Articles & Columns

END USER: Mitchel & Scott Machine Co., (317) 684-8247, www.mitchelgroup.com. CHALLENGE: Provide 100 percent inspection of internal thread pitch and depth and numerous external dimensions for two high-volume automotive parts. SOLUTION: Automated vision inspection and thread verification systems. SOLUTION PROVIDER: Compass Automation, (847) 426-6696, www.compass-automation.com

Manufacturing molds used to produce plastic parts with features that can be too small to be seen with the naked eye or measured with standard devices is challenging. That's why moldmakers that perform this work are specialists in the nuances of designing and building micromolds.

END USER: Royce/Ayr Cutting Tools Inc., (800) 959-5641, www.royceayr.com. CHALLENGE: Increase PCD cutting tool manufacturing capacity, flexibility and capabilities. SOLUTION: A machine tool that combines rotary erosion and grinding. SOLUTION PROVIDER: Vollmer of America Corp., (412) 278-0655, www.vollmer-us.com

Say your machine shop just received an order for 316 stainless fuel-injector nozzles requiring angled holes to be drilled on the workpiece face. Or perhaps your best medical customer needs miniature blood-pump impellers with complex 3-D blade geometries like those on a jet-engine turbine. How are you going to make them?

Aluminum parts that are anodized using electrical energy or chromate conversion coated can offer wear and corrosion resistance, among other benefits.

Shop Operations columnist Tom Lipton offers tips for enhancing the operation of a manual lathe in the April 2012 issue of Cutting Tool Engineering magazine.

United Grinding Technologies Inc. celebrated 30 years in its Fredericksburg, Va., location with an open house on Feb. 22 and 23. The event included technical presentations, facility tours and a ribbon-cutting event for the newly expanded and renovated facility.

Dynomax Inc. is taking self sufficiency to a new level. For example, while machine tool builders often use their machines to produce parts for making other machines, Dynomax stands out by building machines for its own contract part manufacturing operation.

As demand for vehicle transmissions and other systems requiring quieter, more compact and lighter gear mechanisms increases, gear manufacturers seek to continually boost productivity while lowering costs.

States near the Marcellus Shale, a huge natural gas formation centered in Pennsylvania, are feverishly pursuing a $4 billion ethane “cracker” to be built by Royal Dutch Shell. The cracker will process ethane-rich gas from the Marcellus Shale into ethylene, and the ethylene will be used by the pharmaceutical, chemical and plastics industries. The plant will create 10,000 construction jobs and several hundred permanent jobs.

END USER: Machine Tech CNC, (780) 461-0890. CHALLENGE: Accurately bore 14 diameters deep and deeper. SOLUTION: Carbide-reinforced boring bars with built-in vibration damping. SOLUTION PROVER: Sandvik Coromant Co., (800) SANDVIK, www.sandvik.coromant.com/us

Machine Technology column: A machine tool bed serves several important functions. It supports the machine's moving elements and supports them in geometric relation to each other. The relationship between the moving elements is more important than the relationship between the moving elements and the ground the machine is based on.

Many large corporations are well versed in total productive maintenance, but smaller companies are probably not. To learn more about the concept, I attended a 1-day seminar about TPM at a local technical college.

Significant progress in metalworking productivity most often results from the combined efforts of toolmakers, machine tool builders and software developers. Plunge, or Z-axis, milling is a good example.

Shop Operations: The manual lathe is the cornerstone of any machine shop because almost all shop workers find themselves working on one when they start. The manual lathe has been called the "king of machines," for good reason. Some can be enormous; you can bet that if you need a forklift and a ladder to put a tool bit in the machine, some fun is bound to happen.

As the U.S. strives to become less dependent on foreign energy sources, energy producers are increasingly employing hydraulic fracturing, or “fracking,” to drill shale deposits and extract natural gas and some oil. That booming market requires a range of parts from shops around the country.

Where there are drilled holes, there are burrs. The only question is how large the burrs will be, according to Dave Lopes, vice president of sales and marketing for Cogsdill Tool Products Inc., Camden, S.C.

Bar feeders, once known as slow and inefficient ‘rattle tubes,' are now high-speed, automated units.

END USER: Helac Corp., (800) 327-2589, www.helac.com. CHALLENGE: Reduce maintenance and programming time on a large vertical turning center. SOLUTION: Retrofit the VTC with a new CNC and AC digital-axis servodrives and servomotors. SOLUTION PROVIDER: MAG IAS LLC, (859) 534-4600, www.mag-ias.com

Robust and stiff often come to mind when considering the characteristics that make for a productive milling machine. However, Juanjo Zulaika, a researcher at the applied-research center Tecnalia Research & Innovation, thought otherwise and developed a “softer” milling machine with reduced weight and stiffness. That's achieved while increasing productivity.