Articles & Columns

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.

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.

Get with the Program: CNC systems, metrology equipment and other types of machinery often require a linear motion component. This may be because of a need to move a cutting tool back and forth, position measuring probes, convey material or clear debris from the work area.

Part Time: While some shops shy away from difficult projects, others welcome them. According to Bob Perkins, president of PDS (Precision Defense Services) Industries, Irwin, Pa., the company has built its business on doing things others can't do.

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.

At my shop and others I've been in contact with, cash flow and timely payment have become issues that require greater scrutiny. If that's the case at your shop, dealing with them effectively will be a test of your management skills.

END USER: Cincinnati Mine Machinery Co., (513) 728-4040, www.cinmine.com. CHALLENGE: Improve throughput and maintain higher part-quality consistency. SOLUTION: A machining cell with 24 pallets and two horizontal machining centers. SOLUTION PROVIDER: Makino Inc., (513) 573-7200, www.makino.com

When turning 2mm-dia. and smaller parts on a Swiss-style machine, it only makes sense that the radius on the tool should be equally tiny. After all, you can't cut a 0.5mm bone screw with a TNMG-431 insert—the tool's nose radius is nearly as big as the part.

Ever since CNC machining became the dominant method to cut and grind metal, a perception has existed that machining can be manipulated and easily simplified. With computers crunching the numbers, how hard can machining be?

From simple bushings to critical engine components, producing replacement aircraft parts requires unwavering commitment.

END USER: Kline Oilfield Equipment Inc., (918) 445-0588, www.klinetools.com. CHALLENGE: Reduce cycle time and extend tool life when machining 718 Inconel. SOLUTION: An AlTiN-coated, general-purpose endmill and CAM software that generates efficient toolpaths. SOLUTION PROVIDERS: IMCO Carbide Tool Inc., (800) 765-4626, www.imcousa.com; SolidCAM Inc., (866) 975-1115, www.solidcam.com.

Nickel-base superalloys can withstand hot and tough conditions, but are difficult to machine. With the right approach, machinists can keep their cool when cutting them.