Technical_Articles

Articles by Roger Kern

During his fifty plus years dedicated to EDM, Roger Kern has authored hundreds of technical articles about or related to EDM that have been published in EDM Today magazine.  Please browse or search the tables below and visit the linked articles, or click on the Resources tab/ITP EDM Knowledge Base to view an entire index of the articles sorted by EDM discipline and article topic.

ITP Features Index

ISSUECOVER STORYEXPERT’S CORNERFEATURE ARTICLEMANAGEMENT MINUTEQUALITY CORNERTECH TIPS
JAN/FEB, 2006BENCHMARK TEST
MAR/APR, 2006TABLE MANNERS
MAY/JUNE, 2006LIAR, LIAR
JULY/AUG, 2006EDM TAPPING 101
SEPT/OCT, 2006MINI TIPS FOR IMTS ISSUE
NOV/DEC, 2006OVERCUT/ORBIT FUNDAMENTALS
JAN/FEB, 2007EDM WIRE PRIMER
MAR/APR, 2007IMPROVING WIRE EDM PRODUCTIVITY
MAY/JUNE, 2007MANAGING FOR CNC EDM PRODUCTIVITY
JULY/AUG, 2007CNC EDM COST ANALYSIS
SEPT/OCT, 2007QUALITY AND EDM PART1
NOV/DEC, 2007QUALITY EDM PART 2
JAN/FEB, 2008QUALITY AND EDM PART 3
MAR/APR, 2008EDM WIRE SELECTION
MAY/JUNE, 2008SINKER ELECTRODE MATL SELECTION
JULY/AUG, 2008SAFE AND GREEN EDMING
SEPT/OCT, 2008APPLICATION TIPS FOR IMTS
NOV/DEC, 2008IMTS HIGHLIGHTS
JAN/FEB, 2009SINKER DIELECTRIC FUNDAMENTALS
MAR/APR, 2009FLUSHING FUNDAMENTALS
MAY/JUNE, 2009WATERJET FUNDAMENTALS
JULY/AUG, 2009THE ART & SCIENCE OF MAKING EDM WIRE
SPRING, 2010P8 – STRESS&EDM
ROGER KERN
SUMMER, 2010P10- DEIONIZING RESIN
ROGER KERN
FALL, 2010P21 – ELECTRICAL TROUBLESHOOTING
WINTER, 2011P12 – FILTRATION FUNDAMENTALSP20 – EDM & EAPP21 – DEALING WITH SPOOL TANGLES
ROGER KERN
SPRING, 2011P18 – SMALL HOLE EDM FUNDAMENTALSP25 – THE EMPLOYEE FILEP26 – LISTENING TO YOUR MACHINE
ROGER KERNA DETECTIVE STORY (SPOOL SIZE MATTERS)
SUMMER, 2011P25 – SAFE & SMART HIRINGP32 – ACCURATE WEDM PICKUPS
P33-TABLE EXTESNSION
FALL, 2011P4 – GRAPHITE PRIMER
MERSEN
WINTER, 2012P50 – JOB DESCRIPTIONSP22 – EDM SETUP FUNDAMENTALS
SPRING, 2012P18 – INDICATOR PICKUP BASICS
SUMMER, 2012P10 – SINKER TOOLING FUNDAMENTALSP28 – MAKE YOUR OWN GAP CABLES?
BUD GUITRAU & ROGER KERNP29-GUIDE SYSTEM COMPONENTS
FALL, 2012P8 – WEDM TOOLING FUNDAMENTALSP32 – THE JOB OFFERP42 – INSPECT IN QUALITY?P30 – EDM FIXTURE MATERIALS
ROGER KERN
WINTER, 2013P46 – QUALITY MATTERSP22 – TUNNEL GATE TECHNIQUES
SPRING, 2013P22 – FAIR & LEGALP52 – MEASURING HOLESP18 – CHILLER FUNDAMENTALS
SUMMER, 2013P10 – EDM’ING MOLD THREADSP21 – DISASTER PREPARATION
ROGER KERN
FALL, 2013P25 – THE POWER OF NOP32 – CRASH!
WINTER, 2014P24 – PROMISESP32 – MACHINE TROUBLESHOOTING
SPRING, 2014P28 – SWOT ANALYSISP34 – AC POWER PRIMER
SUMMER, 2014P34 – WALKIN’ AROUND
FALL, 2014P44 – CONSTRUCTIVE PRAISEP52 – WRINGING GAGE BLOCKS
WEBBER GAGE BLOCK DIV
WINTER, 2015P4 – HOW BRASS WIRE IS MADEP26 – EXIT PLANP25 – USE & CARE OF GAGE BLOCKSP30 – EDM WIRE SELECTION
GLOBAL
SPRING, 2015P24 – SAFETYP23 – STONING GAGE BLOCKSP30 – MAINTENANCE
SUMMER, 2015P24 – CONTINUING EDUCATIONP30 – OPTIMIZIING WEDM PERFORMANCE
FALL, 2015P8 – EDM GLOSSARYP24 – EMPLOYING FAMILY MEMBERP34 – CALIBRATION FUNDAMENTALSP30 – WHAT’S IN EDM SMOKE?
BUD GUITRAU
WINTER, 2016P8 – EDM GLOSSARY PART 2P24 – READ, LISTEN, LEARNP28 – ORBITING FUNDAMENTALS PART 2
BUD GUITRAU
SPRING, 2016P52 – EDM WIRE CLEANLINESSP22 – WHAT ABOUT STEADY EDDY?P30 – CALIBRATION FUNDAMENTALS 102P24 – IS YOUR CLEAN TANK CLEAN?
ROGER KERN
SUMMER, 2016P68 – EDM WIRE INSPECTIONP34 – ARE EMPLOYEES LAST TO KNOWP36 – SKIM CUT FUNDAMENTALS
ROGER KERN
FALL, 2016P31 – COSTS OF PAID TIME OFFP32- HEALTH INSURANCE FOR YOUR CNC
WINTER, 2017P22 – USE IT OR LOSE ITP30 – ARE YOU IN COMPLIANCE?P24 – THE DIRTY DOZEN
SPRING, 2017P18 – OVERTIME MYTHS AND REALITYP24 – EDM WIRE TENSILE STRENGTH
SUMMER, 2017P34 – INVEST IN TRAININGP48 – ONLY A FOOLP40 – SAFE & EFFECTIVE EDM CLEANING
FALL, 2017P30 – DID YOU CHECK REFERENCES?P42 – CALIBRATION INTERVALSP34 – INVOLUTE SPUR GEAR CAUTIONS
WINTER, 2018P32 – UNJUST REWARDSP42 – THOSE PESKY TENTHSP36 THE BITTER END
SPRING, 2018P10 – SMALL HOLE TUBE FUNDAMENTALSP24 – YOU’RE NOT ALONEP38 – MORE ABOUT CERTSP28 – WIIRE PROPTERTIES & APPLICATIONS
ROGER KERN
SUMMER, 2018P10 – WIRE EDM SURFACE CHARACTERISTICSP36 – MARIJUANA AND YOUR SHOPP62 – ORDER ACCEPTANCE & ISSUANCEP40 – WHAT’S A NEGATIVE RADIUS?
ROGER KERN
FALL, 2018P8 – WIRE EDM SURFACE CHARACTERISTICS-2P36 – BURDEN CALCULATIONP40 – WIRE EDM PRE-FLIGHT CHECKLIST
ROGER KERN
WINTER, 2019P34 – MINDING ACCOUNTS RECEIVABLEP16 – ASSUMEP38 – MEASURING EDM SURFACE FINISH
SPRING, 2019P8 – WIRE EDM SURFACE CHARACTERISTICS-3P30 – TERMS DEFINITIONSP16 – EDM CALIBRATIONP36 – POOR MAN’S CMM
ROGER KERN
SUMMER, 2019P10 – EMR AND EDMP32 – BRAINSTORMINGP18 – HASTE MAKES WASTEP38 – COMPARATOR CHARTS ON YOUR CNC
ROGER KERN
FALL, 2019P10 – FAST HOLE TUBE ANALYSISP34 – EDM EFFICIENCYP18 – DESIGNING FOR QUALITYP42 – DRY AIR FOR EDM’S
ROGER KERN
Winter, 2020P34 – ROGER THAT…WILCOP26 – LAPSES GIVE US A BLACK EYEP38 – HOSES, PIPES & FITTINGS
Spring, 2020P20 – WHO’S IN CHARGEP14 – INSPECTION CONUNDRUMSP24 – MORE ABOUT EDM THREADS
SUMMER, 2020P28 – A PLACE FOR EVERYTHINGP20 – THE OPTICAL COMPARATORP36 – HELP! I NEED SOMEBODY
FALL, 2020P46 – COURAGEP40 – DYI GAGE BLOCK CALIBRATIONP52 – G CODE PRIMER
WINTER, 2021P16 – EDM WIRE CLEANLINESSP34 – WEDM CORNER GEOMETRY
SPRING, 2021P10 – SINKER LOW WEAR INVESTIGATIONP16 – CERTIFIED PROCESS FUNDAMENTALSP34 – COATED WIRE CONUNDRUM
ROGER KERN
SUMMER, 2021P10 – SINKER SURFACE INVESTIGATIONSP32 – ALL FAST HOLE TUBES ARE NOT EQUAL
ROGER KERN
FALL, 2021P44 – PREVENTING WIRE TANGLESP12 – REJECTION!P26 – DC ARCS
ROGER KERNROGER KERN
WINTER, 2022P10 – TAPERING 101P18 – CHANGE CONTROLP32 – EDM WATER TREATMENT SYSTEMS
ROGER KERNROGER KERN
SPRING, 2022P14 – IS QUALITY JOB ONEP22 – FAST HOLE TUBES & GUIDES 101
ROGER KERN
SUMMER, 2022P28 – EQUIVALENT IS NOT IDENTICALP40 – EDM KNOWLEDGE BASE
ROGER KERN
FALL, 2022P36 – CLOSE DOESN’T COUNTP52 – TIME FOR A DIELECTRIC CHANGE?
ROGER KERN
WINTER, 2023P12 – DETERMINING CALIBRATION INTERVALSP36 – POWER FEED CONTACTS 101
ROGER KERN
SPRING, 2023P14 – DEBUNKING EDM METER CALIBRATIONSP36 – SINKER EDM PICUP STRATEGIES
ROGER KERNROGER KERN
SUMMER, 2023P22 – EDM WIRE AUDITSP52 – EDM WIRE FRUSTRATIONS
ROGER KERNROGER KERN
FALL, 2023P18 – MULTI-ELECTRODE BURN ISSUESP56 – DEIONIZING SYSTEM CONSIDERATIONS
ROGER KERNROGER KERN
WINTER, 2024P18 – THE COST OF QUALITY LAPSESP42 – SPINDLE BALL/TABLE BALL PICKUPS
ROGER KERNROGER KERN

Roger’s Rant Index

IssueRoger’s Rant
SPRING, 2010P7 – BUY AMERICAN
SUMMER, 2010P9 – USA QUALITY?
FALL, 2010P11 – CALLING YOUR OEM
WINTER, 2011P9 – ASK ROGER SERVICE
SPRING, 2011P10 – FEELING FEISTY
SUMMER, 2011P28 – ARE YOU READY TO STEP UP?
FALL, 2011P32 – TRAFIC SIGNALS
WINTER, 2012P26 – CAN’T MAKE THIS STUFF UP
SPRING, 2012P22 – CERTS & SELF-AUDITS
SUMMER, 2012P32 – FLAG POLE TALE
FALL, 2012P34 BANKING AIN’T THE SAME
WINTER, 2013P36 – TIPPING POINT
SPRING, 2013P46 – CONSULTING JOB FROM HELL
SUMMER, 2013P40 – ATTACKED!
FALL, 2013P38 – PRICE, QUALITY, & REGRET
WINTER, 2014P42 – ACCEPTING RESPONSIBILITY
SPRING, 2014P40 – GOVERNMENT RUN AMUCK
SUMMER, 2014P54 – AMERICA’S SAD DECLINE
FALL, 2014P54 – DIGITAL DISTRACTIONS
WINTER, 2015P38 – FAR EAST TRIP IMPRESSIONS
SPRING, 2015P36 – P.O.S. ENTERPRISES
SUMMER, 2015P35 – HAVE GUN WILL TRAVEL
FALL, 2015P32 – ROGER’S FAVORITE THINGS
WINTER, 2016P32 – IT’S A LIE!
SPRING, 2016P28 – YOU’RE DAMN RIGHT WE’RE MAD!
SUMMER, 2016P40 – TOO MUCH TECHNOLOGY?
FALL, 2016P36 – DON’T BLAME THE CHINESE
WINTER, 2017P28 – A DANGEROUS CABAL
SPRING, 2017P30 – TIME FOR A VAT?
SUMMER, 2017P46 – TECHNOLOGY-BAH HUBUG!
FALL, 2017P40 – IT’S NOT KIM JUNG UN
WINTER, 2018P40 – MAKING CHOICES
SPRING, 2018P34 – THE FUTURE OF TRANSPORTATION
SUMMER, 2018P48 – PRIVACY IS A THING OF THE PAST
FALL, 2018P48 – PENNY WISE POUND FOOLISH
WINTER, 2019P42 – JUST BECAUSE WE CAN
SPRING, 2019P40 – HYPOCRISY, LIES & BS
SUMMER, 2019P40 – UNITED STATES OF EUROPE?
FALL, 2019P48 – AUTONOMOUS VEHICLES
Winter, 2020P48 – ASSAULTS ON DRIVERS
Spring, 2020P28 – ARE ALL MEN CREATED EQUAL?
SUMMER, 2020P38 – COVID-19 MUSINGS
FALL, 2020P56 – TECHNOLOGY’S ACHILLE’S HEEL
WINTER, 2021P40 – WALK THE TALK
SPRING, 2021P36 – FASTEN YOUR SEATBELT
SUMMER, 2021P36 – TYRANNY OF INFLATION
FALL, 2021P30 – THE COST OF GOING GREEN
WINTER, 2022P36 – HYPOCRISY
SPRING, 2022P28 – HAS CAPITALISM GONE AWRY?
SUMMER, 2022P48 – MINISTRY OF TRUTH
FALL, 2022P54 – WHERE HAVE ALL THE FACTORIES GONE
WINTER, 2023P40- A DIFFERENT KIND OF RANT
SPRING, 2023P46- ANECDOTES FROM 58 YEARS IN INDUSTRY
SUMMER, 2023P66- MY FIRST JAPANESE CAR!
NOVEMBER, 2023THE RETAIL MARIJUANA DEBACLE
DECEMBER, 2023THIS LAND IS MY LAND – REALLY?
JANUARY, 2024NEITHER A BORROWER OR LENDER BE
FEBRUARY, 2024INFLATION – THE CRUELEST TAX OF ALL
MARCH, 2023Debt – Part 2
APRIL, 2024Police under Fire!
MAY, 2024Election Integrety

Ask Roger Index

ISSUEPAGETITLE
Spring, 201019Carbon Deposits on Aluminum Sinker Burns
Spring, 201019Wire EDM’ing Magnesium
Summer, 201025RS232 Communications Issues
Summer, 201025Demagnetizing Steel Before Wire EDM
Summer, 201026Removing Recast Layer
Fall, 201029EDM’ing Sub Gates
Fall, 201030Power Feed and Brass Block Meltdown
Fall, 201030Wire EDM Slug Retention
Winter, 201130pH of Wire EDM Water
Winter, 201130Nadcap EDM Audits
Winter, 201131Skim Cuts Explanation
Spring, 201134Support for EDM Solutions Machine
Spring, 201134Reducting Sinker Corner Wear
Spring, 201134Acidic EDM Cleaner
Spring, 201135Calculating Electrode Undersize for Orbiting
Summer, 201142Sinker EDM Performance Issues
Summer, 201142Cleaner for Wire EDM
Summer, 201143Deep Small Hole Burning in Carbide
Fall, 201146Plating Adherence to EDM Surface
Fall, 201146Surface Pitting in Carbide Sinker Burns
Fall, 201147Preventing Negative Wire Breakthrough Mark
Winter, 201240Best Sinker EDM Electrode Material for PCD
Winter, 201240Orbit Pattern for Sinker Burning Splines Part 1
Winter, 201241Make-up Water for Wire EDM
Winter, 201241Used EDM Resin as Blast Media
Winter, 201241Sources for EDM Surface Finish Gages
Spring, 201238Green Tint on Brass Wire
Spring, 201238Reconditioning Wire Guides
Spring, 201238EDM Wire Tolerances
Spring, 201239WEDM Glue Tabs for Complicated Shapes
Spring, 201258Orbit Pattern for Sinker Burning Splines Part 2
Spring, 201258pH of WEDM and Small Hole Dielectric
Summer, 201250Pickup Issues with Mitsubishi SX10
Summer, 201250Replacement Hoses for Sinker EDM
Summer, 201250Ex-cello Cycle Start Won’t Work
Summer, 201251Water Dielectric for Sinker EDM
Summer, 201251What is CobraCut Type D Wire?
Fall, 201246Electrode Material for Blind Holes in Titanium
Fall, 201246Black Spots in Corners on Sinker Burn
Fall, 201246Threading Issues with .3mm Wire
Fall, 201247Pink Slime and Fishy Smell in WEDM Dielectric System
Winter, 201352Distortion in Precision WEDM Geometry in Copper
Winter, 201352Weep Hole Function in WEDM Diamond Guide
Winter, 201353Does EDM Cause Workpiece Cracking?
Winter, 201353Rebuild That Old Wire EDM?
Spring, 201358Preventing DC Arcs
Spring, 201359Minimizing Strain Movement with Rough and Skim Cuts
Spring, 201359EDM Tapping Quality Issues
Spring, 201360Truing Up Delicate Sinker Electrodes
Summer, 201346Avoiding Wire Breakage in Thick Parts
Summer, 201346Fine Wire Buildup in Wire Basket
Summer, 201347Copper Graphite Electrodes in Vollmer Machine?
Summer, 201347Wire Build-up in the Upper Guide
Summer, 201347Short Circuits in the Final Skim Pass
Fall, 201346Magnets in Sinker Dielectric Tank?
Fall, 201346Wire EDM’ing Copper Tungsten
Fall, 201346Nozzle-to-Workpiece Gap in Submerged Cutting
Fall, 201347Premature Resin Failure
Fall, 201347Deionized Water Gas Explosions
Fall, 201348Machine to Computer Communications Issues
Winter, 201444Part Discoloration in Small Hole EDM
Winter, 201444Small Hole EDM Mystery
Winter, 201444Stress Relief in Carbide Dies
Winter, 201445Wire Edgefinding Problem
Winter, 201445Problems Cutting 303 Stainless
Winter, 201446Black Slim on Side of WEDM Dielectric Tank
Spring, 201450Manual Wire Alignment
Spring, 201451Conductivity Issues on an Mitsubishi FA10
Spring, 201451Fanuc W2 Gives False Indication of Wire Breaks
Spring, 201452Mitsubishi MV 4-Axis Programming Issue
Spring, 201453Recovering from a WEDM Operating System Crash
Summer, 201460Cutting Tall 420 Stainless Parts
Summer, 201460Conductivity Issues on a Brother HS-50A
Summer, 201461Oil WEDM for Carbide?
Summer, 201461Electrode Material for Inconel
Summer, 201461Selecting One’s First Wire EDM
Fall, 201460Burning Dies with Coined Electrodes
Fall, 201461Estimating Software for Sinker EDM
Fall, 201461Wire Cutting a T-Slot in a Tall Part
Winter, 201544Cleaning Dielectric Oil from Parts
Winter, 201544Pitting on WEDM Aluminum Parts
Winter, 201544WEDM Dielectric Conductivity Issues
Winter, 201545Explosive Wire Breakage
Spring, 201544Conductive Glue for Sinker EDM Electrodes
Spring, 201544Clamp Erosion During Small Hole Burn
Spring, 201544Wire EDM using Magnetic Vee Block
Spring, 201545Burning Oblong Holes in a Small Hole EDM
Spring, 201545Wire EDM Not Following Programmed Path
Spring, 201545Same Program for WEDM and CNC Mill?
Summer, 201546Keeping Tapped Holes Clean in WEDM Rails
Summer, 201546Copper Tungsten Porosity and Inclusion Issues
Summer, 201547When to Change Sinker EDM Dielectric
Summer, 201547EDM’ing Anodized Workpieces
Fall, 201548What’s the Best Machine?
Fall, 201548Power Feed Holder Block Erosion
Fall, 201548Does 3-D Orbiting Increase Surface Pitting?
Fall, 201549Cataxtrophic Carbide Cracking After Wire EDM
Winter, 201656Transformer Oil as EDM Dielectric?
Winter, 201656Truing a Sinker Chuck to the Machine Axes
Winter, 201657Chipping on Wire Cut Graphite Electrodes
Winter, 201657Skim Cuts on Punches Don’t Clean Up
Spring, 201644Removing Wire EDM Stress
Spring, 201644Hole Popper Filtration
Spring, 201644Nadcap WEDM Polarity Audit
Spring, 201645Power Feed Contact Issues
Summer, 201650Sinker EDM Dielectric Reservoir Cleanout Procedure
Summer, 201650Adding Salt to WEDM Dielectric to Lower Resistivity?
Summer, 201650Adding Ozone Generation to WEDM
Summer, 201651Failed Recast Layer Testing for Aerospace WEDM Job
Fall, 201644Oxide Issues When Hole Popping and Wire Cutting Aluminum
Fall, 201644Moly Wire Problems
Fall, 201645Tungsten Wire Problems
Winter, 201742Improving Belly on a 5″ Tall Part
Winter, 201742Will Non-Submerged Cutting Damage Upper Wire Guide?
Winter, 201742Sizing a Replacement Chiller
Winter, 201743Dried Out Agie Belts
Winter, 201743Wire EDM’ing a Thread
Winter, 201743EDM’ing Carbon Fibre Reinforced Plastic
SPRING, 201742Small Hole EDM Electrode Jamming in Ceramic Guide
SPRING, 201742Another Conductive Adhesive Question
SPRING, 201742Wire EDM’ing a Thread?
SUMMER, 201756Threading Issues with .002″ Tungsten Wire
SUMMER, 201756Pick Up Horn Stuck On
SUMMER, 201756Who’s Responsible for a Scrapped Part
SUMMER, 201756Threading Issue on an Older Mits
SUMMER, 201757Discoloration of Brass Workpieces
SUMMER, 201757Correcting Taper in a Thick Workpiece
SUMMER, 201758Speeding Up Multi-pass Cuts in a Mits
FALL, 201748Cleaning Wire EDM’d Parts
FALL, 201748Wire Cutting Narrow Ribs
FALL, 201748EDM of CFRP
FALL, 201749Steel Core Wire Applications
WINTER, 201844Poor Filter Life
WINTER, 201844Storing Too Many Programs in CNC
WINTER, 201844Zinc Transfer to Recast
WINTER, 201845Graphite Grade Recommendations
WINTER, 201845Wire Entry/Exit Mark Issues
SPRING, 201840More on Mat’l Transfer from Wire to Workpiece
SPRING, 201841Softer Wire for 30 Degree Taper?
SPRING, 201841Wire EDM’ing Pure Tungsten
SUMMER, 201864Problems Cutting Tall Parts with Zinc Coated Wire
SUMMER, 201864Length of Wire on a Spool
SUMMER, 201864Cutting Large Tapers in Tall Parts
SUMMER, 201865Wire Cutting Thin Plates
SUMMER, 201866Electrode Material for Cutting AMPCO Ribs
FALL, 201850Recommendations for Slug Retention Glue
FALL, 201850Krazy Glue Solvent
FALL, 201851EDM’ing Magnets
FALL, 201851Wire EDM Pitts Cutting Titanium
WINTER, 201944Wire Spool Capacity – 2
WINTER, 201944Water Dielectric for Sinker EDM – 2
WINTER, 201944Correcting Out-of-Square Part with Wire EDM
WINTER, 201945Extending Machine Table Surfaces
SPRING, 201944Wire EDM as an End Mill
SPRING, 201944Wire Cut Strategies for Multiple Parts
SPRING, 2019449″ Deep Hole in Stellite
SPRING, 201945Burning Dicast Mold Threads
SUMMER, 201958Preparation for Ask Roger/Consulting
FALL, 201966Sinker Cleaning Procedure
FALL, 201966Poor Wire EDM Finish on Laminated Material
FALL, 201966Multiple vs Single Electrodes
FALL, 201967Cutting Off Additive Parts
FALL, 201967Welding Cable for Gap Cables?
WINTER, 202060EDM’ing Carbide with Copper Tungsten
WINTER, 202060Reverse Burn Polarity
WINTER, 202061Expanding Toolchanger Capacity
SPRING, 202048What Causes Bannan Shaped Wirecut Punch?
SPRING, 202048Selecting Filter Micron Rating
SPRING, 202048WEDM .0023 Corner Radius Issues
SUMMER, 202062Die Draft or Land First?
SUMMER, 202062HAZ and Recast Question
SUMMER, 202063Wire Cutting Large Titanium Parts
SUMMER, 202063Sinker EDM Replacement Hose Issues
FALL, 202066Cleaning and Protecting Wire EDM Parts
FALL, 202066Brass Wire for Accurate Pickups?
FALL, 202067Cleaning Diamond Wire Guides
WINTER, 202148Wire Stuck in Wire Guides
WINTER, 202148Multiple Part Sinker Burns
WINTER, 202149Conductivity Calibration
WINTER, 202149PMEDM
SPRING, 202148Are All Brass Wires the Same
SPRING, 202148Identifying Mystery Graphite
SPRING, 202149Algae Problems in Wire EDM Water
SPRING, 202149What is a Safety Filter
SUMMER, 202154Unwanted Wire EDM Line Segments
SUMMER, 202154Wire EDM Damascus Steel
SUMMER, 202155Brass Wire Substitution for Certified Process
SUMMER, 202155Choosing a Coated Wire
FALL, 202152X-wire Not Autothreading
FALL, 202152Very Small Holes in Tungsten Carbide
FALL, 202152Sinker EDM Oil Cleaner
FALL, 202153Deionizing Resin Recycling
WINTER, 202256Working with Tiny Small Hole Tubes
WINTER, 202257Coated Wire Conundrum
SPRING, 202250EDM Wire is Undersize
SPRING, 202250EDM Wire is not Straight
SUMMER, 202262Dirty Water in WEDM Work Tank
SUMMER, 202262Generating Pocket Radii in Sinker Applications
SUMMER, 202263Small Hole Location Issues
FALL, 202268Removing Dielectric Oil from Electrodes
FALL, 202268Brass Deposits on Workpieces
FALL, 202269Troubleshooting Wire Breakage
WINTER, 202354Removing Algae from Water Dielectric Systems
WINTER, 202354Dielectric Fires in Cutting Tool Erosion
WINTER, 202355EDM’ing Tall Ampco 18
SPRING, 202364Fixturing in ID for EDM Drilling
SPRING, 202364Parting Line Matching
SPRING, 202364Short WEDM Filter Life
SPRING, 202364Corrosion on Aluminum WEDM Workpiece
SUMMER, 202380Avoiding rusted dielectric filters
SUMMER, 202380MIL-SPEC for EDM wire diameter?
SUMMER, 202380EDM wire spool flange separation issues
SUMMER, 202381Wire “sparking” outside of workpiece area
FALL, 202372Excessive DI Recovery time
FALL, 202372Difficulty Redressing Copper Tungsten Electrodes
FALL, 202373Resin Tank Drain Water Disposal
WINTER, 202464Brass Residue On Wire EDM Surfaces
WINTER, 202464Disposal of Emtpy EDM Wire Spools
WINTER, 202464DI Conductivity Standard Shelf Life
WINTER, 202464Pipe Thread Sealing Issues
WINTER, 202465Conuductivity Light Issues
WINTER, 202465Sinker Burning Niobium

Toolbox Treasures Index

ISSUEPage NumberSUBJECT
FALL, 201034ALLEN WRENCH BLOCK
FALL, 201034WEDM SLUG HOLDERS
FALL, 201034QUALITY POLISH
WINTER, 201119AERO KROIL
WINTER, 201119KNEADED ERASER
WINTER, 201119NORBIDE STICK
SPRING, 201143KRAZY GLUE
SPRING, 201143DYKEM LAYOUT FLUID
SPRING, 2011435 MINUTE EPOXY
SUMMER, 201151CFL BULB
SUMMER, 201151MAGLITE SOLITAIRE
SUMMER, 201151COMPACT TOE CLAMP
FALL, 201155KANT-TWIST CLAMPS
FALL, 201155HARD ARKANSAS STONE
FALL, 201155WIRE START TABS
WINTER, 201255GAGE BLOCK DRESSING PLATE
WINTER, 201255UTILITY PUMP
WINTER, 201255CONDUCTIVITY CALIBRATING FLUID
SPRING, 201259INDICATOR HOLDER
SPRING, 201259SAFEZONE CLEANER
SPRING, 201259BESTEST INDICATOR
SUMMER, 201263THIN PARALLEL SET
SUMMER, 201263COMPARATOR RADIUS CHART
SUMMER, 2012631-2-3 BLOCKS
FALL, 201255WIRE GUIDE DRILLS
FALL, 201255DENTAL MIRROR
FALL, 201255ZEKANT
WINTER, 201335BONDUHS WRENCHES
WINTER, 201335MACHINE IN USE CHECK
WINTER, 201335MO GAGE PIN SETS
SPRING, 201345GAGE PIN DOG
SPRING, 201345TENSION METER
SPRING, 201345DIELECTRIC SQUEEGEE
SUMMER, 2013393R INDEX WHEEL
SUMMER, 201339SNAP-ON BALL ANVIL
SUMMER, 201339PIN MIKE
SUMMER, 201339FLANGE MIKE
FALL, 201337CENTER FINDER
FALL, 201337SURFACE FINISH GAGE
FALL, 201337KNOX BOX
WINTER, 201437SINE STACKS
WINTER, 201437CONDUCTIVITY METER
WINTER, 201437HAND MIRROR
SPRING, 201444EZ-HOOKS
SPRING, 201444AMPROBE
SPRING, 201444JEWELER’S LOOP
SUMMER, 201465FEELER GAGES
SUMMER, 201465JEWELER’S TWEEZERS
SUMMER, 201465FORCEPS
FALL, 201463CHAPMAN WRENCH SET
FALL, 2014636″ STARRETT SCALES
FALL, 201463GERSTNER TOOLBOX
WINTER, 201543ULTRASONIC CLEANER
WINTER, 201543POCKET THERMOMETER
WINTER, 201543IN-LINE RESIN STRAINER
SPRING, 201561FLEXBAR
SPRING, 201561WILKERSON AUTO TANK DRAIN
SPRING, 201561SOURCE FOR DOUBLE JOINTED INDICATOR HOLDER
SUMMER, 201569COSMOLENE RUST VETO SPRAY
SUMMER, 201569STRIP-ALL
SUMMER, 201569TAPPED HOLE CLEANOUT TOOL
FALL, 201571AUTOMATIC AIR RECEIVER DRAIN UPDATE
FALL, 201571REMOTE DIELECTRIC THERMOMETER
FALL, 201571TOE CLAMP HEEL REST SPACER SET
WINTER, 201671METEM UNIVERSAL VIBRATOR
WINTER, 201671CERASTON GAGE BLOCK STONE
WINTER, 201671RYDLYME
SPRING, 201661FLEXIBLE SPRING CLAWS
SPRING, 201661BRASS BAR
SPRING, 201661PARALLEL CLAMPS
SUMMER, 201683TOOLMAKER’S APRON
SUMMER, 201683FINGERMAXX
FALL, 201653TENSION METER HOLDER BLOCK
WINTER, 201753SLUG HOLDER MAGNETS
WINTER, 201753OUTSIDE START HELPERS
WINTER, 201753MACHINERY’S HANDBOOK
SPRING, 201751WEE BLOCKS
SPRING, 201751POCKET SAVER
SPRING, 201751TELESCOPE GAGES
SUMMER, 201769STARRET DRILL CHART
SUMMER, 201769WIRE MARKER KIT
SUMMER, 201769GASKET HOLE PUNCH
FALL, 201767CHARMILLES 310 WATER LEVEL GAGE
FALL, 201767MAINTENANCE TOOL KIT
FALL, 201767CHARMILLES UPPER GUIDE INSTALLATION TOOL
WINTER, 201849CO2 FIRE EXTINGUISHER
WINTER, 201849SMART PHONE
WINTER, 201849WIRE PULLER
SPRING, 201826Screw Type Snap Ring Pliers
SPRING, 201826Sinker Flush Pots
SPRING, 201827Strap Wrench
SUMMER, 201838Handbox U-V Button Guard
SUMMER, 201838Anti-Static Workstation
SUMMER, 201838Cable Snake
FALL, 201838Drum Dolly
FALL, 201838Drum Lifters
FALL, 201838Drum Bung Tool
FALL, 201838Rotary Drum Pump
WINTER, 201937Cable Ramp
WINTER, 201937Headlamp
WINTER, 201937Piercing E-Z Hook Test Leads
SPRING, 201935Circuit Alert
SPRING, 201935Solder Sucker
SPRING, 201935Vise Grip Chain Wrench
SUMMER, 201936Heat Shrink Tubing
SUMMER, 201936Heat Gun
SUMMER, 201936Lanolin
FALL, 201940PanaVise
FALL, 201940Cordless Soldering Iron
FALL, 201940Dremel Rotary Tool
WINTER, 202036Sturdy Bench Vise
WINTER, 202036Copper Vise Jaw Caps
WINTER, 202036Electric Screwdriver
SPRING, 202022Thread Pitch Gages
SPRING, 202022Pitch Diamter Micrometer
SPRING, 202022Thread Pitch Micrometer Master
SUMMER, 202030Goo Gone
SUMMER, 202030Hyde Scraper
SUMMER, 202030Taper Hand Reamer
FALL, 202048Pin Vise Set
FALL, 202048Planar Gage
FALL, 202048Push-to-Connect Fitting Removal Tool
WINTER, 202128Electrical Contact Cleaner
WINTER, 202128Cellophane Shim Stock
WINTER, 202128Bic Butane Lighter
SPRING, 202130Wire Strippers
SPRING, 202130Wire Termination Kit
SPRING, 202130Wire Marker Drum
SUMMER, 202130Bridgeport Quill Stop
SUMMER, 202130Multipurpose Vee Block
SUMMER, 2021316″ Depth Micrometer
FALL, 202122Wire Guide Drill Update
FALL, 202122Snap-On Screwdriver
FALL, 202122Battery Tester
Winter, 202228Circuit Breaker Locator
Winter, 202228Test Leads
Winter, 202228Lockout Station
Spring, 202220Wago Connectors
Spring, 202220Knipex Electrical Pliers
Spring, 202220Key Box
Summer, 202238O-ring Pick Set
Summer, 202238Small Wrench Set
Summer, 202238X-Acto Knife
Fall, 202250Foam Measuring Instrument Pad
Fall, 202250Upgraded Push-to-Connect Removal Tool
Fall, 202250Chalk Line
Winter, 202332Socket Driven O.D. Gripper
Winter, 202332Thickened Silicone Grease
Winter, 2023321/2″ Drive Screwdriver Bits
Spring, 202334Analog Multimeter
Spring, 202334Universal Test Lead Kit
Spring, 202334Vintage TI Calculator
Summer, 202336Refractometer
Summer, 202336Fuse Puller
Summer, 202336Gas Powered Soldering Tool Kit
Fall, 202344Drive Pin Punches
Fall, 202344Test Light
Fall, 202344Canned Air
Winter, 202424TOOTHBRUSH
Winter, 202424BRASS BRUSH
Winter, 202424Q-TIPS

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