When a federally funded organization lands in my hometown of Chicago, where transparency at City Hall is murky at best, I tend to think “boondoggle.”
Therefore, I was pleasantly surprised to find that the Digital Manufacturing and Design Innovation Institute at Chicago’s Goose Island didn’t appear to be a wasteful project.
I visited DMDII Sept. 3 to attend “The Future of Machining – A Guide to Better Processes.” Coordinated by Blaser Swisslube Inc., Goshen, N.Y., the event featured presentations about toolholders, high-pressure coolant, minimum-quantity lubrication and chlorinated paraffins as an extreme-pressure additive in metalworking fluids.
The meeting also included equipment demos and a tour of the factory floor. The national institute, which is housed in a 94,000-sq.-ft. facility that serves as the headquarters for DMDII and its parent organization, UI LABS, began operation in May. It has three principal missions: R&D projects, outreach to manufacturers and workforce development.
The factory floor is comprised of seven cells: multiaxis complex machining, standard machining, emerging technologies, a metrology laboratory, welding and fabrication, microtechnology, and electronics and assembly. The emerging technologies cell, for example, has a 5-axis vertical machining center and will reportedly expand to include a 3D printer, robotics and optical scanning equipment.
Initially, I wasn’t sure why the institute’s name began with Digital, but was informed that the work on the factory floor involves collecting and processing as much machining data as possible to connect all elements of the manufacturing chain so they seamlessly communicate with each other. For instance, DMDII stated that it is developing open-source software, called the Digital Manufacturing Commons, which will be an open-architecture communication platform and enable plug-and-play functionality across the entire “digital thread.” DMC sounds like something that could positively transform a manufacturing organization.
The post-lunch presentation, titled “Metalworking Fluids Wakeup Call – Replacing Traditional Chlorinated Paraffins,” refocused my attention on consuming information rather than nutrients. Given by Ron “Andy” Anderson, Brookfield, Wis.-based product manager for fluids and filtration at DXP Enterprises Inc./Machinery Tooling & Supply, the presentation covered how the Environmental Protection Agency plans to eliminate the chlorinated paraffins that are effective as an EP additive by May 31, 2016.
There are short-, medium-, long- and very long-chain CPs, but short-chain ones are considered highly toxic and not used for EP additives, and the medium ones are generally not used. Those with the longest chains would not be banned, but they have a higher viscosity than the others and, therefore, make it difficult for them to stay in suspension, Anderson noted.
He added that other EP additives are available, but are not suitable for all applications, such as some demanding ones required to make aerospace and defense parts. With no direct drop-in replacement for long-chain CPs, metalworking fluids with CPs will need to be reformulated. While banning CPs is debatable, I’m confident the chemists at coolant manufacturers will develop effective alternative emulsions; they’ll probably just cost more.
Related Glossary Terms
- coolant
coolant
Fluid that reduces temperature buildup at the tool/workpiece interface during machining. Normally takes the form of a liquid such as soluble or chemical mixtures (semisynthetic, synthetic) but can be pressurized air or other gas. Because of water’s ability to absorb great quantities of heat, it is widely used as a coolant and vehicle for various cutting compounds, with the water-to-compound ratio varying with the machining task. See cutting fluid; semisynthetic cutting fluid; soluble-oil cutting fluid; synthetic cutting fluid.
- extreme pressure additives ( EP)
extreme pressure additives ( EP)
Cutting-fluid additives (chlorine, sulfur or phosphorus compounds) that chemically react with the workpiece material to minimize chipwelding. Good for high-speed machining. See cutting fluid.
- machining center
machining center
CNC machine tool capable of drilling, reaming, tapping, milling and boring. Normally comes with an automatic toolchanger. See automatic toolchanger.
- metalworking
metalworking
Any manufacturing process in which metal is processed or machined such that the workpiece is given a new shape. Broadly defined, the term includes processes such as design and layout, heat-treating, material handling and inspection.
- metrology
metrology
Science of measurement; the principles on which precision machining, quality control and inspection are based. See precision machining, measurement.
- minimum-quantity lubrication
minimum-quantity lubrication
Use of cutting fluids of only a minute amount—typically at a flow rate of 50 to 500 ml/hr.—which is about three to four orders of magnitude lower than the amount commonly used in flood cooling. The concept addresses the issues of environmental intrusiveness and occupational hazards associated with the airborne cutting fluid particles on factory shop floors. The minimization of cutting fluid also saves lubricant costs and the cleaning cycle time for workpieces, tooling and machines. Sometimes referred to as “near-dry lubrication” or “microlubrication.”
- robotics
robotics
Discipline involving self-actuating and self-operating devices. Robots frequently imitate human capabilities, including the ability to manipulate physical objects while evaluating and reacting appropriately to various stimuli. See industrial robot; robot.
Author
Alan holds a bachelor’s degree in journalism from Southern Illinois University Carbondale. Including his 20 years at CTE, Alan has more than 30 years of trade journalism experience.
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