Medical and metalworking technologies meld in an effort to heal in Houston, Texas. The two disciplines are working in concert to make cancer "history" at M.D. Anderson's new Proton Therapy Center, located in the heart of the Lone Star State's largest city.
One of only four proton radiation centers in the United States, M.D. Anderson's $125 million facility will serve more patients than any of the other centers, treating 3,500 per year when it reaches full capacity. In order to support such an aggressive treatment schedule, the facility houses its own machine shop that includes four networked CNC vertical machining centers (VMCs).
The primary duty of these machines is to produce two patient-specific components for the center's gantries, or radiation beam delivery devices. One of these components is a brass aperture that receives a window to shape the beam to match a tumor field's outline. The other is an acrylic compensator block into which is machined a cavity to shape the beam to release its energy at the appropriate depth within the patient's body. The ability to manipulate the beam in a way that damages a cancerous tumor without harming nearby healthy tissue is what makes proton therapy such a precise and powerful cancer treatment.
Most hospital-based machine shops are equipped with toolroom-type mills and lathes that are used to produce one-off fixtures or instruments. The shop at M.D. Anderson's proton therapy center does have such equipment for that type of work. However, it is first and foremost a production shop, as John Barr points out. Mr. Barr, the shop's supervisor, selected most of the shop's machine tools and related equipment. Four Mazak Nexus 410 VMCs will bear the brunt of the shop's production work. When the center reaches full capacity, those machines will produce thousands of apertures and compensators each yearMODERN MACHINE SHOP was invited to tour the center and its dedicated shop a few months in advance of the official opening in June 2006. During the visit, Mr. Barr and Paul Wisdom, a deft machinist who is currently "on loan" from M.D. Anderson's nearby instrument shop, explained the role that machining technology plays in support of an effective cancer treatment procedure.
Protons Pack A Punch
The 94,000-square-foot facility is topped by an open, inviting entrance with numerous offices and examination rooms. However, the building is an iceberg of sorts, because 42 feet of it is below ground. Located in this bunker are four proton radiation treatment rooms and the compact machine shop that measures 36 by 44 feet. These rooms are surrounded by 8-foot-thick concrete walls and a ceiling that's 12 feet thick. The subterranean location and beefy enclosure are required to contain stray radiation during treatment.
The apertures and compensators are the final two components in the subatomic beam delivery process. An injector first strips protons from the nucleus of hydrogen atoms and delivers them to a synchrotron, or particle accelerator. The synchrotron, essentially a magnetic "racetrack," accelerates the protons in a vacuum to an energy level approaching 250 million electron volts. The protons then travel at nearly light speed to rotating beam-delivery gantries located in three of the four treatment rooms. Though the huge gantries measure 35 feet in diameter and weigh 190 tons, they rotate smoothly, quietly and precisely 360 degrees around a patient and direct the proton beam to 0.5-mm positioning accuracy. The aperture plates (as many as four identical 2-cm-thick plates may be required) and compensator are inserted into the gantry's snout to shape and focus the beam as it exits the gantry en route to the targeted tumor.
The protons enter the a patient's body at a low energy level, peak their energy level within the tumor and effectively stop there so that surrounding healthy tissue is left unharmed. Apertures and compensators are matched sets specific to each patient and each different beam delivery angle into a patient's body. While no two sets of apertures and compensators are alike, the process for creating these components is the same for all.
Machining From A CAT Scan
The brass aperture plates and acrylic compensator blocks are first squared and face milled to size. The brass is machined dry; the acrylic is machined using high-pressure coolant. One corner of each component receives a notch, which serves as a key to ensure that the components are properly oriented when installed in a gantry snout.
The shapes of the aperture window and compensator cavity are determined by a model of the patient's tumor, which is obtained via a computed tomography scan, or CAT scan. The CAT scan captures the tumor volume one thin 2D slice at a time. The 2D images, taken at discrete depths throughout the tumor, stack together to create what is essentially a 3D model of the tumor. The electronic tumor model is part of each patient's file in the IMPAC treatment planning system, which the shop can access via the network.
Tuesday, October 31, 2006
Sunday, October 29, 2006
American investment continues its slide - The World Machine Tool Output & Consumption Survey
Machine tool purchases by United States metalworking factories have been declining since 1998. The latest annual survey shows the trend continuing in 2002, with the one-time undisputed leader now in fourth place behind China, Germany and Japan.
For most of the 1990s, the United States led all other countries in annual installations of productive new machine tools.
But the capital investment slump that started a few years back continues, and in 2002 the United States consumed only $3.3 billion, down one-third from 2001. A year ago it had moved out of first place among consuming countries for the first time since 1993.
It's some consolation that the decline is widespread among the world's industrialized countries: Of the top dozen purchasers of machine tools, all but one had a lower investment in machine tools than in the year before.
The one exception in that pervasive cutback is China. Last year it actually increased its purchases by 20 percent, to the point where China is now the world's leading consumer of machine tools. It bought an estimated $5.7 billion worth of the machines in 2002, outspending Germany's $4.8 billion and Japan's $3.4 billion. (See Top Consumers table.)
The international statistics come from the 38th World Machine Tool Output & Consumption Survey (WMTO& CS), conducted annually by Gardner Publications, Inc., publisher of this magazine. The study measures output, trade and consumption from major industrialized nations.
The term "consumption" is a derived statistic. It's what economists call "apparent consumption," and it's calculated by taking a country's local production, subtracting out the value of its exports, and adding the value of its imports. So in the case of the United States, domestic builders shipped $l.9 billion and exported $0.9 billion. At the same time, importers brought in $2.3 billion, so apparent consumption for 2002 comes to $3.3 billion.
The United States isn't likely to see a quick rebound. New orders, which predate consumption deliveries by anywhere from a week to many months, continue to slip.
Orders for new machines, tracked by an unconnected series of monthly reports from the two machine tool trade groups, fared poorly again last year. The latest U.S. Machine Tool Consumption (USMTC) survey of participating member companies shows total orders written during the year 2002 at 19 percent below the previous year.
The most recent monthly figure in that series, for January of this year, is also 19 percent behind the bookings posted for January 2002. That ledAlbert W. Moore, president of AMT -- The Association for Manufacturing Technology, which conducts the orders survey, to comment about America's productive capacity. "Over half of U.S. manufacturers are working with machines made in the 1960s and '70s," he says.
"The only way they can regain international competitiveness is to allow hem to fully expense he purchase of equipment in the year that it s acquired," Mr. Moore continues. "The clock s ticking for American manufacturing; the time for action is now!"
While the monthly USMTC reports orders for future consumption within the United States, the annual Gardner Publications' WMTO&CS collects statistics on actual shipments in 28 countries around the world.
Biggest Output
In addition to calculating consumption, the World Survey also lists countries by the output of their domestic machine tool industries. Germany ranks at No. 1 with $6.7 billion in 2002 shipments, slightly ahead of Japan's $6.4 billion. Italy's machinery sector, characterized by many small firms rather than a few big ones, is third, followed by the Peoples Republic of China and then the United States. (See Top Producers table.)
The total output of the surveyed countries in 2002 came to an estimated $31.0 billion, or about 14 percent less than those same 28 participants produced in 2001. The largest bloc of producers is the CECIMO consortium of mostly Western European countries. Its 15 members shipped a total of $16.1 billion, or 52 percent of the world's output.
The survey also tracks export activities. In general, the leading producers are also the top exporters, the top five of which are Germany, Japan, Italy, Switzerland and Taiwan. The latter two export more than 80 percent of their domestic production.
China's spending spree on machine tools in 2002 puts it at the top of the list of importers, which also includes the United States, Germany, Italy and South Korea. The American market continues to be highly import oriented, even though imports dropped one third from the previous year. The $2.3 billion worth of overseas-built machine tools it brought in has the U.S. market with a 70 percent import penetration (imports as a percentage of consumption). Other highly import-oriented markets include the United Kingdom (89 percent) and CanadaSaturday, October 28, 2006
Our machine tool industry--changer or changee?
he United States machine tool industry is experiencing unprecedented change. Our historic business models are no longer applicable. Machine tool consumption has declined by more than 60% since 1997, causing ruthless and seemingly endless hyper-competition. Industrial globalization, outsourcing strategies, customer demands for more services, and the relentless advance of technology are heaping even more stress on machine tool companies.
The predominant feeling in our industry is that the good ole days are a distant memory, never to return again. Let's get real. Are we actually challenging ourselves as an industry, asking the right questions and analyzing root causes? What are we doing, other than lamenting and waiting for the economic turnaround? Are there deeper issues negatively affecting our industry long term we are not confronting?
Let's face some facts. In 2003 China is projected to be the number one machine-tool-- consuming nation in the world. Germany will be second and the United States will plummet to third. Why? Because other countries are aggressively building and protecting their manufacturing base while we let ours slip away. Even a robust United States economic turnaround will not bring back the substantial number of manufacturing jobs permanently lost to other countries in the past several years. Do we want to return to number one, or are we satisfied with third?
More facts. The United States machine tool industry is in danger of losing its technology and manufacturing process knowledge base. The machine tool business has been so difficult for so long that several industry icons have closed their doors forever. Some of the best people in the industry have tossed in the towel and left the business to work in other industries. Further mortgaging our future is our difficulty in attracting young applications engineers, service technicians, and sales personnel because of perceived poor career opportunities.
I believe the writing is on the wall. The US is losing countless manufacturing jobs as we continue to migrate from being a producer-nation to being a consumer-nation. This shift weakens our economic foundation, and makes us vulnerable to ever changing geopolitical scenarios such as we now face with oil-- supplying nations. The end result, if we take no counter measure, will be the decimation of the US machine tool industry, and the rendering of our prospects for future growth, prosperity, and manufacturing competitiveness DOA.
Friday, October 27, 2006
High-volume bar machine
The Romi CNC 30 G features hydraulic collet chuck and automatic parts unloading, as well as "U" shaped cross-slide gang tooling with T slots for toolholder positioning. Interactive programming screens make the machine equally adept at mixed-volume, short-run production, as well as dedicated high-volume applications, says Romi Machine Tools, Ltd.
The machine occupies a 94.5" x 86.6" footprint. Other specifications include maximum bar capacities of 1.625" (round), 1.250" (hex) and 1" (square): a maximum bar length of 47.42"; and a maximum cutting length of 4.72". In addition, the bar machine is capable of rapid traverse rates of 630 ipm and 512 ipm for the respective XZ axes.
In addition to "T" slots for one cut-off toolholder, the ten-station, "'U" shaped cross slide gang tooling system features one mechanical bar puller with a built-in cut-off toolholder; two external turning toolholders; two boring bar holders; one double boring bar holder; and five reduction sleeves.
Potential benefits of using the machine, as cited by the company, are accelerated cycle times and reduced non-cut time.
The machine occupies a 94.5" x 86.6" footprint. Other specifications include maximum bar capacities of 1.625" (round), 1.250" (hex) and 1" (square): a maximum bar length of 47.42"; and a maximum cutting length of 4.72". In addition, the bar machine is capable of rapid traverse rates of 630 ipm and 512 ipm for the respective XZ axes.
In addition to "T" slots for one cut-off toolholder, the ten-station, "'U" shaped cross slide gang tooling system features one mechanical bar puller with a built-in cut-off toolholder; two external turning toolholders; two boring bar holders; one double boring bar holder; and five reduction sleeves.
Potential benefits of using the machine, as cited by the company, are accelerated cycle times and reduced non-cut time.
Companies collaborate to offer on-machine inspection
Delcam and Renishaw have joined forces to offer On-Machine Verification to companies seeking to increase the productivity of their machine tools. Though this technology is advantageous for companies that do not currently have existing inspection capabilities, it is also beneficial to subcontractors that need to machine larger components.
Data for the process can be collected using Renishaw's spindle probes, such as the established MP 700 or the compact OMP 400. Neither of these probes needs to be calibrated in all the vectors in which they are to be used. This reduces the number of points required to measure a given part and therefore produces shorter verification cycle times.
PowerInspect can use the data to gage surface accuracy or to measure features, such as circles, cylinders, cones, spheres and planes. The capability to program complete verification sequences off-line means that there can be minimal interruption of the machining operations, says the manufacturer.
The technology can yield time savings by enabling the quality of the component being machined to be monitored at all stages in the manufacturing process. Therefore, errors can be detected earlier, and thus corrected more quickly. Similarly, the extent of any damage caused, example, by a tool breakage, can be assessed. The user can thus determine whether the part can still be completed within tolerance or if the part will have to be scrapped. If a part has to be transferred to a dedicated CMM and the inspection indicates any errors, then the component must be returned to the machine tool and re-clamped in position before being machined again. Time-consuming for any component, this process might require hours for a heavy item, such as a large aero structure or a press tool for an automotive body panel. In addition, the setup back onto the machine tool might result in a new series of errors in the component and lead to a further cycle of inspection and re-machining.
With On-Machine Verification, the part can be inspected prior to being moved. Errors can thus be detected and corrected before the component is transferred to the CMM for its final inspection. The capability to check that the part is reaching its specifications at the various stages of the manufacturing process will save time, reduce the amount of scrap and increase confidence that time is not being wasted working on components that are already too far out of tolerance, says the manufacturer
Data for the process can be collected using Renishaw's spindle probes, such as the established MP 700 or the compact OMP 400. Neither of these probes needs to be calibrated in all the vectors in which they are to be used. This reduces the number of points required to measure a given part and therefore produces shorter verification cycle times.
PowerInspect can use the data to gage surface accuracy or to measure features, such as circles, cylinders, cones, spheres and planes. The capability to program complete verification sequences off-line means that there can be minimal interruption of the machining operations, says the manufacturer.
The technology can yield time savings by enabling the quality of the component being machined to be monitored at all stages in the manufacturing process. Therefore, errors can be detected earlier, and thus corrected more quickly. Similarly, the extent of any damage caused, example, by a tool breakage, can be assessed. The user can thus determine whether the part can still be completed within tolerance or if the part will have to be scrapped. If a part has to be transferred to a dedicated CMM and the inspection indicates any errors, then the component must be returned to the machine tool and re-clamped in position before being machined again. Time-consuming for any component, this process might require hours for a heavy item, such as a large aero structure or a press tool for an automotive body panel. In addition, the setup back onto the machine tool might result in a new series of errors in the component and lead to a further cycle of inspection and re-machining.
With On-Machine Verification, the part can be inspected prior to being moved. Errors can thus be detected and corrected before the component is transferred to the CMM for its final inspection. The capability to check that the part is reaching its specifications at the various stages of the manufacturing process will save time, reduce the amount of scrap and increase confidence that time is not being wasted working on components that are already too far out of tolerance, says the manufacturer
Thursday, October 26, 2006
Mill-Turn Machine combines lathe and machining center
Barnant Company is offering a 24-channel engine exhaust gas scanner for monitoring gas, as well as oil/water temperatures and other critical parameters. The new gas scanner can be used to observe up to 24 Type J, K, T or E thermocouples to sense exhaust gas at various points. The ABS unit is configured for benchtop, control panel or wall, allowing sequential or selective monitoring of all probes. With accuracy of [+ or -] 0.1 percent, this reliable gas scanner is equipped with RS-232C for out-put to a PC or data logger, selectable F[degrees] or C[degrees] settings, hi/lo set points with audible alarm, store/ recall of 2520 readings per channel, 10 second-to-hourly sequential scan capability, real time digital clock, non-volatile memory, full immunity to RF interference and a three-year warranty. The Integrated mill turn centers in NT Series provide full lathe and machining center capabilities in one package with DCG(TM) (Driven at Center of Gravity) technology, box-in-box construction, and turret with built-in milling motor. Machines contain B-axis that uses direct drive motor, and indexing specifications allow for input by units of 0.0001[degrees]. Max spindle speed is 5,000 rpm, max tool spindle speed is 12,000 rpm, and tool-to-tool change time is 1 sec.
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The full capabilities of a lathe and machining center are now available in one package
Irving, Texas, September 20, 2005 - Mori Seiki's new NT Series of integrated mill turn centers fully combines a lathe with a machining center. In designing the series, Mori Seiki completely rethought the design and construction of multitasking machines to harness the turning ability of a lathe and the cutting ability of a machining center.
The NT Series employs both DCG(TM) (Driven at the Center of Gravity) technology and the box-in-box construction of the NH Series horizontal machining centers, along with the turret with a built-in milling motor from the NL Series CNC lathes. The combination of these features is included with no compromises in terms of their performancestan Machines in the NT Series contain a B-axis that uses a DD (Direct Drive) motor, eliminating backlash and making high-speed rotation possible. Indexing specifications for the axis cater to high precision machining requirements, allowing for input by units of 0.0001 degrees.
To make the NT Series as efficient and productive as possible, special attention has been paid to machine speed. Maximum spindle speed is 5,000 rpm with a maximum tool spindle speed of 12,000 rpm. Additionally, the machines' ATC (Automatic Tool Changer) features a tool-to-tool change time of just 1 sec. and a chip-to-chip time of only 3.4 sec.
Special attention to thermal displacement allows machines in the NT Series to perform at the highest levels of accuracy and precision. The lower turret is located symmetrically in relation to the center of the spindle, forming a construction resistant to the effects of heat. Additionally, ball screw and motor jacket cooling have been implemented to completely eradicate inaccuracy caused by heat variations.
The NT Series will make use of MAPPS III, the latest iteration of Mori Seiki's highly successful control system. MAPPS III allows fast processing and is equipped with a collision prevention function that monitors machine movements in real time. The controls also take advantage of the ease and convenience of conversational input, providing high-speed canned cycles that lead to dramatic increases in programming speed.
The NT Series will contain 9 models, with spindle, lower turret and no center support options bringing the total number of variations to 66. Varieties of the machines will be brought to market sequentially.
Mori Seiki will host an Innovation Days event in early November at its Chicago Technical Center to formally introduce the new line to the North American market. Details on the event will be announced in late September.dard unit weighs only 4 lb
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The full capabilities of a lathe and machining center are now available in one package
Irving, Texas, September 20, 2005 - Mori Seiki's new NT Series of integrated mill turn centers fully combines a lathe with a machining center. In designing the series, Mori Seiki completely rethought the design and construction of multitasking machines to harness the turning ability of a lathe and the cutting ability of a machining center.
The NT Series employs both DCG(TM) (Driven at the Center of Gravity) technology and the box-in-box construction of the NH Series horizontal machining centers, along with the turret with a built-in milling motor from the NL Series CNC lathes. The combination of these features is included with no compromises in terms of their performancestan Machines in the NT Series contain a B-axis that uses a DD (Direct Drive) motor, eliminating backlash and making high-speed rotation possible. Indexing specifications for the axis cater to high precision machining requirements, allowing for input by units of 0.0001 degrees.
To make the NT Series as efficient and productive as possible, special attention has been paid to machine speed. Maximum spindle speed is 5,000 rpm with a maximum tool spindle speed of 12,000 rpm. Additionally, the machines' ATC (Automatic Tool Changer) features a tool-to-tool change time of just 1 sec. and a chip-to-chip time of only 3.4 sec.
Special attention to thermal displacement allows machines in the NT Series to perform at the highest levels of accuracy and precision. The lower turret is located symmetrically in relation to the center of the spindle, forming a construction resistant to the effects of heat. Additionally, ball screw and motor jacket cooling have been implemented to completely eradicate inaccuracy caused by heat variations.
The NT Series will make use of MAPPS III, the latest iteration of Mori Seiki's highly successful control system. MAPPS III allows fast processing and is equipped with a collision prevention function that monitors machine movements in real time. The controls also take advantage of the ease and convenience of conversational input, providing high-speed canned cycles that lead to dramatic increases in programming speed.
The NT Series will contain 9 models, with spindle, lower turret and no center support options bringing the total number of variations to 66. Varieties of the machines will be brought to market sequentially.
Mori Seiki will host an Innovation Days event in early November at its Chicago Technical Center to formally introduce the new line to the North American market. Details on the event will be announced in late September.dard unit weighs only 4 lb
Wednesday, October 25, 2006
Spain, a reference point for the machine tool industry
Surging ahead of countries such as United Kingdom and France, Spain has consolidated its position as one of the world's leaders in the machine tool sector and also as a major industrial country.
The country ranks eighth among the world's main machine tool suppliers, and eighth in terms of export volume. Within the European Union it takes third place, after Germany and Italy.
Behind this significant data lies a long period of effort and initiative to reach such a position since the first mass-produced machine tool was manufactured in Spain in 1863. This is one historical aspect which illustrates the strong industrial tradition within the sector.
AFM, the Association representing the machine tool sector, was founded in 1946 and was one of the first Spanish entrepreneurial associations to become a member of an international professional organization when it joined the CECIMO (European Committee for Co-operation of the Machine Tool Industries).
With regard to the Machine Tool Industry in Spain, it should be said that over roughly the last seven years Spain has been one of the countries which has experienced the most growth in this sector, in proportion to the increasing size and importance of the main machine tool manufacturers. This rate of growth is in terms of both production volume and of exports Data gathered for the year 2002 show that Spain remains among the leading machine tool manufacturer countries.How to pay for that new machine tool: innovative approaches to funding help shops and plants acquire the technology they need
In recent years, many machine shops have experienced a significant decline in sales; compression of margins; increased competition; exportation of machining and manufacturing demand; difficulty in obtaining working capital and acquisition financing resulting in operating losses; and an erosion in tangible net worth. Those shops that have remained profitable and experienced upward trends have several common characteristics: experienced and disciplined management, a diverse customer base, no significant customer concentrations, proper leverage and stringent cash flow management.
A challenge all equipment buyers experience is determining the best means to fund an equipment acquisition: cash/equity, a bank revolving line of credit or an equipment loan. Equipment financing is especially difficult during lean economic periods, when a prudent businessperson needs to monitor and forecast cash flow needs and availability to remain solvent.
All three acquisition payment methods entail both advantages and disadvantages. Cash purchasing is simple, requires no third party intervention and alleviates a buyer from future debt/rental payments--yet a cash purchase may adversely affect a company's solvency. Using a bank working line of credit availability is another simple funding method that requires no third party intervention. The bank line of credit financing method typically offers a competitive, variable rate loan, yet it may adversely affect a company's access to business flow interruptions and impact daily working capital requirements. Leasing has become the most common method of funding equipment needsThe Changing Equipment Finance Marketplace
The equipment finance marketplace has changed considerably in the last decade. As a result of consolidation, industry specialization and contraction of capital markets, machine tool buyers are left with fewer options to find financing sources in the traditional bank and finance marketplace. This has led to the growth of captive finance companies owned and operated by either a manufacturer or a distributor. Captive vendor finance companies provide finance products and services exclusively to their parent companies' customers. Most progressive manufacturers and some of the more prosperous distributors are providing equipment financing as an extension of their selling services in order to promote acquisition.
Captive vendor finance companies provide convenient, creative and alternative finance solutions to equipment buyers. These companies offer distinct advantages over banks, finance companies and brokers. They have an understanding of the industry and equipment, the intended use of the equipment, customer credit profiles and the specific customer equipment applications. Furthermore, captives are able to offer a variety or finance products tailored to meet specific customer needs.
Reviewing Options
Many different finance options are now available. These include a loan, capitol lease, finance lease, operating lease, off-balance sheet lease, tax lease, non-tax lease, promissory note/security agreement, skip payments, step-up or step-down payments, and many others. The variety or product options can often be confusing. To simplify the process, buyers should consider two financial concerns prior to selecting a finance product--tax appetite (the need for depreciation deductions to reduce actual tax paid) and cash flow.
If the buyer seeks the depreciation benefits of ownership, a non-tax lease, lease purchase, finance lease, loan or capital lease may be the product needed. Conversely, if the buyer has no tax appetite, prior or current losses, restrictive loan covenants regarding increased borrowing/leverage, or need for short-term utilization, then a tax lease, operating lease or off-balance sheet lease may be the product needed.
Once the lease product has been identified, the term and payment structure can be developed to meet the borrower's cash flow needs. Other features of the lease such as rate, down payments, balloon payments, deferrals, commencement terms, prepayment penalties and guarantees are then typically negotiated based on the customer's credit strength and specific needs.
In recent years, many machine shops have experienced a significant decline in sales; compression of margins; increased competition; exportation of machining and manufacturing demand; difficulty in obtaining working capital and acquisition financing resulting in operating losses; and an erosion in tangible net worth. Those shops that have remained profitable and experienced upward trends have several common characteristics: experienced and disciplined management, a diverse customer base, no significant customer concentrations, proper leverage and stringent cash flow management.
A challenge all equipment buyers experience is determining the best means to fund an equipment acquisition: cash/equity, a bank revolving line of credit or an equipment loan. Equipment financing is especially difficult during lean economic periods, when a prudent businessperson needs to monitor and forecast cash flow needs and availability to remain solvent.
All three acquisition payment methods entail both advantages and disadvantages. Cash purchasing is simple, requires no third party intervention and alleviates a buyer from future debt/rental payments--yet a cash purchase may adversely affect a company's solvency. Using a bank working line of credit availability is another simple funding method that requires no third party intervention. The bank line of credit financing method typically offers a competitive, variable rate loan, yet it may adversely affect a company's access to business flow interruptions and impact daily working capital requirements. Leasing has become the most common method of funding equipment needsThe Changing Equipment Finance Marketplace
The equipment finance marketplace has changed considerably in the last decade. As a result of consolidation, industry specialization and contraction of capital markets, machine tool buyers are left with fewer options to find financing sources in the traditional bank and finance marketplace. This has led to the growth of captive finance companies owned and operated by either a manufacturer or a distributor. Captive vendor finance companies provide finance products and services exclusively to their parent companies' customers. Most progressive manufacturers and some of the more prosperous distributors are providing equipment financing as an extension of their selling services in order to promote acquisition.
Captive vendor finance companies provide convenient, creative and alternative finance solutions to equipment buyers. These companies offer distinct advantages over banks, finance companies and brokers. They have an understanding of the industry and equipment, the intended use of the equipment, customer credit profiles and the specific customer equipment applications. Furthermore, captives are able to offer a variety or finance products tailored to meet specific customer needs.
Reviewing Options
Many different finance options are now available. These include a loan, capitol lease, finance lease, operating lease, off-balance sheet lease, tax lease, non-tax lease, promissory note/security agreement, skip payments, step-up or step-down payments, and many others. The variety or product options can often be confusing. To simplify the process, buyers should consider two financial concerns prior to selecting a finance product--tax appetite (the need for depreciation deductions to reduce actual tax paid) and cash flow.
If the buyer seeks the depreciation benefits of ownership, a non-tax lease, lease purchase, finance lease, loan or capital lease may be the product needed. Conversely, if the buyer has no tax appetite, prior or current losses, restrictive loan covenants regarding increased borrowing/leverage, or need for short-term utilization, then a tax lease, operating lease or off-balance sheet lease may be the product needed.
Once the lease product has been identified, the term and payment structure can be developed to meet the borrower's cash flow needs. Other features of the lease such as rate, down payments, balloon payments, deferrals, commencement terms, prepayment penalties and guarantees are then typically negotiated based on the customer's credit strength and specific needs.
Valid Machine Tool Setup for Helical Groove Machining
An investigation is reported on identifying valid machine tool setup conditions for grinding or milling of helical grooves using profiled disc-type cutting tools. When using existing analytical models to design cutter profiles for helical groove machining, it is often found that no valid solution can be found if the machine setup is not properly selected. In the present investigation, the criteria for obtaining a valid cutter profile are established and applied to finding the range of allowable setup conditions for both smooth workpiece profiles and profiles with one or more singular points. These results are illustrated using a CAD/CAM software package for helical groove machining.
Helical grooves for drill flutes, milling cutters, gears, screw mechanisms, and so on, are usually machined from cylindrical stock by grinding or milling using profiled disc-type cutters as illustrated in Figure I. During machining of the helical groove, the cutter rotates about its axis, Z^sub 2^, as the workpiece moves along and rotates about its axis, z. The combined motion of the cutter and workpiece generates the helical groove. Due to the nonrectilinear motion of the cutter along the helical cutting path, the cutter profile defined in the cutter axial section (section AA) in Figure 1 is different from the workpiece profile viewed in the same cross section. This makes it difficult to find either the cutter profile to generate a required shape of the helical groove or the helical groove shape generated by a given cutter profile. Furthermore, it is first necessary to specify the machine setup condition, which includes the separation distance, s, between the cutter and workpiece axes and the setting angle, α, as shown in Figure 1. Each machine setup can lead to a different solution for the required cutter or workpiece profile.
Historically, cutter profiles for helical grooves have been designed by graphical trial-and-error methods (Dudley and Poritsky 1943). To overcome the inherent inaccuracy of this approach, analytical methods were developed to design the required cutter profile or to find the helical groove. These methods can be divided into two classes. The first class is based on graphic reasoning (Friedman, Boleslavski, and Meister 1972; Kaldor and Messinger 1988; Veliko, Nankov, and Kirov 1998), which considers the trajectories of selected points on the cutter profile. The results are visually presented as the envelope of the trajectories in the workpiece transverse section. However, this method cannot be directly applied to finding the cutter profile to generate a desired nelical groove shape. The second class is based on the condition that there is a common normal vector at the points defining the line of contact betweeni the cutter and the helical groove surfaces during cutting (Agullo-Batlle, Cardona-foix, and Vinas-sanz 1985; Sheth and Malkin 1990; Ehmann 1990; King, Ehmann, and Lin 1996a, 1996b). After each contact point is found, the corresponding points on the cutter and helical groove profiles are mathematicalfy related to each other. While the desired cutter or workpiece profile is obtained directly, the application of this method is complicated by the need to calculate the derivative of the given profile.
When applying these methods, it is often found that no valid cutter profile can be obtained for a given machine setup and helical groove profile. In such cases, the machine setup must be adjusted to obtain a valid cutter profile (Agullo-Batlle, Cardona-foix, and Vinas-saiiz 1985). However, no general method has been presented on how to adjust the machine setup. Some ressarchers statistically related the machine setup to a critic al portion of the required helical groove profile, but this inevitably leads to some errors in the resulting profile (Ekambaram and Malkin 1993).
The present paper is concerned with selecting valid machine setup conditions for helical groove machining. Beginning with an analytical model for the cutter profile design, criteria for identifying valid machine setups for a given helical groove are analyzed. The mathematical model for machine setup is then further developed for profiles with singularities. These criteria and the mathematical model are then applied to finding the range of valid machine setup conditions. Some examples are presented to illustrate the method.
Taiwan Machine Tool Industry Enjoys High Growth In 2000 - Brief Article
The export-oriented machine tool industry of Taiwan revived substantially after undergoing several hardships in 1999. In 2000, the import and export value of Taiwan's machine tool industry recorded a sharp growth of 31.9 percent and 64.1 percent respectively, with exports reaching a record high of US$1.5 billion.
There are more than 300 suppliers that produce complete units, and 1000 venders if peripheral satellite factories are also included. Most of them are small- to medium-scale enterprises. Two-thirds are metal cutting machine makers, while the rest are metal forming machine makers. The major Taiwan-made machine tools include machining centers, CNC/non-CNC lathes, CNC/non-CNC milling machines, CNC/non-CNC grinding machines, drilling machines, CNC/non-CNC electric discharge machines (EDM), presses and shearing machines. The top ten export markets for Taiwan-made machine tools in 2000 in order of priority are Hong Kong (including China), the United States, Malaysia, Italy, Thailand, United Kingdom, Germany, Singapore, Japan, and the Netherlands.
As the foremost non-profit trade promotion organization in Taiwan, CETRA and its four representative offices in Chicago, New York, San Francisco and Miami have invested tremendous efforts in promoting Taiwan's machine tools in the United States. To increase bilateral trade opportunities, CETRA regularly offers American buyers and Taiwanese suppliers many trade-related activities in the United States that include the following:
Inviting buyers to visit TIMTOS (Taipei International Machine Tools Show)
Offering free trade inquiry services.
Setting up appointments for buyers before they visit Taiwan.
Holding seminars for Taiwanese exhibitors in Chicago's IMTS show.
Holding seminars on finance to solve financial problems and seek support from the government.
Supporting Taiwan makers to participate in machinery shows in the US.
Launching the Image Enhancement Plan to promote a value-added image of Taiwan-made machines.
The American market will no doubt still be one of the most important markets for Taiwan-made machine tools. To keep its competitiveness in the American market, Taiwan's machine tool industry has increased its investment and cooperated with research institutes in developing high speed, high precision automated products. To improve after-sales service and shorten delivery time, many companies have set up their own warehouses or offices in the United States. Taiwan's machine tool manufacturers are one of the major participants in international machine tool show, You can always find them in major machinery shows worldwide, such as IMTS in the United States, EMO in Europe, JIMTOF in Japan, CIMT in China, BI-MU in Italy, and FEIMAFE in BrazilThe United States ranks as the second largest market for exports of Taiwan's machine tools, in which major machine tools purchased by U.S. buyers are lathes, machining centers, milling machines, grinding machines, EDMs and presses. The total export value to the United States was US$273 million in 2000, with a 25.2 percent growth. In the same period, Taiwan also imported US$434 million worth of machine tools from the United States, of which most were used for semiconductor production.
Machine Tool Sales Jump Nearly 35%
Sales of US machine tools continued to rise in November with equipment purchases increasing 34.8% during the month compared to October sales, according to the latest figures available from the American Machine Tool Distributors' Association (AMTDA, Rockville, MD) and AMT-The Association for Manufacturing Technology (McLean, VA).
For November, US machine tool sales reached $210.25 million versus October sales of $156.02 million. The month's sales also were up 54.7% from the $135.94 million in sales reported in November 2002, but year-to-date sales of $1.796 billion declined 8.5% compared to the $1.964 billion for the same period in 2002. The data are based on the totals reported by companies participating in the USMTC program.
"The stars are aligned for a steady manufacturing recovery in 2004," according to Ralph J. Nappi, AMTDA president. "Economic data and anecdotal evidence indicate monetary and tax policy is having the impact many hoped for in the manufacturing community. But a fragile recovery it may be unless Congress makes a genuine effort at dealing with the increasing costs for business and consumers in areas like health care and frivolous litigation."
Regional sales showed increases during November in the Central (115.5%), Midwest (33.9%), and Northeast regions (23.3%), while sales declined in the West (-18.6%) and South regions (-12.9%) versus October sales. Year-to-date sales regionally rose in the South (5.1%) versus YTD 2002 sales, but fell in the West (-21.6%), Northeast (-18.7%), Central (-13.5%), and Midwest regions (-4.4%).
National Tool & Machine Co. Celebrates 75th Anniversary
National Tool & Machine Co., Inc., East St. Louis, Illinois, is celebrating its 75th anniversary.
The company produces a wide range of tools, jigs, fixtures, special machinery and offers general machine work and repair.
Founded in 1929, National Too & Machine has been owned by the same family and stayed in the same location throughout the 75 years.
Sylvester "Syl" Fontana Sr. started the company. In 1969, his son, "Syl" Jr., and brother, John L. Millick took over operations. In 1994, Millick retired and his son, John M. Millick joined Syl Jr. as a co-owner.
"We have always had a willingness to stay on the cutting of technology," stated Syl Fontana. "Combining the technology with lots of effort and an impeccable reputation and one can understand how we lasted 75 years."
An example of staying on the cutting edge of technology is the company's latest equipment acquisition, an OKUMA MX55VB 50 taper CNC vertical machining center with a full 4th axis.
Today, National Tool & Machine operates in a 7,000-sq.-ft. facility (expanded twice over the years) with 12 employees.
The company is divided into several departments including: a CNC department with five pieces of CNC equipment; a Quality Control department; a lathe department with three lathes; a grinding department with eight grinders; a milling department with eight mills; a drilling department with four drill presses; a sawing department with three saws and a welding/fabrication department with welders, presses and shears.
National Tool & Machine's equipment can handle milling jobs up to 20" x 25" x 48" and its lathes go up to 20" swing with four-foot centers.
The programming department utilizes Mastercam software.
The company focuses on small to medium sizedruns and works with virtually all metals and some plastics.
National Tool & Machine serves a wide range of industries within a 200-mile radius of the St. Louis area including: automotive; chemical; aircraft; railroad; medical equipment; appliances; hand tools and general industrial equipment.
"We serve the entire spectrum of manufacturing industries," noted John Millick. "Which is unusual in the marketplace today."
US machine tool consumption steady - Materials Outlook - Brief Article - Industry Overview
U.S. machine tool consumption totaled an estimated $186.93 million in October, virtually even with a revised $186.95 million the previous month but down 0.6 percent from $188.06 million in October 2001, according to a joint report by the American Machine Tool Distributors' Association, Rockville, Md., and the Association for Manufacturing Technology, McLean, Va. "Reports noting the current contraction of the manufacturing economy and excess production capacity for durable goods underscore the need for U.S. manufacturers to adapt to permanent systemic changes taking place," said AMTDA president Ralph J. Nappi. "No doubt, business will improve, but not to prior levels. We must recognize the playing field has changed and that value-added processes are increasingly more pivotal than the rigid product focus embraced in the past." Machine tool consumption in the first 10 months of 2002 totaled more than $1.72 billion, down 26.6 percent from nearly $2.35 billion in the same period last year.
Monday, October 23, 2006
Machine Tool Sales Rebound
The machine tool industry showed continued signs of awakening from its economic doldrums as December US machine tool consumption rose more than 15% compared to November sales, according to the latest data available from the American Machine Tool Distributors' Association (AMTDA, Rockville, MD) and AMT-The Association For Manufacturing Technology (McLean, VA).
Sales in December totaled $220.88 million versus November sales of $210.25 million, an increase of 15.4%, which also, represented a 10.8% increase over sales of $199.43 million in December 2002. For the year, industry sales of $1.993 billion for 2003 trailed 2002 sales of 2.163 billion by 7.9%. The data are based on totals reported by companies participating in the USMTC program.
"Manufacturing technology orders finished strong in the fourth quarter last year," according to John B. Byrd Ill, AMT president. "Our customers' capacity use and profits are growing, a combination that has historically signaled previous recoveries in capital spending."
Regional sales in December showed big improvements versus November sales in four of five regions with sales increases in the South (86.3%), West (64.6%), Northeast (33.1%), and Midwest (21.9%) regions, and only the Central region's sales fell (-36.0%). In regional sales compared to December 2002, sales improved in the Northeast. (28%), Midwest (18.8%), Central (11.2%), and West (7.0%) regions, but declined in the South (-14.1%) region.
The U.S. Metal Cutting Machine and Stationary Tool Consumption Will Reach Over $7 Billion In 2006
We have studied the machine tool, hand tool, power tool and Lawn & Garden markets since 1987. Metal cutting machine tools will reach over $5 billion in 2009 and this is one in a series of tool and machinery reports that accurately accounts for consumption dollars through detailed studies of production, imports and exports with in-depth analysis throughout.
The "U.S. Machine and Stationary Tool Market" entails full color exhibits and charts with commentary that ties them into a cohesive look at a most dynamic market place. This study takes a close-up view of the economy and how it drives machines with up to date facts on production, imports, exports, ultimate consumption and anomalies.
This study offers the product decision maker the opportunity to visualize historical facts with in-depth analysis and reliable forecasts through 2009.U.S. metal cutting machine and stationary tool consumption will reach over $7 billion for 2006 and may well see some of the consumption dollar successes of the last decade. Production will reach over $2.5 billion with strength in numerous product groups.
This complete study shows how machinery interacts with other types of tools and the economy as a whole. In particular, this study depicts the rate and quantity of imports as well demonstrating the actual effect on production values. This study offers the producer and seller essential facts and accurate and insightful analysis for detailed product management decisions.
More tools, faster changes - Westec 2002 - Turretgang machine tool from U.S. Shop Tools
The company introduces Turretgang, a tool that increases the number of tools on CNC lathe turrets and provides rapid tool change.
The Turretgang holds up to three round tools and is mounted in OD tool locations on the turret. It speeds up machining due to the gang-style spacing of tools. Rapid movement from tool to tool permits turret lathes to compete with screw or slide machines. X-axis programming allows the operator to take advantage of the reduced machining cycle benefits of slide-type lathes.
The product is available in several standard models, all in coolant through design, for both channel and tool block style turrets and holds up to three tools. The additional tools on the lathe that are made possible will often eliminate secondary operations, said to result in improved quality and reduce machining time and cost. Turretgang can be special ordered per customer specific sizes and tool pockets.
Friday, September 15, 2006
CNC Control System is suited for machine tool builders
Able to control up to 5 axes and a spindle, Advantage 400 includes 32 digital inputs, 2 analog inputs, 16 digital outputs, and variety of programming features. Product also includes ability to send torque or step and direction command formats. Dual-processor control utilizes dedicated DSP based CPU to service motion control tasks, and Pentium-based PC is at heart of user interface. Unit comes with 8.4 in. color LCD and can include Ethernet and USB utilities.
Chatsworth, Ca. - Delta Tau Data Systems, Inc. has released the Advantage 400 CNC control system. Created for the machine tool builder and retrofitter who require a powerful, feature packed control, which sets up quickly and whose price does not limit performance, capability, or flexibility.
The Advantage 400 will control 5 axes, a spindle, includes 32 digital inputs, 2 analog inputs, 16 digital outputs, and all the programming features customers would expect from a high-performance control package, all in a standard configuration and at a very reasonable price. The Advantage 400 includes the ability to send torque or step and direction command formats.
The Advantage 400 is a dual-processor control utilizing a dedicated DSP based CPU to service the motion control tasks. A Pentium based PC is the heart of the user interface. The DSP motion control CPU ensures the machine is accurate at any speed. The Pentium based interface allows Delta Tau to include utilities such as Ethernet and USB at no additional cost to the user. The control comes standard with an 8.4" color LCD.
The Advantage 400 is a perfect example of how intelligent design and technology is bridging the gap between software and hardware and bringing unprecedented levels of performance and value to the shop floor.
About Delta Tau Data Systems
Delta Tau Data Systems is the global leader in high-performance machine control products. By developing and manufacturing a full range of motion control products, software, and accessories, Delta Tau delivers motion control solutions that solve the simplest to the most complex positioning applications. Products are marketed through a worldwide distribution network and application engineers are located globally to provide timely customer support.
Chatsworth, Ca. - Delta Tau Data Systems, Inc. has released the Advantage 400 CNC control system. Created for the machine tool builder and retrofitter who require a powerful, feature packed control, which sets up quickly and whose price does not limit performance, capability, or flexibility.
The Advantage 400 will control 5 axes, a spindle, includes 32 digital inputs, 2 analog inputs, 16 digital outputs, and all the programming features customers would expect from a high-performance control package, all in a standard configuration and at a very reasonable price. The Advantage 400 includes the ability to send torque or step and direction command formats.
The Advantage 400 is a dual-processor control utilizing a dedicated DSP based CPU to service the motion control tasks. A Pentium based PC is the heart of the user interface. The DSP motion control CPU ensures the machine is accurate at any speed. The Pentium based interface allows Delta Tau to include utilities such as Ethernet and USB at no additional cost to the user. The control comes standard with an 8.4" color LCD.
The Advantage 400 is a perfect example of how intelligent design and technology is bridging the gap between software and hardware and bringing unprecedented levels of performance and value to the shop floor.
About Delta Tau Data Systems
Delta Tau Data Systems is the global leader in high-performance machine control products. By developing and manufacturing a full range of motion control products, software, and accessories, Delta Tau delivers motion control solutions that solve the simplest to the most complex positioning applications. Products are marketed through a worldwide distribution network and application engineers are located globally to provide timely customer support.
Vertical turning debut boosts productivity in aerospace application - Better Production Spotlight: Turning - Thomson Machine and Tool installs Webster
Thomson Machine & Tool (Somerset, England) required a large-capacity turning center for machining aerospace components with diameters of up to 2,000mm, in a range of materials including titanium and nimonic alloys. Although this operation had previously been performed using a traditional horizontal lathe, the nature of the application suggested that a switch to vertical turning would provide advantages leading to significant improvements in productivity.
"After considering a number of options, we decided that a vertical turning center offered the right combination of capacity, rigidity and versatility for this application," explains Thomson Machine & Tool's managing director, Allan Thomson. "We chose a Webster & Bennett (Coventry, England) machine because of the company's expertise in vertical turning, coupled with the unrivalled reputation for performance and build quality enjoyed by its products."
Webster & Bennett supplied Thomson Machine & Tool with a two-axis vertical turning center with 72-inch table and 8-inch square ram, suited to machining large cylindrical components thanks to a maximum height under the cross rail of 57.5 inches, a ram stroke of 48 inches and maximum swing of 84 inches. The machine incorporates a range of features designed to maximize productivity while maintaining the quality of the components being machined.
With a maximum load capacity of 11,363 kg, large and heavy components can be supported on the machine's table and held in place using Webster & Bennett's four-jaw independent chuck, a setup that eliminates inaccuracies associated with the effect of gravity on horizontally clamped components. This inherent advantage of vertical turning, complemented by the inclusion of a Timken table bearing and ballscrews on the X and Z axis, has enabled Thomson Machine & Tool to achieve levels of machining accuracy and consistency that they could not match using horizontal lathes. Operators at the company have also noticed a significant improvement in the surface finish of components manufactured on the Webster & Bennett machine.
"Every aspect of the vertical turning center's design and construction contributes to its overall rigidity, resulting in a superior machining performance, which is reflected in the quality of the components we produce," says Mr. Thomson.
The machine's 18-station automatic tool changer enables multiple machining operations to be performed in a single setup. This is crucial in the manufacture of large and awkward components at Thomson Machine & Tool, and this benefit has contributed to a typical reduction in product cycle times of 20 percent. Another significant benefit of this versatility is the scope for product diversification it has provided. "The machine's ability to perform a wide range of machining operations quickly and efficiently has helped us to reduce throughput times while increasing our scope for diversification into new products and markets," Mr. Thomson explains.
Optimum metal removal is assured by the machine's wide speed range of 5-167 rpm, provided by a two-speed gearbox and 37.5 kw main drive motor, specified by the customer in order to provide the low-speed, high-torque machining required for the successful production of aero engine components. CNC controlled servodrives add to the machine's operational speed and ease of use and contribute to the consistency of its machining accuracy.
Another factor in the vertical turning center's overall appeal has been its trouble-free integration into manufacturing operations at Thomson, made possible by a combination of the machine's easy-to-learn Fanuc l8Ti CNC control system and integral swarf conveyor with coolant system. Mr. Thomson also drew attention to the high level of technical support provided by Webster & Bennett, which enabled the installation of the machine with minimal disruption to Thomson Machine & Tool's manufacturing operations.
Full working area guarding and ease of use have also played a part in the machine's popularity among operators at Thomson Machine & Tool, Mr. Thomson explains. "Those operating the machine have been amazed by the ease with which it can perform a number of high precision machining operations quickly, safely and with a minimal amount of setup, helping to streamline this particular manufacturing process in a way that traditional horizontal turning couldn't match."
"Making the switch to vertical turning with a Webster & Bennett has proved a major success for this demanding application, providing significant improvements in productivity and component quality, while simultaneously creating considerable scope for us to enter into new markets."
"After considering a number of options, we decided that a vertical turning center offered the right combination of capacity, rigidity and versatility for this application," explains Thomson Machine & Tool's managing director, Allan Thomson. "We chose a Webster & Bennett (Coventry, England) machine because of the company's expertise in vertical turning, coupled with the unrivalled reputation for performance and build quality enjoyed by its products."
Webster & Bennett supplied Thomson Machine & Tool with a two-axis vertical turning center with 72-inch table and 8-inch square ram, suited to machining large cylindrical components thanks to a maximum height under the cross rail of 57.5 inches, a ram stroke of 48 inches and maximum swing of 84 inches. The machine incorporates a range of features designed to maximize productivity while maintaining the quality of the components being machined.
With a maximum load capacity of 11,363 kg, large and heavy components can be supported on the machine's table and held in place using Webster & Bennett's four-jaw independent chuck, a setup that eliminates inaccuracies associated with the effect of gravity on horizontally clamped components. This inherent advantage of vertical turning, complemented by the inclusion of a Timken table bearing and ballscrews on the X and Z axis, has enabled Thomson Machine & Tool to achieve levels of machining accuracy and consistency that they could not match using horizontal lathes. Operators at the company have also noticed a significant improvement in the surface finish of components manufactured on the Webster & Bennett machine.
"Every aspect of the vertical turning center's design and construction contributes to its overall rigidity, resulting in a superior machining performance, which is reflected in the quality of the components we produce," says Mr. Thomson.
The machine's 18-station automatic tool changer enables multiple machining operations to be performed in a single setup. This is crucial in the manufacture of large and awkward components at Thomson Machine & Tool, and this benefit has contributed to a typical reduction in product cycle times of 20 percent. Another significant benefit of this versatility is the scope for product diversification it has provided. "The machine's ability to perform a wide range of machining operations quickly and efficiently has helped us to reduce throughput times while increasing our scope for diversification into new products and markets," Mr. Thomson explains.
Optimum metal removal is assured by the machine's wide speed range of 5-167 rpm, provided by a two-speed gearbox and 37.5 kw main drive motor, specified by the customer in order to provide the low-speed, high-torque machining required for the successful production of aero engine components. CNC controlled servodrives add to the machine's operational speed and ease of use and contribute to the consistency of its machining accuracy.
Another factor in the vertical turning center's overall appeal has been its trouble-free integration into manufacturing operations at Thomson, made possible by a combination of the machine's easy-to-learn Fanuc l8Ti CNC control system and integral swarf conveyor with coolant system. Mr. Thomson also drew attention to the high level of technical support provided by Webster & Bennett, which enabled the installation of the machine with minimal disruption to Thomson Machine & Tool's manufacturing operations.
Full working area guarding and ease of use have also played a part in the machine's popularity among operators at Thomson Machine & Tool, Mr. Thomson explains. "Those operating the machine have been amazed by the ease with which it can perform a number of high precision machining operations quickly, safely and with a minimal amount of setup, helping to streamline this particular manufacturing process in a way that traditional horizontal turning couldn't match."
"Making the switch to vertical turning with a Webster & Bennett has proved a major success for this demanding application, providing significant improvements in productivity and component quality, while simultaneously creating considerable scope for us to enter into new markets."
Spain's big splash - Scanning the Horizon - Spanish machine tool industry and BIEMH 2002 - Industry Overview
In the worldwide arena of manufacturing, Spain isn't widely known as a top contender. But the numbers from Gardner Publications' 2002 World Machine Tool Output & Consumption Survey tell a different story. Spain's population is less than one-seventh that of the United States, but Spanish machine tool builders annually produce a number of machine tools equal to nearly one-third the total volume produced by American builders. Furthermore, at the same time that production has declined in the United States, the Spanish machine tool industry has experienced gradual but continuous growth since 1995. For example, in 2001, Spain's machine tool production increased more than 6 percent from the previous year.
The heartland of this dynamic industry is the beautiful and rugged Basque section of northern Spain near the Atlantic coast and the French border. As the commercial center of the industrious Bizkaia region, Bilbao is the host city for one of Europe's largest machine tool shows, the biennial BIEMH. In the past, Bilbao was known primarily as a gritty center of heavy industry. But after undergoing an impressive renaissance, this city of 400,000 residents has emerged as a place of alluring charm.
When the 22nd BIEMH exhibition opened at Bilbao's International Trade Fair on March 11, the Spanish machine tool industry had some important accomplishments to celebrate. For example, Spanish builders currently manufacture more than 2,000 different machine models. Many of these products feature innovative technology that was developed in Spain.
The rapid improvement of Spanish technology in recent years is primarily the result of strong investment in research and development. On the average, Spanish machine tool builders allocate 5 percent of their annual turnover to R&D. For the country's largest builders, this investment may represent 10 percent or more. The success of this industry has been greatly facilitated by inter-company alliances in the areas of process development, marketing, distribution and supply chain management. Many of these cooperative efforts have been coordinated through the Machine Tool Manufacturers' Association of Spain (AFM) and its sister organization, the Export Trade Association of Spanish Manufacturers of Accessories, Component Parts and Tools for Machine Tools (AMT).
Strong investment and effective cooperation enable Spanish machine tool manufacturers to compete aggressively in global markets. Spain's principal machine tool builders offer products for high speed milling, turning, grinding and EDM that incorporate advanced capabilities. As a reflection of the growing reputation of Spanish technology, Germany was the largest customer in 2001 for Spanish machine tools, purchasing more than 18 percent of all the country's exports.
The defining characteristic of the most prominent Spanish machine tools is flexibility in meeting specific user requirements. Thus, many of the large machining centers exhibited at BIEMH 2002 are designed to suit the production systems of important automotive and aerospace clients. At the same time, however, Spanish builders offer a wide range of conventional and CNC machine tools that are suitable for typical job shop applications.
Spanish-American Market
While Spain's largest machine tool builders have established solid marketing networks in the United States, economic conditions during the past 12 months have created a slump in the market for Spanish exports. Because the United States currently accounts for less than 8 percent of Spain's total export trade, however, this doesn't represent a serious problem by itself. Because the appetites of American consumers continue to drive manufacturing activity around the globe, however, many Spanish builders are experiencing the impact of a softer American economy on their customers in Europe and Asia. As a result, AFM predicts that the steady growth its members have enjoyed since 1995 may be interrupted when the final figures for 2002 are recorded.
In this vein, AMT president Ramon Cenar-ruzabeitia recently discussed some of the difficulties that his member companies face in penetrating the American market. AMT recently attempted to put together a consortium of firms to market products in the United States. The combination of a weak machine tool industry, firmly entrenched competitors and unresolved inventory/delivery issues, however, have frustrated this effort. Unlike Spain's larger machine tool builders, the relatively small firms of AMT are still searching for an effective strategy to tap the American market.
Show Highlights
BIEMH 2002 featured the sixth edition of Spain's National Machine Tool Design competition. This year, the award was shared by Kondia Urbano Conde S.A. (Elgoibar, Spain)--in recognition of its P60-V2 high speed precision machining center-and ONA Electroerosion S.A. (Durango, Spain and Dayton, Ohio)--for overall product design strategy. Kondia manufactures a complete line of conventional, CNC-operated and high speed milling machines. ONA is the world's oldest manufacturer of EDM equipment and also the leading EDM builder in the European Union. ONA ram- and wire-EDM machines feature advanced spark-control and automatic programming technologies.
The heartland of this dynamic industry is the beautiful and rugged Basque section of northern Spain near the Atlantic coast and the French border. As the commercial center of the industrious Bizkaia region, Bilbao is the host city for one of Europe's largest machine tool shows, the biennial BIEMH. In the past, Bilbao was known primarily as a gritty center of heavy industry. But after undergoing an impressive renaissance, this city of 400,000 residents has emerged as a place of alluring charm.
When the 22nd BIEMH exhibition opened at Bilbao's International Trade Fair on March 11, the Spanish machine tool industry had some important accomplishments to celebrate. For example, Spanish builders currently manufacture more than 2,000 different machine models. Many of these products feature innovative technology that was developed in Spain.
The rapid improvement of Spanish technology in recent years is primarily the result of strong investment in research and development. On the average, Spanish machine tool builders allocate 5 percent of their annual turnover to R&D. For the country's largest builders, this investment may represent 10 percent or more. The success of this industry has been greatly facilitated by inter-company alliances in the areas of process development, marketing, distribution and supply chain management. Many of these cooperative efforts have been coordinated through the Machine Tool Manufacturers' Association of Spain (AFM) and its sister organization, the Export Trade Association of Spanish Manufacturers of Accessories, Component Parts and Tools for Machine Tools (AMT).
Strong investment and effective cooperation enable Spanish machine tool manufacturers to compete aggressively in global markets. Spain's principal machine tool builders offer products for high speed milling, turning, grinding and EDM that incorporate advanced capabilities. As a reflection of the growing reputation of Spanish technology, Germany was the largest customer in 2001 for Spanish machine tools, purchasing more than 18 percent of all the country's exports.
The defining characteristic of the most prominent Spanish machine tools is flexibility in meeting specific user requirements. Thus, many of the large machining centers exhibited at BIEMH 2002 are designed to suit the production systems of important automotive and aerospace clients. At the same time, however, Spanish builders offer a wide range of conventional and CNC machine tools that are suitable for typical job shop applications.
Spanish-American Market
While Spain's largest machine tool builders have established solid marketing networks in the United States, economic conditions during the past 12 months have created a slump in the market for Spanish exports. Because the United States currently accounts for less than 8 percent of Spain's total export trade, however, this doesn't represent a serious problem by itself. Because the appetites of American consumers continue to drive manufacturing activity around the globe, however, many Spanish builders are experiencing the impact of a softer American economy on their customers in Europe and Asia. As a result, AFM predicts that the steady growth its members have enjoyed since 1995 may be interrupted when the final figures for 2002 are recorded.
In this vein, AMT president Ramon Cenar-ruzabeitia recently discussed some of the difficulties that his member companies face in penetrating the American market. AMT recently attempted to put together a consortium of firms to market products in the United States. The combination of a weak machine tool industry, firmly entrenched competitors and unresolved inventory/delivery issues, however, have frustrated this effort. Unlike Spain's larger machine tool builders, the relatively small firms of AMT are still searching for an effective strategy to tap the American market.
Show Highlights
BIEMH 2002 featured the sixth edition of Spain's National Machine Tool Design competition. This year, the award was shared by Kondia Urbano Conde S.A. (Elgoibar, Spain)--in recognition of its P60-V2 high speed precision machining center-and ONA Electroerosion S.A. (Durango, Spain and Dayton, Ohio)--for overall product design strategy. Kondia manufactures a complete line of conventional, CNC-operated and high speed milling machines. ONA is the world's oldest manufacturer of EDM equipment and also the leading EDM builder in the European Union. ONA ram- and wire-EDM machines feature advanced spark-control and automatic programming technologies.
2004 machine tool consumption
According to AMT--The Association For Manufacturing Technology and the American Machine Tool Distributors' Association (AMTDA), June U.S. machine tool consumption totaled $236.93 million. This total, as reported by companies participating in the USMTC program, was up 19.5 percent from May and up 0.9 percent from the total of $234.79 million reported for June 2003. With a first-half total of $1,249.68 million, 2004 is up 31.9 percent compared with 2003.
U.S. machine tool consumption is also reported on a regional basis for five geographical breakdowns: Northeast, Southern, Midwestern, Central and Western. For more information on these regions, as well as other USMTC data
U.S. machine tool consumption is also reported on a regional basis for five geographical breakdowns: Northeast, Southern, Midwestern, Central and Western. For more information on these regions, as well as other USMTC data
Thursday, September 14, 2006
Spain steps it up: the country is now home to the world's fourth largest machine tool show. That fact, combined with Spain's long metalworking history
This year's Spanish machine tool show was big in many respects. Known as BIEMH, the 2004 edition of this biennial show was its largest in terms of number of attendees and exhibitors. In fact, BIEMH now ranks as the world's fourth largest machine tool show, behind EMO, IMTS and BI-MU.
Show organizers and Spain's association of machine tool manufacturers, known as AFM, have made strides to generate greater interest from the international metalworking community. It seems this effort has paid off, because this year's show drew visitors from 54 countries and featured 1,894 exhibitors from 34 countries. Of course, these numbers would not have been attainable were it not for a new, larger exhibition center. The show's new home is the Bilbao Exhibition Center (BEC), which offers 60,000 square meters of exhibition space (41 percent more than the previous venue) and a layout that features six column-free exhibition halls.
Show organizers and Spain's association of machine tool manufacturers, known as AFM, have made strides to generate greater interest from the international metalworking community. It seems this effort has paid off, because this year's show drew visitors from 54 countries and featured 1,894 exhibitors from 34 countries. Of course, these numbers would not have been attainable were it not for a new, larger exhibition center. The show's new home is the Bilbao Exhibition Center (BEC), which offers 60,000 square meters of exhibition space (41 percent more than the previous venue) and a layout that features six column-free exhibition halls.
US machine tool sales soar in June - Materials Outlook - Brief Article
U.S. machine tool consumption totaled an estimated $244.6 million in June, up a whopping 67.1 percent from a revised $146.4 million the previous month but just 3.3 percent higher than $236.8 million in June 2002, according to a joint report by the American Machine Tool Distributors' Association (AMTDA), Rockville, Md., and the Association for Manufacturing Technology (AMT), McLean, Va. Noting the first monthly year-on-year increase since November 2000, AMT president Albert W. Moore said that "a single instance does not constitute a trend, but a trend must have a starting point." Machine tool consumption in the first half totaled $952.9 million, down 17.9 percent from $1.2 billion in the same period last year.
CAM software for probing: software for creating probing routines off-line promises to make machine tool probing easier to use. As a few examples show,
Shops and plants that are thinking of investing to realize a more automated process may be overlooking an automation tool that already waits in the machining center.
Through the use of a machining center's spindle-mounted probe, a shop can save time and effort in a variety of ways. Prior to machining, probing can be used to automatically confirm that the correct part has been loaded to match the program. Probing can also locate that part, wherever it sits on the table, so time-consuming setup might be eliminated. During machining, probing can check the semi-finished part to see how much of a finishing pass is needed. And after machining is done, probing can be used to perform certain inspections right at the machine tool, before the part is unclamped and taken away.
In fact, because probing can improve efficiency in so many different ways, it is probably sate to say that the probe is underused in almost every shop that owns one.
The shops themselves are not entirely to blame for this. Part of the reason probing is underused is the awkwardness that often comes with adding probing to the process. Shops generate milling and drilling tool paths with ease, using any of a variety of CAM systems. But probing calls for macros that are often either added to the NC code through manual editing, or else entered right at the CNC.
Some recently introduced software tools attempt to address this shortcoming. The systems described in the following pages make it more practical to program probing operations off-line. They could all be thought of as "CAM for probing," in that they generate machine-independent probing routines that can be postprocessed for individual machining centers. However, the three examples of probing software included here also represent three different ways of thinking about the way that probing is used.
One of the systems recognizes the probe-equipped machine tool as a metrology device. This system allows programs to be shared seamlessly between CMM and machine tool, and it allows the same analysis that is applied to CMM data to be applied to data captured with a machine tool probe.
Another system emphasizes the role of probing in specialized machining challenges, seeking to coordinate probing with the machining moves in cases where an important part of the job is unpredictable.
A third approach, and the first one described below, is intended simply to make probing in general a more natural part of the typical machining process. By operating as a plug-in within the CAM software that is used for tool paths, this utility expands the reach of the shop's primary CAM system to include probing moves.
Probing As A Plug-In
Productivity+, pronounced "productivity plus," is a CAM software plug-in from Renishaw (Hoffman Estates, Illinois), the maker of probes and probe accessories. Currently, the plug-in is available with GibbsCAM software from Gibbs & Associates (Moorpark, California).
The point of this plug-in is to allow the CAM software that uses it to call upon the probe as easily as it might call up any cutting tool in its library. That means probing no longer has to be a separate programming consideration apart from the tool paths. In addition to the convenience this provides, improved confidence is another benefit. Like the tool paths, the probing moves can be verified using the CAM software's own verification capability.
This utility supports probing for part setup, identification and inspection. It can also be used with the stationary tool setting probe to automate tool length and diameter measurements.
There is another version of the utility that is not a plug-in. Productivity+ Active Editor is a stand-alone software product. For existing CAM systems that do not include functionality for probing, this software lets the programmer import and modify NC programs, so the programmer can add probing moves as a follow-up step.
Probing The Unknown
PS-Fixture from Delcam (Windsor, Ontario) is part of the company's Power Solution family of integrated CAD/CAM products. That same family includes PowerMill software for generating NC part programs, and also PowerInspect software, which is capable of equipping these programs with probing routines. The focus of PS-Fixture lies between these modules. Its purpose has to do with putting probing to work in ways that overcome unknown variables in the machining of certain complex parts.
Exactly what variables are addressed can vary, depending on the application and the shop. For an ordinary part program, three things can be treated as known. They are: the precise position of the workpiece, the precise shape of the stock before machining and the precise shape that the machining program is supposed to create. When any one of these three aspects of the job cannot be known, PS-Fixture can potentially fill in the gaps.
Here are examples:
* Unknown work position. Plenty of production applications use dedicated, customized fixturing to lock a part in place precisely where the NC program expects to find it. But as the part size gets bigger, setting up the work that precisely becomes more difficult to do. Shifting and rotating a large workpiece can be time-consuming, not to mention fraught with error. It would be easier just to move the program instead--and that is what PS-Fixture attempts to do. After probing a complex workpiece in numerous locations, the software can use best-fit calculations in conjunction with a CAD model to determine the part's location and orientation in space. The software then sends a variety of offsets to the CNC that both shift and rotate the program's coordinate axes so that the program aligns with the part.
Wednesday, September 13, 2006
Mittler Brothers Machine & Tool Moves into Larger Facility & Adds New Equipment
Mittler Brothers Machine & Tool has recently moved to a new facility in Wright City, Missouri Oust west of St. Louis) and installed new CNC equipment and expanded its capabilities.
The 25-year-old firm produces, tools, dies and special machines as well as offering custom CNC machining and fabrication. The company also produces its own lines of products for the racing industry.
The Mittler brothers (Mike and Paul) started their business with the two of them as the only employees in a 2,500-sq.-ft. facility. They eventually grew into 30,500sq.-ft. of space across three adjacent buildings in Foristell, Missouri.
The current and planned growth of the company led the brothers to move to a 3year-old facility with 50,400-sq.-ft. in neighboring Wright City.
"The opportunity to consolidate our operations under one roof with room for expansion is tremendous," stated Mike Mittler.
Since the facility had been designed for manufacturing it has been a great fit for us," commented Paul
Mittler. "We haven't found anything that we would change in the layout or design."
With the larger space and growing business, the company quickly started adding new equipment. Two major pieces of CNC equipment have been added since the move took place.
One is an Okuma MA-40H horizontal machining center with a 10-pallet Fastems automatic loader. It features a 100-tool changer, a 40-taper 15,000-rpm spindle, and a table capacity of 24" x 28" up to 880 pounds.
Another new piece is a Haas SL20 CNC lathe with a magazine-style barfeeder. It features a 5hp motor with 3,000-rpm; a full C-axis on the spindle; a capacity of 24" between centers and live tooling.
"This equipment, with all the advanced technology, will allow us to improve our efficiency and expand our 'lights out' production," stated Mike Mittler.
Other new capabilities at the company include wet painting and shot blasting. Both booths were already in the facility. "The booths will enable us to improve our turnaround time and finish quality," noted Paul Mittler.
Mittler Brothers works with steel, tool steel, aluminum, stainless steel, brass, bronze, titanium and other exotic metals.
It serves such industries as automotive, medical, heavy transportation and automation.
Other equipment at the company includes: four CNC vertical machining centers; a 4-axis horizontal machining center; four CNC turning centers; an Okuma lathe with a Westech gantry loader (for unattended operation) and a CNC high definition plasma cutter.
CAD is used on all software and Virtual Gibbs CAM software is used for programming.
The 25-year-old firm produces, tools, dies and special machines as well as offering custom CNC machining and fabrication. The company also produces its own lines of products for the racing industry.
The Mittler brothers (Mike and Paul) started their business with the two of them as the only employees in a 2,500-sq.-ft. facility. They eventually grew into 30,500sq.-ft. of space across three adjacent buildings in Foristell, Missouri.
The current and planned growth of the company led the brothers to move to a 3year-old facility with 50,400-sq.-ft. in neighboring Wright City.
"The opportunity to consolidate our operations under one roof with room for expansion is tremendous," stated Mike Mittler.
Since the facility had been designed for manufacturing it has been a great fit for us," commented Paul
Mittler. "We haven't found anything that we would change in the layout or design."
With the larger space and growing business, the company quickly started adding new equipment. Two major pieces of CNC equipment have been added since the move took place.
One is an Okuma MA-40H horizontal machining center with a 10-pallet Fastems automatic loader. It features a 100-tool changer, a 40-taper 15,000-rpm spindle, and a table capacity of 24" x 28" up to 880 pounds.
Another new piece is a Haas SL20 CNC lathe with a magazine-style barfeeder. It features a 5hp motor with 3,000-rpm; a full C-axis on the spindle; a capacity of 24" between centers and live tooling.
"This equipment, with all the advanced technology, will allow us to improve our efficiency and expand our 'lights out' production," stated Mike Mittler.
Other new capabilities at the company include wet painting and shot blasting. Both booths were already in the facility. "The booths will enable us to improve our turnaround time and finish quality," noted Paul Mittler.
Mittler Brothers works with steel, tool steel, aluminum, stainless steel, brass, bronze, titanium and other exotic metals.
It serves such industries as automotive, medical, heavy transportation and automation.
Other equipment at the company includes: four CNC vertical machining centers; a 4-axis horizontal machining center; four CNC turning centers; an Okuma lathe with a Westech gantry loader (for unattended operation) and a CNC high definition plasma cutter.
CAD is used on all software and Virtual Gibbs CAM software is used for programming.
Machine Tool Consumption Up 38.4%
In August, US machine tool consumption amounted to $225.52 million, according to AMT-The Association For Manufacturing Technology (McLean, VA), and the American Machine Tool Distributors' Association (AMTDA, Rockville, MD). This number, reported by companies that participate in the US Machine Tool Consumption program, was up 6.4% from July and up 54.2% from the total of $146.27 million reported for August 2003. With a year-to-date total of $1778.59 million, 2004 is up 38.4% compared with 2003.
Jointly compiled by the two trade associations, the USMTC report provides regional and national consumption data on domestic and imported machine tools and related equipment. Machine tool consumption in the US is also reported on a regional basis for five geographic breakdowns.
August machine tool consumption in the Northeast Region totaled $31.39 million, up 5.0% when compared to July's $29.89 million, and 20.6% ahead of August 2003. At $259.45 million, year-to-date machine tool consumption has increased 48.0%.
In the Southern Region, machine tool consumption in August was $32.62 million, 17.6% less than July's $39.59 million, but up 34.8% when compared to last August. Year-to-date, the total consumption of $270.92 million is a 5.4% drop when compared to the same time last year.
At $80.96 million, the August machine tool consumption in the Midwestern Region was 1.6% higher than July's $79.72 million, and 58.9% higher than the total for August 2003. With a year-to-date total of $710.59 million in consumption, the year 2004 is running 46.5% ahead of 2003 at the same time.
Central Region machine tool consumption in August, at $44.06 million, was 20.8% ahead of July's $36.49 million, and up 67.3% from the August 2003 report. Totaling $309.22 million, year-to-date 2004 machine-tool consumption was 47.3% higher than the comparable figure for 2003.
In the Western region, August machine tool consumption reached $36.48 million, up 39.1% compared to the $26.22 million total for July, and 94.4% higher than the August 2003 total. At $228.40 million, year-to-date 2004 is an impressive 77.9% ahead of the same period in 2003.
Jointly compiled by the two trade associations, the USMTC report provides regional and national consumption data on domestic and imported machine tools and related equipment. Machine tool consumption in the US is also reported on a regional basis for five geographic breakdowns.
August machine tool consumption in the Northeast Region totaled $31.39 million, up 5.0% when compared to July's $29.89 million, and 20.6% ahead of August 2003. At $259.45 million, year-to-date machine tool consumption has increased 48.0%.
In the Southern Region, machine tool consumption in August was $32.62 million, 17.6% less than July's $39.59 million, but up 34.8% when compared to last August. Year-to-date, the total consumption of $270.92 million is a 5.4% drop when compared to the same time last year.
At $80.96 million, the August machine tool consumption in the Midwestern Region was 1.6% higher than July's $79.72 million, and 58.9% higher than the total for August 2003. With a year-to-date total of $710.59 million in consumption, the year 2004 is running 46.5% ahead of 2003 at the same time.
Central Region machine tool consumption in August, at $44.06 million, was 20.8% ahead of July's $36.49 million, and up 67.3% from the August 2003 report. Totaling $309.22 million, year-to-date 2004 machine-tool consumption was 47.3% higher than the comparable figure for 2003.
In the Western region, August machine tool consumption reached $36.48 million, up 39.1% compared to the $26.22 million total for July, and 94.4% higher than the August 2003 total. At $228.40 million, year-to-date 2004 is an impressive 77.9% ahead of the same period in 2003.
Monday, September 11, 2006
Ceramic balls—Saint Gobain Advanced Ceramics, booth D-427 - Machine Tool Components and Accessories
According to the manufacturer, Cerbec ceramic balls for bearing applications last longer and provide better performance than steel bearings because of their inherently lower thermal expansion; smoother surface; increased hardness and stiffness; lighter weight; and corrosion/electricalresistant properties. These attributes recommend the use of these ceramic balls for bearings, linear guideways and machine tool spindles.
Autonomous robot cell—Motoman, booth B-6000 - Machine Tool Components and Accessories
In the A.R.C., autonomous robotic cell, one Motoman robot positions parts for one or more additional process robots, eliminating the need for complex part fixtures and positionsers. According to the company, multiple-station processing allows parts to be completed within one workcell, and speeds throughput by eliminating transfer time.
Also on display will be the inverted-mount U50 robot from a servo-controlled overhead rail that is said to save floor space and improve access to two lathes durng tool changes, and the UP20 robot wall-mounted from a servo gallows to provide the extended reach needed to tend three boring and tapping machine tools.
Also on display will be the inverted-mount U50 robot from a servo-controlled overhead rail that is said to save floor space and improve access to two lathes durng tool changes, and the UP20 robot wall-mounted from a servo gallows to provide the extended reach needed to tend three boring and tapping machine tools.
Fully hydrostatic tool grinding machine—Rollomatic, booth B-6838 - Grinding/Abrasive Machining Equipment
The GrindSmart 6000XL is a fully hydrostatic grinding machine. Hydrostatic functions allow friction-free linear and rotary movements for all six axes, including grinding spindle, to enhance the accuracy, speed, rigidity and perpetual repeatability of the machine in production, according to the company.
The machine is a fully automated, CNC super-precision grinding center with six hydrostatic machine axis and three axis for the integrated robot load/unload station. It is designed for the complete manufacture of small-to large-diameter carbide and HSS cutting tools in one clamping with a range of 0.1 mm (0.008") to 32.0 mm (1.250") in diameter.
Also on display will be the GrindSmart 620XS universal tool grinding machine for production grinding of rotary cutting tools in the size range of 0.2 to 16 mm (0.008" to 0.625").
The machine is a fully automated, CNC super-precision grinding center with six hydrostatic machine axis and three axis for the integrated robot load/unload station. It is designed for the complete manufacture of small-to large-diameter carbide and HSS cutting tools in one clamping with a range of 0.1 mm (0.008") to 32.0 mm (1.250") in diameter.
Also on display will be the GrindSmart 620XS universal tool grinding machine for production grinding of rotary cutting tools in the size range of 0.2 to 16 mm (0.008" to 0.625").
Saturday, September 09, 2006
Balanceable toolholder system—Rego-Fix Tool, booth E-2623 - Machine Tool Components and Accessories - Brief Article
The new Hi-Q ring system can be added to any standard holder that has the necessary mounting surface. According to the company, its new balancing ring system will help manufacturers and machine shops meet these balancing requirements. For smooth operation at higher speeds, holders must be balanced to meet the specifications set by machine and tooling manufacturers.
Most holders currently being manufactured by the company will accept the new rings. While the design of the new holders has changed, the end user will get the same high quality with added features as holders purchased in the past, the company says.
The company will also be displaying a new tabletop balancing machine that allows users to balance the Hi-Q balancing ring system using the angular method, or to balance existing holders by material subtraction, material addition or fixed position.
Most holders currently being manufactured by the company will accept the new rings. While the design of the new holders has changed, the end user will get the same high quality with added features as holders purchased in the past, the company says.
The company will also be displaying a new tabletop balancing machine that allows users to balance the Hi-Q balancing ring system using the angular method, or to balance existing holders by material subtraction, material addition or fixed position.
Machine tool economics
The 2004-2005 Economic Handbook of the Machine Tool Industry is now available from AMT--The Association for Manufacturing Technology. This annual guide offers the latest information about the domestic and international machine tool industries, as well as their respective economies. It was compiled from hundreds of domestic and foreign sources, and both product- and company-specific machine tool data are included. Information about capital equipment purchases is outlined for several major consuming industries. The domestic data cover areas such as employment, machine tool shipments, machine tools in use, and the financial condition of the industry. The handbook also provides a range of international facts for almost two dozen foreign countries, typically including production, imports and exports by type of machine tool. The handbook is free to AMT members, or $295 plus $5 postage and handling for non-members.
Machine Tool Sales Hit Four-Year High
Manufacturing industry optimism continued to pay dividends for equipment builders as sales of US machine tools in September reached the highest level in four years. With September sales totaling $389.20 million, machine tool builders saw an increase in sales of 74.6% over $222.86 million reported for September 2003, according to the latest figures of the US Machine Tool Consumption (USMTC) report released by the American Machine Tool Distributors' Association (AMTDA, Rockville, MD) and AMT-The Association For Manufacturing Technology (McLean, VA).
The latest report showed sales rose 89.8% in September compared to August sales of $205.01 million, and the 2004 year-to-date total of $2146.95 million rose 42.2% versus 2003 sales of $1509.41 million through September. The figures are based on the totals of actual data reported by companies participating in the USMTC program.
"Manufacturing in the US continues to show signs of a strong comeback," according to AMTDA President Ralph J. Nappi. "Machine tool orders in September hit their highest level in four years with all regions of the country showing growth."
Regional sales showed strong overall gains paced by robust improvements in the West Region, which totaled September sales of $56.07 million, an increase of 72.1% over $32.59 million in August sales and a 196.1% leap over the September 2003 total of $18.94 million. The West Region's year-to-date total of $279.39 million rose 89.6% over September 2003 sales of $147.33 million.
In the Midwest, September sales of $162.77 million rose 156.5% over the prior month's $63.47 million in sales and increased 46.6% compared with sales of $111.03 million during September 2003. With a year-to-date total of $853.66 million, the Midwest region is 43.2% ahead of $595.99 in sales through September 2003.
With September sales of $72.47 million, the Central Region machine tool consumption increased 50.6% compared to $48.13 million in August and sales were up 115.4% over September 2003 sales of $33.64 million. With a year-to-date total of $386.50 million, the Central Region sales are up 58.7% compared to the YTD 2003 sales of $243.58 million.
Northeast Region sales of $55.03 million rose 102.3% compared to August's $27.21 million and 98.0% compared to $27.79 million last September. At $312.64 million, year-to-date machine tool consumption in the Northeast ran 52.7% higher than $204.71 million through September 2003.
In the South Region, September machine tool consumpdon totaled $42.85 million, 27.5% higher than the $33.62 million in August and 36.2% higher than $31.46 million for September a year ago. The year-to-date South Region total of $314.77 million fell 1.0% compared to $317.80 million through September 2003.
The latest report showed sales rose 89.8% in September compared to August sales of $205.01 million, and the 2004 year-to-date total of $2146.95 million rose 42.2% versus 2003 sales of $1509.41 million through September. The figures are based on the totals of actual data reported by companies participating in the USMTC program.
"Manufacturing in the US continues to show signs of a strong comeback," according to AMTDA President Ralph J. Nappi. "Machine tool orders in September hit their highest level in four years with all regions of the country showing growth."
Regional sales showed strong overall gains paced by robust improvements in the West Region, which totaled September sales of $56.07 million, an increase of 72.1% over $32.59 million in August sales and a 196.1% leap over the September 2003 total of $18.94 million. The West Region's year-to-date total of $279.39 million rose 89.6% over September 2003 sales of $147.33 million.
In the Midwest, September sales of $162.77 million rose 156.5% over the prior month's $63.47 million in sales and increased 46.6% compared with sales of $111.03 million during September 2003. With a year-to-date total of $853.66 million, the Midwest region is 43.2% ahead of $595.99 in sales through September 2003.
With September sales of $72.47 million, the Central Region machine tool consumption increased 50.6% compared to $48.13 million in August and sales were up 115.4% over September 2003 sales of $33.64 million. With a year-to-date total of $386.50 million, the Central Region sales are up 58.7% compared to the YTD 2003 sales of $243.58 million.
Northeast Region sales of $55.03 million rose 102.3% compared to August's $27.21 million and 98.0% compared to $27.79 million last September. At $312.64 million, year-to-date machine tool consumption in the Northeast ran 52.7% higher than $204.71 million through September 2003.
In the South Region, September machine tool consumpdon totaled $42.85 million, 27.5% higher than the $33.62 million in August and 36.2% higher than $31.46 million for September a year ago. The year-to-date South Region total of $314.77 million fell 1.0% compared to $317.80 million through September 2003.
Friday, September 01, 2006
Getting to submicron accuracy: as machine tool builders introduce models designed for submicron accuracies and subminiature workpieces, a variety of d
In nature, scientists are sometimes able to distinguish one species from another only by examining DNA, the unique genetic code in every living cell. In these cases, external appearances do not offer reliable clues. This is much the case with a new breed of vertical machining centers designed for submicron accuracy. These machines do not look strikingly different from other precision machine tools. Yet the submicron model has hidden features and subtle attributes that prove it to be a very different creature, one that has evolved to function in an environment where microns and nanometers (millionths and billionths of a meter) are critical.
Some of the ways in which these machines are likely to deviate from normal expectations for a VMC can be observed in the Hyper2J from Makino (U.S. headquarters in Mason, Ohio). Comparable models from other builders may represent further radical departures from the norm, but looking at this machine helps us understand the design factors that tend to define the "nature of the beast." The chief factors are vibration, heat, rigidity and control unit capability.
* The four-point leveling mounts underneath the Hyper2J rest on a base made of metrology-grade granite that is 250 mm (almost 10 inches) thick. This granite "foundation" isolates the machine structure from vibration in the floor. Granite has 1/10 to 1/20 the thermal conductivity of cast iron, so it resists the effects of ambient temperature changes.
* The spindle is designed to reduce vibration and counter thermal growth. It has a direct tool clamping system that does not require a toolholder or collet. A mechanism inside the spindle uses hydraulic pressure to collapse around the tool shank, much the way the individual hydraulic toolholder would. According to the designers, this feature minimizes rotational vibration inevitably introduced by imperfections in a separate toolholder. Minimizing vibration is a priority because super small cutting tools (end mills with a diameter of 0.03 mm are typical) are susceptible to breakage when subjected to minute vibrations.
* The internal temperature of the spindle is maintained by automatically cooling the lubricant that circulates through it. The work light inside the machine uses LEDs because they are much cooler than other types of lights.
Spindle speeds range from 3,000 to 40,000 rpm (a 170,000-rpm spindle is available.)
* There are no linear motors. Makino has opted for ballscrews and slideways for axis drives, citing the company's ability to achieve the necessary straightness and smoothness in its production techniques. Maximum feed rates and rapid traverse rates are 12 m/min. (472 ipm).
* The machine has provisions for measuring the position of the tool tip to less than 1 micron. An "ultra-low pressure" contact-type measuring device determines tool length. A proximity-style non-contact spindle positioning device allows the position of the tool tip to be corrected in all three (X, Y and Z) axes. After a tool change, the level of machining surfaces will be higher or lower by less than 1 micron. To detect broken tool tips, an electrical current is transmitted through the cutting tool. If the tool breaks, the disrupted circuit triggers an alarm.
Interestingly, Makino says it has the most experience determining appropriate speeds and feeds for a 0.03-mm diameter carbide end mill. Machine settings for other tools are established on an application-by-application basis.
* The axis position feedback system uses a 0.5-nanometer scale to reliably track axis motion commands programmable in steps as small as 10 nanometers. Makino's stated positioning accuracy for this machine is [+ or -]0.3 micron, with a repeatability accuracy of [+ or -]0.2 micron.
* The control unit, which combines Fanuc hardware for CNC processing with a Windows CE graphical user interface, supports nanometer interpolation and millisecond block processing time. A proprietary "Super Geometry Intelligence" servo control system provides smooth machined surfaces. This kind of smoothing feature grows in importance as cutting tools and programmed steps become so small that workpiece features and tool marks approach the same size range.
Makinng Submicron Machining Practical Makino stresses that the Hyper2J is an attempt to make submicron machining in three axes practical for shops intent on moving to this level of accuracy. The company says that the machine is intended for the real world, not the laboratory. The Hyper2J does require a temperature-controlled room. Another version, the Hyper2, incorporates a thermal chamber for controlling its own temperature in ordinary shop environments to achieve submicron accuracy.
Some of the ways in which these machines are likely to deviate from normal expectations for a VMC can be observed in the Hyper2J from Makino (U.S. headquarters in Mason, Ohio). Comparable models from other builders may represent further radical departures from the norm, but looking at this machine helps us understand the design factors that tend to define the "nature of the beast." The chief factors are vibration, heat, rigidity and control unit capability.
* The four-point leveling mounts underneath the Hyper2J rest on a base made of metrology-grade granite that is 250 mm (almost 10 inches) thick. This granite "foundation" isolates the machine structure from vibration in the floor. Granite has 1/10 to 1/20 the thermal conductivity of cast iron, so it resists the effects of ambient temperature changes.
* The spindle is designed to reduce vibration and counter thermal growth. It has a direct tool clamping system that does not require a toolholder or collet. A mechanism inside the spindle uses hydraulic pressure to collapse around the tool shank, much the way the individual hydraulic toolholder would. According to the designers, this feature minimizes rotational vibration inevitably introduced by imperfections in a separate toolholder. Minimizing vibration is a priority because super small cutting tools (end mills with a diameter of 0.03 mm are typical) are susceptible to breakage when subjected to minute vibrations.
* The internal temperature of the spindle is maintained by automatically cooling the lubricant that circulates through it. The work light inside the machine uses LEDs because they are much cooler than other types of lights.
Spindle speeds range from 3,000 to 40,000 rpm (a 170,000-rpm spindle is available.)
* There are no linear motors. Makino has opted for ballscrews and slideways for axis drives, citing the company's ability to achieve the necessary straightness and smoothness in its production techniques. Maximum feed rates and rapid traverse rates are 12 m/min. (472 ipm).
* The machine has provisions for measuring the position of the tool tip to less than 1 micron. An "ultra-low pressure" contact-type measuring device determines tool length. A proximity-style non-contact spindle positioning device allows the position of the tool tip to be corrected in all three (X, Y and Z) axes. After a tool change, the level of machining surfaces will be higher or lower by less than 1 micron. To detect broken tool tips, an electrical current is transmitted through the cutting tool. If the tool breaks, the disrupted circuit triggers an alarm.
Interestingly, Makino says it has the most experience determining appropriate speeds and feeds for a 0.03-mm diameter carbide end mill. Machine settings for other tools are established on an application-by-application basis.
* The axis position feedback system uses a 0.5-nanometer scale to reliably track axis motion commands programmable in steps as small as 10 nanometers. Makino's stated positioning accuracy for this machine is [+ or -]0.3 micron, with a repeatability accuracy of [+ or -]0.2 micron.
* The control unit, which combines Fanuc hardware for CNC processing with a Windows CE graphical user interface, supports nanometer interpolation and millisecond block processing time. A proprietary "Super Geometry Intelligence" servo control system provides smooth machined surfaces. This kind of smoothing feature grows in importance as cutting tools and programmed steps become so small that workpiece features and tool marks approach the same size range.
Makinng Submicron Machining Practical Makino stresses that the Hyper2J is an attempt to make submicron machining in three axes practical for shops intent on moving to this level of accuracy. The company says that the machine is intended for the real world, not the laboratory. The Hyper2J does require a temperature-controlled room. Another version, the Hyper2, incorporates a thermal chamber for controlling its own temperature in ordinary shop environments to achieve submicron accuracy.
Enhancing machine tool productivity
In addition to quickly responding to customer demands, job shops can also reduce programming, tooling and production times with ShopMill version 6.4, says manufacturer Siemens.
Featuring step-by-step, onscreen programming, the software includes 3D views with simulation, including real-time simulation: an engraving cycle; an enhanced tooling list with angle head cutter definition, tap definition and Pace mill geometry; and enhanced workpiece measurements in manual mode.
Users are provided with a 3D view of the part to be cut while in simulation or real-time mode. As a result, possible machining errors can be detected relatively early, says the company.
The new engraving cycle offers the capability of engraving complex text on a radius. This single-button feature can be useful when engraving serial numbers, company names, and dates and times on cut parts.
Additionally, the software can be used in conjunction with the Sinumerik 810D or 840D while running Windows XP.
Featuring step-by-step, onscreen programming, the software includes 3D views with simulation, including real-time simulation: an engraving cycle; an enhanced tooling list with angle head cutter definition, tap definition and Pace mill geometry; and enhanced workpiece measurements in manual mode.
Users are provided with a 3D view of the part to be cut while in simulation or real-time mode. As a result, possible machining errors can be detected relatively early, says the company.
The new engraving cycle offers the capability of engraving complex text on a radius. This single-button feature can be useful when engraving serial numbers, company names, and dates and times on cut parts.
Additionally, the software can be used in conjunction with the Sinumerik 810D or 840D while running Windows XP.
Fast and flexible - EMO, machine tool show
This year's EMO - he premier European machine tool show - saw that continent's builders once again focused on innovative, but practical, product development.
When EMO was last held in Hannover, Germany, four years ago, the show was in a word, depressing. The mighty German machine tool industry, as well as the rest of Europe, was mired in the worst slump in a generation. And the news from this normally technologically elite exhibition had more to do with corporate realignments and cost reduction than with anything else, as so many European companies were moving into a survival mode reminiscent of the American machine tool industry of the mid 1980s.
This time around, however, the story was very different. While the general European economy is still in recession, conditions are far better for the machine tool builders. For one thing, the builders as a group are on stronger financial footing, having cut much of the fat out of their organizations and having established more viable business alignments - we'd call them mergers and acquisitions - where individual companies were in serious trouble going it alone. And equally important, European manufacturing in general is stepping up its investment again, cognizant of the need to cut costs through the development of more efficient production processes.
This situation, thankfully, has many European machine tool builders returning to more aggressive product development strategies of their own. While, like usual, many builders are pursuing a range of approaches to solving the manufacturing puzzle, there were some strong themes that played consistently throughout the halls of EMO. Most apparent were the notions of achieving greater speed and flexibility. By speed, we mean machines that move faster both in and out of the cut. And by flexibility, we mean machines that set up faster or otherwise move more deftly from one workpiece to the next. Here are some of the ways those ideas were on display at EMO.
Simply Fast
Perhaps the most striking presence at EMO is how commonplace high speed machining has become. Most of the leading European machining center builders had high speed models on display, and not just machines with fast spindles, but with significant other machine features that support accurate contouring at high feed rates as well.
High speed spindle makers are looking both to push the speed-and-power combination higher and to make their designs more dependable. Urged on largely by the aerospace industry, some builders are actively pursuing the technological goal of building a 100/100 (100,000 rpm/100 kW) spindle. But more are focused on addressing some lingering practical concerns in the 20,000 to 40,000 rpm range, which is growing common. Once such concern is service life. Currently a good life for a high speed spindle is 3,000 to 6,000 hours. That translates to just about two years.
High speed spindle failure is generally not catastrophic, says Siegfried Weiss, president of the German high speed spindle builder Weiss GmbH (Dyna Drive, Inc., Mentor, Ohio). "We've found that spindles are subjected to numerous little wrecks that over time that add up to a failure." According to Bill Popoli, president of the U.S. arm of Swiss spindle maker Ibag (Milford, Connecticut), there is a need for shops to understand that high speed spindles are not as "tough" as spindles found on standard machine tools. Still, it is a goal for Ibag and other spindle builders to get average service life up to five years.
As for control capabilities, it seems like the whole industry has upgraded to high speed CNCs capable of executing extraordinarily accurate cutter paths at very high feed rates - an enabling technology that has machining centers cutting everything from hardened tool steels (as hard as 62 Rc) to cast iron and aluminum auto and aerospace parts. For die/ mold machining, the newest capability now in the spotlight is curve interpolation, which a number of machine tool builders were touting - mainly those with Siemens and GE Fanuc controls. This feature allows complex curves such as non-uniform rational B-splines (NURBS) to be imported directly into the CNC rather than having to approximate those curves with point-to-point moves as is done in conventional contouring. The CNC interpolator then references the true curve math to contour more accurately, smoothly and, by most accounts, much faster too.
However, not everyone believes that curve interpolation is yet the total answer for high performance contouring. German control builder Heidenhain, Schaumburg, Illinois, for instance, thinks that curve interpolation makes sense only where data points in a conventional part program are clustered too close together to maintain a desirable feed rate. The far larger issue, they contend, is to apply look-ahead capabilities for the sake of real time "jerk control" - that is, to soften abrupt moments of axis acceleration and deceleration in order to create a smoother execution of conventional point-to-point contouring cuts. And that is a feature the builder was emphasizing, though they have introduced a curve interpolator as well.
When EMO was last held in Hannover, Germany, four years ago, the show was in a word, depressing. The mighty German machine tool industry, as well as the rest of Europe, was mired in the worst slump in a generation. And the news from this normally technologically elite exhibition had more to do with corporate realignments and cost reduction than with anything else, as so many European companies were moving into a survival mode reminiscent of the American machine tool industry of the mid 1980s.
This time around, however, the story was very different. While the general European economy is still in recession, conditions are far better for the machine tool builders. For one thing, the builders as a group are on stronger financial footing, having cut much of the fat out of their organizations and having established more viable business alignments - we'd call them mergers and acquisitions - where individual companies were in serious trouble going it alone. And equally important, European manufacturing in general is stepping up its investment again, cognizant of the need to cut costs through the development of more efficient production processes.
This situation, thankfully, has many European machine tool builders returning to more aggressive product development strategies of their own. While, like usual, many builders are pursuing a range of approaches to solving the manufacturing puzzle, there were some strong themes that played consistently throughout the halls of EMO. Most apparent were the notions of achieving greater speed and flexibility. By speed, we mean machines that move faster both in and out of the cut. And by flexibility, we mean machines that set up faster or otherwise move more deftly from one workpiece to the next. Here are some of the ways those ideas were on display at EMO.
Simply Fast
Perhaps the most striking presence at EMO is how commonplace high speed machining has become. Most of the leading European machining center builders had high speed models on display, and not just machines with fast spindles, but with significant other machine features that support accurate contouring at high feed rates as well.
High speed spindle makers are looking both to push the speed-and-power combination higher and to make their designs more dependable. Urged on largely by the aerospace industry, some builders are actively pursuing the technological goal of building a 100/100 (100,000 rpm/100 kW) spindle. But more are focused on addressing some lingering practical concerns in the 20,000 to 40,000 rpm range, which is growing common. Once such concern is service life. Currently a good life for a high speed spindle is 3,000 to 6,000 hours. That translates to just about two years.
High speed spindle failure is generally not catastrophic, says Siegfried Weiss, president of the German high speed spindle builder Weiss GmbH (Dyna Drive, Inc., Mentor, Ohio). "We've found that spindles are subjected to numerous little wrecks that over time that add up to a failure." According to Bill Popoli, president of the U.S. arm of Swiss spindle maker Ibag (Milford, Connecticut), there is a need for shops to understand that high speed spindles are not as "tough" as spindles found on standard machine tools. Still, it is a goal for Ibag and other spindle builders to get average service life up to five years.
As for control capabilities, it seems like the whole industry has upgraded to high speed CNCs capable of executing extraordinarily accurate cutter paths at very high feed rates - an enabling technology that has machining centers cutting everything from hardened tool steels (as hard as 62 Rc) to cast iron and aluminum auto and aerospace parts. For die/ mold machining, the newest capability now in the spotlight is curve interpolation, which a number of machine tool builders were touting - mainly those with Siemens and GE Fanuc controls. This feature allows complex curves such as non-uniform rational B-splines (NURBS) to be imported directly into the CNC rather than having to approximate those curves with point-to-point moves as is done in conventional contouring. The CNC interpolator then references the true curve math to contour more accurately, smoothly and, by most accounts, much faster too.
However, not everyone believes that curve interpolation is yet the total answer for high performance contouring. German control builder Heidenhain, Schaumburg, Illinois, for instance, thinks that curve interpolation makes sense only where data points in a conventional part program are clustered too close together to maintain a desirable feed rate. The far larger issue, they contend, is to apply look-ahead capabilities for the sake of real time "jerk control" - that is, to soften abrupt moments of axis acceleration and deceleration in order to create a smoother execution of conventional point-to-point contouring cuts. And that is a feature the builder was emphasizing, though they have introduced a curve interpolator as well.
KMG Tool & Machine Co. adds more CNC equipment
KMG Tool & Machine Co., Wichita, Kansas, has recently added more CNC equipment.
The 22-year-old firm, which specializes in tooling, precision machining, welding and fabrication, is adding the equipment to handle larger-sized jobs.
Two pieces of equipment were recently installed. The first is a Mazak AN 60/120 3-axis vertical machining center with a 124"X, 58"Y and 23"Z.
The other piece is a Mazak SV-25 4-axis vertical machining center, which features an 80-tool changer.
"This equipment was needed to handle the larger parts and will also help us expand our customer base," stated KMG Tool & Machine's Mike Coffey.
Other equipment in the company's 24,000-sq.-ft. facility includes: a Flow waterjet (6.5' x 24'); a Mazak CNC lathe, four CNC mills; numerous vertical and horizontal mills; grinding equipment; and an 8,000-sq.-ft welding shop (AWS certified) with aluminum-Heli-Arc, steel-MIG, Tig and Arc welding.
KMG works with CATIA version 4 and 5 CAD software and SMARTCAM software with full 3D surfacing, 411 axis and 5th axis indexing.The company also has a QC lab with a CMM (48" x 78") and meets the requirements for DI-9000A, MIL-I-45208A and is a delegated source inspector.
"Our employees have an average of 25 years experience building quality tooling and production parts," stated KMG's Ken Coffey.
He noted that KMG has built long-term relationships with several suppliers and can provide such services as: heat treating; plating; broaching; precision grinding; sandblasting and painting.
The 22-year-old firm, which specializes in tooling, precision machining, welding and fabrication, is adding the equipment to handle larger-sized jobs.
Two pieces of equipment were recently installed. The first is a Mazak AN 60/120 3-axis vertical machining center with a 124"X, 58"Y and 23"Z.
The other piece is a Mazak SV-25 4-axis vertical machining center, which features an 80-tool changer.
"This equipment was needed to handle the larger parts and will also help us expand our customer base," stated KMG Tool & Machine's Mike Coffey.
Other equipment in the company's 24,000-sq.-ft. facility includes: a Flow waterjet (6.5' x 24'); a Mazak CNC lathe, four CNC mills; numerous vertical and horizontal mills; grinding equipment; and an 8,000-sq.-ft welding shop (AWS certified) with aluminum-Heli-Arc, steel-MIG, Tig and Arc welding.
KMG works with CATIA version 4 and 5 CAD software and SMARTCAM software with full 3D surfacing, 411 axis and 5th axis indexing.The company also has a QC lab with a CMM (48" x 78") and meets the requirements for DI-9000A, MIL-I-45208A and is a delegated source inspector.
"Our employees have an average of 25 years experience building quality tooling and production parts," stated KMG's Ken Coffey.
He noted that KMG has built long-term relationships with several suppliers and can provide such services as: heat treating; plating; broaching; precision grinding; sandblasting and painting.
Wednesday, August 30, 2006
Millions of components machined to millionths - Street Smarts - machine tool tolerances
"Inch worm, inch worm. Measuring the marigolds. Seems to me you'd stop and see how beautiful they are."
Let me tell you something about inch worms. We couldn't live without them.
In 1958 a U.S. Air Force contract was let to MIT and Giddings & Lewis Machine Tool to retrofit a standard boring mill for completely automatic operation. The result was the first numerically controlled machine tool, at least in North America. Kearney & Trecker came up with the automatic tool changer and it was off to the races. The advent of PLCs and microprocessors accelerated the manufacturing revolution.
I used to argue with my father that this was clearly the greatest advance in manufacturing in the second half of the 1900s. As he was chief of metrology for the U.S. Army Signal Corps in the early 1970s, his perspective was a little different. He insisted the coordinate measuring machine (CMM) and laser alignment were more important because they provided the foundation for accuracy and interchangeability on a repeatable basis. It really made plants interchangeable as well as parts.
A story told to me many years ago said that it was Henry Ford who brought back the first set of Johansson gauge blocks from Europe to the U.S. to put a sound metrology backbone into his flourishing enterprise. Jo blocks became standard throughout industry but they had limitations. They were ground to an accuracy of 1/100,000th of an inch. The accuracy of anything aligned with Jo blocks would thus be somewhat less than that. And the farther away you got from the master blocks, the looser the assured accuracy would be.
All this came to mind recently as I was visiting the Indianapolis diesel engine plant of International Truck and Engine and later the Sharonville transmission plant of Ford Motor Co. These are the respective homes of the new 6.0 L Power Stroke Diesel and the new R5 TorqShift automatic transmission. The Sharonville plant has recently received the highest score for quality among all Ford powertrain plants.
It is remarkable that both the engines and the transmissions have parts that are machined to the micron level, one millionth of an inch. That means that such parts are actually 10 times more accurate than yesterday's Jo blocks. Just think about that.
The superior shifting characteristics and durability of the new R5 are grounded in the ability to machine to the micron level. The new Siemens G-2 fuel injectors could not approach the level of performance required without micron level accuracy.
It's one thing to achieve micron level accuracy with a couple of parts, but now we're doing it with millions of parts and while it isn't exactly SOP at this point, it is not unusual either. When necessary, it is an advanced weapon available in today's arsenal of mass production manufacturing technology.
Not so long ago, injector parts were often sorted into undersize and oversize classes after machining was complete and then selectively assembled with other components that were broken down the same way Well, that just doesn't cut it anymore. And tell me that isn't an extremely expensive proposition.
Imagine producing over 8000 injectors per day in Carolina and getting them to Indianapolis JIT for tomorrow's 6.0 L production. You sure want to keep selective assembly to a minimum. High precision machining does have an economic payoff. Can you image the havoc that could be wrought by a bad batch of injectors?
There is an extreme need for consistency in order to meet performance and emission standards now and even more so in the future. When we are getting into pilot injection and rate shaping, playing with post injection, when we are peeling a second like an onion, when we need a very precise amount of fuel delivered with an exact atomization pattern, our dependence on micron level accuracy in parts production will only become greater.
It is only with the more accurate metrology base that we have been able to field the new generation of powertrain components and systems. And this is the base on which future progress depends. In short, only the inch worms can help us build a better marigold.
A great new tool for all machine shops
Subtitled The Basic Information You Need to Know in Order to Design and Form Good Parts, no other book about press brakes comes close to equaling the wide breath of information contained in this comprehensive text. Ben Rapien uses his 45 years of experience with press brake tooling applications to provide a thorough understanding of the variables that must be considered in selecting proper tooling, determining minimum machine requirements, using blank size calculations, and arriving at an acceptable bend sequence. Although the information presented is based on a solid engineering background, the technical descriptions have been simplified to allow press brake users to fully comprehend the many complex concepts and techniques used in forming operations. All of the principles and applications provided in the text are derived from "real world" experiences based on the actual parameters that have to be considered in order to produce quality parts. In addition, hundreds of well chosen illustrations, charts, and tables allow the reader to thoroughly comprehend how to get the most out of their press brake.
Contents: Review of the Press Brake. Press Brake Tooling (Normally Called Dies). The Basic 90[degrees] Bend. Air Bend Tonnage. Fundamental Information. Forming Other Types of Material. Gaging. Bend Allowance (What Size Should I Cut My Blank?). Safe Use of a Press Brake. Minimizing Die Marks on the Material. Offsets, Joggles, and "Z" Bends. Simple Channels. Hems and Seams. Radius Dies. Rib shapes. Corrugations. Box Forming. Beads or Curls. Wiping Dies. Plate Forming. European-Style Press Brake Tooling. Punching. Multiple Dies in the Press Brake. Other Important Information Needed for Making Good Tooling Decisions. Determining How to Make a Good Part. Understanding Words Used in the Context of Press Brake Tooling. Index.
Taiwan aspires to a leadership role: finding itself in the forefront of machine tool production, the island gets ready to step forward with its innova
Taiwan has clearly moved into the top ranks of machine tool building countries. It ranks fifth in the world in the dollar value of machine tools produced and fourth in the world in the dollar value of machine tools it exports.
Collectively and individually, Taipei builders are preparing for a leadership role in metalworking technology. This expectation was quite apparent at the most recent Taiwan International Machine Tool Show (TIMTOS) in Taipei. TIMTOS is Taiwan's premier biennial machine tool exhibition (see the box on the next page). The machines on display there would be hard to distinguish in performance or appearance from the best models coming from anywhere in the world.
The only thing lagging a bit is innovative homegrown technology. That is likely to change, however. In a few more years, TIMTOS may well be the show where the world gets its first glimpses of technology developed in Taiwan that is not available anywhere else. The country's current effort to coordinate and enhance R&D initiatives is definitely moving in that direction.
In the meantime, Taiwan builders are working together to change their image. For years, Taiwan presented itself as the source of low-cost machine tools. Today, the country wants the world to see it as the prime source of quality machines at a reasonable price.
Taiwan is especially eager to establish a firm foothold in emerging industrial countries such as Turkey, Russia, Brazil, India and mainland China. These markets are expected to grow rapidly in the short term. Moreover, these markets are not yet dominated by long-entrenched machine tool builders from Japan, Europe or the United States.
A number of Taiwan builders have a strong presence in the U.S. market, but it has taken these companies many years and a relatively large investment to get established. These companies remain deeply committed to the United States, but other builders are showing less patience and resolve in following this path. Their machines are more likely to reach the United States as privately labeled models marketed by U.S.-based importers who understand the U.S. buyer.
Machine tool builders in Taiwan tend to be relatively small, family-owned enterprises. However, all of the builders are well-supported by the national government in the sense that machine tool building is recognized as a key industry essential to the growth and development of high-tech Taiwanese industries. Thus, it is not surprising that the president of Taiwan, Chen Shui-bian, paid a personal visit to TIMTOS, speaking at a press conference and touring the exhibit areas. In his remarks, Mr. Chen characterized machine tools as "the mother of all industries," and reiterated his administration's support for building up central Taiwan as the hub of R&D facilities to promote machine tool building and related activities.
The results of this ongoing national support were evident at the show, especially in two area--the adoption of linear motors and the development of reliable, low-vibration high speed spindles. Compared to leading builders around the world, many Taiwan builders were not able to keep pace with implementing these technologies. With national sponsorship, builders were invited to work together to facilitate the transition to linear motors and advanced spindles. These initiatives made it possible for builders who otherwise lacked the engineering resources to make the transition on their own to do so in a timely and cost-effective manner.
Builders in Taiwan are remarkably realistic and candid about their strengths and about the challenges they face. They see strength in the relatively low wages that prevail on the island. Taiwan is located close to mainland China and India, two of the markets that Taiwan builders have targeted. Finally, Taiwan enjoys a well-developed social infrastructure and strong skills base, making "people power" a key asset.
Challenges are imposing, too. For labor-intensive activities, there is a shortage of job seekers. Companies are restricted from hiring quest workers from overseas above a certain percentage of their workforce. Land for industrial development is limited and facing growing demand. Proponents are seeking a government-backed "machinery industrial park" to be constructed in the central region of the country to solve this problem.
As effective as government funding for shared R&D efforts has been recently, this funding is threatened by spending cutbacks. The cost of steel and iron, the basic raw" materials for building machines, has risen markedly in the last 2 years and is expected to keep rising. On the mainland, the central government has enacted policies to protect and favor state-owned machinery builders, making it more difficult for Taiwan to achieve its goals there. Finally, fluctuations in currency exchange rates are not trending favorably for machine builders.
Machine tool buyers in the United States will do well to keep an eye on machine tool technology from Taiwan. U.S. plants have many options for filling their needs for low- and high-end machine tools. But between these extremes, Taiwan machines will be very well represented and are likely to offer reliable and capable machines at attractive prices.
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