Industrial Machinery Digest - April 2022

IndustrialMachineryDigest.com | April 2022

North America’s Manufacturing Resource for Industry Professionals Since 1986

» Cowles Tool 100 Years of Innovation and Counting » Scotchman Industries Leading The Way From Rural South Dakota » Breaking It Down Chip by Chip Five Things To Know About Chip Formation in Machining » Three Reasons to Robotize Soldering Operations » Think Differently and You’ll Cash In On That New 5-Axis Machine Fast » Eleven Ways to Optimize Efficiency in Automated Plasma Cutting Operations

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Table of Contents

COLUMNS

10

BUSINESS 4.0 Targeting Everything Targets Nothing

By Andrea Belk Olson, CEO of Pragmadik

14

TALKING SHOP HYDMECH: 40-Plus Years of Sawing Innovation

By Loyd McIntosh

22 FEATURES

20

16 16

MANUFACTURING SHOWCASE Cowles Tool

By Peter Nadolny Madsen, CEO & CoFounder, Made4CNC

100 Years of Innovation and Counting

22

INDUSTRIAL FABRICATION & AUTOMATION Scotchman Industries Leading The Way From Rural South Dakota

By Loyd McIntosh

26

WORKFORCE DEVELOPMENT Breaking It Down Chip by Chip Five Things To Know About Chip Formation in Machining

30 32 36

NEW TECH Three Reasons to Robotize Soldering Operations

PROCESS

DEPARTMENTS

6 8 42 44

EDITORIAL DIRECTIONS

49 50

CLASSIFIEDS

INDUSTRY NEWS PRODUCT SHOWCASE SURPLUS BUYING & SELLING

ADVERTISER INDEX

Think Differently and You’ll Cash In On That New 5-Axis Machine Fast

INDUSTRY INSIGHTS Eleven Ways to Optimize Efficiency in Automated Plasma Cutting Operations

By Steve Zlotnicki, Global Product Manager, Cutting Systems, ESAB Welding & Cutting Products

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SAFETY & MAINTENANCE Game-changing Benefits of the Safedoor SD100 System

APRIL 2022

ON THE COVER Cover Sponsor: Over the past forty years, HYDMECH has become a wordwide leader in metal band saw and cold saw technology and metal sawing solutions. For more information, visit www.hydmech.com.

Front cover image by Scotchman Industries.

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Editorial Directions With the first quarter of 2022 in the books, the key economic report indicators continue to show high product demand and continued growth across all the key manufacturing sectors despite some of the supply chain challenges.

Hence, the manufacturing sector's positive growth performance in 2021 and year-to-date in 2022.

In this April 2022 issue, we talked with the president of Scotchman Industries Mr. Jerry Kroetch in our Industrial Fabrication & Automation feature.

Cowles Tools gives us a look at 100 years of innovation and the importance of upgrading machinery that helps then increase production. In our Talking Shop column, we talked with HYDMECH's Rick Arcaro Vice President of Sales and Marketing, and Joanna Wilcox Marketing Manager on the 40-plus years of sawing innovation. A game-changing report on the benefits of retrofitting your legacy CNC machining centers with the new safedoor SD100 system solution for solving machine tending automation with an increase in throughput and production.

Workforce reports on the five things to know about chip formation in machining chip by chip. Industry Insight provides eleven ways to optimize the efficiency in automated plasma cutting operations. These are just a few highlights of the issue.

We hope you enjoy reading cover-to-cover.

Finally, I would like to remind our readers about the upcoming June 2022 Annual Supplier Guide that will be released in early June and is without a doubt our best edition yet. With more than 1,800 companies listed among more than 450 categories of manufacturing and support industries at your fingertips. Be sure to bookmark our searchable supplier database, with new features added to the Industrial Machinery Digest website in 2022.

Please feel free to send your feedback, article ideas, and other comments to our Editorial Team, at editor@indmacdig.com.

SERVING AMERICAN MANUFACTURERS FOR OVER

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Russ Willcutt, Editorial Director russ@indmacdig.com 800-366-0676 ext. 104 | Fax: 866-826-5918

Susan Rochester, Associate Editor srochester@indmacdig.com 800-366-0676 ext. 104 | Fax: 866-826-5918

Shane Bell, Creative Director sbell@indmacdig.com

SALES

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INDUSTRIAL MACHINERY DIGEST (ISSN 1542-5223) is published 12x per year by Source 360 Media. POSTMASTER: Please send change of address to INDUSTRIAL MACHINERY DIGEST, 3590-B US Hwy 31 South, PMB 233, Pelham, AL 35124. Printed in the U.S.A. SUBSCRIPTION POLICY: Individual subscriptions are available without charge in the U.S. to qualified individuals. Publisher reserves the right to reject nonqualified subscribers. Oneyear subscription to nonqualified individuals in the United States: $9600.

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Industry News

INDUSTRY NEWS Industrial Machinery Digest's Industry News features the latest news and press releases from some of the industries top companies.

WANT TO BE FEATURED? Send your press releases to editorial@indmacdig.com

AAON Announces Retirement of Paul K. Lackey, Jr. from Board of Directors

Applications for ARLANXEO Baypren® CRs” this Thursday, March 31, from 2:00 PM – 3:00 PM (ET). The presenter, Dr. Victor Nasreddine, ARLANXEO North American Technical Manager, will cover the basics of Baypren® polychloroprene (CR) polymers.

“RDAbbott and its supplier partners are looking forward to sharing technical insights, processing recommendations, and more with industry professionals,” said Rick Ziebell, Technical Fellow and Vice President of Technology at RDAbbott. “We look forward to building upon last year’s success and taking the 2022 series to an even higher level.”

AAON, Inc. announced today that Paul K. (“Ken”) Lackey, Jr. will retire from the Company’s Board of Directors following the end of his current term at AAON’s Annual Meeting of Stockholders on May 12, 2022. Mr. Lackey, who has served on AAON’s Board since 2007, decided to retire and not stand for re-election to the Board upon completion of his current term as he decreases his professional commitments.

Gary D. Fields, AAON President and CEO, said, “On behalf of the Board, I would like to express our deepest gratitude to Ken for his numerous contributions to AAON during his nearly 15 years on the Board. AAON benefited greatly from the knowledge and experience Ken brought to the Company. Please join me in thanking Ken for his dedicated service to AAON.”

Nathan Turner Appointed President of Fastems LLC Fastems, a leading builder and developer of intelligent CNC automation and software for high-mix-low-volume manufacturers, has named Nathan Turner President of its US operations at Fastems LLC. Mr. Turner brings more than 30 years of automation experience to this role. He is motivated, energized, and positioned to lead Fastems’ growth and expansion in North, Central, and South Americas. He will oversee Fastems’ sales, engineering, and support teams in this region.

Mr. Turner comes to Fastems from Rockwell Automation where he held several leadership roles including Director of Business Development; Director of Integrated Architecture – EMEA, which involved a three-year assignment in Belgium overseeing Europe, the Middle East, and Africa; and Director of Product Development. Prior to Rockwell Automation, Mr. Turner was with Beijer Electronics as Director of Sales, Marketing, and Product Management of the Americas. Other engineering and management positions cited on his impressive resume include those with Miller Electric, Automation, Inc., Mitsubishi Electric, and Yasakawa America.

RDAbbott Announces 2022 Webinar Series and Topics R.D. Abbott Co., Inc. is announcing its 2022 webinar series and preparing to share elastomer solutions from supplier partners like ARLANXEO, Cancarb, Dow, Hallstar, Parker LORD, and NovationSi. All the webinars in this year-long series are live, but registrants will also receive access to webinar recordings—along with additional post-event resources. Registration is free and space is limited, so RDAbbott is encouraging industry professionals to sign-up as soon as possible for these technical events.

This is the second year in a row that RDAbbott has sponsored a webinar series featuring products and technologies from its supplier partners. The 2021 series was well-attended and received incredibly positive reviews from attendees. The 2022 webinar series builds upon this success and starts with “Overview of the Properties and

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“We at Fastems are delighted that Nathan has joined our company,” said Mikko Nyman, CEO. “He brings a robust portfolio of technical knowledge, results management, global sales, smart integration strategy, and international business. Nathan is known for driving growth and profitability with dedicated expertise in delivering automation solutions all over the world.”

In addition to earning a BSME degree in Mechanical Engineering at Northwestern University, Mr. Turner has continued to develop and enhance his knowledge with focused courses in product management, distribution, sales, marketing, and finance. He often speaks to international audiences on engineering and advanced factory topics.

“I am eager and excited to begin this position at Fastems and will work smartly and diligently to leverage my experience in technical, cultural, and team leadership roles at global companies. I plan to take a holistic and practical approach to my responsibilities, supporting our customers and teams across the North and South Americas, to drive growth and boost awareness for Fastems’ intelligent CNC automation solutions.”

Lantek Achieves Market Leadership with 40 Percent Turnover Over the Past Three Years Lantek Sheet Metal Solutions S.L., developer of CAD/ CAM and digital MES and ERP solutions for the sheet metal industry, has solidified its market leadership position

following a record turnover of 26.6 million euros over the past three years, increasing sales to the machine tool manufacturer channel by 40 percent during 2021.

Headquartered in Basque country, Lantek also exceeded 29,000 active customers worldwide, resulting in 3,400 new customers across 100 countries including North American subsidiary Lantek Systems, Inc., based in Mason, Ohio.

A pioneer in the digitization of sheet metal solutions, Lantek has entered the first phase of its Strategic Expansion Plan which involves a 70 percent increase in its commitment to research and development, including expanding its workforce by 50 percent. The company has already experienced marked growth despite the COVID-19 pandemic with a 42 percent increase in sales volume in Asia, 13 percent in the Americas, and 19 percent in the EMA region. Germany and Italy have experienced significant growth helped with the construction of a new 1,200 m2 building in Turin.

“Lantek’s commitment to developing cutting-edge digital solutions for the sheet metal market is evident in the company’s exponential growth even during the toughest of times. The company’s investment in its research and development and its people will help us grow the U.S. market even more and our team is excited to be part of this effort. Lantek is a multinational company with a local focus,” said Anupam Chakraborty, Commercial Director, Lantek Systems, Inc.

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IMD | 9

Business 4.0

Andrea Belk Olson, CEO of Pragmadik ABOUT THE AUTHOR Andrea Belk Olson is a speaker, author, applied behavioral scientist, and customer-centricity expert. As the CEO of Pragmadik, she helps organizations of all sizes, from small businesses to Fortune 500, and has served as an outside consultant for EY and McKinsey. Andrea is the author of The Customer Mission: Why it’s time to cut the $*&% and get back to the business of understanding customers, No Disruptions: The future for mid-market manufacturing, and her upcoming book, What To Ask, coming in June 2022.

She is a 4-time ADDY® award winner and host of the popular Customer Mission podcast. Her thoughts have been continually featured in news sources such as Chief Executive Magazine, Entrepreneur Magazine, The Financial Brand, SMPS Marketer, Rotman Magazine, and more. Andrea is a soughtafter keynote speaker at conferences and corporate events throughout the world.

She is a visiting lecturer and startup coach at the University of Iowa, a TEDx presenter, and TEDx speaker coach. She is also a mentor at the University of Iowa Venture School.

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Targeting Everything Targets Nothing

W

hen looking for growth, most leaders don't want to leave any stone unturned.

Where can we find new customers?

Maybe this segment or that segment?

Why not both? The problem is, the broader the net, the more diluted the message. No matter how hard you try, you can't be everything to everyone. If you try, you lose distinctiveness and differentiation—a key competitive advantage.

For example, take a simple product, such as a vacuum cleaner. Almost everyone needs a vacuum cleaner, barring people who are homeless or nomads.

Therefore, why not reinforce the virtues of our product, its superior engineering, its reliability, suction power, maneuverability, etc.? Why not let everyone know about these differences? Spread the word as far as it can reach?

It seems logical, as there's a perceived safety with targeting everyone. Why would we want to isolate or not speak to a specific group of vacuum users? They all might want to buy a vacuum, and we want them to think of us! However, this isn't different, and it's definitely not distinct.

These two things are what makes a

company stand out, and an offering connect with people on a deeper level.

Anyone can take a bunch of money and throw it into the void trying to get market attention and sales. But it takes talent to identify a distinct space to compete in and a unique way to do it.

Think of it this way - just like a job applicant, you want to stand out from the other people competing for the position, emphasizing those skillsets that are uniquely valuable for that company and industry to give yourself a leg up. Sending the same generic, laundry-list resume to any and all companies get you little to no call-backs unless you're sending in thousands of applications - which is really just playing the odds.

Going back to our vacuum example, Bissell focuses their advertisements on pet owners specifically dog owners. They show their products with dogs, they talk about their products' performance with cleaning up pet hair, they donate to dog shelters. Their objective is to be the go-to vacuum for people who own pets. What if you don't own a pet? Will Bissell not sell you a vacuum? Of course, they will. Do you feel their brand doesn't speak to you if you're not a pet owner? No.

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You may even be more apt to purchase a Bissell, as if it can tackle pet hair, it should be able to handle your pet-free home. Other vacuum companies can claim they "work great for pets" but Bissell is focused on this segment, and positioned to own it.

Another example of positioning is Yeti. There are tons of cooler and thermos brands out there. Everyone says they keep your drinks and food cold. Some perform better than others. But Yeti decided to target professional outdoorsmen - people who were most comfortable outside on a frozen pond or hunting in the woods. This audience has different needs, standards, and demands for products than your average beachgoer. Yeti wanted to focus here where they could target discerning buyers with high-end products. Their advertisements and messaging reflect this, showing the product in rough-and-tumble environments.

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By positioning their offerings to this target, they don't isolate those who aren't rugged outdoorsmen, but quite the opposite - average consumers perceive the products as superior, especially if professionals prefer them - and are willing to pay a premium to join that proverbial club.

Targeting and differentiation are about identifying whom you can cater to, and how to position your offerings uniquely to that market to create a distinct competitive advantage, rather than attempting to be everything to everyone. If you don't take that leap, you'll compete with all the other companies which try to reach everyone as well and at that point, the only way to stand out is money. And it'll take a lot of it.

More information is also available on www.pragmadik.com and www.andreabelkolson.com.

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Talking Shop

HYDMECH: 40-Plus Years of Sawing Innovation

By Loyd McIntosh

F

or more than 40 years, HYDMECH has been a worldwide leader in metal band saw, cold saw technology, and metal sawing solutions. Established in 1978 in Woodstock, Ontario, by Stan Jasinski, a Polish immigrant, and engineer, HYDMECH was initially an engineering consulting firm specializing in hydraulic and forestry equipment.

However, frustrated with searching for a saw to suit his needs, Jasinkski saw an opportunity, putting his engineering knowledge to use, developing a cutting-edge mitering saw.

Jasinski designed a mitering saw with superior performance, gaining the attention of peers and dealers throughout the area. Since that moment in 1980, HYDMECH’s focus on manufacturing quality sawing technology has never wavered. “We pioneer innovations such as swing-head versatility on our scissors-style saws and consistently deliver the widest range of saws to a vast range of industries,” reads the Hydmech website. “The industries we serve include aerospace, automotive, steel service centers, metal fabrications shops, racing, and more.”

Today, HYDMECH manufactures an array of band saws, cold saws, and carbide saws as well as offers a variety of material handling solutions. HYDMECH also designs, manufactures, and installs custom handling equipment for a wide range of applications such as steel fabrication, steel processing and supply machinery and equipment; and oil, gas and energy.

Industrial Machinery Digest caught up with Hydmech’s Vice President of Sales and Marketing Rick Arcaro and Marketing Manager, Joanna Wilcox, to learn more about Jasinski, the fascinating history of HYDMECH, and the innovative technology coming out of the company’s manufacturing plant.

What can you tell us about HYDMECH’s founder, Stan Jasinski?

“Company founder Stan Jasinski, after being released from a prisoner of war camp, completed his engineering degree in East Germany. In 1966 Stan and his family escaped communist Germany and immigrated to Canada with a dream of someday owning his own company.

He worked in various roles at TimberJack in Woodstock and became chief engineer producing forestry equipment.

In 1978, Stan incorporated HYDMECH Engineering which

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was an engineering consulting firm specializing in hydraulic and forestry equipment. Early products included roll forming equipment for eavestrough, bending, power steering systems for heavy equipment, and patented the telescopic dump cylinder for the 300 ton GM mining dump trucks.

In 1980, in a small 4000 square foot building, was Stan’s first involvement with band saws when an internal need for mitering came up. Since he could not find one on the market he built one.

In 1983 Stan purchased our second building, which is the middle of the three plants in Woodstock, approximately 25,000 square feet. He then began manufacturing the S20, S20P, S20A and prototyping the S25.”

– Rick Arcaro, VP of Sales and Marketing

What are some of the innovations and technologies HYDMECH has developed over the years?

“The first miter band saw to rotate the head and not the vices, saving floor space. Rack & Pinion long bar-feed saws, single miter programmable head machines, simple operator controls to set up a machine following our door chart in which anyone can be an operator, and durably built machines with off-the-shelf parts.”

– Rick Arcaro, VP of Sales and Marketing

How do HYDMECH saws assist customers in selecting the right saw and/or customizing machines to meet their needs?

“Our sales staff has over 50 years of combined experience recommending the correct machine for the application. We are a hands-on group that will recommend a machine, assist in

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

the installation of the machine, and train the end-user on how to run the machine - a complete sales and service package.”

– Rick Arcaro, VP of Sales and Marketing

“We have a solid understanding of metal cutting operations and how our saws fit into your business. Many people don’t realize that we sell complete systems – not just the saw.

Our sales team will ensure you have the exact material handling solutions needed to move material into the saw, through it, and out the other side efficiently, saving you time and money.”

– Joanna Wilcox, Marketing Manager

What are some of the newer products HYDMECH has developed recently and what common issues were they designed to solve?

“Our 60-degree vertical miter saws with icon-driven touch screen controls. The 60-degree miter expanded the mitering capability for our end users, and our modern icon-driven interfaces uses graphics, simplifying the operation of the band saw.”

– Rick Arcaro, VP of Sales and Marketing

What traits separate HYDMECH from competing manufacturers of band saws, cold saws, and carbide saws?

“Ease of operation, value for the price, durability, and reliability, low cost of operation, good availability of parts, and factory support.”

– Rick Arcaro, VP of Sales and Marketing

“Our motto is “Reliable Saws, Reliable People” for a reason.

Our machine builders have spent years building the same saw model. They take pride and ownership of the machines they build from start to finish. We care about our customers and supporting their operations.”

– Joanna Wilcox, Marketing Manager

For more information about HYDMECH, visit hydmech.com.

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Safety & Maintenance

Peter Nadolny Madsen CEO & Co-Founder Made4CNC ABOUT THE AUTHOR Peter Nadolny Madsen is CEO & Co-Founder of Made4CNC, a new Danish company that recently launched the world’s first completely automatic CNC door opening solution for robots.

Game-changing Benefits of the Safedoor SD100 System In a recent interview, Madsen explained the game-changing benefits of the Safedoor SD100 system and talked about Made4CNC’s ties to the renowned Danish collaborative robotics sector, coping with supply chain stresses, and why Denmark has become such a hotbed of innovation.

mounted on some sort of beam. The Safedoor 100’s linear actuator design eliminates these concerns which are commonly found in traditional, non-electric, DIY solutions.

The SD100’s intelligent Safedoor Controller monitors all aspects of the door motion, ensuring smooth and reliable operation.

What is the Safedoor SD100?

The Safedoor D100 is a complete solution for automating CNC machine door opening and closing. Its main hardware component is a box that’s easy to mount above the door of your existing CNC machine.

Inside the box, a linear actuator provides the force required to open and close CNC machine doors. The Safedoor SD100’s linear actuator design helps to ensure consistent, durable, and safe operation. With a linear actuator, forces are confined within the actuator itself. Alternative systems require external forces to keep the belt tense and the pulleys must be

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What problem does it solve?

The Safedoor SD100 an easy-to-use solution to a long-standing component feeding challenge in machine tending automation. Most of the world’s CNC machine applications require either an operator or a robot arm to physically open and close the machines’ heavy doors every few minutes. In fact, despite the increasing proliferation of automated solutions across all sorts of industrial applications, only a tiny fraction of the world’s CNC machines are automatically fed components. That’s a missed opportunity.

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Prior to the launch of the SD100, machine shops that wanted to increase production and throughput on machine tending applications faced some stark choices: upgrade their legacy CNC machines, invest in a new CNC machine, or develop an ad hoc, ‘DIY’ solution. CNC machines cost hundreds of thousands of dollars. The Safedoor SD100 costs between USD 4,000-6,000, so the financial upside is clear.

The benefits of the SD100 aren’t limited to that upfront capital cost savings.

DIY door opening solutions typically incorporate pneumatic cylinders, which present a wide range of potential safety hazards. In addition, because they are neither standardized nor tested, DIY solutions force integrators and in-house engineers to build everything from the ground up, including custom brackets and enclosures.

This slows deployment and introduces unnecessary layers of complexity and risk to the overall application.

The fully electric Safedoor SD100 eliminates these problems. It is standardized, fully tested, and proven in the field. Moreover, with safety in mind, the SD100’s software package allows users to adjust the speed of the CNC door, making risk assessments easier to conduct. The product

comes with all the hardware, software and wiring you need to boost machine tending productivity quickly.

What CNC machines and robot arms does the Safedoor SD100 work with?

The SD100 can handle doors that are up to 1 meter wide and weigh 400 kg, at a speed of 500 mm/s. It’s an easy to deploy system that can connect to any robot and CNC machine via galvanic insulated digital inputs and outputs.

For extra integration, we have developed plugins for cobots from Universal Robots and Omron. These plugins are fully integrated on the hardware and software sides and you can access the Safedoor SD100’s intuitive programming interface directly from your existing cobot pendant. We plan to roll out more plugins this year for other robot brands.

How do you deploy it?

To deploy the SD100, all you really need to do is mount two brackets – one on the fixed frame and one on the door.

Next, put the actuator in between and you are done with the mechanical integration. The SD100 is typically up and running in a few hours.

Founders Thomas Visti, Lasse Kieffer, and Peter Nadolny (L to R), bring decades of experience in the Danish collaborative automation sector to Made4CNC, which launched in 2021.

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IMD | 17

This is all good for productivity and throughput. It’s convenient for customers and it saves integrators time and money. For example, one of our customers has moved from 16 hours machine tending per day to 24 hours, because the SD100 enabled full automation of key component feeding processes. That kind of throughput boost can have a phenomenal impact on companies’ bottom lines.

The system is also good for existing workers who appreciate not having to perform the same tedious, unergonomic door opening and closing tasks all day.

So, it’s win-win-win for the manufacturers, workers, and robotics integrators.

Can the Safedoor SD100 be deployed without a robot?

Yes. Quite a few of our customers are attracted to the ergonomic aspect of the system. They have a worker take pieces in and out, but the SD100 takes over the repetitive, physically draining door opening and closing part of the process. If deployed without a robot, the operator simply has to twist a knob and the CNC machine door will open/ close as requested.

How is Made4CNC coping with the current global supply chain crisis?

The uncertainty around the supply chain is a classic double-edged sword from Made4CNC’s perspective. On

The Safedoor SD100 comes with a knob that allows the doors to be opened and closed by a human, if required.

one side, it has been more of a hassle to get parts, from drive components to chips used in the controller and even cardboard. We’ve spent a lot of time sourcing cardboard.

But we have some great suppliers and they have really leaned in on their side, and together we managed to pull through it. We have stock. And will be able to have stock going forward.

On the other side, we have found that the current materials shortage is a great opportunity for a lot of suppliers to introduce automation. When you can’t get the part you ordered from China, or the shipping and transport rates are too high, it drives companies to bring production at least one step closer to their backyard.

The Safedoor SD100 (shown here fitted to the top of a CNC machine) allows companies to easily automate door opening and closing tasks on legacy CNC machines. Easy integration with cobots and lightweight industrial robots makes fully automated CNC machine tending cells feasible for companies of all sizes.

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In turn, this drives all types of automation adoption, including automation of CNC machine tending. So, in that sense, the supply chain problem is a positive for our business, because our solution helps companies make that transition from manual to automated processes.

2021 was a pretty bad time to launch in some respects, but a good time in others.

Made4CNC’s executive team has close ties to the worldrenowned Danish collaborative robotics sector and the company HQ is in Odense, a noted cluster for collaborative robotics innovation. What is the significance of this, both for Made4CNC and its customers?

Our founders have extensive experience in collaborative automation. Thomas Visti, helped pioneer the cobot concept as the first CCO at Universal Robots (UR) before becoming CEO of Mobile

Industrial Robots. Lasse Kieffer and I both worked at UR in our first engineering roles, and later founded Purple Robotics acquired

by OnRobot. Between the three of us, we have extensive experience in disrupting traditional automation.

Cobots address key problems around the costs and complexities of traditional industrial automation.

Cobots are easier to use, safe to deploy around humans following a risk assessment, and have a much smaller footprint than traditional robots. Cobots provide levels of flexibility, speed of deployment, safety, usability, and fast ROI that traditional cannot compete with. Cobots are robots that everyday people can use –not just robotics PhDs. Cobots make for user-friendly experiences.

Made4CNC has the same thought train on easy integration, easy usage and safety that the leading cobots and lightweight industrial robots are known for.

What makes Denmark such a center for automation innovation?

That’s hard to say as a Dane. But we are free thinkers, we don’t care too much about hierarchy, and people are safe to speak their minds. This produces a culture that supports thinking differently and trying new ideas out. These factors lead to innovation, as we have seen with the worldwide success of collaborative robotics and new automation solutions like the Safedoor SD100.

What’s next for Made4CNC? The overall goal of Made4CNC is to make machine tending with robots as easy as possible. Besides releasing additional specialist plugins for leading robot brands, we’re also looking into ways that we can simplify connectivity between the robot and the CNC machine and exploring technologies that make machine tending safer, easier, and more reliable.

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IMD | 19

Manufacturing Showcase

Cowles Tool 100 Years of Innovation and Counting

W

ith over a century of serving the steel industry, Cowles Tools has been an industryleader since the Woodrow Wilson administration. The Cowles Tool line was established in 1917 and has grown to be one of the most respected slitter tooling lines manufacturers in America. In 1997, the company merged with PIC and from its Austintown, Ohio base, Cowles Tools now produces industry-leading slitter tooling, shear blades, lath cutters, and many carbide inlaid cutting and wear products. Today, Cowles Tool supplies manufacturers of steel, aluminum, plastics, wood, paper and refractory brick including numerous

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manufacturers of durable goods with precision carbide inlaid tools, helping them to maximize efficiency and productivity of their operations.

Over the last several years the company has been upgrading its equipment to maintain a high level of quality and improve overall efficiency. One of the upgrades of equipment is the purchase of a C-620NC Cosen Saw to cut the bars of steel into individual knife units. “The Cosen saw was added to our existing saws and increased our capacity both in quantity and maximum diameter,” says David Smith, President of Cowles Tool. “We have found the Cosen Saw to be a

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great improvement to our efficiency as it cuts through a bar in half the time our previous saws were able to cut.

The Cosen saw has also reduced the saw blade usage as we are able to cut a much higher amount of square inches of material per blade.”

Throughout the company’s history, Cowles Tool has been well known for its innovation and ingenuity. For instance, the company began production of its Carbidetipped work rest blades under its ‘PIC’ or Perfection in Carbide banner. The Carbide-tipped work rest blades for centerless grinders were the first carbide-tipped tools manufactured by Cowles Tool PIC division.

Additionally, Cowles Tool recently upgraded its production facility, now covering more than 27,000 square feet. Ergonomically designed with a modern and efficient floor plan, Cowles Tool’s new facility allows for better flow during the vast array of manufacturing steps, shortening times between operations, and getting products to customers at a faster rate than ever before.

“Our upgrades in machinery have been to continue to produce the line of products we currently manufacture. The demand for the Cowles Slitter tooling is high and keeps our facility and personnel very busy,” says Smith. “We are one of a very limited number of manufacturers that produce slitter knives in the United States. We believe this sets us apart from our competitors that import their knives from foreign sources.”

Cowles Tool is a privately owned limited liability company with strong sales and operations leadership teams. “The company looks forward to continued growth and success,” says Smith, “as we continue to upgrade our equipment and meet the needs of our valued customers.”

To learn more about Cowles Tool, visit cowles-tool.com

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IMD | 21

Industrial Fabrication & Automation

Scotchman Industries Leading The Way From Rural South Dakota

By Loyd McIntosh

N

early 60 years ago, Arthur Kroetch, an industrious entrepreneur from the small town of Philip, South Dakota, launched what would eventually become the nation’s leading manufacturer of hydraulic ironworkers. Now under the leadership of Kroetch’s son, Jerry, Scotchman Industries continues to bring innovative products to market, currently producing 13 models of hydraulic ironworkers, ranging from 45 to 150 tons in capacity all manufactured in this small South Dakota town population 779.

“I’m physically in Philip and I have to drive 85 miles either east or west to find the nearest stoplight,” says Jerry Kroetch, President of Scotchman Industries. “If you went

My how proud they were of that first ironworker. Pictured are Mike Johnson, Ed Formanek, Olin Flatt, Art Kroetch, and Bob Bowman. 1968

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north or south, you’d have to drive over 100 miles to find a stoplight. So we are in rural South Dakota.”

Art Kroetch left school after the eighth grade to work on the family ranch before striking out on his own as a young man by starting his own haying business for other ranchers in the area. Before long, Kroetch started manufacturing a cattle oiler under the name Wick-O-Matic Automatic Oiler Company. Developed to keep insects away from cattle, Kroetch was forced to pivot away from the successful cattle oiler business once the EPA banned the device’s insecticide in the early 1960s. He then began making metal gates, chutes, and panels for the livestock industry, the door that eventually led him to the world of ironworker manufacturing.

"He purchased an ironworker from a gentleman out of Minnesota who invented the first hydraulic ironworker in the world," says Jerry Kroetch. At that point, Ironworkers had been around for more than 100 plus years, “but they were all the big flywheel mechanical type machines,” says Kroetch. “The machine Kroetch purchased was one of

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the first hydraulic ironworkers in the world and, during the next few years, Kroetch kept in touch with the machine’s inventor. In 1967, he bought the patent for a small 35-ton hydraulic ironworker, changed the name of the company to Little Scotchman Industries, and started manufacturing machines from a shop in Philip, South Dakota. “So he went from Art’s salvage to Wick-O-Matic Automatic Oiler Company, to Little Scotchman Industries,” says Kroetch. "In the late 70s, we felt we outgrew the “Little” portion of Little Scotchman, and just stayed Scotchman Industries. Today, we are America’s largest hydraulic ironworker manufacturer located in, population 779, Phillip, South Dakota.”

Since the 1960s, the basic functionality and exceptional quality of the Scotchman hydraulic ironworkers haven’t changed very much. However, Kroetch and the Scotchman team have made several innovations over the years that have made their ironworkers vastly more efficient and

customizable. For instance, the original machines had an inboard punching station, which limited the size of the piece of steel that could be inserted into the punching station. Over time, the machine has been redesigned with an outboard punch. “With the punch station being on the outside of the machine users can punch very large pieces of plate with the only limitation being the throat depth,” explains Kroetch.

Over the years we also went from a single operator machine to a dual operator machine, which allows two people to run the machine simultaneously,” he adds. “Our machine gives you a variety of two different functions that can be done at the same time. For example, One user can be punching a piece of plate, while at the same time, another user can be taking a piece of flatiron and shearing it off to lengths,” Kroetch says. “So in a nutshell, you can be shearing or notching plates, and have another INDUSTRIAL MACHINERY DIGEST.COM

IMD | 23

user punching holes without interruption or loss of power” Kroetch says. “Not only can you just punch or shear simultaneously, but I can also be shearing angle iron while somebody else is notching angle iron at the same time. Our machines can be operated by two users doing different functions at the same time.”

As the largest - and one of the few remaining - hydraulic ironworker manufacturers in the U.S., Kroetch says Scotchman’s chief competitors are international manufacturers, especially companies from Taiwan and Spain.

While the team has taken some cues from their European and Asian counterparts, particularly in the look of their machines, Kroetch says Scotchman ironworkers offer far more efficiency, versatility and customization that sets this team of South Dakotans apart. “We all do the same thing. We punch, shear, notch, and bend, but again, the design of the machines are totally different.”

For instance, Kroetch says Scotchman ironworkers offer more versatility than their competitors, in the U.S. and abroad, thanks to an innovative tool table area in which the optional tools, such as the angle shear, channel shears, press brakes, and rod shears, sit on the tool table and the machine’s upper beam actually makes the tool go up and down. An innovation that can save a Scotchman customer loads of time and lead to greater productivity.

Jerry and Karen Kroetch (CEO & CFO)

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"I can change tools faster than any of my European competitors because most of their optional tools have to be installed in the punch station. Having to totally disassemble the punch station in order to put in a press brake might take 30 to 40 minutes for one of my European competitors to change a tool, where I can do it on my tool table in two or three minutes," says Kroetch. "That gives us a huge advantage due to our versatility."

Another advantage Scotchman Industries has over their competitors is the ability to manufacture customdesign machines or modify existing ones. Kroetch says the Scotchman team of 69 people - many of them long-term employees - can create anything the customer can dream up. Most of the company’s customization requests, says Kroetch, are from customers needing a machine that can punch holes in angle iron. Kroetch explains: “They want a machine that can process 22–24 foot sticks of two-inch to six-inch angle iron with the programming ability to punch x number of holes x number of inches apart.’

“They push 'go' and the feed system is going to push that piece of angle iron to whatever dimension you might need and the machine's going to cycle punch the hole,” he adds. “It's going to punch and push that piece of material to the next length and punch a hole.”

Ironworkers aren’t the only machines manufactured

by Scotchman Industries. The company also manufactures a complete line of circular cold saws, and distributes a line of programmable measuring systems, pipe notchers, and hydraulic presses, all from the Scotchman plant in the tiny town of Philip, South Dakota.

To learn more about Scotchman Industries, visit www.scotchman.com

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Breaking It Down Chip by Chip Five Things To Know About Chip Formation in Machining

W

hether examining how tool selection is impacting chips, how coolant plays a role in chip evacuation or looking at the size and shape of chips, chip formation says a lot about the application being run. Knowing what different chip details indicate allows machinists to better manage chip formation, make adjustments and prevent tool failure. Because when it comes down to it, better chip formation means a more successful application.

Shape & Size When looking at chip formation, a key indicator of a good chip is the shape. The preferred outcome for any application is chips shaped as sixes and nines or a single conical shape.

These small, manageable chips are essential for efficient, predictable drilling. Nevertheless, it is important to be aware of what chips in other shapes and sizes can indicate. For example, a straight, flat chip is a result of elasticity. If the chip is a continuous ribbon, then there are likely many adjustments that need to be made in order to achieve ideal chips.

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The size of the chips impacts evacuation as well.

There are two major factors that impact the size of chips in drilling tools: chip breakers, also known as chip splitters, and lip geometry. With chip breakers, the width of the chip is thinned to allow for easier evacuation; the wider the chip the easier it is to get it to roll onto itself and break. Lip geometry acts as a mechanical chip breaker to fracture a chip by curling the chip on top of itself or by impacting the chip forming with the backside of the lip radius. Although harder materials will curl a chip on top of itself to create chip fracture, gummier materials often skip over the lip radius and only fracture after impacting the back of the lip radius.

Still, the purpose of the combined chip breakers and positive lip geometry is to break off the chip so that it is narrow enough to easily evacuate.

Chip fracturing can also occur naturally due to the velocity differential between the outside and inside of a chip, which creates a cone-shaped chip that curls on itself and fractures. Because larger diameter inserts have a higher velocity differential than smaller diameter inserts, it is easier

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to fracture chips i.e., the larger the chip breaker spacing the more chip fracturing that will occur. Smaller diameter inserts are limited to the velocity differential available due to the restriction on the chip width required to easily evacuate chips through the holder gullet.

Thickness The thickness of the chip varies with the feed rate; heavier feed rates form thicker chips while lighter feed rates form thinner chips. The thickness of the chip formed decides how the chip will fracture, but this is also dependent on the material being machined. At the same time, changing the speed impacts the chip thickness; the higher the speed of the tool, the more heat generated in the cut, which makes the material more elastic. So a balance between speeds and feeds is necessary. With many materials, a thicker chip means there is a greater chance of exceeding the elastic limit of the materials, which increases the likelihood of chip fracture; on the other hand, thinner chips are more elastic and, thus, farther away from the elastic limit necessary to fracture the chip.

Soft, gummy materials like soft carbon steels, 300 series stainless steel or pure titanium have a high elastic limit—so much so that increasing chip thickness has a negative effect on chip formation. Materials like these require specific lip geometries to potentially create an acceptable chip. Nevertheless, it is key to look at the chip

deformation ratio of materials to better understand chip thickness. Chip deformation ratio can be defined as the ratio of deformed chip thickness over the undeformed chip thickness (feed rate). For most steels, this ratio is typically 2-3:1; however, it can be as high as 5-10:1 for those soft, gummy materials. Ultimately, though, this measurement is an indicator of chip form and elasticity in the material being cut, and the higher the deformation, the more difficult chip formation will be.

Coolant When it comes to coolant, through-tool coolant when paired with the right drill geometry is critical for the best chip formation and evacuation. Additionally, changing coolant type, pressure and volume influence the thermal shocking of chips. This can change the properties of the chips and make them more or less likely to break into manageable segments. For example, coolants can decrease material elasticity due to the strain hardening that occurs as coolant quickly cools hot, elastic chips. The cooling of elastic, continuous chip formation embrittles chips to the point of fracture by reducing their elastic limit.

For chip evacuation, coolant pressure and volume are important. To evacuate a set volume of chips, a set amount of kinetic energy is provided by the coolant volume. Drilling can occur uninterrupted from the top of the hole to the bottom as long as enough coolant volume is available,

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IMD | 27

which will be evident during the application with a steady load meter reading while drilling. With an insufficient coolant volume, an unsteady load meter will be detected when drilling into the hole. Although this does not mean that drilling with insufficient coolant is not possible, it does demonstrate that the drill must be altered to fit the environment.

Pressure on the other hand is the force behind the coolant that provides a fixed volume of coolant through a given diameter. As coolant pressure is increased through a fixed coolant orifice diameter, the coolant volume will increase. When drilling small diameters, high coolant pressure is needed in order to provide sufficient coolant volume, but as drill diameters increase, high coolant volume becomes more necessary than high coolant pressure. In high-production drilling—especially deep hole drilling—the tool coolant is critical because it provides an upward force on the chip to aid in flushing the chips through the drill flutes and out of the hole. Although flood coolant can be used alternatively to through-tool coolant in short drilling applications under two times diameter, in deeper holes flood does not promote good heat transfer and can also push chips back into the hole, which can cause chip packing.

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Through-tool coolant is also important when factoring in heat because it provides coolant right to the cutting edge where it is needed to cool the tool. When machining, 60% of the heat generated in the plastic deformation of the material remains with the chip formed while the other 40% remains with the tool and workpiece. This portion that stays with the tool must be evacuated by coolant in order to have sufficient tool life. Clearly, when more coolant pressure and volume can go through the tool, the cooler the tool will run.

This then means that there will be greater tool life and that the tool can potentially be run faster.

Chip formation can also indicate whether the best tool is being used. If the chip formation is not meeting the standard, a change to tool geometry may be needed in order to improve the situation. Clearly, the geometry of a cutting tool has a significant impact on the chip formed.

Specifically, increases in rake angles can improve chip formation, yet this does come at a cost because the greater the rake angle the weaker the cutting edge.

Rake angle also highly influences the value of the shear plane angle, which is the angle formed by the pure plastic deformation of the workpiece material. Here, the material starts deforming or chip forming in front of the cutting edge. For both material properties and running parameters, the angle varies; however, it should always be a goal to make the shear plane angle more vertical because the steeper the shear plane the better chip formation.

Chip thickness comes into play here as well. The more elastic a material is the steeper the shear plane angle will be, resulting in a thinner chip. Conversely, the harder the material is, the flatter the shear plane angle will be, which means a thicker chip is formed. All in all, more rake angle means more shear angle, which means better chips, but

balance is key here as well. A really sharp cutting edge will make great chips but will fail and break due to a smaller cutting edge cross section and weaker cutting edge, so find balance in the rake angle—one that is aggressive but not overly so.

Changes in Chip Formation A final thing to look for when examining chips is any changes in chip formation. If chip formation is altered during an application, it could be caused by a myriad of elements: wear on the tool, built up edge on the tool (BUE) or changes in the environment like coolant or material changes. In new applications, it may be best to drill shallow test holes and take a look at the chips to make sure they are small and segmented. Being conservative in the beginning with speeds and feeds could also aid in better understanding chip formation and what adjustments need to be made.

Awareness of any changes in chip formation is key, though. Poor chip formation can cause major problems in drilling applications. Long, continuous chips are difficult to evacuate and can become packed in the drill flutes, damaging the drill or even causing drill failure. These long chips could also become wrapped around the drill body and again cause tool failure. Lastly, poor chip formation impacts the hole quality. If chips are dragging or packing in the flutes, there will be poor hole finish. Noticing any changes

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in chip formation is important not only for tool life and hole quality but also for the overall success of the application.

Knowing more about the chips formed in any metal cutting application enables machinists to better control the outcome and success of drilling operations. While it is necessary to examine chip size, shape and thickness, it is just as important to know how coolant, tool selection and changes in chip formation tie into the application as well. So take a look at the chips being created and break it down chip by chip because both proper chip formation and chip evacuation are required for successful high-production drilling.

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New Technology

Three reasons to robotize soldering operations

I

n 1896, a patent for electric heating apparatus, now commonly known as a soldering iron, was granted. The process of soldering has remained much the same since then. But, that’s about to change. In this article, Nigel Smith, CEO of TM Robotics, international distributor of Shibaura Machine, formerly Toshiba Machine, industrial and soldering robots, explains three reasons why you should automate the soldering process.

As electronics get smaller and manufacturers come under greater pressure to improve efficiency and throughput, the traditional hand soldering method is no longer up to scratch. While soldering is performed by skilled, highly trained workers, the ability to simultaneously improve speed, accuracy and consistency is an almost impossible task for humans — not, however, for industrial robots.

As the fourth industrial revolution sweeps the manufacturing industry, industrial robots are bringing a whole host of benefits to the factory floor, increasing productivity and profitability whether machine tending, assembling, picking and placing or even soldering.

As well as off-the-shelf industrial robots, TM Robotics offers a wide range of other automation manufacturing equipment — including soldering systems. TM Robotics works in partnership with ELMOTEC, a family-owned Swiss company, with more than thirty years’ experience in the soldering industry.

On the other hand, once a robot has been programmed to a certain path and quality level, it will repeat it exactly, soldering each joint precisely and never missing one.

Any errors that do occur can easily be corrected through reprogramming. With human error eliminated, fewer defects will be found — decreasing the amount of rework needed and increasing throughput.

Soldering robots for versatility Soldering robots for speed A major benefit of automating the soldering process is improving speed and efficiency. Not only are soldering robots fast when completing tasks, they don’t require breaks, annual leave, or slow down due to eye strain or fatigue. Soldering robots can operate 24/7 if needs be, vastly increasing production.

Plus, it’s relatively quicker, easier and cheaper to train robot operators than highly skilled manual solderers.

Combine this with the fact that one operator can load, unload and oversee several robot stations and the savings in terms of training costs and manpower begin to add up.

Soldering robots for accuracy Not only are soldering robots faster than manual soldering, they’re also much more accurate. Year on year, electronics are getting smaller, and the demand for smaller, more lightweight electronics is only expected to grow. Nowadays, many printed circuit boards (PCBs) are densely packed with components, making it easy for solder joints to be incorrectly soldered or missed altogether. To make matters worse, errors when soldering manually are inconsistent and difficult to detect.

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The third reason to robotize your soldering operations is versatility. Whatever the soldering application, from single pins to battery cables, there’s a soldering robot to match.

TM Robotics and ELMOTEC offer a range of fully automated soldering systems, combining Shibaura Machine’s accurate and reliable SCARA and 6-axis robots, with soldering heads and peripherals designed by ELMOTEC. These soldering heads are simple to mount onto SCARA robots from Shibaura Machine, and cover a range of soldering types, including laser soldering heads for heat-sensitive electrical components, high-frequency soldering heads for compact induction heating and flame soldering heads for maximum energy when micro-flame soldering. These heads can be combined with nozzles designed for a variety of applications.

Soldering robots in action One TM Robotics customer to take advantage of the power of soldering robots is MIG-O-MAT, a company that makes plasma welding and microflame soldering machines, before this point for manual use. MIG-O-MAT approached Elmotec to find a robot that was extremely

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accurate, consistent and flexible — able to be installed in multiple configurations.

To satisfy this brief, TM Robotics suggested the TVL500.

This compact, light-weight six-axis robot is the smallest robot in the TVL range, offering a maximum payload of 3kg and a reach of 602mm. Thanks to a standard cycle time of less than 0.4 seconds, the TVL500 offers the high speed and accuracy necessary for soldering applications.

“Integrating the TVL500 improved the overall process time of a general soldering operation, but an unexpected advantage was the increased ease in which an operator can detect possible errors during soldering,” explained Burak Maltepe, sales engineer at MIG-O-MAT. “With manual soldering, any errors that do occur are inconsistent and almost impossible to detect. Using automated technology means errors — which have already been drastically reduced — can be identified easily. More importantly, end users can reprogram the robot to the correct adjustments and ensure the error does not occur again.”

With over 30 years’ experience in the robotics industry, TM Robotics prides itself on having the expertise to adapt the ideal robot to a customers’ application, not just offering an off the shelf solution. Not only does the TVL500 make an ideal soldering robot, it also appeals to a broad range of end-users of MIG-O-MAT’s technology, thanks to its small footprint and extra tap holes which allow for the addition of peripheral devices and multiple installation options.

The pressures of today’s electronics production lines make the accuracy, efficiency and consistency offered by industrial robots invaluable. While handheld electric soldering irons may have been the best solution for the past 125 years, soldering robots are the future.

ABOUT TM ROBOTICS: TM Robotics has installed thousands of robots in factories throughout the world, including North and South America, India, Russia, Europe, the Middle East, Africa and Australia. Many of the top manufacturing companies depend on TM Robotics’ product offerings for their reliability, performance, and overall value.

In partnership with Shibaura Machine, TM Robotics is the only company that offers a comprehensive range of all three categories of robots; 6-axis, SCARA, and Cartesian. These are designed and built in-house. TM Robotics delivers cutting-edge solutions, training, and support services for industrial and commercial applications.

For further information contact:

TM ROBOTICS, Unit 2 Bridge Gate Centre, Martinfield, Welwyn Garden City, AL7 1JG, Hertfordshire, United Kingdom Telephone: 01707 290370 www: www.tmrobotics.com e-mail: info@tmrobotics.com

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Process

Think Differently and You’ll Cash In On That New 5-Axis Machine Fast

A

ccording to the Association for Manufacturing Technology (AMT), orders for 5-axis machining centers grew 22 percent year over year—in the middle of the pandemic. Machine shops represent nearly half of all buyers. What those shops understand, or learned quickly, is that getting the most out of 5-axis machinery requires a little different approach; factors like holder interference, productively reaching into deep work envelopes and high-mix part changeover are just a few that come to mind.

What can you do about it?

How should you think differently?

What equipment do you need if you’re adding a 5-axis? We have some answers.

Material sourcing Let’s start with one of the most fundamental steps of making a part, before we’re even thinking about machining: which material to source.

Bar stock is less expensive, readily available and easier to hold than more frequently used billets. The material Yes, 5-axis work can even be a little savings and ease of purchase will probably far outweigh the up-front cost. different here. Here’s just one scenario.

While a square or rectangular billet will save some Tool presetters are a great tool for performing those time when they resemble the shape of the finished part, measurements away from the machine, but they go far the movements a 5-axis machine allows, provide more beyond simple measuring these days too. Presetter data options. There are hidden savings to be found. Bar stock is can be connected to broader tool management systems less expensive, more readily available and easier to hold than and/or machines. They are the ideal setting for assembling more frequently used billets. The material savings and ease of tools and comparing them directly to a catalog, DXF or STP purchase will probably far outweigh the up-front cost. model given to the programmer.

If adjustments do have to be made at the spindle, digital Getting organized heads have on-tool readouts that make it easy for operators You’re in a higher stakes game with 5-axis machining. Don’t to see and make extremely precise diameter adjustments. overlook your tool lists. Since the risk of collision is higher A corresponding mobile app allows for fast lookup of tool with 5-axis work, you should be using accurate 3D models speeds and feeds on the spot. of every tool holder in your CAD system. Body diameters, gauge lengths, etc., in CAD should be as close as possible to Holding parts how it will be put into the spindle.

Workholding can play a huge role in making different jobs Do as much of this offline as possible; keeping spindles easier or even possible. For starters, being forced to match spinning is one of the best ways to realize return on your a workpiece and fixturing to the standard round, square or machine investment as soon as possible. Plus, using a rectangular table or plate can be difficult when angles and ruler with 1/16 increments, trusting every spec or using tool approach are important and parts are high mix. inconsistent in-machine probes are not effective ways to Initially developed for setup-time reduction, zero-point measure when a couple thousandths can make a difference, workholding has evolved and proven valuable for another like they often do in 5-axis machining. distinct reason: access. Systems like the UNILOCK offer

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the added flexibility that's valuable in 5-axis machining on a new machine.

For example, while a standard vise blocks the sides of a part and low-profile vises leave sides more open, they only grip only along the part’s lower edge.

Zero-point workholding offers the option to clamp exclusively on the underside of a part for a freer state of machining and concealed from all interferences.

5-axis workholding is a complex world. There’s no one-size-fits all answer.

Here’s our bottom line for selecting workholding: SPERONI tool presetters are a great tool for performing measurements away from the machine. Presetter data can be » Find a balance between connected to broader tool management systems and/or machines. They are the ideal setting for assembling tools and stability and access. comparing them directly to a catalog, DXF or STP model given to the programmer. » Know what parts are coming next, how finished they are, Holding tools basic size and shape, etc.

The ultimate goal is to make every tooling assembly, » Choose the best chuck for the work you do and lay especially in 5-axis machining, as short as possible. The it out carefully. shorter the tooling, the less room for error. That said, the » Plate material and thickness are key when using unusual angles, sizes and shapes of the parts that require multiple chucks. multiple axes don’t always allow for that. We’ve talked

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IMD | 33

about some workholding solutions for this challenge, but you have options in tooling selections too.

The choice for 5-axis access often comes down to hydraulic chucks and shrink-fit holders. Compared to collet chucks, shrink-fit holders and hydraulic chucks are able to maintain higher rigidity and accuracy, and have a smaller nose diameter relative to the tools they hold. This allows a further reach into mold cavities or other tricky work envelopes without interference.

If you’re deciding between hydraulic chucks or shrink-fit holders, you’ll likely pay less for shrink fit holders upfront but maintaining the heating and cooling systems will require maintenance and training hours over time. These temperature cycles do add to setup time as well.

BIG DAISHOWA hydraulic chucks maintain higher rigidity and accuracy and have a smaller nose diameter relative to the tools they hold. This allows a further reach into mold cavities or other tricky work envelopes without interference.

Maintaining performance We’ve talked about the importance of precision when you’re moving on so many axes. Each point of contact should also be kept clean to maintain performance, i.e., avoid scrap or poor finishes resulting from misalignment

or chatter. These contact points include the spindle taper, clamping bores and, in the case of BIG-PLUS tooling, both the taper and flange mating surfaces of the dual-contact system. It's tedious, dirty and even a little dangerous when chips are involved.

That’s why you can’t overlook the tools out there for keeping your equipment in good working condition. These minor investments may be the last thing on the mind of a shop owner with a new 5-axis machine, but it will certainly pay big dividends if deployed right away. Here are just a few examples: » Bore cleaners remove chip particles, grease, oil and coolant from the hard-to-reach clamping bores of milling chucks, hydraulic chucks and shrink-fit holders. » Taper cleaners serve a similar purpose at the other end of

BIG DAISHOWA spindle cleaners will help you maintain precision and prolong the life of your machine tools, cutting tools and tool holders.

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UNILOCK zero-point workholding offers the added flexibility that’s valuable in 5- axis machining on a new machine. These multi-axis workholding solutions locate and stabilize the workpieces without obstructing access to the top and sides of the part.

the tool, ensuring clean clamping into the machine spindle. » Gages, like our Dyna Contact, make verifying taper tolerances simple. All the operator has to do is apply blue dye to the ceramic gage, insert it in the machine spindle and remove it. A quick visual check will reveal any improper contact. » It’s inevitable that particles and residue find their way into a machine tool spindle. This not only makes it harder to dial in cuts and harms tool life, but it can also damage spindles over time. Spindle cleaners keep this issue under control.

The addition of a 5-axis machining center is a big deal for any metalworking operation. Apart from the financial commitment, it changes how jobs move through the shop and the way people work. Similarly, don’t assume the way things were done on an older machine is the best way. Getting creative and seeking out inventive solutions designed for 5-axis work—even if it’s just an inexpensive accessory—can accelerate all-important ROI, empower the team to succeed and unleash the full capabilities of the business.

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Industry Insight

This 5-axis bevel head is smaller and lighter than traditional plasma bevel heads. It mounts on smaller gantries, making beveling more affordable and saving floor space.

Eleven Ways to Optimize Efficiency in Automated Plasma Cutting Operations

By Steve Zlotnicki, Global Product Manager, Cutting Systems, ESAB Welding & Cutting Products “Touch each piece of paper only once” and “every time you touch the project, move it forward” are golden rules of administrative efficiency. When it comes to automated cutting efficiency, think of the plate as a piece of paper.

The more work you can do at the cutting table, the more productive your operation becomes. When contemplating a new automated plasma system or a retrofit, here are 11 different ways you can accelerate efficiency by expanding the capabilities of a plasma cutting system.

1. Beveling Instead of a standard torch lifter (height control), consider the benefits of a plasma bevel head for beveling steel from 6 to 50 mm thick with cut angles up to 45 degrees (Fig 1). The newest generation of bevel heads, which provides 5-axis motion, cuts the full range of weld preparations, including

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V, Y, X, and K bevels and contours. Beveling at the plasma table reduces and/or eliminates the need for secondary operations (milling or grinding) to prepare the part for the next step.

Plasma beveling also creates precise, consistent cuts that reduce dimensional variances compared to manual edge preparation. As a result, parts fit better, which in turn promotes better weld consistency. Poor part fit-up is one of leading causes of rework, especially in robotic, automated and mechanized welding applications that cannot compensate for irregular root gaps and bevel angles.

To complement the bevel head, look for software with best practice bevel cut sequences integrated into the software to cut V, X, Y, and K bevels. This makes setting up a new job quick and more predictable. Achieving an accurate bevel cut on the first attempt reduces multiple test

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runs and re-programming, minimizing unproductive labor time and scrap.

2. Square Cuts Bevel heads are not just for beveling.

Unlike automated oxy-fuel cutting (which delivers a perfectly square face), even the most accurate high-precision plasma systems inherently create a 1- to 3-degree edge angle because of the swirl of the plasma gas. New “square cut” software technology tilts the torch to compensate for the edge angle on mild steel plate from 6 to 40 mm thick, providing three Adding an oxy-fuel torch to a plasma cutting gantry provides fabricators with the benefits of both distinct benefits: processes, notably cost efficiencies for cutting thicker steel plate.

1. A “high speed” mode that can double speed without increased bevel angle. amperage of their system. It cuts 12 mm steel all the way 2. Cut surfaces with a 0 to 1 degree bevel for optimized up to 400 amps at 4,700 mm/min — which is 75 percent edge geometry (but at slower cutting speeds than faster than usual — while maintaining an acceptable bevel high speed mode). angle. By comparison, a standard high-precision plasma 3. Improved hole cylindricity. A “bolt-ready” hole can system cuts 12 mm steel at a maximum of 200 amps and eliminate post-cut drilling or reaming. With new at speeds of about 2,690 mm/min. Even if a user had a technology, some holes can be cut even smaller than a 400-amp system, trying to cut at higher outputs to improve 1:1 diameter-to-thickness ratio. travel speed without square cut technology would increase the edge angle to 4 or 6 degrees, and the cut surface could As a real-world example of “high speed” cut mode, new then require an unacceptable amount of grinding or milling square cut technology enables users to cut at the maximum for a flush fit.

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3. Adding More Torches The standard configuration for modern CNC controllers lets them manage up to ten oxy-fuel torches and two plasma torches on the same gantry. Even if a fabricator plans to use the plasma process most of the time, many of them are choosing to equip their tables with at least one oxy-fuel torch for those instances where they run into thicker steel, because on plates 50 mm and thicker, using oxy-fuel lowers cost. Adding an oxy-fuel torch to a plasma system (Fig. 2) may add less than 10 percent to the total cost, and it can provide a good payback when it’s needed.

4. Inkjet Marking

Inkjet marking eliminates the potential hazard of operators climbing on the table to mark parts or marking parts while the system cuts.

Plasma and oxy-fuel torches aren’t the only tool that can hang on a gantry. Adding an inkjet marking station to an automated cutting table (Fig. 3) reduces cycle time because the system can mark parts much faster, with less error and in much greater detail than a human operator working by hand.

Inkjet marking options include fixed or rotating heads, as well as Drop On Demand or Continuous Inkjet technology. Inkjet stations are ideal for steel service centers, shipyards and manufacturers that require traceability of their parts within the production environment. Inkjet marking especially appeals to manufacturers who want to identify parts during assembly but then want to shot blast or paint over the marks on the finished product.

6. Drill Stations Adding a drill station to the plasma gantry can enable fabricators to drill precise holes. By combining process technologies, users can produce finished or nearly-finished products on a single automation system. A drill stations eliminates the need to re-orient the plate, reducing cycle time compared to moving the plate to a stand-alone drill.

Drilling capabilities will vary. For example, ESAB’s Auto Drill 30 creates a hole diameter of up to 30 mm through plate thicknesses up to 50 mm. Drill stations can also feature a multiple-tool changer (Fig. 4) to accommodate different tools. Depending on the system and its software capabilities, a drill station may also be able to tap, countersink and counterbore.

5. Permanent Marking

7. Waterjet Cutting

Fabricators that want to permanently mark parts can add a pin stamping station to the gantry or use the plasma marking process. A pin stamp marking system provides automatic text and code marking on metal plates using a fast, independent X-Y motion system to manipulate a pneumatic marking pin. Stamped marks remain visible even after painting, and the equipment is relatively low cost. Plasma marking uses a low-current, constricted arc to create lines or text on the plate surface. It offers the advantages of speed and versatility with variable line width and depth (deeper lines remain visible after applying coatings). Plasma can mark on wet, oily or rusted surfaces, and it is an excellent method of marking text on mild steel or stainless steel.

Waterjet technology provides high precision on contoured shapes, a smooth edge with no bevel, no heat-affected zone and no dross, creating perfectly finished parts that require no secondary cleanup or machining. It also cuts almost any material and can handle sheets up to 150 mm thick. However, it is a comparatively slow and expensive process. To address that issue, some manufacturers offer systems equipped with up to four waterjet cutting heads, to produce multiple parts at the same time. Waterjet can also be combined with oxy-fuel or plasma stations (including a bevel head), to increase productivity on parts where waterjet cut quality is not required on every contour. The technology is available on gantries for cutting over a work area measuring up to 5.5 m wide x 15 m long.

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Large fabricators and steel service center operations benefit from a waterjet-plasma combination (Fig. 5) because they can better meet customer needs when parts lend themselves to cutting fine contours with waterjet, then cutting large contours with plasma. Combining technologies can lower part cost by up to 60 percent or more, as well as increase productivity and enhance safety through reducing part handling.

8. Small Pipe Cutting Plasma cutting systems aren’t just for plate. Recently introduced pipe systems for pipe diameters from 50 to 300 mm operate under the gantry and alongside of a standard cutting table. A CNC controlled pipe turning system coordinates pipe motion with the machine, so pipes can be cut with simple cut-off, saddle cuts, holes, slots, or plasma marks. The pipe system can work with a plasma or oxy-fuel torch station for vertical cuts, or with a plasma bevel station to provide optimized weld preparations on pipe cuts.

9. Paralleling Power Sources High-precision 200-, 300- and 400-amp plasma power sources launched in 2021 enable doubling cutting output to 400, 600 or 800 amps, respectively. The concept is similar to paralleling two welding power sources to use larger diameter electrodes for increased productivity.

This drill stations has a tool changer that holds seven tools, such as different size cutting bits and tools for tapping and chamfering.

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Plasma-waterjet combination tables can handle plate many times larger than the typical waterjet system and cut any material except tempered glass.

Plasma systems with 600- or 800-amp outputs are used for cutting sections of stainless steel and aluminum material up to 160 mm (6.25 in.), typically for the power generation, pressure vessel, chemical and petrochemical processing industries. Users of 600- and 800-amp systems primarily want faster cutting speeds on non-ferrous material that ranges from 50 mm to 100 mm (2 to 4 in.). As an example, the 600-amp system cuts 75 mm stainless steel at 330 mm/minute using H35 (the H35 process uses 35 percent hydrogen/65 percent nitrogen for the plasma gas and nitrogen for the shielding gas).

Other target applications include fabricators and steel service centers that use two torches on the same gantry, giving them the flexibility to operate two systems of the same output independently or together. Putting two plasma torches on the same gantry to cut identical shapes is a common strategy to increase productivity in high-volume applications. When fabricators want to double output to cut thicker materials or increase cutting, all they need to do is switch consumables.

10. Digital Technologies – CAD/CAM After hitting the limits of cutting physics, the next frontier for boosting automated plasma cutting productivity comes by harnessing the full power of two digital technologies: CAD/ CAM programming and nesting software and cloud-based data management applications.

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Optimizing productivity starts with CAD/CAM programming and nesting software developed by cutting machine experts that understand both the plasma process and the ecosystem surrounding automated cutting. As a result, the software can seamlessly integrate with design software, the cutting machine, controller, cutting processes, plate storage and retrieval systems, order administration and ERP systems.

Here are just a few of the fundamental ways cutting software can save thousands of hours of time, lower costs and increase output: » Automate plate nesting to maximize plate utilization in seconds. Given the current spike in metal costs and extended delivery schedules from mills, there has never been a greater need to get as many parts as possible from every available plate. » Plate management. These functions manage and define all plate material in inventory, including remnant plates. It can save large inside cutouts as remnants, make multiple remnants on the same job and interface directly to an inventory control system for real time reporting. » Job planning. These capabilities enable the cutting software to automatically pull in data from their ERP systems and efficiently keep track of job orders. » Production data generation. These tools, such as cost calculators, give users planning and cost control capabilities and can output data at any stage of the process.

11. Digital Technologies – The Cloud Cutting software has long had Machine Data Capture (MDC) capabilities to capture cutting data and store it in a database. From the MDC, users can perform Overall Equipment Efficiency (OEE) calculations, a commonly used key performance indicator for automated machines.

Other data includes that from ancillary equipment, such as plate storage and transportation systems, quality control/ traceability systems and ERP systems.

None of this is new. What is new is being able to use online applications to easily aggregate and analyze data as part of a digital ecosystem. A cutting operation typically has distinct users involved with engineering, production, quality, maintenance and the business operations. Each person wants different data and needs to analyze it in a different way. With applications that run on any web-enabled device, these users can: » See what the cutting machine is doing right now, from anywhere. » Gather and measure the cutting machine’s efficiency and productivity to identify and remove bottlenecks. » Streamline part traceability. Virtually all data related to a part can be linked to its unique ID number and recalled remotely. After just a few clicks and a couple of minutes of processing time, a report can be on its way to a customer. » Improve accuracy of sales quotes by using actual system data.

D2P 2022-Generic-1.indd 1

Pipe cutting stations fit underneath the gantry, adding pipe capabilities to an automated table for cutting plate.

» Generate customized reports and send them via PDF, Excel or other formats. » Use WiFi to connect systems that could not previously be connected (in a shipyard, the cutting table could easily be 1 km or more away).

The suite of application tools can optimize the performance of every step of the cutting process, maximize the ROI on every piece of equipment and immediately combat issues such as spiraling material prices and labor shortages.

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Product Showcase

PRODUCT SHOWCASE Industrial Machinery Digest's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers.

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Flexcon’s New QuickDrain Vented Tote Saves Users Millions!

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KYZEN now makes it easier to get the cleaning help you need!

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TIA Portal V17 The release of v17 of the TIA Portal adds innovation in simulation tools, seamlessly integrated engineering and transparent plant operations for increased flexibility, speed, and productivity. In 2021, Siemens celebrated the 25th anniversary of the Totally Integrated Automation (TIA) concept of end-to-end…

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TurboFil Introduces Assembly & Vial Filling Station for Unidose Liquid Nasal Applicators TurboFil Packaging Machines LLC, an equipment specialist dedicated solely to the design and development of liquid filling and assembly machines, has introduced an assembly and vial filling machine for unidose liquid nasal devices, which are increasingly…

Introducing The Ground Mounted Trailer Support The product innovation team at Ideal Warehouse Innovations, leaders in loading dock and warehouse safety, have developed a new, hands-free, trailer support system – The Ground Mounted Trailer Support (GMTS). With the future of dock safety heading towards automation, the GMTS …

Oceaneering Chooses BlueBotics Navigation Technology for New Product Lines Oceaneering International announced today at MODEX that it has chosen BlueBotics, S.A, to provide navigation technology for its line of industrial autonomous mobile robots. “Our goal is to unlock the full …

New PCD face, shoulder and slot drill milling cutters from Walter reduce cutting forces and vibration.

Walter has introduced the MP060, MP160 and MP260 face, shoulder and slot drill milling cutters with brazed PCD cutting edges, a new suite of products for machining aluminum, Al-Si alloys, magnesium …

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Surplus buying and selling

Integrated Rupture Disk Assemblies for Oil and Gas Hydraulic & Pneumatic Equipment Custom engineered, miniature rupture disk assemblies designed for high cycling at low to high pressure are ideal for many oil and gas OEM applications involving hydraulics and gasses.

F

or decades, rupture disks have served the oil and gas industry as an effective passive safety mechanism to protect against overpressure or potentially damaging vacuum conditions. The disk, which is a one-time-use membrane made of various metals including exotic alloys, is designed to activate within milliseconds when a predetermined differential pressure is achieved.

Because oil and gas equipment operational reliability is essential, this demands high integrity from the pressure relief technology used to protect low-and high-pressure OEM systems. As a result, oil and gas OEMs are increasingly turning to integrated rupture disk assemblies with all components combined by the manufacturer, as opposed to loose rupture disk and holder devices that leave much to chance. These assemblies are being tailored to the application, miniaturized, and utilize a wide range of standard and exotic materials, as required. This approach ensures the rupture disk device performs as expected, enhancing equipment safety, reliability, and longevity while simplifying installation and replacement.

The oil and gas industry utilizes rupture disks on triplex pumps for many field applications including oil extraction and well servicing operations. Triplex pumps are positivedisplacement pumps configured with three plungers.

Commonly referred to as “mud pumps,” the devices typically can handle a wide range of fluid types, including corrosive fluids, abrasive fluids and slurries containing relatively large particulates.

The pressures the pump must endure depend on the depth of the drilling hole and the resistance of flushing fluid, as well as the nature of the conveying drilling fluid, although application specific, hydraulic operating pressures are typically in the 5,000 to 20,000 psi range.

“A three-plunger pump is continuously cycling, so the disk must be able to withstand high pressures with 1,000,000 pressure cycles or more easily experienced,” says Geof Brazier, Managing Director of BS&B Safety Systems Custom Engineered Products Division.

In the oil and gas industries, which depend on hydraulic systems to store energy and smooth out pulsations, standard system components like accumulators require rupture disks. By definition, accumulators hold hydraulic fluid under pressure. If the pressure spikes

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With the availability of integrated, miniaturized rupture disk solutions tailored to the application in a variety of standard and exotic materials, OEMs like BS&B can significantly enhance equipment safety, compliance, and reliability even in extreme work conditions.

too high, there is a risk that without a rupture disk the system, or even accumulator, could experience a catastrophic failure.

Similarly, rupture disk use is also important for safety when utilized with pneumatic pumps in oil and natural gas production. Pneumatic pumps are commonly used for chemical injection to limit processing problems and protect equipment.

Separate components versus integrated assemblies Traditionally, rupture disks began as standalone components that are combined with the oil and gas manufacturer's separate holder device at the point of use. The installation actions of the user contribute significantly to the function of the rupture disk device. When installed improperly, the rupture disk may not burst at the expected set pressure.

There is a delicate balance between the rupture disk membrane, its supporting holder, and the flanged, threaded or other fastening arrangement used to locate the safety device on the protected equipment.

For this reason, an integrated rupture disk assembly is often a better choice than separable parts. Available readyto-use and with no assembly required, integrated units are certified as a device to perform at the desired set pressure.

The one-piece design allows for easier installation and quick removal if the rupture disk is activated.

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The assembly includes the rupture disk and housing and is custom engineered to work with the user's desired interface to the pressurized equipment. The devices are typically threaded or flanged, or even configured for industry specific connections. The rupture disk and holder are combined by the manufacturer by welding, bolting, tube stub, adhesive bonding, or crimping based on the application conditions and leak tightness requirements.

There are additional advantages to this approach.

Integrated assemblies prevent personnel from utilizing unsafe or jury-rigged solutions to replace an activated rupture disk to save a few dollars or rush equipment back online. The physical characteristics of increasingly miniaturized rupture disks as small as 1/8” can also make it challenging for personnel to pick up the disk and place it into a separate holder.

“Oil and gas OEMs are driven to deliver the longest life and lowest cost of ownership to their customers, says Brazier.

“The use of an integral assembly maximizes the longevity, proper function and trouble-free service of the pressure relief technology.”

Integrated Assemblies - Rupture disk design According to Brazier, the most important considerations in oil and gas rupture disk device design are having the right operating pressure and temperature information along with the expected service life, which is often expressed as a number of cycles the device is expected to endure during its lifetime. Since pressure and cycling varies depending on the application, each requires a specific engineering solution.

“Coming up with a good, high reliability, cost-effective, and application specific solution for an oil and gas OEM involves selecting the right disk technology, the correct interface (weld, screw threads, compression fittings, single machined part) and the right options as dictated by the codes and standards,” says Brazier.

Because user material selection can also determine the longevity of rupture disks, the devices can be manufactured from metals and alloys such as stainless steel, nickel, Monel, Inconel, and Hastelloy.

According to Brazier, for the oil and gas industry it can be important for rupture disks to have a miniaturized reverse buckling capability in both standard and exotic materials.

“Where economics is the driver, reverse buckling disks are typically made from materials such as nickel, aluminum, and stainless steel. Where aggressive conditions are required, more exotic materials like Monel, Inconel, Hastelloy, Titanium and even Tantalum can be used,” he says.

In almost all cases, “reverse buckling” rupture disks are utilized because they outperform the alternatives with respect to service life.

In a reverse buckling design, the dome of the rupture disk is inverted toward the pressure source. Burst pressure is accurately controlled by a combination of material properties and the shape of the domed structure. By loading the reverse buckling disk in compression, it can resist operating pressures up to 95% of minimum burst pressure even under pressure cycling or pulsating conditions. The result is greater longevity,

accuracy, and reliability over time.

“The process industry has relied on reverse buckling disks for decades. Now the technology is available to oil and gas OEMs in miniature form as small as 1/8” burst diameter from BS&B. Until recently, obtaining disks of that size and performance was impossible,” says Brazier.

However, miniaturization of reverse buckling technology presents its own unique challenges. To resolve this issue, BS&B created novel structures that control the reversal of the rupture disk to always activate in a predictable manner. In this type of design, a line of weakness is also typically placed into the rupture disk structure to define a specific opening flow area when the reverse type disk activates and also prevents fragmentation of the disk “petal."

“Reverse buckling and therefore having the material in compression does a few things. Number one, the cyclability is much greater. Second, it allows you to obtain a lower burst pressure from thicker materials, which contributes to enhanced accuracy as well as durability,” says Brazier.

Small nominal size rupture disks are sensitive to the detailed characteristics of the orifice through which they burst. This requires strict control of normal variations in the disk holder.

“With small size pressure relief devices, the influence of every feature of both the rupture disk and its holder is amplified,” explains Brazier. “With the correct design of the holder and the correct rupture disk selection, the customer’s expectations will be achieved and exceeded.”

Due to cost, weight and other considerations, Brazier says that BS&B has increasingly received more requests for housings that are made out of plastics and composites.

Because customers are often accustomed to certain types of fittings to integrate into a piping scheme, different connections can be used on the housing. Threading is popular, but BS&B is increasingly utilizing several other connection types to attach the rupture disk assembly to the application.

Once the integral assembly leaves the factory, the goal is that the set pressure cannot be altered.

“If you rely on someone to put a loose disk in a system and then capture it by threading over the top of it, unless they follow the installation instructions and apply the correct torque value, there is still potential for a leak or the disk may not activate at the designed burst pressure,” explains Brazier.

“When welded into an assembly, the rupture disk is intrinsically leak tight and the set-burst pressure fixed.”

While oil and gas OEMs have long relied on rupture disks in their hydraulic and pneumatic equipment, high-pressure, high-cycling environments have been particularly challenging.

Fortunately, with the availability of integrated, miniaturized rupture disk solutions tailored to the application in a variety of standard and exotic materials, OEMs can significantly enhance equipment safety, compliance, and reliability even in extreme work conditions.

For more information, contact BS&B Safety Systems at 7455 East 46th Street, Tulsa, OK 74145-6379, call: (918) 622-5950, e-mail: sales@ bsbsystems.com or visit www.bsbsystems.com INDUSTRIAL MACHINERY DIGEST.COM

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