Featuring 24-bit color and 1-button menu, Glance v2.0 enables sales staff to provide prospects with enhanced communication experience by combining phone call with ability to present sales pitch or demo an application from any PC, Mac, or Linux computer. Prospects enter demos instantly from their own website, without having to download web conferencing software. Presentations can include any application, PowerPoint illustration, graphic art design, or 3D rendering.
********************
- Latest Release Adds Full Color and Even Faster Speeds to its Dependable
One-Button Sales Demo Tool
Arlington, Mass. - September 20, 2005 - Glance Networks, creators of the
"one-button simple" GlanceT screen sharing service, today announced version
2.0, which adds full 24-bit color, faster screen update speeds and easy customer website integration. Used primarily as a sales tool for hosting
instant web demos and presentations, Glance provides a quick and dependable
web demo service. It includes "Guests Connect for FreeT" flat-rate pricing
and the ability to connect instantly to nearly any PC, Mac or Linux computer
without downloading software.
"Simplicity and ease of use have been two challenges inhibiting mass
adoption of web conferencing," observes Mike Gotta, principal analyst,
Burton Group. "There's an underserved audience within this market that
simply wants to deliver a richer communication experience by combining a
phone call with the sharing of a screen. The ability to present a sales
pitch or demo an application should be a natural part of the conversation."
Sales professionals know they need to make every call count. A single
botched demo or presentation can cost them a sale. Whether showing a
software application, pitching a presentation, filling out a form or walking
through a website, sales people need a demo service that is as reliable as
their phone. Their ideal service would be:
oDependable - Their 9:00 a.m. demos need to start at 9:00 a.m., not 9:15
a.m. The service needs to connect the first time, every time.
oFast - Their prospects should enter demos instantly from their own website,
without wasting time downloading complicated web conferencing software.
oSimple - Their guests should be able to focus on the demo, without
distractions from unnecessary web conferencing buttons and menus.
"When we needed a simple, reliable sales tool to walk clients through a
demonstration of our software applications, we turned to Glance," commented
Steven Green, president at PollStream Inc., a direct response software
solution that makes it easy to engage customers in a two-way conversation.
"We tried other conferencing services with frustrating results, experiencing
technical problems with downloads and such. All we wanted was reliability
and ease of use at a reasonable price. Glance 2.0 fits the bill for quick
web demos and sales presentations."
Tuesday, December 26, 2006
Reduce coolant costs with air tool chiller
ChillyBits, a new air chiller from Abanaki Corporation, is suitable for use in a range of industrial, fabrication, assembly and packaging processes. Designed to reduce the safety concerns associated with mist cooling, the air chiller can increase machining speeds by as much as 36 percent while extending tooling life by percent.
Compressed air is used for industrial spot cooling. According to the company, this eliminates mist coolants and heat-related parts growth. The product can also be used in milling, drilling, machining, grinding and sharpening operations. The portable model contains no moving parts and has an adjustable tip for precision airflow.
Compressed air is used for industrial spot cooling. According to the company, this eliminates mist coolants and heat-related parts growth. The product can also be used in milling, drilling, machining, grinding and sharpening operations. The portable model contains no moving parts and has an adjustable tip for precision airflow.
Virtual Machine Language
Virtual Machine Language (VML) is a mission-independent, reusable software system for programming for spacecraft operations. Features of VML include a rich set of data types, named functions, parameters, IF and WHILE control structures, polymorphism, and on-the-fly creation of spacecraft commands from calculated values. Spacecraft functions can be abstracted into named blocks that reside in files aboard the spacecraft. These named blocks accept parameters and execute in a repeatable fashion. The sizes of uplink products are minimized by the ability to call blocks that implement most of the command steps. This block approach also enables some autonomous operations aboard the spacecraft, such as aerobraking, telemetry conditional monitoring, and anomaly response, without developing autonomous flight software. Operators on the ground write blocks and command sequences in a concise, high-level, human-readable programming language (also called "VML"). A compiler translates the human-readable blocks and command sequences into binary files (the operations products). The flight portion of VML interprets the uplinked binary files. The ground subsystem of VML also includes an interactive sequence-execution tool hosted on workstations, which runs sequences at several thousand times real-time speed, affords debugging, and generates reports. This tool enables iterative development of blocks and sequences within times of the order of seconds.
This program was written by Christopher Grasso, Dennis Page, and Taifun O'Reilly with support from Ralph Fteichert, Patricia Lock, Imin Lin, Keith Naviaux, and John Sisino of Caltech for NASA's Jet Propulsion Laboratory. For further information, access the Technical Support Package (TSP) free online at www.techbriefs.com/tsp under the Software category.
This program was written by Christopher Grasso, Dennis Page, and Taifun O'Reilly with support from Ralph Fteichert, Patricia Lock, Imin Lin, Keith Naviaux, and John Sisino of Caltech for NASA's Jet Propulsion Laboratory. For further information, access the Technical Support Package (TSP) free online at www.techbriefs.com/tsp under the Software category.
Monday, December 25, 2006
Creating models and tool paths for CNC machining
With BobArt Pro-X from BobCAD-CAM, users can convert pictures or CAD drawings into 2D toolpath or embossed models for machining within Version 20 2D and 3D CAD/CAM software. The release is intended to assist manufacturers, including mold makers, in creating the appropriate model and tool path for CNC machining, from imported or designed images and CAD geometry.
Users can automatically convert a color, grayscale or black and white picture into a full relief model, says the company. The appropriate toolpath strategy can then be created on the fly. Added mirroring options are useful for creating negative relief models. In addition to this capability, users can form raster to vector operations to create 2D profile tool paths for carving or profile milling directly from pictures.
Once the toolpath is machined in the CAM sphere of the software, the cutting process can be simulated and verified prior to sending the program to the machine
Users can automatically convert a color, grayscale or black and white picture into a full relief model, says the company. The appropriate toolpath strategy can then be created on the fly. Added mirroring options are useful for creating negative relief models. In addition to this capability, users can form raster to vector operations to create 2D profile tool paths for carving or profile milling directly from pictures.
Once the toolpath is machined in the CAM sphere of the software, the cutting process can be simulated and verified prior to sending the program to the machine
Multi-use air powered abrasive belt machine
Dynabrade's Dynafile II air powered abrasive belt machine features a grinding head that pivots 360 degrees, making this tool especially useful for getting into hard-to-reach areas.
The machine features a 20,000-rpm direct-drive air motor that powers abrasive belts 1/4" to 3/4" x 18" long. The motor handle has a 7-degree pitch to help prevent wrist and arm fatigue. The tool features quick and easy abrasive belt change, interchangeable contact arms and trouble-free belt tracking, according to the company. The tool also has a thermal insulated housing, which prevents cold air transmission to the operator's hand while at the same time reducing tool vibration. Additionally, the air motor easily converts to a die grinder by adding a 1/4" collet or to an air drill by adding a chuck.
A versatility kit is also available. It includes the tool, an assortment of contact arms, abrasive belts and a 1/4" collet, all in a carrying case
The machine features a 20,000-rpm direct-drive air motor that powers abrasive belts 1/4" to 3/4" x 18" long. The motor handle has a 7-degree pitch to help prevent wrist and arm fatigue. The tool features quick and easy abrasive belt change, interchangeable contact arms and trouble-free belt tracking, according to the company. The tool also has a thermal insulated housing, which prevents cold air transmission to the operator's hand while at the same time reducing tool vibration. Additionally, the air motor easily converts to a die grinder by adding a 1/4" collet or to an air drill by adding a chuck.
A versatility kit is also available. It includes the tool, an assortment of contact arms, abrasive belts and a 1/4" collet, all in a carrying case
Sunday, December 24, 2006
How to machine "pure abrasion": powder metal is one of the most abrasive materials that a shop will encounter. The key to successfully machining this
Machining powder metal is like machining pure abrasion. So opines Charles Gerlach, president of Gerlach Machine. Located in St. Henry, Ohio, a small town landlocked by corn fields and quaint farm houses, Mr. Gerlach's shop has specialized in machining powder metal parts since the 1980s.
The soil in those nearby cornfields is loosely similar to powder metal, in that it is a mixture of nutrients and organic material that come together to provide the base for what farmers hope will be a bumper crop. Along those lines, powder metal parts are a mixture of tiny metal and alloying elements (think talcum powder tiny) that, after being compacted together and heated, form a near-net-shape component.
Unfortunately (for the powder metal molders, anyway), secondary machining operations are typically required to bring the part to its final form. At this stage, the powder metal part may have an apparent hardness rating that isn't very daunting in terms of machineability (30 Rc, for example). However, those individual powders retain their individual hardnesses--which could be 50 Rc or higher--yen after the part is molded. A tool cutting into such material will be slicing through very small, very hard particles--in essence, it's pure abrasion. The number of powder metal components finding their way into the latest automobile designs continues to rise. In fact, such components are now used in more high-profile engine and transmission applications. Though powder metal parts have become the darling of the auto industry, they can still be a demon for the shops that must machine the finishing touches.
Gerlach Machine didn't set out with the intention of specializing in powder metal machining. The shop's Midwestern location had a lot to do with it. A number of local powder metal molders approached the company 25 years ago to machine the features that couldn't be created in the molding process. Many of these early parts required only boring operations to bring IDs to tolerance or tapping operations, because threads can't be formed in the mold.
In many cases, the ODs of the powder metal part the shop machines are molded to net shape. This is why these materials are especially attractive for gear components, as the traditional hobbing process to form gear teeth is not necessary. The molded teeth can then be induction-hardened for wear resistance, while the core remains soft to reduce the chance of fracture during operation.
It is because of molding process limitations that other part features, such as threads, require secondary machining. While holes that are parallel to the axis of mold compression can be molded, cross holes (those perpendicular to the compression axis) and grooves around the periphery of the part can't be molded. There are also limits to how thin part walls can be molded. In addition, machining may be necessary to reach the tighter tolerances and better surface finishes that are required of the latest automotive components.
Tooling Considerations
Most powder metal parts require turning and tapping operations rather than milling, which is why Mr. Gerlach's shop has more CNC lathes than mills. Because powder metal parts are near net shape, heavy roughing cuts are typically not required. Appropriate tooling, therefore, is that which is geared toward semifinishing and finishing duties. For turning operations, Mr. Gerlach primarily uses cermet inserts from Valenite (Madison Heights, Michigan). These inserts have essentially no edge prep in order to provide an extremely sharp cutting edge and free cutting action, which Mr. Gerlach has found effective in turning powder metal parts.
In certain instances, powder metal parts will be hardened via heat treating or induction hardening prior to machining work. Parts that are induction-hardened may require a finish machining pass because the quality of the finished surface was altered. For these hardened parts, the shop is more likely to use cubic boron nitride (CBN) inserts that are typically used for most hard turning applications. Again, those CBN inserts have minimal edge prep, so that their cutting edge is as sharp as possible.
As for threading, the shop has settled on titanium nitride (TIN) coated taps, and it has machined threads without coolant for the past 20 years. It also tries to mill and turn dry, with some machines fitted with air blast units used more for chip control than to keep tool cutting edges cool. Machining without coolant means that chips remain dry and are less likely to adhere to the part after machining. But more importantly, dry machining reduces the possibility of rust forming on the parts after machining.
The soil in those nearby cornfields is loosely similar to powder metal, in that it is a mixture of nutrients and organic material that come together to provide the base for what farmers hope will be a bumper crop. Along those lines, powder metal parts are a mixture of tiny metal and alloying elements (think talcum powder tiny) that, after being compacted together and heated, form a near-net-shape component.
Unfortunately (for the powder metal molders, anyway), secondary machining operations are typically required to bring the part to its final form. At this stage, the powder metal part may have an apparent hardness rating that isn't very daunting in terms of machineability (30 Rc, for example). However, those individual powders retain their individual hardnesses--which could be 50 Rc or higher--yen after the part is molded. A tool cutting into such material will be slicing through very small, very hard particles--in essence, it's pure abrasion. The number of powder metal components finding their way into the latest automobile designs continues to rise. In fact, such components are now used in more high-profile engine and transmission applications. Though powder metal parts have become the darling of the auto industry, they can still be a demon for the shops that must machine the finishing touches.
Gerlach Machine didn't set out with the intention of specializing in powder metal machining. The shop's Midwestern location had a lot to do with it. A number of local powder metal molders approached the company 25 years ago to machine the features that couldn't be created in the molding process. Many of these early parts required only boring operations to bring IDs to tolerance or tapping operations, because threads can't be formed in the mold.
In many cases, the ODs of the powder metal part the shop machines are molded to net shape. This is why these materials are especially attractive for gear components, as the traditional hobbing process to form gear teeth is not necessary. The molded teeth can then be induction-hardened for wear resistance, while the core remains soft to reduce the chance of fracture during operation.
It is because of molding process limitations that other part features, such as threads, require secondary machining. While holes that are parallel to the axis of mold compression can be molded, cross holes (those perpendicular to the compression axis) and grooves around the periphery of the part can't be molded. There are also limits to how thin part walls can be molded. In addition, machining may be necessary to reach the tighter tolerances and better surface finishes that are required of the latest automotive components.
Tooling Considerations
Most powder metal parts require turning and tapping operations rather than milling, which is why Mr. Gerlach's shop has more CNC lathes than mills. Because powder metal parts are near net shape, heavy roughing cuts are typically not required. Appropriate tooling, therefore, is that which is geared toward semifinishing and finishing duties. For turning operations, Mr. Gerlach primarily uses cermet inserts from Valenite (Madison Heights, Michigan). These inserts have essentially no edge prep in order to provide an extremely sharp cutting edge and free cutting action, which Mr. Gerlach has found effective in turning powder metal parts.
In certain instances, powder metal parts will be hardened via heat treating or induction hardening prior to machining work. Parts that are induction-hardened may require a finish machining pass because the quality of the finished surface was altered. For these hardened parts, the shop is more likely to use cubic boron nitride (CBN) inserts that are typically used for most hard turning applications. Again, those CBN inserts have minimal edge prep, so that their cutting edge is as sharp as possible.
As for threading, the shop has settled on titanium nitride (TIN) coated taps, and it has machined threads without coolant for the past 20 years. It also tries to mill and turn dry, with some machines fitted with air blast units used more for chip control than to keep tool cutting edges cool. Machining without coolant means that chips remain dry and are less likely to adhere to the part after machining. But more importantly, dry machining reduces the possibility of rust forming on the parts after machining.
Job Sites, Machine Tool-Style - Brief Article
During the Internet Revolution, have you utilized the Web to help with your employmentneeds? Chances are, you have.
Sites such as Monster.com (www.monster.com), Hot Jobs (www.hotjobs.com) and others have redefined how many folks look for and interact with prospective employees or employers.
But something's missing from these new channels, particularly when they're utilized for the unique employment demands of a machining environment.
Go visit any of the "Job Exchanges" online and odds are you'll find them touting that they "currently house 'XXX,XXX' job postings" (or words to that effect). Translated, that means you'll have to wade through listings for numerous categories far from the manufacturing realm to find something close to your needs. Or not.
But there is hope. A few recent additions to the Web job site landscape focus on the machining industry exclusively, and they just might be worth a visit and a bookmark MetalIndustryJobs.com is actually three sites that serve vertical sectors of the machining world--Fabricating, Die/Mold and Screw Machining.
MachineToolJobs.com also offers machining-related job postings, but it offers its listings in subcategories, rather than as separate sites.
Each of these offers added specificity that metalworking job or employee seekers will find useful. And, over time, the tools, partnerships and applications these sites develop should improve their overall industry focus.
For job links and many others, visit www.mmsonline.com/links.
Job Shop Site Of The Month
Metalcraft Technologies, Inc. serves the aerospace industries by way of milling, fabricating, finishing, tool design and engineering support. Its Web site (www.metalcraft.net) delivers a depth of information about who the company is and how it does what it does. The navigation used within this site is creative and effective.
Sites such as Monster.com (www.monster.com), Hot Jobs (www.hotjobs.com) and others have redefined how many folks look for and interact with prospective employees or employers.
But something's missing from these new channels, particularly when they're utilized for the unique employment demands of a machining environment.
Go visit any of the "Job Exchanges" online and odds are you'll find them touting that they "currently house 'XXX,XXX' job postings" (or words to that effect). Translated, that means you'll have to wade through listings for numerous categories far from the manufacturing realm to find something close to your needs. Or not.
But there is hope. A few recent additions to the Web job site landscape focus on the machining industry exclusively, and they just might be worth a visit and a bookmark MetalIndustryJobs.com is actually three sites that serve vertical sectors of the machining world--Fabricating, Die/Mold and Screw Machining.
MachineToolJobs.com also offers machining-related job postings, but it offers its listings in subcategories, rather than as separate sites.
Each of these offers added specificity that metalworking job or employee seekers will find useful. And, over time, the tools, partnerships and applications these sites develop should improve their overall industry focus.
For job links and many others, visit www.mmsonline.com/links.
Job Shop Site Of The Month
Metalcraft Technologies, Inc. serves the aerospace industries by way of milling, fabricating, finishing, tool design and engineering support. Its Web site (www.metalcraft.net) delivers a depth of information about who the company is and how it does what it does. The navigation used within this site is creative and effective.
Saturday, December 23, 2006
Bundling With Machine Tools - Brief Article
The company has partnered with Servo Products Company for the bundling of SFP Express programming software with Servo's SAM, IMPACT and SERVO II machine tool product lines. With this software bundled with its machine tools, Servo's customers will have access to powerful shopfloor programming functionality at their machine tools, allowing them to realize greater efficiencies that significantly reduce cycle times and scrap.
SFP Express is an entry-level CNC programming and graphical editing system specialized for the shopfloor environment. The graphical user interface, specifically timed for the machinist, enables users to start making parts the same day they install the system. It includes features such as optimized geometry creation, graphical process verification and built-in training with step-through wizards to speed program creation and eliminate programming errors. Servo Products says SFP Express is a natural extension of its new Windows NT based CNC software
SFP Express is an entry-level CNC programming and graphical editing system specialized for the shopfloor environment. The graphical user interface, specifically timed for the machinist, enables users to start making parts the same day they install the system. It includes features such as optimized geometry creation, graphical process verification and built-in training with step-through wizards to speed program creation and eliminate programming errors. Servo Products says SFP Express is a natural extension of its new Windows NT based CNC software
Cylinder head porting on a turn/mill machine
CNC milling is the machining that an automotive cylinder head is likely to require. Turning is not a capability you would look for in a machine tool meant to run such a part.
Indeed, when Mazak (Florence, Kentucky) first started to work on a better machining process for the benefit of a maker of high-performance heads, the machine tool company's first attempt involved a five-axis machining center. But Robin Cave, national applications engineer for Mazak, says that a more capable and efficient process has now been developed for an Integrex machine.
"Integrex" is the company's brand name for a family of CNC turn/mill machines. The term is traditionally associated with multitasking lathes.
However, the machine tool proving effective at cylinder head porting is no lathe, says Mr. Cave. It's an "e"-series Integrex, and this distinction is significant. Earlier machines in the family have the slanting structure of a lathe, with the wedge-shaped work zone causing Y-axis travel to get progressively more limited toward the bottom of the machine. The e-series design gives the machine's milling spindle the freedom to move like a machining center can move, with a box-shaped work zone permitting the same full field of travel at the machine's top or bottom. The unit is still a turn/mill machine, but while the traditional Integrex might be thought of as a lathe effective for milling, the e-series version is essentially a machining center effective for turning.
The machine permits full five-axis milling. While B-axis motion comes from the tilting of the e-series machine's spindle head, C-axis motion comes from the rotation of the horizontal spindle used for turning. The maker of cylinder heads does no turning on this machine, but instead uses this turning spindle exclusively in the five-axis mode. This direct-driven rotation does not involve a worm gear, unlike a previous process in which the company used indexers on vertical machining centersThe milling cutter is a long-reach lollipop tool capable of cutting from various engagement angles along the inside of a complex channel. Mazak is working with cutting tool supplier Kennametal (Latrobe, Pennsylvania) to develop a diamond-coated version of this tool. The higher spindle speeds on the newer machine (relative to the previous process) will make it possible to use this tool productively. Comparison testing between coated and uncoated tooling in this application shows a clear improvement in finish. With a coated tool incorporated into the process, says Mr. Cave, it may be possible to perform this porting solely through CNC machining, without a subsequent need for finishing by hand
Indeed, when Mazak (Florence, Kentucky) first started to work on a better machining process for the benefit of a maker of high-performance heads, the machine tool company's first attempt involved a five-axis machining center. But Robin Cave, national applications engineer for Mazak, says that a more capable and efficient process has now been developed for an Integrex machine.
"Integrex" is the company's brand name for a family of CNC turn/mill machines. The term is traditionally associated with multitasking lathes.
However, the machine tool proving effective at cylinder head porting is no lathe, says Mr. Cave. It's an "e"-series Integrex, and this distinction is significant. Earlier machines in the family have the slanting structure of a lathe, with the wedge-shaped work zone causing Y-axis travel to get progressively more limited toward the bottom of the machine. The e-series design gives the machine's milling spindle the freedom to move like a machining center can move, with a box-shaped work zone permitting the same full field of travel at the machine's top or bottom. The unit is still a turn/mill machine, but while the traditional Integrex might be thought of as a lathe effective for milling, the e-series version is essentially a machining center effective for turning.
The machine permits full five-axis milling. While B-axis motion comes from the tilting of the e-series machine's spindle head, C-axis motion comes from the rotation of the horizontal spindle used for turning. The maker of cylinder heads does no turning on this machine, but instead uses this turning spindle exclusively in the five-axis mode. This direct-driven rotation does not involve a worm gear, unlike a previous process in which the company used indexers on vertical machining centersThe milling cutter is a long-reach lollipop tool capable of cutting from various engagement angles along the inside of a complex channel. Mazak is working with cutting tool supplier Kennametal (Latrobe, Pennsylvania) to develop a diamond-coated version of this tool. The higher spindle speeds on the newer machine (relative to the previous process) will make it possible to use this tool productively. Comparison testing between coated and uncoated tooling in this application shows a clear improvement in finish. With a coated tool incorporated into the process, says Mr. Cave, it may be possible to perform this porting solely through CNC machining, without a subsequent need for finishing by hand
Friday, December 22, 2006
Tool measurement system works inside grinder
Users can rapidly measure the shape, profile and outer diameter of a cutting tool while it is clamped in the grinding machine, then compare measurements to ideal tool geometry with ANCA's iView system. The benefit is that discrepancies can then be addressed immediately, without the need to remove the tool and measure off-machine. Measured data can be fed back into the grinding cycle for automatic compensation.
A cost-effective solution for high-precision tool measurements, the system includes software that works seamlessly with its machine operating software and a camera that mounts easily inside the tool and cutter grinder in less than 1 minute, the company says. It may be stored outside the machine when not in use. A single system can serve up to four grinding machines and has a standard magnification of 300:1. The accuracy of the system is 2 microns.
The system's software generates the ideal shape for standard tool geometries and protracts it over the actual tool image. It can import DXF overlay files for complex profiles. A high-visibility image of the ground tool as taken by the system's camera is compared to the ideal (as designed) overlay shape. Tolerance bandwidth can be specified and graphically displayed over the tool image. Automatic generation of tangent to the profile simplifies the measurement processSemiautomatic measurement mode means the tool overlay is automatically positioned over the corresponding point on the ground tool. The operator acknowledges the measured point, and the machine advances to the next predetermined point. A 0.005-mm grid or auto shadowgraph can be superimposed over the tool for measurement. Images can be stored in graphical file formats so they can be shared via e-mail. Measurement protocol can also be automatically generated and printed. The system can measure three-point angle; it also offers three-point radium measurement and two-point distance measurement.
A cost-effective solution for high-precision tool measurements, the system includes software that works seamlessly with its machine operating software and a camera that mounts easily inside the tool and cutter grinder in less than 1 minute, the company says. It may be stored outside the machine when not in use. A single system can serve up to four grinding machines and has a standard magnification of 300:1. The accuracy of the system is 2 microns.
The system's software generates the ideal shape for standard tool geometries and protracts it over the actual tool image. It can import DXF overlay files for complex profiles. A high-visibility image of the ground tool as taken by the system's camera is compared to the ideal (as designed) overlay shape. Tolerance bandwidth can be specified and graphically displayed over the tool image. Automatic generation of tangent to the profile simplifies the measurement processSemiautomatic measurement mode means the tool overlay is automatically positioned over the corresponding point on the ground tool. The operator acknowledges the measured point, and the machine advances to the next predetermined point. A 0.005-mm grid or auto shadowgraph can be superimposed over the tool for measurement. Images can be stored in graphical file formats so they can be shared via e-mail. Measurement protocol can also be automatically generated and printed. The system can measure three-point angle; it also offers three-point radium measurement and two-point distance measurement.
Cylinder head porting on a turn/mill machine
CNC milling is the machining that an automotive cylinder head is likely to require. Turning is not a capability you would look for in a machine tool meant to run such a part.
Indeed, when Mazak (Florence, Kentucky) first started to work on a better machining process for the benefit of a maker of high-performance heads, the machine tool company's first attempt involved a five-axis machining center. But Robin Cave, national applications engineer for Mazak, says that a more capable and efficient process has now been developed for an Integrex machine.
"Integrex" is the company's brand name for a family of CNC turn/mill machines. The term is traditionally associated with multitasking lathes.
However, the machine tool proving effective at cylinder head porting is no lathe, says Mr. Cave. It's an "e"-series Integrex, and this distinction is significant. Earlier machines in the family have the slanting structure of a lathe, with the wedge-shaped work zone causing Y-axis travel to get progressively more limited toward the bottom of the machine. The e-series design gives the machine's milling spindle the freedom to move like a machining center can move, with a box-shaped work zone permitting the same full field of travel at the machine's top or bottom. The unit is still a turn/mill machine, but while the traditional Integrex might be thought of as a lathe effective for milling, the e-series version is essentially a machining center effective for turning.
The machine permits full five-axis milling. While B-axis motion comes from the tilting of the e-series machine's spindle head, C-axis motion comes from the rotation of the horizontal spindle used for turning. The maker of cylinder heads does no turning on this machine, but instead uses this turning spindle exclusively in the five-axis mode. This direct-driven rotation does not involve a worm gear, unlike a previous process in which the company used indexers on vertical machining centersThe milling cutter is a long-reach lollipop tool capable of cutting from various engagement angles along the inside of a complex channel. Mazak is working with cutting tool supplier Kennametal (Latrobe, Pennsylvania) to develop a diamond-coated version of this tool. The higher spindle speeds on the newer machine (relative to the previous process) will make it possible to use this tool productively. Comparison testing between coated and uncoated tooling in this application shows a clear improvement in finish. With a coated tool incorporated into the process, says Mr. Cave, it may be possible to perform this porting solely through CNC machining, without a subsequent need for finishing by hand
Indeed, when Mazak (Florence, Kentucky) first started to work on a better machining process for the benefit of a maker of high-performance heads, the machine tool company's first attempt involved a five-axis machining center. But Robin Cave, national applications engineer for Mazak, says that a more capable and efficient process has now been developed for an Integrex machine.
"Integrex" is the company's brand name for a family of CNC turn/mill machines. The term is traditionally associated with multitasking lathes.
However, the machine tool proving effective at cylinder head porting is no lathe, says Mr. Cave. It's an "e"-series Integrex, and this distinction is significant. Earlier machines in the family have the slanting structure of a lathe, with the wedge-shaped work zone causing Y-axis travel to get progressively more limited toward the bottom of the machine. The e-series design gives the machine's milling spindle the freedom to move like a machining center can move, with a box-shaped work zone permitting the same full field of travel at the machine's top or bottom. The unit is still a turn/mill machine, but while the traditional Integrex might be thought of as a lathe effective for milling, the e-series version is essentially a machining center effective for turning.
The machine permits full five-axis milling. While B-axis motion comes from the tilting of the e-series machine's spindle head, C-axis motion comes from the rotation of the horizontal spindle used for turning. The maker of cylinder heads does no turning on this machine, but instead uses this turning spindle exclusively in the five-axis mode. This direct-driven rotation does not involve a worm gear, unlike a previous process in which the company used indexers on vertical machining centersThe milling cutter is a long-reach lollipop tool capable of cutting from various engagement angles along the inside of a complex channel. Mazak is working with cutting tool supplier Kennametal (Latrobe, Pennsylvania) to develop a diamond-coated version of this tool. The higher spindle speeds on the newer machine (relative to the previous process) will make it possible to use this tool productively. Comparison testing between coated and uncoated tooling in this application shows a clear improvement in finish. With a coated tool incorporated into the process, says Mr. Cave, it may be possible to perform this porting solely through CNC machining, without a subsequent need for finishing by hand
Machine Vision Software supports 3rd party cameras
Providing optical character recognition as well as security and data collection for achieving CFR Part 11 compliance, iNspect Vision Appliance software features 1D barcode and 2D matrix reader tools, including support for QR code. It is also equipped with iLabel product for verifying placement and quality of labels on packaged goods. Software offers machine vision solution for range of industries, from precision metrology to pharmaceutical packaging.
********************
STUTTGART, GERMANY (November 8, 2005) - ipd, a DALSA Coreco Group, today announced the release of Version 1.4 of the company's easy-to-use Vision Appliance software, iNspect. Packed with new capabilities, such as Optical Character Recognition (OCR), and advanced user controls, such as security and data collection for achieving CFR Part 11 compliance, iNspect offers an attractive machine vision solution to a broad range of industries, from precision metrology to pharmaceutical packaging.
"The evolution of our Vision Appliance software is very exciting. We are continually adding new features and capabilities without compromising the user interface that customers have come to appreciate," said Steve Geraghty, Director of ipd. "Version 1.4 demonstrates our commitment to bring simplified machine vision technology to ALL users. With iNspect now supporting 3rd party hardware platforms, such as IEEE 1394 cameras, users have an easy-to-use inspection tool with widespread applicability and a choice of hardware deployment options In addition to OCR, security and data collection tools, iNspect includes new and improved versions of its 1D barcode and 2D matrix reader tools, including support for QR code, along with many other features and enhancements. Furthermore, the iNspect software package now includes ipd's iLabel product, which was designed specifically for the Packaging Industry and is used for verifying the placement and quality of labels on packaged goods.
The iNspect product is offered as a standalone software package for use with 3rd party cameras, or combined with ipd's line of Vision Appliance hardware products. Pricing starts at $1,495.
More information about ipd and its product offerings-including Vision Appliances, NetSight II(TM) Vision Systems and Sherlock(TM) inspection software-can be found on the company
About ipd
ipd's mission is simple: to provide robust, intelligent and easy-to-use machine vision solutions to improve quality throughout the manufacturing process. Headquartered in Billerica, MA, ipd manufactures hardware and software machine vision products for end users, OEMs and systems integrators worldwide. ipd offers three product lines that simplify machine vision tasks: iNspect based vision appliances, Sherlock inspection software and the NetSight II family of pre-integrated machine vision systems. ipd is a group within DALSA Coreco (St. Laurent, Canada), a leader in the design and development of hardware and software for high-performance computer vision applications
********************
STUTTGART, GERMANY (November 8, 2005) - ipd, a DALSA Coreco Group, today announced the release of Version 1.4 of the company's easy-to-use Vision Appliance software, iNspect. Packed with new capabilities, such as Optical Character Recognition (OCR), and advanced user controls, such as security and data collection for achieving CFR Part 11 compliance, iNspect offers an attractive machine vision solution to a broad range of industries, from precision metrology to pharmaceutical packaging.
"The evolution of our Vision Appliance software is very exciting. We are continually adding new features and capabilities without compromising the user interface that customers have come to appreciate," said Steve Geraghty, Director of ipd. "Version 1.4 demonstrates our commitment to bring simplified machine vision technology to ALL users. With iNspect now supporting 3rd party hardware platforms, such as IEEE 1394 cameras, users have an easy-to-use inspection tool with widespread applicability and a choice of hardware deployment options In addition to OCR, security and data collection tools, iNspect includes new and improved versions of its 1D barcode and 2D matrix reader tools, including support for QR code, along with many other features and enhancements. Furthermore, the iNspect software package now includes ipd's iLabel product, which was designed specifically for the Packaging Industry and is used for verifying the placement and quality of labels on packaged goods.
The iNspect product is offered as a standalone software package for use with 3rd party cameras, or combined with ipd's line of Vision Appliance hardware products. Pricing starts at $1,495.
More information about ipd and its product offerings-including Vision Appliances, NetSight II(TM) Vision Systems and Sherlock(TM) inspection software-can be found on the company
About ipd
ipd's mission is simple: to provide robust, intelligent and easy-to-use machine vision solutions to improve quality throughout the manufacturing process. Headquartered in Billerica, MA, ipd manufactures hardware and software machine vision products for end users, OEMs and systems integrators worldwide. ipd offers three product lines that simplify machine vision tasks: iNspect based vision appliances, Sherlock inspection software and the NetSight II family of pre-integrated machine vision systems. ipd is a group within DALSA Coreco (St. Laurent, Canada), a leader in the design and development of hardware and software for high-performance computer vision applications
Thursday, December 21, 2006
A winner's view of the machine tool industry
Determination and technical ingenuity enabled Haas Automation to find a respected place in US manufacturing. In this exclusive article, the company's founder, Gene Haas, responds to questions from Manufacturing Engineering on the business
and technology of machine tools.
Manufacturing Engineering: What future do you see for North American manufacturers of machine tools? Gene Haas: If you look far into the future, you'll become very depressed over the situation facing American machine tool builders. Over the past 30 years, imports have gained a larger share of the market in the US every year. Currently they control around two-thirds. This is a very scary truth.
But automation can level the playing field. We've become successful by using our own product to reduce our production costs. As a result, we are not as sensitive to the high cost of labor as companies that use less automation. We've demonstrated that it's possible to build an entire machine in the US and be very successful.
We find it disappointing that so many US builders have trouble competing with imports. Some say they only import the iron and add the high-tech controls to it. Some say they only import the control and add the machine iron. But we-and a small number of other companies-have demonstrated that it's still possible to do it all. Unless this attitude spreads throughout manufacturing, the US machine tool builder may disappear.
ME: How much more consolidation do you expect to see in the machine tool industry in the US, Japan, and Europe?
Haas: The US machine tool industry is consolidating because small builders are having trouble surviving and the larger builders are trying to buy market share. This trend will continue as long as the US builders' market share is falling.
It's also true that consolidation is occurring across international boundaries. In the near future, it may be difficult to determine what country a builder is from, just as it's difficult today to tell where your car was built.
Because supply continues to be higher than demand, there will continue to be consolidation in the machine tool industry on all continents. Sustained over-supply is creating price pressures, and many machine tool builders are not profitable today. Even Southeast Asia isn't immune to this phenomenon. Consolidation is usually associated with shrinking. To survive, machine tool companies must become global and increase market share, so they can have the volume they need to make them price-competitive.
ME: Given the number of low-wage manufacturers in the world, how much manufacturing work will continue to be done in high-wage countries like the US?
Haas: The fact that machine builders in the US are in decline is probably closely related to the fact that manufacturing in general is leaving this country. It's a simple fact that it appears to be cheaper today to make most things outside of the US. The problem with this perception is that it's short-sighted.
We can only keep a great deal of manufacturing in this country by getting much smarter about the way we manufacture. As I said before, automation is the key to reducing manufacturing costs and thus keeping manufacturing here. Low wages affect areas where a great deal of labor is required. Replacing labor with automation wherever it's possible to do so reduces overall cost through labor savings, more consistent production, and better quality.
People in the United States must remember what wealth is and where it comes from. Wealth does not come from cooking hamburgers. Wealth does not come from cleaning one another's windows. Wealth consists primarily of "things." If we continue to import "things" we will, by definition, become less wealthy. At the same time, the nations who do manufacture things will become more valuable to our economy.
ME: How will the Internet change the way your company does business?
Haas: The Internet has already changed our business. We have online quote generation today, along with full product line and options information. We also use the Internet for service support. Software updates and automatic parameter checking can be done over the Internet. We fully expect this trend to continue and to involve sales, support, and service more and more. The Internet will become the universal information source. It will give our customers access to the information they need to make purchasing decisions.
ME: How will the role of your distributors change as more and more business is done via the Internet?
Haas: The role of our distributors is already changing. We have spent the last couple of years developing a common approach to the operations of our dealers. They already use the Internet for sales, service, and training. Ultimately, the distributors will become service organizations-not information sources. Because of the Internet, distributors will provide more technical support to their customers and less sales/information type support.
Machine tool basics--Part 1
This article series is not a comprehensive explanation of manufacturing equipment, but a once-over-lightly discussion of how the major chipmaking machine tools, and supporting elements function. We hope they will help two groups of people: The first consists of recent manufacturing engineering graduates who might need more information about the tools of their trade. The second group are those who have worked in nonmanufacturing fields, but are transferred to a position of responsibility in manufacturing, and find themselves challenged when it comes to knowledge of industry basics.
Turning, drilling, and milling are the three basic manufacturing techniques that use a tool to remove metal. Recently there has been a move to multitasking machine tools in which a single machine performs all three functions, plus grinding in some cases. These multifunction machines can work on a variety of parts and carry out more operations in a single setup. Despite this blurring of distinctions among machine tools the basic operations are still unchangedThis process uses the relative motion between a rotating, multiedge cutter and a workpiece to generate both flat and curved surfaces. During rotation, each tooth of the cutter alternately enters and leaves the cut, removing small amounts of material (chips). Called interrupted cutting, it results in more mechanical shock to the part and tool than occurs with continuous cutting, which is characteristic of turning.
Milling is done by a variety of machines. Simple stand-alone machines perform a minimal number of functions and are chiefly used in job shops. Machining centers have a wider variety of tools and sometimes have additional live spindles for drilling, turning, and even grinding. Milling functions can also be a major part of transfer lines. In these high-volume applications milling is often simple and repetitive.
The capabilities of a milling machine or machining center are measured by motor horsepower, maximum spindle speed, spindle taper size (which determines the size of the toolholder and tool), worktable size, and the amount of cutting tool travel.
Much toolmaking, prototype machining, and low-volume milling machining is done on small, lightweight, vertical spindle ram-type machines called knee mills. They are rarely used for production work.
This design includes a knee-and-column support for the machine table, hence the name, "knee mill." Base and column are one piece and the knee travels vertically on the column. The knee supports the saddle and table. The saddle moves in-and-out from the column, and the table moves side-to-side.
The ram atop the column supports the head and provides horizontal motion in-and-out from the column, parallel to the saddle movement.
At the front of the ram is the milling head, with motor, toolhead, speed-and-feed controls, quill, and spindle. The nonrotating quill holds the rotating spindle and allows the spindle to be fed on its own axis. Tilting the spindle axis allows milling or drilling at an angle to the table. Cutting tools are held in drill chucks or in collets, that are, in turn, held in the spindle, or mounted directly in the spindle.
On manual mills, the operator sets the machine parameters for each cut, positions the tool for the start of the cut, directs all of the machine's motions manually, and changes the settings and tools after each operation.
The two main types of machining centers are the vertical spindle machining center (VMC) and the horizontal spindle machining center (HMC). A third, less-- common type is the universal machine, which is capable of both vertical and horizontal spindle orientations.
Verticals may be preferred over HMCs when working primarily on a single work face. When a rotary table or indexer is added to the VMC machine table, more than one side of a workpiece or a multiple-part setup can be machined without operator intervention. Rotary devices either index the part to present a new work surface to the spindle, or they rotate it slowly, under full CNC control, while it's machined.
There are the three linear axes:
X defines side-to-side table motion,
Y defines in-and-out table motion,
Z defines head movement up and down the column,
B and C may be added as rotary axes, usually as a rotating spindle or mounting table.
T-slots in the machine table are still the primary means of holding work and workholding devices to a machining center table.
Because an HMC's spindle is orientated horizontally, it may be preferred for heavy, boxy parts. Chips fall out of the way better on a horizontal machine, and more workholding and automation options may be possible than on a vertical machine.
The HMC table typically rotates to expose four sides of the workpiece, or fixture, to the tools.
Tombstones, commonly used on HMCs, come in a wide variety of configurations to hold multiple parts. The part program is written to machine all parts on the tombstone before shuttling it out of the machine.
Turning, drilling, and milling are the three basic manufacturing techniques that use a tool to remove metal. Recently there has been a move to multitasking machine tools in which a single machine performs all three functions, plus grinding in some cases. These multifunction machines can work on a variety of parts and carry out more operations in a single setup. Despite this blurring of distinctions among machine tools the basic operations are still unchangedThis process uses the relative motion between a rotating, multiedge cutter and a workpiece to generate both flat and curved surfaces. During rotation, each tooth of the cutter alternately enters and leaves the cut, removing small amounts of material (chips). Called interrupted cutting, it results in more mechanical shock to the part and tool than occurs with continuous cutting, which is characteristic of turning.
Milling is done by a variety of machines. Simple stand-alone machines perform a minimal number of functions and are chiefly used in job shops. Machining centers have a wider variety of tools and sometimes have additional live spindles for drilling, turning, and even grinding. Milling functions can also be a major part of transfer lines. In these high-volume applications milling is often simple and repetitive.
The capabilities of a milling machine or machining center are measured by motor horsepower, maximum spindle speed, spindle taper size (which determines the size of the toolholder and tool), worktable size, and the amount of cutting tool travel.
Much toolmaking, prototype machining, and low-volume milling machining is done on small, lightweight, vertical spindle ram-type machines called knee mills. They are rarely used for production work.
This design includes a knee-and-column support for the machine table, hence the name, "knee mill." Base and column are one piece and the knee travels vertically on the column. The knee supports the saddle and table. The saddle moves in-and-out from the column, and the table moves side-to-side.
The ram atop the column supports the head and provides horizontal motion in-and-out from the column, parallel to the saddle movement.
At the front of the ram is the milling head, with motor, toolhead, speed-and-feed controls, quill, and spindle. The nonrotating quill holds the rotating spindle and allows the spindle to be fed on its own axis. Tilting the spindle axis allows milling or drilling at an angle to the table. Cutting tools are held in drill chucks or in collets, that are, in turn, held in the spindle, or mounted directly in the spindle.
On manual mills, the operator sets the machine parameters for each cut, positions the tool for the start of the cut, directs all of the machine's motions manually, and changes the settings and tools after each operation.
The two main types of machining centers are the vertical spindle machining center (VMC) and the horizontal spindle machining center (HMC). A third, less-- common type is the universal machine, which is capable of both vertical and horizontal spindle orientations.
Verticals may be preferred over HMCs when working primarily on a single work face. When a rotary table or indexer is added to the VMC machine table, more than one side of a workpiece or a multiple-part setup can be machined without operator intervention. Rotary devices either index the part to present a new work surface to the spindle, or they rotate it slowly, under full CNC control, while it's machined.
There are the three linear axes:
X defines side-to-side table motion,
Y defines in-and-out table motion,
Z defines head movement up and down the column,
B and C may be added as rotary axes, usually as a rotating spindle or mounting table.
T-slots in the machine table are still the primary means of holding work and workholding devices to a machining center table.
Because an HMC's spindle is orientated horizontally, it may be preferred for heavy, boxy parts. Chips fall out of the way better on a horizontal machine, and more workholding and automation options may be possible than on a vertical machine.
The HMC table typically rotates to expose four sides of the workpiece, or fixture, to the tools.
Tombstones, commonly used on HMCs, come in a wide variety of configurations to hold multiple parts. The part program is written to machine all parts on the tombstone before shuttling it out of the machine.
Wednesday, December 20, 2006
Machine Tools are available with VDI-driven units
Mazak Quick Turn Nexus, Super Quick Turn, and Multiplex-series machine tools are offered with self-contained VDI-driven units that enable multiple part processes such as milling, drilling, and turning on same part in one setup. Available with KM interface or ER collet style, units feature sealed spindle bearings, recessed spindle configuration, and through-coolant capabilities up to 1,500 psi. Tool setups can be pre-staged offline.
********************
(LATROBE, PA) - Self-contained VDI-driven units from Kennametal for Mazak Quick Turn Nexus, Super Quick Turn, and Multiplex-series machine tools enable multiple part processes such as milling, drilling, and turning on the same part in a single setup. Available with either the Kennametal KM interface or standard ER collet style, setups can be accomplished accurately and efficiently. Since the units make offsets known quantities, tool setups can even be pre-staged offline for greater productivity gains. As Product Manager Curtis Rellick succinctly puts it, "Less setup time, more spindle time."
Individual driven units are designed to work specifically with each model variation of the Mazak machine tools for maximum equipment capability. The units feature high-precision gears and sealed spindle bearings for smooth operation, and a recessed spindle configuration that reduces spindle stress and increases bearing life. High-quality seals and O-rings enhance protection against external contamination. Through-coolant capabilities of up to 1500 psi are available.The driven units increase rigidity by design, enabling higher spindle speeds and feeds and longer tool life. Product life averages of three years before repair or rebuilding are required, compared to nine to 12 months for other drive spindles. One customer described the advantages of a driven unit running a four-tooth, 1.57-in. face mill rough-cutting cast stainless steel at 600 SFM at a depth of 0.07 inches taking a full 1-inch width of cut. "Our maintenance personnel were frequently rebuilding competitive units due to bad gear backlash and blown spindles from the heavy interrupted cut," he says. "Despite the pounding the Kennametal unit takes, we have experienced better tool life, increased surface finishes, and no downtime with broken spindles/gears. That translates into productivity and dollars that go right to the bottom line."
********************
(LATROBE, PA) - Self-contained VDI-driven units from Kennametal for Mazak Quick Turn Nexus, Super Quick Turn, and Multiplex-series machine tools enable multiple part processes such as milling, drilling, and turning on the same part in a single setup. Available with either the Kennametal KM interface or standard ER collet style, setups can be accomplished accurately and efficiently. Since the units make offsets known quantities, tool setups can even be pre-staged offline for greater productivity gains. As Product Manager Curtis Rellick succinctly puts it, "Less setup time, more spindle time."
Individual driven units are designed to work specifically with each model variation of the Mazak machine tools for maximum equipment capability. The units feature high-precision gears and sealed spindle bearings for smooth operation, and a recessed spindle configuration that reduces spindle stress and increases bearing life. High-quality seals and O-rings enhance protection against external contamination. Through-coolant capabilities of up to 1500 psi are available.The driven units increase rigidity by design, enabling higher spindle speeds and feeds and longer tool life. Product life averages of three years before repair or rebuilding are required, compared to nine to 12 months for other drive spindles. One customer described the advantages of a driven unit running a four-tooth, 1.57-in. face mill rough-cutting cast stainless steel at 600 SFM at a depth of 0.07 inches taking a full 1-inch width of cut. "Our maintenance personnel were frequently rebuilding competitive units due to bad gear backlash and blown spindles from the heavy interrupted cut," he says. "Despite the pounding the Kennametal unit takes, we have experienced better tool life, increased surface finishes, and no downtime with broken spindles/gears. That translates into productivity and dollars that go right to the bottom line."
Machine tool consumption up 6% - Brief Article
CHICAGO -- U.S. machine tool consumption totaled $182.66 million in March, up 6 percent from a revised $172.32 million the previous month but down 42.2 percent from $315.8 million in March 2001, according to a joint report by the American Machine Tool Distributors' Association, Rockville, Md., and the Association for Manufacturing Technologies (AMT), McLean, Va. "The poor start to the 2002 machine tool market illustrates that the general economic recovery has not filtered down to manufacturing," said Don F. Carlson, AMT president. "While economic recoveries usually start without a pickup in investments in manufacturing, they never last without sustained manufacturing output." Machine tool consumption in the first quarter totaled $513.62 million, down 35.2 percent fromlast year
Tuesday, December 19, 2006
Versatile Machine Tools
Okuma America Corporation is the US-based affiliate of Okuma Corporation, a world leader in the development of computer numeric controls (CNC) and machining technology, founded in 1898 in Nagoya, Japan.
Okuma is known for its technology leadership and world-class manufacturing, product quality, and dedication to customer service. Okuma products are used in the automotive industry, aerospace and defense, construction and farm equipment, energy, medical, mold and die, and fluidpower industries.
Machines include vertical and horizontal machining centers, lathes, double column machining centers, grinders, and wheel machines that offer users high throughput, high accuracy, and reliable solutions to production machining operations.
Using Mechatronics, our full-circle approach to equipment design, we build machines that have the exact balance of power, speed and size to meet most any application-machines that can hold tight tolerances, perform more sophisticated cuts, and create precision-crafted parts time and again.Okuma has entered into a partnership agreement with the National hot Rod Association and has been named Official Machine Tool Sponsor of the NHRA. This partnership is part of Okuma's High Performance Motorsports Industry program.
With Okuma as your machining partner you are free to imagine a more productive, cost-effective solution, knowing we can work together to make it happen.Okuma has entered into a partnership agreement with the National hot Rod Association and has been named Official Machine Tool Sponsor of the NHRA. This partnership is part of Okuma's High Performance Motorsports Industry program.
With Okuma as your machining partner you are free to imagine a more productive, cost-effective solution, knowing we can work together to make it happen.
Cutting Tool Supplier's Involvement Helps Security Systems Manufacturer Optimize Machining
Pelco (Clovis, California), the world's leading manufacturer of video security systems, is one firm that appreciates the value of involving key suppliers early on. When developing its important new stainless steel product, Pelco called in cutting tool supplier Seco-Carboloy.
The need for greater surveillance around ships, defense installations, power plants and other locations within the marine environment recently led Pelco to begin offering an explosion-proof pan-and-tilt video security system for marine applications. "Our product engineers had a conceptual idea of how to introduce the stainless steel product," explains Lolo Garza, machine shop manager at Pelco.
Daryl Serna, Seco-Carboloy Senior Technical Specialist says, "We came to the conclusion that machining the component from one large 316L stainless steel billet would be the most cost-efficient way to go."
Seco-Carboloy employed its perfoMAX indexable drills with T300D coated inserts, and boring bars using grade TP400 for finishing. The result was a reduction in total cycle time (from previous method) per module from twelve minutes to just threeErgonomic Tool cuts, crimps, and strips wire in one step
Designed for auto repair, PWCS9 features construction cold forged from alloy steel and heat-treated. Tool provides functionality for wire stripping, bolt cutting, and terminal crimping. It strips stranded wire from AWG 20-10 and solid wire from AWG 16-8. In addition to bi-molded, soft-grip handles, tool features narrow pliers tip, lock that maintains closed position during transport or storage, and internal spring that maintains open position during use.
********************
FUNCTIONAL DESIGN COMBINES ERGONOMICS AND VERSATILITY
KENOSHA, Wis., November 28, 2005 - In response to technicians' demands for a high-quality wire stripper/cutter/crimper that would better meet their needs for auto repair, Snap-on has introduced the PWCS9 wire stripper.
The PWCS9 is specifically designed to work on auto wiring and is cold forged from special alloy steel and heat-treated to offer technicians a tool of superior durability and lasting performance. An improvement from the traditional stamped units, the PWCS9's manufacturing process also helps maintain consistency from tool to tool, providing the same performance for every user. This wire stripper also helps technicians complete several tasks while using only one tool - wire stripping, bolt cutting and terminal crimping. These features allow the tool to strip stranded wire from AWG20 to 10, solid wire from AWG16 to 8, crimp insulated and non-insulated terminals, shear wires, and cut both no. 6 and no. 8 machine screws. The wire stripper also features:
- A narrow pliers tip for grabbing or pulling wire
- A lock to keep the tool in the closed position during transport or when it's in storage
- A patented internal spring that will keep the tool in the open, ready-to-use position when technicians need it handy
- Bi-molded, soft-grip handles that provide technicians greater comfort and decrease fatigue incurred from use
Customers can find out more about the Snap-on[R] PWCS9 wire stripper/cutter/crimper by contacting their local Snap-on representative, visiting www.snapon.com or calling toll free 877-SNAPON-2 (877-762-7662).
Snap-on Tools Company, LLC is a subsidiary of Snap-on Incorporated, a leading global developer, manufacturer and marketer of tool and equipment solutions for professional tool users. Product lines include hand and power tools, diagnostics and shop equipment, tool storage products, diagnostics software and other solutions for the transportation service, industrial, government, education, agricultural, and other commercial applications, including construction and electrical. Products are sold through its franchised dealer van, company-direct sales and distributor channels, as well as over the Internet at snapon.com. Founded in 1920, Snap-on is a $2 billion-plus, S&P 500 company headquartered in Kenosha, Wis., and employs approximately 11,400 people worldwide
********************
FUNCTIONAL DESIGN COMBINES ERGONOMICS AND VERSATILITY
KENOSHA, Wis., November 28, 2005 - In response to technicians' demands for a high-quality wire stripper/cutter/crimper that would better meet their needs for auto repair, Snap-on has introduced the PWCS9 wire stripper.
The PWCS9 is specifically designed to work on auto wiring and is cold forged from special alloy steel and heat-treated to offer technicians a tool of superior durability and lasting performance. An improvement from the traditional stamped units, the PWCS9's manufacturing process also helps maintain consistency from tool to tool, providing the same performance for every user. This wire stripper also helps technicians complete several tasks while using only one tool - wire stripping, bolt cutting and terminal crimping. These features allow the tool to strip stranded wire from AWG20 to 10, solid wire from AWG16 to 8, crimp insulated and non-insulated terminals, shear wires, and cut both no. 6 and no. 8 machine screws. The wire stripper also features:
- A narrow pliers tip for grabbing or pulling wire
- A lock to keep the tool in the closed position during transport or when it's in storage
- A patented internal spring that will keep the tool in the open, ready-to-use position when technicians need it handy
- Bi-molded, soft-grip handles that provide technicians greater comfort and decrease fatigue incurred from use
Customers can find out more about the Snap-on[R] PWCS9 wire stripper/cutter/crimper by contacting their local Snap-on representative, visiting www.snapon.com or calling toll free 877-SNAPON-2 (877-762-7662).
Snap-on Tools Company, LLC is a subsidiary of Snap-on Incorporated, a leading global developer, manufacturer and marketer of tool and equipment solutions for professional tool users. Product lines include hand and power tools, diagnostics and shop equipment, tool storage products, diagnostics software and other solutions for the transportation service, industrial, government, education, agricultural, and other commercial applications, including construction and electrical. Products are sold through its franchised dealer van, company-direct sales and distributor channels, as well as over the Internet at snapon.com. Founded in 1920, Snap-on is a $2 billion-plus, S&P 500 company headquartered in Kenosha, Wis., and employs approximately 11,400 people worldwide
Produce good surface finishes without tool breakage
Useful for die mold operations that require accuracy, short cycle times and good surface finishes, Makino's V-series vertical machining centers feature a 30,000-rpm spindle and compact footprint.
Machine rigidity and low vibration that result from the core-cooled spindle technology are said to make the machine particularly suited for high speed milling of deep ribs. Therefore, users can penetrate the part without tool breakage. In addition, benchwork on dies and molds can be virtually eliminated because of the quality of surface finishes, says the company.
Monday, December 18, 2006
Custom Tool Division
Back in 1919 when Matthew Ford introduced the first high-performance steel rotary file in Davenport, he understood the true value of a tool should be measured by its ability to increase productivity through superior craftsmanship, performance, and tool life. Today, M.A. Ford Manufacturing Company continues this tradition by taking advantage of advanced machine tool technology and materials to make the most innovative, high-quality cutting tools available in today's marketplace.
By partnering with select machine tool users, the Custom Tool Division will develop and supply customengineered carbide tools of unmatched quality, which meet or exceed productivity, delivery, and utilized cost expectations. Custom tools are proven to increase speeds and feeds, and save setup and handling time, which leads to faster run times, more efficient manufacturing, and more importantly, increased profits.
M.A. Ford's Custom Tool Division offers application development, design and manufacturing expertise in high-performance drills, G-drills, step drill reamers, subland drills, subland drill reamers, coolant-thru specials, step reamers, coolant-thru reamers, custom end mills, and custom form tools.
Milling on a grinding machine: a grinding machine is not a machining center, but it can sometimes take on milling and drilling to make the overall pro
However, certain profile grinding machines have developed in the direction of this type of multitasking, even when combining operations was not necessarily the goal. The MFP-TC grinding machine pictured, from Magerle (represented in the United States by United Grinding Technologies, Miamisburg, Ohio), provides an example. To support an increasing role for creep-feed grinding (a higher-metal-removal rate process than grinding just for finish), this machine features a powerful spindle and stiff hydrostatic ways. Further, because wheel types such as conventional abrasive, plated CBN and vitrified CBN all excel in different applications, the machine has been equipped with the capability to store different wheels and automatically switch between them.
This latter feature relies on proven technology. Specifically, it relies on a toolchange arm like that of a machining center, along with toolholders (or wheelholders in this case) that use the HSK interface of a machining center's toolholders. Taken together, this machine's tool changing, spindle power and rigidity produce the equivalent of a highly capable machining center. Precise heavy milling can be performed on this machine, and milling and drilling tools can be stored in the tool magazine alongside the grinding wheels.
Minimal Milling
Chris Stine is a vice president of United Grinding Technologies. He says performing chip-making operations such as milling and drilling on a grinding machine is best suited to certain types of parts. It also requires a particular mindset about production.
For a part to benefit from milling or drilling on a grinder, the cycle should consist of mostly grinding. The MFP-TC machine cited above remains a grinder first and foremost, offering precision beyond what might be associated with even a higher-end machining center, he says. As a result, the machine can't compete economically against a machining center if traditional metalcutting makes up most of the work.
However, many ground parts do feature a small but critical amount of this metalcutting. Even on a grinding machine equipped with multiple wheels and capable of high metal removal rates, there are plenty of features that simply cannot be ground. Holes, pockets and slots that don't run completely through the workpiece are examples. When the part has one or more features such as these, performing these cuts on the grinder can save considerable cost by eliminating the need to set up on multiple machines. This is particularly true for parts such as airfoils, in which the location of machined features may be defined with respect to ground surfaces that have complex geometries.
Another argument for consolidating operations relates to the part's size. Large parts magnify the savings in floor space that might result from combining grinding and machining center operations into one machine. Labor savings might also be more significant. The bigger the part, the better it is to set it up in just one place.
For particularly large parts, Mr. Stine says that the range of potential operations expands to include turning. A rotary table that can turn at 70 rpm can deliver 1,500 sfm of cutting speed to a turning tool that cuts at a diameter of 7 feet. This is exactly the solution that GE Gas Turbines (Greenville, South Carolina) adopted for machining large turbine wheels. Parts that used to be machined on a grinder, a vertical lathe and a boring mill now receive all of this machining on one Magerle machine tool. The change saves about 6 hours of setup time and 2 days of queue time, according to engineers at the plant. Overall, there has been a 30 percent cycle time reduction.
This latter feature relies on proven technology. Specifically, it relies on a toolchange arm like that of a machining center, along with toolholders (or wheelholders in this case) that use the HSK interface of a machining center's toolholders. Taken together, this machine's tool changing, spindle power and rigidity produce the equivalent of a highly capable machining center. Precise heavy milling can be performed on this machine, and milling and drilling tools can be stored in the tool magazine alongside the grinding wheels.
Minimal Milling
Chris Stine is a vice president of United Grinding Technologies. He says performing chip-making operations such as milling and drilling on a grinding machine is best suited to certain types of parts. It also requires a particular mindset about production.
For a part to benefit from milling or drilling on a grinder, the cycle should consist of mostly grinding. The MFP-TC machine cited above remains a grinder first and foremost, offering precision beyond what might be associated with even a higher-end machining center, he says. As a result, the machine can't compete economically against a machining center if traditional metalcutting makes up most of the work.
However, many ground parts do feature a small but critical amount of this metalcutting. Even on a grinding machine equipped with multiple wheels and capable of high metal removal rates, there are plenty of features that simply cannot be ground. Holes, pockets and slots that don't run completely through the workpiece are examples. When the part has one or more features such as these, performing these cuts on the grinder can save considerable cost by eliminating the need to set up on multiple machines. This is particularly true for parts such as airfoils, in which the location of machined features may be defined with respect to ground surfaces that have complex geometries.
Another argument for consolidating operations relates to the part's size. Large parts magnify the savings in floor space that might result from combining grinding and machining center operations into one machine. Labor savings might also be more significant. The bigger the part, the better it is to set it up in just one place.
For particularly large parts, Mr. Stine says that the range of potential operations expands to include turning. A rotary table that can turn at 70 rpm can deliver 1,500 sfm of cutting speed to a turning tool that cuts at a diameter of 7 feet. This is exactly the solution that GE Gas Turbines (Greenville, South Carolina) adopted for machining large turbine wheels. Parts that used to be machined on a grinder, a vertical lathe and a boring mill now receive all of this machining on one Magerle machine tool. The change saves about 6 hours of setup time and 2 days of queue time, according to engineers at the plant. Overall, there has been a 30 percent cycle time reduction.
Sunday, December 17, 2006
Shop Floor Inspection Machine measures compressor blades
Non-contact, automated Lightscan measures compressor blade airfoils for comparison with CAD data (with 160,000-point 3D point cloud) to obtain immediate go/no go sentencing. In addition to measuring sensor and associated application software, blade gauging inspection solution uses white light technology and has typ inspection cycle of 20 sec. With accuracy exceeding 0.0005 in., machine can be programmed to inspect new parts in as little as 4 hr.
********************
The new Lightscan non-contact blade gauging inspection from GE Inspection Technologies is a complete, automated, shopfloor solution for quickly and accurately measuring compressor blade airfoils for comparison with CAD data to obtain immediate go/no go sentencing. The new system offers significant cost-saving and time-saving advantages over conventional hard gage inspection and is the first system of its type to feature both measuring sensor and associated application software, providing a total turn-key inspection solution.
Using state-of-the-art white light technology, the operator-friendly, Lightscan has a typical inspection cycle of just 20 seconds, compared with the 60 to 90 seconds required by competitive equipment. It is accurate to greater than 0.0005", which is comparable with more cumbersome CMM equipment, and it can be programmed to inspect new parts in just four hours. Compare that to the 16-18 weeks required to manufacture of new hard gauges. As a result, Lightscan provides significant benefits in terms of production output and reduced tooling costs over hard gage inspection and provides significant improvements in manufacturing flexibility over mechanical and laser CMM systems and other white light systemsIn operation, Lightscan uses LCD technology to project and move software-generated light patterns over the part to be inspected. The reflected pattern is detected by two CCD cameras, using the latest firewire technology. The modulated fringe is then analyzed by the software to create a point cloud, featuring 80,000 measuring points. The part is then turned very precisely rotated and the procedure repeated, so that a total 3-D point cloud of 160,000 measuring points is produced for comparison with the CAD-generated master part model. From this comparison, a surface deviation map is generated and a series of software gauges are used to determine standard gauge outputs such as contour, bow, warp, platform and thickness. These results are then displayed on the system's monitor so that the operator can make a simple go/no go sentencing decision. This entire process is completed in 20 seconds.
The application specific software features advance data filtering to ensure the rapid presentation of the highly accurate results, which can be printed as a report or saved to a data file in standard formats. This data can then be further analyzed to help in the improvement of upstream processes, such as enhanced tool design.
Lightscan is capable of handling blades with a wide range of surface finish. There is no need to tumble components or to apply a white coating, as is the case with competitive products and the system will even handle "benched" parts, which feature a mix of surface finishes.
About GE Inspection Technologies
GE Inspection Technologies is a global leader in technology-driven inspection solutions that deliver customer productivity, quality and safety. The company designs, manufactures and services radiographic, ultrasonic, eddy current and metrology equipment to inspect and test materials without deforming or damaging them. Its products are used in a wide range of industries, including Aerospace, Power Generation, Oil & Gas and Automotive. The company has 11 application centres around the globe and offers a range of services including repair,Release delivers new high speed tool paths—Mastercam/CNC, Inc., booth 427
Mastercam X's latest maintenance release, MR1, includes various new capabilities, such as added high speed machining tool paths, holder definition, the release of Mastercam X and more.
Seven high speed surface machining (HST) tool paths--two roughing and five finishing paths--have been incorporated into the release, including an interface for toolpath creation. These added types are tailored to high speed machining while offering smooth cutting motion and smooth entry/exits, says Mastercam/CNC Software. The high speed tool paths include core roughing, area clearance, waterline, scallop, horizontal area, raster and an enhanced pencil tool path.
Using the release, operators can define a holder (or select one from a library) and gouge-check the holder during toolpath generation. The holder definition can be used to detect possible toolpath gouges.
This release is now available to all maintenance customers. SP2, a service pack release, is also available to those who do not participate in the maintenance programSaturday, December 16, 2006
Multifunctional Tool finishes workpieces in single set-up
Combining concepts of CoroMill 390 and CoroTurn 107, CoroPlex(TM) MT is applied rotating as effective tool for milling applications, or indexed in number of optional positions for stationary turning using 2 different inserts. Multi-tasking machining tool is designed for use of all insert positions possible without support of any extra software. It is also usable on older machines working with software capacity limited to conventional standard cycles.
********************
By introducing the multifunctional CoroPlex(TM) MT Sandvik Coromant establishes a new standard that is of outmost user benefit for operations performed with the latest of machine tool technologies.
CoroPlex MT is a combination of two winning concepts in one - CoroMill 390 and CoroTurn 107. It is either applied rotating as an effective tool for milling applications - or indexed in a number of optional positions for stationary turning using two different CoroTurn 107 inserts.
Sandvik Coromant[acute accent]s multifunctional tool CoroPlex MT is designed for practically unrestricted use of all the insert positions possible without support of any extra software Although CoroPlex MT is dedicated for Multi-Task machining it is easy to use the tool in somewhat older machines working with the software capacity limited to conventional standard cycles.
CoroPlex(TM) MT is an innovative multifunctional tool for finishing the workpieces in a single set-up with reduced downtime on the machine.
It also completes together with CoroPlex TT twin tools, with two inserts in one holder giving the possibility to change operations momentarily, and CoroPlex SL mini-turret, with four turning tools in one, the dedicated tooling Sandvik Coromant provides Multi-Task machining.
********************
By introducing the multifunctional CoroPlex(TM) MT Sandvik Coromant establishes a new standard that is of outmost user benefit for operations performed with the latest of machine tool technologies.
CoroPlex MT is a combination of two winning concepts in one - CoroMill 390 and CoroTurn 107. It is either applied rotating as an effective tool for milling applications - or indexed in a number of optional positions for stationary turning using two different CoroTurn 107 inserts.
Sandvik Coromant[acute accent]s multifunctional tool CoroPlex MT is designed for practically unrestricted use of all the insert positions possible without support of any extra software Although CoroPlex MT is dedicated for Multi-Task machining it is easy to use the tool in somewhat older machines working with the software capacity limited to conventional standard cycles.
CoroPlex(TM) MT is an innovative multifunctional tool for finishing the workpieces in a single set-up with reduced downtime on the machine.
It also completes together with CoroPlex TT twin tools, with two inserts in one holder giving the possibility to change operations momentarily, and CoroPlex SL mini-turret, with four turning tools in one, the dedicated tooling Sandvik Coromant provides Multi-Task machining.
Machine tool basics: Part 2
This second installment of our series looks at key machine-tool elements and addresses the tool, the toolholder, and machine control.
The cutting action in a machine tool when milling and drilling involves the spindle, toolholder, and tools.
Spindle Design
Spindles, which secure the tool and its holder, are key in determining machine tool accuracy. In early machine tools, the spindles were simple bearing-- mounted shafts driven by a constant-speed electric motor, achieving different speeds through belts and gears. Operators changed spindle speed by shifting gears or moving belts to and from various pulleys.
As drive motors achieved higher torque and were designed to operate at variable speeds, belt and gear-driven systems began to wane in popularity, but both are still used. Stronger, longer-wearing, quieter belt and gear-- drive designs have been developed. Variable-speed direct drive, or integral-- motor spindles have replaced geared spindles for high-speed applications. At the same time, spindles with planetary gear systems, much like a car's automatic transmission, are now used to provide a wide torque output.This second installment of our series looks at key machine-tool elements and addresses the tool, the toolholder, and machine control.
The cutting action in a machine tool when milling and drilling involves the spindle, toolholder, and tools.
Spindle Design
Spindles, which secure the tool and its holder, are key in determining machine tool accuracy. In early machine tools, the spindles were simple bearing-- mounted shafts driven by a constant-speed electric motor, achieving different speeds through belts and gears. Operators changed spindle speed by shifting gears or moving belts to and from various pulleys.
As drive motors achieved higher torque and were designed to operate at variable speeds, belt and gear-driven systems began to wane in popularity, but both are still used. Stronger, longer-wearing, quieter belt and gear-- drive designs have been developed. Variable-speed direct drive, or integral-- motor spindles have replaced geared spindles for high-speed applications. At the same time, spindles with planetary gear systems, much like a car's automatic transmission, are now used to provide a wide torque output.
Friday, December 15, 2006
Pistorius Machine Co - Brief Article
Pistorius Machine Co'.s model EMN-14 double miter cut-off saw is extremely versatile. Saw blades will cut nearly any material, including up to 6-inch-wide ornate mouldings, with only one cycle of the saw heads. Each cut is a finished cut suitable for assembly. Built to last with extra-heavy-duty-cast-iron and steel construction, this machine is virtually maintenance free, eliminating costly down-time. Pneumatic or manual models available
Drilling/Trimming Routers machine aircraft materials
HyperMach(TM) System is available as 5-axis head plate mill that delivers 460 cu-in./min metal removal rate for aggressive cutting of large aluminum structures. Twin independent, 5-axis head, dual work zone version offers same cutting capability with large capacity automatic tool changers. Users can load/unload parts in one work zone while machining 2 parts simultaneously in second work zone. Both have internal vacuum system to accommodate dry or near-dry machining.
********************
Ultra high-precision technology will dramatically improve machining of new
materials used in today's aircraft
Hebron, Kentucky, December 20, 2005 - Cincinnati Machine announced today that it has expanded its HyperMach(TM) Series of High Rail Linear Motor Profilers by adding a Drilling and Trimming Router platform. This new machine will serve to meet today's demand for extreme accuracy in high-speed processing of composites. The design is also well-suited for a variety of other new materials, metallic & non-metallic honeycomb and aluminum as well as structures utilizing a combination of these materials.
As the use of new, high-strength/light-weight materials has migrated from military to commercial aircraft, improved drilling and trimming capabilities are required to meet higher volume assembly rates, according to Cincinnati Machine engineers. Less sophisticated routers designed for wood or plastic materials can no longer provide the accuracy or throughput required for determinate assembly processes used to produce today's commercial and military aircraftCurrently, Cincinnati Machine offers two HyperMach platforms. A single 5-Axis head plate mill delivers a 460 cubic in./min. metal removal rate for aggressive cutting of large aluminum structures. The Twin Independent 5-Axis Head, Dual Work Zone Machining System offers the same powerful cutting capability with the added flexibility of large capacity automatic toolchangers. This configuration provides extremely high spindle
utilization facilitated by the ability to load/unload parts in one work zone while machining two parts simultaneously in the second work zone.
The new Router platform incorporates proven Hyper Mach machine modules that include expandable X-Axis travel available in rack & pinion or linear motor direct drive configurations, standard linear direct drive Y-Axis, and vertical ram and A/C spindle head. Additionally, the HyperMach Router is equipped with a fully integrated internal chip and dust vacuum system to accommodate dry or near-dry machining.
The new router will be offered with multi-function options to maximize flexibility in meeting a wide variety of processing approaches. The first HyperMach Drill and Trim Router will be available for delivery in late 2006. Complete information on the HyperMach Drilling & Trimming Router platform can be obtained by contacting Cincinnati Machine toll-free at 1-800-934-0735, or by visiting the company's web site at www.cincinnatilamb.com
News Source:
Ms. Jami Leininger
Cincinnati Lamb
Tel: (859) 534-4839
About Cincinnati Machine (www.CincinnatiLamb.com): Cincinnati Machine, as part of Cincinnati Lamb, designs, builds and integrates high-volume and flexible machining systems as well as stand-alone production equipment for global aerospace, automotive, heavy equipment and general machining markets. The company offers technology-driven solutions that include composites processing equipment, profilers, routers, and
five-axis CNC machining centers; horizontal and vertical machining centers and turning centers; and automated assembly and test machines and systems. Additionally, the company provides the manufacturing industry's most comprehensive package of service and support through its PLUS program.
Cincinnati Lamb is a MAG Industrial Automation Systems business unit; both are headquartered in Warren, Michigan. Other operating locations include: Machesney Park, IL; Hebron, KY; Windsor, Canada; Mildenhall, England; Solihull, England; Birmingham, England; Remscheid, Germany; and Asian operations in China and Korea.
Thursday, December 14, 2006
Smarten up your cardio: which machine blasts the most calories? How hard do you need to exercise? We've got the answers, plus three workouts to help y
You know that cardio workouts are crucial for a healthy heart and lungs and that they burn calories and fat, lower stress and boost energy. But what are the factors that make for the best possible sweat session? Is one machine better than another? How hard should you push yourself? Do you need to do more cardio, or less?
With so much confusion, it's no wonder a lot of us simply climb on our favorite machine (or the one we loathe the least), press the same old buttons and sink into a comfortable routine, inevitably undercutting our results. To the rescue: this exclusive Smart Cardio plan, designed to help you get the most from your workouts.
Created by certified trainer Keli Roberts, group fitness manager at Equinox in Pasadena, Calif., and a competitive cyclist, these mega-effective programs each focus on a specific goal. We'll show you which type of aerobic training is best for losing weight, boosting endurance and staying motivated. If you still have questions about all things cardio, turn the page for enlightening answersfitness experts weigh in on seven common conundrums.
q How much cardio do I really need?
a It depends on your goals, says Glenn Gaesser, Ph.D., an exercise physiologist at the University of Virginia in Charlottesville. For weight loss, at least 200 minutes of moderate-intensity cardio a week may be optimal, he says. In one recent study published in the Journal of the American Medical Association, obese women on calorie-controlled diets who exercised at least 200 minutes each week lost nearly 14 percent of their total body weight, while those who accumulated fewer than 150 minutes of exercise reduced their weight by less than 5 percent. "When it comes to shedding weight, total calories expended is most important, and this is a product of duration and intensity," Gaesser adds. "Since longer duration can usually be tolerated better than higher intensity, duration should be emphasized."
To boost cardiovascular fitness, on the other hand, you'll need to elevate your heart rate, working at higher intensities and, therefore, taking more time off between difficult workouts; 25-45 minutes of moderate- to high-intensity cardio four to five times a week should do the trick.
q Are long, slow, steady workouts better for burning fat?
a No. It is true that lower-intensity aerobic workouts burn a slightly higher percentage of calories from fat (versus carbohydrate), while burning lots of carbs during higher-intensity exercise usually leads to more fat being burned after exercise. However, when it comes to shedding body fat, it doesn't matter what form the calories are stored in or how quickly or slowly you burn them, Gaesser says. The only thing that counts is the total number of calories burned. Steady-state workouts take longer than higher-intensity workouts to get you to the same total, although you may be able to exercise longer at a lower intensity. "Ultimately, it doesn't matter whether you burn your calories long and slow or short and quick," says Cedric X. Bryant, Ph.D., chief exercise physiologist for the American Council on Exercise in San Diego.
q Is there one cardio machine that's most effective for burning calories?
a Only if you work at a higher intensity or stay on a particular machine for more time. The harder and longer you work, the more calories you'll burn, regardless of the type of workout. That said, you may be apt to exert more effort, and thus burn more calories, on certain pieces of equipment. According to a landmark 1996 study, machines such as the treadmill and stair climber raised heart rate more than machines such as the cross-country skier, rowing ergometer and stationary bike. These results could be related to familiarity with the activity demanded by the machine (i.e., for most people, walking, running and climbing stairs are more familiar than skiing and rowing). However, using the same machine day after day just because it could burn a few more calories may not be the smartest idea. "If your program has variety, you're less likely to become bored," Bryant says. "It also helps to prevent overuse injuries and can keep your body from adapting, so you may even see an increase in caloric expenditure." As Roberts says, "Once you've adapted, you stop improving. If you're not making progress, it's definitely time to change."
q How do I know which preprogrammed cardio workout to choose?
a It's really a matter of personal preference, Bryant says. Such preset workouts are essentially a marketing tool developed by equipment manufacturers. Interval workouts that include recurring changes in intensity may be slightly better from a calorie-burning standpoint, he notes. But for the most part, it boils down to how hard you work, which you can control by pushing a button to change the level or resistance, or by speeding up your pace.
Coated tools can provide double output with same tool - machine tooled tools - column
Coated Tools Can Provide Double Output With Same Tool
The F. P. Schmidt Manufacturing Company makes accurately machined parts in high volume, directly from coiled wire stock, on automatic and semi-automatic machines of its own design and construction. These machines knurl, thread-roll, mill, swage, press and cut a variety of materials such as brass, aluminum, carbon steel, 52100 roller bearing steel, and types 303 and 416 stainless steel. Schmidt's products usually form part of everyday consumer items, such as appliances, toys, hand and power tools, plumbing and electrical supplies, office equipment and automobiles.
Each part the company manufactures has its own precision form tool profiled in the shape of the cut, and is made of either T5 or M4 tool steel. Because coated tools are claimed to exhibit high-surface hardness, resist corrosion, and have low coefficients of friction, F. P. Schmidt began researching and sampling various coatings, hoping to reduce their production costs. Based on their findings, they selected Titankote-C, manufactured by Richter Precision, Inc., 1021 Commercial Ave., East Petersburg, PA. This coating is a physical vapor deposition (PVD) titanium nitride (TiN) coating at thickness of 0.0001-inch on each side of the tool.
PVD coatings, such as Titankote-C, are produced in a vacuum chamber at low temperatures as low as 650[degrees] F. In the vacuum chamber, TiN ions are transported by physical means, although they may be "directed" by polarizing the tool surface. The force of the TiN ions bonds the coating to the metal surface Although tools can be coated before or after sharpening, Schmidt decided to coat their tools before sharpening. In practice, and coating covers the side of the tool that wears most, while the front rake remains uncoated. These particular tools have between a 15-degree to 25-degree rake angle, depending on the material and the finish the customer requires.
F.P. Schmidt found that coating not only improves their own form tools, but those in a secondary operation, such as milling cutters, as well. One product operation requires milling the punches for paper punches. These steel punches are cut to form and shape on automtic machines. A V-shaped groove is milled in the one end that is to punch the paper. The punch is then heat treated. Finally, the finished cutting edge is ground in a centerless grinding operation.
The company says that after coating their tools, they notice an increase in tool life. Tools that previously turned out 200,000 workpieces now turned out 500,000 to 600,000 workpieces. In addition, this increase in the number of workpieces includes a variety of materials ranging from aluminum and brass right up to 52100 roller bearing and 303 and 416 stainless steels.
The company feels that utilizing a coated tool coating is relatively inexpensive when compared to the cost of a new tool, even if there is only a marginal increase in tool life. If a coated tool lasts longer than an actual second tool, then any use of the tool after that is all savings. Increased production per minute and better finish, at a lower cost, are the reasons F. P. Schmidt has been coating their tools for four years.
The F. P. Schmidt Manufacturing Company makes accurately machined parts in high volume, directly from coiled wire stock, on automatic and semi-automatic machines of its own design and construction. These machines knurl, thread-roll, mill, swage, press and cut a variety of materials such as brass, aluminum, carbon steel, 52100 roller bearing steel, and types 303 and 416 stainless steel. Schmidt's products usually form part of everyday consumer items, such as appliances, toys, hand and power tools, plumbing and electrical supplies, office equipment and automobiles.
Each part the company manufactures has its own precision form tool profiled in the shape of the cut, and is made of either T5 or M4 tool steel. Because coated tools are claimed to exhibit high-surface hardness, resist corrosion, and have low coefficients of friction, F. P. Schmidt began researching and sampling various coatings, hoping to reduce their production costs. Based on their findings, they selected Titankote-C, manufactured by Richter Precision, Inc., 1021 Commercial Ave., East Petersburg, PA. This coating is a physical vapor deposition (PVD) titanium nitride (TiN) coating at thickness of 0.0001-inch on each side of the tool.
PVD coatings, such as Titankote-C, are produced in a vacuum chamber at low temperatures as low as 650[degrees] F. In the vacuum chamber, TiN ions are transported by physical means, although they may be "directed" by polarizing the tool surface. The force of the TiN ions bonds the coating to the metal surface Although tools can be coated before or after sharpening, Schmidt decided to coat their tools before sharpening. In practice, and coating covers the side of the tool that wears most, while the front rake remains uncoated. These particular tools have between a 15-degree to 25-degree rake angle, depending on the material and the finish the customer requires.
F.P. Schmidt found that coating not only improves their own form tools, but those in a secondary operation, such as milling cutters, as well. One product operation requires milling the punches for paper punches. These steel punches are cut to form and shape on automtic machines. A V-shaped groove is milled in the one end that is to punch the paper. The punch is then heat treated. Finally, the finished cutting edge is ground in a centerless grinding operation.
The company says that after coating their tools, they notice an increase in tool life. Tools that previously turned out 200,000 workpieces now turned out 500,000 to 600,000 workpieces. In addition, this increase in the number of workpieces includes a variety of materials ranging from aluminum and brass right up to 52100 roller bearing and 303 and 416 stainless steels.
The company feels that utilizing a coated tool coating is relatively inexpensive when compared to the cost of a new tool, even if there is only a marginal increase in tool life. If a coated tool lasts longer than an actual second tool, then any use of the tool after that is all savings. Increased production per minute and better finish, at a lower cost, are the reasons F. P. Schmidt has been coating their tools for four years.
Coated tools can provide double output with same tool - machine tooled tools - column
Coated Tools Can Provide Double Output With Same Tool
The F. P. Schmidt Manufacturing Company makes accurately machined parts in high volume, directly from coiled wire stock, on automatic and semi-automatic machines of its own design and construction. These machines knurl, thread-roll, mill, swage, press and cut a variety of materials such as brass, aluminum, carbon steel, 52100 roller bearing steel, and types 303 and 416 stainless steel. Schmidt's products usually form part of everyday consumer items, such as appliances, toys, hand and power tools, plumbing and electrical supplies, office equipment and automobiles.
Each part the company manufactures has its own precision form tool profiled in the shape of the cut, and is made of either T5 or M4 tool steel. Because coated tools are claimed to exhibit high-surface hardness, resist corrosion, and have low coefficients of friction, F. P. Schmidt began researching and sampling various coatings, hoping to reduce their production costs. Based on their findings, they selected Titankote-C, manufactured by Richter Precision, Inc., 1021 Commercial Ave., East Petersburg, PA. This coating is a physical vapor deposition (PVD) titanium nitride (TiN) coating at thickness of 0.0001-inch on each side of the tool.
PVD coatings, such as Titankote-C, are produced in a vacuum chamber at low temperatures as low as 650[degrees] F. In the vacuum chamber, TiN ions are transported by physical means, although they may be "directed" by polarizing the tool surface. The force of the TiN ions bonds the coating to the metal surface Although tools can be coated before or after sharpening, Schmidt decided to coat their tools before sharpening. In practice, and coating covers the side of the tool that wears most, while the front rake remains uncoated. These particular tools have between a 15-degree to 25-degree rake angle, depending on the material and the finish the customer requires.
F.P. Schmidt found that coating not only improves their own form tools, but those in a secondary operation, such as milling cutters, as well. One product operation requires milling the punches for paper punches. These steel punches are cut to form and shape on automtic machines. A V-shaped groove is milled in the one end that is to punch the paper. The punch is then heat treated. Finally, the finished cutting edge is ground in a centerless grinding operation.
The company says that after coating their tools, they notice an increase in tool life. Tools that previously turned out 200,000 workpieces now turned out 500,000 to 600,000 workpieces. In addition, this increase in the number of workpieces includes a variety of materials ranging from aluminum and brass right up to 52100 roller bearing and 303 and 416 stainless steels.
The company feels that utilizing a coated tool coating is relatively inexpensive when compared to the cost of a new tool, even if there is only a marginal increase in tool life. If a coated tool lasts longer than an actual second tool, then any use of the tool after that is all savings. Increased production per minute and better finish, at a lower cost, are the reasons F. P. Schmidt has been coating their tools for four years.
The F. P. Schmidt Manufacturing Company makes accurately machined parts in high volume, directly from coiled wire stock, on automatic and semi-automatic machines of its own design and construction. These machines knurl, thread-roll, mill, swage, press and cut a variety of materials such as brass, aluminum, carbon steel, 52100 roller bearing steel, and types 303 and 416 stainless steel. Schmidt's products usually form part of everyday consumer items, such as appliances, toys, hand and power tools, plumbing and electrical supplies, office equipment and automobiles.
Each part the company manufactures has its own precision form tool profiled in the shape of the cut, and is made of either T5 or M4 tool steel. Because coated tools are claimed to exhibit high-surface hardness, resist corrosion, and have low coefficients of friction, F. P. Schmidt began researching and sampling various coatings, hoping to reduce their production costs. Based on their findings, they selected Titankote-C, manufactured by Richter Precision, Inc., 1021 Commercial Ave., East Petersburg, PA. This coating is a physical vapor deposition (PVD) titanium nitride (TiN) coating at thickness of 0.0001-inch on each side of the tool.
PVD coatings, such as Titankote-C, are produced in a vacuum chamber at low temperatures as low as 650[degrees] F. In the vacuum chamber, TiN ions are transported by physical means, although they may be "directed" by polarizing the tool surface. The force of the TiN ions bonds the coating to the metal surface Although tools can be coated before or after sharpening, Schmidt decided to coat their tools before sharpening. In practice, and coating covers the side of the tool that wears most, while the front rake remains uncoated. These particular tools have between a 15-degree to 25-degree rake angle, depending on the material and the finish the customer requires.
F.P. Schmidt found that coating not only improves their own form tools, but those in a secondary operation, such as milling cutters, as well. One product operation requires milling the punches for paper punches. These steel punches are cut to form and shape on automtic machines. A V-shaped groove is milled in the one end that is to punch the paper. The punch is then heat treated. Finally, the finished cutting edge is ground in a centerless grinding operation.
The company says that after coating their tools, they notice an increase in tool life. Tools that previously turned out 200,000 workpieces now turned out 500,000 to 600,000 workpieces. In addition, this increase in the number of workpieces includes a variety of materials ranging from aluminum and brass right up to 52100 roller bearing and 303 and 416 stainless steels.
The company feels that utilizing a coated tool coating is relatively inexpensive when compared to the cost of a new tool, even if there is only a marginal increase in tool life. If a coated tool lasts longer than an actual second tool, then any use of the tool after that is all savings. Increased production per minute and better finish, at a lower cost, are the reasons F. P. Schmidt has been coating their tools for four years.
New machine guarding policy
The Mine Safety and Health Administration (MSHA) has come out with revised guidelines on how mining operations may safely and lawfully guard machinery and equipment. In MSHA's "Guide to Equipment Guarding," revised 2004, MSHA has done several things that are hoped will provide more flexibility to mine operators.
Possibly the most significant thing about this guide is that it recognizes for the first time the lawfulness of what has been called "area guarding." If properly constructed, implemented and maintained, guards that cover multiple pinch points will be accepted by MSHA as lawful compliance. The guide provides details on what would be necessary to protect multiple pinch points with a single guard It must be remembered that policy is just that. It is not law. Unlike a regulation, which is law because it is developed according to procedures prescribed by Congress, policy may be adopted by an agency without the safeguards of mandatory procedures for rulemaking.
For MSHA to make rules that have the force of law, it must follow all the procedures prescribed by Congress in the Mine Act. These procedures allow the public and all regulated parties ("stakeholders") to: 1) have an opportunity to be informed in advance, by public notice (in the Federal Register), of what rules and standards are being proposed; 2) have an opportunity to comment on those rules and have their comments considered; and 3) have an opportunity to immediately challenge final rules in court after they are finalized by the agency.
In making policy, on the other hand, there is rarely even a semblance of such safeguards. Usually, MSHA simply announces how it thinks a regulation should be followed. However, in the case of the new guarding policy, MSHA worked closely with the National Stone, Sand and Gravel Association to respond to the many issues the association had brought to its attention.
In rulemaking, the agency tries to achieve a rule that is clear and says exactly what the agency believes should be required. Many rules turn out to be less than completely clear and that is when the agency tries to explain what it thinks is required under the rule. That is where policy comes in. It explains what the agency says the regulation means and how the agency thinks the requirements can and should be met.
Possibly the most significant thing about this guide is that it recognizes for the first time the lawfulness of what has been called "area guarding." If properly constructed, implemented and maintained, guards that cover multiple pinch points will be accepted by MSHA as lawful compliance. The guide provides details on what would be necessary to protect multiple pinch points with a single guard It must be remembered that policy is just that. It is not law. Unlike a regulation, which is law because it is developed according to procedures prescribed by Congress, policy may be adopted by an agency without the safeguards of mandatory procedures for rulemaking.
For MSHA to make rules that have the force of law, it must follow all the procedures prescribed by Congress in the Mine Act. These procedures allow the public and all regulated parties ("stakeholders") to: 1) have an opportunity to be informed in advance, by public notice (in the Federal Register), of what rules and standards are being proposed; 2) have an opportunity to comment on those rules and have their comments considered; and 3) have an opportunity to immediately challenge final rules in court after they are finalized by the agency.
In making policy, on the other hand, there is rarely even a semblance of such safeguards. Usually, MSHA simply announces how it thinks a regulation should be followed. However, in the case of the new guarding policy, MSHA worked closely with the National Stone, Sand and Gravel Association to respond to the many issues the association had brought to its attention.
In rulemaking, the agency tries to achieve a rule that is clear and says exactly what the agency believes should be required. Many rules turn out to be less than completely clear and that is when the agency tries to explain what it thinks is required under the rule. That is where policy comes in. It explains what the agency says the regulation means and how the agency thinks the requirements can and should be met.
Wednesday, December 13, 2006
Plungers for Fast, Effective Machining of Cavities - machine tools from Iscar Ltd - Brief Article
ISCAR presents its new milling concept for plunging with high material removal rates. This system incorporates a combination of drilling and milling operations into a single tool. When plunging, the tools are subjected mainly to axial forces -- with minimal radial forces compared to those involved in conventional side machining of cavities. Machining in the axial direction results in increased stability, higher feeds and longer tool life.
This new tool provides efficient metal removal rates in a variety of applications, including the machining of deep cavities, high shoulders, slots, and straight or sloped walls.
Three types of cutters available: one is for plunging into solid material--similar to a drill--in the axial direction only. The second is for plunging but, as a trepanning tool, with a central hole to improve performance. The third is based on HELIQUAD inserts for side plunging with a limited frontal width and for finishing with side cutting.
This new tool provides efficient metal removal rates in a variety of applications, including the machining of deep cavities, high shoulders, slots, and straight or sloped walls.
Three types of cutters available: one is for plunging into solid material--similar to a drill--in the axial direction only. The second is for plunging but, as a trepanning tool, with a central hole to improve performance. The third is based on HELIQUAD inserts for side plunging with a limited frontal width and for finishing with side cutting.
I/O Modules help simplify machine design
SQIO line is comprised of SynqNet Interface Device offering up to 256 digital I/O and 16 analog I/O, plus analog and digital add-on boards. Total of 32 SynqNet Interface Devices can be installed on SynqNet network. Diagnostic capabilities allow for firmware/configuration file upgrade on nodes from any remote host computer. All programming is under single API, and is supported by library of I/O configuration software, including MotionConsole, MotionScope, and VM3.
********************
SQIO delivers flexible bulk I/O solutions for SynqNet networks.
Nurnberg Germany, SPS/IPC/Drives Fair - 23 November 2004 - Motion Engineering, Inc. (MEI) today announced the launch of a new family of modular SynqNet I/O products compatible with any SynqNet network. SQIO product line is comprised of a SynqNet Interface Device (SQID) and flexible analog and digital 'add-on' boards that provides machine builders a modular and cost effective high-count I/O solution. In addition, SQIO can be easily integrated to work with existing machine I/O and is also offered as part of a SynqNet developer kit solution for custom OEM solutions.
"Our goal was to produce a robust SynqNet I/O product that could fulfill a high-count I/O solution for OEMs, and provide a platform that could easily be modified to accommodate existing I/O," said Ross McMillan, SQIO Product Manager. "The fact that machine builders can now implement performance motion and I/O solutions on a single network make this a very attractive solution for further simplifying machine design." MEI's SQIO products work across any SynqNet network and with any SynqNet motion control platform. The SynqNet I/O product family provides up to 256 digital inputs and outputs and 16 analog inputs and outputs per SynqNet Interface Device (SQID). A total of 32 SQIDs can be installed on a SynqNet network. Diagnostic capabilities of SynqNet allow for firmware / configuration file upgrade on nodes from any remote host computer. Breakout boards on the I/O modules allow for convenient prototyping. All programming is under a single API, and is supported by MEI's extensive library of I/O configuration software, including MotionConsole, MotionScope, and VM
SQIO products are available for immediate order and 6-8 week delivery.
Founded in 1987- and now part of the Danaher Motion Group-Motion Engineering Inc. designs, manufactures, markets and sells performance network motion control solutions to high value capital equipment builders in the semiconductor, electronic assembly, robotics and medical markets. MEI's SynqNet[R] motion platforms combined with advanced tools and engineering services allow OEMs to build better machines, faster. Danaher Motion is a leading global manufacturer of motion control products that improve the efficie
********************
SQIO delivers flexible bulk I/O solutions for SynqNet networks.
Nurnberg Germany, SPS/IPC/Drives Fair - 23 November 2004 - Motion Engineering, Inc. (MEI) today announced the launch of a new family of modular SynqNet I/O products compatible with any SynqNet network. SQIO product line is comprised of a SynqNet Interface Device (SQID) and flexible analog and digital 'add-on' boards that provides machine builders a modular and cost effective high-count I/O solution. In addition, SQIO can be easily integrated to work with existing machine I/O and is also offered as part of a SynqNet developer kit solution for custom OEM solutions.
"Our goal was to produce a robust SynqNet I/O product that could fulfill a high-count I/O solution for OEMs, and provide a platform that could easily be modified to accommodate existing I/O," said Ross McMillan, SQIO Product Manager. "The fact that machine builders can now implement performance motion and I/O solutions on a single network make this a very attractive solution for further simplifying machine design." MEI's SQIO products work across any SynqNet network and with any SynqNet motion control platform. The SynqNet I/O product family provides up to 256 digital inputs and outputs and 16 analog inputs and outputs per SynqNet Interface Device (SQID). A total of 32 SQIDs can be installed on a SynqNet network. Diagnostic capabilities of SynqNet allow for firmware / configuration file upgrade on nodes from any remote host computer. Breakout boards on the I/O modules allow for convenient prototyping. All programming is under a single API, and is supported by MEI's extensive library of I/O configuration software, including MotionConsole, MotionScope, and VM
SQIO products are available for immediate order and 6-8 week delivery.
Founded in 1987- and now part of the Danaher Motion Group-Motion Engineering Inc. designs, manufactures, markets and sells performance network motion control solutions to high value capital equipment builders in the semiconductor, electronic assembly, robotics and medical markets. MEI's SynqNet[R] motion platforms combined with advanced tools and engineering services allow OEMs to build better machines, faster. Danaher Motion is a leading global manufacturer of motion control products that improve the efficie
Tuesday, December 12, 2006
Faster machining
The approach is to have a series of LTCs (four- and six-spindle configurations are available) setup in a line. Each of the machines is tooled to perform a limited number of operations, unlike the typical case in a machining center-based line (parallel processing), wherein a single machine typically performs all of the operations required to finish a part. So what happens in an LTC system is that the part, which is fixtured to a pallet (which provides the opportunity for five-axis machining through part positioning), undergoes metal removal in a series of machines that can provide "toolchange" in 0.8 seconds, which means positioning another of tooled spindles to the work, not changing discrete tools from toolchanger to spindle. This is a serial processing approach.
Benz admits that in addition to being quick, this approach is somewhat more expensive if there is a simple comparison made of, say, machining center to LTC. But he notes, "Price isn't everything," and goes on to point out that what needs to be taken into account is "the total cost of ownership."
In other words, if it is possible to produce parts much more quickly--in one time study on an aluminum steering knuckle, the job required 143 seconds with machining centers and could be done in 45 seconds with three LTC six-spindle machines integrated with a rotary part transfer device--then the investment may be well spent, Benz adds, "Our machines are used where labor costs are high." Which means that they're used in places where the machinery and equipment need to be exceedingly productive.
On The Web - automated machine tools using Internet - Brief Article
On occasion, we here at OTW notice "things" that help define an online trend for our industry. These examples are often companies or products that come along and suggest the Web's potential for metalworking.
Well, nothing has caught our online attention more effectively than the potential of "Web-enabled Machine Tools." And activities at two companies suggest that progress in this area is far from comatose.
eMation is a "new" company that espouses Device Relationship Management (DRM). More than just another acronym, the DRM applications are said to transform machine tool data--temperature, fluid levels, tool condition, spindle performance, part run schedule, or any machine condition--into "business intelligence." Simply put, this system defines progress toward applications that allow for more efficient monitoring, maintenance, repair and management.
e-manufacturing Networks, Inc. (www.e-manufacturing.com) has been around for a while. It has been spreading the "Machine Is A Node On The Network" gospel for some time. But this Canada-based company has recently introduced a new line of after-market products that Internet-enable the machine tool through its control. Now, we aren't saying these companies are preferable to others; many OEMs, distributors and suppliers are pursuing their own, noble Internet-enabling efforts. But the efforts of these and other developers suggest strong Internet technology advancements for our industry.
Job Shop Site Of The Month
Metro Mold & Design, Inc., is a full service, nearly 50-person mold shop just north of Minneapolis. Its Web site www.metromold.com) is organized into easily navigable sections, all describing the company's capabilities to support precision injection mold making. Included are sections on Design, Programming, High Speed Machining, EDM and more. Metro has also done a fine job with its "File Area" (for uploading or downloading files) and its "Request for Info" utility. (Check out the nifty selection scheme for getting more specific information).
Well, nothing has caught our online attention more effectively than the potential of "Web-enabled Machine Tools." And activities at two companies suggest that progress in this area is far from comatose.
eMation is a "new" company that espouses Device Relationship Management (DRM). More than just another acronym, the DRM applications are said to transform machine tool data--temperature, fluid levels, tool condition, spindle performance, part run schedule, or any machine condition--into "business intelligence." Simply put, this system defines progress toward applications that allow for more efficient monitoring, maintenance, repair and management.
e-manufacturing Networks, Inc. (www.e-manufacturing.com) has been around for a while. It has been spreading the "Machine Is A Node On The Network" gospel for some time. But this Canada-based company has recently introduced a new line of after-market products that Internet-enable the machine tool through its control. Now, we aren't saying these companies are preferable to others; many OEMs, distributors and suppliers are pursuing their own, noble Internet-enabling efforts. But the efforts of these and other developers suggest strong Internet technology advancements for our industry.
Job Shop Site Of The Month
Metro Mold & Design, Inc., is a full service, nearly 50-person mold shop just north of Minneapolis. Its Web site www.metromold.com) is organized into easily navigable sections, all describing the company's capabilities to support precision injection mold making. Included are sections on Design, Programming, High Speed Machining, EDM and more. Metro has also done a fine job with its "File Area" (for uploading or downloading files) and its "Request for Info" utility. (Check out the nifty selection scheme for getting more specific information).
Monday, December 11, 2006
Automatic Messaging From The Machine Tool - Brief Article
Users of CNC Professional, the company's PC-based CNC machine tool controller software for Windows, are said to now have an added benefit. A machine tool will automatically call the user's cell phone or pager and send a detailed text message on the status of the machine.
The messages from the machine tool can be any ASCII text message, alphanumeric message or tone signals. The messages can be initiated and/or triggered by almost any event. Perhaps an error occurred, M code, end of program, completion notice, number of parts made, laser power, low voltage, loss of motor control or any certain user interaction. Users can arrange for their machine tools to send messages at regular time intervals so that they can receive machine updates. A complete list of national and international SMS (short message service) service providers for all major cell phone and pager carriers is included.
The messages from the machine tool can be any ASCII text message, alphanumeric message or tone signals. The messages can be initiated and/or triggered by almost any event. Perhaps an error occurred, M code, end of program, completion notice, number of parts made, laser power, low voltage, loss of motor control or any certain user interaction. Users can arrange for their machine tools to send messages at regular time intervals so that they can receive machine updates. A complete list of national and international SMS (short message service) service providers for all major cell phone and pager carriers is included.
Large Halogen Machine Lights feature dual lens design
Equipped with double glass lenses, HGW series is comprised of 18 and 32 in. arm models for broad work areas and head only model (HGWK) for compact work areas. Having inner and outer glass lens enclosed in one machine light protects lamp from breakage and causes outer lens to remain cooler. Viewing area stays clear of coolant and other fluids, maintaining consistent illumination of application at hand. Series comes with 12 V, 55 W lamp, or 24 V, 60 W halogen lamp.
Wheeling, IL-Waldmann Lighting Company's Large Halogen Machine Lighting series now features double glass lenses included with all luminaires. Having both an inner and outer glass lens enclosed in one machine light protects the lamp (bulb) from breakage, and causes the outer lens to remain cooler since there is a thermal barrier between the two lenses. This barrier helps to prevent coolant and other chemicals from baking onto the outside lens, and heat generated from the halogen lamp (bulb) is absorbed by the inner glass lens only. Operator safety is also improved because the viewing area stays clear of coolant and other fluids that may be prevalent, and the light consistently illuminates the application-at-hand. See our cooler halogen HGW and our entire line of machine tool lighting solutions at the Westec Trade Show in Los Angeles, California, on March 27-30.
This new standard double lens is available on Waldmann's 18-inch and 32-inch arm HGW for broad working areas. A "head only" (HGWK) double lens model is offered for compact work areas where space is limited. Other features of the HGW double lens series include either a 12V 55-watt lamp, or a 24V 60-watt halogen lamp with polished reflector that provides high intensity light and an estimated lamp life of over 3500 hours. An ergonomically designed handle and heat shield attached to the head provides safe and easy positioning. The light also includes a 4-hole pattern mounting base. All 120V versions include a remote transformer in a waterproof case for plug-in to a 120V power supply.
All HGW Halogen Machine Lights are ideal for heavy coolant environments and provide IP-65 waterproof protection. The lights are used for CNC machinery, conventional mills, lathes, and other metalworking machinery and machine tools. The lights are also ideal for packaging machinery and food processing equipment where coolant, oil, and other fluids are present. The "head-only" models are ideal for grinders, machining centers, CNC lathes, screw machines, turning centers, and packaging and processing machinery where space is limited.
Wheeling, IL-Waldmann Lighting Company's Large Halogen Machine Lighting series now features double glass lenses included with all luminaires. Having both an inner and outer glass lens enclosed in one machine light protects the lamp (bulb) from breakage, and causes the outer lens to remain cooler since there is a thermal barrier between the two lenses. This barrier helps to prevent coolant and other chemicals from baking onto the outside lens, and heat generated from the halogen lamp (bulb) is absorbed by the inner glass lens only. Operator safety is also improved because the viewing area stays clear of coolant and other fluids that may be prevalent, and the light consistently illuminates the application-at-hand. See our cooler halogen HGW and our entire line of machine tool lighting solutions at the Westec Trade Show in Los Angeles, California, on March 27-30.
This new standard double lens is available on Waldmann's 18-inch and 32-inch arm HGW for broad working areas. A "head only" (HGWK) double lens model is offered for compact work areas where space is limited. Other features of the HGW double lens series include either a 12V 55-watt lamp, or a 24V 60-watt halogen lamp with polished reflector that provides high intensity light and an estimated lamp life of over 3500 hours. An ergonomically designed handle and heat shield attached to the head provides safe and easy positioning. The light also includes a 4-hole pattern mounting base. All 120V versions include a remote transformer in a waterproof case for plug-in to a 120V power supply.
All HGW Halogen Machine Lights are ideal for heavy coolant environments and provide IP-65 waterproof protection. The lights are used for CNC machinery, conventional mills, lathes, and other metalworking machinery and machine tools. The lights are also ideal for packaging machinery and food processing equipment where coolant, oil, and other fluids are present. The "head-only" models are ideal for grinders, machining centers, CNC lathes, screw machines, turning centers, and packaging and processing machinery where space is limited.
Sunday, December 10, 2006
Faster machining
When Winfried Benz, managing director, LiCON[MT] (Laupheim, Germany; Ann Arbor, MI; www.licon.com), relates the types of systems and machines that the company has provided to companies (Volkswagen is a big customer) for a variety of parts, ferrous and nonferrous alike, it becomes clear that there is a focus on high uptime, especially as he's talking about equipment that typically runs in the range of 100,000 to two million parts per year. When you get to those kinds of volumes, then whatever time the spindles aren't removing metal is time wasted. So they have developed a machining module called the "Linear Tool Changer" (LTC) that reduces toolchange time to less than one second. That's right: less than one second.
This isn't predicated just on a mechanism but, rather on a rethinking of what is actually occurring in conventional high(er) volume applications. That is, LiCON[MT] engineers have calculated that in the typical production machining operation, the cutting cycle time for a given tool is on the order of three seconds. What's more, they've determined that overall, there are fewer than 20 tools used to machine a given part. So instead of the approach that is often used by machine builders, which is to provide a means where tools can be swapped in and out of the spindle in, say, three seconds, what they've done is essentially eliminate the automatic tool change--which is, perhaps, more astonishing than the one-second time. In this case, "toolchange" means using another tool. And the other tool is fitted to the spindle head that is part of the LTC.
Essentially, each head, which has four to six CNC spindles, is powered all the time by a 15-kW motor (standard). Spindle speeds (standard) of up to 10,000 rpm can be achieved on the four-spindle version; 15,000 rpm on the six-spindle. Distances between each of the spindle centers is 160 mm. Maximum tool diameter is 125 mm. The axis travels are 400 X 400 X 630 mm for the four-spindle version; 600 X 600 X 800 for the six-spindle style; the positioning accuracy and repeatability are 0.01 mm and 0.005 mm, respectively. Rapid traverse can be performed at 60 m/min. The approach is to have a series of LTCs (four- and six-spindle configurations are available) setup in a line. Each of the machines is tooled to perform a limited number of operations, unlike the typical case in a machining center-based line (parallel processing), wherein a single machine typically performs all of the operations required to finish a part. So what happens in an LTC system is that the part, which is fixtured to a pallet (which provides the opportunity for five-axis machining through part positioning), undergoes metal removal in a series of machines that can provide "toolchange" in 0.8 seconds, which means positioning another of tooled spindles to the work, not changing discrete tools from toolchanger to spindle. This is a serial processing approach.
Benz admits that in addition to being quick, this approach is somewhat more expensive if there is a simple comparison made of, say, machining center to LTC. But he notes, "Price isn't everything," and goes on to point out that what needs to be taken into account is "the total cost of ownership."
In other words, if it is possible to produce parts much more quickly--in one time study on an aluminum steering knuckle, the job required 143 seconds with machining centers and could be done in 45 seconds with three LTC six-spindle machines integrated with a rotary part transfer device--then the investment may be well spent, Benz adds, "Our machines are used where labor costs are high." Which means that they're used in places where the machinery and equipment need to be exceedingly productive.
This isn't predicated just on a mechanism but, rather on a rethinking of what is actually occurring in conventional high(er) volume applications. That is, LiCON[MT] engineers have calculated that in the typical production machining operation, the cutting cycle time for a given tool is on the order of three seconds. What's more, they've determined that overall, there are fewer than 20 tools used to machine a given part. So instead of the approach that is often used by machine builders, which is to provide a means where tools can be swapped in and out of the spindle in, say, three seconds, what they've done is essentially eliminate the automatic tool change--which is, perhaps, more astonishing than the one-second time. In this case, "toolchange" means using another tool. And the other tool is fitted to the spindle head that is part of the LTC.
Essentially, each head, which has four to six CNC spindles, is powered all the time by a 15-kW motor (standard). Spindle speeds (standard) of up to 10,000 rpm can be achieved on the four-spindle version; 15,000 rpm on the six-spindle. Distances between each of the spindle centers is 160 mm. Maximum tool diameter is 125 mm. The axis travels are 400 X 400 X 630 mm for the four-spindle version; 600 X 600 X 800 for the six-spindle style; the positioning accuracy and repeatability are 0.01 mm and 0.005 mm, respectively. Rapid traverse can be performed at 60 m/min. The approach is to have a series of LTCs (four- and six-spindle configurations are available) setup in a line. Each of the machines is tooled to perform a limited number of operations, unlike the typical case in a machining center-based line (parallel processing), wherein a single machine typically performs all of the operations required to finish a part. So what happens in an LTC system is that the part, which is fixtured to a pallet (which provides the opportunity for five-axis machining through part positioning), undergoes metal removal in a series of machines that can provide "toolchange" in 0.8 seconds, which means positioning another of tooled spindles to the work, not changing discrete tools from toolchanger to spindle. This is a serial processing approach.
Benz admits that in addition to being quick, this approach is somewhat more expensive if there is a simple comparison made of, say, machining center to LTC. But he notes, "Price isn't everything," and goes on to point out that what needs to be taken into account is "the total cost of ownership."
In other words, if it is possible to produce parts much more quickly--in one time study on an aluminum steering knuckle, the job required 143 seconds with machining centers and could be done in 45 seconds with three LTC six-spindle machines integrated with a rotary part transfer device--then the investment may be well spent, Benz adds, "Our machines are used where labor costs are high." Which means that they're used in places where the machinery and equipment need to be exceedingly productive.
Magazine has revolving disk to reduce tool change time
Toyoda Machinery's Matrix tool magazine is a large capacity, stationary tool storage rack that accommodates as many as 500 tools. It allows Toyoda HMCs to be tooled for more part numbers and keeps backup tools on hand while virtually eliminating time-consuming trips to the toolroom.
The magazine has several features designed to maximize ease of use, including PC-based software, tool identification and monitoring, and OP Supporter software. Its compact design houses an array of tools in a relatively small footprint, says the company. The magazine accommodates tools as long as 21.6", with 9.84" diameter and weighing 59.4 lbs. Features include a revolving disk to reduce tool change time and PC-based software that displays a layout of the entire magazine.
The magazine has several features designed to maximize ease of use, including PC-based software, tool identification and monitoring, and OP Supporter software. Its compact design houses an array of tools in a relatively small footprint, says the company. The magazine accommodates tools as long as 21.6", with 9.84" diameter and weighing 59.4 lbs. Features include a revolving disk to reduce tool change time and PC-based software that displays a layout of the entire magazine.
Saturday, December 09, 2006
Software aids development of machine vision applications
Optimized for use on smart cameras and other systems using TI's TMS320C6400 DSPs, InstantVision Integrated Software Environment v2.2 utilizes C++ programming language running on TI's Code Composer Studio. Multitarget Tracking Library tracks multiple objects moving at high speeds with pinpoint accuracy, even in cluttered environments. Other libraries include complex classification methods as well as optimized processing of images and video stream.
********************
Budapest, Hungary and Berkeley, CA - February 2, 2006 - AnaLogic Computers and Eutecus, Inc. are pleased to announce the release of the InstantVision Integrated Software Environment (ISE) 2.2 for the development of a wide range of machine vision applications. InstantVision ISE makes available all of AnaLogic/Eutecus' award-winning software tools in a comprehensive and easy-to-use package. New features in version 2.2 include improved performance, enhanced interfaces, and better support for rapid application development using Microsoft's .NET platform.
Dr. Csaba Rekeczky, CTO of Eutecus says, "InstantVision enables commercial users to rapidly and cost-effectively develop machine vision, security/surveillance, and other vision applications using the powerful Cellular Visual Technology (CVT) that Eutecus and AnaLogic developed to closely mimic human vision InstantVision ISE's image processing libraries include speed-enhanced versions of the standard vision tools offered by other vision software providers, as well as groundbreaking advanced tools unavailable elsewhere.
Most unique is the Multitarget Tracking Library (MTT Lib), developed in part with funding from several U.S. government agencies. The MTT Lib tracks multiple objects moving at very high speeds with pinpoint accuracy, even in cluttered environments containing a great deal of other visual activity.
The other libraries include complex classification methods (FC Lib) as well as optimized processing of images and video streams (SI Lib and SIF Lib). They run seamlessly with each other and with the MTT Lib to significantly reduce the cost of developing machine vision applications.
Dr. Gusztav Bartfai, CEO of AnaLogic Computers, states, "AnaLogic's multitarget tracking capabilities in concert with the advanced features of the other libraries enable us to enter markets that have not yet embraced advanced vision technology. We have identified applications for our software in science and medicine, the entertainment industry, and traffic management, to name a few examples.
"With the release of InstantVision, AnaLogic and Eutecus have reaffirmed their commitment to solving the most difficult image processing problems, while at the same time raising the bar for speed and accuracy for the industry as a whole."
Optimized for use on Eutecus/AnaLogic's Bi-i family of smart cameras and other systems using Texas Instruments' leading TMS320C6400 series of DSPs, InstantVision takes advantage of the versatile C++ programming language running on Texas Instruments Code Composer Studio. For quick profiling and less complicated tasks, AnaLogic provides an easy-to-learn proprietary programming tool. The InstantVision libraries can also be ported to a wide variety of other platforms and vision systems.
********************
Budapest, Hungary and Berkeley, CA - February 2, 2006 - AnaLogic Computers and Eutecus, Inc. are pleased to announce the release of the InstantVision Integrated Software Environment (ISE) 2.2 for the development of a wide range of machine vision applications. InstantVision ISE makes available all of AnaLogic/Eutecus' award-winning software tools in a comprehensive and easy-to-use package. New features in version 2.2 include improved performance, enhanced interfaces, and better support for rapid application development using Microsoft's .NET platform.
Dr. Csaba Rekeczky, CTO of Eutecus says, "InstantVision enables commercial users to rapidly and cost-effectively develop machine vision, security/surveillance, and other vision applications using the powerful Cellular Visual Technology (CVT) that Eutecus and AnaLogic developed to closely mimic human vision InstantVision ISE's image processing libraries include speed-enhanced versions of the standard vision tools offered by other vision software providers, as well as groundbreaking advanced tools unavailable elsewhere.
Most unique is the Multitarget Tracking Library (MTT Lib), developed in part with funding from several U.S. government agencies. The MTT Lib tracks multiple objects moving at very high speeds with pinpoint accuracy, even in cluttered environments containing a great deal of other visual activity.
The other libraries include complex classification methods (FC Lib) as well as optimized processing of images and video streams (SI Lib and SIF Lib). They run seamlessly with each other and with the MTT Lib to significantly reduce the cost of developing machine vision applications.
Dr. Gusztav Bartfai, CEO of AnaLogic Computers, states, "AnaLogic's multitarget tracking capabilities in concert with the advanced features of the other libraries enable us to enter markets that have not yet embraced advanced vision technology. We have identified applications for our software in science and medicine, the entertainment industry, and traffic management, to name a few examples.
"With the release of InstantVision, AnaLogic and Eutecus have reaffirmed their commitment to solving the most difficult image processing problems, while at the same time raising the bar for speed and accuracy for the industry as a whole."
Optimized for use on Eutecus/AnaLogic's Bi-i family of smart cameras and other systems using Texas Instruments' leading TMS320C6400 series of DSPs, InstantVision takes advantage of the versatile C++ programming language running on Texas Instruments Code Composer Studio. For quick profiling and less complicated tasks, AnaLogic provides an easy-to-learn proprietary programming tool. The InstantVision libraries can also be ported to a wide variety of other platforms and vision systems.
Injection Molding Tool enables zero defect production
Como Injection can optimize, monitor, and document up to 8 channels of cavity pressure or 4 channels of cavity pressure and 4 channels of machine signals. Available with optional touch screen for curve visualization, compact device is machine-mounted and compatible with coaxial and single-wire Kistler sensors. It can also be used to separate non-conforming parts to questionable parts bin. Collected data can be stored to server and accessed remotely via Internet.
********************
Amherst, NY (May 15, 2006) - Kistler Instrument will introduce at NPE 2006 a new system for zero defect production in the injection molding industry. This device will optimize, monitor, and document up to 8 channels of cavity pressure, or 4 channels of cavity pressure and 4 channels of machine signals (typically voltage signals). This new product is available with in a compact device that is machine mounted and with an optional touch screen for curve visualization.
The new Kistler unit is compatible with coaxial and single wire Kistler sensors. New cabling concept is offered with the Como Injection that offers one cable that combines up to 8 cavity pressure signals. The new cable offering allows for quicker set up time and protects users from confusing plug connections during machine and mold setups. Como Injection can be also used to separate non-conforming parts to be separated to questionable parts bin. Parts are continuously monitored and diverted if parts are not produced to optimum standards.
The data collected from the Como Injection system can be stored for use in production analysis and quality assurance, via an Ethernet connection to a server. Data can be accessed remotely from any location via the Internet.
Kistler is a global supplier of precision instrumentation for the Plastics market as well as the Research and Development, Industrial, Aerospace, Engine, and Bio-Mechanical marketplace.
********************
Amherst, NY (May 15, 2006) - Kistler Instrument will introduce at NPE 2006 a new system for zero defect production in the injection molding industry. This device will optimize, monitor, and document up to 8 channels of cavity pressure, or 4 channels of cavity pressure and 4 channels of machine signals (typically voltage signals). This new product is available with in a compact device that is machine mounted and with an optional touch screen for curve visualization.
The new Kistler unit is compatible with coaxial and single wire Kistler sensors. New cabling concept is offered with the Como Injection that offers one cable that combines up to 8 cavity pressure signals. The new cable offering allows for quicker set up time and protects users from confusing plug connections during machine and mold setups. Como Injection can be also used to separate non-conforming parts to be separated to questionable parts bin. Parts are continuously monitored and diverted if parts are not produced to optimum standards.
The data collected from the Como Injection system can be stored for use in production analysis and quality assurance, via an Ethernet connection to a server. Data can be accessed remotely from any location via the Internet.
Kistler is a global supplier of precision instrumentation for the Plastics market as well as the Research and Development, Industrial, Aerospace, Engine, and Bio-Mechanical marketplace.
Friday, December 08, 2006
Protecting machine tool spindle bearings
The most critical components of a machine tool spindle are its bearings. Bearings support the shaft and provide accurate. smooth rotation. Foreign particles and fluids damage bearings, and ultimately shorten spindle life.
Seals placed between the shaft and stationary parts protect the spindle bearings. There are many seal designs, but none are perfect for every application. The main challenge is interfacing with a shaft that can spin, while still providing a good seal. Other factors, such as size constraints, temperature, humidity, environmental air pressure fluctuations, chemical exposure, and particle geometry, influence seal selection.
Historically, machine tool spindles employ rubbing-type lip seals for slower applications, and labyrinth-type gap seals for high-speed applications. In instances where environments are extreme, air purge is added to the labyrinth seals to continuously purge contaminants from the sealing area. In the mid1990s, safety concerns prompted machine tool builders to more completely shroud the working area of machine tools. This change, in conjunction with dramatically increased coolant flow rates and pressures, creates a situation where traditional seals are inadequate. Bearing contamination occurs within a relatively short time.
In 1996, Setco constructed a test apparatus that would enable the replication of in-service seal failures. A further objective was to build a foundation on which seal performance could be assessed. Among the features were:
Seals placed between the shaft and stationary parts protect the spindle bearings. There are many seal designs, but none are perfect for every application. The main challenge is interfacing with a shaft that can spin, while still providing a good seal. Other factors, such as size constraints, temperature, humidity, environmental air pressure fluctuations, chemical exposure, and particle geometry, influence seal selection.
Historically, machine tool spindles employ rubbing-type lip seals for slower applications, and labyrinth-type gap seals for high-speed applications. In instances where environments are extreme, air purge is added to the labyrinth seals to continuously purge contaminants from the sealing area. In the mid1990s, safety concerns prompted machine tool builders to more completely shroud the working area of machine tools. This change, in conjunction with dramatically increased coolant flow rates and pressures, creates a situation where traditional seals are inadequate. Bearing contamination occurs within a relatively short time.
In 1996, Setco constructed a test apparatus that would enable the replication of in-service seal failures. A further objective was to build a foundation on which seal performance could be assessed. Among the features were:
Subscribe to:
Posts (Atom)
