A machining cell combines lathes, a robot and a conveyor system to enable automated production of precision oil-drill couplings.

By Derek Korn

The good news for shops serving oil and energy companies is that they are busy. The downside to this is they often don’t have time to research and integrate new machining strategies because they are running at full capacity, suggests Gayle Vollmer, Okuma’s director of technical resources.
automated oil-drill coupling production cell
This automated oil-drill coupling production cell creates finished couplings in 11 minutes (photos courtesy of Okuma).

Take the manufacture of couplings used to join lengths of oil drill-pipes. Coupling machining has traditionally been performed manually, with operators loading workpieces into relatively old equipment. These heavy couplings are difficult for operators handle, and chip control during requisite turning and threading operations can be a challenge. Plus, the couplings’ ID, OD and threads must be accurately machined so that the pipes they connect don’t leak.

Until recently, an automated system dedicated to manufacturing those couplings hadn’t been created, Mr. Vollmer says. Because demand for precision couplings is increasing, however, Okuma and the Partners in THINC collaborative decided to develop an automated coupling production cell using vertical and horizontal lathes, a gantry robot and a conveyor system.
Vertical turning allows chips produced during threading operations to fall and flow away from the workpiece.
Vertical turning allows chips produced during threading operations to fall and flow away from the workpiece.

The cell was built and tested at the Partners in THINC facility in Charlotte, North Carolina. After experimenting with various tools, coolants, coolant pressures and machining practices, the Partners were able to solve the primary problem of chip accumulation during the turning and threading operations.

Unattended Coupling Production
The automated manufacturing process begins with a Fanuc overhead gantry robot that loads double-length coupling blanks in and out of the machines. The overhead gantry design saves valuable floor space.
A gantry robot and parts conveyor

A gantry robot and parts conveyor eliminate heavy lifting for machine operators.

The roughing and finishing operations for coupling ID and OD are performed on a four-axis Okuma LOC-650 oil-country lathe. This lathe also performs the cutoff operation that separates the blank into two 10-inch-long couplings (the finished coupling below has a diameter of 9 5/8 inches). The workpieces then move down a conveyor to an Okuma Konan V80R vertical turning lathe (VTL). The V80R’s vertical spindle orientation assists in evacuating chips during turning and threading operations. Both machines are fitted with a Schunk “oil country” chuck.

The chips produced during threading operations fall and flow away from the workpiece thanks to the V80R’s modified tooling adapter and ChipBlaster high-pressure, high-volume coolant system. Coolant flow from precisely directed nozzles helps break up the chips and flush them out of the machine. After the threading operation, the workpiece is conveyed out of the cell and delivered to a measuring station, where a Marposs gage inspects its threads and diameters. The cycle time to turn, thread and deliver a completed coupling out of the cell is only 11 minutes.

This cellular production method allows complete OD turning in one operation. This helps meet high-precision threading requirements by avoiding the undesirable blend line that occurs with a two-part operation. In addition to increasing production speed, the cell eliminates the need for a 1- to 2-minute sawing operation.

Labels: Machinery Tool

In high-speed milling applications, axial chip thinning is often used to increase feed rate with a small end mill. This shop uses that same effect to increase metal removal rate with a standard-size end mill run on a moderate-speed machine.

By Peter Zelinski

As the very name of the shop makes clear, Robertson EDM doesn’t specialize in machining center work. This job shop in Edgerton, Ohio, has four wire EDM machines and one sinker EDM machine, but at present only one CNC machining center—a reliable Mazak VTC-16B vertical that the shop purchased used.

However, as the shop continues to succeed and continues to draw more business just by word of mouth, both the range of work and the range of opportunities continue to grow more broad. To take on large-diameter turning work, for example, the shop recently invested in a Johnford ST-40A slant-bed turning center with 31 inches of swing over the bed from Absolute Machine Tools. The volume of work for its machining center is also increasing, and the shop has met this challenge by implementing high speed machining on this VMC—sort of.
The profile of the inserts
The profile of the inserts blends from a 0.106-inch radius to a 0.5-inch radius. Chip thinning occurs because a light depth of cut meets the insert along this curve, allowing feed rate to increase.

The term “high speed machining,” particularly in applications involving steel, often refers to small tools run at high spindle speeds and feed rates with light depths of cut. Despite the light cuts, machining in this way achieves a high metal removal rate by taking the passes very rapidly. The passes can then become even more rapid when using a ballnose end mill, because a ballnose tool making a light cut takes advantage of axial chip thinning. By virtue of this effect, the chip thickness is smaller than the advance per tooth. This means that the advance per tooth can be increased, and correspondingly the linear feed rate in inches per minute can be increased even beyond what the high spindle speed already allows.

But that’s high speed machining. By contrast, Robertson EDM does not have particularly high spindle speed, nor does it have the complex 3D milling work that could benefit from a small-diameter ballnose tool. However, the chip thinning that increases feed rate in high speed machining is still a real and valuable option for this shop, even with a tool that has a larger diameter. To increase its own metal removal rate, the shop employs a tool design supplied by Iscar that realizes the chip thinning effect. The insert design, called “Feedmill,” features a curved profile that makes this possible. Chip thinning, in other words, does not need a ballnose tool and does not need a small tool diameter. At least this one aspect of high speed machining can be applied in a more standard roughing application on a moderate-speed machine.

This part, which was slightly oversize
This part, which was slightly oversize relative to the work zone, was machined in two setups using two different types of inserted end mills. The table captures the difference in performance the shop realized using the chip-thinning insert.




Inserted tool with insert taking advantage of chip
thinning




Shop’s previous inserted roughing end mill
Tool diameter (inch)
0.75 0.75
Number of teeth 1 2
Coolant Air Air
Overhang (inch) 1.5 1.5
Speed (rpm) 3000 2000
Depth of cut (inch) 0.04 0.05
Width of cut (inch) 0.5 0.5
Feed rate (ipt) 0.04 0.0088
Feed rate (ipm) 120 35
Tool life (pieces per edge) 20 15
Cutting time (seconds) 584 977
This part, which was slightly oversize relative to the work zone, was machined in two setups using two different types of inserted end mills. The table captures the difference in performance the shop realized using the chip-thinning insert.

Chip Thinning In Action
One of the shop’s general partners is Jeffrey Robertson. The local sales and applications representative for Iscar is Greg Mallett. Mr. Mallett was meeting with Mr. Robertson to tool up the new turning center when he saw an application for the axial-chip-thinning insert. Robertson EDM was roughing a fixture component out of cold-rolled steel, and the way the shop was machining this part actually provided an excellent basis for a before-and-after comparison. The part was too big for the machining center’s travels, so the shop was machining it in halves.

After the first half was finished with a 0.75-inch inserted tool, the shop agreed to run the second half with a 0.75-inch tool body using the chip-thinning insert design. The tool with the latter insert cut with one tooth instead of two, and it also took a lighter depth of cut. However, because of the higher feed rate resulting from chip thinning, productivity increased. Tool life increased, too. (See table.)

The curved profile of the insert begins as a 0.106-inch radius, blending into a 0.5-inch radius. A depth of cut light enough to fall along this curve features an advance per tooth that can “cheat” its way higher, because the chip thickness is lighter than the advance per tooth instead of being equal to it.

transmission cover
The transmission cover is another part machined using the high-feed-rate tool. This is the part being machined in the photo at the beginning of the article.

The greater tool life the shop saw can be attributed to the curved profile, too, says Mr. Mallett. The tool life increase that Robertson EDM observed was likely the result of a more stable cut, he says. As is the case with a ballnose tool, the material meeting the curve of the tool at a point below the tool’s full radius exerts a cutting force that is not entirely lateral, but instead pushes up toward the centerpoint of the ball. (See p. 98.) In other words, only some of the cutting force is directed along X and Y. The remainder is directed along Z, the direction of the spindle, which is the most rigid of the three axes. With correspondingly less force directed along the side of the tool, there is that much less opportunity for tool deflection, and the cut is that much more stable.

As a result, capacity has increased on the shop’s machining center. The shop now routinely uses this tool for its steel-roughing applications—the transmission cover on p. 98 is another example of a part for which the tool was suited. As the shop continues to grow, no doubt its number of machining centers will grow as well—perhaps one day to include a high speed machine. For now, however, the additional capacity provided by faster roughing feed rates is enough to meet the need.



What Is Axial Chip Thinning?
ballnose tool

On a ballnose tool, any cut that meets the tool at less than the full radius of curvature will behave differently than a more standard milling cut. The chip thickness and the advance per tooth will not be the same—the chip thickness will be less. The diagram shows geometrically why this is. As a result of the thinner chip, the advance per tooth can be increased to achieve a higher linear feed rate, resulting in a higher metal removal rate for an application that was already employing a relatively light depth of cut.

The effect is most commonly associated with ballnose tools in high speed machining. However, it can also benefit milling cutters using circular inserts, as well as cutters using curved profiles designed specifically to realize a chip-thinning effect (such as the Feedmill tool mentioned in this article).

The diagram also shows the direction of force. The force on the tool shown here is not directed laterally, but instead is directed along the diagonal dashed line from the material up to the centerpoint of the tool’s curve. In other words, instead of being directed all along X and Y, some of the cutting force is directed up into Z, a more rigid axis of the machine, resulting in a more stable cut.

Labels: Machinery Tool

Compacted graphite iron is increasingly used for diesel and racing engine components. The choice of cutting tool can dictate how effectively shops can machine this challenging material.

By Derek Korn

Ongoing development of tough, new workpiece materials is driving cutting tool manufacturers to create appropriate new cutter geometries, carbide grades and coating technologies. Shops serving the aerospace industry, for example, must find effective ways to machine 5553 titanium and composites. The same goes for medical shops being asked to machine PEEK polymer, stainless and other exotic materials. One machining-unfriendly material making inroads in the automotive industry is compacted graphite iron (CGI). This material is primarily used to create engine block, cylinder head and bearing cap castings typically used for large diesel trucks. The result is better fuel efficiency for over-the-road vehicles because CGI weighs half as much as conventional gray cast iron. In addition, it has twice the strength and stiffness of gray cast iron, allowing designers to minimize engine block wall thicknesses. As a result, an assembled CGI engine usually weighs about 9 percent less than one made of gray cast iron.

CGI has been used in Europe for some time and is gaining greater acceptance in the United States. It can handle peak firing pressure found in diesel engines—aluminum engine blocks with iron cylinder liners cannot. Some high-performance, V-style racing engines are also made of CGI not only because of reduced weight but also increased stiffness, especially in the valley between cylinders.

One reason why CGI is more challenging to machine is because it has two to three times the tensile strength of gray cast iron, notes Robert McAnally, industry specialist in automotive milling for Sandvik Coromant (Fair Lawn, New Jersey). The higher tensile strength translates to higher cutting forces during milling operations—approximately 15 to 25 percent more machining power is required to machine CGI versus gray cast iron. Therefore, shop equipment tuned to machine gray cast iron might not possess the power to handle CGI machining. Mr. McAnally points out there are other challenges in that:

* CGI has relatively low thermal conductivity, so heat generated during machining is pushed into the workpiece, adversely affecting tool wear. Conversely, gray cast iron possesses high thermal conductivity, which allows heat to be carried away with the chip during a machining operation.
* The casting crust on a CGI component has a ferritic structure, causing material to stick to the tool’s cutting edge. This doesn’t occur with gray cast iron because it has a pearlitic structure.
* Unlike gray cast iron, CGI does not contain sulfur. The sulfur in gray cast iron deposits on the tool’s cutting edge and acts as a lubricant that extends tool life.
* Titanium is used as an alloying element during the CGI casting process, creating a tougher casting skin. This also causes the formation of abrasive free carbides throughout the casting. The amount of alloying elements in CGI has a big impact on machineability and tool life.

Here are the results of a milling test Sandvik performed on a fluid control component using its CoroMill 365 cutter designed for machining cast iron. The thick insert used has 12 degrees positive geometry, but it installs in a negative pocket to produce a slightly positive total angle. This also allows a higher density of inserts in order to maximize productivity.
machine tool
Heller PFV2
depth of cut 3 mm (0.118 inch)
engagement 80 mm (0.315 inch)
cutting speed 130 m/min (426 sfm)
revolution 414 rpm
feed 298 mm/min (11.73 ipm)
feed per tooth 0.36 mm (0.014 inch)
number of inserts 2 inserts for test purposes
total area milled 3.08 m² (33.15 ft2)
tool life 130 min (full engagement)
tool life per insert 1.54m² (16.57 ft2)
Here are the results of a milling test Sandvik performed

Because of these factors, tools used to cut CGI generally last half as long as those cutting gray cast iron.

Milling And Boring
CGI does provide approximately 50 percent better milled surface finish (Rz) than gray cast iron, which means that either fewer machining passes may be needed or a separate finishing tool may not be necessary to deliver the requisite finish. During machining, CGI does not produce component edge breakout as the tool exits the cut. Gray cast iron can produce chipping, which could scrap the block with extreme breakout. CGI acts more like steel in that respect, producing a burr rather than a breakout.

Because of the reduced cutting speed required to machine CGI, it can take nearly three times as long as it would to cut gray cast iron using conventional processes. Sandvik has performed many tests to determine more effective ways to machine CGI. For milling operations, the tool material it has determined works best is carbide coated with thick layers of titanium carbon nitride (TiCn) and aluminum oxide (Al2O3). Mr. McAnally describes a thick coating as being 7 to 10 microns; thin coatings are typically 2 to 3 microns.
CGI engine designs
Because CGI has twice the tensile strength of gray cast iron, new CGI engine designs such as the one on the right can have thinner wall thicknesses, reducing engine weight.

For turning and boring operations, the company recommends a carbide substrate with high abrasive wear characteristics coupled with wear-resistant thick coatings applied using medium-temperature chemical vapor deposition (CVD). It has found that boring CGI using a CBN insert offers only one-tenth the tool life of boring gray cast iron. A slightly positive geometry is appropriate (between 5 to 10 degrees), and it is recommended that CGI operations are performed sans coolant.

Sandvik worked with Makino to develop a boring process that can finish a rough-bored cylinder in one pass. The multiple-insert tool that was developed is called the Long-Edge Tool. The tool is fed in a helical path down a cylinder and is said to finish a bore in approximately the same amount of time as gray cast iron. A subsequent honing operation is all that’s required before engine assembly.

While developing this new finish-boring process, the companies determined that roughing is best attacked using a traditional, single-headed milling cutter with inserts having Si3Ni4 coating and geometry optimized for boring CGI.

Labels: Machinery Tool

By Mark Albert

Synthetic-diamond dressing tools are often a superior alternative to natural-diamond dressing tools for conditioning a grinding wheel. The reason is the consistency that the synthetic-diamond tools bring to the process. That is a key point in the case for synthetic diamond dressing tools made by William D. James, a product engineer in the stationary tool group at Saint-Gobain Abrasives (Worcester, Massachusetts).

According to Mr. James, synthetic tool stones start out as more consistent products because the manufacturing process that creates them is tightly controlled and predictable. Synthetic stones are available in a variety of close-tolerance sizes, are longer than most elongated natural stones and have a uniform rectangular shape through their entire length. As he explains, all dressing tool diamonds (natural or synthetic) develop wear flats over time. With natural diamonds, problems begin as wear flats increase in size and eventually become too big to sharpen the wheel. Instead of opening the wheel’s grain structure, the dressing tool closes it, leaving the wheel dull. Synthetic diamonds are consistently shaped so that their wear flats never get large enough for this to happen.

This “non-dulling” property means that synthetic stones never need indexing as natural stones do. Likewise, the longer synthetic stones simply outlast the shorter natural diamonds. For these reasons, using synthetic-diamond dressing tools avoids two causes of machine downtime—interruptions for indexing the tool or replacing it outright.
three- and five-stone 'uniform synthetic blade' tools
These three- and five-stone “uniform synthetic blade” tools are shown with CVD diamonds. The tools have straight or angled diamond section configurations.

Mr. James identifies six steps for transitioning to synthetic-diamond dressing tools:

1. Choose between monocrystalline and CVD (chemical vapor deposition) diamonds. Both types work well, but the monocrystalline stones tend to be more durable (and a little more expensive).
2. Specify the correct diamond size and shape. These must be matched to the specific grinding application.
3. Decide how many stones to use. Unlike single-point natural-diamond tools, an equivalent synthetic-diamond tool may have as many as five stones or more mounted in a blade-like configuration. Generally, the larger the wheel size, the more stones are needed to dress it.
4. Be sure the individual diamond stones are oriented correctly. They must be angled up for general use and straight on for heavy-duty applications.
5. Configure the tool properly. Blade configurations with multiple stones must be mounted vertically so that the wheel sees only one diamond width as the tool moves across the wheel.
6. Use appropriate dressing parameters and stick to them. Synthetic tools use the same parameters as those for natural-diamond tools, but synthetic tools weaken faster if overheated because recommended speeds and feeds are exceeded.

Mr. James concludes that whether you’re considering the use of synthetic diamonds to improve wheel-conditioning consistency or to eliminate downtime associated with having operators interrupt production to index the diamonds, synthetic dressing tools have much to offer.

Labels: Machinery Tool

By Christina Bramlet

Remote Machining melds two seemingly antithetical concepts—control and freedom—so that shops can do some reconnaissance work or tweak parameters on their own terms. The manufacturer’s self-titled, all-hardware interface grants real-time access to all CNC functions via the Internet so that shop personnel can manipulate the process, regardless of their proximity to the actual machine.

Operators can edit programs, check cut progression or troubleshoot from any PC—be it in a hotel lobby or a home office—as long as there is Internet connectivity. The interface assuages logistical concerns for the user without taxing the machine’s brainpower. It consists of an adapter and a centralized controller, which are completely independent of software, operating system or controller type. The virtual “spy” does not encumber the CNC. Rather, it gains access by splicing into the I/O from the controller side. In essence, the machine is not even cognizant of this “spy.”

“The product is piggybacking, not taxing the control with extra functions,” explains Tim Zott, president of Remote Machining (West Bloomfield, Michigan).

The product is compatible with machining centers, grinding machines, lasers, lathes, plasma cutters, waterjets, EDMs and other CNC-controlled machines. Thus far, it has been predominantly adopted in EDMs because they are generally run unattended more frequently than other machines. Makino offers the interface as a third-party option for its wire and ram EDMs.

Basic shopfloor requirements are at least one PC with Internet connectivity in the building and a LAN connection (within cabling distance) to the machine. Shop personnel can log on to their company’s own internal infrastructure to tinker with certain parameters and functions, but in such a way that does not interfere with the integrity of the process. All modifications must be in accordance with OSHA regulations, which stipulate that axes cannot move without an interlock system. Thus, Mr. Zott says, users can’t execute changes that cause direct movement of the cutting axes outside of what is specified in the loaded program. They can, however, check in periodically to see if alarms have been triggered or to gauge overall machining efficiencies and possibly make adjustments.
The hardware interface essentially places the control in front of the user The hardware interface essentially places the control in front of the user
The hardware interface essentially places the control in front of the user regardless of his/her proximity to the actual machine. The proximity of an Internet connection is the more important consideration in this case.

“With EDMs, for instance, the shop could modify cutting parameters remotely,” explains Brian Pfluger, Makino senior applications engineer. “Although it can’t start the machine, the shop could edit the speeds and feeds and power elements, as well as halt production.”

From an application support standpoint, the product can better equip engineers to bridge the gap between perceptions of what is going on with the reality of what is actually occurring at the machine. Mr. Pfluger says the system is beneficial when providing technical assistance and when training new users, especially during the first year of machine ownership.

“This often helps us make machining adjustments so that the customer’s part is running more efficiently,” he comments.

This first year of ownership, Mr. Zott says, typically represents the highest incurrence of costs related to technical services and support as well as machine downtime. This product can ease some of those expenses.

“Now, a 15-minute conversation might suffice instead of the lengthy and often frequent exchanges between the application engineers and new machine users,” he says. “The manufacturer’s engineer need only log-in through a secure access port to view the CNC screen and adjust parameters—all of this can be done live with the machine operator logged on as well.”

Labels: Machinery Tool

By Derek Korn

A different breed of turn-mill machine was recently introduced at EMO 2007 in Hannover. The UniCen 504 from Monforts combines turning and four-axis milling with integral laser hardening and laser welding in one workpiece setup. The machine platform enables shops to bring often-outsourced laser treatment in-house to reduce lead times, allow better control over secondary laser operations and offer improved flexibility to respond to changing customer needs.

The multipurpose UniCen machine, which is currently available in the United States from Sunbelt Machine, Inc., is the result of a German Federal Department of Education and Research (BMBF) project. It was developed by Monforts (Monchengladbach, Germany) in cooperation with partners including the Fraunhofer Institute for Production Technology, Laserline GmbH, Precitec KG, EXAPT GmbH and Sempell AG.
Integral laser units Integral laser units
Integral laser units on this turn-mill allow welding (shown at right) and/or hardening of workpieces in one setup.

The turn-mill machine can accept workpieces as long as 900 mm and offers maximum swing diameter over bed of 600 mm. In addition to its turning turret, the UniCen has a 12,000-rpm, B-axis spindle that provides ± 95 degrees of rotation for milling and drilling operations. The turn-mill’s two modular laser units—one for hardening and the other for welding—each install via HSK 63 interface into the B-axis spindle. This allows the laser units to be automatically removed from the spindle and stored outside the machining environment, protecting sensitive optical components from damage by coolant and chips during turning and milling operations.
The laser units have HSK interfaces and install in the B-axis machining spindle.
The laser units have HSK interfaces and install in the B-axis machining spindle. They are protectively located outside the machine when turning and milling operations are performed.

The laser welding unit can perform deposit welding and alloying at specific areas of a workpiece. This is often done to repair worn or damaged components—weld material is added and then the workpiece feature is machined back to original specifications. The coating unit contains the optics to form and guide the laser beam in addition to a welding wire feeder and a process sensor. A coaxial gas supply protects the focusing lens against contamination during the welding process. Laser-deposit welding is said to cause virtually no workpiece distortion, as the localized absorption of laser energy causes minimal heat induction.

The laser hardening unit performs case hardening of specific workpiece features that will encounter wear due to mating components, such as bearing journals, keyways and splines. The maximum hardening depth is 1.5 mm with almost no workpiece distortion. The unit can generate a variable laser spot as large as 20 mm by 50 mm on the workpiece. This is appropriate for quenched and tempered steel, cold- and hot-forming steel, high-speed steel, stainless steel and cast iron.

The machine’s high-power diode laser source delivers a beam through a guiding system to each laser unit. All the laser and machining processes are controlled by the machine’s central control system. The control units for the laser equipment are connected via a profibus interface to the machine’s control. The machine control includes a CAD/CAM module that offers an intuitive, user-friendly interface for programming multiple operations.

Labels: Machinery Tool

Two very different shops illustrate the potential value of software that works between the CAM software and the CNC.

By Jeff Werner
CGTech

Shops wishing to reduce their costs and increase efficiency often invest heavily in automation equipment and high-speed machinery. But what many shops fail to realize is that the savings they are looking for don't necessarily have to come from hardware used on the shop floor ...they can also come from software used in the office. A small amount of time spent at the computer to prepare NC tool paths properly and thoroughly before sending them to the shop can deliver big savings at the machine. One tool developed specifically for this preparation work is NC verification software.

Many shops now rely on verification software to prove-out their programs. The software can ensure the first part is a good part, so no operator has to stand by the machine to watch the first part run. Thus, dry runs and cutting test parts become a thing of the past.

In addition, verification software can offer automatic feed rate optimization features that can deliver several benefits. Cycle time, part quality and tool life can all improve as a result of more refined control over feed rate. A program with "optimized" feed rates may also make it easier for the operator to turn attention away from the machine.

Verification

NC verification software enables a programmer to check the integrity of tool path files before sending them to the shop floor to begin cutting metal. Not only does this reduce the possibility of an expensive machine crash, it also saves re-work during the prove-out cycle, and it often eliminates the physical prove-out process altogether. This can mean big savings in terms of materials, labor costs and machine hours, as various shops have discovered.

One such shop is Contour Aerospace (Everett, Washington), a manufacturer of components and subassemblies for aerospace applications. Before adding verification software to the production process, the manufacturing team at Contour had to cut a test part, lay it out and perform an inspection. If there were any problems, the shop would have to correct the NC program, cut another test part and re-inspect it before proceeding with production.



"On our large parts, this was very time consuming," says NC programming manager Dan Hornung. The company makes wing spars in the range of 20 to 40 feet long, and the freedom to prove out jobs for parts like these in the computer instead of in real life offers an important advantage.

A maker of big parts of a very different sort is Delaware Machinery & Tool (Muncie, Indiana). Delaware Machinery specializes in designing and building large die-cast molds used to make engine blocks and transmission cases. The company also has a reputation for using the latest manufacturing software technology. The first transmission dies for Ford, GM and Chrysler to be designed and built using CAD were provided by Delaware.

Today the shop's software toolkit includes verification software. "Checking tool paths at the computer has enabled us to reduce the number of shopfloor prove-outs and reduce redundancy," says CAM manager Dennis Main.

The software also helps streamline the programming process. It offers the capability to check for gouges by embedding the design model inside the virtual stock model. When the cutting tool contacts the design model within a user-specified tolerance range, an error is reported.

CGTech's Vericut is the software both shops use. Delaware's Mr. Main says, "After posting our code, we're able to run the G-code for an electrode job through Vericut and electronically check the cut-under for spark gap. We can intentionally cut the part to 0.020 ‘under,' then check the as-machined model against the CAD model to make sure that all areas have been cut into the graphite blank . . . and to verify that no areas of the electrode will cause an over-burn." This feature helps Delaware meet tight machining tolerance requirements.




Contour's Mr. Hornung sees similar advantages. "The constant gouge protection feature really started to pay off around the time we began manufacturing parts for the Boeing 777...because that's when the customer went to solid design models."

Optimization

For Delaware, it was when company director of engineering Dan Swartz sent an engineer to a verification software update course that the shop learned about feed rate optimization functionality available as an add-on module for the same software. That engineer returned excited about what he saw as a way to dramatically improve the company's machining process.

Screen Capture
Cutting test parts for wing spars 20 to 40 feet long used to consume significant labor and machine time at Contour Aerospace. Now, programs for wing spars like the one shown are proven out at the PC using verification software.

With the optimization function, the software reads NC tool path files and automatically adjusts the existing feed rates to more appropriate values based on cutting conditions and tool capacity. Machining with feed rates tailored to each individual cut increases machine tool efficiency, so parts take less time to cut. In machining graphite electrodes, Delaware's team calculated that feed rate optimization saves 30 percent in machine run time. "We've seen 45 percent in some cases," says Mr. Swartz.

Feed rate optimization works by reading the NC tool path file (G-code or APT format) and dividing motion into a number of smaller segments. Based on the amount of material removed in each segment, the software assigns the best feed rate for the cutting condition encountered. It then outputs a new tool path that is identical except for the feed rate setting. The tool path trajectory is unchanged.

This solution could be said to offer the best of both worlds. On one hand, the optimization is automatic and works before the NC program is ever loaded on the machine. On the other hand, it draws on the expertise of the NC programmer and machinist in the way it responds to specific cutting conditions. Users input ideal feed rates for a number of pre-determined machining conditions. Factors include machine tool capabilities such as horsepower, spindle type, rapid traverse speed, coolant and other characteristics; plus fixture and clamp rigidity; as well as cutting tool characteristics including material, design, length and number of teeth. These factors suggest the chip thickness, volume removal rate, entry feed rate and other parameters used to calculate the optimum feed rate for each segment of the cut.

Typically, different types of optimization techniques are best suited for different materials or machining processes. During planar roughing of aluminum structural components, for example, material is removed at a constant axial depth, but the radial width of cut varies greatly throughout the cycle. In an operation such as this, maintaining a constant volume removal rate keeps the cutter at its maximum rate of advance into material for the varying cut width. Employing the same information used to verify the tool path, the software is able to determine the amount of material removed in each toolpath segment. The software then assigns the appropriate feed rate based on information supplied by the NC programmer and/or machine tool operator.

A very different operation is semi-finishing or finishing a tool steel mold cavity. Here, the cutting is typically characterized by widely varying chip loads as the tool profiles over the contours of the workpiece. In order to achieve a constant chip load, feed rates are optimized based on the maximum chip thickness for each cut segment. The software takes into account where the material meets the cutter along its profile, and it adjusts the feed rate to keep chip thickness constant. This is especially critical when cutting with a ball end mill, or when contouring a surface with a small step-over. The feed rates continually change over the course of the cut in order to maintain the constant maximum chip thickness. The result is an improvement in both tool life and surface finish.

Milling Electrode
Using feed rate optimization to maintain a more constant chip load lets Delaware Machinery mill electrodes with delicate thin fins with less chance of breakage.

Engineers at Contour Aerospace were quick to see the benefits of machining with optimized tool path files. Mr. Hornung says, "We see a big savings in areas like pocketing routines." The optimization let the shop abandon a preference for conservative feed rates, he says. In addition, "Optimized feed rates provide a more constant spindle load—usually around 80 to 90 percent—and eliminate our reliance on manual feed rate changes to cut the pockets correctly."

The rear wing spars and ribs for the Gulfstream IV corporate jet are typical of the parts Contour manufactures. The company uses three-spindle, three-axis gantry machines with 30-hp spindles and 2-inch carbide insert cutters to rough the parts. The stock billet for the rear spar measured 480 inches and weighed 2,500 pounds before machining, but with 95 percent of the material removed during machining, the finished part weighed 128 pounds.

"On parts like this, we use the software to maintain a constant volume removal rate—in this case around 85 cubic inches per minute—to keep the spindle load where we want it," says Mr. Hornung. By optimizing the roughing passes on the part, Contour cut about 25 percent from the machining time. "That equates to saving thousands of dollars a year," he says.

Process Improvements

Software optimization not only speeds machining, but also helps make the entire manufacturing environment more efficient. Before optimizing tool paths, Delaware's graphite electrode machining department had not been able to take full advantage of its high speed milling machines, even those equipped with robust look-ahead capability. According to Mr. Main, those machines were "a bit ineffective when machining intricate or involved shapes." They tended to slow down in areas where the axes changed direction and not slow down in areas of heavy material removal, so manual feed rate adjustment at the machine was necessary. This required the shop to assign one operator per machine on each job. If the operator needed to leave the machine even for a short time, he had to "dial down" the feed rate until he returned.

The optimization software changed that. Now, when running optimized programs, operators are able to run two or more machines at a time. "It's really reduced our costs and increased our manpower productivity," says Mr. Swartz.

It can make for a "smarter" process, too. For example, Contour Aerospace's machines have a variety of controls. "The great thing about the optimization software is that it takes the particular control into account, so we're running the most efficient feeds for each individual machine/control combination," says Mr. Hornung.

In addition, most shops have at least one "resident expert" who knows the best feed rates to use for different machines, cutters, cutting conditions and types of material. Storing this information in the software creates a "machining database" available to everyone in the shop. This library of information can help the shop achieve more consistent machining results between different operators, machines and shifts. "We see a lot more consistency and all around better part quality with the optimized feed rates," says Delaware Machinery's Mr. Main.

In fact, the improvement in part quality is a major benefit to mold maker Delaware, because this shop is accustomed to devoting significant labor hours to polishing. With the optimization software, the shop has been able to eliminate this labor-intensive process. Driving the machine with a more constant chip load results in a smoother machined surface.

The tool often comes away looking better, too. "With the improved feed rates and constant chip load, our cutters are lasting longer and we're spending less time changing out tooling," says Mr. Main.

Contour Aerospace's Mr. Hornung agrees. By running optimized feed rates on the machine, he says, the shop is able to more accurately project how long tooling will last. Contour stops production less often to replace worn inserts.

Different Thinking

A good example of how Delaware Machinery benefits from optimizing tool paths came from a recent job for a small engine block containing many small cooling fins. "This isn't the type of job we necessarily specialize in, but we've done these before," says Mr. Swartz. "In the past, we really needed to be careful when machining and handling these electrodes because the fins can be broken easily." But this time, due to the more constant chip load and cutting pressure resulting from optimization, the shop had no problems with breakage. "The capability is helping us gain a new type of business," he says.

Contour Aerospace is also seeing improved part quality from the more targeted feed rates. "Because the feed rates are pre-determined by the optimization software, they run the same way each time, regardless of who is at the machine," says Mr. Hornung. "This supports our quality-based variability reduction and lean manufacturing efforts."

And the move to computer-optimized feed rates as an alternative to overriding feed rate manually has generally been accepted by programmers, operators and management alike, he says. "At first, some of them thought we were nuts. They're used to seeing the feed rate needle stay somewhat constant when we start cutting a part, usually around 80 ipm. With the optimized programs, the needle is jumping up and down from the very beginning." It was only after seeing the results that most were convinced, he says.

About the author: Jeff Werner is marketing communications manager for CGTech of Irvine, California.

Labels: Machinery Tool

Machine tools will continue to find their way into unexpected locations thanks not only to their shrinking sizes and prices, but also to their pairing with 3D scanning technology.

By Derek Korn

Machine tools are becoming smaller and less expensive. CAD/CAM software and 3D scanning technologies are becoming easier to use. As these trends continue, so too will the trend of machining work being performed outside of the traditional machine shop by non-machinists.

Machine tools will be used in hospitals and dental laboratories. They will be used in jewelry makers' shops. They will be used in upper levels of downtown office buildings without disrupting daily business activities.

One of the reasons that machining technology is becoming attractive outside the realm of the metalworking industry is that it offers a way to reduce or eliminate handwork. These often-time-consuming processes are common to components made for medical, dental and jewelry-making applications to name just a few. Another reason for their growing popularity is the chance to eliminate any disconnects or delays resulting from the separation of designer and machine shop. This is accomplished by allowing the part designer to quickly create a prototype on a machine tool located in the CAD department. For some manufacturers, the capability to machine one's own prototypes offers added assurance that proprietary concepts will be kept under wraps.

Smaller Sizes

The main obstacles to installing machine tools in a space such as an office have been the equipment's size and weight. Most machine tools are too heavy for a typical freight elevator to handle and too bulky to fit through a standard 36-inch-wide doorway. Haas Automation (Oxnard, California) is addressing these needs with its Office CNC mills and lathes. Sized to fit comfortably in an office, these machines can be moved with a pallet jack or equipment dolly. Alternately, casters can be installed on the machines for easy maneuverability. These machines operate on 240-volt single-phase power, which any facility should be able to accommodate without much trouble.
Prediction:
The number of machine tools operated by non-machinists outside the machine shop will increase.

According to Dave Hayes, Haas product manager, the Office machines are likely to find themselves in a variety of places where very small parts machining capability is needed. One non-traditional industry where these machines are likely to nest is the jewelry business. A jewelry designer can machine the bulk of a new product's general shape into a wax mold, leaving only fine details to be finished by hand. Another possibility would be to bypass the casting process and machine the actual piece of jewelry from stock. Rings, for example, might be turned on a lathe and then taken to a mill to machine the final details. The goal here is to reduce or eliminate the amount of hand carving in the creation of new jewelry.

A manufacturer or shop that is currently using machine tools to create its parts may also use such very small machines to take prototype machining off of the shop floor and into the CAD department. The result could mean quicker new product development and speedier time to market.
shrinking size of some CNC machine tools
The shrinking size of some CNC machine tools will allow them to be located in a variety of non-traditional locations.

Scanning, Then Milling

The union of machine tools and 3D scanning capability is a marriage of technologies that is driving machining operations to atypical locations, often for rapid prototyping and one-off work. Hospitals and dental laboratories are two of these locations. The ability to directly machine a body part or dental profile, or to create a mold for such parts from a patient's scanned 3D feature, greatly speeds the generation of these unique parts.

For some, the term "rapid prototyping" is synonymous with additive-material processes, such as stereolithography. Subtractive processes, on the other hand, can be just as effective in generating a prototype post-haste and may even be able to produce it in the part's specified material. Such is the case with what Roland DGA Corporation (Irvine, California) calls the subtractive rapid prototyping (SRP) process, which combines a benchtop 3D scanning system with a benchtop milling machine. Among other applications, this system is being used in medical labs by anaplastologists who create prostheses for facial reconstruction. The capability to quickly mill the basic form of a patient's prosthesis allows anaplastologists to focus their clinical energy on the final details that make the prostheses look as realistic as possible. In the case of ear reconstruction, for example, a plaster cast of a patient's good ear can be scanned, mirrored and then milled for reconstructing the damaged ear.

Similar milling/scanning systems are being used to create inlays, crowns, bridges and other dental components. These systems are used in dental labs to scan a patient's damaged tooth, then design the part to fit precisely and mill the actual profile from ceramic or other dental material.
3D scanning technology and CNC milling
The combination of 3D scanning technology and CNC milling is helping push machine tools into a variety of atypical locations. This benchtop device is capable of scanning and milling parts.

Scanning capability will send machining work to even more unlikely places. These systems would be appropriate for developing new toys, sculptures and a variety of other artistic pieces. For example, one scanning/milling system was used to help create the infamous black mask worn by Darth Vader in "Star Wars Episode III: Revenge of the Sith."

The CAD/CAM developers are helping bridge the gap between artists and machine tools, as well. A number of these companies offer artistic software that can allow users to turn a 2D drawing or sketch into a 3D piece of artwork, and then the software will generate the appropriate tool paths. Software geared specifically to the jewelry-making industry is also becoming available.

Take Away

Shops should take note of these new machining opportunities, but not necessarily because said shops should consider delving into these niche areas and producing their own product lines. What this trend should reinforce in shops is the concept of continuing to offer their customers more than a part completed on spec and on time. These offerings may be in the form of component assembly, combined machining and fabrication under one roof, successful management of a lean supermarket—whatever it takes to give customers more than they thought they needed from a single vendor.

Labels: Machinery Tool

Overview and Trends

Textile industry in India is considered as a pioneer industry, as India's industrializations in other fields have succeeded through the resources generated by textile industry. Though, from the early 1970s to the beginning of liberalization in 1992, the industry tended to be isolated as measures taken by the Government (with the apparent objective of protecting the cotton growers, the large labor force and the consumers) have constantly eroded its prosperity.

World over, the Indian textile industry is considered as the second largest industry. It has the biggest cotton acreage of 9 million hectares and is considered as the third largest producer of this fiber. In terms of staple fiber production it comes fourth and sixth for filament yarn production. The country reports about one fourth of global trade in cotton yarn.

With over 15 million people employment, the textile industry accounted for 20 percent of its industrial production. Covering textiles and garments, thirty percent of India's export comes from this sector, in terms of exports it is the largest contributors for the growth of Indian economy. In spite of high capital and power cost, the Indian textile and garment sector's strength comes from the availability of cotton, lower labor costs, well skilled supervisory staff and plentiful technical and managerial skills.

Although very few countries are endowed with such resources, today's globalization has brought new opportunities for the India textile industry. Concurrently, it is exposed to threats, particularly from cheap imported fabrics. Thus, India has to fight for her share in the international textile trade. Even if it is assumed that WTO will mean better distribution of the world trade, the benefits for India will not be any different than for the other developing countries. The Indian textile industry would, therefore, have to not only rely on its strengths but should also endeavor to remove its weakness.

India's apparel exporters, though, have been employing various strategies to make sure that they remain competitive in the liberalized trading environment of 2005 and beyond. Many manufacturers are taking action for improving production efficiency through advanced automation system, re-engineering of production systems, merging separate production units and backward and forward integration of operations and are keen to expand their production capacity in anticipation of enhanced demand in 2005 and beyond Among other manufacture are seeking changes through diversifying their product ranges, exporting high value apparel and improving their design capabilities and some of are planning to raise added value by setting up joint ventures with foreign firms, to take benefit of their technical, design and marketing proficiency. Others are making relationships with foreign buyers to increase their marketing capability.

Support has also arrived from the Indian government in the removal of restrictions on investment by large companies and foreign investors. The Government has also provided assistance to expand the infrastructure for exporters and has given incentives for techno-logical up-gradation. Though, most important restriction is the inflexibility in labor laws, which cause it hard for large firms to cut their workforces when require.

Textile industry in tenth plan

The Tenth Five Year Plan of India (2002-2007) forecasted a GDP growth rate of 8 percent for which an industrial growth of 10 percent is predicted.

The aim of the Tenth Plan is to facilitate the textile and apparel industry to:

. Develop world class state-of the-art production facility to accomplish and maintain a leading global position in production and export of textiles and clothing.

. Withstand demands of import penetration and uphold a dominant existence in the domestic market.

. To accomplish these aims heavy funds are needed in technology and modernization in critical areas particularly in spinning, weaving, knitting, finishing and apparel sectors.

. The technology up-gradation scheme (TUFS) introduced in 1999 intended to make investments component attractive. This scheme has been established to promote modernization and technology up-gradation in the specified sectors of textile and jute industries.

. The Government of India has also declared the National Textile Policy-2000 to expand a sound and vibrant textile industry. The objectives and plunged areas of the national textile policy cover technology up-gradation, enhancement of productivity, quality consciousness, product diversification and so on.

Schemes to strengthen investment in textiles during the Tenth Plan cover:

Rearranging spinning capacity

At present nearly 38 million spindles are already existed. About 10 million old spindles required to be scrapped, and another 15 million spindles to be modernized. Adding on, about 3 million new spindles have to be set up during the Tenth Plan period.

Loomage

The decentralized power loom sector, which reported 68 percent share of the cloth in the country, is in very strong and immediate need of renovation. The textile package declared in the Central Government included renovation of the weaving sector with 2.50 lakhs semi-automatic/automatic shuttle looms and 50,000 shuttleless looms.

Finishing

There are nearly 2324 precessing establishments in the country of which 83 belong to composite units, 165 to semi composite and others 2076 are self-governing processing houses. Among of 227 establishments are modern, 1775 are of medium technology and 322 are obsolete establishments. Reconstruction of finishing units will need a huge financial expenditure.

Schemes for expansion and development of the knitting sector, technical textiles, and woolen and jute industries are to be considered. The textile Engineering Industry is to be encouraged to modernize and offer state-of-the-art technology to the textile industry and through focused textile machinery R&D efforts, domestic reaches and development are to be initiated.

Growth in the textile machinery

Due to high investments on renovation of plant and machinery in the textile manufacturing industry, the manufacturing of textile machinery, their parts and accessories rose last fiscal by 25 percent to Rs 1,668 crore from Rs 1,341 crore in the previous fiscal.

According to the Textile Machinery Manufacturers' Association of India (TMMAI), the industry also witnessed its capacity of consumption at 55 percent during the year.

But, on the other hand the total projected demand of Rs 4,200 crore of the textile industry, a major contribution was satisfied through imports. This has identified for an urgent requirement on the part of both the user-textile industry and the textile engineering industry (TEI) to start a joint assessment to reverse this movement, said the outgoing Chairman of TMMAI, Sanjay Jayavartanavelu.

On the event of the 45th annual general meeting of Textile Machinery Manufacturers' Association of India, Jayavartanavelu said the surge in demand for textile machinery has initiated the TEI to make production capacity bigger to satisfy the increasing demand, particularly in the spinning machinery sector. The units in the industry were dynamic to step up production to cut down the delivery period.

This is regardless of the truth that they had to compete with longer delivery schedules from main machinery suppliers. In spite of this, the TEI should make an effort to satisfy the demand in volume/quality and performance with effective after sales service.

The TMMAI Chairman felt amendment in fiscal policy and elimination of hurdles being faced by the TEI required to be effected to make the indigenous textile machinery sector gain strength and scale up its technology and export competitiveness. The areas of fiscal modification needed are letting down the rate of excise duty on textile machinery from 16 percent to the merit rate of 8 percent, continuation of the relaxation in excise duty, which should be extended to inputs required for making of specified textile machines.

The intermediate products required in producing textile machinery as well as spares should be put at four percent excise duty subject to actual-user stipulation. At the same time, the present customs duty concessions on specified machines must be detached and one common rate of import duty of 10 per cent should be charged for all textile machines.

The TMMAI Chairman also emphasize the requirement for early creation of a Rs 2,500-crore development fund for TEI to facilitate the units to use on R&D, infrastructure building, export promotion and plans on environmental protection.

Recent developments in technology

In the international textile and clothing trade, the elimination of decades old quota system has thrown up new challenges as well as unlocks new prospects for the Indian textile industry.

According to the vision statement made by the ICMF for the textile sector, by 2010 the Indian textile industry has the potential to have the market size of worth of $ 85 billion from the present size of $ 36 billion. This development can be gained by the opening of new domestic as well as export segments. Textile export could arrive at $ 40 billions mark by 2010 from current 12 billion dollar level. Result on export side can be measured satisfactory during the last six months. For receiving the prospective business, the textile industry has to move towards value added products. The most value addition in textile segment is created by the apparel segment. Processing, fabric manufacturing and spinning segments in order to make quality apparels will require up-gradation

During last decade, there has been observed fast progress in machinery/technology. A concise representation of modern developments in a range of areas is given below.

Spinning

Manufacturing facility in blowroom line has enhanced to 800 kg/hr with a prerequisite to work 3 mixings all together. To process broad range of cottons, the latest blowroom is provided with automatic bale opener with integrated mixer and cleaning systems. For the latest carding machine as a substitute of one licker-in, multiple licker-ins is built-in serially. And provide more stationary flats. For feed roll, doffer, web doffing, maintenance free digital drives are used. The whole card clothing can be separated with a less function of operation. For full flange of operation, a variety of systems like NEP control, flat control and waste control etc., are integrated.

For modern draw-frame machine, delivery speed up to 1000 mt/minute made possible with an alternative of automatic draft control mechanism which gives out requirement for gear change for controlling draft and delivery speed. In few machines separate deliveries can be restricted without help. Supplier also offers draw frame which can be connected to carding machine. It is stated that owing to digital autoleveller the precision measurement is in its height on an average one meter CV of sliver can be controlled below 0.4 percent.

Combers speed up to 400 nips/min is possible due to technological advancement. From latest comber up to 1.3 tones/day productions is achieved. Touch screens display system also provided with these machines. The display covers production data, process setting, machine parameters setting and fault message display. To save installation time many machines are provided with fully assembled in four modules.

Latest speed frame are offered in atomization system including all the operations. All the functional set ups can be fitted on electronic panel. Bobbin size 6" x 16" or 7" x 16" can be available. There is an availability of alternative of manual or auto doffing. Machines are provided upto 160 spindles capacity hence considerable saving in the operational cost possible.

In the latest ring spinning system winding geometries are further give to maximize result with less winding tension. Hence, superior draft up to 80 are received with higher spindle speed (above 20000 rpm). A number of other features of modern ring frames are adopted with inverter drive for spindles, independent spindle ring rail and drafting system drives, fast doffing system with no trailing ends. Ring frame up to 1344 spindles are provided. In presents rotor spinning system, diverse yarn can be spun in several part of the machine. It is feasible to get package of changeable density. All the technical factors and machine adjustment can be controlled by computer. In the latest rotor machine it is viable to make a package with 30% higher package density than old rotor machine.

In the latest winding machine path of ring cop from bottom to winding head is further developed. Hence, superior control of winding tension produces lower augmentation in hairiness. The adaptable knotting cycle combined with tailored acceleration dynamics facilitates to alter production system. The immediate controlled cylinder inverter and suction motor inverter are provided for energy conservation. Modern vortex spinning system is available to spin cotton yarn at a speed of 400 mt/min. The technology was previously applied for spinning synthetic blended yarn only.

The latest DREF spinning system can make numerous kinds of multi-component yarns. The drafting unit can manage all kinds of synthetic fibers such as aramid, preoxidised fiber, polyamide, phenol resin fibers and melamine fibers. The machine is able to perform with several cores. The manufacturing facility is achieved as high as 250 mtr/min and fineness of yarn can be from 0.5 to 25 nm.

Weaving The important aspects of modern weaving preparatory/ weaving machines are reviewed as under:

Machinery producers of both weaving preparatory and weaving machines have received gain in technological aspects to make fault free fabric for the garment sector. Nearly all the machines are provided with electronic control panels and micro-processors controls which monitors and control the machine utility to satisfy the fabric quality need and modification in design styles.

Maintenance of machine has turn out to be stress-free due to proficient lubrication system and improved machine design and substitution of mechanical tools with electronic control system. There is an obvious progress to resource the components and auxiliary equipment from the selected good manufacturers rather than making themselves, hence decreasing the cost of the machines. In latest rapier looms weft insertion rate ranges from 1200 - 1500 mt/min. Many looms are provided with weaving a broad range of fabrics. In many weaving machines weft insertion rate is achieved at higher and ranges from 1800-2500 mt/min.

Latest sizing machine is provided with uniform size pick up facility across the warp sheet and for least amount hairiness and loss in elongation. These are maintained by temperature control and moisture control devices. Squeeze pressure can be maintained by programmable controller to synchronize the compressing at all the speeds. Stretch monitoring instrument is imparted to control the stretch.

Knitting

In recent times the quality requirements imposed on a knitting factory by its customer have become even more precise due to greater emphasis on the reproducibility in case of repeat order. Typically a modern knitting machine has following features as:

Automatic computation of fabric reduces speed, feeders per course, stitch/cm and elongation

Automatically managed thread infeed by inflowing the needed thread infeed per cm

Automatic management of height modification through computer

Automatic supervision of yarn infeed and yarn tension

Through user friendly software, computer helps to make the goods on the selected pattern

Processing

New generation processing machine incorporates microprocessor controls. Various process parameters can be programmed in microprocessor for strict adherence of processing conditions. Apart from good control, machines are also energy efficient and features are incorporated for the reduction of consumption of chemicals, water and steam etc. The developments are also taking place keeping environment requirement and eco-friendly processing while manufacturing the textile products and safer conditions for those involved in the manufacturing.

Process control or quality control

In the area of cotton testing, latest instruments are mostly available as High Volume Instruments (HVI) and are prepared with automatic sampling. They also evaluate short fiber content and maturity index values besides testing of length, strength and fineness parameters. It is stated that maturity values are fairly precise. Instruments are also provided with test color, trash neps and fluorescence values. Few suppliers are offering bale management systems.

For the manmade fibers and its connected instruments offered with the measurement in denier, tenacity, elongation and crimp properties. From the creel, robotic arm can carry the fiber samples automatically.

In the part yarn quality, latest evenness tester can measure, evenness, imperfection and intermittent errors at a greater speed. Many of them instruments are prepared to measure hairiness, diameter variation, shape, and dust as well as trash contents. Single thread strength testing machine are provided with a testing speed of 400 mt/min. The machine is prepared to take out 30000 tests per hour. It is noted that weaving operation of the yarn can be expected advanced with this machine. Some of the single thread strength machines are fitted with automatic yarn count determination device.

Yarn fault classification device has shifted to the winding machine from the laboratory. Data of entire yarn lot can be readable from the winding machines. Electronic check Board can perform the yarn grading, based on yarn output and observed by applying CCD camera and software to measure yarn report. Instrument can also offer fabric simulations if needed.

In fabric testing, automatic fabric inspection device can examine grey and single cotton dyed fabrics for all materials covering air bag fabrics and glass fiber fabrics. The imperfection can be recovered from their reports and images. In the area of process control and management ERP systems are establish which supply 3-tier solution covering the online data acquisition, offline data entry cum reporting device and intelligent business management device.

Conclusion

Today, Indian industry is extremely fragmented. In the organized spinning sector there are nearly 2300 players with 280 composite mills, There are 1000 weaving units and around 1,45,000 independent processing units and innumerable garment makers. The position of machinery technology is not well apart from the spinning sector. Nearly 100000 modern shuttleless looms are needed to set up and to satisfy the target by 2010. Processing sector will also require big amount of up-gradation. It is calculated that a total investment of 35 billion dollar might be needed to achieve the growth intended by ICMF.

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Labels: Machinery Tool

If you are truly passionate about your lawn and garden then you have probably either seriously considered a hedge trimmer or are the proud owner of one. Hedge trimmers are great for trimming hedges as their name would imply, they operate by creating nice clean cuts that do not shred the plant your are trimming.

That being said, hedge trimmers are not toys and can be quite dangerous. There are however several steps you can take, however, to make your use of this tool as safe as possible.

1) Make sure your hedge trimmer is lightweight enough for you to hold it for expended periods of time? Dropping is not a risk you want to take, nor is damaging your back. You want to be able to safely operate and support the hedge trimmer you choose. It will not be good for anyone if no one in your family can operate it.

2) Make sure your fingers, or anyone else’s that will be operating this piece of machinery, cannot fit between the cutting teeth and the guards.

3) Make sure that the blades are sharpened properly and well before each use. Sharper blades make cleaner cuts, which leaves a smaller opportunity for catches and tears and other things that can go wrong.

4) Read the manual for extra precautions you may need to take with your particular tool. This is self-explanatory and yet most people never bother reading the manual. This is an important step that could save someone’s life or in the very least, someone’s limb.

5) Wear adequate protection for your eyes and ears.

6) Never trim above your head. This is another tip that should never need to be explained and yet people are injured doing exactly this all the time. If you need to trim high, get a ladder and climb to the height you need to be in order to operate your machinery properly.

These steps are just a few safety tips for the proper and safe use of hedge trimmers. Reading the manual is always a good idea and will be an excellent source of information for further safety procedures you should keep in mind.

John Gibb is the owner of Hedge Trimmers sources, For more information on Hedge Trimmers please check out http://hedge-trimmers-advice.info

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Labels: Machinery Tool

In various industrial settings and woodworking shops CNC machines are used. For personal use nearly all are out of the price range. But it can be purchased second-hand for about half the cost. When doing large jobs or repetitive tasks these machines are just perfect in case of speed and accuracy.

Usability

In various industrial settings, manufacturing processes and woodworking shops CNC equipment is used. To drill holes CNC routers are used. A number of machines have the capacity of holding several apparatus. Thus at a time they make more than one function and save time and offer accurateness.

Computer Numerated Control is the full name of CNC. In the 1970s this technology was introduced. Before operation the machines require to be programmed and arranged appropriately. When the primary set up is finished, they are quite easy to activate and go on operation.

CNC routers can be arranged to drill holes in an automatic manner. In comparison to manual drilling this is faster and more perfect over a number of pieces and the outcome is more consistent. For larger jobs this technique is very helpful where a lot of drilling is required. Physical drilling can become exhausting and when the machinist becomes tired, the outcome can become conflicting.

Various types

For cutting wood a CNC lathe is an excellent piece of apparatus. Different ranges from 15 to 40 horsepower of different models can be found in the market. You will use the amount of power according to the amount of wood you will be using with the lathe machine. Top quality models operate in several different modes, from entirely manual to all CNC lathe and lets you tailor the machine's operations for every function.

In milling technology a Bridgeport mill is the top. In many industries both large and small shops, mills are used. These are proficient and dependable. They are built to last a life span though they are very costly. It is so out of range that most people cannot afford a milling machine.

In milling technology the CNC mill is a specialty piece of apparatus. To provide accurate function it uses computer programming and robotics and the results are more perfect than any individual could ever do. Thus, Bridgeport mills are often used in the airline engineering. Once you enter the specs, it's up to the CNC to decide the particular tools that will be needed and it will also change the tools automatically when needed.

If you want a better option, you should look for renovated apparatus. Machines that are inspected at the factory, replaced if any part is broken. The machine is also painted and new decals are even applied in many cases. Thus you can get a new machine in a much low-cost. Also you may get a one year warranty with repaired apparatus which will make you sure that it is functioning accurately and if not, you will have it fixed at no cost.

Greg Hansward's long articles are published on a variety of websites related to woodworking tools and cnc machinery. His writings on cnc machines and tools are found on http://www.insidewoodworking.com

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Labels: Machinery Tool

Regardless of whether your work is in wood or metal, setting up a workshop is an easy task when you have a supplier that can provide you with Jet power tools. These high quality woodworking and metalworking tools can be found at more than nine thousand dealers throughout the world.

Jet power tools are made from a collection of the finest materials and technology world-wide. These tools are manufactured in places where engineers have fine-tuned the craft of tool making and designed the tools to support them. One of the qualities specific to Jet power tools is that they offer the accessories that are most useful to that particular tool. For instance, power saws are supported by accessories such as the Cyclone Dust Collector and Parallel clamps, which both make working with the saw easier and more efficient. These power tools are backed by warranties on each product and authorized distributors of jet tools also stand behind this warranty. All tools can be serviced and maintained at authorized jet service centers throughout the world. If you need a part, it will be available to you since replacement parts are well stocked with more than three million dollars in parts in stock at all times.

Jet has receipt many prestigious awards within the power tool industry, but these awards are not won easily. All tools within a certain category, world-wide and at all price levels are ranked and compared. Woodworking magazines have consistently rated Jet tools as the finest power tools on the market.

Not only does Jet offer the highest quality tools, it also offers the widest variety of power tools. Jet’s lathe, table saw and long bed jointer are some of the most convenient woodworking tools Jet manufactures. The portable horizontal band saw is one of the more special items from Jet. The lightweight series of saws are great for projects carried out in a location other than the workshop, since they are small yet capable of a lot. The blades can be adjusted from forty-five to sixty degree angles which are great for miter cuts. The bi-metal blade is durable and able to handle jobs normally requiring larger saws. Further, the optional floor stand instantly turns this saw into a multi-functional table saw.

To get the most from Jet’s portable saws, tools and other machinery, Jet has created training videos presenting all of its top products. The training series is known as the “Shopclass Series.” WMH Tool Group or specific Jet product distributors should be able to provide you with a list of titles to help you complete any project.

Leroy Calstard continually makes summaries on topics similar to automotive tools and portable power tools. His publications on jet power tools are found on http://www.insidewoodworking.com and also other web publications.

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Labels: Machinery Tool

The wire EDM manufacturing business is becoming popular, as the system has provided a significant growth in manufacturing sector. The rising demand for the wire EDM has attracted many big entrepreneurs in the business. It facilitates the achievement of the desired speed in machine cutting.

Companies in China and Taiwan are leading the race in the business. One of them is Accutex Technologies Co. Ltd., from Taiwan that holds a good reputation in the industry. Accutex Technologies are manufactures of quality precision CNC machine tools, CNC wire cutting machines type submarines, flushing type cutting machines, EDM machines, wire EDM machining, wire cut EDM and CNC machines. It has worldwide export markets with annual sales of $ 2,000,000. The company favors USD as the currency in transactions.

Oscar EDM Company Ltd is another leading company from Taiwan that specializes in the manufacturing of EDM drilling machines, EDM machining, wire EDM machining, wire cut EDM, electrical discharge machines, CNC EDM, CNC wire EDM machinery and spark erosion.

Similarly Ocean Techologies Co., Ltd is another Taiwan company with worldwide exports in Wire EDM. Ocean Techologies is also well known for supplies in ceramic guide, electrode tubes, instrument equipments and spare parts.

Shenzhen Joint Industry Co., Ltd is one of leading manufacturers in wire EDM from China. The company manufactures CNC machinery & equipment, including milling machinery, electrical discharge machines, central machinery, grinders, bench grifers, roll grinders and EDM machines. Ocean Techologies has also acquired an ISO 9001: 2000 quality management international standard in 2003.

Mainly all wire EDM manufacturers prefer USD as currency and make shipments in accordance with the FOB trade terms. The rising demand of wire EDM and the increasing number of manufacturers has developed a healthy competition, which has resulted in production of better Wire EDM machines at low prices.

Wire EDM provides detailed information on Wire EDM, Wire EDM Machining, Wire EDM Machines, Used Wire EDM and more. Wire EDM is affiliated with Shock And Vibration Testing.

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Labels: Machinery Tool

The mini CNC machine gives the manufacturer a way to reduce cycle time. The mini CNC machine helps the manufacturer to avoid a long void between the end of one operation and the start of the next operation. The manufacturer who decides to purchase a mini CNC machine has chosen to apply the principles of cycle time to the area of production machinery.

The nature of the mini CNC machine creates three ways by which miniaturization can pave the way for cycle time reduction. This article will list three ways by which a manufacturer can reduce cycle time. It will also provide details concerning how the mini CNC machine permits the manufacturer to apply the principles of cycle time reduction to the operation of the mini CNC machine, and ultimately to the process of machine production.

The effort to reduce the manufacturers cycle time begins with an attempt to minimize the amount of time that operators spend loading and unloading various materials. The operator of a CNC machine will work more efficiently if he or she is able to minimize the workplace loading and unloading. This minimization is achieved through use of the mini CNC machine.

The operator of the mini CNC machine can save time by using large bed sizes and a small footprint. The operator of a mini CNC machine will save money by loading into the machine a wide piece of material and then limiting each process (cutting, engraving, routing, and drilling) to a small footprint.

The operator of a CNC-based piece of equipment can reduce cycle time by reducing the tool maintenance time. Such a reduction is made possible by the mini CNC machine. The small size of the miniaturized machines facilitates the creation of multiple design options. The large number of options leads to creation of a generous number of spare parts. Meanwhile the surplus of spare parts guarantees the ready replacement of any malfunctioning parts.

The operator of a mini CNC machine also reduces cycle time by decreasing the program execution time. The clamping of small elements to the mini CNC machine and the automation of the tiny machine parts leads to a lowering of operator intervention. Whenever operators can afford to devote less time to matching the quality of a previous result, then the manufacturer saves money.

It thus becomes obvious that the characteristics of the mini CNC machine guarantee the application by the operator of the principles of cycle time. Three aspects of any CNC program fall under the control of the product manufacturer.

1) The time required for workplace equipment to accomplish the loading and unloading of the material that requires a transformation (a cutting, drilling, routing or engraving),
2) The length of the program execution time,
3) The length of the tool maintenance time.

The ability of a mini CNC machine to substantially alter any of the above three aspects could lead to a reduction in cycle time. A reduction in cycle time could improve performance of the process machinery.

Peter Vermeeren is the owner and webmaster of: Machines and Tools - Airsoft GOT | Tactical Gear - Kamikaze Martial Arts.

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Labels: Machinery Tool