Non-Traditional MacHining Handbook

by Sommer, Carl

• ISBN13: 9781575373256
• ISBN10: 1575373254
• Format: Hardcover
• Copyright: 1999-08-01
• Publisher: Advance Pub

Summary

This book covers such topics as: wire and ram EDM; fast hole EDM drilling; waterjet and abrasive waterjet machining; plasma and precision plasma cutting; photochemical and electrochemical machining; abrasive flow and ultrasonic machining; rapid prototyping and manufacturing; and lasers for cutting, welding, cladding, alloying, heat treating, marking, and drilling. It also includes chapters on outsourcing, purchasing equipment, building a successful business, and closes with a chapter on the future revolutionary non-traditional machine.

Table of Contents

About the Author	iii	(2)
Acknowledgments	v	(2)
Dedication	vii
Unit 1 Fundamentals of Non-Traditional Machining	27	(12)
1 Fundamentals of Non-Traditional Machining	27	(12)
Understanding the Processes of Non-Traditional Machining	27	(2)
The Machining Revolution	29	(1)
The Two Phases of the Computer Revolution	29	(3)
Six Basic Processes to Alter Material in Non-Traditional Machining	32	(1)
A. Electricity	32	(1)
B. Water	32	(1)
C. Abrasives	32	(1)
D. Chemicals	32	(1)
E. Plasma	32	(1)
F. Light	32	(1)
Speed and Accuracy	33	(1)
Understanding Accuracy	33	(1)
The Future	34	(5)
Unit 2 Wire EDM	39	(78)
2 Fundamentals of Wire EDM	39	(16)
Revolutionizing Machining	39	(1)
Wire EDM Beginnings	40	(1)
Wire EDM a Serious Contender With Conventional Machining	41	(1)
New Demands by Design Engineers	42	(2)
Fully Automated Wire EDMs	44	(1)
How Wire EDM Works	45	(2)
The Step by Step EDM Process	47	(2)
A. Power Supply Generates Volts and Amps	47	(1)
B. During On Time Controlled Spark Erodes Material	47	(1)
C. Off Time Allows Fluid to Remove Eroded Particles	48	(1)
D. Filter Removes Chips While the Cycle is Repeated	48	(1)
Super Precision Band Saw	49	(1)
Three Types of Wire EDM	50	(3)
A. Two Axis	50	(1)
B. Simultaneous Four Axis	50	(1)
C. Independent Four Axis	51	(2)
Understanding Independent Four Axis	53	(2)
3 Profiting With Wire EDM	55	(16)
Users of Wire EDM	55	(1)
Benefits Of Wire EDM	55	(6)
A. Production Runs	55	(1)
B. Various Shapes and Sizes	55	(1)
C. Accuracy and Finishes	56	(1)
D. Eliminates Extra Machining Processes	56	(1)
E. Burr Free and Perfectly Straight Machining	57	(1)
F. Damaged Parts Can Be Repaired with Inserts	57	(1)
G. Less Need for Skilled Craftspersons	58	(1)
H. Material Hardness Not a Factor	58	(1)
I. Computers Can Perform Calculations	58	(1)
J. Digitizing is Possible	59	(1)
K. Miniaturization of Parts	60	(1)
L. Air Machining is Possible	60	(1)
M. Reliable Repeatability	61	(1)
Parts for Wire EDM	61	(7)
A. Precision Gauges and Templates	61	(1)
B. Keyways vs. Broaching	62	(1)
C. Shaft Slots	62	(1)
D. Collets	62	(1)
E. Parting Tubes and Shafts	63	(1)
F. Shaft Pockets	63	(1)
G. Fabrication of Graphite Electrodes for Ram EDM	63	(1)
H. Punches and Dies From One Piece of Tool Steel	64	(1)
I. Short Run Stampings	64	(1)
J. Molds	65	(1)
K. Special and Production Tool Cutters	65	(1)
L. Difficult-to-Machine Shapes	66	(1)
M. Other Cost-Reducing Parts	66	(2)
Cutting Shim Stock Absolutely Burr Free	68	(1)
Single Cavity Cut Into One Side of a Tube	69	(1)
Materials That Can be EDMed	69	(1)
Machining Costs	70	(1)
4 Proper Procedures	71	(6)
Starting Methods for Edges and Holes	71	(1)
Three Methods to Pick Up Dimensions	71	(1)
A. Pick Up Two Edges as in Figure 4:1	71	(1)
B. Pick Up a Hole as in Figure 4:2	71	(1)
C. Pick Up an Edge and Holes or Two Holes as in Figure 4:3	72	(1)
Edge Preparation	72	(2)
A. Square Edges	72	(1)
B. Scale	73	(1)
C. Pick-Ups	74	(1)
Starter Holes	74	(3)
A. Automatic Pick-up	74	(1)
B. Unsquare Holes	75	(1)
C. Relieved Holes	75	(1)
D. Smooth Holes	75	(1)
E. Placement and Location of Starter Holes	76	(1)
5 Understanding the Wire EDM Process	77	(12)
Accuracy and Tolerances	77	(1)
Finishes	77	(1)
Wire Path	78	(1)
A. Wire Kerf	78	(1)
B. Corners and Radii	79	(1)
Skim Cutting	79	(3)
A. Barreling Effect and Wire Trail-Off	80	(1)
B. Metal Movement	81	(1)
C. Finishes and Accuracy	81	(1)
Carbide	82	(1)
Polycrystalline Diamond	82	(1)
Ceramics	83	(1)
Flushing	83	(1)
Cutting Speed	84	(1)
Impurities	84	(1)
Recast and Heat-Affected Zones	85	(1)
AC Non-Electrolysis Power Supplies	85	(1)
Heat-Treated Steels	86	(1)
Cutting Large Sections	86	(1)
Cutting Sections From a Block	87	(1)
A. Leaving a Frame	87	(1)
B. Strength of Frame	88	(1)
C. Material for Clamping	88	(1)
Understanding the Wire EDM Process	88	(1)
6 Reducing Wire EDM Costs	89	(8)
Create One Slug	89	(2)
Keeping Flush Ports on the Workpiece	91	(1)
Machining After Wire EDM	92	(1)
Cutting Multiple Plates and Sheet Metal Parts	93	(1)
Production Lots	94	(1)
Stipulating Wire Sizes	95	(1)
Pre-Machining Non-Complicated Shapes	96	(1)
7 Wire EDM Applications	97	(20)
Production Wire EDM	97	(2)
A Great Problem	99	(1)
Examples of Wire EDM	99	(7)
A. Tall Parts	99	(1)
B. Modified Machines	100	(1)
Submersible Cutting	100	(1)
C. Large Heavy Gears	101	(1)
D. Various Tall Parts	102	(1)
E. Overhanging Parts	102	(1)
F. Long Tubes	103	(1)
E. Other Applications	103	(1)
Cutting Cavities in One Side of a Tube	104	(1)
Large Carbide Rock Bit Being Cut in the Air	104	(1)
Cutting an Inside Diameter and a Keyway of a Large Gear	105	(1)
Machined Parts that Need to be Split	105	(1)
Cutting a Test Specimen	106	(1)
Advantages of Wire EDM for Die Making	106	(7)
A. Old-Fashioned Tool and Die Making	106	(3)
B. The Revolution	109	(1)
C. Advantages of Wire EDM Dies	109	(1)
1. One-Piece Die Sections	109	(1)
2. Exact Spare Parts	110	(1)
3. Dowel Holes EDMed	110	(1)
4. Better Tool Steels	110	(1)
5. Accuracy	110	(1)
6. Die Repairs	110	(1)
7. Fine Textured Finish	111	(1)
8. Eliminates Distortion	111	(1)
9. Inserts for High Wear Areas	111	(1)
10. Smaller Dies	111	(1)
11. Longer Lasting	111	(1)
12. Punches and Dies From One Piece of Tool Steel	112	(1)
13. Cutting Stripper and Die Section Together	112	(1)
Wave of the Future	113	(4)
Unit 3 Ram EDM	117	(56)
8 Fundamentals of Ram EDM	117	(8)
Ram EDM Machining	117	(2)
Ram EDM Beginnings	119	(2)
How Ram EDM Works	121	(1)
The Step-by-Step Ram EDM Process	122	(2)
Polarity	124	(1)
No-Wear	124	(1)
Fuzzy Logic	124	(1)
Fumes From the EDM Process	124	(1)
Benefits of Understanding the Process	124	(1)
9 Profiting With Ram EDM	125	(6)
Users of Ram EDM	125	(1)
Benefits of Ram EDM	126	(2)
A. Different Shapes and Sizes	126	(1)
B. Accuracy and Finishes	127	(1)
C. Workpiece Hardness Not a Factor	127	(1)
D. EDMing Threads Into Hardened Parts	127	(1)
Parts for Ram EDM	128	(2)
A. Molds	128	(1)
B. Blind Keyways	128	(1)
C. Internal Splines	129	(1)
D. Hexes for Special Bolts and Parts	129	(1)
E. Helical Gear Machining	129	(1)
Materials For Ram EDM	130	(1)
Speeding the Mold Processing	130	(1)
EDMing Carbide	130	(1)
Proper Procedures for Ram EDM	130	(1)
10 Ram EDM Electrodes and Finishing	131	(14)
Electrodes	131	(8)
A. Function of the Electrode	131	(1)
B. Electrode Selection	131	(1)
C. Type of Electrode Materials	131	(1)
D. Galvano Process for Metallic Electrodes	132	(1)
E. Custom Molded Metallic Electrodes	133	(1)
F. Graphite Electrodes	133	(2)
G. Determining Factors for Choosing the Proper Graphite	135	(1)
H. Electrode Wear	135	(1)
I. Abrading Graphite Electrodes	136	(2)
I. Ultrasonic Machining for Graphite Electrodes	138	(1)
J. Wire EDMing Metallic and Graphite Electrodes	138	(1)
K. Electrode Overcut	138	(1)
Recast and Heat-Affected Zone	139	(1)
Finishing	140	(1)
Mirror Finishing	141	(1)
Micro Machining	142	(3)
11 Dielectric Oil and Flushing for Ram EDM	145	(14)
Dielectric Oil	145	(1)
Coolant System	146	(1)
Flash Point	146	(1)
Flushing	146	(11)
A. Proper Flushing	146	(1)
B. Volume, Not Pressure	146	(1)
C. Types of Flushing	147	(1)
1. Pressure Flushing	147	(1)
a. Pressure Flushing Through the Electrode	148	(3)
b. Pressure Flushing Through the Workpiece	151	(1)
2. Suction Flushing	152	(1)
3. Combined Pressure and Suction Flushing	153	(1)
4. Jet Flushing	154	(1)
5. Pulse Flushing	154	(1)
a. Vertical Flushing	155	(1)
b. Rotary Flushing	155	(1)
c. Orbiting Flushing	156	(1)
Filtration System	157	(1)
The Challenge of New Procedures	157	(2)
12 Reducing Costs for Ram EDM	159	(14)
Preparing Workpieces for Ram EDM	159	(1)
Difference Between Ram and Wire EDM in Reducing Costs	159	(1)
Prolonging Electrode Life With No-Wear EDMing and No Premachining	160	(1)
Electrode and Workpiece Holding Devices	161	(1)
Orbiting	162	(4)
Manual Machines Mounted With Orbiting Devices	166	(1)
Repairing Molds With Microwelding	166	(1)
Abrasive Flow Machining	167	(1)
Automatic Tool Changers	167	(2)
Hard Die Milling	169	(1)
Future of Ram EDM	170	(3)
Unit 4 Fast Hole EDM Drilling	173	(14)
13 Fast Hole EDM Drilling	173	(14)
How Fast Hole EDM Drilling Works	175	(4)
A. Dielectric and Flushing Pressure	176	(1)
B. The Electrode	176	(2)
C. Electrode Guides	178	(1)
D. Servo Motors	178	(1)
Metal Disintegrating Machines Compared to Fast Hole EDM Drilling	179	(1)
Other Methods to Produce Holes	179	(1)
Disadvantages in Fast Hole EDM Drilling	179	(1)
A. Electrode Wear	179	(1)
B. Hole Quality	179	(1)
C. Inability for EDMing Miniature Holes Below .012 is less than or equal to (.3 mm)	179	(1)
D. Reduced Speed for Large Holes	180	(1)
E. Blind Holes are Difficult to Control	180	(1)
Advantages in EDM Drilling	180	(2)
A. Drilling on Curved and Angled Surfaces	180	(1)
B. No Hole Deburring	181	(1)
C. Drilling Hardened Materials	181	(1)
D. Materials That Produce Gummy Chips	181	(1)
E. Drilling Deep Holes	181	(1)
F. Preventing Broken Drills	181	(1)
G. Creating Straight Holes	182	(1)
Accuracy of Fast Hole EDM Drilling	182	(1)
Versatility of Fast Hole EDM Drilling	182	(1)
Conclusion	183	(4)
Unit 5 Abrasive Flow, Thermal Energy Deburring, and Ultrasonic Machining	187	(14)
14 Abrasive Flow, Thermal Energy Deburring, and Ultrasonic Machining	187	(14)
Abrasive Flow Machining	187	(7)
A. How Abrasive Flow Machining Works	189	(2)
B. Abrasives	191	(1)
C. Viscosity	191	(1)
D. Extrusion Pressure	192	(1)
E. Finishes	192	(2)
Thermal Energy Deburring	194	(2)
Ultrasonic Machining and Polishing	196	(1)
How Ultrasonic Machining Works	196	(1)
Conclusion	197	(4)
Unit 6 PhotochemicalMachining	201	(14)
15 Photochemical Machining	201	(14)
Fundamentals of Photochemical Machining	201	(4)
Designing the Part	201	(1)
Imaging	201	(2)
Etching and Stripping	203	(2)
Materials and Products for Photochemical Machining	205	(1)
Tolerances	205	(1)
Corner Radii	205	(1)
Beveling	206	(1)
Cutting and Etching in One Operation	207	(1)
Three Dimensional Chemical Machining	208	(1)
Disadvantages of Photochemical Machining	208	(1)
A. Bevel Slots and Holes	208	(1)
B. High Run Production	208	(1)
C. Limited Metal Thicknesses	208	(1)
Advantages of Photochemical Machining	208	(1)
A. Eliminates the Need for Hard Tooling	208	(1)
B. Just In Time Machining	208	(1)
C. Freedom of Burrs	208	(1)
D. Stress-Free Machining	208	(1)
E. Delicate and Complex Parts Can be Produced	209	(1)
Photochemical Machining of Micro-Etched Screens	209	(1)
Electroformed Process for Micro-Etched Screens	210	(1)
Conclusion	211	(4)
Unit 7 Electrochemical Machining	215	(10)
16 Electrochemical Machining	215	(10)
How Electrochemical Machining Works	215	(2)
Disadvantages of Electrochemical Machining	217	(1)
A. The Shaped Workpiece is Not a Replica of the Electrode	217	(1)
B. Shaped Electrodes are Difficult to Machine	217	(1)
C. Electrolyte and Sludge Removal	217	(1)
Advantages of Electrochemical Machining	218	(2)
A. Practically No Electrode Wear	218	(1)
B. No Recast Layer or Thermal Stress	218	(1)
C. Material Hardness and Toughness Not a Factor	218	(1)
D. Rapid Metal Removal	218	(1)
E. Deburring and Radiusing of Holes	218	(2)
Stem Drilling	220	(1)
Capillary Drilling	221	(1)
Conclusion	221	(4)
Unit 8 Plasma and Precision Plasma Cutting	225	(14)
17 Plasma and Precision Plasma Cutting	225	(14)
How Plasma Cutting Works	226	(1)
Plasma Processes	227	(3)
A. Conventional Plasma Cutting	227	(1)
B. Dual Gas Plasma Cutting	228	(1)
C. Water Shield Plasma Cutting	228	(1)
D. Water Injection Plasma Cutting	228	(1)
E. Precision Plasma Cutting	228	(2)
Difference Between Regular Plasma and Precision Plasma Cutting	230	(1)
A. Beveled Cuts	231	(1)
B. Double Arcing	231	(1)
Materials for Plasma Cutting	231	(1)
Heat Distortion and Heat Affected Zone	231	(1)
Accuracy	231	(1)
Consumables	232	(1)
Plasma and Shield Gases	232	(1)
Advantages and Disadvantages of Plasma Cutting Systems	232	(1)
Plasma and Turret Punch Presses	232	(2)
Other Applications for Plasma	234	(1)
Understanding Plasma Cutting	235	(4)
Unit 9 Waterjet and Abrasive Waterjet Machining	239	(22)
18 Waterjet and Abrasive Waterjet Machining	239	(10)
Fundamentals of Waterjet, and Abrasive Waterjet Machining	239	(2)
Introducing Abrasive Into the Waterjet	241	(2)
Abrasives for Cutting	243	(1)
The Abrasive System	243	(1)
The Abrasive Cutting Head	244	(1)
Motion Control Systems	244	(2)
Catcher System	246	(3)
19 Profiting With Waterjet and Abrasive Waterjet Cutting	249	(12)
Materials Cut With Waterjet	249	(1)
Materials Cut With Abrasive Waterjet	250	(1)
Accuracy	251	(1)
Safety	251	(1)
Disadvantages of Waterjet and Abrasive Waterjet Machining	252	(1)
A. Frosting From Abrasive Waterjet Cutting	252	(1)
B. Slower Speed Rates and Higher Costs Than Plasma and Lasers	253	(1)
C. Catchers Needed With Multi-Axis Cutting	253	(1)
D. Large Cuts Become Stratified	253	(1)
Advantages of Waterjet and Abrasive Waterjet Machining	253	(2)
A. Material Savings	253	(1)
B. No Special Tooling Required	253	(1)
C. Moisture Absorption Not a Problem	253	(1)
D. Focusing the Waterjet is Not Critical	253	(1)
E. Simple Fixtures Required	254	(1)
F. Entry Hole Not Required	254	(1)
G. No Heat Affected Zone or Microcracking	254	(1)
H. No Fumes	254	(1)
I. Eliminates Some Difficult Cutting Problems	255	(1)
J. Burr Free Cutting	255	(1)
K. Easily Attached to Robots	255	(1)
Cutting With Multiple Heads and Stacking Materials	255	(1)
Glass Sculpturing	255	(1)
Turning With Abrasive Waterjet	256	(1)
Waterjet and Abrasive Waterjet Capabilities	256	(5)
Unit 10 Lasers	261	(56)
20 Fundamentals of Lasers	261	(10)
Lasers: The Revolutionary Concept	261	(1)
Laser Cutting	261	(3)
How Lasers Work	264	(1)
Resonator	264	(1)
Laser Mirrors	264	(2)
Laser Optics	266	(1)
Assist Gases	266	(1)
The Laser Cut	267	(1)
Sensing Unit	268	(1)
Laser Safety	268	(1)
Fumes From Laser Cutting	269	(2)
21 Understanding Laser Cutting	271	(6)
Kerf Width	271	(1)
Material Distortion	271	(1)
Heat-affected Zone	271	(1)
Edge Quality	272	(1)
Test Cuts	272	(1)
Reducing Costs	272	(3)
Speed of Lasers	272	(1)
Tolerances	272	(1)
Surface Condition	273	(1)
Beam Quality	273	(1)
Beam Focal Length	274	(1)
Quantity	274	(1)
Redesigning Parts	275	(1)
Lasers and Turret Punch Presses	275	(1)
Cutting Laser Increasingly in Demand	276	(1)
22 Various Lasers and Their Configurations	277	(12)
How YAG Lasers Work	277	(1)
Increasing Power for Nd: YAG Lasers	278	(1)
Various Lasers	278	(1)
Benefits of Nd: YAG Lasers	278	(1)
1. Fiber Optics	278	(1)
2. Smaller Focusing Beam	279	(1)
Excimer Lasers	279	(1)
How Excimer Lasers Work	280	(1)
Capabilities of Excimer Lasers	280	(4)
Optical Microlithography--Laser for Integrated Circuits	284	(1)
Traveling Methods of Laser Cutting Machines	285	(1)
1. Beam Traveling	285	(1)
2. Workpiece Traveling	285	(1)
3. Combination of Beam and Workpiece Traveling	285	(1)
Custom-Made Laser Systems	285	(1)
Beam Splitting	286	(3)
23 Profiting With Laser Cutting	289	(12)
Materials for Laser Cutting	289	(1)
Determining Factors on Material Thickness	289	(1)
Lacquered Metals	290	(1)
Tube Cutting	290	(1)
Multiaxis Laser Cutting	291	(1)
Lasers With Pallet Changers or Sheet Loaders	292	(1)
Lasers With Robots	293	(1)
Part Trimming	294	(1)
Time Sharing	294	(1)
Advantages of Laser Cutting	295	(3)
1. Material Savings	295	(1)
2. Minimum Heat-Affected Zone	295	(1)
3. Edge Quality	295	(1)
4. Minimum Distortion and Thermal Stress	296	(1)
5. Close Nesting of Parts	296	(1)
6. Thin Webs	296	(1)
7. Elimination of Hard Tooling	297	(1)
8. Just-In-Time (JIT) Machining	297	(1)
9. Various Shapes and Sizes	297	(1)
10. Material Hardness	298	(1)
11. Consistent Laser Beam	298	(1)
12. Prototypes Can be Fabricated Easily	298	(1)
13. Repeatability	298	(1)
14. Ideal for Short Run Production	298	(1)
Disadvantages of Lasers	298	(3)
24 Lasers for Welding, Cladding, Alloying, Heat Treating, Marking, and Drilling	301	(16)
I. Laser Welding	301	(5)
A. Laser Welding Compared to Electron Beam Welding	302	(1)
B. Two Types of Laser Welding: Spot and Continuous Welding	302	(2)
C. Welding Dissimilar Metals	304	(1)
D. Keyhole Welding	304	(1)
E. Focusing the Beam and Through-The-Lens TV Viewer	305	(1)
F. Considerations for Laser Welding	305	(1)
II. Laser Cladding	306	(1)
A. Conventional Cladding	306	(1)
B. Advantages of Laser Cladding	307	(1)
III. Laser Surface Alloying	307	(1)
A. Lasers the Ideal Tool for Surface Alloying	307	(1)
B. Difference Between Laser Alloying and Laser Cladding	307	(1)
IV. Laser Heat Treating	308	(1)
A. Procedures for Laser Heat Treating	308	(1)
B. Advantages and Disadvantages of Surface Heat Treating	309	(1)
V. Laser Marking	309	(3)
A. How Laser Marking Works	310	(1)
B. Advantages of Laser Marking	311	(1)
VI. Laser Drilling	312	(2)
A. How Laser Drilling Works	312	(1)
B. Disadvantages of Laser Drilling	313	(1)
C. Advantages of Laser Drilling	314	(1)
The Future of Lasers	314	(3)
Unit 11 Rapid Prototyping and Manufacturing	317	(26)
25 Rapid Prototyping and Manufacturing	317	(18)
The Photopolymer Rapid Prototyping Process	319	(2)
A. Computer Aided Design	319	(1)
B. Laser Drawing	319	(1)
C. Photopolymerization	319	(1)
D. Translator	319	(1)
E. Sweep and Z-Wait	319	(2)
F. Postcuring	321	(1)
G. Finishing	321	(1)
H. Size Capabilities	321	(1)
Laminated Object Prototyping	321	(3)
Selective Laser Sintering	324	(2)
The 3D Keltool^(TM) Process	326	(1)
Solid Ground Curing	327	(1)
Fused Deposition Prototyping	328	(2)
Ballistic Particle Manufacturing	330	(1)
Multi-Jet Modeling Prototyping	330	(2)
The ProMetal Process	332	(2)
Advantages of Office Modeling Systems	334	(1)
Expanding Field of Manufacturers and Methods	334	(1)
26 Understanding the Rapid Prototyping and Manufacturing Process	335	(8)
Advantages of Rapid Prototyping and Manufacturing	335	(4)
A. Eliminates Time-Consuming and Costly Model Making	335	(1)
B. Fast Turnarounds	336	(1)
C. Redesigned Models Easily Produced	337	(1)
D. Enhanced Visualization for Design Verification	338	(1)
E. Rapid Prototyping and Investment Casting	338	(1)
F. Producing Hard Tooling With Rapid Prototyping	339	(1)
Rapid Milling for Prototypes	339	(1)
New Developments	339	(1)
Conclusion	339	(4)
Unit 12 Purchasing Equipment	343	(12)
27 Purchasing Equipment	343	(12)
Staying Abreast With New Technology	343	(1)
Benefits of Purchasing Equipment	343	(1)
Making the Right Selection	344	(3)
A. Selecting the Right Process	344	(2)
B. Selecting the Right Machine	346	(1)
Various Machines and Their Cutting Capabilities*	347	(1)
A. Wire EDM	347	(1)
B. Laser (1500 watt CO2)	347	(1)
C. Precision plasma (70 amp)	348	(1)
D. Abrasive water jet	348	(1)
Choosing the Brand of Machine	348	(2)
A. Service	349	(1)
B. Capability	349	(1)
C. Reliability of Company	349	(1)
Retrofitting or Building a Machine	350	(1)
Factors in Purchasing Equipment	350	(1)
Machine Installation	350	(1)
Decision Making	351	(4)
Unit 13 Outsourcing	355	(10)
28 Outsourcing	355	(10)
Advantages of Job Shops	356	(1)
A. Competitive Outsourcing	356	(1)
B. Guaranteed Quality	356	(1)
C. Reliable Service	356	(1)
D. Efficiencies of Job Shops	356	(1)
Costs to be Considered For In-House Work	356	(4)
A. Fixturing and Machine Modification	356	(1)
B. Programming and Inspecting Equipment	357	(1)
C. Training Personnel	357	(1)
D. Costly Support Equipment	358	(1)
E. Cost of Unused Machines Due to Economic Slowdown	358	(1)
F. Machine Maintenance	358	(1)
G. Machine and Operation Costs	359	(1)
The Final Decision	360	(1)
Maximizing Core Competency	361	(4)
Unit 14 Building a Successful Business	365	(24)
29 Building a Successful Business	365	(24)
Technological Revolution	365	(1)
Author's Background	366	(1)
Beginnings of Reliable EDM	366	(1)
Philosophy of Success	367	(1)
The Golden Rule	367	(1)
Loving People	367	(1)
Applying the Golden Rule and Loving People	367	(2)
A. Quality Products	367	(1)
B. Reliable Service	368	(1)
C. Value	369	(1)
The Most Important Principle	369	(1)
Time-Tested Principles for Success	370	(1)
Hiring Workers	371	(1)
Gaining Knowledge	372	(1)
Seeking Advice	373	(1)
Hard Work	374	(1)
Hasty Decisions	374	(1)
Taking Correction	375	(1)
Experience	376	(1)
Permanent Diligence	376	(2)
Keeping Abreast With Technology and Striving to be Unique	378	(1)
Establish Your Credibility	379	(1)
Having Proper Priorities	380	(1)
Build A Company With Character	380	(1)
When Trouble Strikes	381	(1)
Company and Personal Goals	382	(2)
Facing the World of Tomorrow	384	(5)
Unit 15 The Revolutionary Future Non-Traditional Machine	389	(4)
30 The Revolutionary Future Non-Traditional Machine	389	(4)
The Problem	389	(1)
Possible Solutions	389	(1)
Conclusion	390	(3)
Unit 16 Questions	393
31 Questions*	393
Index