The June 2018 edition of Manufacturing Engineering is available as a digital magazine. Links to individual articles are below:
While cylindrical grinding has been used for some time, its capabilities may not be fully appreciated. New grinding wheel technology, controls, materials and dressing processes, coolant and pump options—as well as smarter software—make today’s machines worth getting acquainted with.
Lots of shops say they want to automate operations, but how many actually have? Errol Burrell, product specialist for Okuma America Inc. (Charlotte, NC) recently said only 10% of all machine tools are automated. And, according to John Lucier, national automation manager for Methods Machine Tools Inc.(Sudbury, MA), the Robotics Industries Association reports that only 3–4% of new machines have a robot.
Basic trends in modern manufacturing are driving growth in 3D optical metrology. Metrology is no longer viewed as a cost but as a cost-saving investment. Manufacturers no longer want only to prove the quality of the supplied part or product.
When wrestling with vexing issues such as product complexity, lightweighting, advanced materials and new manufacturing methods, today’s manufacturing engineers increasingly use high-fidelity simulations to visualize solutions to these challenges. The latest simulation software can offer clues to improving product design and performance with high-end CAE packages and NC simulation software.
If John Winter of toolmaker Sandvik Coromant (Fair Lawn, NJ) were to start his own machine shop, all of his machines would be equipped for through-spindle coolant (TSC). The advantages of high-pressure coolant applied through the spindle vs. flood coolant drive Winter’s opinion: longer, more predictable tool life, better surface finish on the workpiece, the ability to flush chips from deep holes, and higher productivity.
Cryogenics offer an alternative to traditional liquid coolants when conventional cooling methods can’t or don’t do the job well enough. For example, the Cryogenic System from 5ME LLC (Cincinnati) moves liquid nitrogen (LN2) through the machine, spindle, and cutting tool to just behind the cutting edges. This approach yields a cutting tool refrigerated to −321°F (−196°C).
Formula SAE competitions challenge teams of university undergraduate and graduate students to design and fabricate a small, formula-style vehicle. Once completed after eight to twelve months of work, the vehicles are judged in a series of static and dynamic events including technical inspection, cost, presentation, and engineering design, solo performance trials, and high-performance track endurance.
Smart wearable tools are setting the tone with Industry 4.0 for Italy’s auto factories of the future in today’s Maserati plants. Developing and using technology within today’s Smart Factories is providing a level of intra-connectivity that is changing the very framework of modern manufacturing.
When a growing backlog in the inspection room began to slow production and delay deliveries, Voisard Tool Service Inc. (Russia, OH), a division of Arch Global Precision, found a solution in a new advanced tool measurement system and software from United Grinding (Miamisburg, OH). Tool inspection times were slashed by more than half and the company’s ability to maintain full-speed production by coordinating every facet of the company’s operations was maintained.
On May 9, Alan Rooks, editor in chief, took a whirlwind tour of change in manufacturing by visiting several open house events. First up was BIG Kaiser Precision Tooling Inc. in Hoffman Estates, IL, and across the parking lot (literally) was DMG Mori, hosting its annual Technology Days.
ADVANCED MANUFACTURING NOW
We need a sense of urgency around the use of artificial intelligence (AI) in manufacturing. The urgency is driven by how quickly technology can move today, and how an unexpected breakthrough can quickly dominate. AI is used in facial recognition, converting speech to written word, and in winning chess matches. Surely, there must be a horde of potential applications in manufacturing.
Composite materials have clear benefits for manufactured parts in aerospace, medical, automotive applications and many other industries. Ensuring the highest part accuracy is critical. Force measurement and material testing are essential processes for product designers and manufacturers to gain insightful data to create high-quality composite components.
Today, laser technology in manufacturing touches all of our lives on a daily basis; lasers cut air bag material and weld air bag detonators for our in-car safety; lasers weld the batteries in many of our mobile devices; lasers drill aero-engine components for planes; lasers cut the glass for our smart phones and tablets screens; lasers weld the drivetrains in our cars and trucks; lasers cut medical stents that increase and enhance our lives, just to name a few.
Manufacturing, meet Gen Z. Gen Zers, the youngest American generation, are different than their millennial predecessors. Raised during the recession by their conservative and resilient Gen X parents, they are hardworking, independent-thinking realists who are ready, willing, and inspired to help change the world.
Patrick Waurzyniak, senior editor, interviews Clinton Perry, product marketing manager for Autodesk Inc., about the latest PowerMill 2019 update, adding a new additive plug-in module. Learn about the benefits offered by hybrid type CNC/AM machines over pure CNCs or traditional additive systems.