Bare Metal Linux (BML), a tool that we implemented to accelerate the bring up of POWER5 * (1)-based systems, is described in this paper. The POWER5 processor, released in 2004, is the latest version of the POWER architecture from IBM (POWER is a RISC [reduced instruction set computer] architecture). The POWER5 design implements two-way simultaneous multithreading (SMT) on each of the two processor cores on the chip. SMT combines multithreading, which consists of multiple threads utilizing the same processor in one-at-a-time fashion, with the simultaneous use of the multiple execution units present in a modern processor. In the two-thread SMT architecture of POWER5, the execution units not needed by the first thread are available to the second thread in the same clock cycle.
Non-Uniform Memory Access (NUMA) refers to a computer memory architecture where the memory access time depends on the memory location. Specifically, access to local memory is faster than nonlocal memory. For increased efficiency the operating system must incorporate in its algorithms knowledge about NUMA, such as the ratio of access times to local and remote memories. Although POWER5 systems, which contain multiple memory controllers distributed throughout the machine, are not NUMA in the classical sense (remote memory latency is very close to local memory latency), they still benefit from NUMA-aware scheduling.
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When a new system is designed, it is necessary to put the hardware through a series of tests to verify that it functions as expected. Booting a general-purpose operating system is a complex exercise requiring hardware errors to be addressed, initializations to be set up correctly, and firmware to be functional before operating-system testing can commence. This bring-up process is usually done in stages, incrementally increasing the scope and coverage of the hardware tested.
Typically the bring up of a processor chip begins at wafer test, when test patterns are run on the wafer to detect any circuits that are not working correctly. After good test sites (on the wafer} have been identified, the chips are diced and mounted on substrates to form modules. The bring up then continues on these modules by mounting them in test fixtures, which provide the system environment. At this point the chips execute functional code sequences intended to verify proper instruction execution. These low-level tests consist of the following steps: (1) generate a stream of instructions, initial conditions, and expected results, (2) load and run the generated stream and save the results, and (3) compare these results to the expected results.
After the low-level tests have verified basic processor functions, more complex exercisers are then used to verify functions in the processor and memory subsystems. After this stage is completed, the verification process continues at the operating-system level. Support is provided to execute larger, more complex programs that require a file system for storing code, data, and supporting tools. At this point support for I/O devices is needed. Whereas it is fairly straightforward to develop and employ low-level exercisers for processor core and memory, when I/O is required, then the flexibility of a general-purpose operating system is typically needed.
The POWER5 system predecessor, using POWER4 * processors, (2) supported two methods of booting an operating system. In the first method the operating system is booted directly on the hardware by firmware. In the second method the firmware loads a hypervisor and, at the same time, the system resources are allocated to a number of hypervisor-controlled partitions. Each partition behaves as a separate virtual computer, on which an operating system may be loaded.
The POWER5 hypervisor provides additional virtualization capabilities compared to those for POWER4 systems, and in particular a high degree of resiliency to runtime errors. Supporting such advanced functions necessarily involves complexity. Although the architecture of the hypervisor has been designed to support additional virtual resources, these advanced functions were integrated throughout the hypervisor and the supporting firmware. As a result, POWER5 firmware no longer supports booting the operating system directly on the hardware.
This presented a problem during the bring-up phase of system development, when the hardware and the software were brought together. At this stage, the I/O had very limited testing. Without a general-purpose operating system running, the POWER5 bring-up team could not run operating system-based exercisers on the new hardware. Yet, the hypervisor had to be functional before an operating system could be booted. Complex error recovery during early bring up was not desirable because it had the potential to hide errors from the debug engineers. For these reasons relying on the hypervisor for the bring up was ruled out.
Friday, April 13, 2007
Friday, April 06, 2007
Tool and Cutter GRINDING
Do you get the point?
Keeping tools and cutters sharp is one of those inescapable overhead costs all manufacturers have to accept.
Like most other decisions in industry, deciding how and where to sharpen tools is a product-specific choice. It depends on overall cost, not just the rework fee.
Do-it-yourself sharpening is normally done by companies that can afford to have staff dedicated to this work or that need very specialized work.
But, overall, the trend seems to be greater use of outside sharpening specialists as manufacturers reduce labor costs. These services are frequently offered by tool manufacturers and by a large number of "regrind houses."
One company that has benefited from the trend to custom tooling is Acu-Grind Tool Works (Bradenton, FL). This operation specializes in both tool rework and the manufacture of specialized tools. Its president, Tony Antony, reports particular growth in the aerospace industry where tapered tools and tools for thin-wall cutting of aluminum are in demand.
In addition to reworking tools to custom specs the company also offers a design service to improve tool performance and life. "While this adds to up front cost, those who look at total cost per hole or cost per part will find we offer a cost advantage," according to Antony.
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According to Ed Sinkora, Walter Grinders (Fredericksburg, VA), their machines are optimized for tool grinding with a design that combines complete geometric freedom with high rigidity. "For example, with our machines, you are always grinding near the center of the work envelope. Overhang is minimal so vibration is minimized. These are patented features.
Walter's latest machine is called the Helitronic Vision, a 3D gantry design that has linear motors driving the linear axes and frameless torque motors for the rotating axes.
"We also beefed up the base, which is a 14,000-lb [6350-kg] mineral casting, to accommodate the extreme acceleration of the linear motors," he notes. (The machine weighs 20,000 lb [9071 kg].)
"Measuring the finished tool is an important issue," Sinkora says. "We use two systems. For in-process compensation, we use a probe system built into the machine that measures and adjusts diameter, flute depth, rake angle, helix angle, and back taper.
"But you can't certify a tool on the same machine on which it was made or reworked. It has to be an independent, off-line unit. We offer a machine that can measure down to ±0.7µm, proven with a NIST-certified gage.
As to market trends, Sinkora says, "The hottest new tools are those with variable helixes within the flute or helixes that vary from flute-to-flute on the same tool. Handling this work requires special programming."
Walter offers Tool Studio software to meet this need and other development challenges. It allows the user to create a grinding program while modeling the tool in 3D-the two functions are completely integrated. When you change the model, you change the program. There is no need to rewrite codes.
"Our software also contains a number of proprietary programs," Sinkora says. "We have a number of partnerships with major tool developers.
"The overall goal is achieving good surface-finish and accuracy at high speed. For example, we are able to grind and measure a K land.
Anca (Farmington Hills, MI) is a grinding machine builder specializing in tool sharpening. According to VP, Russell Riddleford, "Our company serves three markets: tool manufacturers, resharpening houses, and individual companies that have their own sharpening operations.
"Both the resharpening and individual companies are expanding, particularly those operations that can't afford a long turnaround time. You can't wait two weeks for a tool with a million-dollar machine sitting idle."
Riddleford says much of Anca's development work is aimed at improving software. "We have the dual goals of making it simpler, and handling the more complex geometries that tool designers continue to generate.
"We provide the customer 'lightsout' capability. You load the tools, set the programs, and that's it. The user need only program the tool's major parameters such as tool type [mill, drill], and key dimensions. On the other hand, these machines can be programmed for one-off capability.
"A unique feature of our machine is automated dressing. The user simply sets the frequency [every five tools, for example] and the dresser does the rest.
Measuring the reworked tool is an important aspect of the process. One example of the equipment used for this task is the Genius 3 from Zoller Inc. (Ann Arbor, MI). An automatic system that measures and inspects tools using incident and transmitted light, it magnifies the tool up to 200×. There is a measuring program for all critical parameters including radius contour, and tool contour and concentricity. It measures tools up to 600-mm long and 200 mm in diameter with repeatability of ±2µm and accuracy of 1µm.
Keeping tools and cutters sharp is one of those inescapable overhead costs all manufacturers have to accept.
Like most other decisions in industry, deciding how and where to sharpen tools is a product-specific choice. It depends on overall cost, not just the rework fee.
Do-it-yourself sharpening is normally done by companies that can afford to have staff dedicated to this work or that need very specialized work.
But, overall, the trend seems to be greater use of outside sharpening specialists as manufacturers reduce labor costs. These services are frequently offered by tool manufacturers and by a large number of "regrind houses."
One company that has benefited from the trend to custom tooling is Acu-Grind Tool Works (Bradenton, FL). This operation specializes in both tool rework and the manufacture of specialized tools. Its president, Tony Antony, reports particular growth in the aerospace industry where tapered tools and tools for thin-wall cutting of aluminum are in demand.
In addition to reworking tools to custom specs the company also offers a design service to improve tool performance and life. "While this adds to up front cost, those who look at total cost per hole or cost per part will find we offer a cost advantage," according to Antony.
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According to Ed Sinkora, Walter Grinders (Fredericksburg, VA), their machines are optimized for tool grinding with a design that combines complete geometric freedom with high rigidity. "For example, with our machines, you are always grinding near the center of the work envelope. Overhang is minimal so vibration is minimized. These are patented features.
Walter's latest machine is called the Helitronic Vision, a 3D gantry design that has linear motors driving the linear axes and frameless torque motors for the rotating axes.
"We also beefed up the base, which is a 14,000-lb [6350-kg] mineral casting, to accommodate the extreme acceleration of the linear motors," he notes. (The machine weighs 20,000 lb [9071 kg].)
"Measuring the finished tool is an important issue," Sinkora says. "We use two systems. For in-process compensation, we use a probe system built into the machine that measures and adjusts diameter, flute depth, rake angle, helix angle, and back taper.
"But you can't certify a tool on the same machine on which it was made or reworked. It has to be an independent, off-line unit. We offer a machine that can measure down to ±0.7µm, proven with a NIST-certified gage.
As to market trends, Sinkora says, "The hottest new tools are those with variable helixes within the flute or helixes that vary from flute-to-flute on the same tool. Handling this work requires special programming."
Walter offers Tool Studio software to meet this need and other development challenges. It allows the user to create a grinding program while modeling the tool in 3D-the two functions are completely integrated. When you change the model, you change the program. There is no need to rewrite codes.
"Our software also contains a number of proprietary programs," Sinkora says. "We have a number of partnerships with major tool developers.
"The overall goal is achieving good surface-finish and accuracy at high speed. For example, we are able to grind and measure a K land.
Anca (Farmington Hills, MI) is a grinding machine builder specializing in tool sharpening. According to VP, Russell Riddleford, "Our company serves three markets: tool manufacturers, resharpening houses, and individual companies that have their own sharpening operations.
"Both the resharpening and individual companies are expanding, particularly those operations that can't afford a long turnaround time. You can't wait two weeks for a tool with a million-dollar machine sitting idle."
Riddleford says much of Anca's development work is aimed at improving software. "We have the dual goals of making it simpler, and handling the more complex geometries that tool designers continue to generate.
"We provide the customer 'lightsout' capability. You load the tools, set the programs, and that's it. The user need only program the tool's major parameters such as tool type [mill, drill], and key dimensions. On the other hand, these machines can be programmed for one-off capability.
"A unique feature of our machine is automated dressing. The user simply sets the frequency [every five tools, for example] and the dresser does the rest.
Measuring the reworked tool is an important aspect of the process. One example of the equipment used for this task is the Genius 3 from Zoller Inc. (Ann Arbor, MI). An automatic system that measures and inspects tools using incident and transmitted light, it magnifies the tool up to 200×. There is a measuring program for all critical parameters including radius contour, and tool contour and concentricity. It measures tools up to 600-mm long and 200 mm in diameter with repeatability of ±2µm and accuracy of 1µm.
CNC analysis aids machine design
Moore Tool (Bridgeport, Connecticut) currently designs, engineers and builds machines in conjunction with its sister company, Producto, in a 200,000-square-foot facility with approximately 200 employees. When the company set out to build a five-axis, high speed machining center for use in the production of critical components, it faced numerous challenges. The machine was intended to serve critical needs of the turbo machinery, mold and die, scroll compressor and medical markets. To help meet the needs of these applications, a control supplier analyzed the machine's control system in order to optimize the performance of this particular design.
The machine needed to possess capabilities such as high speed (30,000 rpm to 40,000 rpm) cutting capability when milling materials ranging from aluminum to hardened Steel and titanium; dynamic response; good stability and vibration dampening; automation adaptability; a user-friendly Windows working environment; onboard cooling; substantial onboard memory in a CNC without external devices for downloading complex programs; and, above all, high precision.
Moore Tool embodied a "from the ground up" approach to develop its Five-Sided Precision (FSP) line of machining centers. Speed and accuracy were considered when evaluating the needs of working with various materials, as were the differing requirements of production and part accuracy. The requirements of machining aluminum and titanium with high production rates can differ when compared to the intricate contours and features of mold components produced directly in hardened steel. Adding the requirements for efficient graphite machining also produces significant challenges.
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The company says the need for a combination of high precision and high material removal rates was evident. The complex contour surface profiling on leading and trailing edges of blades, and especially blisks and IBRs, made a high speed processor essential to maintain acceptable feed rates. The machine configuration, particularly as it relates to the position and configuration of the rotary tables and spindle, would also play an integral role in meeting the needs of Moore Tool's customers.
The machine's CNC is an 840D from Siemens (Elk Grove Village, Illinois). To maximize machine performance, Siemens performed a detailed dynamic analysis of the machine, control and servodrive system. This service is called "Mechatronics." Data gathered during the Mechatronics process are used to optimize the complete machine concept.
In complex blade contour and finishing operations, the CNC provides an aerospace-specific software feature, CompCAD, by which the control's compressor function smoothes point-to-point programming. The real benefit of the control is realized when processing the part using Non-Rational Uniform B-Splines (NURBS), with which the machine can reach an advanced level of smooth contouring and chatter elimination. This is achieved by using splines in an axis-specific tolerance window. According to the manufacturer, contour violations are thus avoided; the efficiency of acceleration/deceleration curves is increased; and slowdowns/speed-ups at block transitions are virtually eliminated.
According to Moore Tool's engineers, in programming, the open architecture of the CNC, along with its high speed, user-defined macros and block search capabilities, have made it an "ideal choice" for the FSP300X. They go on to say that the ability of the CNC to handle large programs, which are typical for intricate mold and die applications, without "drip feed" is also noteworthy.
Optional features that are available with the machine include high-frequency spindle options as high as 80,000 rpm; a range of robotic part loaders, all of which are designed and built by Moore Tool, with the control parameters incorporated into the host CNC; a graphite machining package; a laser tool-setter with measurement and compensation standards; and various customized configurations. The machine can be enhanced with Siemens' Simodrive 611D drive packages.
The machine needed to possess capabilities such as high speed (30,000 rpm to 40,000 rpm) cutting capability when milling materials ranging from aluminum to hardened Steel and titanium; dynamic response; good stability and vibration dampening; automation adaptability; a user-friendly Windows working environment; onboard cooling; substantial onboard memory in a CNC without external devices for downloading complex programs; and, above all, high precision.
Moore Tool embodied a "from the ground up" approach to develop its Five-Sided Precision (FSP) line of machining centers. Speed and accuracy were considered when evaluating the needs of working with various materials, as were the differing requirements of production and part accuracy. The requirements of machining aluminum and titanium with high production rates can differ when compared to the intricate contours and features of mold components produced directly in hardened steel. Adding the requirements for efficient graphite machining also produces significant challenges.
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The company says the need for a combination of high precision and high material removal rates was evident. The complex contour surface profiling on leading and trailing edges of blades, and especially blisks and IBRs, made a high speed processor essential to maintain acceptable feed rates. The machine configuration, particularly as it relates to the position and configuration of the rotary tables and spindle, would also play an integral role in meeting the needs of Moore Tool's customers.
The machine's CNC is an 840D from Siemens (Elk Grove Village, Illinois). To maximize machine performance, Siemens performed a detailed dynamic analysis of the machine, control and servodrive system. This service is called "Mechatronics." Data gathered during the Mechatronics process are used to optimize the complete machine concept.
In complex blade contour and finishing operations, the CNC provides an aerospace-specific software feature, CompCAD, by which the control's compressor function smoothes point-to-point programming. The real benefit of the control is realized when processing the part using Non-Rational Uniform B-Splines (NURBS), with which the machine can reach an advanced level of smooth contouring and chatter elimination. This is achieved by using splines in an axis-specific tolerance window. According to the manufacturer, contour violations are thus avoided; the efficiency of acceleration/deceleration curves is increased; and slowdowns/speed-ups at block transitions are virtually eliminated.
According to Moore Tool's engineers, in programming, the open architecture of the CNC, along with its high speed, user-defined macros and block search capabilities, have made it an "ideal choice" for the FSP300X. They go on to say that the ability of the CNC to handle large programs, which are typical for intricate mold and die applications, without "drip feed" is also noteworthy.
Optional features that are available with the machine include high-frequency spindle options as high as 80,000 rpm; a range of robotic part loaders, all of which are designed and built by Moore Tool, with the control parameters incorporated into the host CNC; a graphite machining package; a laser tool-setter with measurement and compensation standards; and various customized configurations. The machine can be enhanced with Siemens' Simodrive 611D drive packages.
Dual-spindle gang tool lathe
New from Miyano, the BX-26S gang tool lathe with two spindles offers complete part machining of complex bar work (1" diameter and under) in a single setup. Two gang slides and a 3D linear turret are said to further contribute to the lathe's precision and faster cycle times.
The lathe's linear turret and traverse-type identical left and right spindles, both with 5 hp, ensure stable cutting from end to end and make the lathe especially good for long shaft work, the company says. High speed turning at up to 8,000 rpm maximum is possible by built-in spindle motors and high-rigidity linear guides. The built-in motors with the same collet capacity also allow faster cycle times because of overlapping operations. The elimination of a guide bushing speeds up operation time with less maintenance.
The lathe also offers revolving tool (eight tools max at 4,000 rpm max); L-spindle brake; cut-off confirmation (by spindle torque); parts catcher and parts conveyor; high pressure coolant (160 psi); right spindle inner conveyor; high pressure coolant (160 psi); fight spindle inner coolant and all axis rapid traverse (944 ipm); and an optional hinge-type chip conveyor (right side discharge).
The lathe's linear turret and traverse-type identical left and right spindles, both with 5 hp, ensure stable cutting from end to end and make the lathe especially good for long shaft work, the company says. High speed turning at up to 8,000 rpm maximum is possible by built-in spindle motors and high-rigidity linear guides. The built-in motors with the same collet capacity also allow faster cycle times because of overlapping operations. The elimination of a guide bushing speeds up operation time with less maintenance.
The lathe also offers revolving tool (eight tools max at 4,000 rpm max); L-spindle brake; cut-off confirmation (by spindle torque); parts catcher and parts conveyor; high pressure coolant (160 psi); right spindle inner conveyor; high pressure coolant (160 psi); fight spindle inner coolant and all axis rapid traverse (944 ipm); and an optional hinge-type chip conveyor (right side discharge).
Tool Calibrator helps align/verify CNC punch press turret
Designed to verify and restore angular alignment of turret press punching stations, Pilot(TM) Tool Calibration System consists of matched set of upper and lower interlocking components loaded into machine's turret upper and lower chambers. It operates in Verification and Alignment modes and features tri-color indicator lights to warn when system is not aligned, aligned angularly and concentrically within 0.012 in., or aligned angularly and concentrically within 0.0003 in.
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Call 1-800-328-4492 For FREE Brochure
Anoka, Minnesota: Mate Precision Tooling leads the punching industry with another "first" - the Mate Pilot(TM) Tool Calibration System. Designed to verify and restore the angular alignment of punching stations of a turret press, this system is highly accurate and easy to use.
The Pilot Tool Calibration System provides punch press users with an effective and reliable means for maintaining top punch press performance while safeguarding tooling and eliminating scrapped parts because of turret alignment problems.
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System Ensures Precision Concentric And Angular Tool Component Alignment
Consisting of a matched set of upper and lower interlocking components, which are loaded into the machine's turret upper and lower chambers, the system operates in two modes:
Verification mode - Confirms the precise concentric and angular alignment of the punch press turret to maintain high quality piece part production and maximum tool life.
Alignment mode - Restores the concentric and angular alignment of each station with the same precision as the initial machine installation.
System Is Easy And Fast To Use
Simply install the two halves of the calibration instrument into the press turret station to be aligned. Then rotate the turret to position the station to be aligned under the machine's ram. Tighten the integral adjustment handle which draws the two halves of the calibration instrument together.
As this engagement occurs, the interlocking design of the interface causes the loosened die holder assembly to draw precisely together into concentric and angular alignment relative to the upper bore of the turret.
During this process, tri-color indicator lights on the top of the instrument signal alignment. When the indicator shows: Red - system is not yet aligned; Yellow - system is aligned angularly and concentrically within 0.012 inch / 0.030 mm; Green - system is aligned angularly and concentrically within 0.0003 inch / 0.008 mm (recommended when punching materials 0.078 inch / 2.00 mm thickness or less).
High Precision Components Ensure Accuracy, Long Life
Like Mate's high precision, long-life tooling, the Mate Pilot Tool Calibration System is quality manufactured to provide years of alignment service thereby ensuring top punch press and tool performance. Each calibration instrument is machined from a single piece of the highest quality tool steel. Upper and lower halves of the instrument are separated near the end of the production process and just prior to the installation of hardware. This ensures that the two components are a precisely matched set with high accuracy, thereby eliminating any possibility of cumulative tolerances adversely affecting instrument accuracy.
Mate Pilot Tool Calibration Sets Available For Amada And Finn Power Presses
Mate Pilot Tool Calibration sets are available for Amada thick turret and Finn Power presses in: A Station 1/2 inch (12.70 mm), B Station 1-1/4 inch (31.80 mm), C Station 2 inch (50.80 mm), D Station 3-1/2 inch (88.90) and E Station 4-1/2 inch (12.70 mm). Accessory kits consisting of alignment and adjusting bars are required that work with any station size.
********************
Call 1-800-328-4492 For FREE Brochure
Anoka, Minnesota: Mate Precision Tooling leads the punching industry with another "first" - the Mate Pilot(TM) Tool Calibration System. Designed to verify and restore the angular alignment of punching stations of a turret press, this system is highly accurate and easy to use.
The Pilot Tool Calibration System provides punch press users with an effective and reliable means for maintaining top punch press performance while safeguarding tooling and eliminating scrapped parts because of turret alignment problems.
Advertisement
System Ensures Precision Concentric And Angular Tool Component Alignment
Consisting of a matched set of upper and lower interlocking components, which are loaded into the machine's turret upper and lower chambers, the system operates in two modes:
Verification mode - Confirms the precise concentric and angular alignment of the punch press turret to maintain high quality piece part production and maximum tool life.
Alignment mode - Restores the concentric and angular alignment of each station with the same precision as the initial machine installation.
System Is Easy And Fast To Use
Simply install the two halves of the calibration instrument into the press turret station to be aligned. Then rotate the turret to position the station to be aligned under the machine's ram. Tighten the integral adjustment handle which draws the two halves of the calibration instrument together.
As this engagement occurs, the interlocking design of the interface causes the loosened die holder assembly to draw precisely together into concentric and angular alignment relative to the upper bore of the turret.
During this process, tri-color indicator lights on the top of the instrument signal alignment. When the indicator shows: Red - system is not yet aligned; Yellow - system is aligned angularly and concentrically within 0.012 inch / 0.030 mm; Green - system is aligned angularly and concentrically within 0.0003 inch / 0.008 mm (recommended when punching materials 0.078 inch / 2.00 mm thickness or less).
High Precision Components Ensure Accuracy, Long Life
Like Mate's high precision, long-life tooling, the Mate Pilot Tool Calibration System is quality manufactured to provide years of alignment service thereby ensuring top punch press and tool performance. Each calibration instrument is machined from a single piece of the highest quality tool steel. Upper and lower halves of the instrument are separated near the end of the production process and just prior to the installation of hardware. This ensures that the two components are a precisely matched set with high accuracy, thereby eliminating any possibility of cumulative tolerances adversely affecting instrument accuracy.
Mate Pilot Tool Calibration Sets Available For Amada And Finn Power Presses
Mate Pilot Tool Calibration sets are available for Amada thick turret and Finn Power presses in: A Station 1/2 inch (12.70 mm), B Station 1-1/4 inch (31.80 mm), C Station 2 inch (50.80 mm), D Station 3-1/2 inch (88.90) and E Station 4-1/2 inch (12.70 mm). Accessory kits consisting of alignment and adjusting bars are required that work with any station size.
Laser Projector does not require mold and tool targets
Eliminating need for cooperative retro-reflective targets on molds and tools used in manufacturing and assembly, TLP uses laser projector to scan features of object. Data acquired from those features is used to align laser projector with tools. Suited for use in composites, marine, and aerospace industries, targetless system also eliminates need for metrology systems and operator time spent acquiring and evaluating targets.
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Eliminates Costly Mold and Tool Targets Currently Required in Manufacturing
Manchester NH - July 20, 2005 - Laser Projection Technologies, Inc., the leading innovator and manufacturer of laser projection systems for manufacturing and assembly, launches its targetless laser projector system. Laser Projection Technologies' (LPT) newest product, called TLP, eliminates the need for cooperative retro-reflective targets on molds and tools used in manufacturing. The TLP system uses a laser projector to scan features of an object and use the data acquired from those features to align the laser projector with the manufacturing tools. This saves manufacturers valuable manufacturing time by eliminating the cumbersome task of placing targets and installing expensive targeting systems on their tools and molds. These tooling targeting systems have been required by all laser projectors until now. LPT's targetless laser projectors offer significant cost reductions and gains in manufacturing flexibility to OEMs in complex manufacturing and assembly, including the advanced composites, marine and aerospace industries.
Currently, most manufacturers make use of traditional hard tooling solutions in their manufacturing processes. Rigid material templates made from aluminum, Mylar, or even plywood serve as a guide for the manufacturing assemblers of products such as aircraft fuselages and boat hulls, as well as positioning ribs, brackets and substructures within a fuselage or hull. These templates have to be manually moved into position from their storage locations and are often heavy or unwieldy due to their size and weight. Templates are very costly to make, store and maintain. Most importantly, they are subject to human error in positioning and suffer distortion from alterations to the template material itself.
Traditional laser positioning systems replace the manual templates by projecting the outline of parts under manufacture onto the manufacturing surface or tools, eliminating the hard tooling previously required. In typical laser positioning applications, technicians must place reflective targets on the tooling for the laser positioning system to "see" and coordinate its projected images.
Targetless laser projection eliminates the expense of the targets, the expensive metrology systems (such as a laser tracker, a coordinate measuring machine or other similar types of measurement systems), and the system operator time to acquire and evaluate the targets.
Pricing & Availability
LPT offers its targetless laser projection system at a list price of $250,000 and is shipping units now. For information on custom installation and multiple unit pricing contact LPT's sales office, (603) 421-0209, or visit the company's website www.lptcorp.com for the representative closest to your location.
About Laser Projection Technologies, Inc.
Founded in 2000 and privately held, LPT has the largest installed base of laser positioning systems in the world. The world's leading manufacturers recognize LPT's laser positioning systems as the most accurate, easy-to-use, and robust laser projection systems available in the world. LPT's customers are constantly seeking leaner production methods to speed up manufacturing and lower costs.
********************
Eliminates Costly Mold and Tool Targets Currently Required in Manufacturing
Manchester NH - July 20, 2005 - Laser Projection Technologies, Inc., the leading innovator and manufacturer of laser projection systems for manufacturing and assembly, launches its targetless laser projector system. Laser Projection Technologies' (LPT) newest product, called TLP, eliminates the need for cooperative retro-reflective targets on molds and tools used in manufacturing. The TLP system uses a laser projector to scan features of an object and use the data acquired from those features to align the laser projector with the manufacturing tools. This saves manufacturers valuable manufacturing time by eliminating the cumbersome task of placing targets and installing expensive targeting systems on their tools and molds. These tooling targeting systems have been required by all laser projectors until now. LPT's targetless laser projectors offer significant cost reductions and gains in manufacturing flexibility to OEMs in complex manufacturing and assembly, including the advanced composites, marine and aerospace industries.
Currently, most manufacturers make use of traditional hard tooling solutions in their manufacturing processes. Rigid material templates made from aluminum, Mylar, or even plywood serve as a guide for the manufacturing assemblers of products such as aircraft fuselages and boat hulls, as well as positioning ribs, brackets and substructures within a fuselage or hull. These templates have to be manually moved into position from their storage locations and are often heavy or unwieldy due to their size and weight. Templates are very costly to make, store and maintain. Most importantly, they are subject to human error in positioning and suffer distortion from alterations to the template material itself.
Traditional laser positioning systems replace the manual templates by projecting the outline of parts under manufacture onto the manufacturing surface or tools, eliminating the hard tooling previously required. In typical laser positioning applications, technicians must place reflective targets on the tooling for the laser positioning system to "see" and coordinate its projected images.
Targetless laser projection eliminates the expense of the targets, the expensive metrology systems (such as a laser tracker, a coordinate measuring machine or other similar types of measurement systems), and the system operator time to acquire and evaluate the targets.
Pricing & Availability
LPT offers its targetless laser projection system at a list price of $250,000 and is shipping units now. For information on custom installation and multiple unit pricing contact LPT's sales office, (603) 421-0209, or visit the company's website www.lptcorp.com for the representative closest to your location.
About Laser Projection Technologies, Inc.
Founded in 2000 and privately held, LPT has the largest installed base of laser positioning systems in the world. The world's leading manufacturers recognize LPT's laser positioning systems as the most accurate, easy-to-use, and robust laser projection systems available in the world. LPT's customers are constantly seeking leaner production methods to speed up manufacturing and lower costs.
Wednesday, April 04, 2007
Machining outside the shop: machine tools will continue to find their way into unexpected locations thanks not only to their shrinking sizes and price
Machine tools are becoming smaller and less expensive. CAD/CAM software and 3D scanning technologies are becoming easier to use. As these trends continue, so too will the trend of machining work being performed outside of the traditional machine shop by non-machinists.
Machine tools will be used in hospitals and dental laboratories. They will be used in jewelry makers' shops. They will be used in upper levels of downtown office buildings without disrupting daily business activities.
One of the reasons that machining technology is becoming attractive outside the realm of the metalworking industry is that it offers a way to reduce or eliminate handwork. These often-time-consuming processes are common to components made for medical, dental and jewelry-making applications to name just a few. Another reason for their growing popularity is the chance to eliminate any disconnects or delays resulting from the separation of designer and machine shop. This is accomplished by allowing the part designer to quickly create a prototype on a machine tool located in the CAD department. For some manufacturers, the capability to machine one's own prototypes offers added assurance that proprietary concepts will be kept under wraps. The main obstacles to installing machine tools in a space such as an office have been the equipment's size and weight. Most machine tools are too heavy for a typical freight elevator to handle and too bulky to fit through a standard 36-inch-wide doorway. Haas Automation (Oxnard, California) is addressing these needs with its Office CNC mills and lathes. Sized to fit comfortably in an office, these machines can be moved with a palletjack or equipment dolly. Alternately, casters can be installed on the machines for easy maneuverability. These machines operate on 240-volt single-phase power, which any facility should be able to accommodate without much trouble.
According to Dave Hayes, Haas product manager, the Office machines are likely to find themselves in a variety of places where very small parts machining capability is needed. One non-traditional industry where these machines are likely to nest is the jewelry business. A jewelry designer can machine the bulk of a new product's general shape into a wax mold, leaving only fine details to be finished by hand. Another possibility would be to bypass the casting process and machine the actual piece of jewelry from stock. Rings, for example, might be turned on a lathe and then taken to a mill to machine the final details. The goal here is to reduce or eliminate the amount of hand carving in the creation of new jewelry.
A manufacturer or shop that is currently using machine tools to create its parts may also use such very small machines to take prototype machining off of the shop floor and into the CAD department. The result could mean quicker new product development and speedier time to market.
Scanning, Then Milling
The union of machine tools and 3D scanning capability is a marriage of technologies that is driving machining operations to atypical locations, often for rapid prototyping and one-off work. Hospitals and dental laboratories are two of these locations. The ability to directly machine a body part or dental profile, or to create a mold for such parts from a patient's scanned 3D feature, greatly speeds the generation of these unique parts.
For some, the term "rapid prototyping" is synonymous with additive-material processes, such as stereolithography. Subtractive processes, on the other hand, can be just as effective in generating a prototype post-haste and may even be able to produce it in the part's specified material. Such is the case with what Roland DGA Corporation (Irvine, California) calls the subtractive rapid prototyping (SRP) process, which combines a benchtop 3D scanning system with a benchtop milling machine. Among other applications, this system is being used in medical labs by anaplastologists who create prostheses for facial reconstruction. The capability to quickly mill the basic form of a patient's prosthesis allows anaplastologists to focus their clinical energy on the final details that make the prostheses look as realistic as possible. In the case of ear reconstruction, for example, a plaster cast of a patient's good ear can be scanned, mirrored and then milled for reconstructing the damaged ear.
Machine tools will be used in hospitals and dental laboratories. They will be used in jewelry makers' shops. They will be used in upper levels of downtown office buildings without disrupting daily business activities.
One of the reasons that machining technology is becoming attractive outside the realm of the metalworking industry is that it offers a way to reduce or eliminate handwork. These often-time-consuming processes are common to components made for medical, dental and jewelry-making applications to name just a few. Another reason for their growing popularity is the chance to eliminate any disconnects or delays resulting from the separation of designer and machine shop. This is accomplished by allowing the part designer to quickly create a prototype on a machine tool located in the CAD department. For some manufacturers, the capability to machine one's own prototypes offers added assurance that proprietary concepts will be kept under wraps. The main obstacles to installing machine tools in a space such as an office have been the equipment's size and weight. Most machine tools are too heavy for a typical freight elevator to handle and too bulky to fit through a standard 36-inch-wide doorway. Haas Automation (Oxnard, California) is addressing these needs with its Office CNC mills and lathes. Sized to fit comfortably in an office, these machines can be moved with a palletjack or equipment dolly. Alternately, casters can be installed on the machines for easy maneuverability. These machines operate on 240-volt single-phase power, which any facility should be able to accommodate without much trouble.
According to Dave Hayes, Haas product manager, the Office machines are likely to find themselves in a variety of places where very small parts machining capability is needed. One non-traditional industry where these machines are likely to nest is the jewelry business. A jewelry designer can machine the bulk of a new product's general shape into a wax mold, leaving only fine details to be finished by hand. Another possibility would be to bypass the casting process and machine the actual piece of jewelry from stock. Rings, for example, might be turned on a lathe and then taken to a mill to machine the final details. The goal here is to reduce or eliminate the amount of hand carving in the creation of new jewelry.
A manufacturer or shop that is currently using machine tools to create its parts may also use such very small machines to take prototype machining off of the shop floor and into the CAD department. The result could mean quicker new product development and speedier time to market.
Scanning, Then Milling
The union of machine tools and 3D scanning capability is a marriage of technologies that is driving machining operations to atypical locations, often for rapid prototyping and one-off work. Hospitals and dental laboratories are two of these locations. The ability to directly machine a body part or dental profile, or to create a mold for such parts from a patient's scanned 3D feature, greatly speeds the generation of these unique parts.
For some, the term "rapid prototyping" is synonymous with additive-material processes, such as stereolithography. Subtractive processes, on the other hand, can be just as effective in generating a prototype post-haste and may even be able to produce it in the part's specified material. Such is the case with what Roland DGA Corporation (Irvine, California) calls the subtractive rapid prototyping (SRP) process, which combines a benchtop 3D scanning system with a benchtop milling machine. Among other applications, this system is being used in medical labs by anaplastologists who create prostheses for facial reconstruction. The capability to quickly mill the basic form of a patient's prosthesis allows anaplastologists to focus their clinical energy on the final details that make the prostheses look as realistic as possible. In the case of ear reconstruction, for example, a plaster cast of a patient's good ear can be scanned, mirrored and then milled for reconstructing the damaged ear.
The incentive effect: an expanded variety of targeted cutting tool solutions is coming, and the reasons go beyond just the needs of production. Change
You get what you pay for. That time-worn statement is true in more ways than we may realize. You can't expect high value from an item purchased cheaply--that's what the statement usually means. But it also applies to the money we intend to spend. Whenever a group or an industry decides to pay for a particular thing, the decision creates an incentive that brings more of that very thing into existence. Whatever we are determined to pay for, that is what we're likely to get.
All of this may sound rather vague. But in a concrete way, the changing financial incentives in metalworking today represent a force that will drive the development of more capable, more targeted cutting tools during the next several years.
Bernard North makes this case. He is the vice president of research, development and engineering for cutting tool supplier Kennametal (Latrobe, Pennsylvania). While one might expect a VP of research to view the future in terms of the technologies being researched right now, that's not the way he sees things. All of the cutting tool technology we will need for much of the next decade probably has already been invented or identified, he says. The foreseeable future of cutting tools--that is, the tooling we will use in the next 5 or 10 years--will be determined not by what is newly discovered, but instead by what is brought out of the laboratory for commercial development. Economic incentives will shape and drive that progress.
The easiest example of an economic incentive affecting cutting tool development is the changing nature of the machining work that shops are asked to perform. Today, a larger share of metalcutting involves near-net-shape workpieces. Workpiece materials such as aluminum and magnesium are gaining favor as alternatives to iron and steel. Stainless steel, high temperature alloys and composites are also seeing more widespread use. Trends such as these obviously affect cutting tool development. But set aside the changes in the machining work, and Mr. North sees other forces in play. The three changes described on the following page are also powerful where cutting tool development is concerned, even though these changes relate to nothing more than how money is viewed and awarded.
1. Different terms for tooling suppliers
Metalworking businesses that are large consumers of cutting tools are starting to use their clout to make tool suppliers accountable for productivity. The agreement often goes like this: The customer awards a particular vendor all of its tooling business, but in return that vendor agrees to improve the customer's efficiency by X percent every year.
Such an agreement can dramatically change the calculus of cutting tool implementation. In the past, there was a clear and obvious risk for the tool supplier in bringing a new tool to market. In cases where the existing offerings were adequate and customers knew how to use them well, a new product might not win acceptance. But now, the greater risk lies in not applying new technologies and new ideas. Unless it can come up with continually better products for key applications, the tooling supplier might risk falling short of its improvement goal.
2. Different compensation models for manufacturing professionals
Mr. North says he finds it more common for managers and engineers overseeing production operations to have an element of their compensation tied to the operations' performance. That is, they stand to get paid more if the processes produce better. Decision-makers who have this personal incentive tend to be more aggressive about embracing and implementing change. This attitude not only makes it more likely for new products to win acceptance, but it also makes it more likely that the advantages of new products will be fully exploited through the use of aggressive cutting conditions.
3. Different ways of looking at cost
A particular shop's choice between higher performance and lower performance tooling would seem to be driven by the technical merits of the two tools. In fact, that's often not the case. The choice may instead be determined by how the shop looks at costs. If the tooling budget is distinct and separate from other monies, then the lower purchase price of lower performance tooling may be compelling. However, if savings in other parts of the process are included in the analysis--that is, savings in machine time, labor, utilities, real estate, work-in-process inventory and so on--then the higher performance tooling may be more attractive, simply because of this change in perspective.
Many manufacturers are changing their decision-making process to take this broader view of tooling into account. Consumable tooling accounts for 3 to 4 percent of the total cost of machining operations, but because of its influence on cutting parameters, cycle times and the extent of operator involvement in the process, the choice of tooling helps to determine many other cost components that go into each piece. The broader view recognizes that tooling with a higher purchase price may deliver a lower cost per workpiece in the end
All of this may sound rather vague. But in a concrete way, the changing financial incentives in metalworking today represent a force that will drive the development of more capable, more targeted cutting tools during the next several years.
Bernard North makes this case. He is the vice president of research, development and engineering for cutting tool supplier Kennametal (Latrobe, Pennsylvania). While one might expect a VP of research to view the future in terms of the technologies being researched right now, that's not the way he sees things. All of the cutting tool technology we will need for much of the next decade probably has already been invented or identified, he says. The foreseeable future of cutting tools--that is, the tooling we will use in the next 5 or 10 years--will be determined not by what is newly discovered, but instead by what is brought out of the laboratory for commercial development. Economic incentives will shape and drive that progress.
The easiest example of an economic incentive affecting cutting tool development is the changing nature of the machining work that shops are asked to perform. Today, a larger share of metalcutting involves near-net-shape workpieces. Workpiece materials such as aluminum and magnesium are gaining favor as alternatives to iron and steel. Stainless steel, high temperature alloys and composites are also seeing more widespread use. Trends such as these obviously affect cutting tool development. But set aside the changes in the machining work, and Mr. North sees other forces in play. The three changes described on the following page are also powerful where cutting tool development is concerned, even though these changes relate to nothing more than how money is viewed and awarded.
1. Different terms for tooling suppliers
Metalworking businesses that are large consumers of cutting tools are starting to use their clout to make tool suppliers accountable for productivity. The agreement often goes like this: The customer awards a particular vendor all of its tooling business, but in return that vendor agrees to improve the customer's efficiency by X percent every year.
Such an agreement can dramatically change the calculus of cutting tool implementation. In the past, there was a clear and obvious risk for the tool supplier in bringing a new tool to market. In cases where the existing offerings were adequate and customers knew how to use them well, a new product might not win acceptance. But now, the greater risk lies in not applying new technologies and new ideas. Unless it can come up with continually better products for key applications, the tooling supplier might risk falling short of its improvement goal.
2. Different compensation models for manufacturing professionals
Mr. North says he finds it more common for managers and engineers overseeing production operations to have an element of their compensation tied to the operations' performance. That is, they stand to get paid more if the processes produce better. Decision-makers who have this personal incentive tend to be more aggressive about embracing and implementing change. This attitude not only makes it more likely for new products to win acceptance, but it also makes it more likely that the advantages of new products will be fully exploited through the use of aggressive cutting conditions.
3. Different ways of looking at cost
A particular shop's choice between higher performance and lower performance tooling would seem to be driven by the technical merits of the two tools. In fact, that's often not the case. The choice may instead be determined by how the shop looks at costs. If the tooling budget is distinct and separate from other monies, then the lower purchase price of lower performance tooling may be compelling. However, if savings in other parts of the process are included in the analysis--that is, savings in machine time, labor, utilities, real estate, work-in-process inventory and so on--then the higher performance tooling may be more attractive, simply because of this change in perspective.
Many manufacturers are changing their decision-making process to take this broader view of tooling into account. Consumable tooling accounts for 3 to 4 percent of the total cost of machining operations, but because of its influence on cutting parameters, cycle times and the extent of operator involvement in the process, the choice of tooling helps to determine many other cost components that go into each piece. The broader view recognizes that tooling with a higher purchase price may deliver a lower cost per workpiece in the end
Machine molds/dies—no manual polishing required
o accomplish high-precision machining of complex molds and dies, close tolerances and favorable surface finishes are essential. The result, in many cases, is lengthy throughput time. According to Mazak Corp., such precision machining can now be accomplished without necessitating manual polishing, with its new Super Mold Maker 2500 [micro].
Standard features such as a 40-hp, 25,000-rpm spindle with 30-tool magazine; 0.8-second tool-change time; and a machining area of 40.1" x 22.0" x 18.1" enhance machining performance. Three-phase spindle balancing can also reduce spindle vibration from 0.0012" to 0.000059", while the base has modified reinforcement ribs and a wider mounting span for linear-guide blocks to improve rigidity. Also included is a Fanuc 18iCNC, which allows users to chose from as many as ten selectable cutting parameters for each workpiece. High-resolution scale feedback of 0.000002" is standard for all axes.
Standard features such as a 40-hp, 25,000-rpm spindle with 30-tool magazine; 0.8-second tool-change time; and a machining area of 40.1" x 22.0" x 18.1" enhance machining performance. Three-phase spindle balancing can also reduce spindle vibration from 0.0012" to 0.000059", while the base has modified reinforcement ribs and a wider mounting span for linear-guide blocks to improve rigidity. Also included is a Fanuc 18iCNC, which allows users to chose from as many as ten selectable cutting parameters for each workpiece. High-resolution scale feedback of 0.000002" is standard for all axes.
EDM Machine offers fine hole option
EDGE2 Ram EDM Machine is capable of burning holes as small as 0.0012 in. using tungsten rods that are 0.008 in. in diameter. With sapphire die guides as small as 0.0008 in., length-to-diameter ratios of 10:1 and 15:1 are achievable. Machine can be converted from fine hole function to standard Ram EDM functions in less than 5 min without changing dielectric fluid. It is available with 8, 16, or 24 station ATC, capable of changing electrodes as small as 0.004 in. dia.
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Advanced Technology and Superior Quality Ideal For Micromachining
AUBURN HILLS, MI-June, 2005- The EDGE2 Ram EDM machine with fine hole option has the capability to do fine diameter holes that are more accurate and precise than any water-based, hole-popping machine available. The vast majority of hole poppers in the market are water based machines that are dedicated to doing hole popping, and which have dimensional limitations on holes of around 0.010-inches in diameter.
The EDGE2 Fine Hole machine is capable of burning holes as small as 0.0012-inches (0.03048 mm) using tungsten rods that are 0.0008-inches (0.02032 mm) in diameter. With the use of sapphire die guides as small as 0.0008-inches (0.02032 mm) and a high-speed spindle, the length-to-diameter ratios of 10-to-l and 15-to-l are achievable. Fine Hole and Standard Burning
Most of the other manufacturers of oil based hole poppers that are capable of creating small holes below 0.010-inches (0.25400 mm) are bench top models. These are primarily dedicated to fine hole work, and have very limited capabilities to do other EDM work.
The EDGE2 Fine Hole machine can be converted from a fine hole function to standard Ram EDM functions in less than 5 minutes without changing dielectric fluid. And, this machine is capable of 60 amp burning with full orbiting capabilities the same as all other Makino Ram EDMs.
Also, with other bench top hole popping models, automation capability is either limited or nonexistent. The EDGE2 Fine Hole machine can be ordered with an eight-, 16- or 24-station automatic tool changer (ATC), capable of changing electrodes with diameters as small as 0.004-inches (0.10160mm).
The machine can also be ordered with an automatic guide changer (AGC) with a capacity for six different die guide sizes. This allows for users to program the burning of up to six different hole diameters with 24 different tools for maximum unattended machine time gains.
The machine's intelligent monitoring system measures the length of the electrode after each hole burn. It then determines when to put it away and take out the next available electrode of sufficient length and diameter to complete the process in a quick and high-quality fashion.
Achieving Results
With Makino's high-pressure pump system capable of pressures up to 1450 PSI, the EDGE2 Fine Hole machine provides reliable flushing through copper pipe electrodes as small as 0.004-inches (0.10160 mm). With this capability, length-to-diameter ratios greater than 25-to-l are achievable.
Due to the EDGE2 Fine Hole machine's orbiting capabilities, it is possible to size and shape specific hole diameters. This allows users to generate tapered holes or flared holes that can be square at the opening and round at the exit.
In a recent test, a series of six holes were burned 0.100-inches (2.5400 mm) deep with a 0.004-inch (0.10160 mm) diameter copper electrode. This resulted in holes with an entrance burn of 0.0048-inches (0.12192 mm) and an exit burn of 0.0045-inches (0.11430mm).
In another test, a part was generated using 0.005-inch (0.12700 mm) copper pipe going 0.200-inches (5.08000 mm) deep into a blind hole. This is accomplished using a length to diameter ratio of 40-to-l on 30 holes with maximum repeatability and reliability.
EDGE2 Fine Hole Features
The EDGE2 with fine hole option features 12 x 10 x 10 inch (304 x 254 x 254 mm) travels and weighs a sturdy 6,000 pounds (2,722 kg). The machine bed is a heavily ribbed, single piece casting. Anti-friction linear guides and bearings complete the high-performance design, combining excellent rigidity with low-mass dynamics. This heavy-duty construction, combined with the fixed table, brings high levels of rigidity to every application.
Makino's award-winning drop tank design with zero fill time and dielectric chiller completes these features. The drop tank improves many aspects of the EDM process, as the retractable tank walls provide wide-open table access for safe, simple slide-on loading and faster, more accurate setups. And the adjustable tank depth allows optimal matching of dielectric fluid level to workpiece size for overall dielectric savings.
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Advanced Technology and Superior Quality Ideal For Micromachining
AUBURN HILLS, MI-June, 2005- The EDGE2 Ram EDM machine with fine hole option has the capability to do fine diameter holes that are more accurate and precise than any water-based, hole-popping machine available. The vast majority of hole poppers in the market are water based machines that are dedicated to doing hole popping, and which have dimensional limitations on holes of around 0.010-inches in diameter.
The EDGE2 Fine Hole machine is capable of burning holes as small as 0.0012-inches (0.03048 mm) using tungsten rods that are 0.0008-inches (0.02032 mm) in diameter. With the use of sapphire die guides as small as 0.0008-inches (0.02032 mm) and a high-speed spindle, the length-to-diameter ratios of 10-to-l and 15-to-l are achievable. Fine Hole and Standard Burning
Most of the other manufacturers of oil based hole poppers that are capable of creating small holes below 0.010-inches (0.25400 mm) are bench top models. These are primarily dedicated to fine hole work, and have very limited capabilities to do other EDM work.
The EDGE2 Fine Hole machine can be converted from a fine hole function to standard Ram EDM functions in less than 5 minutes without changing dielectric fluid. And, this machine is capable of 60 amp burning with full orbiting capabilities the same as all other Makino Ram EDMs.
Also, with other bench top hole popping models, automation capability is either limited or nonexistent. The EDGE2 Fine Hole machine can be ordered with an eight-, 16- or 24-station automatic tool changer (ATC), capable of changing electrodes with diameters as small as 0.004-inches (0.10160mm).
The machine can also be ordered with an automatic guide changer (AGC) with a capacity for six different die guide sizes. This allows for users to program the burning of up to six different hole diameters with 24 different tools for maximum unattended machine time gains.
The machine's intelligent monitoring system measures the length of the electrode after each hole burn. It then determines when to put it away and take out the next available electrode of sufficient length and diameter to complete the process in a quick and high-quality fashion.
Achieving Results
With Makino's high-pressure pump system capable of pressures up to 1450 PSI, the EDGE2 Fine Hole machine provides reliable flushing through copper pipe electrodes as small as 0.004-inches (0.10160 mm). With this capability, length-to-diameter ratios greater than 25-to-l are achievable.
Due to the EDGE2 Fine Hole machine's orbiting capabilities, it is possible to size and shape specific hole diameters. This allows users to generate tapered holes or flared holes that can be square at the opening and round at the exit.
In a recent test, a series of six holes were burned 0.100-inches (2.5400 mm) deep with a 0.004-inch (0.10160 mm) diameter copper electrode. This resulted in holes with an entrance burn of 0.0048-inches (0.12192 mm) and an exit burn of 0.0045-inches (0.11430mm).
In another test, a part was generated using 0.005-inch (0.12700 mm) copper pipe going 0.200-inches (5.08000 mm) deep into a blind hole. This is accomplished using a length to diameter ratio of 40-to-l on 30 holes with maximum repeatability and reliability.
EDGE2 Fine Hole Features
The EDGE2 with fine hole option features 12 x 10 x 10 inch (304 x 254 x 254 mm) travels and weighs a sturdy 6,000 pounds (2,722 kg). The machine bed is a heavily ribbed, single piece casting. Anti-friction linear guides and bearings complete the high-performance design, combining excellent rigidity with low-mass dynamics. This heavy-duty construction, combined with the fixed table, brings high levels of rigidity to every application.
Makino's award-winning drop tank design with zero fill time and dielectric chiller completes these features. The drop tank improves many aspects of the EDM process, as the retractable tank walls provide wide-open table access for safe, simple slide-on loading and faster, more accurate setups. And the adjustable tank depth allows optimal matching of dielectric fluid level to workpiece size for overall dielectric savings.
Engraving Tool provides precise depth control
Suited for applications requiring precise depth of engraving on various materials, Depth Controlling Nosepiece System enables CNC machine operator to control exposure of engraving toolbit to engraved part in increments down to 0.001 in. It is used in conjunction with 2L Spring Loaded Engraving Tool, which provides flexibility of engraving on materials with inconsistencies and odd shapes. Software creates incremental serial numbers, text, logos, and drawings.
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2L inc. Depth Controlling Nosepiece System now available
Hudson, Massachusetts - 2L inc. announced today the release of the newest product in its' Engraving Tool Line. The Depth Controlling Nosepiece System is a significant advancement to engraving technologies currently available for companies who desire precise depth of engraving on a wide variety of materials.
The Depth Controlling Nosepiece System enables the CNC machine operator to control the exposure of the engraving toolbit to the engraved part in increments as small as 0.001". Designed to meet the specific needs of customers performing engraving that requires accurate depth control, the Depth Controlling Nosepiece System is used in conjunction with the patented 2L Spring Loaded Engraving Tool and allows for absolute depth control for engraving using CNC machines.
"We are pleased to be able to continue enhancing our products and offering simple and effective solutions to our engraving customers," A company spokesman said. "Our patented Spring Loaded Tool provides customers the unique flexibility of engraving on a large variety of inconsistent materials. The Depth Controlling Nosepiece System now expands on our goal of helping customers solve their most challenging high-production engraving problems by allowing for precise user-defined engraving depths on those same materials."
The 2L Engraving Tool Line now features products which simplify engraving on a diverse range of materials of most densities including aluminum, plastic, brass, copper, steel, and glass.
* The Spring Loaded Engraving Tool allows the engraving toolbit to float over inconsistencies and odd-shapes in engraving materials, prolonging the life of the toolbit and enabling more consistent engraving.
* The 2L Engraving Software creates incremental serial numbers, engraves text, logos and drawings by creating standard g-code that is compatible with any CNC control that recognizes G0 and G1 commands.
* The Reducing Shaft attachment allows the Spring Loaded Tool to be held in any common one-half-inch collet or endmill holder.
* The Depth Controlling Nosepiece allows precise engraving depth control by limiting the toolbit extension from the Spring Loaded Engraving Tool.
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2L inc. Depth Controlling Nosepiece System now available
Hudson, Massachusetts - 2L inc. announced today the release of the newest product in its' Engraving Tool Line. The Depth Controlling Nosepiece System is a significant advancement to engraving technologies currently available for companies who desire precise depth of engraving on a wide variety of materials.
The Depth Controlling Nosepiece System enables the CNC machine operator to control the exposure of the engraving toolbit to the engraved part in increments as small as 0.001". Designed to meet the specific needs of customers performing engraving that requires accurate depth control, the Depth Controlling Nosepiece System is used in conjunction with the patented 2L Spring Loaded Engraving Tool and allows for absolute depth control for engraving using CNC machines.
"We are pleased to be able to continue enhancing our products and offering simple and effective solutions to our engraving customers," A company spokesman said. "Our patented Spring Loaded Tool provides customers the unique flexibility of engraving on a large variety of inconsistent materials. The Depth Controlling Nosepiece System now expands on our goal of helping customers solve their most challenging high-production engraving problems by allowing for precise user-defined engraving depths on those same materials."
The 2L Engraving Tool Line now features products which simplify engraving on a diverse range of materials of most densities including aluminum, plastic, brass, copper, steel, and glass.
* The Spring Loaded Engraving Tool allows the engraving toolbit to float over inconsistencies and odd-shapes in engraving materials, prolonging the life of the toolbit and enabling more consistent engraving.
* The 2L Engraving Software creates incremental serial numbers, engraves text, logos and drawings by creating standard g-code that is compatible with any CNC control that recognizes G0 and G1 commands.
* The Reducing Shaft attachment allows the Spring Loaded Tool to be held in any common one-half-inch collet or endmill holder.
* The Depth Controlling Nosepiece allows precise engraving depth control by limiting the toolbit extension from the Spring Loaded Engraving Tool.
Thursday, March 29, 2007
Software Keeps Jobs On Track - at Smith Machine Works
Smith Machine Works of Wichita, Kansas, is a 32-employee aircraft industry job shop founded in 1955 and incorporated in 1991. The majority of the company's business involves supplying small aluminum parts (typically less than 300 pounds and smaller than 2 feet by 4 feet by 1 foot) to Cessna-Raytheon and other manufacturers. To machine these aircraft parts, the shop uses two Y-axis lathes, four dual-axis lathes and nine vertical mills.
One issue the company was dealing with was scheduling. Smith had its own tracking system. "It was just a homemade setup," says Smith Machine's owner Chris Lette, "and we were having scheduling problems on our machines. We were also having problems tracking parts."
As a result, two Smith employees began gathering information on shop management software systems. Their year-long search culminated in a visit to the 1998 IMTS tradeshow, where they saw the Visual EstiTrack system from Henning Industrial Software (Hudson, Ohio).
"We had looked at quite a few systems, and we were impressed by this software's capabilities, so I made the decision to go ahead," Mr. Lette recalls. Smith installed the software in late 1999. "We've been very happy with what it has done so far. Previously, all our job tracking information was written on time cards. By eliminating the hand calculation required to determine how much was spent on each job, we experienced enough savings to more than pay for the software in a year." Because Smith bought the software primarily for its scheduling features, the savings derived from its job-tracking functions came as a pleasant surprise. These features were also important to meet documentation requirements from the shop's aircraft customers. Mr. Lette says that aircraft manufacturers must be able to trace all finished products back to the raw material stage, documenting who handled parts during production, what operations were executed and when they took place. With the new system, Smith's operators simply scan a bar code before and after each operation, and the software automatically charges their time to the corresponding job. Thus, the operation performed, the number of parts completed, the operator's name and duration of the job are all recorded.
It's also much easier for Mr. Lette to retrieve this information than it was previously. If a customer calls with a question about how a part was produced or how a job is progressing, Mr. Lette can find the answers with a few keystrokes and mouse clicks instead of rummaging through paperwork. Thus, he often tells his customers what they want to know immediately instead of having to look up the information and call them back.
"I can instantly find out where a customer's job is and how long it should take to finish. As a result, I can give them a good shipping date. We have a lot of people calling who want to know when they will receive their parts. Now, we're able to make our customers happy, because we can tell them where their parts are and when they'll get them," Mr. Lette explains.
With the system installed on the company's network, Mr. Lette says the information recorded in Visual EstiTrack is available to anyone in the shop who needs it. He also notes that, because information now moves around the shop more readily, jobs also move onto the shop schedule faster and easier. Additionally, Mr. Lette is impressed by the software's drag-and-drop scheduling module that helps juggle jobs to meet deadlines while it shows schedulers how their adjustments affect the daily or weekly plan.
The software allows schedulers to drag jobs from their current locations and drop them at icons for different workstations. When the schedule is altered, the software automatically recalculates the number of hours scheduled on each workstation affected by the change. If the scheduled hours exceed a predetermined capacity, the workstation icon turns red, indicating an overload that requires either a schedule change or overtime work.
"Drag-and-drop scheduling lets you move jobs to meet your schedule, so you can squeeze in a job that's hotter. That way, you can get the most from your machines and keep customers happy," Mr. Lette explains. "To see how it will affect other jobs on our schedule, we re-arrange jobs to meet delivery dates and customer requests. You can tell right away if you have open time on a machine, or whether you must work overtime or juggle jobs to meet delivery dates."
This instant feedback helps Smith Machine improve its delivery schedule. Mr. Lette attributes this improvement to shop managers' access to the company's schedule and material inventory. Hc bclicvcs these improvements in efficiency will continue, allowing his shop to win more jobs.
One issue the company was dealing with was scheduling. Smith had its own tracking system. "It was just a homemade setup," says Smith Machine's owner Chris Lette, "and we were having scheduling problems on our machines. We were also having problems tracking parts."
As a result, two Smith employees began gathering information on shop management software systems. Their year-long search culminated in a visit to the 1998 IMTS tradeshow, where they saw the Visual EstiTrack system from Henning Industrial Software (Hudson, Ohio).
"We had looked at quite a few systems, and we were impressed by this software's capabilities, so I made the decision to go ahead," Mr. Lette recalls. Smith installed the software in late 1999. "We've been very happy with what it has done so far. Previously, all our job tracking information was written on time cards. By eliminating the hand calculation required to determine how much was spent on each job, we experienced enough savings to more than pay for the software in a year." Because Smith bought the software primarily for its scheduling features, the savings derived from its job-tracking functions came as a pleasant surprise. These features were also important to meet documentation requirements from the shop's aircraft customers. Mr. Lette says that aircraft manufacturers must be able to trace all finished products back to the raw material stage, documenting who handled parts during production, what operations were executed and when they took place. With the new system, Smith's operators simply scan a bar code before and after each operation, and the software automatically charges their time to the corresponding job. Thus, the operation performed, the number of parts completed, the operator's name and duration of the job are all recorded.
It's also much easier for Mr. Lette to retrieve this information than it was previously. If a customer calls with a question about how a part was produced or how a job is progressing, Mr. Lette can find the answers with a few keystrokes and mouse clicks instead of rummaging through paperwork. Thus, he often tells his customers what they want to know immediately instead of having to look up the information and call them back.
"I can instantly find out where a customer's job is and how long it should take to finish. As a result, I can give them a good shipping date. We have a lot of people calling who want to know when they will receive their parts. Now, we're able to make our customers happy, because we can tell them where their parts are and when they'll get them," Mr. Lette explains.
With the system installed on the company's network, Mr. Lette says the information recorded in Visual EstiTrack is available to anyone in the shop who needs it. He also notes that, because information now moves around the shop more readily, jobs also move onto the shop schedule faster and easier. Additionally, Mr. Lette is impressed by the software's drag-and-drop scheduling module that helps juggle jobs to meet deadlines while it shows schedulers how their adjustments affect the daily or weekly plan.
The software allows schedulers to drag jobs from their current locations and drop them at icons for different workstations. When the schedule is altered, the software automatically recalculates the number of hours scheduled on each workstation affected by the change. If the scheduled hours exceed a predetermined capacity, the workstation icon turns red, indicating an overload that requires either a schedule change or overtime work.
"Drag-and-drop scheduling lets you move jobs to meet your schedule, so you can squeeze in a job that's hotter. That way, you can get the most from your machines and keep customers happy," Mr. Lette explains. "To see how it will affect other jobs on our schedule, we re-arrange jobs to meet delivery dates and customer requests. You can tell right away if you have open time on a machine, or whether you must work overtime or juggle jobs to meet delivery dates."
This instant feedback helps Smith Machine improve its delivery schedule. Mr. Lette attributes this improvement to shop managers' access to the company's schedule and material inventory. Hc bclicvcs these improvements in efficiency will continue, allowing his shop to win more jobs.
Machine tool trade with Japan and Taiwan
The President has directed that the US Trade Representative negotiate a limited extension of the voluntary restraint agreements (VRAs) with Japan and Taiwan on machine tools. These VRAs were negotiated in 1986 for national security reasons and were scheduled to expire on December 31, 1991.
Import restrictions on machining centers, computer-controlled lathes, computer-controlled punching and shearing machine tools, and computer-controlled milling machine tools will be removed progressively over a 2-year period beginning in January 1992.
To allow sufficient time for negotiations with concerned countries over the phase-out schedule, we are requesting that Japan and Taiwan extend the existing VRA restrictions on machining centers, computer-controlled lathes, computer-controlled punching and shearing machine tools, and computer controlled milling machine tools, scheduled to expire on December 31, 1991, for an additional 30 days.The Secretary of Commerce, as chairman of the cabinet-level Trade Promotion Coordinating Committee, will give special focus to ways to promote machine tools exports.
* US export control regulations will be reviewed to ensure that restrictions on machine tools are kept to the minimum consistent with national security.
* The Secretaries of Defense, Commerce, and Labor will designate officials at the Assistant Secretary level to work together to monitor the industry's performance and to consult regularly with industry representatives.
* The Secretary of Labor will help the machine tool industry improve technical training, human resource management, and the utilization of new and emerging technologies.
* The Secretaries of Commerce and Energy will examine which research and development efforts in the national laboratories could benefit the domestic machine tool industry and will recommend appropriate investment and technology transfer to realize such benefit.
* The Secretaries of Commerce and Defense will continue to implement the Domestic Action Plan of programs to support the revitalization of the US machine tool industry. Key elements of the Domestic Action Plan are as follows:
-- Support for the National Center for Manufacturing Sciences (amounting to $50 million during fiscal years 1988-91); and
-- Support by the Defense Department's Manufacturing Technology (MANTECH) research and development program. More than $33 million has been spent for research on machine tools and related technologies over the past 3 years. Funding for related technologies is estimated at $82 million over the FY 1991-95 period.
* The Secretary of Commerce will continue efforts under the US-Japan Cooperation Plan, which was begun in May 1990 to help promote US products to Japanese machine tool users and their subsidiaries in the United States.
Import restrictions on machining centers, computer-controlled lathes, computer-controlled punching and shearing machine tools, and computer-controlled milling machine tools will be removed progressively over a 2-year period beginning in January 1992.
To allow sufficient time for negotiations with concerned countries over the phase-out schedule, we are requesting that Japan and Taiwan extend the existing VRA restrictions on machining centers, computer-controlled lathes, computer-controlled punching and shearing machine tools, and computer controlled milling machine tools, scheduled to expire on December 31, 1991, for an additional 30 days.The Secretary of Commerce, as chairman of the cabinet-level Trade Promotion Coordinating Committee, will give special focus to ways to promote machine tools exports.
* US export control regulations will be reviewed to ensure that restrictions on machine tools are kept to the minimum consistent with national security.
* The Secretaries of Defense, Commerce, and Labor will designate officials at the Assistant Secretary level to work together to monitor the industry's performance and to consult regularly with industry representatives.
* The Secretary of Labor will help the machine tool industry improve technical training, human resource management, and the utilization of new and emerging technologies.
* The Secretaries of Commerce and Energy will examine which research and development efforts in the national laboratories could benefit the domestic machine tool industry and will recommend appropriate investment and technology transfer to realize such benefit.
* The Secretaries of Commerce and Defense will continue to implement the Domestic Action Plan of programs to support the revitalization of the US machine tool industry. Key elements of the Domestic Action Plan are as follows:
-- Support for the National Center for Manufacturing Sciences (amounting to $50 million during fiscal years 1988-91); and
-- Support by the Defense Department's Manufacturing Technology (MANTECH) research and development program. More than $33 million has been spent for research on machine tools and related technologies over the past 3 years. Funding for related technologies is estimated at $82 million over the FY 1991-95 period.
* The Secretary of Commerce will continue efforts under the US-Japan Cooperation Plan, which was begun in May 1990 to help promote US products to Japanese machine tool users and their subsidiaries in the United States.
Machine tool considerations come to the surface - Cover Story
When all the design, NC code generation and fixturing are complete, it's a machine tool that gets down to the business of contoured surfaces: cutting. Here are some things to consider about the machine you choose for the job.
A trip through any supermarket provides more than enough evidence to explain why machining of contoured surfaces is a growing segment of manufacturing. For example, each of the thousands of uniquely shaped plastic containers, found along the miles of aisles, gets its shape from a mold. And the mold gets its shape from a machine tool. It's estimated that 60 percent of all parts made today--a percentage that's growing--are made from plastic.
But there are more contoured surfaces to machine than just molds, although as our supermarket tour illustrates, they do make up a large chunk of the surface machining universe. Manufacturing is applying contoured surface machining technology across many industries such as automotive, power generation, aerospace, die and mold making, and health care.
Design considerations that take into account form as well as function increase the demands that are placed on manufacturers for contoured surfaces. Ergonomics--the physical interface between people and equipment--is also a force behind smoothing the square edges of many products. These design directives are showing up in virtually all manufactured products, whether they are made fromThis article is about machine tools that make such design a reality--specifically, machine tools that sculpt contoured surfaces--in metal. The end product of that sculpting may be a stainless steel mold and core for a plastic bottle, a medical implant or a highly contoured titanium spar to strengthen an aircraft fuselage. But without machine tools that are capable of efficiently performing such complex machining, the molds and spars themselves--as well as the end products that rely on them--would be much more costly.
To get a sense about the most important equipment-related issues, we spoke to LeBlond Makino (Mason, Ohio) and Cincinnati Milacron (Cincinnati, Ohio) about their surface cutting machines. While each builder approaches problems associated with machining surfaces somewhat differently, their customer goals are identical--machine more accurately to reduce labor and time spent doing non-value-added benchwork, thereby increasing throughput and quality.
Machining Surfaces 101
Probably the most basic requirement for machining surfaces is a machine tool that can adequately manipulate a cutter to impart the desired shape onto a raw workpiece. In other words, it needs the ability to perform simultaneous axis moves. While there are techniques for doing surfaces with less than three axes, we're going to concentrate on contour machining using at least Cartesian coordinates (X-Y-Z) and up to five axes--all capable of independent and simultaneous movement--linear as well as rotary.
The machining process for cutting a contoured surface is complicated not only by the rise and fall of the surface but also by the relatively small-diameter cutting tool that's used. On a 12-inch-wide flat surface, for example, two passes of a six-inch face mill will machine the surface. A 12-inch contoured surface, using a 3/4-inch ballnose end mill, may take 98 passes to cover the same area, because the ballnose design cuts a width that is a fraction of the tool's 3/4-inch diameter. And generally, surface machining is further divided into two operations: roughing and finishing.
In mold and die shops, roughing accounts for about 15 percent of the total machining time of a workpiece. While roughing may only use about 15 percent of machining time, it removes the majority of material, leaving just enough stock for the second operation--finishing.
Finish machining on a surface doesn't take up the other 85 percent of cycle time for producing a surface. Actually the percentage is closer to 50. Of the 35 percent that's left, 25 percent of that is hand machining (benchwork) needed to finish the surface. The last 10 percent is called tryout in the mold and die industry, which equates to measurement or verification in other surface applications.
Many shops perform roughing operations and finishing operations on different machines. Historically, a big beefy machine tool that didn't move very fast but sure could hog metal was the roughing machine. For finishing, the workpiece, mold or die would be moved to another lighter, more nimble, machine tool to remove the remaining stock.
A trip through any supermarket provides more than enough evidence to explain why machining of contoured surfaces is a growing segment of manufacturing. For example, each of the thousands of uniquely shaped plastic containers, found along the miles of aisles, gets its shape from a mold. And the mold gets its shape from a machine tool. It's estimated that 60 percent of all parts made today--a percentage that's growing--are made from plastic.
But there are more contoured surfaces to machine than just molds, although as our supermarket tour illustrates, they do make up a large chunk of the surface machining universe. Manufacturing is applying contoured surface machining technology across many industries such as automotive, power generation, aerospace, die and mold making, and health care.
Design considerations that take into account form as well as function increase the demands that are placed on manufacturers for contoured surfaces. Ergonomics--the physical interface between people and equipment--is also a force behind smoothing the square edges of many products. These design directives are showing up in virtually all manufactured products, whether they are made fromThis article is about machine tools that make such design a reality--specifically, machine tools that sculpt contoured surfaces--in metal. The end product of that sculpting may be a stainless steel mold and core for a plastic bottle, a medical implant or a highly contoured titanium spar to strengthen an aircraft fuselage. But without machine tools that are capable of efficiently performing such complex machining, the molds and spars themselves--as well as the end products that rely on them--would be much more costly.
To get a sense about the most important equipment-related issues, we spoke to LeBlond Makino (Mason, Ohio) and Cincinnati Milacron (Cincinnati, Ohio) about their surface cutting machines. While each builder approaches problems associated with machining surfaces somewhat differently, their customer goals are identical--machine more accurately to reduce labor and time spent doing non-value-added benchwork, thereby increasing throughput and quality.
Machining Surfaces 101
Probably the most basic requirement for machining surfaces is a machine tool that can adequately manipulate a cutter to impart the desired shape onto a raw workpiece. In other words, it needs the ability to perform simultaneous axis moves. While there are techniques for doing surfaces with less than three axes, we're going to concentrate on contour machining using at least Cartesian coordinates (X-Y-Z) and up to five axes--all capable of independent and simultaneous movement--linear as well as rotary.
The machining process for cutting a contoured surface is complicated not only by the rise and fall of the surface but also by the relatively small-diameter cutting tool that's used. On a 12-inch-wide flat surface, for example, two passes of a six-inch face mill will machine the surface. A 12-inch contoured surface, using a 3/4-inch ballnose end mill, may take 98 passes to cover the same area, because the ballnose design cuts a width that is a fraction of the tool's 3/4-inch diameter. And generally, surface machining is further divided into two operations: roughing and finishing.
In mold and die shops, roughing accounts for about 15 percent of the total machining time of a workpiece. While roughing may only use about 15 percent of machining time, it removes the majority of material, leaving just enough stock for the second operation--finishing.
Finish machining on a surface doesn't take up the other 85 percent of cycle time for producing a surface. Actually the percentage is closer to 50. Of the 35 percent that's left, 25 percent of that is hand machining (benchwork) needed to finish the surface. The last 10 percent is called tryout in the mold and die industry, which equates to measurement or verification in other surface applications.
Many shops perform roughing operations and finishing operations on different machines. Historically, a big beefy machine tool that didn't move very fast but sure could hog metal was the roughing machine. For finishing, the workpiece, mold or die would be moved to another lighter, more nimble, machine tool to remove the remaining stock.
Brazil looks outward: the United States is one of Brazil's prime targets for exporting machine tools
Brazil offers more than just futbol and Carnaval. That's the message machine tool builders showing their wares at the recent FEIMAFE show in Sao Paulo hoped would be instilled in show attendees. Modern Machine Shop was honored to be the only U.S. trade publication invited by ABIMAQ, the Brazilian machine tool builders association, to attend the tenth edition of this biennial show held in the third-largest city in the world.
The ABIMAQ group is a collection of various metalworking and fabrication equipment makers. Newton de Mello, president of Mello grinders, heads the association. Henry Goffaux, president of ThyssenKruypp Metalcutting Brazil, leads the association's chamber of machine tools, which is comprised solely by machine tool builders.
Brazil, which ranks 13th worldwide in machine tool production, started this year on a positive note. First quarter 2005 numbers show a 19.3 percent increase for overall machine tool sales in Brazil and a 177 percent increase in exports. According to ABIMAQ, the United States and Germany top the list in terms of export destinations, followed by Mexico, Spain and China. The automotive industry is currently one of the strongest sectors in terms of machine tool purchases. More than 63,000 attendees from 42 countries walked the aisles of the Anhembi Park Exhibition Hall during the show (both of these statistics are higher than the 2003 show edition). Many of the 1,342 exhibitors were the Latin-American arms of the top international metalworking companies. While the country is focusing on increasing exports, the importing of equipment continues to be an issue of dispute between the government and foreign machine tool builders wishing to sell to the Brazilian market. Importers are faced with what some consider exceedingly high tariffs, which were put in place to boost sales of Brazilian machine tools to the domestic market. Some Brazilians involved in metalworking think this is ultimately a tax on productive investment. In fact, one foreign machine tool builder went so far as to post a sign in protest of the high tariffs.
Most of the large Brazilian machine tool builders have their own sales offices in the United States. Many smaller companies sell through distributors. Some, including Mello Grinders, would like to sell into the United States, but say they have had difficulties locating a distributor that can serve the entire country, rather than just a single region.
The ABIMAQ group is a collection of various metalworking and fabrication equipment makers. Newton de Mello, president of Mello grinders, heads the association. Henry Goffaux, president of ThyssenKruypp Metalcutting Brazil, leads the association's chamber of machine tools, which is comprised solely by machine tool builders.
Brazil, which ranks 13th worldwide in machine tool production, started this year on a positive note. First quarter 2005 numbers show a 19.3 percent increase for overall machine tool sales in Brazil and a 177 percent increase in exports. According to ABIMAQ, the United States and Germany top the list in terms of export destinations, followed by Mexico, Spain and China. The automotive industry is currently one of the strongest sectors in terms of machine tool purchases. More than 63,000 attendees from 42 countries walked the aisles of the Anhembi Park Exhibition Hall during the show (both of these statistics are higher than the 2003 show edition). Many of the 1,342 exhibitors were the Latin-American arms of the top international metalworking companies. While the country is focusing on increasing exports, the importing of equipment continues to be an issue of dispute between the government and foreign machine tool builders wishing to sell to the Brazilian market. Importers are faced with what some consider exceedingly high tariffs, which were put in place to boost sales of Brazilian machine tools to the domestic market. Some Brazilians involved in metalworking think this is ultimately a tax on productive investment. In fact, one foreign machine tool builder went so far as to post a sign in protest of the high tariffs.
Most of the large Brazilian machine tool builders have their own sales offices in the United States. Many smaller companies sell through distributors. Some, including Mello Grinders, would like to sell into the United States, but say they have had difficulties locating a distributor that can serve the entire country, rather than just a single region.
Weld Inspection Tool has rotating video head
Able to handle tubes from 14-150 mm, INVIZ Site Weld Inspector utilizes rotating head for uninterrupted weld seam inspection. Head unit, which can be controlled from drum unit for remote operation, is illuminated by Xenon lighting source and offers 60[degrees] field of vision and adjustable focus. Head unit can be mounted on 8 or 15 m cable, and centering tool can be used to maintain position of head unit in tube. Machine can be used with optional LCD display unit.
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Orbimatic (UK) Limited, the manufacturer of technology leading Orbital TIG Welding equipment, have introduced the INVIZ Site Weld Inspector to their range of weld inspection products.
The INVIZ Site Weld Inspector can be used for inspection of tubes from 14mm to 150mm and includes a rotating head which allows for uninterrupted weld seam inspection. The rotating head can be controlled from the drum unit for remote operation.
The head unit is illuminated by a Xenon lighting source which is housed in the main drum unit which is also used for storage of the cable and the whole unit weighs only 12.3kg. The INVIZ Site Weld Inspector has an adjustable focus and gives a 60 degree field of vision. The head unit can be mounted on an 8m or 15m meter cable and a centring tool can be used to maintain the position of the head unit in the tube.
The adjustable focus and a large depth of view mean that the head unit only needs to be roughly centred in the tube for a good image quality.
The INVIZ Site Weld Inspector can be used with an optional LCD Display unit which can also be supplied with an image capture facility.
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Orbimatic (UK) Limited, the manufacturer of technology leading Orbital TIG Welding equipment, have introduced the INVIZ Site Weld Inspector to their range of weld inspection products.
The INVIZ Site Weld Inspector can be used for inspection of tubes from 14mm to 150mm and includes a rotating head which allows for uninterrupted weld seam inspection. The rotating head can be controlled from the drum unit for remote operation.
The head unit is illuminated by a Xenon lighting source which is housed in the main drum unit which is also used for storage of the cable and the whole unit weighs only 12.3kg. The INVIZ Site Weld Inspector has an adjustable focus and gives a 60 degree field of vision. The head unit can be mounted on an 8m or 15m meter cable and a centring tool can be used to maintain the position of the head unit in the tube.
The adjustable focus and a large depth of view mean that the head unit only needs to be roughly centred in the tube for a good image quality.
The INVIZ Site Weld Inspector can be used with an optional LCD Display unit which can also be supplied with an image capture facility.
Friday, March 23, 2007
Trade Fair Showcases Robot and Machine Tool Safety
YPSILANTI, Mich. -- North America's largest robot safety Trade Fair will be at the Ypsilanti Marriott on October 25 as part of National Robot Safety Conference XVII, a four day Conference from October 24 through October 27. Sponsored by Ann Arbor based Robotic Industries Association, Trade Fair only passes are available for $25 in advance, $40 on-site.
"This is the robotics industry's biggest trade fair for robot and safety suppliers," said Donald A. Vincent, RIA's Executive Vice President. "It includes top vendors for machine tool safeguarding. There will be about 45 displays and a catered reception at 4:30 (p.m.). Every year we hear about great business connections getting made at the Conference, and the Trade Fair is a big part of that." Several Workshops are held on Monday before the Conference, and Thursday after the Conference. Tuesday and Wednesday (October 25-26) make up the general sessions which draw connections between OSHA, North American safety standards, international standards and technical issues like circuit design and risk assessment.
Session leaders include speakers from OSHA and case studies from actual users. Discussions cover experiences from those who have implemented safety programs compliant with the ANSI/RIA R15.06-1999 Robot Safety Standard, the B11 series for Machine Tool Safety, ISO standards and Canadian standards. On Thursday, a panel of standards authors act as special consultants in a Question and Answer forum.
Official sponsors include (alpha order): ABB Inc., Business Wire, FANUC Robotics America, Inc., Motoman, Inc., Nachi Robotic Systems, Inc., Pilz Automation Safety, Scientific Technologies Inc., SICK, Inc.
Founded in 1974, RIA is North America's leading robotics trade group, representing some 240 robotics manufacturers, component suppliers, system integrators, end users, research groups, and consulting firms. RIA is the official secretariat for the ANSI/RIA R15.06-1999 Robot Safety Standard and offers in-house training on safety and robotic applications.
"This is the robotics industry's biggest trade fair for robot and safety suppliers," said Donald A. Vincent, RIA's Executive Vice President. "It includes top vendors for machine tool safeguarding. There will be about 45 displays and a catered reception at 4:30 (p.m.). Every year we hear about great business connections getting made at the Conference, and the Trade Fair is a big part of that." Several Workshops are held on Monday before the Conference, and Thursday after the Conference. Tuesday and Wednesday (October 25-26) make up the general sessions which draw connections between OSHA, North American safety standards, international standards and technical issues like circuit design and risk assessment.
Session leaders include speakers from OSHA and case studies from actual users. Discussions cover experiences from those who have implemented safety programs compliant with the ANSI/RIA R15.06-1999 Robot Safety Standard, the B11 series for Machine Tool Safety, ISO standards and Canadian standards. On Thursday, a panel of standards authors act as special consultants in a Question and Answer forum.
Official sponsors include (alpha order): ABB Inc., Business Wire, FANUC Robotics America, Inc., Motoman, Inc., Nachi Robotic Systems, Inc., Pilz Automation Safety, Scientific Technologies Inc., SICK, Inc.
Founded in 1974, RIA is North America's leading robotics trade group, representing some 240 robotics manufacturers, component suppliers, system integrators, end users, research groups, and consulting firms. RIA is the official secretariat for the ANSI/RIA R15.06-1999 Robot Safety Standard and offers in-house training on safety and robotic applications.
Machine Automation System works with graders and dozers
GradeStar v5.0 software provides 3D grader and dozer automation system for construction industry. Built on ruggedized hardware platform, it is based on CAN interface and utilizes WinXP OS. Consolidated sensor module, GSM5, acts as central communications point between positioning sensors and GradeStar interface. Site Manager software, together with GradeStar system simulator, lets user view, check, and analyze jobsite before starting grading operation.
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Leica Geosystems today announced the introduction of GradeStar V5.0, a fifth-generation 3D grader and dozer automation system for the construction industry.
GradeStar V5.0 incorporates advances in hardware and software, providing a versatile easy-to-use machine automation system on a reliable ruggedized hardware platform.
The new GradeStar V5.0 software is based on the industry standard Controller Area Network (CAN) interface and utilizes the WinXP operating system. It features a new consolidated sensor module, the GSM5, which is designed to be a central communications point between positioning sensors and the GradeStar interface. The GSM5 can be configured with an internal GPS module for space savings and ease of installation. The component design facilitates removal for exchange between machines.
GradeStar V5.0 can work with Leica's total stations and GPS positioning sensors, for maximum flexibility and unmatched grade accuracy. The system has full forward and backward compatibility with Leica's existing 2D and 3D machine automation products, including the GS496, ProControl, SonicMaster and MC1200, offering an easy upgrade path to the new state-of-the-art technology.
"The GradeStar V5.0 3D control provides more cost-effective machine use and savings in costs and time with higher grading accuracy on different terrain for all work sites, from bulk earth moving to fine grading," said Bob Flynn, machine automation product marketing manager at Leica Geosystems. "It is an easy-to-use system that allows operators to be more aware of their surroundings due to the real-time blade control, allowing grading to be on line at the correct elevation."
GradeStar is designed as a simple tool for machine operators and site managers. Leica's Site Manager software, together with GradeStar's system simulator streamlines projects by allowing the user to view, check and analyze the jobsite before starting the grading operation. System indicators can be activated and sensors switched with one touch of a button, while a live moving map guides cutting and filling operations. A universal control panel reduces operator training when moving from machine to machine.
"It has been shown that systems pay for themselves often on the first project," Flynn said.
GradeStar V5.0 retains all of the popular user features from earlier versions of GradeStar, including a mast tilt compensator which allows the operator to tilt the blade forward and backward on the grader. Automatic side shift is also a feature that controls the blade in and out automatically to maintain a break line edge.
"The new version of GradeStar builds on Leica Geosystems' 30 years experience in developing, testing and fielding advanced machine control and automation products for a wide range of jobsite applications," said Flynn.
About Leica Geosystems
With close to 200 years of pioneering solutions to measure the world, Leica Geosystems products and services are trusted by professionals worldwide to help them capture, analyze, and present spatial information. Leica Geosystems is best known for its broad array of products that capture accurately, model quickly, analyze easily, and visualize and present spatial information in 3D. Those who use Leica products every day trust them for their dependability, the value they deliver, and the superior customer support. Based in Switzerland, Leica Geosystems is a global company with tens of thousands of customers supported by more than 2,300 employees in 21 countries and hundreds of partners located in more than 120 countries around the world. Leica Geosystems is a publicly listed company, registered with the Swiss Stock Exchange (SWX).
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Leica Geosystems today announced the introduction of GradeStar V5.0, a fifth-generation 3D grader and dozer automation system for the construction industry.
GradeStar V5.0 incorporates advances in hardware and software, providing a versatile easy-to-use machine automation system on a reliable ruggedized hardware platform.
The new GradeStar V5.0 software is based on the industry standard Controller Area Network (CAN) interface and utilizes the WinXP operating system. It features a new consolidated sensor module, the GSM5, which is designed to be a central communications point between positioning sensors and the GradeStar interface. The GSM5 can be configured with an internal GPS module for space savings and ease of installation. The component design facilitates removal for exchange between machines.
GradeStar V5.0 can work with Leica's total stations and GPS positioning sensors, for maximum flexibility and unmatched grade accuracy. The system has full forward and backward compatibility with Leica's existing 2D and 3D machine automation products, including the GS496, ProControl, SonicMaster and MC1200, offering an easy upgrade path to the new state-of-the-art technology.
"The GradeStar V5.0 3D control provides more cost-effective machine use and savings in costs and time with higher grading accuracy on different terrain for all work sites, from bulk earth moving to fine grading," said Bob Flynn, machine automation product marketing manager at Leica Geosystems. "It is an easy-to-use system that allows operators to be more aware of their surroundings due to the real-time blade control, allowing grading to be on line at the correct elevation."
GradeStar is designed as a simple tool for machine operators and site managers. Leica's Site Manager software, together with GradeStar's system simulator streamlines projects by allowing the user to view, check and analyze the jobsite before starting the grading operation. System indicators can be activated and sensors switched with one touch of a button, while a live moving map guides cutting and filling operations. A universal control panel reduces operator training when moving from machine to machine.
"It has been shown that systems pay for themselves often on the first project," Flynn said.
GradeStar V5.0 retains all of the popular user features from earlier versions of GradeStar, including a mast tilt compensator which allows the operator to tilt the blade forward and backward on the grader. Automatic side shift is also a feature that controls the blade in and out automatically to maintain a break line edge.
"The new version of GradeStar builds on Leica Geosystems' 30 years experience in developing, testing and fielding advanced machine control and automation products for a wide range of jobsite applications," said Flynn.
About Leica Geosystems
With close to 200 years of pioneering solutions to measure the world, Leica Geosystems products and services are trusted by professionals worldwide to help them capture, analyze, and present spatial information. Leica Geosystems is best known for its broad array of products that capture accurately, model quickly, analyze easily, and visualize and present spatial information in 3D. Those who use Leica products every day trust them for their dependability, the value they deliver, and the superior customer support. Based in Switzerland, Leica Geosystems is a global company with tens of thousands of customers supported by more than 2,300 employees in 21 countries and hundreds of partners located in more than 120 countries around the world. Leica Geosystems is a publicly listed company, registered with the Swiss Stock Exchange (SWX).
Sales Demo Tool hosts web demos and presentations
Featuring 24-bit color and 1-button menu, Glance v2.0 enables sales staff to provide prospects with enhanced communication experience by combining phone call with ability to present sales pitch or demo an application from any PC, Mac, or Linux computer. Prospects enter demos instantly from their own website, without having to download web conferencing software. Presentations can include any application, PowerPoint illustration, graphic art design, or 3D rendering.
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- Latest Release Adds Full Color and Even Faster Speeds to its Dependable
One-Button Sales Demo Tool
Arlington, Mass. - September 20, 2005 - Glance Networks, creators of the
"one-button simple" GlanceT screen sharing service, today announced version
2.0, which adds full 24-bit color, faster screen update speeds and easy
customer website integration. Used primarily as a sales tool for hosting
instant web demos and presentations, Glance provides a quick and dependable
web demo service. It includes "Guests Connect for FreeT" flat-rate pricing
and the ability to connect instantly to nearly any PC, Mac or Linux computer
without downloading software.
"Simplicity and ease of use have been two challenges inhibiting mass
adoption of web conferencing," observes Mike Gotta, principal analyst,
Burton Group. "There's an underserved audience within this market that
simply wants to deliver a richer communication experience by combining a
phone call with the sharing of a screen. The ability to present a sales
pitch or demo an application should be a natural part of the conversation."
Sales professionals know they need to make every call count. A single
botched demo or presentation can cost them a sale. Whether showing a
software application, pitching a presentation, filling out a form or walking
through a website, sales people need a demo service that is as reliable as
their phone. Their ideal service would be:
oDependable - Their 9:00 a.m. demos need to start at 9:00 a.m., not 9:15
a.m. The service needs to connect the first time, every time.
oFast - Their prospects should enter demos instantly from their own website,
without wasting time downloading complicated web conferencing software.
oSimple - Their guests should be able to focus on the demo, without
distractions from unnecessary web conferencing buttons and menus.
"When we needed a simple, reliable sales tool to walk clients through a
demonstration of our software applications, we turned to Glance," commented
Steven Green, president at PollStream Inc., a direct response software
solution that makes it easy to engage customers in a two-way conversation.
"We tried other conferencing services with frustrating results, experiencing
technical problems with downloads and such. All we wanted was reliability
and ease of use at a reasonable price. Glance 2.0 fits the bill for quick
web demos and sales presentations."
Over 2,000 companies worldwide use Glance for demonstrating their products
online and giving sales presentations. Glance recently interviewed users
from over 100 of these companies. The most common reasons they cited for
having selected Glance are that the service is:
oReliable - Their prospects can connect instantly from nearly any PC, Mac or
Linux computer, even highly secured machines that cannot download software.
oFast - They nearly always connect without installing any software.
oCustomer-centric - Prospects can join their demos from the sales person's
own web page or company website. The demos start and end on web pages
customized with their company's look and call-to-action.
oColorful - Their sales staff can show any application, PowerPoint
illustration, graphic art design or 3D rendering to prospects, now in full
24-bit color, directly from their PC screen.
oEasy - Customers report that even people uncomfortable with technology find
Glance easy to use. Their sales staffs often master its one-button menu in
their very first demo.
"Nearly every salesperson who has used a traditional web conferencing
service to host sales demos can tell some gut-wrenching story about a hot
deal that went cold when their web demo didn't connect," says Dr. Rich
Baker, CEO of Glance Networks. "We increasingly find that sales prospects
are not allowed to download the software needed to join a web conference or
they are on a traditionally unsupported machine, like a Mac or UNIX box. And
often, they get confused or frustrated by a bunch of unfamiliar buttons or
windows. Companies need a web service designed specifically for sales demos.
Glance 2.0's simple design makes it possible for prospects to connect
instantly from nearly any computer, without the risk or confusion of
downloading unfamiliar software. And the better their demo experience, the
more likely the sale."
********************
- Latest Release Adds Full Color and Even Faster Speeds to its Dependable
One-Button Sales Demo Tool
Arlington, Mass. - September 20, 2005 - Glance Networks, creators of the
"one-button simple" GlanceT screen sharing service, today announced version
2.0, which adds full 24-bit color, faster screen update speeds and easy
customer website integration. Used primarily as a sales tool for hosting
instant web demos and presentations, Glance provides a quick and dependable
web demo service. It includes "Guests Connect for FreeT" flat-rate pricing
and the ability to connect instantly to nearly any PC, Mac or Linux computer
without downloading software.
"Simplicity and ease of use have been two challenges inhibiting mass
adoption of web conferencing," observes Mike Gotta, principal analyst,
Burton Group. "There's an underserved audience within this market that
simply wants to deliver a richer communication experience by combining a
phone call with the sharing of a screen. The ability to present a sales
pitch or demo an application should be a natural part of the conversation."
Sales professionals know they need to make every call count. A single
botched demo or presentation can cost them a sale. Whether showing a
software application, pitching a presentation, filling out a form or walking
through a website, sales people need a demo service that is as reliable as
their phone. Their ideal service would be:
oDependable - Their 9:00 a.m. demos need to start at 9:00 a.m., not 9:15
a.m. The service needs to connect the first time, every time.
oFast - Their prospects should enter demos instantly from their own website,
without wasting time downloading complicated web conferencing software.
oSimple - Their guests should be able to focus on the demo, without
distractions from unnecessary web conferencing buttons and menus.
"When we needed a simple, reliable sales tool to walk clients through a
demonstration of our software applications, we turned to Glance," commented
Steven Green, president at PollStream Inc., a direct response software
solution that makes it easy to engage customers in a two-way conversation.
"We tried other conferencing services with frustrating results, experiencing
technical problems with downloads and such. All we wanted was reliability
and ease of use at a reasonable price. Glance 2.0 fits the bill for quick
web demos and sales presentations."
Over 2,000 companies worldwide use Glance for demonstrating their products
online and giving sales presentations. Glance recently interviewed users
from over 100 of these companies. The most common reasons they cited for
having selected Glance are that the service is:
oReliable - Their prospects can connect instantly from nearly any PC, Mac or
Linux computer, even highly secured machines that cannot download software.
oFast - They nearly always connect without installing any software.
oCustomer-centric - Prospects can join their demos from the sales person's
own web page or company website. The demos start and end on web pages
customized with their company's look and call-to-action.
oColorful - Their sales staff can show any application, PowerPoint
illustration, graphic art design or 3D rendering to prospects, now in full
24-bit color, directly from their PC screen.
oEasy - Customers report that even people uncomfortable with technology find
Glance easy to use. Their sales staffs often master its one-button menu in
their very first demo.
"Nearly every salesperson who has used a traditional web conferencing
service to host sales demos can tell some gut-wrenching story about a hot
deal that went cold when their web demo didn't connect," says Dr. Rich
Baker, CEO of Glance Networks. "We increasingly find that sales prospects
are not allowed to download the software needed to join a web conference or
they are on a traditionally unsupported machine, like a Mac or UNIX box. And
often, they get confused or frustrated by a bunch of unfamiliar buttons or
windows. Companies need a web service designed specifically for sales demos.
Glance 2.0's simple design makes it possible for prospects to connect
instantly from nearly any computer, without the risk or confusion of
downloading unfamiliar software. And the better their demo experience, the
more likely the sale."
Manager's Workshop - machine shop management - Brief Article
When conflicts arise over goals, there is a need to spell out and clarify the ownership of the decision (who will be held accountable for its end result) and whether there is a basic concurrence on essential objectives (shoulds, musts and oughts) as opposed to nonessential objectives (needs, wants and desires). Wrangling about objectives is usually strategic squabbling: for example, a difference of opinion over whether to pursue an increase in market share or an increase in productivity and profitability. Conflict about goals requires both an objective and subjective exchange of ideas and an ongoing evaluation among the interested parties. All of this, of course, is based on the fundamental recognition that it's the end result that's truly important.
Conflict about ways to achieve goals, however, is usually tactical and operational, as you would expect, and can occur even when there is consensus and agreement about the goals. To pursue an increase in market share, you can add to the sales force, increase advertising, cut prices and so on. Conflict about these options is usually best worked out through common sense and pragmatic analysis of the facts as they relate to both reward and risk. Those most affected by the goal should play a crucial role in evaluating alternative methods to accomplish it and in deciding which one(s) to use.
Resolving conflicts in the workplace is a constructive and critical management activity. It demands, however, applicable behaviors, some of which the manager can intentionally adjust to accomplish such resolution. The manager must recognize the conflict situation, must be aware of his or her own behaviors, must know the behaviors that are more effective in resolving the conflict, must want to make any necessary adjustments and must be capable of making those adjustments. This is a straightforward and uncomplicated process, but one necessitating management attention and scrutiny. Conflict is constructive when it is skillfully and intelligently managed. It is lethal when it is left to chance and haphazard behaviors.
To this end, the manager must recognize each subordinate's style and separate the style from the content, deal with the message and its delivery as separate issues and, thus, reduce stress levels in the workplace. On the other hand, a subordinate must recognize the style that the boss is most responsive to, adjust his or her delivery to match that style and, thus, reduce the stress levels in the workplace.
Conflict about ways to achieve goals, however, is usually tactical and operational, as you would expect, and can occur even when there is consensus and agreement about the goals. To pursue an increase in market share, you can add to the sales force, increase advertising, cut prices and so on. Conflict about these options is usually best worked out through common sense and pragmatic analysis of the facts as they relate to both reward and risk. Those most affected by the goal should play a crucial role in evaluating alternative methods to accomplish it and in deciding which one(s) to use.
Resolving conflicts in the workplace is a constructive and critical management activity. It demands, however, applicable behaviors, some of which the manager can intentionally adjust to accomplish such resolution. The manager must recognize the conflict situation, must be aware of his or her own behaviors, must know the behaviors that are more effective in resolving the conflict, must want to make any necessary adjustments and must be capable of making those adjustments. This is a straightforward and uncomplicated process, but one necessitating management attention and scrutiny. Conflict is constructive when it is skillfully and intelligently managed. It is lethal when it is left to chance and haphazard behaviors.
To this end, the manager must recognize each subordinate's style and separate the style from the content, deal with the message and its delivery as separate issues and, thus, reduce stress levels in the workplace. On the other hand, a subordinate must recognize the style that the boss is most responsive to, adjust his or her delivery to match that style and, thus, reduce the stress levels in the workplace.
Thursday, March 08, 2007
Mahr Federal launches precision measuring machine - New Products - Brief Article - Product Announcement
With BobArt Pro-X from BobCAD-CAM, users can convert pictures or CAD drawings into 2D toolpath or embossed models for machining within Version 20 2D and 3D CAD/CAM software. The release is intended to assist manufacturers, including mold makers, in creating the appropriate model and tool path for CNC machining, from imported or designed images and CAD geometry.
Users can automatically convert a color, grayscale or black and white picture into a full relief model, says the company. The appropriate toolpath strategy can then be created on the fly. Added mirroring options are useful for creating negative relief models. In addition to this capability, users can form raster to vector operations to create 2D profile tool paths for carving or profile milling directly from pictures.
Once the toolpath is machined in the CAM sphere of the software, the cutting process can be simulated and verified prior to sending the program to the machine.
Users can automatically convert a color, grayscale or black and white picture into a full relief model, says the company. The appropriate toolpath strategy can then be created on the fly. Added mirroring options are useful for creating negative relief models. In addition to this capability, users can form raster to vector operations to create 2D profile tool paths for carving or profile milling directly from pictures.
Once the toolpath is machined in the CAM sphere of the software, the cutting process can be simulated and verified prior to sending the program to the machine.
Multi-use air powered abrasive belt machine
Dynabrade's Dynafile II air powered abrasive belt machine features a grinding head that pivots 360 degrees, making this tool especially useful for getting into hard-to-reach areas.
The machine features a 20,000-rpm direct-drive air motor that powers abrasive belts 1/4" to 3/4" x 18" long. The motor handle has a 7-degree pitch to help prevent wrist and arm fatigue. The tool features quick and easy abrasive belt change, interchangeable contact arms and trouble-free belt tracking, according to the company. The tool also has a thermal insulated housing, which prevents cold air transmission to the operator's hand while at the same time reducing tool vibration. Additionally, the air motor easily converts to a die grinder by adding a 1/4" collet or to an air drill by adding a chuck.
A versatility kit is also available. It includes the tool, an assortment of contact arms, abrasive belts and a 1/4" collet, all in a carrying case
The machine features a 20,000-rpm direct-drive air motor that powers abrasive belts 1/4" to 3/4" x 18" long. The motor handle has a 7-degree pitch to help prevent wrist and arm fatigue. The tool features quick and easy abrasive belt change, interchangeable contact arms and trouble-free belt tracking, according to the company. The tool also has a thermal insulated housing, which prevents cold air transmission to the operator's hand while at the same time reducing tool vibration. Additionally, the air motor easily converts to a die grinder by adding a 1/4" collet or to an air drill by adding a chuck.
A versatility kit is also available. It includes the tool, an assortment of contact arms, abrasive belts and a 1/4" collet, all in a carrying case
Monday, March 05, 2007
Creating models and tool paths for CNC machining
With BobArt Pro-X from BobCAD-CAM, users can convert pictures or CAD drawings into 2D toolpath or embossed models for machining within Version 20 2D and 3D CAD/CAM software. The release is intended to assist manufacturers, including mold makers, in creating the appropriate model and tool path for CNC machining, from imported or designed images and CAD geometry.
Users can automatically convert a color, grayscale or black and white picture into a full relief model, says the company. The appropriate toolpath strategy can then be created on the fly. Added mirroring options are useful for creating negative relief models. In addition to this capability, users can form raster to vector operations to create 2D profile tool paths for carving or profile milling directly from pictures.
Once the toolpath is machined in the CAM sphere of the software, the cutting process can be simulated and verified prior to sending the program to the machine.
Users can automatically convert a color, grayscale or black and white picture into a full relief model, says the company. The appropriate toolpath strategy can then be created on the fly. Added mirroring options are useful for creating negative relief models. In addition to this capability, users can form raster to vector operations to create 2D profile tool paths for carving or profile milling directly from pictures.
Once the toolpath is machined in the CAM sphere of the software, the cutting process can be simulated and verified prior to sending the program to the machine.
Mahr Federal launches precision measuring machine - New Products - Brief Article - Product Announcement
Mahr Federal announces its new precision length-measuring machine -- the Precimar PLM 600. The new machinery combines high accuracy, motorized drive with joystick control and advanced software for gage calibration and precision part measurement applications. It comes with a free-standing mounting cabinet and dedicated PC. The PLM 600, says Mahr, reduces the time and cost of calibration and inspection of plug, ring, thread and snap gage, indicator and micrometers. Mahr Federal, 800-333-4243
Multi-use air powered abrasive belt machine
Dynabrade's Dynafile II air powered abrasive belt machine features a grinding head that pivots 360 degrees, making this tool especially useful for getting into hard-to-reach areas.
The machine features a 20,000-rpm direct-drive air motor that powers abrasive belts 1/4" to 3/4" x 18" long. The motor handle has a 7-degree pitch to help prevent wrist and arm fatigue. The tool features quick and easy abrasive belt change, interchangeable contact arms and trouble-free belt tracking, according to the company. The tool also has a thermal insulated housing, which prevents cold air transmission to the operator's hand while at the same time reducing tool vibration. Additionally, the air motor easily converts to a die grinder by adding a 1/4" collet or to an air drill by adding a chuck.
A versatility kit is also available. It includes the tool, an assortment of contact arms, abrasive belts and a 1/4" collet, all in a carrying case.
The machine features a 20,000-rpm direct-drive air motor that powers abrasive belts 1/4" to 3/4" x 18" long. The motor handle has a 7-degree pitch to help prevent wrist and arm fatigue. The tool features quick and easy abrasive belt change, interchangeable contact arms and trouble-free belt tracking, according to the company. The tool also has a thermal insulated housing, which prevents cold air transmission to the operator's hand while at the same time reducing tool vibration. Additionally, the air motor easily converts to a die grinder by adding a 1/4" collet or to an air drill by adding a chuck.
A versatility kit is also available. It includes the tool, an assortment of contact arms, abrasive belts and a 1/4" collet, all in a carrying case.
Tuesday, February 27, 2007
Machine vision inspection for the protrusion rate of a diamond tool
The performance of a diamond tool is based on the protrusion rate. The protrusion rate inspection is a costly, labor-intensive activity in industry. Normally, about 20 to 35% of the protrusion rate is provided for the final inspection of diamond tools. There are five known methods used for the protrusion measurement: mechanical dial gage, electrical dial gage, surface roughness measuring machine, focusing by microscope, and manual comparison. In this study, a machine vision system was used as an inspection tool to determine the protrusion rate of a diamond tool. The method developed is a noncontact method without manual judgment. Three sets of field samples were used to demonstrate the proposed method for determining protrusion rate.
The diamond tool is a widely used tool for hard materials, such as concrete, asphalt, all sorts of stones and glasses, optical glasses, hardened alloys, tungsten carbide, and so on. The diamond used to make the tools could be from natural diamonds, artificial diamonds, or other types of superabrasive material, such as cubic boron nitride. The application of diamond tools includes lapping, polishing, grinding, sawing, drilling, cutting, turning, and so forth. Among all applications, about 20% of the diamond tools are used for hard material (such as stones) drilling. These types of tools consist of about 50 to 60% of the revenue of the diamond tool industry (Chen 1993).
The process for making a diamond tool is first mixing the diamond grinding material with a metallic or resin-type abrasive material. The tool is then formed through a "sintering" process (see Figure 1). At this point, the diamonds have not protruded from the tool surface. The next step in the process is "truing," that is to use a SiC or A1203 sand wheel to balance the centers of the inner and outer cylindrical surfaces. This is followed by "dressing," which causes the diamonds to protrude through the surface. Chen (1995) reviewed various truing and dressing methods. The finished tools are shown in Figure 2. The surface of the tool is shown in Figure 3.
The protrusion rate (PR) is defined as the ratio of the height (h) of the diamond above the tool surface and the diameter (d) of the tool. The ideal PR is h = 1/3d, shown in Figure 4. If excessive dressing occurs, that is, h>> 113, then the diamonds fall out easily. On the other hand, if insufficient dressing occurs, that is, h
Traditionally, there are five known methods used for the measurement of PR (Busch 1989, Chen 1993, Chen 1995, Sheiko et al. 1993, Weck 1984, Lo 1992):
(1) A mechanical dial gage to rotate the diamond tool with a fixed centering device and measure the variations in the surface smoothness using a mechanical dial gage.
(2) An electrical dial gage. This is similar to using a mechanical dial gage except that the gage is an electrical gage.
(3) A surface roughness measuring machine. This device is usually used to measure in flat surface roughness, and it can be set up for measuring the protrusions in a diamond tool.
(4) An optical microscope (Brinksmeier, Hoper, Riemer 1996). A sample object (i.e., a piece of coated diamond tool) is placed under a microscope, with the focus on the high and low spots to determine the PR.
(5) Manual comparison. This is similar to the surface roughness specimens normally used in a machine shop. The PR is determined by comparing the specimens and the diamond tool surface with the naked eye.
The first three methods must use a contact-type stylus, whose size can affect the measurement results. All five methods require extensive manual work and are difficult to automate. The objective of this study was to use a CCD-- based machine vision system to determine if PR can be automatically determined with a noncontact device.
Methods and Results
The original thought was to use a vision system to measure the protrusion rate of a diamond tool and compare the results using a traditional surface profilometer. Figure 5 shows the flowchart for this process.
The vision system used in this study consisted of a CCD camera (Toshiba IK-530S) with 256 x 256 pixel resolution, a TV monitor (SAMPO BMC-1202T), and an IBM-compatible PC with a frame grabber (HRT512-8 from Caten Systems). A Misutoyo SURF-400 profilometer was used to measure the surface roughness of the diamond tool. The idea behind this was that the protrusion rate, surface roughness, and diamond area from the CCD image might have a good correlation. Figure 6 shows the hardware and software setup.
The diamond tool is a widely used tool for hard materials, such as concrete, asphalt, all sorts of stones and glasses, optical glasses, hardened alloys, tungsten carbide, and so on. The diamond used to make the tools could be from natural diamonds, artificial diamonds, or other types of superabrasive material, such as cubic boron nitride. The application of diamond tools includes lapping, polishing, grinding, sawing, drilling, cutting, turning, and so forth. Among all applications, about 20% of the diamond tools are used for hard material (such as stones) drilling. These types of tools consist of about 50 to 60% of the revenue of the diamond tool industry (Chen 1993).
The process for making a diamond tool is first mixing the diamond grinding material with a metallic or resin-type abrasive material. The tool is then formed through a "sintering" process (see Figure 1). At this point, the diamonds have not protruded from the tool surface. The next step in the process is "truing," that is to use a SiC or A1203 sand wheel to balance the centers of the inner and outer cylindrical surfaces. This is followed by "dressing," which causes the diamonds to protrude through the surface. Chen (1995) reviewed various truing and dressing methods. The finished tools are shown in Figure 2. The surface of the tool is shown in Figure 3.
The protrusion rate (PR) is defined as the ratio of the height (h) of the diamond above the tool surface and the diameter (d) of the tool. The ideal PR is h = 1/3d, shown in Figure 4. If excessive dressing occurs, that is, h>> 113, then the diamonds fall out easily. On the other hand, if insufficient dressing occurs, that is, h
Traditionally, there are five known methods used for the measurement of PR (Busch 1989, Chen 1993, Chen 1995, Sheiko et al. 1993, Weck 1984, Lo 1992):
(1) A mechanical dial gage to rotate the diamond tool with a fixed centering device and measure the variations in the surface smoothness using a mechanical dial gage.
(2) An electrical dial gage. This is similar to using a mechanical dial gage except that the gage is an electrical gage.
(3) A surface roughness measuring machine. This device is usually used to measure in flat surface roughness, and it can be set up for measuring the protrusions in a diamond tool.
(4) An optical microscope (Brinksmeier, Hoper, Riemer 1996). A sample object (i.e., a piece of coated diamond tool) is placed under a microscope, with the focus on the high and low spots to determine the PR.
(5) Manual comparison. This is similar to the surface roughness specimens normally used in a machine shop. The PR is determined by comparing the specimens and the diamond tool surface with the naked eye.
The first three methods must use a contact-type stylus, whose size can affect the measurement results. All five methods require extensive manual work and are difficult to automate. The objective of this study was to use a CCD-- based machine vision system to determine if PR can be automatically determined with a noncontact device.
Methods and Results
The original thought was to use a vision system to measure the protrusion rate of a diamond tool and compare the results using a traditional surface profilometer. Figure 5 shows the flowchart for this process.
The vision system used in this study consisted of a CCD camera (Toshiba IK-530S) with 256 x 256 pixel resolution, a TV monitor (SAMPO BMC-1202T), and an IBM-compatible PC with a frame grabber (HRT512-8 from Caten Systems). A Misutoyo SURF-400 profilometer was used to measure the surface roughness of the diamond tool. The idea behind this was that the protrusion rate, surface roughness, and diamond area from the CCD image might have a good correlation. Figure 6 shows the hardware and software setup.
Detection of machine tool contouring errors using wavelet transforms and neural networks
The accuracy and precision of computer numerical control (CNC) machine tools directly affect the dimensional accuracy of machined parts. Fast detection of machine tool contouring errors is required to guarantee the accuracy of the manufacturing process and, further, to eliminate errors through error compensation techniques. In this paper, several typical contouring error patterns of CNC machine tools (i.e., cyclic, backlash, scale mismatch, etc.) are presented. Detection of machine tool contouring errors is conducted in two steps using wavelet transforms (WT) and neural networks (NN). In the first step, wavelet transform is applied to contouring error signals to extract error features. In the second step, wavelet coefficients are grouped into proper input units for neural networks; that is, data were compressed by omitting unnecessary details. In this study, cascade-correlation (CC) neural networks are selected to recognize the seven basic patterns of CNC contouring errors. Multiple contouring errors can also be identified quantitatively in the WT-NN approach.Computer numerical control (CNC) machine tools are widely used throughout the manufacturing industry. Accuracy and good machining conditions are critical to the dimensional accuracy of parts produced using these tools. In general, CNC machine tool errors can be classified into four types:
1. Geometric errors of machine components and structures,
2. Errors induced by thermal distortions,
3. Deflection errors caused by cutting forces, and
4. Other errors-for example, those caused by servo errors of machine axes (for example, tracking errors) or numerical control interpolation algorithmic errors.1
Currently, two approaches exist for improving the accuracy of CNC machine tools: error avoidance and error compensation. The error compensation technique, which is an economical way to improve machine tool accuracy, was first applied by Hocken on a Moore NS CMM.2Error compensation identifies machine errors through either direct mapping or indirect modeling. Direct mapping of machine errors is accomplished through the use of precision artifacts and measurement instruments. Indirect modeling is performed using a kinematic model to express the error of tools relative to the position of parts. This technique was successfully applied to a multiaxis machine tool' and a CMM.4
The fundamental step in error compensation is the error identification technique, which can be classified as either direct or indirect. The feature-based error identification technique involves the measurement of machined parts. It involves tools such as pattern recognition, fuzzy systems, decision trees, expert systems, and neural networks.5 After the machine tool errors are detected with a feature-based method, inverse kinematic techniques and statistical methods can be used to identify individual machine error components. An adaptive error identification method was proposed by Mou.6,7 In this method, a feature-based comparison method is used to correlate the dimensional and form errors of a manufactured part to the systematic machine tool errors.
Compared with direct error component measurement, feature-based error identification is a more efficient way of estimating the components of machine tool error. Further, it is more useful for shop-floor applications of error identification.
The objective of this study is to develop an approach that can effectively detect the composition and amplitudes of error patterns from the machine tool contouring error signals. This approach is developed based on two techniques, wavelet transformations (WT) and neural networks (NN). The following sections describe the details of this approach.
Measurement and Classification of Machine Tool Contouring Errors
Accuracy and good machining conditions are critical to the dimensional accuracy of parts produced using CNC machine tools. Various machine errors affect the dimensions and forms of the resulting parts. Every type of machine error (such as backlash, axis reversal characteristics, vibration, nonsquareness, scale mismatch, and so on) can be reflected through how well a machine can interpolate a circle. Thus, machine errors can be revealed by measuring the circular cutting path of a CNC machine and comparing the path to predetermined reference error patterns.
1. Geometric errors of machine components and structures,
2. Errors induced by thermal distortions,
3. Deflection errors caused by cutting forces, and
4. Other errors-for example, those caused by servo errors of machine axes (for example, tracking errors) or numerical control interpolation algorithmic errors.1
Currently, two approaches exist for improving the accuracy of CNC machine tools: error avoidance and error compensation. The error compensation technique, which is an economical way to improve machine tool accuracy, was first applied by Hocken on a Moore NS CMM.2Error compensation identifies machine errors through either direct mapping or indirect modeling. Direct mapping of machine errors is accomplished through the use of precision artifacts and measurement instruments. Indirect modeling is performed using a kinematic model to express the error of tools relative to the position of parts. This technique was successfully applied to a multiaxis machine tool' and a CMM.4
The fundamental step in error compensation is the error identification technique, which can be classified as either direct or indirect. The feature-based error identification technique involves the measurement of machined parts. It involves tools such as pattern recognition, fuzzy systems, decision trees, expert systems, and neural networks.5 After the machine tool errors are detected with a feature-based method, inverse kinematic techniques and statistical methods can be used to identify individual machine error components. An adaptive error identification method was proposed by Mou.6,7 In this method, a feature-based comparison method is used to correlate the dimensional and form errors of a manufactured part to the systematic machine tool errors.
Compared with direct error component measurement, feature-based error identification is a more efficient way of estimating the components of machine tool error. Further, it is more useful for shop-floor applications of error identification.
The objective of this study is to develop an approach that can effectively detect the composition and amplitudes of error patterns from the machine tool contouring error signals. This approach is developed based on two techniques, wavelet transformations (WT) and neural networks (NN). The following sections describe the details of this approach.
Measurement and Classification of Machine Tool Contouring Errors
Accuracy and good machining conditions are critical to the dimensional accuracy of parts produced using CNC machine tools. Various machine errors affect the dimensions and forms of the resulting parts. Every type of machine error (such as backlash, axis reversal characteristics, vibration, nonsquareness, scale mismatch, and so on) can be reflected through how well a machine can interpolate a circle. Thus, machine errors can be revealed by measuring the circular cutting path of a CNC machine and comparing the path to predetermined reference error patterns.
Vertical Honing Machine produces bores from .750-8 in
Employing one motor for spindle and another for stroker, SV-10 Vertical Honing Machine can run traditional tools as well as DH-series diamond hone head, which offers 16 points of cutting action. Full bore profile display projects real-time graphical display of bore cross section, while zoom feature maximizes bore view. Variable spindle RPM and stroke speed allow infinitely variable crosshatch angle for any bore diameter and cylinder length combination.
********************
Sunnen's new SV-10 Vertical Honing Machine combines the latest technology with the consistency and dependability of Sunnen's legendary CV-616.
With two motors, one for the spindle and one for the stroker, the SV-10 has the capability to run traditional tools as well as Sunnen's new DH-series diamond hone head. Sunnen's expertise, with multiple-diamond honing on the top-of-the-line CK-21, is now available on the competitively-priced SV-10. The DH-series diamond hone, with 16 points of cutting action, is the choice for truly round bores. The mechanical stroke guarantees precision surface finish with consistent crosshatch angle in each cylinder no matter what tool is used.
Another new feature is the patented full bore profile display which projects a real time graphical display of the bore cross section. This feature actually displays the geometry of the bore ... there is no need for visualization and guesswork. A zoom feature maximizes the bore view. Also, during the cycle the SV-10 lets the operator dwell the honing tool anywhere throughout the bore. The dwell pointer can be moved to the position where the bore is visually smaller and the tool will dwell there as long as necessary.
********************
Sunnen's new SV-10 Vertical Honing Machine combines the latest technology with the consistency and dependability of Sunnen's legendary CV-616.
With two motors, one for the spindle and one for the stroker, the SV-10 has the capability to run traditional tools as well as Sunnen's new DH-series diamond hone head. Sunnen's expertise, with multiple-diamond honing on the top-of-the-line CK-21, is now available on the competitively-priced SV-10. The DH-series diamond hone, with 16 points of cutting action, is the choice for truly round bores. The mechanical stroke guarantees precision surface finish with consistent crosshatch angle in each cylinder no matter what tool is used.
Another new feature is the patented full bore profile display which projects a real time graphical display of the bore cross section. This feature actually displays the geometry of the bore ... there is no need for visualization and guesswork. A zoom feature maximizes the bore view. Also, during the cycle the SV-10 lets the operator dwell the honing tool anywhere throughout the bore. The dwell pointer can be moved to the position where the bore is visually smaller and the tool will dwell there as long as necessary.
Machine Tools are available with VDI-driven units
Mazak Quick Turn Nexus, Super Quick Turn, and Multiplex-series machine tools are offered with self-contained VDI-driven units that enable multiple part processes such as milling, drilling, and turning on same part in one setup. Available with KM interface or ER collet style, units feature sealed spindle bearings, recessed spindle configuration, and through-coolant capabilities up to 1,500 psi. Tool setups can be pre-staged offline.
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(LATROBE, PA) - Self-contained VDI-driven units from Kennametal for Mazak Quick Turn Nexus, Super Quick Turn, and Multiplex-series machine tools enable multiple part processes such as milling, drilling, and turning on the same part in a single setup. Available with either the Kennametal KM interface or standard ER collet style, setups can be accomplished accurately and efficiently. Since the units make offsets known quantities, tool setups can even be pre-staged offline for greater productivity gains. As Product Manager Curtis Rellick succinctly puts it, "Less setup time, more spindle time."
Individual driven units are designed to work specifically with each model variation of the Mazak machine tools for maximum equipment capability. The units feature high-precision gears and sealed spindle bearings for smooth operation, and a recessed spindle configuration that reduces spindle stress and increases bearing life. High-quality seals and O-rings enhance protection against external contamination. Through-coolant capabilities of up to 1500 psi are available.The driven units increase rigidity by design, enabling higher spindle speeds and feeds and longer tool life. Product life averages of three years before repair or rebuilding are required, compared to nine to 12 months for other drive spindles. One customer described the advantages of a driven unit running a four-tooth, 1.57-in. face mill rough-cutting cast stainless steel at 600 SFM at a depth of 0.07 inches taking a full 1-inch width of cut. "Our maintenance personnel were frequently rebuilding competitive units due to bad gear backlash and blown spindles from the heavy interrupted cut," he says. "Despite the pounding the Kennametal unit takes, we have experienced better tool life, increased surface finishes, and no downtime with broken spindles/gears. That translates into productivity and dollars that go right to the bottom line."
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(LATROBE, PA) - Self-contained VDI-driven units from Kennametal for Mazak Quick Turn Nexus, Super Quick Turn, and Multiplex-series machine tools enable multiple part processes such as milling, drilling, and turning on the same part in a single setup. Available with either the Kennametal KM interface or standard ER collet style, setups can be accomplished accurately and efficiently. Since the units make offsets known quantities, tool setups can even be pre-staged offline for greater productivity gains. As Product Manager Curtis Rellick succinctly puts it, "Less setup time, more spindle time."
Individual driven units are designed to work specifically with each model variation of the Mazak machine tools for maximum equipment capability. The units feature high-precision gears and sealed spindle bearings for smooth operation, and a recessed spindle configuration that reduces spindle stress and increases bearing life. High-quality seals and O-rings enhance protection against external contamination. Through-coolant capabilities of up to 1500 psi are available.The driven units increase rigidity by design, enabling higher spindle speeds and feeds and longer tool life. Product life averages of three years before repair or rebuilding are required, compared to nine to 12 months for other drive spindles. One customer described the advantages of a driven unit running a four-tooth, 1.57-in. face mill rough-cutting cast stainless steel at 600 SFM at a depth of 0.07 inches taking a full 1-inch width of cut. "Our maintenance personnel were frequently rebuilding competitive units due to bad gear backlash and blown spindles from the heavy interrupted cut," he says. "Despite the pounding the Kennametal unit takes, we have experienced better tool life, increased surface finishes, and no downtime with broken spindles/gears. That translates into productivity and dollars that go right to the bottom line."
Versatile Machine Tools
Okuma America Corporation is the US-based affiliate of Okuma Corporation, a world leader in the development of computer numeric controls (CNC) and machining technology, founded in 1898 in Nagoya, Japan.
Okuma is known for its technology leadership and world-class manufacturing, product quality, and dedication to customer service. Okuma products are used in the automotive industry, aerospace and defense, construction and farm equipment, energy, medical, mold and die, and fluidpower industries.
Machines include vertical and horizontal machining centers, lathes, double column machining centers, grinders, and wheel machines that offer users high throughput, high accuracy, and reliable solutions to production machining operations.
Using Mechatronics, our full-circle approach to equipment design, we build machines that have the exact balance of power, speed and size to meet most any application-machines that can hold tight tolerances, perform more sophisticated cuts, and create precision-crafted parts time and again.
Okuma has entered into a partnership agreement with the National hot Rod Association and has been named Official Machine Tool Sponsor of the NHRA. This partnership is part of Okuma's High Performance Motorsports Industry program.
Okuma is known for its technology leadership and world-class manufacturing, product quality, and dedication to customer service. Okuma products are used in the automotive industry, aerospace and defense, construction and farm equipment, energy, medical, mold and die, and fluidpower industries.
Machines include vertical and horizontal machining centers, lathes, double column machining centers, grinders, and wheel machines that offer users high throughput, high accuracy, and reliable solutions to production machining operations.
Using Mechatronics, our full-circle approach to equipment design, we build machines that have the exact balance of power, speed and size to meet most any application-machines that can hold tight tolerances, perform more sophisticated cuts, and create precision-crafted parts time and again.
Okuma has entered into a partnership agreement with the National hot Rod Association and has been named Official Machine Tool Sponsor of the NHRA. This partnership is part of Okuma's High Performance Motorsports Industry program.
Saturday, February 24, 2007
Milling on a grinding machine: a grinding machine is not a machining center, but it can sometimes take on milling and drilling to make the overall pro
When the word "multitasking" is applied to machine tools, the term generally refers to a machine that is capable of both turning and milling. That definition is fine as far as it goes. However, turning and milling are two fairly similar operations. They both use a cutting edge to make a chip, and they both occur at roughly the same stage in a production process. If the argument for multitasking has to do with reducing both the delay and the potential for error that come from transporting parts between different machines, then that argument gains strength if the multitasking machine can combine operations that are even further removed from one another in the production process.
For example, what about combining milling and grinding?
Grinding, of course, is typically thought of as a finishing operation. Milling is more about removing a stock envelope. In many plants, these two operations are performed in different locations. In an even larger number of plants, they are performed by different employees who have different skills. Combining the two operations would not seem to be an obvious choice.
This latter feature relies on proven technology. Specifically, it relies on a toolchange arm like that of a machining center, along with toolholders (or wheelholders in this case) that use the HSK interface of a machining center's toolholders. Taken together, this machine's tool changing, spindle power and rigidity produce the equivalent of a highly capable machining center. Precise heavy milling can be performed on this machine, and milling and drilling tools can be stored in the tool magazine alongside the grinding wheels.
Minimal Milling
Chris Stine is a vice president of United Grinding Technologies. He says performing chip-making operations such as milling and drilling on a grinding machine is best suited to certain types of parts. It also requires a particular mindset about production.
For a part to benefit from milling or drilling on a grinder, the cycle should consist of mostly grinding. The MFP-TC machine cited above remains a grinder first and foremost, offering precision beyond what might be associated with even a higher-end machining center, he says. As a result, the machine can't compete economically against a machining center if traditional metalcutting makes up most of the work.
However, many ground parts do feature a small but critical amount of this metalcutting. Even on a grinding machine equipped with multiple wheels and capable of high metal removal rates, there are plenty of features that simply cannot be ground. Holes, pockets and slots that don't run completely through the workpiece are examples. When the part has one or more features such as these, performing these cuts on the grinder can save considerable cost by eliminating the need to set up on multiple machines. This is particularly true for parts such as airfoils, in which the location of machined features may be defined with respect to ground surfaces that have complex geometries.
Another argument for consolidating operations relates to the part's size. Large parts magnify the savings in floor space that might result from combining grinding and machining center operations into one machine. Labor savings might also be more significant. The bigger the part, the better it is to set it up in just one place.
For particularly large parts, Mr. Stine says that the range of potential operations expands to include turning. A rotary table that can turn at 70 rpm can deliver 1,500 sfm of cutting speed to a turning tool that cuts at a diameter of 7 feet. This is exactly the solution that GE Gas Turbines (Greenville, South Carolina) adopted for machining large turbine wheels. Parts that used to be machined on a grinder, a vertical lathe and a boring mill now receive all of this machining on one Magerle machine tool. The change saves about 6 hours of setup time and 2 days of queue time, according to engineers at the plant. Overall, there has been a 30 percent cycle time reduction.
Process Perspective
These savings overcome the fact that the multitasking grinder is unlikely to be cost-efficient when it comes to milling or turning as isolated operations. Accepting this seeming inefficiency within the machining cycle, for the sake of a more efficient process overall, is part of the recipe for implementing these machines effectively.
For example, what about combining milling and grinding?
Grinding, of course, is typically thought of as a finishing operation. Milling is more about removing a stock envelope. In many plants, these two operations are performed in different locations. In an even larger number of plants, they are performed by different employees who have different skills. Combining the two operations would not seem to be an obvious choice.
This latter feature relies on proven technology. Specifically, it relies on a toolchange arm like that of a machining center, along with toolholders (or wheelholders in this case) that use the HSK interface of a machining center's toolholders. Taken together, this machine's tool changing, spindle power and rigidity produce the equivalent of a highly capable machining center. Precise heavy milling can be performed on this machine, and milling and drilling tools can be stored in the tool magazine alongside the grinding wheels.
Minimal Milling
Chris Stine is a vice president of United Grinding Technologies. He says performing chip-making operations such as milling and drilling on a grinding machine is best suited to certain types of parts. It also requires a particular mindset about production.
For a part to benefit from milling or drilling on a grinder, the cycle should consist of mostly grinding. The MFP-TC machine cited above remains a grinder first and foremost, offering precision beyond what might be associated with even a higher-end machining center, he says. As a result, the machine can't compete economically against a machining center if traditional metalcutting makes up most of the work.
However, many ground parts do feature a small but critical amount of this metalcutting. Even on a grinding machine equipped with multiple wheels and capable of high metal removal rates, there are plenty of features that simply cannot be ground. Holes, pockets and slots that don't run completely through the workpiece are examples. When the part has one or more features such as these, performing these cuts on the grinder can save considerable cost by eliminating the need to set up on multiple machines. This is particularly true for parts such as airfoils, in which the location of machined features may be defined with respect to ground surfaces that have complex geometries.
Another argument for consolidating operations relates to the part's size. Large parts magnify the savings in floor space that might result from combining grinding and machining center operations into one machine. Labor savings might also be more significant. The bigger the part, the better it is to set it up in just one place.
For particularly large parts, Mr. Stine says that the range of potential operations expands to include turning. A rotary table that can turn at 70 rpm can deliver 1,500 sfm of cutting speed to a turning tool that cuts at a diameter of 7 feet. This is exactly the solution that GE Gas Turbines (Greenville, South Carolina) adopted for machining large turbine wheels. Parts that used to be machined on a grinder, a vertical lathe and a boring mill now receive all of this machining on one Magerle machine tool. The change saves about 6 hours of setup time and 2 days of queue time, according to engineers at the plant. Overall, there has been a 30 percent cycle time reduction.
Process Perspective
These savings overcome the fact that the multitasking grinder is unlikely to be cost-efficient when it comes to milling or turning as isolated operations. Accepting this seeming inefficiency within the machining cycle, for the sake of a more efficient process overall, is part of the recipe for implementing these machines effectively.
Hydraulic machine makes straight and angle cuts
The Blockshear is an easy, dust-free, and convenient onsite method for making straight and angle cuts. It produces split-face cuts on brick pavers and precast concrete blocks from 2.5-8-in. thick. The cordless, foot-operated hydraulic tool has a table that lowers and rises under pressure, much like air-assisted units. It cuts pavers, cast stone, and masonry retaining walls.
Release delivers new high speed tool paths—Mastercam/CNC, Inc., booth 427
Mastercam X's latest maintenance release, MR1, includes various new capabilities, such as added high speed machining tool paths, holder definition, the release of Mastercam X and more.
Seven high speed surface machining (HST) tool paths--two roughing and five finishing paths--have been incorporated into the release, including an interface for toolpath creation. These added types are tailored to high speed machining while offering smooth cutting motion and smooth entry/exits, says Mastercam/CNC Software. The high speed tool paths include core roughing, area clearance, waterline, scallop, horizontal area, raster and an enhanced pencil tool path.
Using the release, operators can define a holder (or select one from a library) and gouge-check the holder during toolpath generation. The holder definition can be used to detect possible toolpath gouges.
This release is now available to all maintenance customers. SP2, a service pack release, is also available to those who do not participate in the maintenance program.
Seven high speed surface machining (HST) tool paths--two roughing and five finishing paths--have been incorporated into the release, including an interface for toolpath creation. These added types are tailored to high speed machining while offering smooth cutting motion and smooth entry/exits, says Mastercam/CNC Software. The high speed tool paths include core roughing, area clearance, waterline, scallop, horizontal area, raster and an enhanced pencil tool path.
Using the release, operators can define a holder (or select one from a library) and gouge-check the holder during toolpath generation. The holder definition can be used to detect possible toolpath gouges.
This release is now available to all maintenance customers. SP2, a service pack release, is also available to those who do not participate in the maintenance program.
Shop Floor Inspection Machine measures compressor blades
Non-contact, automated Lightscan measures compressor blade airfoils for comparison with CAD data (with 160,000-point 3D point cloud) to obtain immediate go/no go sentencing. In addition to measuring sensor and associated application software, blade gauging inspection solution uses white light technology and has typ inspection cycle of 20 sec. With accuracy exceeding 0.0005 in., machine can be programmed to inspect new parts in as little as 4 hr.
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The new Lightscan non-contact blade gauging inspection from GE Inspection Technologies is a complete, automated, shopfloor solution for quickly and accurately measuring compressor blade airfoils for comparison with CAD data to obtain immediate go/no go sentencing. The new system offers significant cost-saving and time-saving advantages over conventional hard gage inspection and is the first system of its type to feature both measuring sensor and associated application software, providing a total turn-key inspection solution.
Using state-of-the-art white light technology, the operator-friendly, Lightscan has a typical inspection cycle of just 20 seconds, compared with the 60 to 90 seconds required by competitive equipment. It is accurate to greater than 0.0005", which is comparable with more cumbersome CMM equipment, and it can be programmed to inspect new parts in just four hours. Compare that to the 16-18 weeks required to manufacture of new hard gauges. As a result, Lightscan provides significant benefits in terms of production output and reduced tooling costs over hard gage inspection and provides significant improvements in manufacturing flexibility over mechanical and laser CMM systems and other white light systems.
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The new Lightscan non-contact blade gauging inspection from GE Inspection Technologies is a complete, automated, shopfloor solution for quickly and accurately measuring compressor blade airfoils for comparison with CAD data to obtain immediate go/no go sentencing. The new system offers significant cost-saving and time-saving advantages over conventional hard gage inspection and is the first system of its type to feature both measuring sensor and associated application software, providing a total turn-key inspection solution.
Using state-of-the-art white light technology, the operator-friendly, Lightscan has a typical inspection cycle of just 20 seconds, compared with the 60 to 90 seconds required by competitive equipment. It is accurate to greater than 0.0005", which is comparable with more cumbersome CMM equipment, and it can be programmed to inspect new parts in just four hours. Compare that to the 16-18 weeks required to manufacture of new hard gauges. As a result, Lightscan provides significant benefits in terms of production output and reduced tooling costs over hard gage inspection and provides significant improvements in manufacturing flexibility over mechanical and laser CMM systems and other white light systems.
The Hidden Benefits Of Machine Tools - Association For Manufacturing Technology report - Brief Article
The Association For Manufacturing Technology--AMT (McLean, Virginia) has released a new study detailing the substantial, unmeasured economic benefits of machine tools and advanced manufacturing techniques. The study concludes that traditional measurements of productivity do not include all the products and industries that have been positively affected by machine tool technology. AMT estimates that these unmeasured contributions have averaged nearly $200 billion per year during the past 5 years.
The organization recommends government policies that will extend the environment of rapid innovation and high R&D investments that has led to the nation's recent resurgence in productivity. Among other policy positions, AMT recommends keeping interest rates stable, encouraging additional investment through corporate tax reductions, accelerating capital expense write-offs and permanently extending the R&D tax credit.
The organization recommends government policies that will extend the environment of rapid innovation and high R&D investments that has led to the nation's recent resurgence in productivity. Among other policy positions, AMT recommends keeping interest rates stable, encouraging additional investment through corporate tax reductions, accelerating capital expense write-offs and permanently extending the R&D tax credit.
Tuesday, February 20, 2007
Toolholding for improved surface finishes—Rego-Fix Tool Corp., booth 3145
Rego-Fix Tool Corp. offers the Zero-Z, which is appropriate for multiple turning centers and small VMCs. The toolholder features a short projection, allowing for increased Z-axis stroke while accommodating greater workpiece size. The design involves a flush collet nut, whereby tool overhang is virtually eliminated.
Cartridge system provides the stability of an integral shank tool
The MTC Serrated Locking System (SLS) cartridge system from ManchesterTool Company consists of a toolholder and a cartridge, which simplifies the standard multicomponent design into one piece. Both the toolholder and the cartridge have serrations or interlocking ridges on the inner sides. These serrations create a tight fit between the cartridge and the toolholder, says the company. Once the toolholder and cartridge are locked together, the system provides stability that is said to be comparable to that of an integral shank tool.
The cartridge accommodates any of the MTC double-ended, double V design inserts. Each insert locks into position with one screw. These components perform cutoff, plunge-and-turn, plunge-and-contour and face grooving operations.
The cartridge accommodates any of the MTC double-ended, double V design inserts. Each insert locks into position with one screw. These components perform cutoff, plunge-and-turn, plunge-and-contour and face grooving operations.
Tool removes extraneous material—Brush Research Mfg., booth 5044
Brush Research Mfg. Co. has made several new additions to its line of miniature Flex-Hone products. Among the tooling offered is the FlexHone, which is applicable for bore sizes as small as 0.156" (4 mm). Comprised of abrasive globules that are laminated onto flexible nylon filaments, the tool is self-centering and aligns to the bore. It also compensates for wear. In addition to removing peaks from the surface, the tool removes cut, torn and folded metal that may linger after previous machining operations
Redesigned collet line—Somma Tool, booth 3153
Somma Tool Company has reintroduced the C series Flexi-Grip collets that were previously supplied by Sandvik and Balas. The company offers C3, C4, C6, C8 drill collets, along with STC4 tap collets. The C6 and C8 series have both been redesigned: however, the collets are interchangeable with the old design.
The company also offers chucks that are compatible with the collets.
The company also offers chucks that are compatible with the collets.
Cutting tool works with titanium alloy
Sandvik Coromant Co. offers Xcel as a solution for machining of titanium alloy and heat-resistant super alloy materials. According to the company, the tool provides design advantages not previously available with one tool when semi-rough turning into shoulders. In addition, the cutting tool is also said to offer the accessibility and programming of an 80-degree insert, along with reduced wear when compared to a square insert used at 45-degree entering angle.
Two insert sizes in three grades are available to suit depths of cut from 0.5 mm to 3 mm in intermediate stage machining. Machining into corners to produce complex shapes and the capability of machining in two directions are among the product's noteworthy capabilities
Two insert sizes in three grades are available to suit depths of cut from 0.5 mm to 3 mm in intermediate stage machining. Machining into corners to produce complex shapes and the capability of machining in two directions are among the product's noteworthy capabilities
New high speed tool paths—Mastercam, booth 5527
Mastercam X's latest maintenance release, MR 1, includes various new capabilities, such as added high speed machining tool paths, holder definition and more.
Seven high speed surface machining (HST) tool paths--two roughing and five finishing paths have been incorporated into the release, along with an interface for toolpath creation. These added tool paths are tailored to high speed machining while offering smooth cutting motion and smooth entry/exits, says CNC Software. The high speed tool paths include core roughing, area clearance, waterline, scallop, horizontal area, raster and enhanced pencil.
Seven high speed surface machining (HST) tool paths--two roughing and five finishing paths have been incorporated into the release, along with an interface for toolpath creation. These added tool paths are tailored to high speed machining while offering smooth cutting motion and smooth entry/exits, says CNC Software. The high speed tool paths include core roughing, area clearance, waterline, scallop, horizontal area, raster and enhanced pencil.
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