A video created by Acoustech Systems includes footage of holes being drilled with and without ultrasonic-assisted machining. This company’s newly developed system is essentially a toolholder that has ultrasonic actuation built in. Adding this toolholder to the process can actually increase a shop’s machining capacity, because standard machines and tools can cut faster thanks to the friction reduction that the ultrasonic effect achieves. Comparison cuts in the video seen here show a standard drill doubling its speed and cutting more smoothly in both 1-inch-thick steel and 1-inch-thick titanium. Learn more about ultrasonic-assisted machining in this article.
Photos of sample inserts such as this one illustrate wear patterns that help diagnose cutting tool misalignments in turning.
Tooling expert Mike Fagan suspects that many programmers and machinists could use a refresher on the importance and effects of insert alignment in turning operations. This short, amply-illustrated paper is his effort to clear up some of the misunderstanding.
It covers signs of misalignment and suggests ways to fix problems, with additional tips and advice to improve turning operations. To find the paper, click here.
An event yesterday at Sandvik Coromant's U.S. headquarters in Fair Lawn, New Jersey, celebrated the opening of a new Productivity Center (photo above), part of a now-completed 2-year renovation of this site.
The layout, architecture and offerings of the site now match other, more modern Sandvik locations both in North America and around the world. The company's original Fair Lawn site was built in 1955 and significantly expanded in 1966. Since then, priorities have shifted.
One of the priorities today is collaboration. An open design encourages movement through the facility and interaction among both employees and guests at the site. Within the Productivity Center (Sandvik's term for its training and process-development facilities), spacious machining areas equipped with sophisticated CNC machines provide capacity for company personnel to be working with various customers on various different projects at any given time. A machining area that is not so open (the ITAR-certified shop can be closed off, and frosted glass blocks the view) provides machining capacity for customer projects that are sensitive or secret.
Another priority, as company president Klas Forsström stressed in his remarks at the event, is outreach. This latest investment in the company's U.S. presence is coupled with an awareness that it needs to support manufacturing here by attracting talented people into this field. As it also does at its Chicago-area Productivity Center, for example, the company will routinely seek opportunities to bring groups of young people and their parents and teachers into the new New Jersey site in order to provide an up-to-date view of manufacturing technology, as well as an appealing glimpse at what a modern manufacturing career could look like for those who might thrive in this field.
This interior shot of AutoCrib’s TX750 tool vending system shows its vertical columns of adjustable shelves. To the left, you can see the inside of the system’s rolling dual-tambour door, capable of opening 2" to 60" to correspond with the selected bin.
Many industrial vending systems on the market today are based on pie-like trays divided into wedges. An operator calls up a tool or other expendable, and round carousels rotate until the appropriate wedge faces out. The operator can then open the door and remove the drill, insert or whatever it may be.
The system has its advantages, but according to Stephen Pixley, founder of AutoCrib, the wedge-shaped spaces also pose a dilemma. “Things come in rectangular boxes,” he points out, which means that in stocking the wedges, companies must waste either time (unpacking the boxes) or space (storing a square or rectangular box in a wedge-shaped hole).
Rather than pie-shaped trays system, AutoCrib’s TX750 vending system uses a carousel with slots more accommodating to box-shaped contents. The vending system features columns with adjustable shelving to accommodate boxes—as well as other objects of varying shapes and sizes. The slots can be adjusted to hold everything from a tiny insert to a 2-foot-plus fluorescent light bulb. The customizability of the slots reduces vertical bin height waste and increases the capacity that can be stored within a compact footprint. As many as 900 bins can be packed into the unit, which occupies 9.8 square feet of floor space.
The TX750 has another advantage that enables it to provide just the right product at the right time: rolling dual-tambour doors. When an operator calls for a product in a particular slot, the two doors rotate to the appropriate shelf and open only that slot. The doors can open to anywhere from 2" to 60" in half-inch increments.
The vending system is controlled by AutoCrib’s user interface with 19" touchscreen, and a native bin assignment process simplifies stocking the unit on the fly. Operators can identify themselves with an ID card or a fingerprint and search the system to retrieve items.
Last week, I attended an open house at GF Machining Solutions’ newest “Center of Competence” in Irvine, California, part of a 106,000-square-foot Georg Fischer facility shared with sister company GF Piping Systems. Established to strengthen support for West Coast customers, many of which serve the aerospace industry, the Center includes a machine demonstration area with high-speed machining centers and wire and sinker EDM equipment as well as solutions for laser texturing and automation. It also includes customer training rooms, resources for sales, service and applications staff, and an extensive spare parts and consumables warehouse.
Here are a few shots I took while touring the facility:
This Form 30 features an ATC design whereby the 26-position tool carousel wraps around the machine column unlike a conventional ATC that would consume additional floor space.
Note the removable access panel on the left side of the System 3R Workpartner automated pallet system serving a Form 200 SP wire EDM unit. This enables the easy addition of another EDM unit to share the automated pallet system.
The company suggests that the precursor to automation is establishing a common part reference plane, which is possible using workpiece palletizing systems such as those offered by System 3R.
Toyota Racing Development in Southern California now uses five-axis machining equipment from GF Machining Solutions to enable faster, more accurate milling of cylinder head ports.