This research is intended to provide a solution to the problem of conventionally machining hard steels and nickel based alloys turning, milling, drilling and tapping at rates and costs superior to grinding. This has to be achieved in the manufacturing environment of the jobbing shop, where batch size is small, geometric shape is variable, set-up, turn-round time and delivery are expected to be short and flexibility at a maximum, yet operating and capital costs need to be low. The main objective is to describe a cost effective method based on the use of ultra hard tools. The method will extend research already carried out by large companies by carrying out selected machining tests on surface hardened steels and nickel alloy steels by observing wear mechanisms, chip/tool interface metallography & temperatures and cutting forces. This will be followed by process trials, product and cost evaluation. The participating Sees will rapidly introduce successful methods.