Articles & Columns

END USER: Antron Engineering and Machine Co. Inc., (877) 225-2362, www.antroneng.com. SOLUTION PROVIDER: Eltool Corp., (877) 435-8665, www.eltool.com. CHALLENGE: Mill a long, interrupted slot in a small-diameter bore. SOLUTION: A coolant-driven angle head.

If you’re shopping for a Swiss-style CNC lathe, the available options and machine configurations are truly staggering. Spindle speeds that compete with many machining centers, convertible spindles that turn a sliding-headstock machine into a chucker, thread whirling capabilities, laser cutting heads and enough axis letters to become the next Words With Friends champion.

There are numerous advantages to rigidly holding a workpiece: feed rates can be increased and cutting times reduced, cutters last longer and impart finer surface finishes, and more-accurate parts are produced. At trade shows where vendors offer demonstrations, you rarely see flimsy, difficult-to-hold parts being machined. In the real world, however, such parts are common. Holding parts for secondary operations, such as drilling holes on an edge, can also be challenging.

I’m thankful to share that our machining business has picked up and we’re running near capacity. I can’t get overly optimistic just yet, but good news nonetheless. We haven’t required new equipment, new employees or a second shift, but that could change if business continues at this pace or improves. While this uptick has been a nice morale booster, our energy-focused market remains unpredictable. Even so, we’re getting a bit more confident with our forecasts and planning.

When it comes to highly accurate machining technology, jig boring is better. So say proponents of the century-old machining technique. In the early part of the last century, jig boring started as a better way to make holes. But the technology has since evolved into a more-versatile machining option.

To bring all kinds of useful information right to a machine and facilitate a company’s implementation of Industry 4.0 processing tools, INDEX Corp. has begun supplying its machine tools with a new operating system. Called Xpanel, the OS integrates a machine into a corporate network, allowing machine operators to receive information from other parts of an enterprise. Operators can access drawings, setup sheets, user manuals, quality requirements, and circuit and hydraulic diagrams on a machine’s control panel.

Vertical machining centers are machine shop mainstays, owing in no small part to their versatility, small footprint and relatively low cost. However, in high-volume environments, they tend to lag behind their horizontal counterparts. Fortunately, a pallet system provides a fairly simple fix.

Setup reduction is a common goal of every machine shop. Setup does not add value because it does not provide any measureable productivity. In short, when you are not running a machine, you are not making chips, and, therefore, you are not making money. Setup involves numerous non-value-added activities, including tool measurement, fixture alignment and setting coordinate systems, or offsets. As the term suggests, value-adding activities make a workpiece more valuable by changing its shape or physical properties. Many years in and out of machine shops and manufacturing plants have given me ample opportunities to see and establish some unique and familiar methods for reducing setup times and generating savings. 

END USER: Homeyer Precision Manufacturing, (636) 433-2244, www.homeyertool.com. SOLUTION PROVIDER: BIG Kaiser Precision Tooling Inc., (888) 866-5776, www.bigkaiser.com. CHALLENGE: Minimize endmill runout to extend tool life when producing aluminum-based forceps. SOLUTION: A collet chuck that provides minimal runout.

END USER: Greene Tool Systems Inc., (800) BUY-TOOL, www.greenetool.com. SOLUTION PROVIDER: ANCA Inc., (248) 926-4466, www.anca.com. CHALLENGE: Produce microscale cutting tools more accurately while lowering setup times. SOLUTION: Two grinding machines designed to produce tools smaller than 2mm in diameter that feature robotic arms for loading and unloading tools and wheel packs.

Machine tool idling, unnecessary pump rotation and continuously running peripheral equipment drive up machining costs. These energy wasters are in the crosshairs of a new suite of power-cutting control applications from Japanese machine tool builder Okuma Corp.

Dear Doc: I sell grinding wheels and frequently find myself pulling my hair out when recommending wheels to customers. One customer achieved great success with a resin-bond, 400-mesh diamond wheel when grinding ¾"-dia. carbide endmills. It performed like a “superwheel.” I then took that same wheel to a customer who also grinds ¾” carbide endmills on the same machine model with the same coolant and it’s a disaster. Why?

Troubleshooting machining operations can be a daunting task, especially boring operations. This is because when machining the outside of a part, you can see what causes the tool to fail. However, when a tool is buried in a hole, as is the case when boring, you can’t see what is happening to the tool.

Though Rosie the Riveter and a multitude of her sisters proved that women were perfectly capable of working in manufacturing when the men were called to serve during World War II, many of these patriotic women graciously stepped aside to allow the returning soldiers to resume their jobs. Since then, the number of women in manufacturing jobs has yet to recover. According to a 2015 report by consultancy Deloitte LLP, in conjunction with The Manufacturing Institute and the APICS Supply Chain Council, women hold only 27 percent of U.S. manufacturing jobs, even though they make up 47 percent of the total labor force. “Women are underrepresented in every manufacturing sector in the U.S.,” the report stated.

Teach your robot well: A new control system can reduce the time to set up and program industrial robots from an hour or more to just minutes, according to the Finnish research organization that developed it.

Networking option: Could the introduction of a small electrical cabinet turn out to be a big step toward more widespread implementation of the Industrial Internet of Things? This special electrical cabinet, called the SmartBox, was developed by machine tool builder Mazak Corp., working in collaboration with networking equipment provider Cisco Systems Inc. The SmartBox is designed to overcome concerns about complexity and security that have led to resistance to connecting machine tools to a plantwide network.

Presented this month are more programming tips to help prevent machine tool crashes.

When CNC wire EDMs came on the market in the mid-’70s, feeding wire from a spool through a machine’s elaborate series of rollers and guides was a tedious manual exercise. Luckily, electrical discharge machining was an exceedingly slow process back then, so replacing wire had to be done less frequently than on today’s machines, which erode conductive metal 10 to 20 times faster than earlier models.

The chip collection bin at a shop’s turning center is full, so a worker grudgingly begins the mundane task of moving the bin via a forklift to the chip collection station at the opposite end of the plant. Unfortunately, the bin leaks and coolant drips on the shop floor, causing the shop’s biggest customer to slip and fall while visiting to check on his latest order. There’s got to be a better way.

Careful consideration when implementing inspection processes yields efficiencies. Manufacturers continually search for ways to increase profits and reduce costs. Trying to find cost savings where chips are made makes sense and is usually where the most-significant improvements are found. However, efficiency gains can also be made in nonvalue-adding areas, like inspection.