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Machining

Reducing setup times frees up time for making chips

04/01/2016
Author:
Christopher Tate
Setup reduction is a common goal of every machine shop. Setup does not add value because it does not provide any measureable productivity. In short, when you are not running a machine, you are not making chips, and, therefore, you are not making money. Setup involves numerous non-value-added activities, including tool measurement, fixture alignment and setting coordinate systems, or offsets. As the term suggests, value-adding activities make a workpiece more valuable by changing its shape or physical properties. Many years in and out of machine shops and manufacturing plants have given me ample opportunities to see and establish some unique and familiar methods for reducing setup times and generating savings. 
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METAV metalworking expo: AM revolution not here yet

Additive manufacturing (AM) will neither displace existing machining processes nor revolutionize industrial production operations—at least not for the next 5 to 7 years, according to Myron Graw, an AM authority who spoke at METAV 2016, the 19th International Exhibition for Metalworking (Metallverarbeitung) Technologies. Graw, who heads up AM operations at KEX Knowledge Exchange AG, in Aachen, Germany, wasn't just sharing his personal opinion. He was delivering the results of a five-stage AM study conducted by KEX, the Fraunhofer Institute for Production Technology and the Fraunhofer Institute for Laser Technology, according to  a news release posted to the METAV 2016 website Feb. 23.

Machining process targets moldmakers and more

Imagine a machining process that removes material five times faster than milling and 10 times faster than sinker EDMing, machines Inconel and hardened steel with ease, holds tolerances to ±0.0006" and utilizes the same tool to process thousands of parts with virtually no tool wear. Machine builder EMAG LLC USA, Farmington Hills, Mich., calls this process pulsed electrochemical machining (PECM). A subset of electrochemical machining, PECM is far more accurate than the decades-old ECM and has matured into a viable alternative to more-traditional machining processes over the past few years, according to the company. 

Cool and clean

03/01/2016
Hypertherm Inc. designs and manufactures plasma, laser and waterjet cutting systems, as well as CNC motion and height controls, CAM nesting software and consumables. The Hanover, N.H.-based company opened a 165,000-sq.-ft. facility—Hypertherm’s newest—in Lebanon, N.H., in 2012. Among other machinery, the facility contains 26 multiple-axis, Swiss-style CNC lathes, which are used in the manufacturing of plasma cutting torch components, primarily electrodes and nozzles. The components are made of nonferrous materials.
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Gaging nonconforming parts

03/01/2016
Author:
Michael Deren
Do you know why your last part run had a high defect rate, why parts from an outside supplier were nonconforming, and what you are going to do with those parts? If your company has a material review board, it can probably answer those questions.
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Multitask Machines

Editor's Note: This video report is presented as a supplement to Cutting Tool Engineering's January cover story, "Down-hole, High-tech." The animation from Phillips Engineering Technologies was created to clearly illustrate the operation of a twin-ram vertical turning lathe.

Powdered metallurgy

Watch a video presentation from Seco Tools LLC about the tools and techniques suggested for machining powdered metallurgy. The company reports that inserts with Seco Tool’s Duratomic CVD aluminum-oxide coating can work well for P/M components. The Duratomic technology promotes growth of coating crystals in certain crystallographic directions to improve coating properties.