Industry News for 01/2019

Manufacturing innovation institute installs 5-axis machining center
Lightweight Innovations For Tomorrow, a national manufacturing innovation institute, announces its Heller FP 6000 5-axis machining center has been installed, and is ready for use, at its research and manufacturing facility in the Corktown neighborhood of Detroit. With the installation of this machine, Heller is assisting LIFT and its members to further develop next generation processes in lightweight metal manufacturing.
Run machines to their full potentials with new facemilling technology
Almost every machine shop uses facemills for roughing, semifinishing and finishing, but many of these shops miss out on increased material-removal rates because they run yesterday’s tooling on today’s machine tools. The larger spindle tapers and higher horsepower ratings, feeds and speeds of modern machines need to run with the latest in facemilling cutter and insert technology to maximize a machine’s facemilling potential and thus significantly speed up production, increase efficiency and reduce cost per part, especially on larger workpieces.
Increasing production capacity, the right way
Expand existing capacity or turn down orders? Many companies are caught in this dilemma. Every time a company turns down an order, it risks losing that customer and potential orders. If the company has no alternative but to accept new orders, at some point the existing machines will reach their limits. What then?
Third trade fair for deburring technologies and precision surface finishing
Whether they’re required for downstream manufacturing steps or for error-free functioning, surface characteristics are decisive with regard to part and product quality. Processes such as deburring and precision surface finishing are becoming more and more significant as a result – regardless of whether the parts are produced by means of erosion, forming, primary forming or additive manufacturing. DeburringEXPO, the world’s only trade fair that deals exclusively with the removal of burrs and the production of precision surface finishes, will be held at the Karlsruhe Exhibition Centre from Oct. 8-10, 2019.
CNC machining is one of the most common methods used to manufacture parts and products. The use of computer numerical controls allows parts to be manufactured using a highly automated process, which has the upper hand on many conventional manufacturing methods in terms of speed, production rate and accuracy. However, determining the right material for the process can be a daunting task.
It is time to put smarter manufacturing into production. An increase in the data and sensors available to the manufacturing industry has made it much easier to gather data on manufacturing efficiency through the internet of things. However, IoT systems tend to look at sensors at an individual level, which limits the ability to forecast anomalies across a manufacturing operation, as each sensor can measure only a specific part of the operation. To address this issue, a team of researchers has created a framework for system-level anomaly prediction in manufacturing.
The next generation of surface profilometer for in-process inspection
As the aerospace industry in Canada and around the world continues to increase its use of automated composite manufacturing techniques to produce large aircraft components, the industry is eager to find solutions to manufacture reliable, safe, and cost effective composite structures. The National Research Council of Canada (NRC) and Fives are working together to improve the efficiency of manufacturing composite parts. They are developing an advanced profilometer that will provide faster and more accurate part inspection.
Thermal expansion poses significant constraints on the accuracy achievable in positioning
It becomes increasingly important as the table travel is increased. Ambient temperature changes are one obvious source of thermal expansion. As the positioning table warms, its constituent parts undergo expansion, at a specific rate for any material. Accordingly, to permit any two users to agree on what constitutes an “accurate” positioning system, all critical dimensional measurements world-wide are understood to take place at 20 degrees C (68 degrees F).
Cloe Poisson/Hartford Courant
Connecticut’s manufacturing future continues to evolve. The dirty, dark and dangerous shop floors of yesterday have increasingly become bright spaces with smart technology. Advanced manufacturing, robotics and the internet of things are more than buzzwords—they’re happening. But with all the advancements on the manufacturing floor comes a corresponding need to improve the approach to developing the workforce necessary to ensure success.
The big technology platforms get all the attention these days. But the biggest tech news of 2019 may turn out to be the rise of manufacturing platforms: companies that rewrite the rules of production and product development and in the process create opportunities for local manufacturing.
Avoiding patterns caused by traversing rotary dressing - straight-line chatter
Generally, when using abrasive wheels to grind parts, a dressing tool is required to maintain form and finish within specifications. Several options exist when choosing the type of dressing tool for an operation. These include single-point diamond tools, diamonds blade tools, form or plunge roll diamond wheels and “rotary single-point,” or “traversing rotary,” dressing.
A trend in manufacturing is toward tailor-made products in smaller lots with shorter delivery times. This change may lead to frequent production modifications resulting in increased machine downtime, higher production costs, product waste and the need to rework faulty products. To satisfy the customer demand behind this trend, manufacturers must move quickly to new production models. Quality assurance is the key area that information technology must support.
The National Institute of Standards and Technology's Manufacturing Extension Partnership has a unique position in the federal government that allows the MEP to collect and analyze feedback directly from clients served by the MEP's national network. This provides the MEP program with a wealth of information that guides the MEP's approaches to serving the U.S. manufacturing industry both now and in the future. At the start of a new year, it is important to take a step back and look at what clients are saying. Being responsive to the needs of manufacturers and helping mitigate their challenges are two of the program's goals. Integrating client feedback to help clients prepare for future challenges is important.
Chip Bobbert eyes a sheet of shiny aluminum that is several feet long and crimped on one end. He guesses that this was once the backsplash of a restaurant kitchen. Nearby, he spots another piece of metal with a square opening at the center. When he mentions that it likely once framed the entry to a roof or ventilation shaft, the shape of the piece makes sense. He then picks up a softball-size chunk of dense stainless steel. With an intricate series of holes shooting through the thickest part, it looks like a central piece of a complex engine. “Some of this stuff is crazy,” Bobbert said, pointing out the holes. “If you look at the precision machining, somebody paid thousands of dollars for that.”
As manufacturers invest in industrial internet of things-enabled devices to collect more data throughout production processes, many are also deploying edge computing to improve the analysis of data. Edge computing uses dedicated, on-premises resources at the shop-floor level rather than the remote servers that cloud computing relies on. This significantly increases the rate and amount of data that manufacturers can process in real time.
Whether building spacecraft, commercial aircraft, military helicopters or single-engine planes, manufacturers in the aerospace industry must lift, turn and position large, heavy components every day. There are many ways to do this, from ride-on vehicles like forklifts to conveyor belts and overhead equipment. However, aerospace manufacturers are increasingly turning to cranes and other hoist systems to precisely place critical equipment in ongoing construction projects.
There will be 4.6 million new manufacturing jobs in the United States to fill between 2018 and 2028, according to a report from Deloitte. Unless manufacturers start exploring new strategies, they won’t be able to find enough people qualified to work in their specialized factories.
Prototype to production: a case study
At ShopBot, we’re understandably passionate about making things with CNC machines and about the power of digital fabrication tools. We’re always looking for ways to help show what these amazing tools can do, and for items that are made with a ShopBot that showcase several of the processes that a ShopBot tool can handle. Things that use multiple materials and techniques to give a broad overview of the power of CNC in a small, tangible package.
Toolmaker broaches the machine operator skills gap with technology
AB Tools are leading experts in the special cutting tools market as a specialty house in high performance rotary cutting tools. Started in 1977 by Alan Baker and Jonathon Baker joined in 1979 as the first employee. Today, they service almost every industry, from smaller shops to large facilities, including aerospace, automotive medical part manufacturers.
'Poly-poly-or what?' Part five: Diamonds show profile
It is October 1978. On Oct. 13, my discovery at the former Matra company in Frankfurt that PCD can be eroded by means of electric sparks was registered at the patents office. In October 2018, we looked back at 40 years of experience in the application of spark erosion for manufacturing and versatile application with polycrystalline blades of PCD- and PCBN-tipped tools.