Industrial Machinery Digest - January 2021

» Embracing Knowledge » Lowest Life-cycle Costs vs. Lowest Price » Efficient Automatic Feeding of CNC Machines » Greater Versatility

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January 2021

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Table of Contents

COLUMNS

10

14

BUSINESS 4.0 Becoming A Master of All Trades Diversification will help manufacturers navigate the unpredictable COVID-19 markets

TALKING SHOP Chris Pollack Manager, Virtual Technical Application Center, Siemens

20 FEATURES

20

16

MANUFACTURING SHOWCASE The Schaeffler Group By: Russ Willcutt

22 26

WORKFORCE DEVELOPMENT Embracing Knowledge Introducing the Mastercam Educators Alliance and a new collaboration provides increased exposure of resources

NEW TECH

30 PROCESS

Efficient Automatic Feeding of CNC Machines

32

INDUSTRY INSIGHTS Greater Versatility Leading cutting tool manufacturer Taylor Toolworks increases its versatility and improves performance by investing in ANCA’s technology

SAFETY & MAINTENANCE Reducing Environmental Friction with High-Performance Coatings

DEPARTMENTS

Lowest Life-cycle Costs vs. Lowest Price By: Dan Janka, president and CEO of Mazak Corporation

16

6 EDITORIAL DIRECTIONS 8 INDUSTRY NEWS 36 PRODUCT SHOWCASE 44 SURPLUS BUYING AND SELLING 49 CLASSIFIEDS 50 ADVERTISER INDEX

ON THE COVER

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Editorial Directions SERVING AMERICAN MANUFACTURERS FOR OVER

The past year has forced all of us to make changes in how we do things that we'd once only discussed theoretically. Funny how reality can force your hand that way. I still have moments when I see how we now live – everyone wearing masks, stopping at every hand sanitizer station for a quick squirt, maintaining distance from the next person in line – and I’m amazed that things have come to this. But rather than feeling sad, I find myself in awe of our sheer ability to adapt to the reality of the given situation.

Just looking to my friends and family, I see so many changes in behavior in response to the coronavirus threat. Wearing masks is just the beginning, as is this miserable state of quarantine that’s still confining us to our homes – most of us, at least. Food procurement is almost unrecognizable, as restaurants rely on curbside pickup and drive-thru windows to survive. Grocery stores actually deliver orders to your kitchen door; I know some people who haven’t set foot inside a supermarket in months. Medical appointments have become surreal, what with Covid checks and tests, patient separation, and stickers doled out denoting your status in the clinical scheme of things. Haircuts, dental appointments, handshakes, hugs… so many things require a second thought these days.

And in business we’ve found ways to cope with similar changes. Simply surrendering and shutting down operations is not an option. Manufacturers, their salesforces, and distributors haven’t missed a beat in developing new approaches to reaching out to their existing and potential vendors and customers in ways that are safe and effective. The normal activities of business must go on. Virtual meetings, webinars, online training sessions, YouTube demos, and many other communication channels have become familiar stand-ins for how we once came together. Many of us miss the camaraderie of travel and tradeshows and look forward to their return, but for now the focus is on the core concerns of manufacturing, production, and distribution.

While I’ve heard some people express a longing for the way things once were, I can’t recall a single person complaining about what’s required of us now. I think that says a lot about what we’re really capable of deep down, when we have no choice but to be tough and get busy.

35 YEARS

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Industry News Cosen Saws Hires New Service Operations Manager

American Company ARCH Cutting Tools Takes Out Top Place In ANCA’s Third Tool Of The Year Competition

Cosen Band Saws, a leading bandsaw manufacturer and developer of MechaLogix, has announced that Bob Meier has been hired as service operations manager. With over thirty years of experience, Meier has worked in all phases of the bandsaw manufacturing process including assembly of production and special machines, production management, research and development, and service management. A graduate of the Dunwoody College of Technology’s Automotive Division, Meier also has a strong background of leadership training and multiple courses in hydraulic, electric, and pneumatic trouble shooting techniques.

“In my first month on board, I am excited about the staff that I am so lucky to work with,” says Meier. “A company is only as good as its employees and that makes Cosen a great company. The level of expertise and professionalism amongst the entire organization is second to none and I am honored to be part of that group.”

With 28 entries, 1.2 million social impressions and almost 4500 votes, ANCA’s Tool of the Year loudly celebrates the contribution modern cutting tools make to manufacturing, surgery, woodworking and other diverse industries. The overall winner, ARCH Cutting Tool’s entry demonstrated excellent use of multiple iGrind operations with several complex profiles. The tool came out in front of others when compared to the DXF and measured on the Zoller for Profile OD and Runout. The surface finish measurement on the Alicona produced a superb result. The tool also stood out in terms of complexity of grinding and was a large diameter (1-inch) multi-functional cutting tool with many features. Overall the tool was complete - ticking every box to be the Tool of the Year winner and was an exceptional effort from the team at ARCH. “We entered to present and showcase our capabilities as a cutting tool manufacturer and to demonstrate the complex capabilities of the ANCA Tool and Cutter Grinder,” said Jim Gray, president and general manager, ARCH Cutting Tools – Latrobe. “Additionally, we entered to share with customers our own custom capabilities with solid carbide tools.

Universal Robots Reaches Industry Milestone with 50,000 Collaborative Robots Sold Collaborative robots, or cobots, remain the fastest growing segment of industrial automation, projected to grow at a Compound Annual Growth Rate (CAGR) of 30.37 percent during 2020–2025. Cobot market pioneer Universal Robots (UR) solidified its frontrunner position today by selling the 50,000th UR cobot, which was purchased by a German manufacturer to enable higher productivity and better employee safety.

The 50,000th cobot came in a special delivery as Jürgen von Hollen, president of Universal Robots, personally handed over the cobot to VEMA technische Kunststoffteile GmbH and VEMA Werkzeug- und Formenbau GmbH located in KrauchenwiesGöggingen, Germany, at a ceremony held at VEMA. “We have worked very hard in the past 15 years to develop an entirely new market segment with a mission to enable especially small- and medium sized companies to automate tasks they thought were too costly or complex,“ says von Hollen, emphasizing how UR has created a new global distribution network, a new ecosystem of developers, and ultimately a completely new business model. “As a pioneer in this market, we put a lot of work into creating awareness, influencing standards, and changing customers’ perceptions influenced by their experience of traditional robots.”

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FANUC Named Top Workplace In 2020 FANUC was named a top work place in Michigan by the Detroit Free Press for the ninth consecutive year. FANUC ranks 15 out of 30 companies in the large employer category in Michigan. In addition, the Chicago Tribune named FANUC’s Hoffman Estate, IL regional office a top workplace in Illinois for the third year in a row.

“I’m so honored that even during these challenging and unprecedented times of a global pandemic we’ve been named a top workplace,” said Mike Cicco, President and CEO, FANUC America.

"This recognition is based on our employees’ feedback, and I’m proud they feel that FANUC is an ideal place to work.”

“Our team of talented professionals is our greatest asset – integral to our company’s mission and key to FANUC’s competitive advantage,” added Cicco.

FANUC America’s Achievements in 2020 include a number of new CNC and robotics products, a new facility in Alabama, national recognition for helping close the manufacturing skills gap, and a first-ever virtual event.

Cincinnati Incorporated Welcomes New President & CEO Cincinnati Incorporated (CI) is pleased to announce the appointment of Timothy L. Warning as president and chief executive officer effective November 30, 2020. Tim has also been elected to the Board of Directors at CI. Tim has a strong track record and has consistently demonstrated the ability to build highly skilled and innovative teams to bring growth and profitability to the companies

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he has served. Most of his career was spent growing businesses for Occidental Chemical Corporation (20 years) and various Dover Corporation companies (16 years).

“It is both an honor and a privilege to lead a great Cincinnati company with such a rich history,” Tim said. “CI’s reputation for high quality and long-lasting durable machines is widely known throughout the industry, as is their commitment to the well-being of their employees.”

Life Flight Network Selects 70-Foot Bifold Door From Schweiss Doors For New Emergency Response Hangar Attached to the hangar is a Schweiss Doors 70-foot by 17-foot bifold liftstrap door. The custom-made door is equipped with autolatches and was framed for four 4-foot square windows which allow a considerable amount of natural light into the hangar. It is also wind-rated at 120 mph. The well-insulated door was clad with 26-gauge metal sheeting. Dillingham said he did have input on what type of door would be installed on the hangar, relying on a recommendation from the general contractor who highly recommended the Schweiss bifold door from past experience.

“The bifold door works great,” Dillingham says. “It’s heavy-duty and easy to operate. A small amount of education is required so staff know not to leave it open during windy days, but the door is exactly what we needed. We had windows installed to let light into the building and make sure the area outside is free from obstructions. It works great for us.”

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Norton | Saint-Gobain Abrasives Announces New Online Safety Resource Saint-Gobain Abrasives, one of the world’s largest abrasives manufacturers, has announced a new Safety Resource Microsite offering a wide range of resources to help ensure the safe design, application, and use of Norton abrasives products. Educational content on the new Online Safety Resource includes Safety Data Sheets which are accessed by entering the UPC code found on Norton products.

Safety Guides for Norton’s most popular products such as Grinding Wheels, Portable Wheels and Coated/ Non-Woven Abrasives are offered.

Ten informative Safety Videos cover a range of applications including using form belts, precision grinding and dressing, guard conversions on right angle grinders, wheel mounting, abrasives use on railroads and in foundries, and grinding wheel safety presented in English, Spanish and French.

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Business 4.0

Becoming A Master of All Trades

Diversification will help manufacturers navigate the unpredictable COVID-19 markets “You must be diversified enough to survive bad times, so that skill and good process can have the chance to pay off in the long-term,” said American academic and investor Joel Greenblatt. This is certainly true for companies that are branching out into new sectors to overcome the uncertainties of COVID-19, while other manufacturers are falling behind. Here, Claudia Jarrett, US country manager at automation parts supplier EU Automation, explains how software is giving some businesses the edge.

The advantages for Industry 4.0 technology are well-known.

From improved productivity and operational savings, to increased collaborative working and better experiences for the end customer, it has become a no-brainer. Despite this, the roll-out of digitalized processes is still low among manufacturers in 2020, according to IoT Analytics’ latest Industry 4.0 and Smart Manufacturing Adoption Report.

Less than 30 percent of manufacturers say they have extensively adopted these new technologies, although North American manufacturers were revealed to be the greatest adopters of the Industrial Internet of Things (IIoT). Unsurprisingly, automotive manufacturers, always the leading innovators when it comes to any new form of technology, were revealed to be the most digitalized

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sector. Yet, despite these advancements, why is there still so much reluctance to digitalize?

There are a number or reasons. One is that manufacturers assume that integrating Industry 4.0 will be expensive — a wrong assumption, as we’ll examine below. Other companies are set in their ways and see no reason to upgrade their existing machining setups. There are manufacturers that are simply unsure as to how modern, digitalized processes can fit into their existing ways of doing things.

Manufacturers will need to put these hesitancies to one side in the era of COVID-19. In its recent COVID-19 briefing note, analyst McKinsey and Company describes the upcoming climate for manufacturers as the “next normal”, characterized by unpredictable high or low demand scenarios. The report says that resilience will be needed if manufacturers are to navigate an economically and socially viable path.

This is confirmed in Pricewaterhouse Coopers’ (PwC) report, COVID-19: What it means for industrial manufacturing. PwC recommends that companies expand into new industries, and take advantage of fresh revenue streams, to sidestep defunct markets and fully embrace new opportunities. In other words, diversification.

Machine shops that once specialized in a particular area, like automotive, are branching out into new areas. Defense, aerospace, oil and gas or commercial applications are all examples. In a practical sense, this means introducing all kinds of tough-to-machine materials to their CNC lathes and mills — aluminum one day, hard non-alloyed steels the next — with the utmost productivity and machine utilization.

Savvy machine shops know that best way to achieve this is through Industry 4.0. That is, consolidating multiple machines under a centralized Enterprise Resource Planning (ERP) system with Human Machine Interfaces (HMIs), which can handle these material changeovers and unfamiliar components.

But how can manufacturers outside of IoT Analytics’ 30 per cent — those that are wary or unwilling to embrace the IIoT — get onboard?

As Easy as CNC It is completely understandable that many manufacturers are wary of how Industry 4.0 technologies can integrate into their existing setup and systems. Yet, a quote by Machiavelli, the father of modern political philosophy, comes to mind. ”Whosoever desires constant success must change his conduct with the times.”

Digitalization is, therefore, a balancing act of sorts. Let’s focus on multi-axis CNC machines for a moment. Generally speaking, a key signifier of growth for machine shops is acquiring more machines. This goes hand-in-hand with successful diversification, as does purchasing machines with wider range of capabilities. CNC machines with full five-axis capabilities, or multifunctional machines, bring more processes into one station to process a wider variety of tough materials like aluminum or unalloyed steels.

The next step is to control these machines through a centralized ERP to ensure the overall production setup runs smoothly, while machine utilization is optimized to the fullest. The challenge here is that the manufacturer might operate dozens of machines from different makers that were manufactured years apart, each with their own way of working. How can machine shops bring all these systems together, cost-effectively, and without compromising their existing processes?

automotive brakes was able to capture and supply real-time accurate historical data up to ten-times faster with the system. The end result was that the manufacture was able to maximize production and minimize metallurgical defects in the components it produced.

There is an example of how software can directly benefit Quality Management Systems (QMSs), and help manufacturers win accreditations like the ISO 9001:2015, or the AS 9100 quality standard for aerospace. Both standards have proven essential for manufacturers seeking to diversify, and win contracts, in new sectors.

With these system in place, machine shops can address the practicalities of running a wider variety of challenging materials through their CNC lathes and machines. In doing so, to quote Greenblatt, they can be “diversified enough to survive bad times, so that skill and good process can have the chance to pay off in the long term” — despite the challenging and unpredictable times ahead.

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Soft Approach One solution is through the use of software, upon which manufacturers and machinists around the world are becoming more heavily reliant on each year.

Popular examples include Sandvik Coromant’s CoroPlus® Machining Insights platform, a Cloud-based platform that is designed to give manufacturers greater visibility of CNC machine tools and machining processes. Any easy-to-use HMI allows operators to analyze, identify, and eliminate common sources of downtime and inefficiency. the tool can also integrate seamlessly into existing ERP systems.

There is also the Mitutoyo’s MeasurLink® data management software system. According to one case study, a manufacturer of

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destination, at very short notice.

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Talking Shop

FEATURING:

TALKING SHOP WITH: Chris Pollack — Manager, Virtual Technical Application Center, Siemens Describe the founding, purpose, and evolution of the Virtual Technical Application Center, or VTAC. When I began working for Siemens about nine years ago, I was in the field promoting the Sinumerik control systems, the 808, 828, and the 840. We were reaching out to machine tool OEMs, distribution sales operations, and end-customers. That led to the establishment of our brick-and-mortar Technical Application Center here in Elk Grove, Illinois, where we held training seminars and things of that nature. Then, about four years ago, we asked ourselves how we could do a better job of interacting with our customers, so we began developing the concept of “virtual outreach,” in which anyone who was interested in Sinumerik CNC technology could access the initial learning stages online, at their own speed, and progress through increasingly advancing levels of knowledge from their own desktops.

We utilized various social media avenues and posted webinars on YouTube. Once we began pursuing this kind of outreach in Elk Grove, we became the only Virtual Technical Application Center, although Siemens has Technical Application Centers located around the world.

So what are the levels someone would move through who’s engaged in this process from start to finish?

Again, it all begins with a visit to our website, which has links to familiar social media platforms like YouTube, called Mr. CNC, where we post fresh webinars every six weeks. The content is basic and broad-ranging, building a nice foundation of knowledge for higher levels of learning. There are also some 70 webinars on a wide variety of subjects archived there, so visitors can access information on other Siemens technologies and services they’d like to know more about. The next level involves online training with classes led by Siemens instructors. We limit class sizes to 12 attendees since this is

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an interactive format, where everyone signs on in the morning for a three-hour session and is then given an assignment to complete that afternoon or evening. These courses generally last four-five days. Once that has run its course, the attendees who are interested in progressing to the advanced training level will travel here to the Technical Application Center in Elk Grove for in depth, hands-on meetings covering topics like 5-axis controls, variable machining technologies, and additive manufacturing.

What kind of support do you provide end-users moving forward as they encounter challenges and as your technologies evolve?

In terms of staying in touch with our customers, we are constantly sending them information about available upgrades, upcoming seminars, and any Siemens event from which they might benefit.

We have an incredible wealth of resources to offer our customers, and we’re constantly developing more utilizing the most up-to-date social media platforms available. We also offer what’s called the Virtual Product Expert, where a customer can schedule phone and web time with a Siemens technical or product specialist to discuss a specific goal or challenge they’ve encountered. Since the whole motivation behind creating the Virtual Technical Application Center was to find better, smarter, more convenient ways – and safer ways, in light of the coronavirus, it turns out – we’re continuing in that same spirit of concentrating on the customer, making it easy for them to continue learning about new technologies and to master the Siemens CNC products they’ve already invested in. It’s a long-term relationship, and we’re committed to holding up our end of that bargain.

More information is available at usa.siemens.com/cnc4you.

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Safety & Maintenance

Reducing Environmental Friction with High-Performance Coatings

Mobility, energy and general engineering operations benefit from lower energy consumption, reduced CO2 emissions and longer equipment operating life

S

pecialized physical vapor deposition (PVD) coatings are widely recognized for the critical role they perform in enhancing operational performance and extending the life of parts across countless manufacturing and industrial sectors. Less understood is the value that these coatings provide in reducing the environmental impact of the industrial processes where they are used.

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It starts with one of the primary reasons to use PVD coatings in the first place, which is to reduce friction between mated parts to improve performance. This can result in direct energy savings and, by extension, reduced CO2 emissions. Because these coatings extend the life of component parts that require frequent replacement, the raw materials, metals and energy that are required to manufacture a replacement part, are also saved.

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In fact, some specialized coatings manufacturers are making a strong case that coatings are a significant contributor to improving the environment. They not only point to these environmental benefits, but also to the enhancements they have made in their own coating equipment to operate more efficiently. In addition, continued advancements in specialized PVD coatings are also playing an important role in the design of components for new and emerging green technologies.

Reducing Friction With Specialized Coatings Reducing friction when mated components are in contact with each other is critical, particularly in punishing environments where there are high loads and high wear. Bearings, gears, rollers and other precision components suffer from excessive wear, surface fatigue, pitting, galling and corrosion which can also cause failure especially in high-load applications.

To prevent these issues from occurring, specialized PVD coatings are applied in thicknesses of typically only a few micrometers to further harden the surface of these parts and through mechanisms such as altering the surface chemistry they can also lower the coefficient of friction. As a result, less energy is used and less emissions are generated.

Carbon-based coatings such as Diamond-Like Carbon coatings (DLC) from specialized coatings formulators like Oerlikon Balzers, are even more durable. Produced mainly through PlasmaAssisted Chemical Vapor Deposition (PACVD), these well adhering

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coatings provide a unique combination of high hardness and low friction coefficients.

Such coated components are utilized for a variety of applications including wind turbine shaft bearings and planetary gears; stainless steel cutting blades and piston pumps; and sliding components across many industries. The coatings are also a proven technique for upgrading critical rotating parts in hydraulic drives, pumps and valves.

Advanced, hydrogen-free DLC coatings provide even higher hardness along with a very low coefficient of friction. These coatings can be applied in the most demanding environments for high friction, wear and contact areas such as in hydraulic pump parts, mechanical seals and high-pressure valve components.

Today, they are also playing an increasingly important role in e-mobility applications.

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Small Efficiencies Add Up Even small percentage gains in energy savings can really add up in large scale industrial environments. “Consider that a single percent gain in efficiency for a 200-megawatt gas turbine represents the equivalent power needed for 1500 homes,” said Alessandro Zedda, title, at Oerlikon Balzers.

Seemingly minor factors such as a smoother surface finish can improve fuel efficiency. In the aerospace and energy sectors, for example, PVD erosion coatings are applied to compressor blades to protect polished surfaces from degrading over time. This can reduce fuel usage by up to 0.5 percent while promoting component longevity. These fuel reductions translate into comparable CO2 reductions.

Similarly, in the automotive sector, DLC-coated valve and power train components can reduce the friction mean effective pressure

(FMEP) by ten percent. This translates to a two percent reduction in fuel. A 20 percent reduction in FMEP will generate a five percent fuel consumption reduction.

More stringent environmental regulations and standards worldwide are also causing industry to focus on reducing their carbon footprint and design greener products.

Take large cargo ships as an example. Today operators need to reduce the sulfur content of their fuel in order to be compliant with current sulfur cap requirements. With a cleaner fuel mandate, marine engine manufacturers required a new fuel injection technology because clean fuels typically do not lubricate as effectively as those with a higher sulfur content.

As a result, the coatings used in diesel marine engines also needed to be redesigned to ensure the new clean fuels will work well. Coatings that meet this new requirement have become an enabler of more efficient, higher performance, cleaner and smoother running machinery.

Extending The Life Of Parts Saves Energy The environmental benefit of high-performance coatings is also realized by how they extend the life of parts and tools. When parts last longer they are replaced less frequently which reduces the raw materials, metals, and energy it takes to manufacture them.

In the automotive sector, forming tools are made from multi-ton pieces of steel in the negative shape of a car. Used to make millions of cars, the forming tools will degrade over time and require reworking. To ensure optimal performance and long life, they require polishing and a PVD coating application. In addition to saving energy by keeping the forming tool in optimal condition, additional energy is saved by less frequently moving equipment of this size and weight to a separate location to be repaired.

In the energy sector, applying a DLC coating to roller bearings in wind turbines extends their life and lowers maintenance expenses.

Consider that changing one main shaft bearing costs between $200-300,000 in addition to the disruption caused by taking the turbine off of the grid.

Enabling Green Technology Development Beyond improving the efficiency and carbon emissions of existing systems, PVD coatings can be an enabler of new green technologies in categories such as fuel cells and high-power energy density batteries.

“Within the fuel cell sector, we are working with a client who manufactures bipolar plates, a key component in fuel cells,” said Alessandro. “Here the role for a PVD coating will be to promote conductivity while at the same time resisting corrosion. Together these attributes will promote the longevity of the fuel cells extending their environmental benefits.”

Alessandro adds, “we are also working with clients to apply PVD coatings on some exciting and highly innovative projects in high power energy density batteries. As industry continues to develop environmentally friendly innovations, there will be more opportunities for coatings to be engineered to support their performance and overall life span.”

Efficiencies in coating application generate an environmental ROI Further up the specialized coatings supply chain, coatings manufacturers themselves have examined their processes for applying coatings since it consumes both materials and energy.

When the energy consumed to produce coatings is compared to the energy savings they generated in their application, either through the improved efficiency and longevity of an engine or a cutting tool, an ‘energy payback’ or return on investment is generated.

“We are constantly striving to reduce the energy consumption of our coating equipment,” said Alessandro. “Our new coaters consume 40 percent less energy by using new more efficient plasma sources. Multiply this saving on every batch at all our coating centers around the world and the environmental benefit is huge.” He adds, “While the impetus to explore a new source was environmentally-driven, it is also in our customers’ economic best interests because it reduces their coating cost and shortens the manufacturing cycle.”

Specialized coatings have an important role to play in reducing our environmental impact. Energy consumption and carbon emissions of manufacturing and operations processes can be reduced significantly. While industry continues to use specialized coatings for their ability to enhance operating performance, the environmental impact is an important value-add that should not be overlooked.

For more information about coating solutions for components with Oerlikon Balzers e-mail: balzers.components@oerlikon.com; or visit www.oerlikon.com/balzers INDUSTRIAL MACHINERY DIGEST.COM

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IMD 19

Manufacturing Showcase

The Schaeffler Group By: Russ Willcutt

T

he foundation for the Schaeffler Group as it is known today was laid in 1946 when brothers Dr. Wilhelm Schaeffler and Dr.-Ing. E.h. Georg Schaeffler launched Industrie GmbH in Herzogenaurach, Germany. The company’s rise began in 1949 when Dr. Georg Schaeffler invented the cage-guided needle roller bearing, which was swiftly followed by the large-scale production of INA needle roller bearings for the German automotive industry. Today, INA is part of the Schaeffler Group, whose portfolio of product brands also includes FAG and LuK. After following its automotive customers around the world – Volkswagen in particular –Schaeffler eventually made landfall in

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20 IMD JANUARY 2021

the U.S. as a joint venture with Textron in 1964. Schaeffler became the sole proprietor of the business in 1969, ultimately establishing its North American headquarters in Fort Mill, South Carolina. This campus now features two administration buildings, an R&D center, and two manufacturing facilities: one dedicated to bearings for transmissions, and the other to linear bearings. The company has 11 additional manufacturing plants and over 13,000 employees throughout North and South America According to Ulrich “Uli” Mayr, vice president of Industrial Automation, Americas, U.S. activities are basically divided into three divisions; Automotive Technologies, Automotive Aftermarket, and

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Industrial. “In the first category, we are focusing on engine components, transmission, chassis, and e-mobility to automakers such as Ford, GM, and Chrysler,” he says. “Aftermarket replacement parts enter the market through all the major automotive aftermarket distributors and they are labeled as Schaeffler or LuK, which is known for its clutches.”

The Industrial division, Mayr’s specialty, is defined by markets rather than products. They include off-road (think John Deere and Caterpillar) wind turbines, two-wheelers (such as Harley-Davidson), railway, raw materials (mining and oilfield), power transmission, industrial automation (machine tools, medical manufacturing), and aerospace. Mayr

goes on to say that Schaeffler’s sales and application engineers conduct due diligence on each customer so that they understand their processes and potential challenges to the greatest extent possible at the beginning and throughout their relationship. They listen to end-user concerns and take them back to R&D for possible incorporation into future design improvements from which everyone benefits. This approach has resulted in some 2,400 patents being awarded to the Schaeffler Group in 2019 alone – making it Germany’s second-most innovative company, according to the German Patent & Trademark Office (DPMA).

That number is bound to rise. Just take a look at the company’s robotics portfolio. In 2020 Schaeffler introduced the new XZU bearing, with 20 percent less friction and 30 percent greater rigidity for articulating arm positions. This bearing is the culmination of 70 years of experience in the design and manufacture of needle roller bearings.

This same bearing is also used as the main bearing of its new precision gearbox (RTWH); a silk hat-type strain wave generator speed reducer.

The RTWH combines high gear ratios with relatively lightweight construction for clearance-free operation, high positioning accuracy, and compactness. The RTWH offers gear reductions of up to 150:1.

Also creating a stir are the new Vacrodur spindle bearings, which provide a service life that is 25 times longer (under mixedfriction conditions) as compared to 52100 steel, 2.4 times higher in terms of dynamic load carrying capacity, while offering much better thermal stability at higher temperatures.

Since bearings are generally acknowledged as the leading cause of expensive spindle failure events, improvements on this scale are welcome news. Decreasing downtime, as well as maintenance, repair, and replacement costs, is an accomplishment to be celebrated.

“This is a publicly-traded company that is still majority-owned by the Schaeffler family, which is rare these days,” says Mayr, “and we’re celebrating the 70th anniversary of Dr. Schaeffler’s invention of the cage-guided needle roller bearing, which remains our original claim to fame. And I think we do our best to live up to that every day.”

For more information visit schaeffler.us INDUSTRIAL MACHINERY DIGEST.COM

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IMD 21

Workforce Development

Embracing Knowledge

Introducing the Mastercam Educators Alliance and a new collaboration provides increased exposure of resources

M

astercam is pleased to announce the latest development in their commitment to the technical education community. The Mastercam Educators Alliance (MEA) is an organization designed to bring together the community of educators that teach and use Mastercam and provide a platform—a private MEA Facebook group—for sharing valuable information.

Within the first several weeks of launching the MEA, the group has already surpassed 500 members.

Members of the MEA are invited to join the private MEA Facebook group. This group is a place for educators to interact with other instructors and the Mastercam educational community. Additionally, Mastercam provides access to subject matter experts and content that is tailored to the needs of the MEA members. For those that do not use Facebook, a newsletter has also been created to keep MEA members informed of the content.

Peter Mancini, Education Product Manager, CNC Software states, “We have a very large and loyal group of Educators around the world that are teaching with Mastercam. These educators are responsible for introducing the next generation to manufacturing and teaching the skills necessary to keep the manufacturing industry strong.

We wanted to create a community where they could get together to share ideas and useful information like curriculum, projects,

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22 IMD JANUARY 2021

support, and more. We launched the MEA in July, and we have been overwhelmed by the great response. We have a nice balance of secondary and post-secondary educators, and we have members from thirteen different countries. The MEA community has been very active, and we are excited about how it will grow and evolve.”

Regarding the MEA, Jason Hill, Educator at Rowan-Cabarrus Community College in North Carolina shared, “The MEA has engaged my students and I with the videos and content on this page. I think this is the best Mastercam page yet, and I am excited to see where it leads. I believe, as instructors, we should embrace the knowledge and help that this page is providing. I know there are a lot of followers of this page, but we as instructors need to be asking more questions and posting more projects that we are using Mastercam to create.

Mastercam has been my rock in machining for 13 years—and it is not a company—it's a family. So, keep posting, keep asking questions. The answers and help are right there on the MEA page.”

Mastercam University Welcomes In-House Solutions Training New collaborative efforts with third party training providers deliver valuable educational content via Mastercam University.

This initiative will enhance the content already provided by CNC

Mastercam Announces New Optimized 5-Axis Post Processor for FANUC CNCs The post processor allows advanced machine tool operators to reduce their cycle times while boosting part accuracy, particularly for CAD/CAM generated 5-axis simultaneous contouring part processes.

“Growing our relationship with FANUC was an opportunity that would continue to benefit our customer base and enhance our post processors. Working with the FANUC team was beneficial on the creation of the new FANUC 5-axis post to run the FANUC 30i-B and 30i-B Plus series controls. This collaboration ensured that we provided FANUC’s best methods of running their controls. Without a doubt, our new 5-axis post processor will bring the highest productivity gains to machine tools for customers,” says Mastercam Post Department Manager Pedro Sanchez, Jr. Key functions of this post processor include: » Table/Table (AC/BC/Nutating) Support. » Rotary and Vector Programming. » Artificial intelligence contour control (G05.1) Positioning Accuracy (R1 - R10). » Workpiece setting error correction (G54.4P1 - G54.4P7). » Tilted Working Plane Command (G68.2) with Controls tool axis direction (G53.1). » Feature coordinate system setting by Euler's angles, Roll-Pitch-Yaw, setting by two vectors, setting by tool axis direction. » Tool center point control. » Type 1 Rotary output (G43.4) /Type 2 Vector output (G43.5). » Work offset support matching control capabilities (G54 - G59 / G54.1 P1 - G54.1 P300). » Drilling Cycles (G89, G74, G82, G81, G83, G73, G84, G85, G86, G76).

For information on their 5-axis solutions, visit www.fanucamerica.com/ solutions/applications/five-axis-machining

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24 IMD JANUARY 2021

Software and provide an outlet for increased exposure of Mastercam training resources from the company’s global network. In-House Solutions is the first such partner to provide content on Mastercam University. The company’s 2021 Mill Essentials Training Tutorial is available now.

Regarding this opportunity, David Mitchell, Director of Products and Services at In-House Solutions shared, “We have been producing training materials for both the Industrial and Educational markets for over 20 years. We are very excited to be contributing some new content on the Mastercam University platform.

This site allows us to present our material in an easy to follow and interactive way. We are looking forward to creating some exciting new content in the future.”

Mastercam University provides online, video-based training for computer-aided design and manufacturing.

Using this platform, people can sharpen their skills on their own Mastercam 2021 Roughing: The new 3+2 Automatic Roughing toolpath automatically makes multiplane 3-axis roughing toolpaths by evaluating the model and stock, creating a cut, calculating what remains, and repeating the process until roughing is complete. schedule with easy-to-use, real-world training applications.

Courses are available for purchase from Mastercam Resellers and expense with efficient machining strategies and advanced toolpath cover all levels of Mastercam skills, from basic to advanced. technologies like Accelerated Finishing™ and Dynamic Motion™.

A Lathe Training Tutorial, a Mill Advanced Training Tutorial, and Mastercam is the world’s #1 CAM software, with more than 274,000 a Multiaxis Essentials Training Tutorial, all designed by In-House installations in industries such as moldmaking, automotive, medical, Solutions, will be made available on Mastercam University as well. aerospace, consumer products, education, and prototyping. It is Russ Bukowski, Chief Experience Officer CNC Software has distributed through an international channel of authorized Mastercam stated, “We are very excited to partner with In-House Solutions to Resellers in 75 countries, providing localized sales, training, and provide additional training offerings on the Mastercam University support for 2- through 5-axis routing, milling, and turning; 2- and platform. In-House is a strong Mastercam partner and training 4-axis wire EDM; 2D and 3D design; surface and solid modeling; provider and we are glad to be able to extend the reach of their artistic relief cutting; and Swiss machining. content to our international customer base.”

To learn more about the Mastercam Educators Alliance, email the Education Team at education@mastercam.com

ABOUT CNC SOFTWARE To learn more about In-House Solutions, visit: Founded in 1983, CNC Software, Inc. is a privately held company

www.inhousesolutions.com

headquartered in Tolland, Connecticut, with corporate offices in Switzerland and China. The company develops Mastercam, a suite

To learn more about Mastercam University, visit:

of CAD/CAM software created to reduce production time and

university.mastercam.com INDUSTRIAL MACHINERY DIGEST.COM

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IMD 25

New Technology

Lowest Life-cycle Costs vs. Lowest Price By: Dan Janka, president and CEO of Mazak Corporation

F

or manufacturers overseeing major capital investments, understanding the true cost of a product or service can be difficult. This is probably why most prefer to simplify their purchasing decisions by basing it on the bottom-line price alone.

While this approach theoretically makes sense – a dollar saved today is a dollar to spend on more tomorrow – it fosters a very serious problem: It fails to take into account the total cost of ownership across the full life cycle of an investment.

Understanding total life-cycle costs for machine tools, for example, can be a difficult task, even for experienced manufacturers. Consider the scenario of a customer that discovered they were losing a gallon of coolant per machine per day as wet chips carried it out on the machines’ part conveyor belts. With 14 machines using coolant that can be over $25 per gallon, those costs might be invisible on a day-to-day basis, but at the end of the year, they can balloon to upwards of $150,000.

This is a part of the total life-cycle cost for a machine tool, which also includes such costs as the downtime during spindle rebuilds, waiting for a spare part, machine power consumption or the cost of annual machine maintenance.

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For a more effective approach, the total life-cycle cost of a machine should be calculated as the purchase price plus all other costs associated with running and maintaining that machine minus the machine’s resale value. This last factor acts as one of the only ways to reduce the life-cycle costs of a given purchase after installation, and in the world of manufacturing, it can make a significant difference in the actual price of owning a machine tool.

Consider a budget-friendly machine tool that costs, for example, $60,000 over a typical five-year financing plan. For many shops, the five-year cycle also serves as a way to keep integrating new technology and expanding capabilities; after you pay off a machine, you resell it and use the funds to purchase new machines. After five years of use, that machine might be worth around $12,000, which means its total life-cycle cost was $48,000. There are typically two reasons for such a low resale amount. One is that the machine wears out in a shorter amount of time, and two is that there is a lack of aftermarket support.

Conversely, that same shop might opt for a more expensive machine, perhaps a high-performance model that costs, for instance, $100,000. At $40,000 more than the previous example,

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some shops would balk at the high upfront costs. But with a significantly higher resale value of $50,000 because the machines last longer, the five-year cost of ownership is only $50,000. Calculated this way, the more expensive machine is actually more cost-effective by a significant amount.

If the $100,000 machine also offers faster cycle times, greater throughput and increased durability, the costs may plunge even further. And when paired with service packages that reduce downtime or training opportunities that push your workforce forward, it becomes very clear that focusing on a machine tool’s sticker price fails to give manufacturers the entire picture.

In addition to the faster cycle times, greater throughput and increased durability of today’s higher quality machine tools, there are several other contributors to life cycle cost that also impact lowest cost per piece. These include the elimination of unplanned downtime and the reduction of scrap and rework. Machine speed – in terms of faster programming, tool changes, acceleration/deceleration and pallet changes – also contribute to lower cost per piece, as do multi-tasking capabilities. Multi-tasking machines help lower costs per piece by eliminating the need for multiple machines and operations, which in turn reduces necessary tooling, setups and fixturing.

At Mazak, we’ve dedicated ourselves to maximizing our customers’ returns on their machine tool investments. Whether it’s developing a new method to recapture coolant or building machines with Done In One part processing that also retain their value through years of use, our goal has always been to empower customers and help them achieve financial success in a globally competitive industry. And by taking advantage of these properties in five-year cycles of machine tool purchases and sales, these customers have discovered the most effective way to keep life-cycle costs as low as possible.

Mazak Unveils New Ez Machine Series and Smooth Ez Control With both affordability and high performance for job shops in mind, Mazak has officially launched the new Ez machine series, the new MAZATROL SmoothEz control and the accompanying MazakUSA. com/Ez website. The new machine family and control were developed specifically to help remove the cost barriers to acquiring the latest manufacturing technology without sacrificing machine capability or production performance, while the new Ez website further streamlines the customer experience and offers visitors focused access to Mazak’s newest product line.

Machine configurations within the new series include both horizontal turning and vertical machining center models, all of which feature the MAZATROL SmoothEz control and are designed and built

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in Kentucky. Among the turning center configurations are the QT-Ez 8, QT-Ez 10 and QT-Ez 12 models each offered in a 2-axis, M, MY and MSY versions.

M versions include milling capability, MY machines feature milling and Y-axis off-centerline capability and MSY machines are a combination of both milling and Y axis capability paired with second turning spindles for complete DONE IN ONE® part processing.

For further increased productivity and unmanned operations, the machines seamlessly integrate with bar feeders and robots.

Each QT-Ez model number indicates the standard chuck size, but Mazak also offers a smaller size optional chuck for each machine to provide greater maximum rpm capability. These include a 6”

chuck option for the QT-Ez 8, an 8” for the QT-Ez 10 and 10” for the QT-Ez 12. Each model is available in a 20” bed length and an optional 40” bed length for the QT-Ez 12 model. Available machine turrets include 2-axis drum style, with a bolt-on or BMT55 turret for rotary tool applications, and tailstocks are offered with either manual positioning with hydraulic quill or servo positioning capability.

Mazak’s VC-Ez Vertical Machine Series begins with the initial introduction of the VC-Ez 20, and soon will include both smaller and larger machines, the VC-Ez 16 and VC-Ez 26. All VC-Ez Series machines sport C-frame designs with X and Y axis motion via moving table and saddle along with Mazak’s high-rigidity MX linear systems and pre-tensioned ball screws that together ensure rigidity, accuracy and reliability.

Axis travels for the VC-Ez 20 measure 41.34” in X, 20.08” in Y and 25” in Z that allow the machine to accommodate maximum workpiece sizes of 49.21” long, 19.37” wide and 22.4” tall and weighing up to 2,204 lbs. All within an ergonomically designed machine that has a 26.5 percent smaller foot as compared to other models and one that measures only 102.65 sq-ft for significant floor space savings.

The VC-Ez 20 features a powerful 40-taper, 12,000-rpm, 25-hp spindle and 30-tool magazine automatic tool changer. Options include a versatile 15,000-rpm, 29.5-hp spindle with 81.13 ft-lb torque and a 50-tool capacity tool changer.

For fast and easy QT-Ez and VC-Ez machine programming, Mazak’s new MAZATROL SmoothEz CNC provides dual 800 MHz processors, 512 MB of RAM and a vibrant 15" capacitive touch screen that includes a full keyboard and displays up to 60 lines of code. Within the control, EIA/G-code and MAZATROL programming languages support a full range of programming options directly on the machine, while the MAZATROL TWINS function enables offline programming and simulations that draw real-time condition and performance data directly from the machine.

The MAZATROL SmoothEz control also features Mazak’s new LAUNCHER interface, accessible in every screen, and that uses the entire display to make screen selection smooth and seamless. To further streamline programming, the control’s QUICK MAZATROL function simplifies program creation and confirmation through touch screen editing and confirmation of 3D models.

In addition to the Ez website, Mazak recently rolled out its reimagined Virtual Technology Center to extend the product and technology experience beyond traditional events, as well as bring the benefits of its 800,000 sq. ft. campus to customers across North America on demand. The Virtual Technology Center features a rotating lineup of groundbreaking machines, automation systems and digital technology, as well as the ability to request quotes, schedule in-person visits and innovative ways for customers to connect with Mazak experts.

ABOUT MAZAK CORPORATION Mazak Corporation is a leader in the design and manufacture of productive machine tool solutions. Committed to being a partner to customers with innovative technology, its world-class facility in Florence, Kentucky produces over 100 models of turning centers, Multi-Tasking machines and vertical machining centers, including 5-axis models.

For more information on Mazak's products and solutions, visit www.MazakUSA.com or follow on Twitter and Facebook.

INDUSTRIAL MACHINERY DIGEST.COM

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IMD 29

Process

Efficient Automatic Feeding of CNC Machines

K

ASTO has opened up a new line of business with the introduction of its UNITOWER cnc tower storage system.

The system is specially designed for automatic feeding of CNC machines and buffer storage. Users will benefit from greater flexibility in production, better ergonomics and maximum machine operating times.

With the introduction of its UNITOWER cnc tower storage system, KASTO has entered new markets and opened up a new line of business: automatic feeding of CNC machines. The system

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significantly improves productivity by continuously supplying CNC machining centers and milling machines with loaded pallets that employees prepare at separate workstations. The storage tower is loaded during machine operation. There are no expensive downtimes, and the entire system, including capitalintensive machinery, can run unmanned for long periods, for example at night.

Users can connect several machines, regardless of manufacturer, to one tower storage system. The UNITOWER CNC can be

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connected fully automatically to several setup stations and transfer stations by means of shunting units and roller tracks. The storage and retrieval machine (SRM) transfers workpieces to a shuttle wagon which automatically takes them to locations assigned by the controller. Partially and fully processed pieces are returned to intermediate or final storage in the same way.

The new system is based on KASTO’s highly successful UNITOWER tower storage system. With system heights of up to 20 meters, it offers maximum storage space on a minimum footprint.

The UNITOWER CNC can accommodate pallets measuring up to 3,000 x 1,500 millimeter, and the loading height can be set anywhere up to 1,700 millimeters for optimum use of the available space.

This is possible because the UNITOWER CNC uses a practical and economical zero-point clamping system instead of machine tables.

In this way users gain flexibility in terms of height, and they benefit from an especially attractive price-performance ratio. Each storage compartment has a maximum payload of three tons, permitting trouble-free storage even of very heavy workpieces. Pallets are handled by a storage and retrieval machine with a crossbeam.

Compared with paternoster systems, for example, this has the advantage that it is not necessary to move the entire stock, but only the relevant cassette. Together with the superbly efficient drives, this ensures fast access times and saves energy.

determines the optimum order-handling sequence. Malfunctions can be quickly and easily rectified via remote maintenance, ensuring reliable operation of the entire system.

The UNITOWER CNC also scores high when it comes to ergonomics. It reduces manual handling of the workpieces, which can weigh tons, to a minimum. This protects the health of employees and gives them time for other tasks. The modular design of the storage system allows it to be expanded almost without restriction – a big advantage for dynamically growing companies.

When developing the UNITOWER CNC, KASTO was able to draw on extensive experience from its own manufacturing. The result is a practical, sustainable automation solution for manufacturers in all sectors.

ABOUT KASTO: KASTO Maschinenbau GmbH & Co. KG, based in Achern, Germany, specialises in sawing and storage technology for bar stock. The company is a global leader in the manufacture and sale of metalcutting saws and semi-automatic and automatic storage systems for bar stock and sheet metal. It is also a leading manufacturer of automatic handling systems for metal bars, sheet metal and pre-cut parts, as well as the corresponding software. One of Europe’s oldest family-owned companies, KASTO celebrated its 175th anniversary in 2019. In the course of its successful history it has registered 170 patents, delivered

Intelligent Control System and Ease Of Use

more than 140,000 sawing machines to all parts of the world and

The UNITOWER CNC is managed by KASTOlogic, KASTO’s software for warehouse management and production control. The software provides the machines with the workpieces required for each order, checks whether the necessary NC programs and tools are available, monitors production processes, calculates completion dates and

installed more than 2,200 automatic storage facilities. In addition to a branch in Schalkau, Thuringia, KASTO has subsidiaries in England, France, Switzerland, Singapore, China and the USA. For more information, visit www.KASTO.com INDUSTRIAL MACHINERY DIGEST.COM

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IMD 31

Industry Insight

Solid carbide end mills fabricated by Taylor Toolworks

Greater Versatility

Leading cutting tool manufacturer Taylor Toolworks increases its versatility and improves performance by investing in ANCA’s technology

D

esigning tools online, varied batch sizes, six-wheel packs and 38 kw peak spindle power of ANCA’s MX7 tool grinder offers new capabilities that are helping Taylor Toolworks beat competition in the woodworking and metal industry. Capital investment can be a daunting project, but Taylor Toolworks have found that with the right research and understanding of your business needs, the benefits offered by new technology can be a game changer.

Located in Alberta, Canada, Taylor Toolworks Ltd. is one of North America’s technological leaders in the manufacturing and

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service of cutting tools for the woodworking and metal industries.

This remains the biggest part of their business. The company is run

by President Jesse Taylor and his sister Kristyn, who has worked there for more than 15 years. With state-of-the-art five-axis CNC grinding, combined with the use of the finest micro grain carbide products, Taylor Toolworks maintains the highest tooling tolerances and mirror finishes needed for high performance tooling. Services offered include reconditioning, end mills and custom tooling.

Reconditioning involves tool regrinding, tool re-cutting and tool re-coating. End mills include super polished flutes, special grade

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carbides and special coating for maximum performance. Custom tooling is made to specifications for both the woodworking and metal industry. These can be micro grain carbide inserts, custom profile tools, step drills, and more.

Jesse Taylor said that ANCA’s MX7 Linear machine allowed them to have greater versatility in their manufacturing. Another factor that influenced the purchasing decision was ANCA’s tool simulation software. According to Taylor, “This allows us to program tools [virtually] on a desktop before they are processed on the actual machine. This saves valuable machine time.”

This machine helped Taylor Toolworks produce complex tools better compared to competing companies that offer 2 wheel packs.

The company purchased an MX7 Linear machine because it is a powerful, versatile Jesse Taylor, President of Taylor Toolworks in front of ANCA’s MX7 Linear CNC tool grinder used for production up to six-wheel packs. In addition, the machine uses ANCA LinX grinding. It meets the demand of high Linear Motors for axis motion (X and Y axis), has an integrated output, high precision manufacturing. Key features include 38 kw wheel dresser and its automation options include RoboMate or (51 HP) peak spindle power, linear scales as standard on the X and FastLoad-MX Compact Loader. The MX7 Linear is a hard-working, Y axes, standard 6-station wheel changer that stores and changes

Premium Features: Included Introducing the new Tormach 1300PL CNC Plasma Table.

We’re known as the company that pioneered the meeting point of compact, affordable, and capable CNC machine tools. So, it’s no surprise that our first plasma table sits at a fair price point and is loaded with value.

Some impressive features that come with the 1300PL include: • • • • • •

Closed-loop servo motors for reliable accuracy Floating head with Digital Torch Height Control that help make cuts to uneven surfaces like corrugated metal Standard breakaway torch holder with collision detection to minimize machine damage if things go wrong Minimized run times with fast rapids (1,000 in./min., 400 in./min. cuts) and acceleration (30 in./sec./sec.)

Integrated water table mounted on sliding rails, ideal for cutting pipes and larger parts The only plasma table built with PathPilot, Tormach’s award-winning CNC controller, and access to PathPilot HUB, Tormach’s browser-based version of PathPilot

Everything-but-the-Torch starts under $14,500!

Build your 1300PL at tormach.com/1300PL/IMD INDUSTRIAL MACHINERY DIGEST.COM

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IMD 33

Taylor Toolworks production manager, Glen Taylor

high productivity system with unique features that enable it to handle varied batch sizes with minimum set-up time. It is ideal for high volume production for tools up to 25 mm (1”) diameter. The new cylindrical linear motor design increases reliability and ensures a superior surface finish.

Taylor also highlighted the reasonable lead times at ANCA for purchases of what are sophisticated and highly technical machinery.

This made a big difference for Taylor, who commented, “A lot of times in our industry when you’re buying a machine you may be six months to a year out for receiving your machine. When I got to work with ANCA and found out that they had machines readily available that really allowed us to jump on this and get a good start versus waiting for a machine.”

According to Taylor, the tools produced on ANCA machines are complex profile tools as well as step drills, thru-coolant drills and form tools. Applications for these tools range from aerospace, to woodworking, to general machining and cutting of plastics. On ANCA machines, the company uses ANCA’s Tool Room software.

The software provides specific applications for each tool produced at Taylor Toolworks such as a step tool editor or a profile tool editor.

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Being in the industry for over 20 years, Taylor saw ANCA machines at various trade shows. He talked to several people at the shows, including ANCA application specialists. This made him take a closer look at the machines and he saw that they were suitable for his needs.

Solid carbide of complex profile

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Solid carbide ballend milling cutters for aerospace applications by Taylor Toolworks

Drop Forged Hoist Rings

Mold Handler™ Swivel & Pivot Hoist Rings

Forged Swivel Hoist Rings

Round Base Swivel & Pivot Hoist Rings

In terms of service issues, Taylor commented that ANCA was good at solving any issues that come up, whether it was by calling or sending someone on-site. Besides using the MX7 Linear machine, the company has three other ANCA machines. One is the ANCA Fastgrind for resharpening tools. Taylor said, “ANCA is a big part of our operation.”

To sum up his experience, Taylor was satisfied with the quality and service he received from the company. He remarked, “Buying more ANCA [machines] is definitely in our future.”

ABOUT ANCA ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.

ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.

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IMD 35

Product Showcase

PRODUCTSHOWCASE WANT TO BE FEATURED? Send your latest product information to editorial@indmacdig.com

IMD's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers.

Scotchman Introduces New Optional Automated Program for 90-Degree Cuts Scotchman’s SUP-600 NF AngleMaster Upcut Circular Cold Saw is designed specifically for cutting Non-Ferrous material such as aluminum, copper, PVC, and wood. Featuring a 24-inch (600 mm), 132 tooth carbide blade that is capable of producing round cuts up to eight-inch in diameter and rectangular cuts up to 9-inch x 5-inch at 90-degrees, the SUP-600 NF offers an increased cutting capacity not found in traditional pivot saws.

This SUP-600 upcut saw coupled with the Scotchman AngleMaster digital material positioning system, creates a semi-automatic programmable saw system that automatically rotates to any cut angle, pushes material into the saw & automatically rotates to the next desired angle. » For more information, visit www.scotchman.com

Tormach Inc. Launches New 1300PL Plasma Table Tormach Inc., an industry-leading supplier of compact and affordable CNC machines, has added a plasma table to its CNC equipment lineup.

The 1300PL CNC Plasma Cutting Table can easily accommodate 4-feet x 4-feet sheets of metal and comes standard with a host of premium features. Tormach recommends a Hypertherm torch for use with the 1300PL. Entry-level 1300PL packages including the torch, which features Digital Torch Height Control and a magnetic breakaway safety feature with collision detection, start at $17,150. The 65 amp plasma cutter works well for cuts up to one-inch thick material, and the table can hold up to 750 pounds. » For more information, visit www.tormach.com

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36 IMD JANUARY 2021

Larger 303SS Air Conveyor Converts Standard Pipe to Convey in Corrosive Environments EXAIR’s new Type 303 Stainless Steel 3 NPT Threaded Line Vac Air Operated Conveyors convert ordinary pipe into a powerful conveying system for parts, scrap, trim, and other bulk materials.

This chemical and corrosion-resistant Line Vac operates seamlessly at higher temperatures providing a long-lasting and low maintenance solution ideal for food, chemical, pharmaceutical, and medical processes. The durable construction of the Threaded Line Vac employs a larger inside diameter, aiding in conveying bigger parts and larger volumes of material over long distances with ease. » For more information, visit www.exair.com

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Coxreels Roller Bracket for the Challenger Series Reels Coxreels offers roller bracket assemblies for the Challenger Series.

The function of the roller bracket, as it is on other models such as the 1125-Series and the 1175-Series, is to assist in guiding the hose during both extension and retraction. The roller bracket assembly is available only in a four-way upper roller format, due to the compact size of the Challenger platform. Coxreels® has remained steadfast and focused on manufacturing high-quality professional-grade hose, cord, and cable reels since 1923. Coxreels® takes great pride in designing, building, and supporting all of their products right here in the United States. » For more information, visit www.coxreels.com

500° Fahrenheit Top-Loading Oven from Grieve This Grieve oven is a 500° Fahrenheit top-loading, electrically heated oven, currently used for heat-treating parts at the customer’s facility.

Workspace dimensions of this oven measure 96-inches wide by 20-inches deep by 20-inches high. 18 kilowatt are installed in Incoloy heating elements, while a 2 HP blower provides back to front airflow to the workload. This Grieve top-loading oven features 6 inches insulated walls, 16-gauge aluminized steel interior and a bottom reinforced for 800-pound capacity. Additional features include a heat chamber mounted below the workspace and a pneumatic “L” shaped door. » For more information, visit www.grievecorp.com

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IMD 37

Bystronic Introduces New 15kw Fiber for Bystar Fiber 3015 And 4020

Siemens Introduces Sinamics V20 Smart Access Web Server Module By providing a wi-fi hot spot, the wireless connection on this module facilitates setup, programming, commissioning, production monitoring, and maintenance on a variety of machines and production equipment. A simple, embedded graphical user interface (GUI) enables easy use of the Sinamics V20 in every phase of operation. No separate app is required, nor is a written operator manual needed, making the operation of this new server module and subsequent drive control highly intuitive and easy-to-learn.

Smart Access provides convenient access to the Sinamics V20, up to 100 meters away, even when the drive is located in difficult-toaccess installations.

On average, thanks to the new 15kW laser, the cutting speed of the ByStar Fiber increases by up to 50 percent (when cutting with nitrogen) compared to a 10kW laser source. This means that sheet metal processing companies can benefit from higher productivity with relatively low unit costs. The 15kW laser output now also enables extended applications in stainless steel and aluminum up to 1.5-inch thick and thus offers maximum flexibility for customer orders.

Regardless of whether cutting aluminum, non-ferrous metals, or steel, the high-performance Bystronic SSC cutting head excels with maximum precision in both thin and thick sheets and profiles. » For more information, visit www.bystronicusa.com

» For more information, visit www.usa.siemens.com/sinamics-v20

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New 5-Axis, Twin-Spindle Precision Machining Center From CHIRON

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38 IMD JANUARY 2021

The new twin-spindle series DZ 22, with spindle clearance of 600 millimeters, is designed to completely and rapidly machine complex, large workpieces, including housings for electric motors and transmissions, oil pumps, chassis components, and more. CHIRON introduced the DZ 22 W five-axis at its virtual open house in May. The company also offers a four-axis variant of the Series 22. Key to the success of the small-footprint innovative machine concept is a machine platform using a moving gantry design. The rigid machine bed and active component cooling enable the required degree of precision on the workpiece. » For more information, visit www.chironamerica.com

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Dillon Pin Location Jaws for Air Chucks Provide Accurate Location Gripping for Deformation Sensitive Parts Dillon Manufacturing, Inc. full grip (pie) blank jaws manufactured for Northfield®, Microcentric®, and others, are CNC milled to provide maximum accuracy for workpiece location, enabling air chucks to hold thin wall and deformation sensitive workpieces firmly. The full grip jaws are manufactured for chuck sizes ranges between four-inch and 10-inch diameters. Full grip jaws are available in 1018 steel and 6061 aluminum. Jaw heights are available between one-foot and four-inches. Jaws can be customized per customer request – a quotation of these engineering services are performed at no charge by experienced Dillon application engineers.

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Doosan Unveils the New Lynx 2600SY The new machine incorporates all the design features of the popular Lynx 2100LSYB, but is built on a slightly bigger platform. Customer feedback played a large role in the development of the new model.

The Lynx 2600SY was designed to provide maximum flexibility and versatility for job shops that want to handle a wider range of projects without stepping up in size to a PUMA Series boxway machine. The maximum turning diameter is 14.9-inches and the maximum turning length is 24-inches, and the main spindle incorporates a 10-inch chuck while the sub-spindle handles either a 6- or 8-inch chuck size. » For more information, visit www.doosanmachinetools.com

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IMD 39

Emuge Corp. Introduces New Generation of Taps for Hardened Steel, Cast Iron Materials

ESAB Autorex Fully-Enclosed Automation System Maximizes Cutting Safety And Productivity

The EMUGE A-H family of taps is the best solution for tapping extremely abrasive materials and those materials with elevated hardness levels, such as cast iron, common in the heavy equipment and agricultural vehicle markets. EMUGE A-H Taps are now available with or without coolant through holes and with TiCN coating, or NT nitride surface treatment, for improved tool life. Emuge HSSE-PM A-HCUT Taps can tap materials between 44 and 55 Rc hardness and feature a hard, heat resistant, powdered metal substrate for enhanced cutting performance and extended tool life.

“The AutoRex system is essentially a cutting machine inside its own room combined with shuttle table for automated plate loading and parts unloading,” explains Steve Zlotnicki, Global Product Manager, ESAB Cutting Systems. “The enclosure completely blocks out harmful UV light emissions and dramatically reduces noise, while ensuring that the ventilation system captures 100 percent of cutting smoke inside the cabin. AutoRex creates a much safer working environment, appealing to high-production, high-performance companies in the marine, offshore, heavy fabrication, wind tower, and steel service center industries.”

» For more information, visit www.emuge.com

» For more information, visit www.esab-cutting.com

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40 IMD JANUARY 2021

FANUC America And Plus One Robotics Deliver StateOf-The-Art Automation Solutions To E-Commerce Fulfillment Customers The new flexible fulfillment solution incorporates a FANUC robot and Plus One’s AI-powered PickOne perception system to identify, singulate, and sort a wide range of conveyable items without the need for traditional vision training. Powered by AI, the system can adapt to variations in product material, size, and shape, as well as intermixed, random delivery. If any exceptions occur, Plus One’s “Yonder” human-in-the-loop function notifies a “Crew Chief” who can remotely manage the exception, minimizing the interruption and providing seamless sustained automatic operation. Combined with a high-performance FANUC industrial robot, the system can outperform a comparable manual operation.

Industrial Magnetics, Inc. Introduces Magnetic Clamping Blocks for Clamp-Free Holding

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» For more information, visit www.magnetics.com

The magnetic blocks have two, opposing, magnetic sides, which can be turned on and off, and are designed to "clamp", or hold, workpieces to steel surfaces, such as machinery or worktables. They work in horizontal or vertical orientation and can accommodate flat, round, square, or custom profiles for operations such as tapping, machining, or deburring. Unlike standard clamps, magnetic clamping blocks allow access to five-sides of the work-piece at once, reducing setup time and the number of operations needed. They can be quickly turned on/off from either end for fast, easy setup and release.

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IMD 41

MakerBot Offers Three New ABS Composite Materials from Kimya for METHOD 3D Printers

Jorgensen Conveyor and Filtration Solutions’ EcoFilter® Conveyor The EcoFilter® Conveyor from Jorgensen Conveyor and Filtration Solutions is the first competitively priced conveyor and filtration system for entry-level and mid-priced turning and machining centers.

This patent-pending, self-cleaning design works on larger, higherpriced machines as well. The second-generation EcoFilter® utilizes an innovative two-stage metal chip removal and coolant filtration design.

A hinged steel belt conveyor handles the primary removal of large chips. It dramatically reduces the number of chips that migrate to the coolant tank, which decreases the frequency of tank cleanout and the amount of downtime required for maintenance at the same time that it greatly improves pump, tooling, and coolant life.

Composites are one of the most in-demand material categories for manufacturing applications due to their enhanced properties compared to unfilled thermoplastics. The new materials include Kimya ABS Kevlar for parts with high strength, abrasion-resistance, and dimensional stability; Kimya ABS-ESD, which protects against electrostatic discharges; and Kimya ABS-EC, a new and unique material that is electrically-conductive. Kimya ABS Kevlar, Kimya ABS-ESD, and Kimya ABS-EC are available to print on the METHOD X 3D printer with the new MakerBot LABS GEN 2 Experimental Extruder, the latest edition of the LABS extruder. » For more information, visit www.makerbot.com

» For more information, visit www.jorgensenconveyors.com

C-FRAME PRESSES • Heavy Gauge Steel Design • Press Bed bolted on, not welded, to prevent distortion.

• Large press bed to accommodate a variety of tooling other than just punching.

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• Large rectangular tubes used at base of machine to give safe, instant portability.

Mate Precision Technologies to Launch New Workholding System

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42 IMD JANUARY 2021

Available in January 2021, this new line of vises, bases, and mounting systems maximizes holding power in a compact, quick-change modular design that reduces setup time and process variability. It is designed for 3-, 4- and 5-axis machining centers. The Mate 52/96 workholding system includes QuickSpecs™, Mate’s unique product identification system. QuickSpecs allows real-time access to critical user data, CAD models, and potential integration into business systems. Additionally, the product supports common robotic interfaces and palletizing systems to support factory automation.

The workholding system is backed by the company’s sophisticated technical support, unsurpassed product quality, responsive customer service, and 100-percent satisfaction guarantee. » For more information, visit www.mate.com

New High-Speed Video Measuring System for Quality Control

Deluxe Vertical Turret Milling Machine

To measure components reliably and efficiently, whether in an inspection room or on the shop floor, Nikon Corporation has developed a new CNC video measuring system that provides unparalleled accuracy, repeatability, and reliability. Also known as a vision measuring system, the NEXIV VMZ-S3020 is optimized for automated quality control applications in a production line, as its high speed allows real-time feedback of measured results to the manufacturing process. The system is ideal for inspecting a wide variety of mechanical, electrical, electronic, molded, cast, and pressed components that fall within its 300 x 200 x 200-millimeter working volume.

Combining the key features of Palmgren’s standard Vertical Turret Milling Machine, the Deluxe model delivers the same quality, durability, and value. The addition of a two-axis digital readout, a “X” table power feed, and a “Y” axis power feed are standard features on the deluxe milling machine. In addition, the Turret Milling Machine guarantees rigidity for a lifetime of vibration-free accuracy due to the extra fine Meehanite castings. The machine’s long-term reliability and precision are the results of high-quality components and expertly crafted construction. Now observing its 100th anniversary, Palmgren is a C.H. Hanson brand.

» For more information, visit www.nikonmetrology.com

» For information, visit www.palmgren.com

agro-hytos hydraulic products

filtration… The range of filter solu-

tions implemented at Argo-Hytos extends from fixed-position industrial plants to highly mobile applications, primarily tailored to individual customer requirements. As a result of their vast experience with custom applications over a wide variety of sectors, Argo-Hytos offers a comprehensive range of innovation standard solutions: Suction Filters; Return and Return-Suction Filters; Pressure/ High Pressure Filters; Filling and Ventilating Filters; Filter Accessories; Sensor Technology.

fluid and motion control…

New Rapid Machine Operator Can Be Up And Running In Hours, No Systems Integration Required Rapid Robotics has announced the first ready-to-work robotic machine operator, giving contract manufacturers an easy, affordable way to automate common machine tasks and compete with offshore facilities. The Rapid Machine Operator is a revolutionary industrial cobot that needs no programming or systems integration.

‘Out of the box,’ it can operate machines performing simple tasks such as injection molding, pad printing, heat stamping, pick-andplace, and dozens of others across manufacturing sectors including medical devices, electronics, automotive, and more. » For more information, visit www.rapidrobotics.com

Directional control ValVes D02/D03/D05/D07/D08: Argo-Hytos DC and dual frequency AC coils can be rotated to locate connectors to your need. DIN, Deutsch Flying Leads and Wire Box Connection are available as standard Manual Override. Full line of Sandwich Controls.

FiVe series oF ValVes rate to 5000 Psi: RPE3-04, providing 8.0 GPM; RPE3-06, providing 21.0 GPM; RPE4-10, providing 37.0 GPM; RPE4-16, providing 80.0 GPM; RPE4-25, providing 160.0 GPM Gear PumPs: Argo-Hytos gear pumps provide high reliability, high volumetric efficiency, and low noise levels over the entire operating range. three series: GP1-P, maximum pressures from 2300-4350 flows 1.0 gpm; GP1-T, maximum pressures from 1700-4200, flows 1.0 to 17.0 gpm; GP1-Q, maximum pressures from 29004500, flows 7.1 to 42.8 gpm.

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IMD 43

Surplus Buying and Selling

Knives Out:

Shredding Plastics and a Wide Variety of Materials to Size in Single Pass By: Del Williams

T

raditionally, recyclers have shredded bottles and various plastic products, followed by granulating them to a size suitable to mix with virgin plastic pellets for use by manufacturers. However, the cumbersome process of shredding, screening, and grinding the plastic to size with different equipment in separate processes has not only been inefficient but also a bottleneck to processing.

Now, for the recyclers of a wide range of plastic products such as car bumpers, barrels, bottles, garbage cans, gas cans, paint cans,

44

| IMD

JANUARY 2021

as well as film and wrap, industry innovation has developed a much more efficient alternative: a shredder knife technology that can cut, screen, and size in a single pass with one machine on-site.

Because the sizing of reduced plastic scrap can be specified, uniform, and even tailored to suit the manufacturing process, more material can be successfully processed by recyclers with less labor, boosting profits. Shipping costs are also reduced for scrap transported off-site to buyers since any voids (i.e.- empty spaces) within the container are minimized.

IMD – The Industry’s Most Extensive Industrial Publication

In addition to plastics, the knife system design effectively shreds and sizes a wide variety of materials including rubber, paper, cardboard, wood, fabric, copper wire, aluminum, fiberglass, and even garbage, and batteries. Since the knife technology simultaneously does the work of both a typical shredder and granulator, it is also more energy efficient and takes less space on the production floor. The technology is flexible enough to be incorporated into the smallest to largest recycling, shearing and grinding equipment.

Conventional Equipment Limitations For decades in recycling, the reduction of large plastic scrap or unusable product has usually involved shearing equipment such as dual or quad shaft shredders. To further decrease size, this is typically followed by the use of grinding machinery such as granulators, stone mills, tub grinders, or chippers.

Screeners are often used at various points, which decreases processing speed. As an example, a standard dual shaft shredder typically turns shredder material into strips and requires the use of a re-screening device to reduce plastic material to a specific size, says Doug Bartelt, President of Milwaukee, WI-based BCA Industries, a developer and manufacturer of industrial shredding and recycling equipment.

According to Bartelt, conventional shredders like this are usually used in conjunction with granulators. A single shaft granulator is a simple device consisting of a knife (or multiple knives) attached to a shaft which mates with a stationary bed knife. Material is randomly chopped and continues to be cut until small enough to fit through a sizing screen in the bottom of the machine.

“Both the shredder and granulator create various sized material. Usually, this is determined by a random event in how the material is fed into the system in terms of speed, timing, which results in about 40 to 50 percent incorrectly sized material. Efficiency on either of these systems only approaches around fifty percent,” explains Bartelt.

Efficiently Reducing Scrap to Size Seeking a better way to size scrap material like plastic, Bartelt and his brother discovered a more efficient way to size without a screen. The insight was developed into BCA’s patented Triplus knife system technology, which changes a standard shredder to a hybrid between a dual shaft rotary shear shredder and a single shaft granulator.

The approach uses the precision grabbing action of the high torque, dual shaft shredder to cut the width of the material, while the bed knife design of the shredder sizes the length. This is accomplished in one operation, which produces accurately sized material in one pass without a screen. The end-product size is based on the size and geometry of the knives.

Unlike traditional equipment, the knife system is capable of shredding, chipping, and sizing any kind or size of plastics in a single pass without utilizing a screen. A shredder utilizing this design can produce over 85 percent correctly sized material in one pass with less than 10 percent oversized material, according to Bartelt.

With the knife system, a recycling operator just specifies the chip size needed, and it produces chips in the specified size. The design works with wet or difficult to screen materials, and clean cuts those that normally create fines and dust. With a traditional system, fines and dust must be air vacuumed away, and are considered undesirable for many reasons.

Functionally, for recyclers looking to streamline plastic scrap processing, the knife system increases efficiency and throughput that surpasses the typical granulators, hammer mills, chippers, and quad shaft shredders used in the industry.

By eliminating separate equipment and steps to shred, screen, and grind scrap to size – and combining this into a single function – the manufacturing process is expedited.

Another factor increases production output for recyclers, the RPMs of the knives can be adjusted to the load needed for optimal production efficiency. Unlike typical shredders that tend to operate at low speed and high torque, BCA shredders using the knife design can be operated at high speed and low torque for higher production speeds. When more torque is required for anything tougher to grind, the system automatically provides the RPMs necessary; it then readjusts to the higher speed, lower torque setting for faster production within seconds.

Additionally, the knife system can reduce plastic scrap to the appropriate size with much less energy than typical shearing and grinding equipment. Power efficiency approaches 150% over any standard shredder or granulator.

As an example, with this technology, a 50-horsepower single pass shredder can produce the same amount of recyclable product per hour as a standard 100-150 horsepower conventional system.

This can reduce recycler energy costs by $1,500-$5,000 per month while producing a more consistently sized product, ready for cost-effective transport to a purchaser.

The technology is flexible enough to be installed in any size shredder that BCA builds, from 10 HP to 800 HP, from 15-inch x 12-inch cutting chamber to 48-inch x 72-inch cutting chamber, in both stationary and portable units.

Recyclers needing to reduce the size of plastic scrap, plus a wide variety of other materials, have long resorted to overly complex in-house shredding, screening, and grinding processes as well as costly shipping to customers.

With industry innovation, however, recyclers now have the ability to quickly and efficiently cut plastic and other scrap materials to size onsite. This has the potential to both simplify production and reduce shipping costs to boost the bottom line.

ABOUT THE AUTHOR: Del Williams is a technical writer based in Torrance, California.

For more information: Call 414-353-1002; fax 414-353-1003; email john@bca-industries.com; visit www.bca-industries.com; or write to: BCA Industries, 4330 W. Green Tree Rd., Milwaukee, WI 53223 INDUSTRIAL MACHINERY DIGEST.COM

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IMD 45

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YEARS YEARS

Betenbender Manufacturing, Inc — www.betenbender.com ......................................................... 7 Carell Corporation — www.carellcorp.com ........................................................................................ 5 Clamprite — www.clamprite.com ....................................................................................................... 37 Cosen Saws, USA — www.cosensaws.com ...................................................................................... 15 Denver Breaker & Supply — www.denverbreaker.com .................................................................. 47 DHM Associates, Inc. — www.dhmassociates.com ........................................................................49 Dynabrade, Inc. — www.dynabrade.com ......................................................................................... BC Eagle Bending Machines — www.eaglebendingmachines.com ..................................................... 5 ENM Co — www.enmco.com ..............................................................................................................49 Essex Structural Steel Co. — www.essexstructuralsteel.com ........................................................ 47 Formdrill USA Inc. — www.formdrill-usa.com .................................................................................40 H&K Equipment, Inc. — www.hkequipment.com ............................................................................48 HMI div of Betenbender Manufacturing — www.betenbender.com ...........................................42 IMDauctions.com — www.imdauctions.com ....................................................................47, 49, IBC Kanetec USA Corp — www.kanetec.com ..........................................................................................48 Lenzkes Clamping Tools, Inc. — www.lenzkesusa.com ............................................................... IFC

ARE YOU LISTED?

We have launched our online, searchable directory with over 400 categories specifically designed for the industrial machinery industry.

IF YOU’RE NOT LISTED, YOU’RE MISSING OUT!

L&L Special Furnace Co., Inc. — www.llfurnace.com .....................................................................49 MacMillin Hydraulic Engineering Corporation — www.macmhydraulic.com ...........................43 Pro-Line — www.1proline.com ............................................................................................................49 Radwell International, Inc. — www.Radwell.com ............................................................................FC Royal Products — www.mistcollectors.com .....................................................................................49 Schweiss Doors — www.schweissdoors.com ..................................................................................49 Scotchman Industries, Inc. — www.scotchman.com ....................................................................... 3 Select Equipment Company — www.selectequipment.net ..........................................................46 Standard Direct.com — www.Standard-Direct.com .......................................................................48 Stor-Loc — www.storloc.com ............................................................................................................. 27 Suhner Industrial Products — www.suhner-machining.com .......................................................... 9 The Caldwell Group, Inc. — www.caldwellinc.com ........................................................................ 23 Tormach — www.tormach.com .......................................................................................................... 33 Trim-Lok — www.trimlok.com .............................................................................................................39 US Shop Tools — www.usshoptools.com ..........................................................................................11

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50 IMD JANUARY 2021 IMDdirectory-TV-042020.indd 1

3/23/20 4:36 PM

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WE LISTEN. WE OBSERVE. WE OPTIMIZE.

BUILT TO ENDURE During these tough times, we are honored to help keep manufacturing moving! n n

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