Milling Around – The Google Blogger Version

We're Moving!

2009-09-10T16:36:00.003-04:00

Milling Around is affiliated with
MachineShopWeb.com
Your Guide to Machine Shop Products, Shops and Services

It's Blogger-iffic!
Milling Around is now echoed on Google Blogger
at www.MillingAroundUSA.Blogger.com

Big Changes

While Milling Around is a cute title, it is a little opaque for search engines. With that in mind, I'm migrating this blog to a better title: Machining Business News.

I'll be co-posting here until September 15, then the big show will be at MBN. See you there.

Mission(ary) Position

2009-09-09T15:48:00.002-04:00

Milling Around is affiliated with
MachineShopWeb.com
Your Guide to Machine Shop Products, Shops and Services

It's Blogger-iffic!
Milling Around is now echoed on Google Blogger
at www.MillingAroundUSA.Blogger.com

It's not that hard

For a while, back at the turn of the century, it seemed awfully important to companies to generate mission statements. Why? It's hard to tell. I think a lot of the need was produced by middle managers who read too many management books.

What is a mission statement? It's a short – well, it's supposed to be – phrase that capsulizes what a business, or business unit, is supposed to be doing. How hard could that be? Wouldn't a business know its . . . well . . . business? Not if you read some of those things.

They're usually put together by committees of people who have, or are working on, MBAs. They may know the theory of business, but in most cases, they are just a shade beyond pre-verbal. Instead of boiling-down the essence of their work into a 25-words-or-less statement, most of these people come from the "more is better" school of writing, especially if they can use the word "utilize."

If they can't think of the correct word, they reach into their limited vocabulary and cobble together portmanteau hyphenated words, like "war-fighter" instead of "soldier" or "warrior." They think it makes them sound erudite.

In my days as a tech writer for National City Bank, a section of the IT department came up with a 50-word mission statement that included such clinkers as "thought-leader." What the heck is that?

The whole mission statement fad became so popular that the Dilbert comic strip had, for a time, an online mission statement generator that produced such vacuous statements as

"Our goal is to efficiently utilize inexpensive data while continuing to professionally leverage other's excellent intellectual capital in order to solve business problems"

"We have committed to synergistically fashion high-quality products so that we may collaboratively provide access to inexpensive leadership skills in order to solve business problems"

"It is our job to continually foster world-class infrastructures as well as to quickly create principle-centered sources to meet our customer's needs"

"Our challenge is to assertively network economically sound methods of empowerment so that we may continually negotiate performance based infrastructures"

Sadly, the parodies sounded much like those produced by the corporate drones.

But, a true statement of a business' goals should be simple. Feel free to use these:

"Do good, avoid evil."

"We're here to produce good stuff for money."

"Keep the customers satisfied."

See, it's not that hard.

Unilock is the key

The Unilock Starter Kit from Stevens Engineering and BIG Kaiser

Stevens Engineering Inc. and BIG Kaiser Precision Tooling Inc. introduce the Unilock Starter Kit. The kit lets users plug the components into their production cell when it supports a Stevens Engineering mounting grid pattern to eliminate setup time. The kit contains universal pallets that lets the user attach and detach positioning and clamping components or workpieces. Starter Kits support the Stevens Engineering grid pattern with other grid spacing available upon request. Unilock can be used to exchange work pieces in excess of 5,000 lb, however these kits are designed for use with small parts and fixtures that can be shuttled by hand or robot from one process to another. For information about Stevens Engineering products, call 800-635-0657, or e-mail the company. For more information about BIG Kaiser Unilock Starter Kits or other products, call 847-228-7660, e-mail BIG Kaiser.

Beveled edges with a waterjet

The OMAX A-Jet waterjet nozzle cuts beveled edges

OMAX introduces its A-Jet, which cuts beveled edges at angles determined by the machine operator or part program. Controlled by the company’s proprietary Intelli-MAX software, the A-Jet adds two motion axes that allow nozzle tilting of 0 to 60° from the vertical position. The component can be used to produce beveled edges when cutting countersunk holes. It also can cut parts with complex geometries. The accessory features a fixed focal point design, where the X-, Y-, and Z-axes need not be moved as the head tilts. The A-Jet is supplied with a diamond-integrated MAXJET 5i nozzle. It has large-diameter tubing with minimal pressure loss, for the use of large high-power nozzles. For more information, call Sandra McLain at 800-838-0343, and tell her you saw this at Milling Around.

Two-axis table for laser machining

The Steinmeyer LT490-450-EDLM 2-axis stage system for laser machining

Steinmeyer, Inc. offers its LT490-450-EDLM 2-axis system for laser machining as well as other extended travel applications. It’s an enclosed 2-axis stage with 450mm stroke. It contains iron-core linear motors, linear guideways, linear measuring system and E-chain cable carriers. Maximum speed is 500mm per second with acceleration of 5m/s². Accuracy in each direction is 1µ with ±0.5µ repeatability. For further information, call 781-273-6220.

Cam levers for workholding

Cam levers by Kipp and Imao from Fixtureworks

Fixtureworks has just released a series of cam levers developed by Kipp, a manufacturer of manual operating elements and Imao, a producer of fixturing clamps, and machine tool accessories. The cam levers are designed to provide ergonomic clamping of part fixtures. There is a selection of 17 different handles with mounting options, sizes, profiles and clamping force ratings. The levers are outfitted with either internal female threads or with male threaded studs for attaching to fixture bases, plates, tombstones, machine tables, or other workholding elements. Once the preliminary assembly and tightening of the threaded elements is completed – like traditional clamping fasteners – the cam action handles allow for quick final clamping or unclamping without the use of tools. The cam lever is pushed downward with minimal hand force, which generates approximately 200 to 1,800 lb of clamping force, depending upon the size range of the lever. Forces are created with as little as 0.050"/0.060" lever travel in the Kipp units, and 0.07" to 0.129" travel with the Imao handles. To unfasten, the handle is pulled up which releases the clamping pressure, allowing part removal for unloading and loading. In addition to male or female thread mounting options, the cam levers come in inch and metric internal threads, plus inch and metric external threaded selections. The Imao levers have female threaded bushings only, with thread sizes from M4 to M8 for mounting to fixture bases. Kipp cam lever handles are constructed from cast aluminum or stainless steel, while the Imao levers are fabricated from steel with black oxide finish; a setscrew and internal pad are included to help prevent the levers from backing off and loosening during operation. For more information, call 586-294-1188.

Honing in on smoothness

Sunnen\'s TC tool for honing small two-stroke cycle engine cylinders

Sunnen's TC tool is custom-engineered for honing small two-stroke cycle engine cylinders to solve problems such as blind, ported, and tapered bores, and hard surface coatings, such as Nikasil and chrome plating. The tool easily fractional micron – 0.00004" – accuracies and specific surface finishes for increased power production, fuel efficiency, reduced emissions and engine durability. Equipped with metal-bond superabrasives, TC tools use customized abrasive mounting, that holds up to a dozen stone segments of various lengths. Strategic placement of the abrasives produces roundness and a consistent finish from top to bottom in blind bores. Each tool is tuned to the application based on length and number of abrasives that lets the tool bridge across ports, minimizing washout of the port edges to maintain ring seal for increased power and engine life. For additional information, call 800-325-3670, or e-mail Sunnen.
–30–

Blog Search Engine

How are you going to ruin a wetland when you're up to your keister in endangered species?

2009-09-04T11:28:00.003-04:00

Milling Around is affiliated with
MachineShopWeb.com
Your Guide to Machine Shop Products, Shops and Services

It's Blogger-iffic!
Milling Around is now echoed on Google Blogger
at www.MillingAroundUSA.Blogger.com

I was crossing the street the other day, not looking where I was going when I was run over by a bus. Ouch.

My legs were crushed to strawberry jam, so I wasn’t feeling in tip-top shape. Thankfully, a charismatic African-American politician was walking by and came to my aid. He took my pulse and laid a hand to my forehead to see if I had a fever.

“You’re running a little hot. I’d better take care of that,” he said.

He took my wallet from my ruined pants and ran to the nearby drugstore. He came back with a bottle of Aleve and popped one into my mouth before I could tell him that I was allergic to naproxin.

I also noticed that a third of what I had in my wallet was gone.

“I saw a homeless man in front of the drugstore,” the politician said. “He looked so sad that I used what was left from the $20 in your wallet to buy him a bottle of Night Train. We all have to share the burden of our fellow man’s misfortune, you know.

“I also took a 20 to get myself this nice FeatherBed™ goose-down, hyperallergenic, contour pillow. I’m sure you’ll feel better knowing that I’ll sleep much better tonight.”

While I was being lectured about my civil duty and how I couldn’t expect to eat as much as I wanted or could afford, or how I couldn’t heat or cool my home to make it as comfortable as I’d like, a second bus came by and ran over me again since the politician hadn’t moved me from the gutter. My shoes would never be the same. But, since it didn’t look like I’d be walking anymore, their usefulness was moot.

The slim gentleman then gave me a bill for the drycleaning his suit would need for the mess my blood made of his cuffs.

“Don’t worry about paying that now,” he said. “I’m sure your kids will be more than happy to pay that once they grow up and get jobs.”

He then thanked me for my service to him and went off to what I’m sure was a very important meeting in Washington. Eh, who needs legs nowadays anyway?

If you draw any parallels between my misfortune and the Washington’s monomaniacal focus on health-care to the expense of all of our domenstic troubles, you’re reading too little into this parable.
• • •
Well, rather than taint manufacturers with my opinions, I'll concentrate on news today, rather than new products.

The state of manufacturing
The U.S. Census Bureau released some stats on Sep. 2, and the news, while not happy, jolly fun-time looks a bit better than it’s looked for a while. My analyses, for what it’s worth – it and $4 will get you a venté latté – are in italics.

According to the report, new orders for manufactured goods in July, up for five of the last six months, increased $4.6 billion or 1.3 percent to $355.5 billion

This followed a 0.9 percent June increase. Excluding transportation, new orders decreased 0.7 percent. Shipments, down 11 of the last 12 months, decreased $0.2 billion to $359.7 billion. This followed a 1.8 percent June increase.

Looks like a mixed message to me.

Unfilled orders, down 10 consecutive months, decreased $0.1 billion to $740.6 billion. This was the longest streak of consecutive monthly decreases since the series was first published on a NAICS basis in 1992.

Not a real sign of a robust economy flexing it’s economic muscles. More like how I feel getting out of bed in the morning: creaky, stiff, and slow.

This followed a 0.8 percent June decrease. The unfilled orders-to-shipments ratio was 5.95, down from six in June. Inventories, down 11 consecutive months, decreased $3.6 billion or 0.7 percent to $503.1 billion. This was the longest streak of consecutive monthly decreases since the March 2003 to January 2004 period, and followed a 1.1 percent June decrease. The inventories-to-shipments ratio was 1.40, down from 1.41 in June.

So, on the balance, it looks to me, a layman, like there’s some hope, but we may not have hit bottom yet.

New orders for manufactured durable goods in July, up three of the last four months, increased $8.2 billion or 5.1 percent to $169.0 billion, revised from the previously published 4.9 percent increase. This followed a 1.1 percent June decrease.

New orders for manufactured nondurable goods decreased $3.6 billion or 1.9 percent to $186.5 billion.

Shipments of manufactured durable goods in July, up two consecutive months, increased $3.4 billion, or 2 percent, to $173.3 billion, unchanged from the previously-published increase. This followed a 0.8 percent June increase.

Shipments of manufactured nondurable goods, down following two consecutive monthly increases, decreased $3.6 billion or 1.9 percent to $186.5 billion. This followed a 2.8 percent June increase. This decrease was led by petroleum and coal products, which decreased $2.7 billion or 7.2 percent to $34.3 billion.

I suppose the greenies will welcome the news that we’re using less oil and coal, thus sparing Mother Gaea, but to me it means were using less energy. Decreased energy usage means less production, and less production means less manufacturing, and less manufacturing means . . . well you get the picture, and it’s not a pretty one.

Unfilled orders for manufactured durable goods in July, down 10 consecutive months, decreased $0.1 billion to $740.6 billion, revised from the previously-published 0.1 percent decrease. This was the longest streak of consecutive monthly decreases since the series was first published on a NAICS basis in 1992 and followed a 0.8 percent June decrease.

Inventories of manufactured durable goods in July, down seven consecutive months, decreased $2.9 billion, 0.9 percent, to $313.7 billion, revised from the previously-published 0.8 percent decrease. This followed a 1.5 percent June decrease.

Inventories of manufactured nondurable goods, down 11 consecutive months, decreased $0.7 billion or 0.4 percent to $189.4 billion. This followed a 0.4 percent June decrease. Plastic and rubber products led the decrease, down $0.4 billion, 2 percent, to $18.9 billion.

By stage of fabrication, July materials and supplies decreased 1.8 percent in durable goods and increased 0.7 percent in nondurable goods. Work in process decreased 0.1 percent in durable goods and 0.8 percent in nondurable goods. Finished goods decreased 1.1 percent in durable goods and 1.0 percent in nondurable goods.

Yeah, but what’s it mean?
Okay, there were a lot of stats above, some seemed to be pointing to a recovery, others showing we haven't bottomed-out yet. I'll leave it up to an expert to interpret what's happening.

In this case, it's Cliff Waldman, economist for the Manufacturers Alliance/MAPI, and his interpretation of the durable goods report for July.

The July report on durable goods demand squares with recent data in suggesting that the U.S. and global economies have entered a slow, if somewhat uncertain economic recovery.

Excluding the volatile transportation category, total new orders for long-lasting manufactured goods were up less than 1 percent, continuing a string of modest advances that are now leading to more positive manufacturing production activity as inventories are brought into line with the still weak realities of market demand.

The mixed industry data for July, with primary and fabricated metals demand showing solidly positive activity but machinery demand suffering a sizable decline, indicates that factory activity will, for a time, likely return to the mixed situation that was indicative of the earlier months of this long recession.

Disappointingly, new orders for non-defense capital goods, excluding aircraft, a proxy for business equipment spending, slipped a bit after two strong months and remains more than 20 percent below year-ago levels.

U.S. and global activity has stabilized and financial conditions have improved modestly. But business decision-makers are going to have to see firmer and more consistent evidence of a return to the type of economic conditions that will produce solid profits before they are willing to more consistently strengthen their investment commitments and add capacity.

So, it looks like, at least to me, that we'll be in a belt-tightening mode for at least another year.
–30–

Blog Search Engine

2009-09-02T15:04:00.004-04:00

Milling Around is affiliated with
MachineShopWeb.com
Your Guide to Machine Shop Products, Shops and Services

It's Blogger-iffic!
Milling Around is now echoed on Google Blogger
at www.MillingAroundUSA.Blogger.com

Lots of new stuff

New products keep flooding in, so it's about time I got on the stick and showed you some of them.
• • •

New Products

This takes the crankiness out of crankshaft grinding
The VTC 315 DS grinding machine from EMAG has two grinding wheels that machine the same bearing simultaneously.

The VTC 315 DS grinding machine from EMAG

It has a work headstock at the top, tailstock below, two compound slides, to the left and right a grinding spindle each with a CBN-compatible power rating of 30 kW and cutting speeds of 150 m/s. Also integrated are functions for gap control and automatic balancing. The work headstock does not have to be equipped with a special driver. It is equipped with two measuring sensors. The longitudinal alignment of the crankshaft is carried out with the aid of a pivoting length measuring device, whereas the diameters are checked with a type of in-process gauging head. Two integral dressing spindles with solid-borne sound sensors and a maximum speed of 15,000 rpm allow for simultaneous wheel dressing.

Shrink-fit
Kennametal introduces a shrink-fit toolholding system program for machining centers and multi-tasking machines. The program is in two lines.: the GP – general purpose – line of carbide, HSS, and steel shanks with clamping torques suitable for most general engineering, die and mold, automotive, and other machining tasks; and the HT – high torque – line for heavy roughing operations requiring higher clamping torque level, or for machining difficult-to-cut materials.

The Kennametal GP and HT shrink-fit toolholding systems

The HT line has a 30 to 50 percent higher clamping torque compared to GP line. For tolerancing hollow-shank (HSK) toolholders, taper is much tighter than that of any conventional 7/24 taper shanks. Due to the trend toward higher cutting speeds, all HSK-shrink fit toolholders have balancing quality of G2.5 at 25,000 rpm. The shrink-fit program also accommodates steep taper, BT, CV, and DV back-ends. Other factors in the program include a shrinking and cooling process that will not last more than 30 seconds, 3µm concentricity, slim profile for chucks for milling deep cavities, through-hole for coolant, and axial adjustment/ backstop. For more information visit the Kennametal website or call 800-446-7738

50 hp milliing
Mazak’s INTEGREX e-1060V/8 II Multi-Tasking Center provides turning and milling capabilities and features a milling spindle that tilts up to 150° for both horizontal and vertical machining operations, angle boring, and milling multiple faces. The machine also offers full simultaneous 5-axis cutting for large complex parts.

The Mazak INTEGREX e-1060V/8 II Multi-Tasking Center

The e-1060V/8 II headstock features a 50 hp, 10,000 rpm milling spindle. It offers six different workholding pallets, including square or round pallet or chuck, which can be expanded to a Mazak Palletech system. With the 39.3" square pallet, the machine accommodates workpieces to a maximum 49.2" diameter and 49.2" height, weighing up to 5,950 lb. Axis travels are 73.8"×41.7"×52.9" on the X-, Y-, and Z-axes, with a rapid traverse rate of 1,653 ipm. The C-axis rotates at 0.0001° incrementally, while the B-axis travels 150°. It has an Intelligent Balance Analyzer, which aids in the machining of heavy parts by monitoring the distribution of fixture and part weight to determine if an unsafe, unbalanced condition exists. If so, it identifies the locations in need of adjustment to re-balance the load. It also will stop the table rotation if an unbalanced condition exists.

A real cut-up
ESAB Welding & Cutting Products introduces the PowerCut 900 manual cutting package. The 60-amp unit cuts ⅞" and severs 1¼". It offers a Tool-less Quick Disconnect Torch that disconnects from the machine without the use of wrenches or special tools.

The ESAB Welding & Cutting Products PowerCut 900

A digital readout display shows the exact pressure or amperage. The display also shows Help Codes to assist in troubleshooting minor errors. Blow Back Technology eliminates high frequency startups that can disrupt CNC controls and nearby computer systems. Additional features include a side-mounted automatic fan control; a built-in power line conditioner that protects against damage from power line noise and spikes, even with poor quality power; a torch wrap and spare parts kit holder; and a plug-and-play mechanized option that transform the manual cutting system into a mechanized system for a gantry machine. It comes with a three-year warranty and an option to purchase an extended warranty for a total of five years. For more information, visit the ESAB website, or call 1-800-ESAB-123

Engraved invitation

NCCS\' NCL Version 9.7 multi-axis machining software

NCCS introduces engraving tools for multi-axis machining within NCL. The multi-axis machining software, NCL Version 9.7, gives users the ability to define, manipulate, and engrave annotations. Lettering can be machined onto the part using a simplified profile routine to follow the strokes of the defined font, and letters can be engraved onto planar and contoured surfaces using single or multiple depths. Users can change the settings for annotations, create annotation entities, modify existing annotation entities, and engrave annotation entities. For more information, visit the NCCS website
–30–

Blog Search Engine

Shhh! It's a secret! Aw, get over it

2009-08-31T17:29:00.000-04:00

Milling Around is affiliated with
MachineShopWeb.com
Your Guide to Machine Shop Products, Shops and Services

It's Blogger-iffic!
Milling Around is now echoed on Google Blogger
at www.MillingAroundUSA.Blogger.com

Mention reality TV shows and a for a lot of people, shows like "Survivor" or "Big Brother" come to mind. Not to denigrate anyone's taste, but these are the bottom feeders of "real" TV. I, of course, view on a much higher plain. No, not PBS's "This Old House." That's just turned into welfare for the rich.

I've fallen for shows like "Renovation Realities" and "Under Construction." The first is what happens in real-life DIY: things always take longer and cost more. It's the anti-"Home Time." On PBS's "Home Time," the hosts usually add a second story to a house in 30 minutes without breaking a sweat. See, anyone can do this!

In "Renovation Realities," they show how a task, like drilling a fence post hole that should take 30 minutes takes a day and a half because the auger gets stuck in the ground.

In "Under Construction," the two hosts spend about half the show revealing the secrets of 20 years in the contracting business and the other half of the show exposing the trials and tribulations of running the business.

These shows got me thinking – yes, that's dangerous, and yes, that's smoke you're smelling. How come there aren't any shows like that about machining? I'm sure there are stories out there as fascinating as putting down a rubber roof membrane.

One reason could be shops are unwilling to reveal their trade secrets. Who want to show how they mill a titanium blank better than their competitors? Once they other guys learn how, they'll be tougher competition.

Maybe not. I believe we can work together to produce a story – and maybe some video – about a tough task done elegantly, without giving away the store.

So, I'm asking my tens of readers who want to brag about a job to write me at milling@redhottypewriter.com and tell me about it. If I like the story, I'll contact you and prepare your story for presentation here.
• • •

New Products

Nature abhors a vacuum, but shops will love this one
The Smart Vac Workholding System from Pierson Workholding has a universal base that accepts a variety of 8"×12" interchangeable top plates. The plates come with pre-cut gasket grooves for holding common part shapes, or blank plates so users can create their own gasket grooves contoured to fit unique part outlines.

The Smart Vac Workholding System from Pierson Workholding
The system has a built-in vacuum pump. The tankless pump does not require any air, vacuum filters, or an external vacuum pump. The pump converts 80 psi of air pressure at 0.8 cfm to 26" Hg of vacuum force which meets, or exceeds, most competing vacuum systems. The system is sold as a starter package which includes a universal base, a choice of one top plate – styles include a 1" grid pattern, single concentric-circle, double concentric-circle, multiple-concentric circle, or a blank pattern – an air regulator, table-mounted air valve, and tubing, fittings and clamps. For more information, call 800-352-2894.

Haas now speaks Fadal
The Haas CNC control now translates and runs most Fadal-specific CNC programs, without re-posting or manual editing. It converts Fadal-specific program formats and codes to standard Haas format and codes at the Haas control. The program can then be set up and run like any Haas program.

The process: Access the Fadal converter while loading the program into the Haas control, and follow the on-screen instructions. The converter translates the Fadal program into a Haas program, loading it into memory, ready to run. If anything in the Fadal program isn't understood, the Haas control highlights that section, letting the user correct ambiguities in the program before operation. The majority of Fadal programs translate into the Haas control edit-free, according to Haas.

Most Fadal programs will run on a Haas CNC machine software version 16.05A – or later.

For more information call 800-331-6746 or visit the Haas website

The eyes of NSK are upon you
NSK Precision America offers two types of photo sensor kits for use with its MCM and MCH Monocarrier linear actuators.

NSK Precision America offers two types of photo sensor kits for use with its MCM and MCH Monocarrier linear actuators

The sensor variety for the Monocarrier lines includes PNP output sensors, as well as NPN output sensors. Both types of sensors are RoHS compliant. The Monocarrier linear actuators integrate multiple products, including ball screws, linear guides, and support bearings. Products in the line offer an all-in-one structure, maintenance-free operation, a compact design, and can be used in assembly, inspection, transporting equipment, and other applications. Call 317-738-5089 for more information or e-mail Don Passero

Sweating the small stuff
The Rush Machinery Inc. Model FC-300 Grinding Oil Filtration System filters grinding oils to 1µ with edge filtration technology.

Rush Machinery's Model FC-300 Grinding Oil Filtration System
Designed to integrate with most grinding, lapping and honing machines, the system provides continuous filtration, automatic back-flush, and clean oil on demand. An optional cooling system can be incorporated. It has a filter element life expectancy of approximately 15,000 hours; can be customized to fit machines and shop floor layout; is compatible with mineral and synthetic oils; and is available for use with both carbide and HSS.

For more information, call 800-929-3070, or e-mail Ted Hildebrant

A tight fix
The limited-edition Allmatic Titan SC 125 Vise from DAPRA can be used for horizontal and sideways clamping, making it suitable for vertical CNC-controlled milling machines. The high-pressure vise features multi-function jaws. It allows for multiple clamping positions without the need to retool its jaws.

The Allmatic Titan SC 125 Vise from DAPRA

It is suitable for clamping unmachined parts – such as flame- and saw-cut materials – using screw-in gripper inserts, and for clamping parallel pre-machine work pieces by using its step jaws. Through October 15, DAPRA offers the limited-edition vise in a package that includes a torque wrench, side clamps, gripper inserts, and socket screw wrenches. For more information, and full technical specifications, visit DAPRA website, call 800-243-3344, or e-mail the company

Getting real
Geometric Limited released 3DPaintBrush ver. 2.0. The software is a visualization and rendering tool to create near photo-realistic images, animations, and videos from 3D models in real-time. It is used for repurposing of 3D models and creating digital content for architectural and interior design, industrial and product design, presentations and instruction manuals, marketing collateral, and other applications.

Geometric Limited's 3DPaintBrush ver. 2.0 visualization and rendering tool software

Features include ray tracing (beta) for exporting realistic images; lights movement for visualizing and positioning lights in the scene as well as modifying light properties like color and direction, modifications are reflected in real time; export to 3D PDF (beta) and executable file formats for helping users to export their scenes; support for Google SketchUp 7.0, while importing SketchUp files; export to GIF format; and camera views for storing camera views and orientation.

Interested parties can download a 15-day free evaluation version–30–

Blog Search Engine

This stuff is just plain weird

2009-08-28T10:13:00.004-04:00

Milling Around is affiliated with
MachineShopWeb.com
Your Guide to Machine Shop Products, Shops and Services

It's Blogger-iffic!
Milling Around is now echoed on Google Blogger
at www.MillingAroundUSA.Blogger.com

And now for something completely different

Every now and then, I run across something really odd that is peripherally-related to the machining biz. These two items fall into that catagory. Yeah, this is a bit beyond the usual coverage, but what's life if you can't take time out of a little fun.

• • •
I think I need two of these
Everyone needs a little laugh now and then. If you're not inclined to guffaw yourself, there's a handy device to relieve you of that burden. Nobumichi Tosa, president of Maywa Denki*, built a manually-operated WAHHA GO GO laughing machine. This is a clockwork mechanism to reproduce human-sounding (kinda, sorta) laughter. Here's a video of it doing its thing.

Sorry, but the narration is in Japanese. Doesn't matter though, the point of the video is to hear WAHHA GO GO laugh. It's not exactly Joker-quality cackling, but at least it takes a lot of effort.

Notice how the "teeth" seem to need some orthodontia.

I can just imagine a shop manager looking at these plans: "You want me to build a clock-work laughing machine that doesn't do anything but reproduce a creepy laugh? That'll be ¥32 million . . . in advance."

* Be warned, the website is a wonder of style over function: lots of needless animation. Be sure to check out the company history to see how it went from producing useful stuff to this . . . I don't know what the hell you'd call it, "art" maybe.

Now this is retro

Converting a typewriter into a computer keyboard

I've been searching for years for the perfect keyboard. I still haven't found it. In some cases, the backslash key – \ – is in an inconvenient spot. I hate the CAPS LOCK key, I'm forever HITTING IT WHEN I MEAN TO HIT THE TAB KEY. Oops. And, don't get me started on those goofy Windows keys along the bottom row.

The best keyboard I had was back in the Stone Age. It was by NCR and one of the first light-weight PC keyboards with rubber dome technology instead of the mechanical spring technology. It only cost $200.

I was at the computer store the other day and bought a comparable keyboard for $3.99. Of course, it only last two weeks, but I could get 50 of them for the price of that NCR. Then again, the NCR didn't have those annoying Windows keys. Does anyone really use those things?

To add to my eccentricity factor, I collect typewriters and related technology. I've got more than a dozen typewriters, ranging from small portables circa 1965 to 50-pound office monsters from the beginning of the XXth Century. I've also added some computers, such as an NEC PC-8201A notebook computer.

The NEC PC-8201A notebook computer

It was the fraternal twin of the Radio Shack TRS 80 Model 100. Programs and data were stored on cassette tape. You can imagine how conveninet that was.

I've also got an NEC Mobile Pro 790 in the collection.

The NEC Mobile Pro 790

Kind of a predecessor to the netbooks on the market today.

One thing I discovered while adding to my collection was the effort it takes to work those typewriter keys, especially the old office models. It's a wonder that secretaries back in the '50s and '60s didn't have forearms like Popeye. But, some people like that. There's a guy – Eric – who converted a portable manual typewriter into a computer keyboard. He tells his story here.

It's an interesting tale and looks like a lot more effort than he says it was. Just the amount of wiring and soldering looks daunting.
–30–

Blog Search Engine

2009-08-27T10:58:00.005-04:00

Milling Around is affiliated with
MachineShopWeb.com
Your Guide to Machine Shop Products, Shops and Services

It's Blogger-iffic!
Milling Around is now echoed on Google Blogger
at www.MillingAroundUSA.Blogger.com

"There's a light, over at the Frankenstein Place . . . ”

Some of you might recognize that line from The Rocky Horror Picture Show. Brad and Janet saw that there were lights at the home of Dr. Frank-N-Furter and were given hope that there would be some relief from their troubles. It was literally the light at the end of the tunnel. Little did they realize – as the cliché goes – that the light was just the beginning of their troubles.

Well, there's been a lot of jawboning from the feds, and other sources, that the leading economic indicators are showing there's a light at the end of the tunnel of our economic woes.

According to a ThomasNet report by David R. Butcher, "Orders for durable goods rebounded sharply in July, representing their biggest gain in two years. Demand for motor vehicles alone rose 0.9 percent, on the back of the government's CARS program.

Manufacturers' orders for durable goods rose 4.9 percent last month to a seasonally adjusted $168.4 billion, the United States Department of Commerce reports today. That was the third increase in the last four months and the largest since the 5.4 percent bump in July 2007."

Sounds like the downhill slide has slowed and may have hit bottom, so we may be back on the upside of the economic growth curve. Keep your fingers crossed that the light at the end of the tunnel isn't an oncoming train.

• • •
It's time for a case history.

The Clean Plate Club

Machining a large polycarbonate plate wasn’t the problem for this shop, it was how to hold it in place. Taping it down worked, but entailed after-work cleaning. Then the shop found the answer in a vacuum.

What do teenagers know? Sometimes quite a bit. Two teens – best friends Carlos Barrientos and Lino Covarrubias – had an interest in machining and decided to turn it into careers. They began their own business, and today, with 30 years of machining experience between them, own Motiv Design Group, Inc., in San Jose, CA.

“We knew how we wanted to run our business and we are proud that we are still running it the way we want,” Barrientos said.

As with many start-up shops, there is the desire to own every piece of equipment available. Realizing it is easy to get overly equipped and deep into debt, the two co-owners were careful to buy only the machines and tools that would keep them competitive and benefit their shop’s bottom line.

During their experience, they learned what would work for their business and what would not. They had experience with CNC mills, so they purchased a CNC lathe to make their business more competitive.

“We learned that the best way to go was to keep work in-house,” Covarrubias said.

Soon after they bought the lathe, they purchased a CNC horizontal milling machine to expand their shops capabilities and respond to customer demands. They realized that the worst reply they could make to a request for a quote was not to bid because they didn’t have the capability to do the work.

Besides the machine tools, the duo realized that an integral part of their capability was proper workholding. For their work, they chose the Mitee Bite VacMagic vacuum chuck.

Going to Tape
Before buying the vacuum chuck, they tried different hold-down methods, such as tape-down, thinking that a vacuum chuck would cost too much, considering the extra investment needed in a compressor or pump. They knew a vacuum chuck would be the ideal solution, but they considered the investment too daunting.

The VacMagic workholding system allows pieces to be held for machining without the use of clamps

One of Motiv Design’s continuing orders was for one of its major customers and involved tooling a 3/16"-thick, 18½"×27½" polycarbonate window. Quality was a major priority. Using the tape-down method to hold the piece for machining caused problems. It required applying alcohol to the tape – which would get on the part as well – using a scraping tool to remove the piece from the work table, then removing the protective paper which had tape stuck to it, and reapplying a new protective paper.

If the alcohol smudged the window, they needed to wipe it clean. Sometimes they would scratch the polycarbonate while trying to pry the piece from the work table, reducing it to scrap.

The use of tape wasn’t as inexpensive as they thought at first, since it involved purchasing the two-sided tape, alcohol, and protective paper.

Where Motiv Design once had to use double-sided tape – and the mess involved with its use – it now uses a vacuum workholding system to keep polycarbonate workpieces stable during machining

A visit to a machine tool distributor during an open house familiarized Barrientos and Covarrubias with VacMagic’s vacuum holding system and convinced them it was the way to go. With the next order of the polycarbonate windows, they purchased the system. Their biggest concern was the system’s ability to hold the 20"×30" subplate.

“I spoke to tech support at the company and they suggested a few ideas about how to make it work,” Barrientos said. “But, they told me our needs might be beyond the limits of the system.”

Customization
Working with technical support from Mitee Bite, Center Ossipee, NH, they made their own subplate out of ¾" thick aluminum, following the specs for hole locations and slot locations. They planned to use the rubber gasket that came with the VacMagic, but it didn’t fit the perimeter of the plate, but to their surprise, the vacuum held the material while cutting without the gasket. They used pins to position the material in place and then remove them once the vacuum seal is established. The VacMagic holds both the subplate and the material. The vacuum workholding system works without the gasket.

Compared to using double-sided tape and all that entails, using the vacuum workholding system is cost-free after the initial investment.

The system made the job easier, cleaner, and faster. One area where they gained efficiency was not having to take the time to let the alcohol soak the double-sided tape to make it easier to remove, then cleaning the subplate of tape and alcohol. It’s about 90 percent faster to remove a finished part and load a new piece of material.

With the tape-down method, the finished part was removed from the machine, and then placed where the tape wouldn’t stick to anything. It required a lot of table space to keep parts from touching and sticking when there wasn’t time to peel off the old protective paper and apply new protective paper.

Carlos Barrientos (right) and Lino Covarrubias were teens when they opened their shop, Motiv Design

Now that tape is no longer used, parts can be stacked on top of each other without worry. Also, there is much less part scrap since completed parts don’t have to be pried off the work table which resulted in occasional scratches, ruining the piece. Original protective paper stays on the piece from the start until the customer removes it, insuring there are no scratches, fingerprints, or smudges on their parts.

The VacMagic system resulted in about a 40 percent savings for the job. Not only has it made the work more profitable, it lets anyone, no matter what type of experience they have in machining to setup – and run the job. Clamping the VacMagic to the machine table and connecting the air supply is quick and simple.

“The VacMagic paid for itself within a couple orders,” Covarrubias said. “With it we can respond to an RFQ for a part that can’t be clamped in a vice. Though we’ve only used the VacMagic for the one job, we plan to build more fixtures to help speed up production of our aluminum jobs.”
–30–

Blog Search Engine

Readin', 'Ritin', 'n' 'Rithmatic

2009-08-25T19:15:00.020-04:00

It's Blogger-iffic! — Milling Around
is echoed on
www.RedHotTypewriter.com/wordpress
at Milling Around

Milling Around is affiliated with
MachineShopWeb.com
Your Guide to Machine Shop Products, Shops and Services

Try the Un-college

There was once an ad campaign for 7-Up that urged viewers to try the "un-cola." My play on the phrase has to do with the idea that everyone in high school has to go on to college in order to become a self-fulfilled member of society. Balderdash! if you'll excuse my strong language.

While a college education has some advantages – Where else can one study in-depth the obscure Scottish poets of the 14th Century? – there are a lot of people out there who don't need to spend another four years [or in my case five] taking classes that may, or may not, prepare them to make a living.

Ask the guy on the shop floor running the CNC lathe just how often he'd use the information he'd gained in his Women's Studies course to advance his career.

Not to say that there's anything wrong with getting a bachelor's degree, but on the other hand, there's nothing wrong with not getting a degree.

There's the old argument that a college degree will mean a higher life-time income, but there have been several studies that show that may not be the case. For instance, compare the guy who gets out of high school with machine shop training who goes to work immediately, with a guy who spends four years and incurs a mountain of debt to get a degree in History.

There are only so many spots for history teachers, and those usually go to people who have Masters or Ph.D.s. So, our shop guy has made pretty good money for those four years the history guy was in school. He's also gained four years of experience and seniority. And, he hasn't accumulated a mountain of school loan debt.

With any luck, the history major will find a job making $20k/year if he's lucky. Doing what? I dunno, probably something menial in an office cube farm. He'll be able to come home after a hard day at the office and be proud of pushing a stack of paper from the "In" box into the "Out" box. Where the shop guy can actually point to a piece of shiny metal that makes something real and say, "I made that."

Okay, I set up a straw-man example I knocked down pretty easily. Not everyone going to college gets a semi-useless degree. Some people, like my neice and nephew, are going into medical careers where they'll make more dough before they're 40 than I made during my whole career.

But, the point is that there is no shame working with your hands. In fact, machinists, carpenters, plumbers, electricians, and others I'd classify as artisans, should take pride in their professions. There's no need to have any feelings of inferiority for not getting a sheepskin.

New Products

Modular connection

The CKN modular connection for large boring tools from BIG Kaiser Precision Tooling Inc.

BIG Kaiser Precision Tooling Inc. introduces the CKN modular connection for large boring tools
BIG Kaiser Precision Tooling Inc. introduces the CKN modular connection for large boring tools using both steel and lightweight aluminum components. The system features a three-screw interface between steel double-connector couplings and aluminum extensions. When tightened, the slotted male connector expands to give additional rigidity. For large, heavy-duty roughing applications, various CKN components are available for optimized tool assemblies. However, the connection is almost 100 percent compatible with the existing Kaiser KAB system. Existing Kaiser modular components can be incorporated for lower torque operations such as finish boring. For more information contact BIG Kaiser at 888.866.5776, or by e-mail

Strong attraction

Magnetic disk couplings from Sterling Instrument

A series of magnetic disk couplings from Sterling Instrument features no friction or wearing parts, uses no electricity, and leaks no magnetic particles. The S50DCM, in inch sizes, and the S50DCMM, in metric sizes, are stocked in eight different bore sizes ranging from 0.1875" to 1". The couplings consist of two opposing disk halves with rare earth magnets. The torque applied to one disk is transferred through an air gap to the other disk. Because of its flat design, one can have angular misalignment or parallel misalignment and still transmit nearly full rotational torque. The 416 stainless steel couplings incorporate an NdFeB, nickel plated magnet. The hub sections are offered singularly, with or without a keyway, and are fastened to shafts with an included set screw. The coupling OD ranges from 1.72" to 2.86". Other features include repeatable torque control. Quotes, online orders, and 3D CAD models are available at the company's eStore. Details are available by calling 516.328.3300, or online.

For aluminum welding, it's Miller time

Miller Electric's XR-AlumaFeed and AlumaPower 350 MPa power supply

The XR-AlumaFeed and AlumaPower 350 MPa power supply from Miller Electric, combine for a synergic system for MIG and pulsed MIG aluminum welding applications. The AlumaFeed’s built-in pulsed MIG programs set the optimal parameters for the most commonly used aluminum alloys, such as 4000 and 5000 series, with wire diameters up to 1/16" for high-deposition applications. The AlumaFeed System is portable. The ergonomic design of the XR-Aluma-Pro torch allows access into the tight quarters. Coupled with the XR-AlumaFeed feeder and the AlumaPower 350 MPa synergic power supply it has a push-pull wire feed system. The AlumaPower power supply features Auto-Line Power Management Technology for any input voltage hook-up – 208 to 575 volts – with no manual linking required; a Fan-On-Demand cooling system that operates only when needed; dual digital meters; inverter arc control technology; line voltage compensation if input power varies by ±10 percent, and other features.

A MAG-nificent machine

MAG's HyperMach series of processing cells

MAG's HyperMach series of processing cells comes in three models. The three H-Series models encompass the H6000, H8000, and H12000. The H12000 allows horizontal part loading on a 12m×2m pallet for machining wing spars, ribs, fuselage frames and floor components, or nested part groups. It offers a choice of 30,000 rpm at 60kW or 100 kW HSK63A motorized spindles, or 20,000 rpm at 85kW a HSK100A motorized spindle. The spindles deliver metal removal rates of 8066.5cc/min on aluminum plate or forgings. All HyperMach H-Series machines feature a full-portal, open-center design. Cutting operations are enclosed with chip fall-through to a high-volume conveyor, avoiding chip recutting and the need for a chip blow-off attendant. There is scale/encoder feedback on all five axes. The 4m, 6m, and 8m machine models use a fixed-column, traveling-table/pallet design, while the 12m model use a traveling-column, stationary-pallet receiver. Water-cooled servomotors are used on all five axes of H-Series machines to eliminate thermal influence of the motors and maximize performance for high acceleration/deceleration and feedrates. For more information visit MAG

Psy-cological waterjet advantage

WARDJet's Psy-Winder 5-axis abrasive waterjet cutting head
WARDJet has released the Psy-Winder 5-axis abrasive waterjet cutting head. Improvements include a height and crash sensor option, fixed mechanical tool tip – no kinematic model, greater range of travel with a capacity of 12" to 24" vertical travel on the Z axis, and cutting angles from 0 vertical to 90° horizontal. Software allows programming of bevels on parts or for taper compensation. Post processors are available for both 2D and 3D CAM software. Up to nine 5-axis cutting heads can be installed on one cross beam with a single X-Classic controller, which can be retrofitted to all past WARDJet systems and to most other waterjet systems. Depending on the waterjet system, speeds can be up to 2,000 ipm.

For more information call 330.677.9100, ext. 6, or e-mail WARDJet sales

–30–

Blog Search Engine

Some animals are more equal than others — Animal Farm

2009-08-23T15:28:00.007-04:00

Liberté! Égalité! Fraternité! Pick any two

Liberty, equality, and brotherhood were the goals of the French Revolution of 1789 to 1799. Pretty noble sounding. Who could argue with those sentiments? Too bad that revolution ended up eating itself. Makes you stand in that much more awe of how we accomplished ours without the usual reign of terror that accompanies most revolutions [see French, Russian, etc.].

But, liberty, equality, and brotherhood, like that other tripartite slogan – Time, Quality, Money – are somewhat mutually exclusive. It's possible to have any two, but impossible to have all three.

Of course, it doesn't sound like that on first blush, but liberty means having the freedom to take one's fate into one's own hands and either succeed or fail. Equality – beyond one's standing before the law – means that everyone is kept even, usually by legal mandate. No one can be better than anyone. We're all reduced to the lowest common denominator.

Kurt Vonnegut wrote a good example of the extremes to which equality can be imposed in his short story Harrison Bergeron. Harrison is shot to death at the end of the story by United States Handicapper General Diana Moon Glampers for the crime of showing his superiority, his inequality.

Where's this going? It's headed to that third rail, the whole health-care issue before congress.

One of the fears is that we will lose our freedom to determine our own health-care needs. We're now at liberty to spend as much as we care to, or can afford, on maintaining our health. Sometimes that can be overwhelming in the case of a catastrophic illness. I have an acquaintance who went to heroic measures to find a cure for a spouse's lung cancer, even to the point of taking part in investigational drugs and procedures. The spouse died more than 10 years ago and this person is still working two jobs to pay the expenses.

But, they were both at liberty to seek the health-care they wanted.

Under federally-mandated rules, where people are treated "equally," there is the fear that the government will not only deny such experimental treatment, but also make it illegal for people to pay for it themselves.

A lot has been said about how the health-care system in this country is broken, with citations about the number of uninsured in the U.S. But, since when is health-insurance a right? How about all of the people without life insurance? Does everyone deserve equal coverage for their deaths?

Right now, I'm worth about $20,000 dead. Not much considering the expense of taking care of my remains and filling the income loss to my wife. But, that's what I can afford. I'm sure the president of Government Motors is insured for a lot more. I'm also sure that the guy we pay to mow our lawn may not have any life insurance at all. Should all three of us be treated equally in terms of life insurance? Should there be government spending to be sure that my lawn guy's heirs get an "equal" amount of death benefit?

Sure, there are problems with health coverage in the U.S., but there are better solutions than the government taking charge of it.

For those who are demanding government health-care, let them remember the last time they stood in line at the post office.

A bit o' news

Siemens PLM Software give big to Arizona State University
Arizona State University will enrich its engineering education and provide students more advanced preparation to enter the workforce through an in-kind software grant from Siemens PLM Software to the university's Ira A. Fulton Schools of Engineering. Siemens PLM Software, a business unit of the Siemens Industry Automation Division, is a provider of product lifecycle management – PLM – software and services. The grant has a commercial value of nearly $245 million, and is the largest in-kind grant in the university’s history. The grant was made through the Siemens PLM Software Global Opportunities in Product Lifecycle Management program – called GO PLM – and includes engineering software, student/instructor training and specialized software certification programs.

“Advanced tools, such as the PLM software, are essential to preparing our engineers for the challenges they will face in a complex and global economy. They will be able to meet demand for designing and analyzing systems that transcend traditional boundaries,” Deirdre Meldrum, dean of the engineering school, said.

"It will definitely open more doors," Adam Dixon, ASU grad student, said. "Training on the technology will make ASU engineering grads more marketable."

"Our mechanical and aerospace engineering graduates go to work for major engineering companies that use these kinds of high-end computer –aided design and finite element analysis software packages,” Jami Shah, and engineering professor and director of the school's Design Automation Lab, said. “It’s important to instruct students with tools they're use in business."

New Products

Until it's measured, it just opinion (Have I written that before?)

EasyForm 3.0 dimensional metrology system from Mahr Federal Inc.

EasyForm 3.0 dimensional metrology system from Mahr Federal Inc. provides a touchscreen interface that guides operators through measurement setup and operation. A teach-in mode remembers every step taken and can easily combine steps to perform repetitive multi-feature measurements. Measurement results are displayed on the screen, including 3D representation, with color or grid lines, providing an interactive graphic preview. Results can be printed, saved in file formats such as PDF, or exported for analysis in ASCII or optionally in QS-Stat formats. The software can exclude certain trace data after measuring or analyzing part features. This allows inadvertent data from dirt, or from recurring features such as splines or grooves, to be removed from consideration without remeasurement. Also included are options for output formatting to enhance the usability of the results for different users. To support applications on CNC systems as well as basic manual systems, abilities to separate positioning movement of the probe or measuring device from evaluation has been added. For manufacturers of high-precision parts interested in harmonic analysis, EasyForm offers a variety of analysis methods including basic Fourier analyses, input of multiple bands, and generation of tolerance curves for the histogram. For additional information, e-mail Mahr Federal Inc. or call 800.333.4243.

Home, home on mid-range

LVD Strippit introduces a line of PPEC mid-range press brakes

LVD Strippit introduces a line of PPEC mid-range press brakes for less challenging forming applications. The line includes the PPEC-6 and PPEC-7 models with capacities from 80 tons and 2m, up to 220 tons and 4.2m, with four to seven CNC controlled axes, depending upon machine model. The press brakes have a welded one-piece frame machined without repositioning. Hydraulic cylinders are machined from a solid steel billet. Pistons are steel forgings, precision ground, and micropolished. Microprocessor technology is linked to servo-controlled hydraulics and electronics for optimum control of the bending. Double bed referenced encoders are connected to the bed in such a way that deformation of the side frames during bending does not influence the positioning accuracy of 0.01 mm of the upper beam – Y1-Y2. A two-axis backgauge allows X-axis depth and R-axis height positioning of the two standard backgauge fingers. The standard PPEC backgauge fingers allow gauging to 39.4" and serve as material supports. PPEC-4 and PPEC-5 models can be fitted with an additional third finger support for bending channels. For more information, call 800.828.1527, or visit the LVD Strippit website.

A real cut-up

The Pro Pegasus DS Mitre Semi-Automatic Saws, from Pat Mooney Inc. – The Saw Company

The Pro Pegasus DS Mitre Semi-Automatic Saws, from Pat Mooney Inc. – The Saw Company, feature 1¼"-wide saw blades. The gear-drive saws have an electronic display of the cutting angle. the saws perform semi-automatic operations, including positive hydraulic cutting control, hydraulic clamping, and auto return of the saw head after the cutting cycle. Its swivel saw head mitre cuts up to 60º both left and right. The saw head rotates via a rack and pinion system. The saws have a locking cabinet, carbide blade guides with roller guides, and case-hardened and ground helical gears. Variable blade speeds from 50 to 400 fpm are controlled via the saw’s inverter. Cutting capacities are 12½"×20". For more information, e-mail Pat Mooney Inc. – The Saw Company or call 800.323.7503.

Micro manipulator with macro features

The MP63 3-axis micro manipulator module from Steinmeyer, Inc.

The MP63 3 axis micro manipulator module from Steinmeyer, Inc., is a fully-enclosed 3-axis positioner with 25mm stroke in each direction. Included are DC gear motors, rotary encoders, lead screws, and non-contact limit switches. Accuracy in each direction is 5µ with ±1 micron repeatability. Standard straightness and flatness is ±3µ, with 1µ available as an option. The assembly weighs about 2 kg. All cable connectors are located on one end. For more information call 781.273.6220.

Take this rotary table for a spin

The 5AX-201 rotary table from Lyndex-Nikken

The 5AX-201 rotary table from Lyndex-Nikken features a 8" faceplate trunion work envelope that can be incorporated in smaller BT30 vertical machining centers such as the Fanuc Robodrill, Brother Drill and Tap, and Kitamura Mycenter. It provides a workholding space once associated with larger 40-taper machines, but with a body design for use in conjunction with BT30 machines. The carbide worm system uses a carbide worm screw and ion nitrided worm wheel rather than a conventional bronze or bronze-alloy actuation mechanism. The result is a reduction in friction and wear by up to eight times, according to the manufacturer. The worm screw consists of a less brittle V-grade form of carbide, while the worm gear is ion nitrided to a depth of 0.1mm and an external surface hardness of 68R_C. These properties, as well as a steel way hardened to 58-60 R_C, add to system rigidity and longevity. To machine five sides of a workpiece, the 5AX-201 features a drop trunion and rotary/tilting axis clamping torque of 434 and 452 ft/lb. For more information, visit the Lyndex-Nikken, Inc., website, call 800.543.6237, or e-mail Lyndex-Nikken
–30–

Blog Search Engine

Milling Around

2009-08-21T19:33:00.006-04:00

Back in the olden days when MAN was being printed as a monthly magazine I was faced with the problem [today the politically-correct word is "challenge"] of getting contributed case histories into print on an exclusive basis. Well, semi-exclusive. My criteria was that a case history would either appear in MAN first among our direct competitors [American Machinist, Cutting Tool Engineering, Manufacturing Engineering,or Modern Machine Shop] or not have appeared in any of those other magazines for at least six months.

That put something of a crimp in our selection, since many of the agencies and representatives would send their submissions out simultaneously to several magazines. There were more than a few times when I had to turn down a good story because a competitor had it in their pipeline or recently printed it.

While a blog doesn't have the prestige of a printed magazine, or even an e-mag, it does have the advantage of immediacy. The following case history came in at 4:38 p.m. on Aug. 19, and I'm able to present it a day later. Pretty quick turn-around.

Seven Kilowatts of Advantage

Incremental improvement is no longer enough in these times of increased competition and decreased financial security. Securing a long-term competitive advantage takes vision. That's a quality that Debro Steel, a division of Premetalco, Inc. of Brampton, Ontario, Canada, showed when it became one of the first steel service centers in North America to deploy a TLX-1480 three-axis laser system 7 kW laser.

The machine, from NTC America – Laser Group, Novi, MI, let Debro cut thicker parts than it had in the past. The laser cutter provides the foundation for improvements in the company's competitiveness.

"This was a calculated decision on the technology," Gunar Zenaitis, Debro president said.

The NTC TLX-1480, with 7 kW laser and a 14\'×80\' cutting table from NTC America – Laser Group, provides for processing of large parts for Debro Steel and adds flexibility for faster processing of smaller parts"]

The company once relied on a four-head underwater plasma cutting system. Many of Debro's competitors, though, had advanced to newer high-definition plasma systems.

"Our market is served with hi-def plasma machines," Zenaitis said, referring to the industrialized belt of southern Ontario from which Debro draws most of its customers.

"When we looked at upgrading our cutting technology we asked ourselves ‘Do we want to be one of the pack, or do we want to offer high-precision cutting with a laser?' "

Debro went the high-tech route with the TLX. It is designed to optimize the cutting of longer and thicker materials. The high-precision 3-axis laser is fast, powerful, and more compact than traditional bridge-type laser systems with comparable work envelopes.

The NTC TLX series places the laser and chiller on the system's gantry, offering a smaller footprint and shorter beam path, which translates into space and labor savings, increased flexibility, and greater cutting quality. The cantilever design and redesigned controller both allow easier loading and unloading of parts.

When Zenaitis joined Debro in 2006, his mandate was to revitalize the company. A laser purchase was being considered when he came onboard, however, it was a 6 kW laser system with a conventional cutting table. Zenaitis and his team opted instead for the 7 kW laser with a 14'×80' cutting table, along with modifications to the building in order to house the new table.

Debro Steel processes a variety of parts and applications with its NTC TLX-1480 laser-processing machine, such as elevator parts

"The large table was part of our vision for the system," Zenaitis said. "It opens the door for processing large parts and, because of our ability to stage jobs, faster processing of small parts. This, along with reduced part costs, adds value for customers and enhances their competitiveness."

Looked before they leapt
Training and support for a leap into the unknown can be daunting, but not in this case. Debro negotiated a complete turnkey installation, including training, with NTC distributor Paramount Machinery of Mississauga, Ontario.

"NTC, Paramount, and our staff worked together to get this done so we could accept our first commercial orders," Zenaitis said. "Setting up the cutting library and conditions was done before we performed the actual work; there have been no support issues."

He said the investment also sent an affirmative message to Debro's employees.

"By showing we were prepared to reinvest during tough times it said we were in this for the long haul. Our people embraced both the challenges and the opportunities presented by the laser."

The new production system let Debro provide additional services and court new customers.

"For instance, in the crane industry, where other methods would construct a long boom from several parts using multiple weldments, we provide a laser-cut 30' part, saving time and money," Zenaitis said. "Similarly, the large table facilitates the production of long-run small parts, increasing our productivity and reducing the cost per part."

The addition of a conveyor system, which Debro installed to help automate the laser's production of smaller parts, reduces costs, and the savings is passed to customers.

Faster than plasma, more powerful than oxy-fuel, able to leap tall orders in a single bound
David Vachon, Debro's general sales manager said he believes the laser cutting system produces parts better than plasma or oxy-fuel cutting.

"The laser-produced parts require less work after being cut," he said. "We can produce a finished part rather than a semi-finished part."

"Creating added-value through the elimination of redundant machining, welding, handling, and transportation results in a lower total cost for our customers," Zenaitis said. "Improving our customers' competitive position is the secret to our long-term success: better margins and better profitability for all of our supply partners.

"Our customers challenge us to create their complex parts in a cost-effective manner. Since the installation of the laser system we see new orders and find new customers interested in the long, laser-cut parts that we can produce."

Debro is considering the addition of forming capability to its mix and more automating parts handling, increasing the laser's beam-on time, boosting productivity, and reducing cost-per-part.
–30–

Blog Search Engine