Williams Machine & Tool Co., Inc., Galena, Kansas, has recently installed a new Mori Seiki NV5000 vertical machining center.
The 23-year-old company offers CNC machining, precision grinding, heat treating, black oxide coating and magnesium phosphate coating.
Started by Dennis Williams (as the sole employee) in the family garage in 1979, the company has grown into its current 41,000-sq.ft. facility with 42 employees.
The company maintains a family feeling with Dennis' sons Kelly and Brian, daughter Denise Titus, and numerous other family members on staff.
The new CNC vertical machining center is part of Williams Machine & Tool's ongoing effort to utilize the latest technology to improve quality and turnaround. The company already has numerous pieces of CNC equipment with auto bar feeders, gantry loaders and pallets.
"We were looking for size and speed when we picked the Mori, Seiki," noted Kelly Williams, vice president. "The NV5000 met our needs with its rapid traverse rate of 1,653/ipm, quick tool change time (2.6 seconds) and large spindle range 31.5" x 20" x 20".
Besides the new vertical machining center, the company's machining area also has: 12 CNC lathes; five CNC vertical machining centers; two 32mm CNC Swiss lathes; 11 screw machines; three turret lathes; two engine lathes; and a wire EDM.
The grinding area has five CNC grinders, 15 conventional grinders (including centerless and blanchard) and various honing and gearing equipment.
The heat treating area has 21 pieces of equipment including internal quench furnaces, draw furnaces and an induction hardening machine.
Welding, sawing and inspection equipment round out the assortment.
Williams Machine & Tool serves customers across the country and around the world in such industries as hydraulic (internal components); agriculture; construction and consumer goods.
"Our success has come about by being a family-oriented business that caters to our customers' requirements," noted Kelly Williams. "We can take an emergency part order in the morning, machine it, finish grind it, heat treat it, inspect it and ship it out at the end of the day."
Saturday, November 25, 2006
Friday, November 24, 2006
Machine tool consumption off by 35% in first quarter.
March U.S. machine tool consumption totaled $182.66 million, according to AMT - The Association For Manufacturing Technology and AMTDA, the American Machine Tool Distributors Association. This total, as reported by companies participating in the USMTC program, was up 6.0% from February but down 42.2% from the total of $315.80 million reported or March 2001. With a first quarter total of $513.62 million, 2002 is down 35.2% compared to the same period in 2001.
These numbers and all data in this report are based on the totals of actual data reported by companies participatingThursday, November 23, 2006
Security Tool Can 'Frisk' PCs
Automated IP address management has been used for years to streamline the administration of IP addresses, but one small company and a couple of its customers have discovered a new use for the tool: to create an extra layer of endpoint security and access control.
MetaInfo, a spinoff of Check Point Software Technologies Ltd., is working with customers and partners to use the point at which users are given access to the corporate network—the IP address assignment—as a mechanism to stop and "frisk" the machine.
This lets the company ensure that the device is legitimate and complies with corporate security policies, according to Grant Asplund, president and CEO of the Seattle-based companyWednesday, November 22, 2006
The role of balance in high speed finish boring: Precision boring is particularly vulnerable to unbalance, but not every high speed boring application
A single-point boring tool with adjustable cutting diameter may be used for the tightest-tolerance cutting that a given machining center is likely to perform. At the same time, this tool is probably the most inherently unbalanced object the machine will ever use to take a cut.
This irony has real consequence as spindle speed increases, because the centrifugal force resulting from unbalance increases as the square of rotational speed. Raising the speed from 4,000 to 8,000 rpm, without any change in tooling, causes centrifugal force to quadruple. Raising the speed of the same process to 12,000 rpm raises the force from unbalance to 9 times what it was at the original speed. Because of the exponential increase, an effect that was once negligible may be amplified to the point that tight tolerances can no longer be held.
One company providing variable-diameter precision boring tools is KPT Kaiser of Elk Grove Village, Illinois. During the past decade, as maximum spindle speeds for all classes of machining centers were increasing significantly, this company introduced updated versions of its tools better suited to boring at high rpm. Among the newer versions are adjustable-balance models that use moving counterweights to compensate for the change in unbalance that comes from changing the radial position of the cutting insert But not every boring application--not even every high speed application--is a candidate for one of these balanceable tools. Vice president of engineering Jack Burley says that tools with adjustable balance account for only 10 percent of the company's sales of the variable-diameter tooling. Tools that are not balanceable by means of a moving counterweight are nevertheless engineered to be balanced at the middle of the tool's adjustable diameter range. And for most finish boring applications, just this level of balance is enough.
Understanding unbalance as it applies to single-point boring is useful for shops that want to machine precision holes at faster cutting speeds. In addition, the same understanding is also useful in a larger context. Shops moving to higher spindle speeds for various applications are often concerned about the potential effects of unbalance. The example of high speed finish boring, which combines a highly asymmetric tool with a very light depth of cut, can provide a useful benchmark for these shops. The extreme set of conditions shows the extent of the impact that unbalance can have on the performance of the process.
Mr. Burley says a common mistake in high speed machining is to give too little consideration to balance. Another common mistake, he says, is to give too much consideration to balance. Higher speeds do make it worthwhile to use high-quality tools and toolholders manufactured to tight balance requirements, but where end mills and other inherently symmetrical tools are concerned, just choosing quality tooling is probably enough to ensure that balance is sufficient. Trying to improve balance further through some off-line adjustment to the tool is likely to be overkill, resulting in a change in centrifugal force that's tiny compared to the force from the cut. The reason is that single-point boring tools are more prone to require balance adjustment precisely is that the light depth of cut makes a small unbalance force more significant by comparison.
And even at that, the effect of unbalance would not be considered significant to everyone. Comparison testing at 10,000 rpm between balanceable and non-balanceable single-point tools showed a difference in hole roundness error of about 5 microns (see Figure 1). Many machining operations could tolerate error of a comparable magnitude. But in precision boring, error of this magnitude has to be addressed.
This irony has real consequence as spindle speed increases, because the centrifugal force resulting from unbalance increases as the square of rotational speed. Raising the speed from 4,000 to 8,000 rpm, without any change in tooling, causes centrifugal force to quadruple. Raising the speed of the same process to 12,000 rpm raises the force from unbalance to 9 times what it was at the original speed. Because of the exponential increase, an effect that was once negligible may be amplified to the point that tight tolerances can no longer be held.
One company providing variable-diameter precision boring tools is KPT Kaiser of Elk Grove Village, Illinois. During the past decade, as maximum spindle speeds for all classes of machining centers were increasing significantly, this company introduced updated versions of its tools better suited to boring at high rpm. Among the newer versions are adjustable-balance models that use moving counterweights to compensate for the change in unbalance that comes from changing the radial position of the cutting insert But not every boring application--not even every high speed application--is a candidate for one of these balanceable tools. Vice president of engineering Jack Burley says that tools with adjustable balance account for only 10 percent of the company's sales of the variable-diameter tooling. Tools that are not balanceable by means of a moving counterweight are nevertheless engineered to be balanced at the middle of the tool's adjustable diameter range. And for most finish boring applications, just this level of balance is enough.
Understanding unbalance as it applies to single-point boring is useful for shops that want to machine precision holes at faster cutting speeds. In addition, the same understanding is also useful in a larger context. Shops moving to higher spindle speeds for various applications are often concerned about the potential effects of unbalance. The example of high speed finish boring, which combines a highly asymmetric tool with a very light depth of cut, can provide a useful benchmark for these shops. The extreme set of conditions shows the extent of the impact that unbalance can have on the performance of the process.
Mr. Burley says a common mistake in high speed machining is to give too little consideration to balance. Another common mistake, he says, is to give too much consideration to balance. Higher speeds do make it worthwhile to use high-quality tools and toolholders manufactured to tight balance requirements, but where end mills and other inherently symmetrical tools are concerned, just choosing quality tooling is probably enough to ensure that balance is sufficient. Trying to improve balance further through some off-line adjustment to the tool is likely to be overkill, resulting in a change in centrifugal force that's tiny compared to the force from the cut. The reason is that single-point boring tools are more prone to require balance adjustment precisely is that the light depth of cut makes a small unbalance force more significant by comparison.
And even at that, the effect of unbalance would not be considered significant to everyone. Comparison testing at 10,000 rpm between balanceable and non-balanceable single-point tools showed a difference in hole roundness error of about 5 microns (see Figure 1). Many machining operations could tolerate error of a comparable magnitude. But in precision boring, error of this magnitude has to be addressed.
Tuesday, November 21, 2006
Pullback CNC collet chucks—Royal Products, booth E-2146 - Machine Tool Components and Accessories - Brief Article
This line of pullback-style CNC collet chucks has been redesigned to provide a lighter and more streamlined shape, while maintaining high strength and rigidity. Benefits of the new design include reduced wear on machine tool spindle bearings and improved tool clearance, the company says. A built-in coolant slinger and internal O-ring seals provide protection from coolant and chips. Accuracy is guaranteed to be under 0.0003" TIR. Collet chucks are often used in place of three-jaw chucks for CNC turning applications such as bar feeding, small diameter work (under3") and high-volume productions runs. All of the company's CNC collect chucks include a machined drawtube connector for quick and easy installation. They are stocked in all popular A-mounts and are available for the following collet styles: 5C, 16C, 3J, S-20, S-26 and S-30.
Also on display will be the rest of the company's line of metalworking accessories, Filtermist mist collectors, and Albrecht precision drill chucks and toolholders.
Also on display will be the rest of the company's line of metalworking accessories, Filtermist mist collectors, and Albrecht precision drill chucks and toolholders.
Monday, November 20, 2006
Turning/Machining Cell—Takisawa USA, Booth A-8741 - Takisawa Machine Tool Company Ltd - Brief Article - Product Announcement
The company will introduce a new automated production cell composed of the Model TT-200 (C type) turning center and the model MAC-V10/APC machining center.
The production cell starts with the TT-200 turning cell with a type C loader/feeder system. This is a self contained, two spindle, dual ten-tool turret turning center, integrated with a gantry load/unload system and a turnover unit, fed from a 16-pallet work feeder from the left side and discharged on the right side, into the Model MAC-V10/APC machining center. The Model MAC-V10/APC is a vertical column vertical machining center (6,000-rpm spindle, 20-station tool magazine, that has servodrive indexing) fed by an automatic, revolving, double pallet changer.
Sunday, November 19, 2006
The ultimate mass machine: make a food scale your number-one bodybuilding tool - Nutrition
Gaining muscle or losing fat means being vigilant about what you eat, in quality and quantity. The key to increasing muscle mass is to consistently take in more calories than you burn over time, but not so many calories that you get fat. Your ability to strike this balance can be greatly improved by using a scale to weigh your food. This tool may be exactly what you need to help you accurately add muscle mass or lose bodyfat.
SCALING TO NEW HEIGHTS Food scales aren't just for bodybuilders who have not yet learned to gauge portion size--many top bodybuilders, including Dorian Yates, Jay Cutler and Dennis James, weigh their food. These guys have learned that although a guess may be close, a measurement is precise. For professional bodybuilders, placings at shows are all about precision of bodyweight and composition.
Without a food scale, most people seriously underestimate portion sizes. The U.S. Department of Agriculture's servings are actually very small. By USDA standards, one half cup of berries is one serving of fruit and one serving of meat is the size of a deck of cards--clearly bodybuilders eat more than that as a serving. Package labels can also be deceptive. For example, most bags of potato chips list about 120 calories "per serving" on the label. It's only when you look more closely that you see that a serving is only two ounces and that there might be seven servings in a whole bag. However, an accurate food scale never lies and won't distort your perceptions of portion size or how many calories you're really getting.
EYEBALLING: A SKILL TO MASTER
It takes only a few weeks with a good food scale to learn to accurately gauge bodybuilding portion sizes by inspection. Learning to eyeball portion sizes accurately is key when a scale isn't available or convenient. No matter what system you use to find out what's in your food, the first thing you need to know is how much there is--the weight of the food--in a way that's convenient enough to use 24/7.
Through consistent use of a scale, you'll get accustomed to the visual cues of a portion size. In the long run, you'll be able to make much more accurate estimations when measuring the weight of your food isn't an option. That will lead to more accurate control of your physique in terms of both muscle mass acquisition and bodyfat management.
SCALING TO NEW HEIGHTS Food scales aren't just for bodybuilders who have not yet learned to gauge portion size--many top bodybuilders, including Dorian Yates, Jay Cutler and Dennis James, weigh their food. These guys have learned that although a guess may be close, a measurement is precise. For professional bodybuilders, placings at shows are all about precision of bodyweight and composition.
Without a food scale, most people seriously underestimate portion sizes. The U.S. Department of Agriculture's servings are actually very small. By USDA standards, one half cup of berries is one serving of fruit and one serving of meat is the size of a deck of cards--clearly bodybuilders eat more than that as a serving. Package labels can also be deceptive. For example, most bags of potato chips list about 120 calories "per serving" on the label. It's only when you look more closely that you see that a serving is only two ounces and that there might be seven servings in a whole bag. However, an accurate food scale never lies and won't distort your perceptions of portion size or how many calories you're really getting.
EYEBALLING: A SKILL TO MASTER
It takes only a few weeks with a good food scale to learn to accurately gauge bodybuilding portion sizes by inspection. Learning to eyeball portion sizes accurately is key when a scale isn't available or convenient. No matter what system you use to find out what's in your food, the first thing you need to know is how much there is--the weight of the food--in a way that's convenient enough to use 24/7.
Through consistent use of a scale, you'll get accustomed to the visual cues of a portion size. In the long run, you'll be able to make much more accurate estimations when measuring the weight of your food isn't an option. That will lead to more accurate control of your physique in terms of both muscle mass acquisition and bodyfat management.
Saturday, November 18, 2006
Web-based Machine Tool Monitoring - Systems and Software
The company has released the Internet version of the JobPack Machine Tool Monitoring System based on a Web server. Now machine status, real-time events and historical reports of performance and efficiency can be viewed anywhere across the globe via Internet PCs or PDAs, Up until now, engineers and managers had to be on a specific PC, connected to their network to get data. That has changed with the data being resident on the Web server in an HTML format.
Friday, November 17, 2006
Integrate TLC Tool Management - ITC Integrated Systems Inc.'s software with Infimacs II ERP suite for machine shops - Brief Article
The TLC Tool Management System from ITC Integrated Systems, Inc. is now integrated within the Infimacs II ERP suite. It allows companies to more easily enforce discipline and management control over the flow of tools between one or more tool cribs and the shop floor. Without having to build an interface, Infimacs II users can schedule and reserve critical tools and kits for upcoming production. Calibration instructions and periodic maintenance schedules can be analyzed and enforced. Issues and receipt transactions are logged and appear on reports.
The system provides scheduling and maintenance information based on a tool's usage and duration between repairs. Inspection and warning reports inform the tool crib manager when to pull a gauge, fixture or other item for maintenance.
Versions of the system are offered for small, medium and large organizations, and users can migrate from the smaller versions through upgradesThe Independent Tool Code Standard (ITCS) numbering system standardizes the tooling nomenclature to accommodate both shopfloor users and automated tracking systems. An ITCS database and instructional documentation are provided.Moving Day - Mitsubishi Machine Tool - Brief Article
Mitsubishi Machine Tool has relocated its North American headquarters to Addison, Illinois. Mitsubishi has closed the Hopkinsville, Kentucky, location and concentrated customer support in Addison. The company hopes the location will enhance customer support and communication with distributors
Thursday, November 16, 2006
Global industry profiling: Machine tool industry
ABSTRACT: As their businesses globalize at increasing rates, managers need frameworks for analyzing industry activities on a worldwide basis. In this paper, a framework for global industry analysis is presented, using the machine tool industry to illustrate how industry overviews, global consumption and production analyses can be used to gain worldwide perspectives on industry behaviors. Breakdowns by company, segment, region and country markets help strategy formulation and resource allocations in the worldwide marketplace. Obtaining the right sorts of information is the key to insightful global analyses. The globalization of industry trade associations and on-line business news services are major sources of worldwide industry developments.
As world trade and investments have become common in increasing numbers of industries, the old tools of industry analysis have become less relevant. As companies have gone global, so the need to examine industry activities on a worldwide basis has become more acute. Various writers have looked at particular aspects of global industries (e.g., Porter, 1986) but the task of profiling global industries has largely been ignored. Contemporary treatments of industry analysis have traditionally stopped at national borders (e.g., Thompson and Strickland, 1999). But as resource allocations are increasingly made on a worldwide basis, companies should have frameworks to highlight the global dimensions of their industries.
The objective of this article is to present a framework for global 4industry analysis. The machine tool industry is used to illustrate the major facets of worldwide industry analysis, and to provide a framework managers can use for strategy crafting activities.
WHAT MANAGEMENT NEEDS FROM GLOBAL INDUSTRY ANALYSES
Managers need global overviews of industries to craft their international resource allocation strategies and to gain insights about market developments and competitor activities. Such overviews should include the following:
* Global Industry Overviews show how industries are structured from a national perspective (which countries are major players), a company perspective (leading firms), and where country and product expertise lie on the global market spectrum.
* Global Consumption Analyses show worldwide patterns of demand in aggregate, and at regional and country levels. Additional insights can be gained by looking at: market sizes and machine tool expenditures per capita; key market profiles; and country sales by major product groupings.
* Global Production Analyses show which countries are major producers and how firms deploy their resources to maximize their global sales impacts. Figure 1 summarizes the strategic significance of these analyses.
Wednesday, November 15, 2006
Vision-Based Tool Presetting Machine - Brief Article - Product Announcement
The Smile V300 vertical automatic cutting tool presetting machine provides consistent, user-independent measuring of virtually any type of cutting tool geometry, according to the company. It is installed on plant floors next to CNC machine tools.
The machine can accommodate tool length (Z) of 15.72" (400 mm), radius (X) of 4.88" (125 mm), and diameter of 9.76" (250 mm). Heidenhain measuring scales, one hand control linear axis movement and electronic axis fine adjustment assure precise positioning of the cutting toolTuesday, November 14, 2006
Vision-Based Tool Presetting Machine—Zoller, Booth D-4521 - Brief Article
The company will introduce a new vision-based tool presetting machine. The Smile V300 vertical automatic cutting tool presetting machine provides consistent, user-independent measuring of virtually any type of cutting tool geometry, according to the company. It is installed on plant floors next to CNC machine tools.
The machine can accommodate tool length (Z) of 15.72" (400 mm), radius (X) of 4.88" (125 mm), and diameter of 9.76" (250 m). Heidenhain measuring scales, simple one hand control linear axis movement and electronic axis fine adjustment assure simple, rapid and precise positioning of the cutting tool. The machine permits consistent presetting of boring bars to a nominal position, with convenient right hand orientation adjustment.
The company integrated a calibration edge to the left of the spindle nose in all adapters, eliminating the need for a separate zero gauge to calibrateA 50-taper high precision spindle is standard, and ISO 50 steep taper, HSK and straight-shank adapters are available, as are 30, 40 and 45 taper adapters. For presetting turning tools, such as VDI tooling, an indexing device permits rapid 4 x 90-degree spindle positioning.
Capabilities of the system include 35x magnification; display accuracy of 0.0002" (0.005 mm); measurement in radius or diameter mode; and storage of 99 adapter zero points band at least 300 tool data recordsMonday, November 13, 2006
Machine tool Data Transmission Unit - Systems and Software
The company announces its new Data Transmission Unit-III (DTU-3), which is said to provide a reliable method for DNC plus the ability to collect machine events, both automatic and manual, in one shop-hardened Ethernet device.
Thc unit collects data from the CNC with options for operator manual input. Data is presented via a Management-Administration module, featuring realtime status, event timeline and historical analysis reports via Microsoft Excel about what your machinery has been doing, what it hasn't been doing and why.
Sunday, November 12, 2006
Simmons Machine
Simmons Machine Tool Carp, now offers Mobiturn[R] Wheel Truing Services[R]. The company provides seasonal and/or incremental maintenance wheel truing to customers in their own facilities,
Saturday, November 11, 2006
Arm your machine tool with a portable CMM - Rapid Traverse
FARO Technologies (Lake Mary, Florida) is best known for its FaroArm portable, articulated-arm CMMs that are used to measure large parts, weldments, assemblies and other components that would be difficult or impossible to bring to a conventional CMM. Now the company has introduced a smaller "personal CMM" designed expressly for the machine shop. Called the FARO Gage, the measuring device has an articulating arm with a 24-inch reach that can reach all exposed features and surfaces of a part without having to be repositioned. A magnetic base allows the unit to be mounted right on a machine tool (see photo at right) or a surface plate on a close-by inspection bench. The measuring arm offers 0.0002-inch accuracy, which reflects the increasing need of shops to hold "tenths" tolerances.
Part measurements are recorded on a laptop computer equipped with the company's Cam2 Measure software developed for feature measurement/inspection and CAD-to-part comparisons where every measured part can be compared to engineering design files. The software is user friendly enough that it can be used by machine operators with no computer skills as a step-by-step guide through an inspection routine. It not only tells the user what area of the part (top, bottom, left side, and so forth) to measure next, but it also tells him or her where and how to position the probe for the reading. The software can also be used for advanced measurement and statistical analysis such as SPC and geometric dimensioning and tolerancing (GD&T). The system records all of the user's measurements automatically and creates comprehensive reports The gage allows the part to be inspected right on the machine, which not only saves time but also avoids the problems that come with removing the part from the machine, inspecting a critical feature and trying to put the part back in the fixture exactly the way it was before. It can be used for a variety of measurements that might otherwise require several conventional hand tools, eliminating their costs and maintenance. It also eliminates the variation in measuring results from hand tool to hand tool and from operator to operator. The gage's articulated arm enables it to measure features and relationships between features that would be impossible to measure with conventional hand tools. Plus, automatic recording of the inspection data eliminates "pencil and paper" errors by operators responsible for maintaining SPC charts.
Right-Now Results
Perhaps best of all, the machinist can check the part immediately after it is machined--or pause to check a feature while the part is still in the chuck or fixture--right at the machine and replace a worn insert, change a tool offset or in some other way make an immediate correction to avoid making bad parts. The operator is also spared having to leave the machine, carry the part to the quality department, and wait in line for time on the CMM.
According to the company, in shops where a machine tool stands idle for 1 hour per shift (at $75 per shift, 3 shifts per day) because it must wait on an operator who is busy inspecting the previous part, the FARO Gage will pay for itself in 4 months. It takes up no extra floor space, an important consideration for crowded shops, and it easily can be moved from one machine to another
Part measurements are recorded on a laptop computer equipped with the company's Cam2 Measure software developed for feature measurement/inspection and CAD-to-part comparisons where every measured part can be compared to engineering design files. The software is user friendly enough that it can be used by machine operators with no computer skills as a step-by-step guide through an inspection routine. It not only tells the user what area of the part (top, bottom, left side, and so forth) to measure next, but it also tells him or her where and how to position the probe for the reading. The software can also be used for advanced measurement and statistical analysis such as SPC and geometric dimensioning and tolerancing (GD&T). The system records all of the user's measurements automatically and creates comprehensive reports The gage allows the part to be inspected right on the machine, which not only saves time but also avoids the problems that come with removing the part from the machine, inspecting a critical feature and trying to put the part back in the fixture exactly the way it was before. It can be used for a variety of measurements that might otherwise require several conventional hand tools, eliminating their costs and maintenance. It also eliminates the variation in measuring results from hand tool to hand tool and from operator to operator. The gage's articulated arm enables it to measure features and relationships between features that would be impossible to measure with conventional hand tools. Plus, automatic recording of the inspection data eliminates "pencil and paper" errors by operators responsible for maintaining SPC charts.
Right-Now Results
Perhaps best of all, the machinist can check the part immediately after it is machined--or pause to check a feature while the part is still in the chuck or fixture--right at the machine and replace a worn insert, change a tool offset or in some other way make an immediate correction to avoid making bad parts. The operator is also spared having to leave the machine, carry the part to the quality department, and wait in line for time on the CMM.
According to the company, in shops where a machine tool stands idle for 1 hour per shift (at $75 per shift, 3 shifts per day) because it must wait on an operator who is busy inspecting the previous part, the FARO Gage will pay for itself in 4 months. It takes up no extra floor space, an important consideration for crowded shops, and it easily can be moved from one machine to another
Friday, November 10, 2006
Software automates tool inventory tracking
Mentioning the state of Nebraska might conjure images of farmland, goldenrods and cornhusks. From a manufacturer's point of view, the state is home to facilities of all sizes, some of which are located in small towns.
Nestled in a farming community of 1,500 people, MetalQuest Unlimited (Hebron, Nebraska) is a 40-person shop serving the petroleum, energy distribution, hydraulics, agriculture, electronics and automotive parts sectors. At its inception in 1996, the company had one multi-axis CNC lathe. It has since added a variety of multi-functional CNC machining centers and lathes.
Desiring a better method of managing its tooling inventory, the company turned to ToolBoss from Kennametal Inc. (Latrobe, Pennsylvania). Scott Harms, president and founder of MetalQuest, became acquainted with ToolBoss, an e-storage tool inventory control system with imbedded tool management software, when attending the International Manufacturing Technology Show (IMTS) in September 2000. By July 2002, MetalQuest had purchased a one-bay unit. Six months later, a second bay was added, and in early 2004, the company purchased two additional bays. Today, using its four-bay unit, the company stores more than 2,500 tools and controls keys to other cabinets that contain hundreds of other items. Capabilities such as tracking tool inventory, raising operator accountability and providing data about tool usage have provided the company with a means to save time and money. As another result of using the new system, the company reports that machine operators now have an orderly place to store inserts, tools, tool parts and unrelated tools that are commonly used in the shop.
Another benefit is the ability to store multiple items, including non-Kennametal tools, in one drawer, and in a more organized fashion than before. The company has noticeably improved its real-time knowledge of inventory levels. As a result of this upgrade, machine operators can locate tools in 30 seconds, compared to 5 minutes of searching through drawers, toolboxes and canisters on the shop floor. Likewise, it is virtually impossible to run out of tools because restocking of inserts, drills, taps and end mills occurs on an as-needed basis.
Customers also have the option to use job status or "setup" sheets, as well as the optional bar code reader to accelerate setup and production times. This can reduce probable operator errors, such as choosing an incorrect tool for a particular job.
MetalQuest has integrated ToolBoss with its setup sheets, which instruct operators as to how to prepare machines for specific jobs. The appropriate inserts, toolholders, and toolholder parts needed are conveyed to operators. To obtain the necessary tools, users can search or scroll down the computer screen.
"The program was well received on the shop floor," says Mr. Harms. "Within a couple of days, our personnel had familiarized themselves with how the system works and had integrated it into their routine."
During the past several years, the company has transformed itself from a shop producing maximum orders of 500 pieces to one that now produces 500-piece minimum orders. Additionally, its operator-to-CNC lathe ratio to has been reduced to 0.5:1.
The company speculates that if its operations resembled a traditional custom-machined parts manufacturer, it would need to employ ten additional machinists.
The Pentium class computer is loaded with Microsoft Windows 2000 to run Kennametal's Automated Tool Management Solutions (ATMS) software. The menu includes a real-time ordering option that complements the system's tool kitting, presetting and tool assembly management features.
MetalQuest says the network card allows it to maintain the database on its existing network for checking stock, doing analyses and placing orders from other computers.
Although the company has a four-bay setup, each system can control as many as ten bays in one unit, all of which are programmed to store an infinite number of items.
Nestled in a farming community of 1,500 people, MetalQuest Unlimited (Hebron, Nebraska) is a 40-person shop serving the petroleum, energy distribution, hydraulics, agriculture, electronics and automotive parts sectors. At its inception in 1996, the company had one multi-axis CNC lathe. It has since added a variety of multi-functional CNC machining centers and lathes.
Desiring a better method of managing its tooling inventory, the company turned to ToolBoss from Kennametal Inc. (Latrobe, Pennsylvania). Scott Harms, president and founder of MetalQuest, became acquainted with ToolBoss, an e-storage tool inventory control system with imbedded tool management software, when attending the International Manufacturing Technology Show (IMTS) in September 2000. By July 2002, MetalQuest had purchased a one-bay unit. Six months later, a second bay was added, and in early 2004, the company purchased two additional bays. Today, using its four-bay unit, the company stores more than 2,500 tools and controls keys to other cabinets that contain hundreds of other items. Capabilities such as tracking tool inventory, raising operator accountability and providing data about tool usage have provided the company with a means to save time and money. As another result of using the new system, the company reports that machine operators now have an orderly place to store inserts, tools, tool parts and unrelated tools that are commonly used in the shop.
Another benefit is the ability to store multiple items, including non-Kennametal tools, in one drawer, and in a more organized fashion than before. The company has noticeably improved its real-time knowledge of inventory levels. As a result of this upgrade, machine operators can locate tools in 30 seconds, compared to 5 minutes of searching through drawers, toolboxes and canisters on the shop floor. Likewise, it is virtually impossible to run out of tools because restocking of inserts, drills, taps and end mills occurs on an as-needed basis.
Customers also have the option to use job status or "setup" sheets, as well as the optional bar code reader to accelerate setup and production times. This can reduce probable operator errors, such as choosing an incorrect tool for a particular job.
MetalQuest has integrated ToolBoss with its setup sheets, which instruct operators as to how to prepare machines for specific jobs. The appropriate inserts, toolholders, and toolholder parts needed are conveyed to operators. To obtain the necessary tools, users can search or scroll down the computer screen.
"The program was well received on the shop floor," says Mr. Harms. "Within a couple of days, our personnel had familiarized themselves with how the system works and had integrated it into their routine."
During the past several years, the company has transformed itself from a shop producing maximum orders of 500 pieces to one that now produces 500-piece minimum orders. Additionally, its operator-to-CNC lathe ratio to has been reduced to 0.5:1.
The company speculates that if its operations resembled a traditional custom-machined parts manufacturer, it would need to employ ten additional machinists.
The Pentium class computer is loaded with Microsoft Windows 2000 to run Kennametal's Automated Tool Management Solutions (ATMS) software. The menu includes a real-time ordering option that complements the system's tool kitting, presetting and tool assembly management features.
MetalQuest says the network card allows it to maintain the database on its existing network for checking stock, doing analyses and placing orders from other computers.
Although the company has a four-bay setup, each system can control as many as ten bays in one unit, all of which are programmed to store an infinite number of items.
Tool presetting ensures tool quality while saving time
The Edon, Ohio, plant of Metaldyne (Plymouth, Michigan) produces one of the most complex parts on an automobile: the steering knuckle. Irregularly shaped with a variety of surfaces and holes to mill, drill and bore, steering knuckles provide a machining challenge that usually requires some finesse to meet.
Automobiles have either two or four knuckles, which are typically made of steel, cast iron or aluminum, as part of the suspension. Production volume, as well as product quality, is an important consideration when machining these components. To achieve adequate production levels for several knuckles, the plant employs dual-spindle machining centers. Each spindle performs similar operations on left- and right-hand knuckles located in a fixture. Toolholders are shrink-fit HSK 100 and HSK 80.
"We felt that shrink-fit holders were essential," says Chris Filoso, Metaldyne manufacturing engineer. "When compared to collet chucks, hydraulic chucks or other types, shrink-fit holders offer the best possible concentricity and gripping power while eliminating the expense of parts such as collets."Because each spindle performs mirror image operations, our operators must match the tooling used in the twin-spindle machining centers to within 20 microns," he adds.
Previously, the company believed that a shrink-fit tool changing machine and a separate presetter would accomplish adequate tool changing and setting. However, this two-stage process proved to be time-consuming because one machine was needed for shrinking/unshrinking the tool, while a second device was required to measure and preset the tool. Other cons of this arrangement were that the tool setting accuracies mandated by plant standards could not be achieved, and the tool presetter could not automatically write tool data to the Balluff chip embedded in the company's holders.
Anticipating that adequate accuracy and time savings would be realized, the plant acquired a redomatic heat-shrink tool presetter and measuring machine from Zoller Inc. (Ann Arbor, Michigan). Including features such as a Z-axis measuring range of 23.58 inches (600 mm) and a diameter of 15.72 inches (400 mm), the three-axis CNC vertical tool setter and measuring machine is now employed by the company to preset, heat shrink, cool and measure tools in one automated process.
Heat shrinking to a nominal length is only possible when one unit performs the entire process. The system has a 10 kW capacity for shrink fitting shank diameters ranging from 0.12 inches to 1.26 inches (3 mm to 32 mm), and in lengths as large as 600 mm, with heating times varying from 5 to 10 seconds. Cooling requires approximately 30 seconds or less with reliable water-cooled cooling adapters, according to plant engineers.
The machine used at Metaldyne incorporates a vision system that provides automated measuring and inspection of each tool in the plant's arsenal. Two CNC-driven linear slides--vertical and horizontal--position the optic carrier, and the spindle rotation permits focusing on the tool.
"The image processing technology permits automated measurement of tool length, diameter, corner radius and two cutting edge angles," explains Mr. Filoso. "The software detects cutting edges almost instantly, and then the camera in the optic carrier transmits the image of the tool edge to the control and screen."
Mr. Filoso comments that, in addition to ease of use, the system offers various benefits. "The machine can set any shrink-fit tool to the required length within [+ or -] 10 microns," he reports.
"To shrink clamp a tool to a nominal length, our operator need only input data, such as the nominal length, toolholder diameter and tool material (HSS or carbide), via an easy-to-comprehend human-machine interface," explains Mr. Filoso. "Each tool contains an ID number to enable users to retrieve and use this data later on."
The induction-heating coil is positioned over the holder, where the coil then heats the holder. The tool is loaded into the holder, and the CNC-driven tool length stop is said to ensure correct tool positioning--for example, tool tip to gage line. The operator selects one of five cooling adapters and positions it over the holder. After this step, the tool is checked again automatically, and measurement results are transferred to the tool identification chip.
"The entire procedure is carried out in about 2 minutes," says Mr. Filoso, "which includes changing the tools and achieving the accuracies we need." Any correction values are stored and can be used in the next shrink-clamping process
Automobiles have either two or four knuckles, which are typically made of steel, cast iron or aluminum, as part of the suspension. Production volume, as well as product quality, is an important consideration when machining these components. To achieve adequate production levels for several knuckles, the plant employs dual-spindle machining centers. Each spindle performs similar operations on left- and right-hand knuckles located in a fixture. Toolholders are shrink-fit HSK 100 and HSK 80.
"We felt that shrink-fit holders were essential," says Chris Filoso, Metaldyne manufacturing engineer. "When compared to collet chucks, hydraulic chucks or other types, shrink-fit holders offer the best possible concentricity and gripping power while eliminating the expense of parts such as collets."Because each spindle performs mirror image operations, our operators must match the tooling used in the twin-spindle machining centers to within 20 microns," he adds.
Previously, the company believed that a shrink-fit tool changing machine and a separate presetter would accomplish adequate tool changing and setting. However, this two-stage process proved to be time-consuming because one machine was needed for shrinking/unshrinking the tool, while a second device was required to measure and preset the tool. Other cons of this arrangement were that the tool setting accuracies mandated by plant standards could not be achieved, and the tool presetter could not automatically write tool data to the Balluff chip embedded in the company's holders.
Anticipating that adequate accuracy and time savings would be realized, the plant acquired a redomatic heat-shrink tool presetter and measuring machine from Zoller Inc. (Ann Arbor, Michigan). Including features such as a Z-axis measuring range of 23.58 inches (600 mm) and a diameter of 15.72 inches (400 mm), the three-axis CNC vertical tool setter and measuring machine is now employed by the company to preset, heat shrink, cool and measure tools in one automated process.
Heat shrinking to a nominal length is only possible when one unit performs the entire process. The system has a 10 kW capacity for shrink fitting shank diameters ranging from 0.12 inches to 1.26 inches (3 mm to 32 mm), and in lengths as large as 600 mm, with heating times varying from 5 to 10 seconds. Cooling requires approximately 30 seconds or less with reliable water-cooled cooling adapters, according to plant engineers.
The machine used at Metaldyne incorporates a vision system that provides automated measuring and inspection of each tool in the plant's arsenal. Two CNC-driven linear slides--vertical and horizontal--position the optic carrier, and the spindle rotation permits focusing on the tool.
"The image processing technology permits automated measurement of tool length, diameter, corner radius and two cutting edge angles," explains Mr. Filoso. "The software detects cutting edges almost instantly, and then the camera in the optic carrier transmits the image of the tool edge to the control and screen."
Mr. Filoso comments that, in addition to ease of use, the system offers various benefits. "The machine can set any shrink-fit tool to the required length within [+ or -] 10 microns," he reports.
"To shrink clamp a tool to a nominal length, our operator need only input data, such as the nominal length, toolholder diameter and tool material (HSS or carbide), via an easy-to-comprehend human-machine interface," explains Mr. Filoso. "Each tool contains an ID number to enable users to retrieve and use this data later on."
The induction-heating coil is positioned over the holder, where the coil then heats the holder. The tool is loaded into the holder, and the CNC-driven tool length stop is said to ensure correct tool positioning--for example, tool tip to gage line. The operator selects one of five cooling adapters and positions it over the holder. After this step, the tool is checked again automatically, and measurement results are transferred to the tool identification chip.
"The entire procedure is carried out in about 2 minutes," says Mr. Filoso, "which includes changing the tools and achieving the accuracies we need." Any correction values are stored and can be used in the next shrink-clamping process
Grinding Machine targets automobile industry
ertical Generating Grinding Machine, Model S 250 G features cast iron machine bed and light metal subassembly, consisting of spindle with electric drive, absolute position encoder, and tailstock. Spindle offers output of 48 kW and max speed of 20,000 rpm. Siemens CNC control system and magnetic encoder ensure synchronization between tool and workpiece. Modular gantry loader allows grinding machine to be directly incorporated in existing production lines.
At EMO 2005, the trade fair for machine tools, production systems and technologies taking place in Hanover this year, Samputensili is presenting this new compact high-capacity machine - guaranteeing gear manufacturers top levels of productivity (above all in the automobile sector).
Bologna, 26th September 2005 - Samputensili, one of the leading companies in the gear-cutting machine and tool industry, is presenting the new S 250 G generating grinding machine at EMO 2005 in Hanover, the trade fair for the entire mechaMachine Tool Controller Software—CamSoft Corp - Brief Article
The company will be demonstrating Version 12 of its PC-based CNC machine tool controller software, CNC Professional, which now has the ability to do eight axes of simultaneous coordinated motion. The company also will be debuting its latest PC-based CNC machine tool controller software package titled CNC Plus, CNC Plus includes configurable operator screen, limited configurable G and M codes, diagnostic software, servo tuning software, visual logic process editor, automatic machine maintenance reminders, remote machine monitoring, ActiveX and DLL source code, (G40, G41, G42) tool comp, (G94, G95) ipm and ipr for lathes, (G74) lathe peck drilling, (G96, G97) constant surface feed for lathes, (M98, M88) dubroutine calls, threading and tapping, backlash axes compensation, leadscrew axes mapping compensation and advanced mid-program start, allowing the program to begin anywhere.
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