), etc. Read Full Article (PDF)

Controlling machine wear is a fundamental function of lubrication. By properly specifying lubricant viscosity, using appropriate modifying additives, and controlling contamination, wear rates can be minimized to extend equipment life. However, other influencing factors can still result in less than optimal component wear performance, including equipment loads, design issues, and environmental factors. Cryogenic treatment of tooling steels is a proven technology to increase wear resistance and extend intervals between component replacements for blades, bits, and machining mills. Recent work has also shed light on the effects of cryogenic treatment on bearings, gears and engine components to reduce wear and improve performance. Combining optimized lubrication, correct mechanical configuration, and cryogenic treatment of wearing parts results in the maximum performance of lubricated components, and can significantly extend component life. Read Full Article (PDF)