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The advent of high speed machining has resulted in the development of machining centers that are able to deliver efficiencies that were once considered impossible. The increase in the speed of the latest machines has contributed to efficiencies that have gone beyond even the machining process. Some machining shops have taken advantage of the technology involved in high speed machining to reinvent the traditional technology used in making parts., High Speed Machining means more than justtaking the old cuts faster. It means rethinking the manufacturing strategy to reap the most benefit from the speed now at your command. The [...]

Innovations in the workholding segment of the metalcutting process likely represent the best value in metalworking technology. Suitable workholding equipment costs only a fraction of the collective cost of an up-to-date computerized machine tool, the cutting tools and toolholders in the toolchanger or tool turret and the hardware/software devoted to programming. The potential savings in time and the potential process improvements furnished by innovative workholding solutions are considerable., Innovative workholding solutions help you hold onto productivity and profit in a machining process. Five new ideas show the value of creative clamping and fixturing. Dollar for dollar, workholding innovations [...]

Helio Precision Products Inc is a prime example of a metalworking shop that has successfully managed to tap into three of its most valuable resources, namely, reliable customers, suppliers and resources. It reaps tremendous benefits from having applied closed loop machining technology which it has implemented in two machining cells, one with manual loading and the other with robotic load and unloading capability. Its two main advantages are overall reduction of process variability and improved throughput. Ultimately, it is the relationships outside the shop that determine success., Looking for a way to reduce process variability, speed setup, simplify your operation? Automatic measurement and machine compensation (Closed Loop Machining) may be something to consider. Here's a shop where [...]

Innovations in machining shops include the incorporation of milling, drilling and tapping capabilities in machining centers. While basic turn/mill machines are ideal for simple drilling and tapping operations, the addition of servo-controlled actuation of the rotary C-axis makes the machine capable of spiral-milling cuts and other complex interpolated geometries processes. Addition of secondary or subspindle also improves the productivity of turn/mill machines., Most shops are looking to reduce throughput time. One sensible method is to eliminate multiple part handlings and work-in-process time. Advances in machine tool capability and programmability enable more job [...]

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 [...]

Rotary transfer machining technology are growing popular due to the imposition of stringent standards in both production speeds and flexibility. Competitive rotary transfer machines are those with high production capabilities and machine uptime and reduced cycle times. This can be attributed to the elimination of secondary machining operations and the incorporation of unit positioning controls and chuck indexes., There doesn't seem to be only one reason why, either. Machine tool builders are a crafty lot when it comes to explaining the apparent success of a machine concept. There [...]

Medical devices implanted in the human body are products of a technology known as micromedical machining. The process involves the use of lasers, software, prototypes and isostatic procedures. Various methods and materials are utilized for the manufacturing of each workpiece which largely depend on patients' requirements. Laser manufacturers are bent on further developing the system into micromachining equipment of highest precision and reliability., The heart keeps pumping, the knees keep striding, but materials and machining really keep us going. Micromedical machining is proving to be a success for devices implanted throughout the human [...]

Although jobshops are still churning out small parts by the millions on their trusty multi-spindle screw machines, jobshops may also consider CNC and rotary transfer machines for high-volume production. Only [...]

Machine tool suppliers are actively helping their customers in their agile manufacturing efforts with high-speed machining products. These systems allow manufacturers to pursue just-in-time production, quick-change manufacturing and high-level efficiencies. They also reduce lead times, cycle times and per-part costs; make fixturing, material and tooling processes easier; and improve machined finishes. Other benefits include lower heat effects, reduced cutting forces and wider machine range. The two fastest machines in the market are the #40 taper machines, with up to 20,000 rpm with 30-hp spindle, and the #50 taper machines, with up to 15,00 rpm with 40-hp spindle. Despite the promising features, manufacturers may be skeptical about such radical high-speed machining technologies. To placate their uncertainties, suppliers should provide a turnkey service that includes solution engineering and performance guarantees., Across industry, the drive is toward agile manufacturing--shortening time-to-market, reducing lead times, lot sizes and in-process inventories, reacting faster to market changes, and implementing continuous improvement in both processes and [...]

LeBlond Makino Machine Tool Co has developed the technology for carrying out finish grinding and machining operations on a single computer-numerical-controlled machining center. This has led the machine tool maker to enhance grinding capabilities and consistency, improve efficiency and lower leadtimes during the manufacture of metal parts. However, precise process engineering is required for both operations to be integrated., One machine tool builder is using grinding tools on a machining center to finish-grind workpieces. This concept has many attractive benefits, but it calls for the kind of careful engineering [...]

The objective of unmanned operation is to automatically perform stable, high quality machining for extended period in machine factories. This paper introduces a case study of current 72 h unmanned operation of a flexible automation system. Further, an application example of expanding existing MAP based Flexible Manufacturing System to 72 h unmanned system is introduced.

The properties of electrical discharge machining (EDM) and its increasing use in various applications are discussed. EDM has substantially influenced fields of medicine, optometry, dentistry, jewelry industries, automotive and aerospace. However, the tool, die and moldmaking industries used the EDM most extensively. The EDM allows machining tiny parts, requires little or no user machining supervision and is self-adjusting when programmed with fuzzy logic., Throughout its history, Electrical Discharge Machining (EDM) has been associated with some less than flattering descriptions. Initially, it was referred to as a 'black art,' relying more on an operator's [...]

Nontraditional machining operations such as laser machining, water jet and abrasive water jetcutting, electrical discharge machining, and ultrasonic-assisted machining have become necessary with the development of new metal-matrix and ceramic-matrix [...]

Remmele Engineering Inc's Production Division showed that it was possible to adapt electrical discharge machining (EDM) technologies to traditional machining processes. They proved that precision and repeatability could be imposed on traditional machining operations. As proof, Remmele developed an integrated tooling system which used EDM technology for the production of computer parts. The modified system enabled pallet clamping and featured a spring steel centering plate. Remmele showed that EDM concepts could be transferred to general metalworking and manufacturing in the future., The demands for precision and repeatability that once distinctly characterized EDM are now widely applied to all machining. One critical component that ensures precision, accuracy and efficiency in the use [...]

Manufacturer TD Williamson Inc (TDW) supplies pipes for refineries, waterworks and gas distributors, among others. TDW used to manufacture the larger pipes using a manual engine lathe rigged as a horizontal press. However, the resulting products were of substandard quality. A low-cost horizontal machining center, CELL-CON H-15, made by Cellular Concepts was integrated with a workpiece handling system that suits TDW's needs. The new machine system minimized substandard quality pipes and improved manufacturing efficiency., A low-cost horizontal machining center, and a little workhandling ingenuity, solved this shop's problem with machining the perimeter of large round parts. Large parts often present a problem. Particularly when [...]

Once viewed as a specialty process for single-piece production, especially in mold making and platen industries, Electrical Discharge Machining (EDM) has undergone a true metamorphosis in the last 10 years. [...]

The evolution of nonmetallic materials-composites, structural plastics, ceramics-continues. The face of metalworking is changing. How much further will the shift go?-What will be the impact on the companies, employees, and [...]

High enthusiasm for electrical discharge machining in Japan reflects that country's response to challenging conditions in its metalworking industry. Key trends were evident at JIMTOF. EDM is big in Japan. [...]

Both surface finish and surface integrity are important in an EDM'd (electrical discharge machined) workpiece. Although there will always be some surface disorder, modern controls and power supplies can reduce [...]

It's hard to think of a down side to machining multiple parts in a single setup. It can substantially increase the amount of work you get out of a machining [...]

Machining centers are undergoing technological changes, and now are available in all sizes and specifications Purchasers can choose between either US or Japanese styles with a horizontal or vertical fixed-type spindle or a European-style arcing and dual type. Machines have either 16- or 32-bit controls but it is more important for the machine to have an open architecture in order to link up with the UNIX operating system. The manufacturers are constructing better machines by: reducing the number of gears; replacing spline shafts with ball screws; and moving from hydraulics to electronics. Electronics has made the machines more reliable and have given them the capacity to indicate problems. Vertical-spindle machining centers range in price from $70,000 to $5 million., Production State-of-the-Technology Report: The questions are simple: When going out to buy a new machining center, what should be expected? What is the nature of the machine today, in 1990? [...]

The impact of materials technology on tennis racket design is discussed.

Knowledge-based machining (KBM) technology allows manufacturers to increase productivity and profits through minimal costs. This is achieved by using the KBM method of programming, a technique that allows computers to evaluate a model, identify the machining strategies that are necessary and acquires existing strategies stored in the KBM database. The machining processes required in product development are therefore simplified., Knowledge-based machining offers NC benefits. New machining technologies have allowed us to become more productive, but also make shops become more competitive. Today there is a new technology that can [...]

A machining center does the unexpected, polishing surfaces and dressing superabrasive grinding wheels. A new technology, using suspended abrasive particles, provides machining centers with a surface-polishing option as well as [...]

Expensive R&D has brought new technology to quick-change tooling, but price is something buyers are looking at very closely. The faster you make something, the more money you earn, provided [...]

Rotary tables can increase productivity more than most sophisticated machines, thereby expanding profits. Their most important feature is their ability to automatically position the workpiece such that two or more sides of a part can be machined with only a single setup. Aside from eliminating extra setups, other benefits of rotary tables include minimizing handling, tool changes, special fixtures and cycle time. They also cost less than most machines., Job shops can hike productivity 10% with a rotary table mounted on a VMC. The battle for productivity is won by knowing one's tools. Everybody knows sophisticated machining centers cut [...]

Computer numerical control (CNC) machining technology has been used by race car designers to develop powerful dragster engines. CNC has replaced hand grinding as the preferred process for creating cylinder head ports. A program called Mastercam is used to create and duplicate complex surfaces in an engine's intake and exhaust ports. The ability to duplicate configurations have ensured consistency in engine performance., The designers of top fuel dragsters are constantly trying to squeeze more speed from their creations. Until recently, they rarely broke the 300 mph barrier. This season, however, 300-mph dragster [...]

By optically projecting intersecting grid patterns onto a complex model part, manufacturers can quickly machine a copy of the part, check quality, or modify CAD data. Manufacturers can shorten product [...]

Saginaw Machine Systems Inc. has devised a production system that corrects both geometric and thermal errors on a variety of two-axis and three-axis machine tool types. The PC-based Real Time Error Correction System eliminates 80% of a machine tool's errors while enhancing accuracy. The project focuses on three objectives, namely: to include all thermal and geometric error components in one synthesis model, to make the method valid for most types of machine tools and to provide suitability for different measuring positions due to different measurement methods and instruments., The search for machining's Holy Grail--real time compensation of thermal expansion--is going on in earnest at Saginaw Machine Systems Inc. A series of three research and development projects has already [...]

New machining centers rely heavily on leading edge technologies including distributed I/O, a new position-feedback system, modular construction, and highly optimized structures. A line of horizontal machining centers recently introduced [...]

The development of third-generation machining centers is coming to fruition. While earlier generations focused on multi-function versatility and speed, third-generation machines are more concerned with simplicity which helps eliminate custom application engineering. These machining centers emphasize the 'start a part, finish a part' approach to manufacturing to enable the elimination of queue time, multiple setups and the use of multiple machines. Third-generations aim to reduce idle shop time by optimizing processes through the expansion of machine functionality. In the future, one can expect to use a single, versatile machine that performs such tasks as turning, grinding, boring, milling, drilling, tapping and laser work in just one part cycle. These machines include standardized elements that can be easily combined and recombined to satisfy the specific needs of its users. What this results to is a standard machine that provides custom capability., Modern CNC machining centers are taking over more and more roles in metalcutting production. They are the machines of choice in pre-engineered, low-cost cellswhich are taking the place of expensive [...]

Laser machining, abrasive waterjet, ultrasound assisted electro-erosion, TGV machining... Some of these so-called unconventional procedures are already operational Nontraditional machining procedures still are not used extensively in industry, but are [...]

With the emphasis in quality shifting from post-process to in-process inspection, manufacturing engineers and quality control inspectors are making touch probes as commonplace in machine-tool magazines as extractors are. Touch [...]

By viewing manufacturing as more of a continuous process, machine tool builders and users can put their heads together to solve tough production problems. . . flexibly. Metalworking manufacturing produces [...]

3D surface mapping aids programming Fast 3D surface mapping takes tens of thousands of measurements and creates CAD wireframe and NC files to reverse engineer existing parts THERE IS GOOD [...]

Just when you thought high speed machining or hard milling would steal the best applications from ram-type elertrical discharge machines, linear motor technology is taking 'sinker EDM' to levels unattainable [...]

Many of today's machined parts incorporate various features located on multiple planes or faces of the parts. When using a three-axis mill or machining center to produce such parts, multiple [...]

This shop finds the process practical, productive and predictable, an indispensable technology that supports all of its manufacturing capability. By its nature, wire EDM (electrical discharge machining) attracts a lot [...]

Work on a five-year, $11 million cost-shared program directed to enhancing the air flow passages of automotive components has recently been completed. A joint venture was formed for the collaborative [...]

By using a new five-level polysilicon surface micromachining process pioneered at the Department of Energy's Sandia National Laboratories (Albuquerque, NM) manufacturers will be able to produce more reliable microelectromechanical systems […]