Abstract: A milling method includes moving a milling tool having at least two axially spaced apart sets of cutting inserts to an axial position within a bore in a material and rotating the milling tool about a longitudinal axis. The method further includes initiating contact between the milling tool and a wall of the bore in a region of the wall having a least amount of material at the axial position. The method further includes moving the milling tool around a perimeter of the bore.

Abstract: A milling method includes moving a milling tool having at least two axially spaced apart sets of cutting inserts to an axial position within a bore in a material and rotating the milling tool about a longitudinal axis. The method further includes initiating contact between the milling tool and a wall of the bore in a region of the wall having a least amount of material at the axial position. The method further includes moving the milling tool around a perimeter of the bore.

Abstract: Milling tools and methods are disclosed. The method may include moving a milling tool having at least two axially spaced apart sets of cutting inserts to an axial position within a bore in a material and rotating the milling tool about a longitudinal axis. Contact between the milling tool and a wall of the bore may be initiated in a region of the wall having a least amount of material at the axial position. The milling tool may include a tool shaft having a longitudinal axis, a first set of radially spaced cutting inserts coupled to the tool shaft, and a directly adjacent second set of radially spaced cutting inserts coupled to the tool shaft and spaced from the first set of cutting inserts along the longitudinal axis. The first and second sets of cutting inserts may be staggered from each other by at least 10 degrees.

Abstract: A workpiece fixture assembly is provided herein. The workpiece fixture assembly includes a baseplate including an engagement surface. First and second static risers are configured to maintain a position of a workpiece. The first static riser includes a first gage bore thereon. A dynamic riser is configured to abut the workpiece and has a second gage bore thereon. A numerical control machine has a probe to measure an offset distance between the first and second gage bores. A linearly actuable workpiece support is disposed on the baseplate.

Abstract: A method of manufacturing a transmission case housing is provided wherein a minimum quantity of lubrication as a compressed air/oil mist is supplied as the housing is rough bored and face milled. The transmission case defines a plurality of transmission fluid drainage holes for draining transmission fluid from the transmission when installed in a vehicle. The housing is positioned with the fluid drainage holes below a central axis of the housing and a plurality of internal bores and faces are bored and face milled on the housing. The compressed air/oil mist is sprayed from the cutting head to cool and lubricate the boring and face milling tools. Machining chips are blown off the rough bored housing through the fluid drainage holes.

Abstract: A method of manufacturing a transmission case housing is provided wherein a minimum quantity of lubrication as a compressed air/oil mist is supplied as the housing is rough bored and face milled. The transmission case defines a plurality of transmission fluid drainage holes for draining transmission fluid from the transmission when installed in a vehicle. The housing is positioned with the fluid drainage holes below a central axis of the housing and a plurality of internal bores and faces are bored and face milled on the housing. The compressed air/oil mist is sprayed from the cutting head to cool and lubricate the boring and face milling tools. Machining chips are blown off the rough bored housing through the fluid drainage holes.

Abstract: A workpiece fixture assembly is provided herein. The workpiece fixture assembly includes a baseplate including an engagement surface. First and second static risers are configured to maintain a position of a workpiece. The first static riser includes a first gage bore thereon. A dynamic riser is configured to abut the workpiece and has a second gage bore thereon. A numerical control machine has a probe to measure an offset distance between the first and second gage bores. A linearly actuable workpiece support is disposed on the baseplate.

Abstract: A workpiece holding fixture is provided herein. The workpiece holding fixture includes a baseplate including an engagement surface. A first static riser including a position control member is configured to removably couple a workpiece to the first static riser. A second static riser includes a rotation control member and is configured to removably couple the workpiece to the second static riser. A dynamic riser is configured to abut the workpiece, the dynamic riser being movable by a spindle.

Abstract: Milling tools and methods are disclosed. The method may include moving a milling tool having at least two axially spaced apart sets of cutting inserts to an axial position within a bore in a material and rotating the milling tool about a longitudinal axis. Contact between the milling tool and a wall of the bore may be initiated in a region of the wall having a least amount of material at the axial position. The milling tool may include a tool shaft having a longitudinal axis, a first set of radially spaced cutting inserts coupled to the tool shaft, and a directly adjacent second set of radially spaced cutting inserts coupled to the tool shaft and spaced from the first set of cutting inserts along the longitudinal axis. The first and second sets of cutting inserts may be staggered from each other by at least 10 degrees.

Abstract: A workpiece holding fixture including a base plate having an engagement surface including a travel slot. A first static riser includes a position control member configured to removably couple a workpiece to the first static riser. A second static riser includes a rotation control member and is configured to removably couple the workpiece to the second static riser. A dynamic riser is configured to abut the workpiece by automatic, semi-automatic, or manual movement into secure engagement with the workpiece. The dynamic riser is slidably coupled with the travel slot and is operable between a plurality of positions associated with workpiece variants having different locating features and geometries.

Abstract: A workpiece holding fixture including a base plate having an engagement surface including a travel slot. A first static riser includes a position control member configured to removably couple a workpiece to the first static riser. A second static riser includes a rotation control member and is configured to removably couple the workpiece to the second static riser. A dynamic riser is configured to abut the workpiece by automatic, semi-automatic, or manual movement into secure engagement with the workpiece. The dynamic riser is slidably coupled with the travel slot and is operable between a plurality of positions associated with workpiece variants having different locating features and geometries.

Abstract: An apparatus and method which utilize electrical discharge machining equipment and techniques to prepare an electrically conductive surface for thermal spray coating or for other purposes. The apparatus includes one or more electrodes, with each electrode having a working face, defining a plane. The one or more electrodes are mounted on the leading end of a shaft and can form part of an electrode assembly. The shaft is at least moveable axially by a shaft actuating mechanism and, in some applications, may also rotate the shaft. Each electrode is moveable by a gap setting mechanism in response to and in a direction different than the axial movement of the shaft to form a voltage gap between each working face and the surface being prepared. A supply of dielectric fluid is disposable in the voltage gap. An electrical discharge circuit conducts an electric current through the dielectric fluid in the gap to produce a gap voltage. The shaft actuating mechanism is controlled by a gap voltage control system.