Derek Korn , Senior Editor
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Does your shop have a disaster preparedness plan? If so, tell me a bit about it. And if your shop was damaged by Hurricane Katrina and your plan helped you bounce back, I’d like to hear your story.

Please share your thoughts on this topic. If we publish your response, you’ll receive your choice of one free book from the Hanser Gardner bookstore.

To respond, send your e-mail to Derek Korn (dkorn@mmsonline.com)

This is a cool part - - a guitar machined from 6061 aluminum.

In our July newsletter edition, Pete asked you to send in a photo and brief description of some interesting parts you’ve recently machined. James Wilton from Coast Precision CNC sent in some shots of a beautiful guitar body he machines from billet 6061-T6 aluminum. After machining, the body is smothered in chrome.

James machines bodies and other miscellaneous guitar components for upstart Liquid Metal Guitars. First, the top face is skimmed and clamping holes drilled. Next, the workpiece is flipped so that the backside cavity with stand-offs can be machined (see middle image). This brings the wall thickness to 1/8 inch.

The body is flipped again to machine the topside radius and holes for the pickups and electronic controls. Then, the angled neck pocket is created using a dedicated jig. Finally, the body is fixtured to an angle plate to cut the hole for the 1/4-inch cord jack.

The backside cover is machined from 1/8-inch aluminum sheet. James currently uses a dedicated fixture for the covers, but plans to use a vacuum workholding table as soon as guitar sales take off. The truss rod cover (a small plate at the top of the guitar neck typically made of plastic) is also machined from aluminum sheet. At first, these fixtured with double-sided tape and machined using small depths of cut. Now, James uses a custom fixture which allows him to machine six pieces in one setup faster than he could machine one piece with the original method. He notes that the scrap rate is much lower, too.

The guitar body was designed in Solidworks. Tool paths and fixture design were created using OneCNC, which accepts native Solidworks files. Because the software can create solids, James can model every setup complete.The work-shift function allows him to use the Renishaw probe option on his Haas VF-3 to pick up the zero in a flash and maximize spindle time.

James says he still has a few ideas up his sleeve to speed part changeover and cycle time. He grooves on this work because he likes machining and loves guitars. To him, combining the two is magic - - it brings out the best of the machinist that’s inside.

We’re still interested in seeing your cool machining work. If you have an interesting recent job that you’re particularly proud of, shoot us a photo and briefly describe what makes it cool, interesting and/or challenging. Send me an e-mail at dkorn@mmsonline.com.

By combining laser deposition and conventional milling, Purdue University’s Center for Laser-Based Machining has developed an alternate way to machine complex internal features.

Laser deposition is often used to create complex parts, such as jet turbine components and next-generation computer memory devices. However, the technique alone can’t be used to create accurate internal features and is mostly limited to metal parts. That’s because the part is machined after it is completely formed. Purdue researchers say they have created a method that not only overcomes these barriers, but is one that’s faster and more cost-effective than traditional laser-deposition techniques.

Laser deposition combined with conventional milling creates parts with multiple internal features.

The technique involves depositing layers of powder materials - - melting the powder with a laser and then immediately machining each layer. Enabling parts to be formed and machined one layer at a time is especially promising for parts containing many internal features. Plus, the new method can be used to create parts from ceramics, which are difficult to manufacture and can’t be machined without first softening the material with a laser. It also possible to have layers alternate between metal and ceramic.

Adding the in-process machining step is said to make the process approximately 20 times more accurate than traditional laser deposition. And by providing a practical way to economically machine brittle ceramic materials, the technique could be used to quickly manufacture parts that are not produced in large enough quantities to justify the expense of creating costly dies.

September’s issue of Modern Machine Shop includes five turning-related articles.

Our September issue includes four feature stories describing turning’s role in some broader shop strategy. The four stories detail how CNC lathes helped shops draw new business, implement lean manufacturing, achieve more flexible production and reduce inspection. Plus, a fifth turning article explains how wire EDM can be used to “turn” parts to diameters as small as 0.002 inch.

Don’t miss this issue! Subscribe or renew your subscription at www.mmsonline.com/subscribe.

2007 Makino Die/Mold Expo
Machining demos & expert speakers discussing ways to
improve sales, diversify customer base, and increase profitability.
www.makino.com/expo