Recognizing that the future of American manufacturing lies with today's youth, Rockford Systems LLC launched its "Selfie for Safety" campaign to help raise student awareness of the importance of machine safeguarding and to help fund the upgrading of safety equipment in the machine shops of several high schools in Rockford, Ill., where the company's headquarters is located.

Three primary elements play a heightened role when machining molds for plastic injection molding of microparts compared to moldmaking for the macro realm: part size, feature size and dimensional tolerances. 

Colson Group USA, a manufacturer of casters, wheels and other mobility products, continues to make significant investments to its production and distribution operations while reshoring manufacturing.

In the machine shop of the future, a digital thread will weave through the pre-, in- and post-machining processes. Prior to machining, those processes include design, process and operations planning, and production logistics. After machining, part verification and outbound logistics enter the picture.

END USER: Zodiac Engineering, www.zodiaceng.com. SOLUTION PROVIDER: Brush Research Manufacturing Co. Inc., (323) 261-2193, www.brushresearch.com. CHALLENGE: Reduce programming and cycle time, and eliminate the need to regrind or replace chamfering tools when deburring part edges. SOLUTION: Apply in-line abrasive nylon disc brushes.

Shop Profile: MTU America machines parts for large diesel engines while helping fill the skills gap.

On Robot ApS, a Danish manufacturer of grippers for collaborative robots (cobots) that was founded in 2014, is introducing its technology to the North American market and has appointed Gary Eliasson as its general manager for North America. He will be based in Charlotte, N.C. “My goal is to set up a North American distribution channel,” he said.

Commit to a German-style, dual-training apprenticeship program so your shop can produce its own skilled workers, suggests the director of the German American Chamber of Commerce of the Midwest Inc.

END USER: Greenlee Textron Inc., (815) 784-5127, www.greenlee.com. SOLUTION PROVIDER: Keyence Corp. of America, (888) 539-3623, www.keyence.com. CHALLENGE: Relieve capacity constraints on conventional coordinate measuring machines. SOLUTION: A portable 3D measurement system.

Economic pundits anticipate global machine tool consumption will increase 2.1 percent in 2017, reaching a market value of $73.6 billion, according to the German Machine Tool Builders’ Association, Frankfurt am Main, Germany. The group released the machine tool business data at a March 9 press conference in Chicago for the EMO trade show, which takes place Sept. 18 through Sept. 23 in Hanover, Germany.

It’s no secret that shop owners and managers frequently bellyache about the difficulty of attracting skilled workers and poach staff from other manufacturers by offering better pay.

One of the activities I enjoy most in connection with my job is visiting production facilities, because I get a chance to see how parts and products are made and have face-to-face interactions with talented metalworking professionals—not to mention that it gets me out of the office now and then.

Automated inspection equipment can offer advantages, such as enabling lights-out machining, but manual methods are typically less expensive and can provide quicker results. One example is a manually operated gage for inspecting round cutting tools.

In an interview conducted by CTE Editor Alan Richter, Kennametal Inc. President and CEO Ronald De Feo discusses the past year, the business outlook for Kennametal, Pittsburgh, the cutting tool industry and the company’s modernization efforts.

In an article posted Feb. 9 at Forbes.com, Bill Conerly of Conerly Consulting LLC, Oswego, Ore., discussed how U.S. manufacturers need engineers to thrive because engineers invent products and optimize production methods.

Time-tested workholding allows a parts manufacturer to target other areas for improvement, if needed. Husky Corp., for example, needed space-saving hydraulic components when refixturing a dial machine with limited space for fixtures and conducted an extensive search 30 years ago for a solution, said Darrell Vilmer, senior manufacturing engineer – machine/fixture designer for Husky.

Being able to broach a blind keyway while keeping the part on the same CNC machine tool used to perform the other machining operations provides a significant improvement in setup, reliability and accuracy, compared to moving the part to a dedicated broaching machine. 

One of the activities CTE Editor Alan Richter enjoys most about his job is touring production facilities. The visits give him a chance to see how parts and products are made while meeting face-to-face with talented metalworking professionals.

END USER: North Bucks Machining Ltd., +1908-611-669, www.northbucksmachining.co.uk. SOLUTION PROVIDER: Open Mind Technologies USA Inc., (888) 516-1232, www.openmind-tech.com. CHALLENGE: Efficiently rough-machine a mountain bike frame from a solid piece of aluminum stock. SOLUTION: A CAM software’s high-performance roughing module.

Running a small to medium-sized machine shop business presents many challenges. Alliance Broach & Tool, East China, Mich., has been in the business of building its operations and client base for more than 35 years; the company knows about some of these challenges. In spite of a tough economic climate, however, Alliance continues to significantly grow. After nearly 40 years, that is an impressive accomplishment.

Working in the bleak midwinter while the metalcutting sector transitions through a downturn sounds like a recipe for the blues. But it doesn’t have to be. When things are a bit slow, it can be a good time to do some housekeeping and other chores around the shop that get put on the backburner during more active times. Investing in automation and other productivity-boosting equipment can also be wise during a soft stretch.

According to Autonetics LLC, automated gaging units (AGUs) for threads are hot. The Cary, N.C.-based AGU manufacturer reported that it shipped 10 systems in the third quarter of last year to U.S. pipe mills that produce oil country tubular goods. No shipments occurred in the fourth quarter because the industry experienced a downturn, so capital expenditure projects got cut or delayed, noted Jeff Heath, COO of Autonetics. However, he said, the projects are starting to receive funding again. “We have about four in the build phase.”

Although the James Webb Space Telescope isn’t scheduled to be launched on an Ariane 5 rocket from French Guiana until October 2018, NASA announced that the 18th and final primary mirror segment was recently installed on what will be the biggest and most powerful space telescope.

suitX, a California-based robotics company designing and manufacturing medical and industrial exoskeletons, recently announced the official launch of MAX, a flexible exoskeleton that can be adapted to a variety of workplace tasks. MAX comprises three exoskeleton modules: backX, shoulderX and legX.

END USER: Modern Machining Technology Inc., (303) 945-7570, www.destroked.com; SOLUTION PROVIDER: Industrial Coolant Systems LLC, (303) 968-1707, www.industrialcoolantsystems.com; CHALLENGE: Reduce the cycle time when drilling a large quantity of holes in a 1018 steel part. SOLUTION: A high-pressure coolant system.

Economic activity in the manufacturing sector expanded in December, and the overall economy grew for the 91st consecutive month, say the nation’s supply executives in the latest Manufacturing ISM Report On Business.

It’s hard for Babatunde Ogunnaike to contain his excitement at the thought of a new federal grants program aimed at improving the U.S. manufacturing workforce. Last week, President Barack Obama signed the 2017 National Defense Authorization Act (NDAA), a bill setting policy for all activities at the Department of Defense (DOD). Buried within the 969 pages of legislation (S. 2943) is a manufacturing engineering education program to be run by the Office of the Secretary of Defense. Ogunnaike, dean of engineering at the University of Delaware (UD) in Newark, has been an advocate for the program ever since two Washington, D.C.–based think tanks first floated it 4 years ago as a network of manufacturing universities.

On the one hand, many employers in the manufacturing industry view millennials as being self-absorbed, unfocused, disloyal, addicted to mobile devices and lazy. On the other, most millennials don’t view a career in manufacturing as something they want to pursue.

While manufacturing technology sales were down in October compared to September (and the high order volume that came along with IMTS), the latest U.S Manufacturing Technology Report from AMT - The Association For Manufacturing Technology shows October sales were 0.2 percent higher than October 2015. 

MITGI has been honored as a finalist for a 2017 Community Impact Award from Minnesota Business magazine in the Youth Initiative category. This award category recognizes companies for creating or supporting programs designed to enable youth to develop abilities in areas such as leadership, social responsibility, skilled trades, education and community involvement.

A circular shape provides multiple benefits in the machining world. For example, round inserts are stronger than inserts with any other shape. However, when it comes to coolant channels in cutting tools and toolholders, channels that don’t have circular cross sections can enhance operations.

END USER: Mast Motorsports, (936) 560-2218, www.mastmotorsports.com. SOLUTION PROVIDER: Hurco North America, (800) 634-2416, www.hurco.com. CHALLENGE: Replace technologically obsolete production equipment. SOLUTION: Purchase two new 5-axis CNC milling machines

END USER: lllinois Carbide Tool Co. Inc., (800) 323-2414, www.crobaltusa.com, www.brakedrumtool.com. SOLUTION PROVIDER: Agathon Machine Tools Inc., (203) 730-8741, www.agathon.com. CHALLENGE: Keep up with increasing production demands for carbide brake lathe inserts. SOLUTION: A 4-axis grinding machine that enables lights-out production.

Allied Machine & Engineering offers a program of technical education seminars. Allied’s highly trained and knowledgeable engineers focus the 3-day TES program on problem-solving.

ANCA Inc. will expand its plant in Wixom, Mich., by 50 percent, expanding its inventory and spare parts warehouse capacity, adding a dedicated customer focus and training center, and doubling its machine demonstration area. The announcement was made by Russell Riddiford, ANCA president. ANCA, a private company, did not disclose the dollar value of the investment.

IMTS 2016 featured more tools and systems for the Industrial Internet of Things (IIoT) than ever, observed Cutting Tool Engineering Editor Alan Richter in his October 2016 Lead Angle column.

Manufacturer Seco Machine primarily serves the railroad industry while seeking to diversify.

People in the industry continue to proactively do something about overcoming the skills gap, and I’d like to highlight two such efforts.

This issue of CTE includes our IMTS 2016 Show Preview, featuring show highlights, information about the various pavilions, a guide to Chicago attractions and an extensive array of announcements about what exhibitors plan to showcase. The latter includes machine tools, software, workholders, automation equipment and cutting tools. 

The technology to form, press and grind indexable carbide inserts has evolved to such a high degree that the methods to effectively clamp inserts in a cutter body have struggled to keep up, but strides are being made. Some insert shapes have advanced to the point where they have a true, 100-percent, 3D geometry with almost no flat surfaces. This requires a tool-body pocket that is dynamically shaped to accommodate the optimal geometry. For example, an insert with a wavelike feature across its back requires it be seated in a pocket with a matching shape to ensure accurate fixation with high stability.

Numerous factors determine whether a manufacturer is profitable or not. Lately, one of those factors for a U.S. manufacturer is whether it is is focused on the domestic market or pursuing a global approach.

I was saddened to hear about the passing of David A. Dornfeld, professor of mechanical engineering at the University of California, Berkeley, who died of a heart attack on March 27 at age 66. Although I never met him, I considered him to have a brilliant mind and be a great editorial source—someone who returned my phone calls and had something intelligent to say.

It’s fitting that “Technology” is part of Indiana Technology and Manufacturing Cos.’s name. In addition to providing a full slate of machining and assembly services, ITAMCO created what it says is the first industrial Bluetooth transmitter (called iBlue) and continues to develop a broad range of manufacturing apps for mobile devices and Google Glass. What's more, ITAMCO has produced a virtual manufacturing showroom and developed a manufacturing forklift simulator that allows users to interact with factory equipment using the MTConnect protocol, Autodesk Factory Suite, Unity 3D game development platform, Oculus Rift virtual-reality headset and Leap motion controller.

Early in my stint here, I called Alan Baker, founder of toolmaker A.B. Tools Inc., in connection with an article I was writing about thread milling small-diameter holes. I started the interview with a general question about available thread mills sizes for these applications and was encouraged to first gather that information from Machinery’s Handbook and then call him back. I thanked him before ending the call and turning to the appropriate section of “The Bible of the Mechanical Industries,” published by Industrial Press Inc. 

As the plans for more and more machined metal parts include numerical surface finish specifications, the need diminishes to visually qualify that a part has, for example, “a mirror finish with no burrs” or to have the machinist with the finest touch scratch the surface with his fingernail to make sure it’s “matte and rough.”

One of the most enduring issues in the metalworking world is finding and retaining skilled workers, and the 10th annual Metalworking Trends Survey from LoSasso Integrated Marketing, Chicago, showed that this challenge continues. 

To enable junior and senior high school students to follow a specific direction in the manufacturing industry, their education must be diverse. Ensuring such diversity is the goal of the Machine Technology Program at Cuyahoga Valley Career Center, Brecksville, Ohio, according to Rich Parrott, machine technology instructor. 

Virtually every established manufacturer has experienced at least one major setback during its history. For Taurus Tool & Engineering, it was losing its main tool grinding area and CNC machines to a fire in June 2014, after a 37-year run at its previous facility in Schaumburg, Ill. No injuries were reported, thankfully, and the cause of the fire is unknown. 

... in these golden years,” crooned the late David Bowie in one of his smash hits. The term “golden years” is also used in Albert B. Albrecht’s book “The American Machine Tool Industry: Its History, Growth, Restructuring & Recovery,” which he revised in 2015 for the third edition. AMT—The Association For Manufacturing Technology sponsored the book. Albrecht defines the golden years of the machine tool industry as being from 1948 to 1998. “It was during this period that the United States machine tool industry led the world in both machine tool production and consumption,” Albrecht wrote.

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.