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illus por bibliog, Part 1: Number two; helicopter pioneer Stewart Ross Graham. v57 no 2 (Summer 2012): p127-139; Part 2: Number two: Helicopter pioneer Stewart Ross Graham, part II. v57 no 3 (Autumn 2012): p162-175

illus bibliog, Part 1: Number two; helicopter pioneer Stewart Ross Graham. v57 no 2 (Summer 2012): p127-139; Part 2: Number two: Helicopter pioneer Stewart Ross Graham, part II. v57 no 3 (Autumn 2012): p162-175

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This month we're very happy to present the new PRODUCTION MACHINING Web site. The URL is still the same, www.productionmachining.com, but what you'll find there is a site that is [...]

The European machine tool industry's future prospects are very bright and the aggressive momentum in product development that began within the industry in 1997 has continued and was evidenced in the EMO trade show held in Paris, France, on May 5, 1999. The exhibition featured a broad variety of innovative products, whose development has been fueled largely by strong and stable sales levels that have enjoyed by European machine tool manufacturers since roughly 1995., The dominant theme of this year's EMO - Europa's premier machine tool show - was doing much more on a single machine. Things are looking up in the European machine [...]

The 1999 TIMTOS machine tool show in Taiwan was attended by 46,000 visitors and 300 machine tool builders. Several computer-numerical control machines were introduced. These include Sintec Technology's SMV-500HiSP vertical machining center, Leadwell Corp's V-30, SV 500 and 700 vertical machining equipment, Mighty USA's five-axis C-frame machine, Absolute Machine Tools' fix-axis contouring head and Yang Machine Tool's M Series cutting machines., This spring's TIMTOS machine tool show displayed a Taiwanese machine tool industry that continues to exhibit steady technological and commercial progress. Not so long ago a major point to note [...]

Greenville, SC-based Ellcon National retrofitted an auxiliary pallet changer to realize a horizontal-like production efficiency from a vertical machining center. The pallet allowed the company to manufacture air and hand brakes for railroad cars, and other types of parts with lower cycle time. It also allowed the firm to produce parts with much greater efficiency and accuracy, and less in-process inventory., Being productive doesn't necessarily mean being complicated. Indeed, for most shops it works the other way around. The simpler solution is almost always the better solution, even when more highly [...]

Metrology systems manufacturer Renishaw PLC's Gloucestershire, England, plant reflects the company's constant efforts to achieve perfection in its production process. The Gloucestershire plant machines the mechanical parts for Renishaw's CMM and machine tool probes. Its deceptively simple but highly sophisticated manufacturing process integrates innovative, automated workholding and work handling with finely engineered process controls., This small-parts machining operation combines superbly automated workholding and handling with total machining process management. While there is no such thing as a perfect production process, some manufacturers strive mightily [...]

The advantages of open architecture, personal computer (PC)-based computer numerical controls (CNCs) in metalworking or machining have been discussed within the industry since about 1993. However, relatively few users have witnessed the apparently major benefits of such PC-based CNC functionalities on their shop floors. Controls with PC-based interfaces have, among other demonstrated advantages, proven to be generally very easy to network and permit ultra-high speed data transfer., To most users, the folk so far about the potential of 'open' PC-based CNCs has greatly exceeded the benefits. Here's one application that delivers the goods. While many people in [...]

Aikoku Alpha Engineering Corp has employed five-axis machining technology since 1975. Since then, it has increased its five-axis equipment to a total of 17 which led its workers to acquire skills in NC programming and five-axis machining technique. To cope with the demands for higher efficiency and rising production costs, the firm had to resort to high speed machining. In 1998, Aikoku Alpha installed a Toshiba MPF-5A, its first high speed five axis machine., This Japanese five-axis aerospace shop believes that high speed machining is their future. Here's why, and some of what they've learned so far. Aerospace shops tend to look fairly similar [...]

Jeannette, PA-based Elliott Turbomachinery Company Inc has added to the advantages offered by NC programming by developing its customize macro programs. The shop offers turbochargers, multi-stage compressors, steam turbines and plant compressed air systems. Elliott's own automated NC programming was conceived with the stationary diaphragm disk. After several tests, engineers were able to develop a standard program based on the ESPRIT CAD/CAM system from DP Technology., How long should it take to program a part? That, of course, depends on the complexity of the workpiece. Most knowledgeable people would agree that the greater the number of [...]

Several machine tool manufacturers participated in the 1999 JIMTOF machine tool show held in Osaka Japan. The companies showcased various innovative products designed to support machine shop operations. These include personal computer-based computer numerical control systems supporting remote diagnostic features and monitoring functions. A number of high-speed machining systems were also introduced during the show. The equipment were designed for various applications such as die/mold, construction and linear motors, and cutting operations., Undeterred by a sluggish domestic market, Japanese machine tool builders are moving ahead with aggressive product development. More than a few Japanese machine tool executives joked about the Osaka jinx, [...]

Aerospace manufacturing company Dowty Aerospace Log Angeles supports a no-offset policy in their computer numerical control machining operations. Dowty Aerospace, which manufactures hydraulic actuation systems for the aerospace industry, utilizes a numerical control program management system to specify, change and evaluate tools. The system is supported by a graphical tool management software that narrows the information gap associated with programming, the tool crib and machine setup processes., Tool management for this aerospace manufacturer begins in NC programming and reaches throughout the shop floor. In most shops, conventional wisdom has it that the creation of NC programs is [...]

Mechanical shaft seal manufacturer John Crane International's adoption of quick-change chucks has led to improved quality and efficiency. The chucks feature a serrated interface between master and top jaws while jaws are locked into the serrated seat with a quater-turn of a locking screw. The chucks allow quick jaw changes and short setup times. Reboring operations can also be eliminated on repeat setups with an existing set of jaws., This is so fundamental, it's hard to know where to begin. So let's just take it from the top. There are only two modes a machine tool can be in [...]

This company quickly transformed itself from a small machine shop to a high value-added supplier largely through the purposeful broadening of its manufacturing process knowledge. The trick was matching company [...]

High speed turning in machining processes offers several advantages to machine operators. Reduction of cutting cycle time and the reduction of additional grinding operations are two of the most important benefits of high speed turning. While innovations in various processes such as milling and drilling are being developed, problems with centrifugal force barriers limit the creation of new technologies in the turning process. However, some companies are developing chucks capable of 10,000 rpms to solve these limitations., With chucks capable of holding a part at 10,000 rpm, cutting tools approaching 10,000 sfm, and increasingly faster lathes, true high speed turning is poised to become a reality for [...]

Machining company Industrial Pattern of Benton Harbon, MI, decided to shift to solids-based modeling computer-aided design/computer-aided manufacturing (CAD/CAM) system from a pure surfacing system. The decision was partly based on the need for the two CAD/CAM personnel to share files which previously was not allowed because one used a UNIX system while the other used a PC-based system. Moreover, Industrial's clients have already shifted to solid modeling. The two programmers later found out that it was easy to learn the rudiments of the new solids-based modeling system., It wasn't that Barry Bundesman was dissatisfied with surfacing. Quite the contrary, he had a top-notch CAD/CAM system, was really good at using it, and he could model any job [...]

Machine shops should consider a number of mechanical machine design-related factors when selecting high speech machining systems. These include the presence of computer numerical control for the quick processing of part programs, acc/dec characteristics and spindle design and lubrication. Shops must also determine ways to control the heat generated during the high speed machining process to maintain mechanical accuracy., Some shops want to do high speed machining (HSM), but don't want to do it all the time. Maybe they can afford to do the necessary HSM process planning for [...]

Minnesota Rubber achieved highly flexible and accurate production of mold inserts at a small capital investment with a standard high-density vise workholding system. The workholder clusters multiple clamping stations on a single iron base and the milling program can be run completely on a single part. The method minimized tool changes and enabled continuous production reducing time-consuming hole-making operations., Many shops that do high production machining are well acquainted with the notion of high-density workholding. Most frequently done with tombstone fixtures on horizontal machining centers, the idea is to [...]

Active/Burgess Mould and Design Custom Tooling Division has successfully compressed the mold making cycle by employing NC programming and faster machine tools on the shop floor. With the use of Delcam International's PowerMILL, a programming software, machinists are enabled to quickly produce and visualize tool paths. They are also allowed by this CAM system to program and machine simultaneously, thus, streamlining the job path of the mold., It's hard for some people to believe that the shop floor is a fitting venue for any kind of NC programming, let alone the complex 3D contouring necessary for cutting [...]

Machine parts maker Urschel Manufacturing adopted the Anvil Express integrated CAD/CAM system to improve its entire production process from design to manufacturing. The system allows the company to move smoothly between CAD and CAM applications to allow changes in the design model following the generation of part programs and the improvement of process plans on the shop floor by modifying speeds, feeds and modal settings., This combination product line manufacturer and job shop is a classic example of on environment that coils for o fully integrated CAD/CAM system. There are an awful lot of CAD/CAM [...]

DG Industries discovered that a centralized tool setup system has advantages even for a small machine shop of only 25 people. The system required the replacement of the usual tool crib attendant with an experienced machinist who gathers the tools for each job and ensures proper placement. Shop manager William Rogers discovered that setup time can be reduced by half even though cycle time would remain basically the same., Some people think tool presetting can be justified only in large operations. This Arizona shop shows how it makes sense almost anywhere. Effective isn't always complicated. Take DG Industries for [...]

Tech Mold Inc utilizes CNC grinders in the process of manufacturing multicavity plastic molds because CNC grinding machines offer accuracy in its applications. Although a CNC grinder, which is first rate and medium in size, costs $35,000, Tech Mold prefers to use them because of its effectiveness and consistency in the grinding application compared to manual grinding. The consistency in the grinding process is very important for the company since it is demanded by its customers.

EMO 1997, the Europe's premier machine tool show, was held in Hannover, Germany. The 1997 show was more successful than the last one even though the European economy is still in recession. European machine tool builders have become more financially stable as evidenced by their more aggressive product development strategies. The main theme in EMO 1997 was the introduction of faster and more flexible machine tools., This year's EMO - he premier European machine tool show - saw that continent's builders once again focused on innovative, but practical, product development. When EMO was last held in [...]

Non-uniform rational B-splines (NURBS) curve interpolation is a mathematically-based formula to enhance contour cutting. Machine shops such as Mitsubishi Electronic Automation, GE Fanuc, Heidenhain, and Siemens Energy and Automation were able to prove the feasibility of NURBS and have developed NURBS-based formulas. However, it is difficult to determine the most effective formula since several computer-aided manufacturing developers are still on the process of developing curve output capabilities., The ability to import complex curves into CNCs promises to let shops finally get beyond old limitations imposed by contouring with linear interpolation. Faster and smoother cutting will be the [...]

Numerical control codes for high speed machining can be enhanced through the adoption of proper programming techniques. These include the avoidance of sudden changes in cutting directions, the application of gentle entry cuts and the maintenance of constant cutting conditions whenever possible. Machinists must also consider the features of computer-aided manufacturing systems such as remaining stock analysis, pencil milling, rest milling and true scallop capabilities., You'll have to change your NC programming strategy for high speed machining. Here are some quick tips, and some features to look for in your CAM system. Programming NC code [...]