Category: Machining

Sinker EDM: Deep Rib Cavities in a Multi-Cavity Injection Mold

Sinker EDM burning deep narrow rib cavities in a four-cavity H13 injection mold at 50 HRC using copper graphite electrodes and orbital flushing.

---

Wire EDM: Cutting Hardened Punch and Die Sets for Stamping

Wire EDM cutting of five hardened D2 progressive stamping punch and die sets at 62 HRC, holding 0.003" punch-to-die clearance with 38 hours of unattended run time.

---

Boring: Large Diameter Bearing Housing on a Horizontal Boring Mill

Boring two large ductile iron gearbox bearing housings to a 6.000" H7 fit on a horizontal boring mill, measuring to within 0.0005" throughout.

---

Surface Grinding: Hardened D2 Tool Steel Wear Plates

Precision surface grinding of D2 tool steel wear plates hardened to 62 HRC, achieving flatness under 0.0001" and 12 Ra surface finish for a stamping die application.

---

Tapping: Solving Thread Quality Issues on Aluminum Enclosures

Diagnosing and fixing a thread quality problem in aluminum enclosures by switching to spiral flute machine taps with rigid tapping cycles and proper cutting fluid.

---

Drilling Project: High-Volume Hole Pattern on Carbon Steel Flanges

High-volume drilling of 8-hole bolt circle patterns on 1,200 carbon steel ANSI flanges using a radial drill press and cobalt drill bits.

---

Milling Case Study: Tool Steel Mold Core for Plastic Injection

A complex P20 tool steel injection mold core machined on a Makino V56 with full 3D contouring in Mastercam, delivered within tolerance and on schedule.

---

CNC Turning: Stainless Steel Shaft Production for Pump Industry

200-piece production run of 316 stainless steel pump shafts turned on a Mazak QuickTurn 200, holding ±0.0005" journal tolerances.

---

CNC Machining: Aluminum Aerospace Bracket Production Run

A production run of 500 aluminum 6061-T6 aerospace brackets machined on a Haas VF-2, hitting ±0.002" tolerances across the full batch.

---