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Posted by: Miles Free 31. August 2015

Popular Heat Treat Colors for Steel Chart is Back

Heat treat colors for steel by temperature.

My “Temper Colors for Steel Chart” post remains very popular, so I thought I'd repost the chart illustrating the heat treat colors for steel.

These days, pyrometers are affordable. But it is the mark of a craftsman to be able to tell temperature by eye, if only to validate the instrumentation (or suspect it).

These colors were obtained from a 0.40 wt. percent carbon, alloy steel, as seen through a furnace peep hole during average daylight conditions.

 

Originally posted on PMPAspeakingofprecision.com blog. 


Posted by: Emily Probst 28. August 2015

Seven World Premiers Highlighted at Innovation Days Event in Japan

More than 8,900 people visited DMG MORI's newly remodeled Iga Solution Center
during "Innovation Days" in Japan.

During DMG MORI's “Innovation Days” event July 22-25 in Japan, the company showcased 58 machine tools in its newly renovated Iga Global Solution Center, which boasts 3,500 m2 (37,674 ft.2) of floor space. I, along with other members of the international press, got the chance to visit the spacious new addition, which also houses "Excellence Centers" for automotive, aerospace, die and mold, and medical—four industries in which the company expects continuous growth. The DMG MORI Porsche car is also on display.

During the event, Dr. Thorsten Schmidt, deputy chairman of the executive board, commented on the high stability of machine tool consumption this year. He says that machine tool consumption in the United States is up 6.9 percent, with Japan seeing an 8.1 percent increase, and a worldwide consumption increase of 3.3 percent. Dr. Masahiko Mori, president of DMG MORI, outlined the company’s product offering plans for the future. By 2020, he says DMG MORI wants to reduce its product models from 300 to 150, and provide a wider range of solutions with extensive applications. The company’s goal is to achieve the capacity to produce 18,000 machines a year.

Dr. Schmidt and Dr. Mori spoke to the international press.

 

Seven machine tools were introduced during the event, one of which was the Lasertec 4300 3D. Perhaps the most fascinating machine for me to see in person, the Lasertec integrates additive manufacturing into a turning/milling machine. The machine uses a directed energy deposition process by means of a powder nozzle, which is said to be 20 times faster in deposition than a powder bed. And as many as five deposition heads can be automatically parked in a secure docking station while turn/mill operations are being performed. The deposition heads can be prepared for ID deposition, OD deposition, large diameters of deposition, or small, heat-treating, surface-hardening, or welding.

 

According to Rory Dudas of DMG MORI, “Additive is where the future is going.” The fact that the technology can be used to produce complex parts with exotic materials—and it can be used in combination with traditional subtractive machining methods on the same platform means the technology is no longer restricted to the production of prototypes and small parts. Prior solutions were restricted to the build of a single alloy, while the new method enables the machine to use multiple materials—via laminations or gradual transitions from one alloy to another.

According to Dr. Mori, the company is currently selling one additive machine per month, but his goal is to raise that number to five or six.

Other machines that made their world premieres at the event include:

  • The NLX 300 | 300. This high-rigidity, high-precision CNC lathe features 3,000 mm between centers. It is well-suited for machining workpieces ranging to 3,123 mm long and 430 mm in diameter.

 

  • The A-18S (DMG MORI Wasino). This high-precision, compact, multi-processing turning center is equipped with a Y-axis turret and milling functions. It features 18 tool stations—the largest number in its class.
  • The G-07 (DMG MORI Wasino). The super-high-precision lathe reduces cycle times due to its gantry-type tool post. The gang-type lathe is said to achieve high accuracy in finishing, hard turning and high added-value machining.
  •  The ecoMill 600 V, ecoMill 800 V and ecoMill 1100 V. The newly designed ecoMill V series of vertical machining centers features 6 micron accuracy (without direct scales) due to direct coupling in the X and Y axes. The series does not include a belt drive, which eliminates backlash. To increase productivity, the machines feature a 12,000-rpm spindle speed, 119 Nm of torque and 560 mm of stroke in the Y axis.

 


Posted by: Chris Felix 26. August 2015

United Grinding to Host Technology Event

 

Manufacturers in search of the latest grinding technology, techniques and turnkey solutions to increase their competitive advantage might want to take a look at the United Grinding Universe Event, taking place September 16 and 17 at the company's North American headquarters in Miamisburg, Ohio. Throughout the symposium-style event, the company will use machines from its Studer, Blohm, Walter and Ewag lines to demonstrate how ID/OD, match, creep feed, centerless, radius, universal and other modern grinding techniques can improve productivity and boost part quality.

Among these machines are the Studer S151, a universal internal cylindrical grinding machine, and the Blohm Profimat MT, a high-performance production grinding machine. The company will also showcase an advanced automation cell to demonstrate the use of its machines in lights-out manufacturing.

Application engineers will be available during the more than 16 technology demonstrations to answer questions and discuss how new developments in surface and profile, cylindrical and tool grinding can produce precision parts at the best possible value. Supplementary technical lectures will follow these demonstrations so attendees can further explore the new grinding frontier.

Other key topics of discussion at the event will include how in-process and post process gaging, automation, software, coolant, abrasive technology and preventive maintenance play important roles in optimizing the overall grinding process. Furthermore, United Grinding staff will be available to assist attendees in finding the best grinding strategy for growing and/or optimizing their unique operations. Company representatives available during the event will include applications engineers, customer care representatives, executive team members and experts who represent each of the United Grinding brands in Europe. Several ancillary grinding machine suppliers will also be on hand to share technology advancements within their respective areas and how they relate to United Grinding equipment.

According to Terry Derrico, president and CEO of United Grinding North America, Inc., the United Grinding Universe Event is a great opportunity for any company that wants to reshore or grow its business in the highly competitive global marketplace. “Our event will be this year’s primary source for all things grinding. And those who attend will leave having complete knowledge of the latest grinding technologies and techniques for improved productivity and profitability,” he says.

As part of the United Grinding Universe Event, the company will host a special evening event at the Boonshoft Museum of Discovery on September 16 for those who wish to further network with peers. The evening’s agenda will include dinner, entertainment and a special guest speaker from the world of space travel.

Attendees can register for the event at the company’s website, where more information such as the complete presentation schedule and a full list of machine demonstrations is also available.


Posted by: Lori Beckman 25. August 2015

A Story of Growth and Innovation during Hard Times

Stacey and Sara are owners of Bales Metal Surface Solutions.

Stacey Bales, co-owner of Bales Metal Surface Solutions in Downers Grove, Illinois, often hears complaints from other business owners about how business is slow. She thinks to herself, “Do something about it. Market yourself. Don’t give up.”

Ms. Bales and her sister, Sara Mortensen, are businesswomen who have earned the respect of the manufacturing community. After taking over their father’s business when he passed away suddenly in 2009, during the Great Recession, they have grown the company. They recently picked up a business excellence award from a Chicago newspaper because of their tremendous growth, innovation, entrepreneurship and contribution to their community.

To read the full story about the sisters’ gritty determination, periods of grief, savvy business skills and an unstoppable work ethic, visit “The Bales Girls are Making Dad Proud,” and look for this article in the September 2015 issue of PM.

 


Posted by: Miles Free 24. August 2015

Causes of Part Length Variation on Screw Machine Parts

Photo Credit: "Acme Gridley Multiple Spindle Bar Machine Manual," First Edition 1961 page C11.

There are many different ways part length can vary when using a cut-off tool on multi- spindle automatic screw machines. Here are some of the major ones grouped into a rough classification by where the cause exists.

The cut-off tool itself:

  • Tool is dull
  • Tool is improperly ground (point angle too large)
  • Tool loose/improperly inserted into holder
  • Tool blade is too thin
  • Cut-off tool is hitting while in high speed
  • Cut-off tool being hit by die head or chasers

Cut-off toolholder:

  • Toolholder itself is loose
  • Toolholder is hitting work spindle
  • Toolholder is hitting tool post
  • Toolholder is warped or bent
  • Toolholder is worn

The work spindle:

  • Spindle has end play
  • Spindle has worn bearings
  • Spindle carrier has end play
  • Index lock pin spring is broken
  • Finger holder not adjusted properly
  • Broken pins or fingers in finger holder
  • Feed tubes bent or beat up
  • Wrong stock feed cam—overfeeding stock will cause bounceback from stock stop resulting in short part
  • Incorrect collet tension

The cross slide:

  • Cross-slide play
  • Cross-slide loose
  • Cam is loose
  • Cut-off cam is too large and causes too much feed
  • Cam drum is loose

Other tools:

  • Stock pushed back into collet by drill (dull drill pushing stock rather than cutting chip)
  • Stock pushed back into collet by reamer
  • Face-off tool is loose
  • Face-off tool is dull
  • Face-off toolholder is loose
  • Die head pulling stock out of collet, making part long

Part length can occasionally go awry when using cut-off tools on automatic screw machines.

This post lists more than 30 reasons that I can think of. What did I miss?

 

Originally posted on PMPAspeakingofprecision.com blog. 


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