Machining

Deciding whether to use a turret or gang tooling is one of many topics that seems to engender religious fervor from one side to the other. Let’s start by providing a brief overview of each approach and then dive into the details.

Machine tools are heavy. Moving them yourself can be dangerous, causing damage to people and machinery alike. But with the right tools, knowledge of how to use them and some common sense, DIY machine moving is possible—though not always recommended. 

END USER: Manes Machine & Engineering Co., (970) 224-3311, www.manesmachine.com. SOLUTION PROVIDER: Lang Technovation Co., (262) 446-9850, www.lang-technovation.com. CHALLENGE: Eliminate the time spent machining dovetail cutouts and holes in a workpiece so it could be held in a dovetail-type vise for machining. SOLUTION: A stamping unit that creates dimples in a workpiece for holding it in a self-centering vise, referred to as form-closure technology.

END USER: Amsted Rail – Brenco Inc., (804) 732-0202, www.amstedrail.com. SOLUTION PROVIDER: Jorgensen Conveyors Inc., (800) 325-7705, www.jorgensenconveyors.com. CHALLENGE: Eliminate bushy stringers from repeatedly jamming chip conveyors. SOLUTION: A chip conveyor with a dual-belt conveyor that reduces or eliminates jamming problems.

As new composite materials are developed, parts manufacturers face new challenges when routing them. Fortunately, cutting tool manufacturers continually develop new solutions so parts manufacturers are not forced to cut tomorrow’s composites with outdated routers. 

Most folks who run an engine lathe often work on the ends of long shafts, or rods, that protrude unsupported out of the headstock. Depending on the shaft diameter and how much unsupported length sticks out, this operation can be dangerous because of the high potential for shaft whip. However, with the proper tooling, this operation is a cinch to perform safely. 

Machine tool builder Zimmermann Inc., Wixom, Mich., the U.S. arm of Neuhausen, Germany-headquartered Zimmermann GmbH, specializes in very large machine tool installations. The company offers milling machines with working ranges from 2.5m to 30m (8.2' to 98.4') along the X-axis and from 3m to 6m (9.8' to 19.7') along the Y-axis. 

Just in time (JIT) manufacturing, by nature, increases setups and shrinks batch sizes. This puts shops in a bind, because more setups and smaller batches are typically less profitable; but saying "no" to work can be even more painful. The burden to search out creative ways to reduce cycle and setup time in order to realize a profit falls to the shops that commonly perform JIT work and on the shops that can’t afford to turn it down when the opportunity arises.

A new CS-50 deposition system from Duralar Technologies uses a process called DualArmor that is capable of applying DLC coatings of 50µm or thicker — and apply them at rates averaging 15µm to 20µm per hour. Conventional DLC coatings, which have a practical total thickness limit of around 5µm, are deposited one or two atoms at a time. As a result, it can take more than 8 hours to deposit a 1µm-thick DLC coating.