American Machinist articles from March 2009

American Machinist archives from March 2009

Correction.(Correction notice)
March 1, 2009... Stephen Jean, milling products manager for Emuge Corp., was the author of the article "Say 'Nix' to Extra Stock" published in the January issue. His name was inadvertently omitted from the article. Information and graphics for that article were...

A triumph in aerospace: shop keeps an eye on the horizon for manufacturing success and growth.(AEROSPACE)
March 1, 2009... [ILLUSTRATION OMITTED] Extensive aluminum extrusion machining capabilities have set Triumph Structures-Kansas City (www.triumphgroup. com), apart from the competition. About three-quarters of the aerospace shop's work involves parts made...

Grind and turn for less part handling.(AUTOMATION)
March 1, 2009... [ILLUSTRATION OMITTED] The more processes shops can do on one machine tool the less automation is needed for part handling. When parts come off one machine complete, they don't have to be transferred - either by automation or manually to...

Automated ten-millionths bore accuracy.(AUTOMATION)
March 1, 2009... When holes produced satisfactorily Won lathes suddenly have to meet a process capability of 1.67 or 2.0 Cpk, turning operations may fall short. That capability requires a process that makes it easy to "dial in" high precision, and one that is...

Two spindles, two turrets, more unmanned operation.(AUTOMATION)
March 1, 2009... Automation opportunities are plentiful with the multitasking Hyper Quadrex 100MSY from Mazak Corp. (www.mazak.cum), which allows long periods of unmanned operation over breaks, nights and weekends. In addition to a coordinated "hand-off"...

Multimedia HMI.(AUTOMATION)
March 1, 2009... The GT16 Series, a new top-of-the-line multimedia human machine interface (HMI) from Mitsubishi Electric Automation Inc. (www. meau.rom), adds a new dimension of visualization and operation to the company's GOT1000 family of HMIs. The GT16...

The collapse of manufacturing.(Editorial)
March 1, 2009... Wrenching changes in the way that business is done around the world are underway. Automobile assembly in the United States dropped 60 percent in January compared with the same month a year ago and, in the last quarter of 2008, industrial...

Whither Obama and the Congress.(GOVERNMENT MATTERS)(Barack Obama)
March 1, 2009... Even though President Barack Obama will not admit it, it is clear that Congress went much further than the President wanted it to by inserting pet projects and other unnecessary spending into the stimulus bill. But no matter what the...

Shop works its way into production.(MACHINE TOOLS)
March 1, 2009... [ILLUSTRATION OMITTED] [ILLUSTRATION OMITTED] Many of today's high-volume production shops have geared up to take on more low-volume, close-tolerance, precision-machining jobs that are less likely to be lost to overseas suppliers. ...

EDM for the long stuff.(MACHINE TOOLS)
March 1, 2009... The AT Spirit 4 OFS (oil field special) from GF agiecharmilles (www.gfac.com/us), a completely integrated die-sinking EDM system, accommodates workpieces typically considered too long for EDM. a special opening on the machine worktable allows...

Linear scales provide lift for aerospace accuracy.(MACHINE TOOLS)
March 1, 2009... [ILLUSTRATION OMITTED] Votaw Precision Technologies (www.votaw.com) in Santa Fe Springs, Calif., considers itself a "go-to" source for critical parts for aerospace and defense projects. Some of the more notable projects that the shop...

Grid system tackles the traffic of aircraft component work.(MACHINE TOOLS)
March 1, 2009... [ILLUSTRATION OMITTED] Sub-plates with hardened precision bushings and hardened threaded inserts on a 2-in. grid system make all the difference at Bombardier Aerospace in Wichita, Kan. The facility, which produces Bombardier Learjet Models...

Precision EDMed holes.(MACHINE TOOLS)
March 1, 2009... [ILLUSTRATION OMITTED] As the brainchild of Tech Mold Inc. in Tempe, Arizona, a manufacturer of precision multi-cavity, multi-technology injection molds, the Universal Electrode Guide ensures precise EDMed small holes and eliminates the...

Hyper aerospace output.(MACHINE TOOLS)
March 1, 2009... [ILLUSTRATION OMITTED] Touted as the industry's highest output 5-axis horizontal machining center for clean, contained cutting of parts as large as 2 m by 4 m, the HyperMach h4000 is designed for high throughput precision machining of...

Shop constantly re-invests for the future.(MACHINE TOOLS)(Forest City Gear Inc.)
March 1, 2009... Customers of Forest City Gear, an American Machinist 10 Best Shop, always expect the shop to lead the way in devising new production techniques for making gears better and at more-competitive costs, as well as provide superior customer service....

Not all doom and gloom for some.(MACHINE TOOLS)
March 1, 2009... MFG.com (http://www.mfg.com), a large global online marketplace for the manufacturing community, reported that 45 percent of the 570 North American Suppliers that responded to its January, 2009, MFGWatch Survey are projecting growth in 2009....

Employee free choice: this is wrong for American manufacturing.(NTMA NOTES)
March 1, 2009... Legislation is being debated in Congress that has a great name but dire, long-term effects on U.S. manufacturing. The Employee Free Choice Act (EFCA) is an attempt to pay Big Labor back for its support in the last elections. However, it has...

The tool-purchasing decision.(PRACTICAL IDEAS)
March 1, 2009... For the most part, I ran generic tooling that, I believed, would do the job for the least amount of cost. But now most people rely on tooling suppliers/representatives to keep up to date with innovative changes in tooling. In addition, a lot of...

Practical ideas for weathering a stormy economy.(PRACTICAL IDEAS)
March 1, 2009... "In a storm, people can either be victims, or they can take positive steps to rescue themselves. The idea of mastering your destiny instead of letting circumstances master you is not a platitude or a bumper sticker. It is very real, and many of...

Faster milling in a busy forging die shop: milling cutter technology cuts time in skin milling and cavity milling.(OPERATIONS)
March 1, 2009... In the captive die shop of any large forging operation, the pressure is always on to recondition worn dies faster to return them to duty sooner. Much of the pressure falls on milling operations that account for the bulk of machining time...

Chips-n-burrs.(Cartoon)
March 1, 2009... [ILLUSTRATION OMITTED] "It's the latest micro drill. Try not to breath you'll blow it right off the table."

Consider these economical alternatives to scrapping older machine tools.(OPERATIONS)
March 1, 2009... Often when a machine tool has accumulated lots of hours and isn't functioning with its original precision and reliability, shop owners and plant managers get out the check book and start shopping for a new piece of equipment. But there are...

Precise CAD data repair.(SOFTWARE & CONTROLS)
March 1, 2009... [ILLUSTRATION OMITTED] [ILLUSTRATION OMITTED] Optical system design often includes importing 3D mechanical CAD files for opto-mechanical stray-light analysis, LED illumination system design and other optical design tasks into optical...

High-speed machining in 2D toolpaths.(SOFTWARE & CONTROLS)(Brief article)
March 1, 2009... High-speed machining has traditionally been available only in the Mastercam 3D machining suite of toolpaths, that is until now. CNC Software Inc. (www.mastercam.com) has released Mastercam X3, which introduces high-speed machining into a suite...

Savings in automated 3D translations.(SOFTWARE & CONTROLS)
March 1, 2009... Theorem Solutions, Inc. (www. theorem.co.uk) said several North American automotive suppliers have adopted its Theorem Process Manager (TPM), a software program designed to automate the translation of CAD and other data. Theorem Solutions...

Thread milling takes off: advanced machine tool and cutting tool technologies reduce the cost and boost the quality of producing internal threads in aerospace materials.(MACHINING)
March 1, 2009... [ILLUSTRATION OMITTED] [ILLUSTRATION OMITTED] [ILLUSTRATION OMITTED] One of the most challenging metalworking applications is the production of internal "J" threads in difficult-to-machine aerospace materials such as 718 Inconel,...

Custom tools from standard components.(CUTTING PRODUCTS)(Brief article)
March 1, 2009... [ILLUSTRATION OMITTED] It is no secret that making parts faster brings down costs. Cycle time reduction is a common theme, and a common focus is getting tools to run faster. However, optimizing tools to the applications that they are...

New endmills and facemills.(CUTTING PRODUCTS)
March 1, 2009... Sandvik Coromant (www. coromant_sandvik.com) has introduced the CoroMill 316--a new "split-tool" endmill system designed for small to medium diameters ranging from 0.375 in. to 1.00 in. The company said the high-performance tools, with a unique...

Indexable insert chamfering tool.(CUTTING PRODUCTS)
March 1, 2009... [ILLUSTRATION OMITTED] The new cinch carbide insert chamfering tool from Fitz-rite Products Inc. (www. fitzrite.com) uses a square ANSI standard insert and is available in 60,82 , 90 and 120-degree included angles. The compact yet rigid...

Grooving cutters.(CUTTING PRODUCTS)
March 1, 2009... Iscar (www.iscarmetals.com) said its new high-performance grooving cutters for O-rings, retainers, circle clips and related applications offer 50 percent higher insert density than other cutters for faster cutting. The new cutters, additions to...

Shoulder-milling tools.(CUTTING PRODUCTS)
March 1, 2009... [ILLUSTRATION OMITTED] Widia (www.widia. com), based in Essen, Germany, said its new Widia M6800 milling series is designed for the roughing and finishing of steel, stainless steel, cast irons, aluminum or difficult-to-machine materials...

What is a wiper insert?(CUTTING PRODUCTS)
March 1, 2009... Sandvik Coromant (www.coromant. sandvik.com) explained: The wiper technology for turning is based on a carefully developed series of radii that make up the cutting edge. On a conventional insert, the nose of the edge is just one radius. The...

Icing plates for holding delicate parts.(TOOLING & WORKHOLDING)
March 1, 2009... [ILLUSTRATION OMITTED] GF Series Icing Plates that use the power of ice to hold parts for milling, turning or grinding has been introduced by AMCC (www.amcc.fr). The clamping system is said to be rigid, holds parts stress-free on a single...

Hydraulic vise column.(TOOLING & WORKHOLDING)
March 1, 2009... [ILLUSTRATION OMITTED] Jergens Inc. (www.jergensinc.com) has introduced its new hydraulic Vise column with features such as a swivel coupling that saves operator time by eliminating the need to disconnect and reconnect the two hydraulic...

Why do some collets have serrations?(TOOLING & WORKHOLDING)
March 1, 2009... Heavy axial or radial forces, intermittent cuts and off-center applications may cause the workpiece to push back into the collet, spin, slip or walk out of the collet. Serrations located in the gripping area of the collet will add additional...

How to guarantee success.(Editorial)(Brief article)
March 1, 2009... Gerard Vacio, Workholding Product Manager at BIG Kaiser Precision Tooling (www.bigkaiser.com) has some advice for shops trying to cope with the constantly changing North American manufacturing market. He feels manufacturers should only...