American Machinist articles from July 2005

American Machinist archives from July 2005

Americanmachinist.com.
July 1, 2005... AMERICAN MACHINIST is pleased to announce the re-launch of americanmachinist.com. The site is faster, easier to navigate, and has more information than ever before. Check out these website exclusives... Jesse James shoots from the hip...

Bookmark this site.(from the editor)
July 1, 2005... Anyone searching for information on-line knows how frustrating it sometimes is to find what you need. Go to Google and type in turning, and you'll see what I mean. But finding information about metalworking has just gotten a lot easier. ...

More letters on May editorial.(we've got mail)(Letter to the Editor)
July 1, 2005... I read your May editorial ("Decreasing the fuel tax to reduce gas prices," p. 8) and understand the ludicrousness of pumping money--and oil--to Iraq. We should emphasize and reward oil-usage reduction instead of crying for more subsidies on the...

Other issues clouding view.(we've got mail)(Letter to the Editor)
July 1, 2005... I read your April editorial ("Let's get happy," p. 8) and have to ask why anyone has not considered a reduction in healthcare costs? I believe this would make workers happy. We are occupied by issues that do not address the quality of life at...

U.S. automakers' downfall mirrors machine tool business.(we've got mail)(Letter to the Editor)
July 1, 2005... read your March editorial (Big Three automakers strike out, p. 8) and believe we are witnessing what has occurred within the machine tool business. I watched as a business I worked for went from being one of the largest machine tool producers...

Americans losing voice to enact change.(we've got mail)(Letter to the Editor)
July 1, 2005... In his response published in February to your editorial about complacency ("We've got mail," p. 11), Paul Stanuch is right when he says that Americans should buy U.S.-made goods and support their economy. Unfortunately, there is a flaw in using...

Corrections.(we've got mail)(Correction Notice)
July 1, 2005... Roger J. Sustar of Fredon Corp. in Mentor, Ohio, did not receive credit for his "We've got mail" letter (June, p. 10). "Toolholding eases dental-chair production pains" (April, p. 42), incorrectly identified the company that increased...

Swiss show off extreme turning precision.(technology trends)
July 1, 2005... Two new turning machines made their world debut at a special exhibition hosted by Tornos SA, Moutier, Switzerland. The company invited a select group of end users, distributors, and international press to the world premiere of the MultiDeco...

Shop ensures a clean environment for medical work.(technology trends)
July 1, 2005... Shop cleanliness is important for manufacturers dealing with high-precision machining of components for the medical industry. Just ask Brian Rosenkranz, vice president of Marox Corp., Holyoke, Mass. His company adheres to strict environmental...

Machine tool consumption continues to climb.(technology trends)
July 1, 2005... Manufacturers continue to invest in metalworking equipment, according to the recent machine tool consumption report released by AMT--The Association For Manufacturing Technology and the American Machine Tool Distributors Association. ...

Prophecy plans.(technology trends)
July 1, 2005... With future upgrades to GE Fanuc Automation Americas Inc.'s Proficy automation and production software family, shops will manage real-time operations on one standardized manufacturing IT platform. The platform's scalability will cover...

Toolholders for MQL.(cutting tool digest: Tooling and workholding)
July 1, 2005... The modified internal design of Schunk's Tendo hydraulic toolholders resembles a spray-nozzle system without pockets or "dead areas" and reduces coolant consumption to 0.01 gallon/hr. The minimum quantity lubrication (MQL) coolant-air mixture...

Customized miniturrets.(cutting tool digest: Tooling and workholding)
July 1, 2005... Multitask miniturrets with CoroTurn SL adaptor plates, cutting heads, and blades are for turning and grooving. Four cutting heads integrate into one toolholder for internal and external use to reduce tool-change time and maximize tool-magazine...

U.S. cutting tool institute billings index.(cutting tool digest: Tooling and workholding)
July 1, 2005... Index for March '04-February '05 March $154,823,146 145.4% April $142,985,844 134.7% May $135,776,786 127.8% June $150,760,547 141.2% July $136,045,837 126.8% August ...

China trade troubles: more than just currency.(government matters)
July 1, 2005... National security concerns always trump economic concerns. In 2004, the bilateral U.S. trade deficit with China totaled $162 billion. If economics were driving policy in the U.S. Government, every effort would be made to diminish that trade...

Designed for accuracy and built for productivity.(machine of the month)
July 1, 2005... Introduced at Eastec 2005 by Charmilles, Lincolnshire, Ill., the Robofil 2050TW dual-wire EDM works with two spools of wire and delivers both high accuracy and productivity in one package. To ensure high productivity levels, the 2050TW accepts...

Insurance doesn't cover replacing nonconforming product.(law & liability)
July 1, 2005... On Feb. 23, 2003, Die-Cutting Diversified Inc., a Missouri corporation with a die-cutting plant in St. Louis, made a retail display for Color Art Inc. However, the product produced did not conform to Color Art's instructions. So Die-Cutting...

Termination a 'procedural,' not 'substantive,' contract violation.(law & liability)
July 1, 2005... Preussag International Steel Corp. (PISC), an American subsidiary of a German conglomerate, hired Reiner Botterbusch in 1981 as its president and CEO. A written employment contract with the company dated Jan. 1, 1986, designated Botterbusch as...

Machining beautiful music: without today's CNC technology, a well-known company couldn't manufacture its guitars.(recreational manufacturing)
July 1, 2005... Bob Taylor stuck his neck out, so to speak, when he presented to the music world his first attempt at guitar making. He mistakenly carved his guitar's neck too thin, and because he lacked dovetailing skills, he simply bolted the neck to the...

Ideal software: designers quickly develop ideas and accurately convey them to engineers.(recreational manufacturing)
July 1, 2005... Consumers often make product choices based on aesthetics, gravitating toward the "look" or "feel" of an item. Such purchasing habits force manufacturers to constantly revamp, improve, or just make their products different to stay competitive....

Little cars are big business: a manufacturer of parts for radio-controlled cars revs up production to meet the demands of hardcore racers.(recreational manufacturing)(Cover Story)
July 1, 2005... Radio-controlled (R/C) cars aren't child's play to Eustace Moore, president of Moore's Ideal Products, Covina, Calif. His company started as a one-man operation making aftermarket hop-up parts for R/C cars and has become a leading producer for...

Machines power engine building.(case books)
July 1, 2005... High-performance motorcycle-engine builder R&R Cycle in Manchester, N.H., differentiates its product by being the only manufacturer in the country producing full-billet engines. While these engines result in superior performance as compared to...

Software slices golf-club manufacturing time.(case book)
July 1, 2005... Today's clubs combine golf aesthetics with practical features for controlled and long-distance play. Such a combination involves complicated mold shapes made to exacting accuracies, which is why Dynamic, a Taiwanese golf-club manufacturer,...

PLM picks up design time.(case book)
July 1, 2005... Nissan Rally Raid's design team accelerates its racing pickup-truck development using PLM software that seamlessly integrates design and analysis for quick computer simulations (structural analysis). By modeling and evaluating different pickup...

Shop taps into fluid solution.(case book)
July 1, 2005... Fairris Dean, machining division manager at Ward Corp., a Fort Wayne supplier of aluminum parts and components to marine, motorcycle, recreational equipment, and other industries, couldn't figure out what was causing a persistent and erratic...

Washer for large parts.(SPOTLIGHT: PARTS WASHING)
July 1, 2005... The Cuda 2518 top-loading, automatic parts washer from C-Tech Industries is large enough to clean transmission bells and other big parts. Its wash cabinet is 18-m. high with a rotating turntable 25 in. in diameter. Like other Cuda washers, the...

Bioremediation part washers.(SPOTLIGHT: PARTS WASHING)
July 1, 2005... GrayMills Corp.'s Bio436 and Bio536 bioremediation part cleaners are made of high-density polypropylene with solid-state electronic controls. A 300-gallon/hr pump delivers heated, aqueous, pH-neutral, nonhazardous cleaning solution through a...

Washer for lean manufacturing.(SPOTLIGHT: PARTS WASHING)
July 1, 2005... For use in lean or cellular manufacturing processes, Ransohoff Inc.'s Lean-Jet RB-2 aqueous parts-cleaning system handles individual parts or multiple parts in a basket. It features multistage rotational cleaning, rinsing, and drying in a...

Clean cylinder heads.(SPOTLIGHT: PARTS WASHING)
July 1, 2005... Sugino Corp.'s 1,015-psi U-Jet III water-washing system cleans up to six sides of complex components such as machined aluminum cylinder heads, cylinder blocks, and hydraulic manifolds. Its triplex pump delivers 13 gallons/min at sonic...

VMCs sport quick-change fixtures.(new equipment)
July 1, 2005... Wheel Machine (WM) VMCs from Chiron America Inc. include quick-change fixtures with radial clamp arms and spring-loaded pins replacing screws. They also feature cylinder-bracket designs for additional robot clearance and built-in fixture...

Heavy cutting from HMC.(new equipment)
July 1, 2005... The redesigned Mitsui Seiki HU63A-5X HMC provides a wide range of motion and high torque for improved heavy cutting applications. It has a work envelope of 35.433 x 31.496 x 31.496 in. (X, Y, and Z axes) and holds 0.00012-in. true position...

High-speed VCMs tackle graphite.(new equipment)
July 1, 2005... The E33 VMC from Makino offers 1,574-ipm rapid traverse and cutting feedrates on all axes for high-speed milling of graphite and steel and maintains low vibration qualities. SGI.4, the manufacturer's 3D software, and Pro.5 controller come...

Cutter and grinder coolant.(new equipment)
July 1, 2005... Valenite's VNT-755 semi-synthetic coolant works well in general-purpose machining and with various ferrous and nonferrous materials. The fluid is useful in turning, milling, reaming, drilling, and tapping, plus I.D. and O.D. grinding in...

Five-axis laser-welding.(new equipment)
July 1, 2005... The power head of Mitsubishi Laser/Me Machinery Systems Inc.'s VZ2 3D, multi-axis laser-welding/ cutting system uses a reflective parabolic-mirror system for optimized welding. This C[O.sub.2] head reportedly provides noncontact welding and...

Quench furnaces.(new equipment)
July 1, 2005... Lucifer Furnaces' #7022 EQ protective-atmosphere elevator quench furnaces combine a preheat section, hardening chamber, cooling vestibule, and quench tank into integrated units. Suitable for low-production, scale-free applications, these...

Measurements displayed via 3D graphics.(new equipment)
July 1, 2005... Quick Vision Apex Series vision measuring systems from Mitutoyo America Corp. feature QVPAK software that displays measurements in 2D/3D graphics for easy interpretation. Abnormal data elimination, noise filters, data fit, SmartEditor part...

Measure flat metal sheets.(new equipment)
July 1, 2005... Thermo Electron Corp.'s Radiometrie line consists of isotope and X-ray-based thickness and coating-weight gages for the metals, especially flat sheets, and web processing industries. These noncontact gages provide real-time measurements for...

End mills incorporate high-feed geometries.(new equipment)
July 1, 2005... Minimaster small-diameter end-milling systems from Seco-Carboloy now include high-feedcutting geometries for the mold/die and energy industries. They work in small cavities and pockets. Inserts come 0.31496, 0.3937, 0.47244, and 0.629928 in....

Open front bar/chucker.(new equipment)
July 1, 2005... The six-spindle MS52 bar/chucker by Index Corp. sports an open front workarea, which accommodates robot loading of 4-in.-diameter forgings, castings, and extrusions. The machine's electrical system is on top and there is no end-slide tool...

Remotely monitor gas systems.(new equipment)
July 1, 2005... Concoa's software for Advantium 8 remote alarms monitors the company's line of automatic switchovers and blender equipment. Compatible with Windows 98, ME, NT, 2000, or XP, Advantium software lets users or distributors remotely monitor gas...

Grinder series.(new equipment)
July 1, 2005... G-Series industrial grinders by Ingersoll-Rand tackle various grinding, cutting, and material-removal applications. Suitable for light material removal, cleaning rough castings and welds, deburring parts, and other finishing, the G1 has 0.4 hp...

Medium-pitch gearmaking.(new equipment)
July 1, 2005... Using high-speed, direct-drive spindles for workheads and spindles, Gleason Corp.'s P 90G horizontal grinding and hobbing machines tackle medium-pitch gears and worms. Software packages are available for the grinding performed by these...

Software functions for fabricators.(new equipment)
July 1, 2005... Henning Industrial Software has added three features to its Visual EstiTrack shop-management software for the fabricating industry. These include an alternate sheet calculator, which does the math for the optimal sheet size for a single...

Create and run palletizing applications.(new equipment)
July 1, 2005... PalletTech version 3.3 palletizing software from Kuka Robotics Corp. USA has two modules--PalletEdit tool and PalletRun Time application package. PalletEdit is an off-line engineering and programming tool that lets operators develop palletizing...

Barfeeder for small barstock.(new equipment)
July 1, 2005... LNS America Inc.'s Quick Six is a compact automatic barfeeder that handles 18 to 72-in. long and 5/16 to 3 1/8-in. in diameter barstock. Unlike headstock-length barfeeding systems, the Quick Six reportedly requires fewer bar cuts, reduces...

Press for cells or as standalone.(new equipment)
July 1, 2005... For intricate press-fit assemblies, integration into lead manufacturing cells, and as standalone assembly stations, Schmidt Technology Corp.'s ManualPress 307/3000 systems provide 25 to 900-lb press force, force and distance monitoring, and...

Machine tool shields.(new equipment)
July 1, 2005... Rockford Systems' flexible-arm shields protect operators of lathes, drills, small mills, grinders, bandsaws, and similar equipment from flying chips, sparks, and coolant. The arms are made from spring steel and vinyl coated, which protects them...

Proximity sensors.(new equipment)
July 1, 2005... IWRM 12Z8704/S14C analog-inductive proximity sensors from Baumer Electric provide precise, noncontact, proximity, position, and distance sensing for metal objects and can identify two different metal substrates in the same application. Besides...

Collect SPC data and control machines.(new equipment)
July 1, 2005... Kurt Manufacturing's USB modular building blocks for SPC data collection and machine control include digital modules for digital gages to interface with systems for data collection; LVDT or analog modules; DC I/O modules for applications...

Carbide-tipped sawblades.(new equipment)
July 1, 2005... Lenox's carbide-tipped circular saw blades tackle angle iron, sheet metal, pipe, and steel plate. They are made from titanium carbide, which reportedly provides smooth, clean cuts with less sparks and dust than abrasives and reduces secondary...

Plasma/laser dust collectors.(new equipment)
July 1, 2005... GS4P Gold Series Package fume and dust collectors by Farr Air Pollution Control manage emissions from plasma and laser-cutting tables. They come fully assembled and wired with fans, controls, filters, and automatic reverse-pulse cleaning...

Collets deliver shrink-fit force.(new equipment)
July 1, 2005... The powRgrip collet system from Rego-Fix uses toolholders and collets that reportedly generate high clamping forces equal or higher than shrink-fit toolholders. It works off 110-V AC and fits on a workbench. The system relies on interference...

Clamps support machined molds.(new equipment)
July 1, 2005... De-Sta-Co 350,353, and 359 clamps for moldmaking mount directly to the mold's parting line, reducing manufacturing time and cost. These clamps hold up to 2,800 lb with clamping bars that open to 75[degrees]. They are made of carbon and...

Collet chucks easily open.(new equipment)
July 1, 2005... Lexair's wrench-operated collet chucks have a universal flat-back design for any application, but are well-suited for hybrid CNC/manual lathes. They do not require a drawbar or cylinder and operate manually with a standard chuck key. The Lexair...

Vertical turning centers.(new equipment)
July 1, 2005... Okuma & Howa VTM-80Y B vertical turning centers distributed by KGK International Corp. tackle large, complex aircraft and automotive parts with X,Y,Z travels of 44, 13.98, and 44.69 in., respectively. An 18.5/15-kW tool-spindle drive and...

Optional press feature.(new equipment)
July 1, 2005... An optional, infinitely adjustable stroke mechanism is available for The Minster Machine Co.'s E2H, P2H, and HB series presses. Its primary benefit is for increasing and optimizing production using the same press. This feature lets users...

Upgradeable CMMs.(new equipment)
July 1, 2005... Xspect Solutions Inc.'s X-Cite CMMs are manual and direct-computer-controlled (DCC) machines that job shops can upgrade as customer needs develop. Their granite and honeycomb-alloy structures naturally dampen vibration, and air bearings preload...

Automate OSHA recordkeeping.(new equipment)
July 1, 2005... J.J. Keller & Associates Inc.'s Keller-Soft Workers' Comp Manager Plus OSHA 300 Recordkeeper software automates workers' comp and OSHA 300 recordkeeping. It provides a step-by-step process to complete and submit a First Report of Injury form...

Rigid index chucks.(new equipment)
July 1, 2005... Tecnomors MD Series automatic index chucks supplied by NorthTech Workholding Inc. sport rigid bodies and components. Standard, preloaded, solid rollers increase support surface and ensure rigidity and wear-resistance. The chucks' 90[degrees]...

Machine-protection systems.(new equipment)
July 1, 2005... Muting sensors of the IMS Safety Muting system from Scientific Technologies Inc. yield signal combinations that distinguish between material and people entering a dangerous machine area. If the proper sensor sequence or combination occurs on...

Roll-out shelf racks.(new equipment)
July 1, 2005... Suitable for storing parts for automotive and aircraft assembly lines, Proper Storage Systems Inc.'s double-sided, roll-out shelves are up to 10-ft high and 20-ft deep. They hold 200 to 2,000 lb/shelf and include custom brackets for holding...

Calendar of events.(Calendar)
July 1, 2005... July July 16, 2005, Basic Troubleshooting of Stamping Dies, Arlington Heights, Ill., Tooling and Manufacturing Assoc., tmanet.com July 18-22, 2005, Coordinate Metrology Systems Conference 2005, Austin, CMSC, cmsc.org July 18-22,...

Idea sticks it to a drilling problem.(practical ideas)
July 1, 2005... I often drill 1/16-in.-diameter angled bleeder holes deep within workpiece cavities. Since standard-length drills don't reach, I use an extension made from drill rod. The trick, however, is securing the drills in the extension. After...

A shim-stock organizer.(practical ideas)
July 1, 2005... My idea is a simple, easy-to-construct shim rack that keeps shim stock in proper order. I cut 32 pieces of 1.5x2.5-in. aluminum tubing with 0.125-in. wall thicknesses to 12-in. lengths. I then weld these pieces together four tubes/sections wide...

Clock watchers.(50 years ago in AMERICAN MACHINIST)
July 1, 2005... In the July 4, 1955, issue, editors were wondering about the future for daylight-savings time. Only half the U.S. population was springing forward and falling back, reported the article, which also noted that only the New England States, New...

Still decent pay in 1955.(50 years ago in AMERICAN MACHINIST)
July 1, 2005... The Independence Day issue also recounted how foundry workers of Eaton Mfg. Co. had accepted a 61-cent cut in hourly wages to keep the company's Vassar, Mich., plant from closing. Average hourly wages after the cut were $2.06.

Press survives atom bomb test.(50 years ago in AMERICAN MACHINIST)
July 1, 2005... A hydraulic press manufactured by Hydraulic Press Mfg. Co., Mt. Gilead, Ohio, was one of a few items to make it through an atom bomb test in 1955. A photo that appeared in the July 18 issue shows the press, which was set up 4,700 ft from...

Canadians cross the border, eh?(50 years ago in AMERICAN MACHINIST)
July 1, 2005... The same issue reported that Cleveland's mushrooming industrial expansion was causing a shortage of skilled metalworking craftsmen. So manufacturers poached tool and diemakers, patternmakers, and machine repairman from a foreign country. Which...

What's good for manufacturing is good for the U.S.(Editorial)
July 1, 2005... Let's face it. The U.S. is the focal point of the world. Other countries are envious of our standard of living, and justifiably so. Anyone who does not believe the manufacturing sector of our economy is the No. 1 reason for our success needs to...

Finding and training tomorrow's machinists: U.S. manufacturers are still hungry for technically competent, skilled labor.
July 1, 2005... The popular media are full of gloom-and-doom reports of the loss of millions of manufacturing jobs to other countries and as a result of the recent recession. The manufacturing-sector job loss is estimated at 2.9 million since July 2000....

Change. It's better than the alternative.(PARTNERS Opinion)
July 1, 2005... Charles Kettering, the prolific inventor and businessman, said, "The world hates change, yet it is the only thing that has brought progress." It is wise to remember Kettering's words during this time of dramatic change in the world of...

The 15 billion dollar question! The saving in choosing the right priority.(PARTNERS Opinion)
July 1, 2005... In the United States, the manufacturing industry could save 15 billion dollars by using the right tools from the start, even if companies paid more for the tools. Sounds impossible? In fact, it's not. It's manufacturing economics--a smart and...

Ensuring a strong industrial base: how government and industry can work together to lighten the domestic burdens that weigh down U.S. competitiveness.
July 1, 2005... American manufacturers are burdened by forces they can't control, including the rising costs associated with healthcare, regulatory compliance, taxes, tort litigation, and energy. Combined, these add at least 22% to the overhead costs of U.S...

Why the dominant players manufacture in the US.(PARTNERS Opinion)
July 1, 2005... For complicated products like machine tools, dominating the US market requires manufacturing in the US, because market leaders must offer superior support and stability. The leader will be an importer only when the niche is so small it doesn't...

Leveling the international playing field: while some foreign trade practices are simply unfair, recognizing that is one thing; doing something about it is another.
July 1, 2005... Bruce Cain is trying to save his livelihood. He's pleaded with Congressmen and Senators, testified at hearings and commissions in Washington D.C., and joined every possible organization and coalition to make his voice heard. He's not looking...

Technologies to reduce production costs: how manufacturers can make themselves more competitive by setting up quality systems, investing in R&D, and designing products with manufacturing in mind.
July 1, 2005... The day of the dedicated machine is dead. Shops must be lean, flexible, do more with less, and design for manufacturability. To do these, average manufacturers are shifting to lean manufacturing or Six Sigma principles, exploiting the...

Eliminate labor costs. Minimize cycle times. Maximize Throughput: Do this and you can compete anywhere.(PARTNERS Opinion)
July 1, 2005... Through the use of ingenuity, focus and quality equipment, manufacturers can and will achieve their productivity, goals and compete successfully in the international marketplace. CHIRON uses these qualities everyday in an effort to help...