Industrial Machinery Digest - November 2019

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Manufacturing Showcase: Cleaning Technologies Group IndustrialMachineryDigest.com

November 2019

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Table of Contents

COLUMNS

9 10

TALKING SHOP Kim Williams Director of Marketing US Metal Crafters

BUSINESS 4.0 The Importance of Networking By: Nick Boliek

12

16 FEATURES

16

MANUFACTURING SHOWCASE Cleaning Technologies Group

By Russ Willcutt

18 24

WORKFORCE DEVELOPMENT

NEW TECH

DEPARTMENTS

30 PROCESS

34

Improving EDM Speed and Operations Market leader in high-precision pneumatic valves and other components machines 316SS and other materials, achieving better finish in less time with reduced power and less wire breakage, due to proprietary product from Global Innovative Products

INDUSTRY INSIGHTS

Dynamic Fixturing: The Secret Behind Precision Machined Parts

24 |

SAFETY & MAINTENANCE Preventative Maintenance Strategies

Robotic Welding: Taking the First Steps By: Ryan Lizotte, technical service manager, Tregaskiss

12

CNC Education in America Why tech schools are taking the LEAP into Siemens’ advanced CNC training

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6 7 38

EDITORIAL DIRECTIONS INDUSTRY NEWS ON EXHIBIT FABTECH

48 PRODUCT SHOWCASE 52 SURPLUS BUYING AND SELLING 57 CLASSIFIEDS 58 ADVERTISER INDEX

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Editorial Directions SERVING AMERICAN MANUFACTURERS FOR OVER

Everyone involved in manufacturing knows that fall is a heavy tradeshow season, with a variety of events being held across North America and around the world. Thinking of the remarkable technology both on display and supporting these massive enterprises puts me in mind of how far we’ve come over the past 30-40 years. It’s hard to imagine navigating a show without a smartphone handy, a tablet in your backpack, a digital camera, and flash drives that eliminate schlepping all those brochures and folders back to the office.

Websites allow attendees to navigate the halls and to schedule and keep track of appointments, and we’ve even gotten used to seeing people walking around talking to themselves on wireless earbuds.

As the scale of these shows increase, these support technologies actually make it possible to spend your time efficiently and to get as much value as you can from the significant investment you’ve made, whether as an exhibitor or an attendee. If you will take the time to plan your route in advance so that you can visit booths, meet with vendors, and attend educational sessions in the same general area, there will be less mental stress and physical wear and tear, and you’ll have more energy to enjoy networking events later in the evening.

And that’s one thing that hasn’t changed: the camaraderie. Having the chance to catch up with longtime associates is an important part of maintaining a healthy professional outlook, as is cultivating new relationships that can lead to exciting opportunities. That’s another good reason to try to stay fresh, because sometimes the most interesting conversations occur during a shuttlebus ride or while sharing a taxi to the hotel.

So a little advance planning will result in a more productive show experience and prevent you from being that poor schmo covered in flop sweat racing through the crowd at McCormick Place. Believe me, it’s no fun!

33 YEARS

William C. Strickland III, Publisher william.strickland@indmacdig.com 800-366-0676 ext. 103 | Fax: 866-826-5918

Russ Willcutt, Editorial Director russ@indmacdig.com

Nick Boliek, Editor nick@indmacdig.com 800-366-0676 ext. 104 | Fax: 866-826-5918

Shane Bell, Creative Director sbell@indmacdig.com

SALES

Lisa Hanschu, Sr. Account Executive lisa@indmacdig.com 785-965-9159 | Fax: 785-965-7199

David Marlow, National Sales Director David@indmacdig.com 800-366-0676 ext 200

William C. Strickland III, National Sales 205-903-9178 | fax 866-826-5918

Adrienne Gallender, Media Adviser agallender@indmacdig.com 888-407-7737

Susan Strickland, Accounting susan@indmacdig.com 205-542-1098 | Fax: 866-826-5918

Sarah Mayo, Interactive Specialist sarah.mayo@indmacdig.com 800-366-0676 | Fax: 866-826-5918

Russ Willcutt Editorial Director, Industrial Machinery Digest

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Industry News Markforged Opens Manufacturing Facility in Massachusetts to Support its Accelerating Demand for 3D Printers Markforged announced the opening of a new manufacturing facility in Billerica, Massachusetts. The 25,000 square-foot space will enable the company to more than double its production capacity, support increased demand for Markforged 3D printers, and create new jobs.

This is their third major footprint expansion this year — following a new European headquarters in Dublin, Ireland and an AI innovation center in Cambridge, Massachusetts. The Billerica facility has also already received recognition as the October Project of the Month by the New England Real Estate Journal. With tens of thousands of users in more than 50 countries, demand has exploded for Markforged materials and 3D printers. This has resulted in the company boosting material production by 81 percent in the past year. The new facility will support the fabrication of all Markforged materials that are used by companies in the aerospace, automotive, and manufacturing fields.

Hunter Fan Company Acquires Industrial Fan Provider Jan Fan Hunter Fan Company, a portfolio company of MidOcean Partners and a leading manufacturer of ceiling and industrial fans, has acquired Entrepreneurial Pursuits, Inc. (d/b/a “Jan Fan”).

Headquartered in Michigan and Ohio, Jan Fan is a manufacturer and distributor of fixed and rolling-mount caged fan solutions for commercial and industrial workspaces. The combination of these

two businesses further strengthens Hunter’s rapidly growing position in the industrial fan segment of the market. Jan Fan has operated for more than 60 years and serves customers across the United States, Canada and Mexico. The company’s products include heavy-duty pedestal fans, mounted fans, shop fans, floor fans and mobile fans.

Emuge Corp. Hosts Grand Opening of Newly Expanded Manufacturing Facility Emuge Corp., manufacturer of high-performance taps, thread mills, drills, end mills and other rotary tools, held a Grand Opening ceremony of its significantly expanded, custom-designed manufacturing facility on October 15, 2019. Marking a 35 year presence in the U.S. along with increased growth in North America, the Emuge expansion includes more manufacturing and tool reconditioning space, the addition of a new PVD coating center as well as an expanded Technology and Training Center. The expanded facility doubles the size of the original building to over 50,000 square feet total.

Mazak and Oak Ridge National Laboratory Partner for Wire Additive Research and Development Continuing collaborative efforts for the technological advancement of manufacturing processes, Mazak Corporation and Oak Ridge National Laboratory’s (ORNL) manufacturing demonstration center in Oak Ridge, Tennessee, have entered into a cooperative research and development agreement (CRADA). Working on behalf of the U.S.

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Department of Energy, ORNL and Mazak will further develop the use of HOT WIRE DEPOSITION (HWD) in additive manufacturing part production operations.The project addresses Mazak’s HYBRID MultiTasking HWD technologies as a commercially viable solution which, upon completion, will result in a closed-loop control system featuring the ability to make on-the-fly adjustments according to sensor feedback during the HWD builds.

Cincinnati Incorporated To Showcase New Machines, Hendrick Motorsports Partnership at FABTECH Hendrick Motorsports, 12-time NASCAR Cup Series champions, recently welcomed CI as an official partner with a team-record 10-year agreement that runs from 2019 through 2028. In addition to being named Hendrick Motorsports’ Official Metal Fabrication and Additive Equipment Provider, CI will become a full-season associate sponsor of the team’s entire four-car stable for the next decade.

Cincinnati Incorporated will showcase its latest machines, and Hendrick Motorsports’ #88 car, driven by Alex Bowman, will also be on display at the show.

ESAB Sponsors Leading Sculptor of Welded Art World ESAB today announced that it is sponsoring world-renowned metal artist David Madero, Mexican-American sculptor and founder of Madero/Co., a welded art company located in Torreón, Mexico.

From tiny to colossal, Madero produces an array of dreamlike sculptures and functional pieces from steel, brass, copper and

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IMPACTING DROP ZONE

» Don’ t Fear The Robotics How the coming automatio changing n revol the work ution force, for » Enab ling On-T the bette is r he-Fly The New Product Era of Experts: Sales and Manufac Mark turin

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Xometry and ProvenCut Announce Strategic Partnership Xometry Supplies, the materials and tooling eCommerce arm of the US’s largest on-demand marketplace for custom parts, has announced a strategic partnership with ProvenCut, an online platform that provides proven cutting recipes to machinists. Xometry Supplies’s materials and tools will be recommended for use in ProvenCut’s recipes and available for purchase. Xometry will also promote ProvenCut’s offerings on the Xometry Supplies site. ProvenCut is an online platform that redefines Speeds & Feeds by using real-world, unbiased testing to deliver proven CNC machining recipes. ProvenCut users can search for recipes by CNC machine, cutting tool, raw material, CAM strategy, and more. ProvenCut recipes help machinists by maximizing process reliability and demonstrating the performance of the machine tool and cutting tool.

FANUC America Opens New North Campus Robotics and Automation Facility

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bronze. ESAB will kick off its sponsorship of Madero at FABTECH 2019, where Madero will create a sculpture based on ESAB’s We Shape the Future brand campaign in ESAB booth B17087. Madero’s most notable work includes a 500-ft. monumental steel ‘Serpentina’ for Albuquerque International Airport and an epic ‘Eagle & Serpent’ (Mexican coat of arms) installed in front of official residence of the President of Mexico. Madero is not only obsessively creative but also exceptionally passionate about education as it relates to artistic welding and cutting. He attends workshops around the world to educate people on the artistic possibilities and opportunities outside of typical welding industry vocations.

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FANUC America held the grand opening celebration at its new 461,000 square-foot North Campus robotics and automation facility in Auburn Hills, MI on Tuesday, Oct. 22, 2019. FANUC invited customers, local officials, educators, suppliers, and the media to an official program, ribbon cutting ceremony and facility tour. Constructed and in full operation just one year after breaking ground, the new facility houses several departments including engineering, product development, manufacturing and warehousing. Now, to keep pace with the growing demand for robots and automation, FANUC occupies over one million square feet of building space in Oakland County, Michigan.

FANUC will have an automation tour path that includes over 20 robot demonstrations, from its smallest M-1iA delta robot, to the mighty M-2000iA, the world’s strongest robot able to lift 2.3 tons.

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7/29/19 12:07 PM

Talking Shop

We will honor delivery deadlines and price points. As we like to say, it’s a matter of “promises made, and promises kept.”

FEATURING:

TALKING SHOP WITH: Kim Williams — Director of Marketing, US Metal Crafters I understand that you and your colleagues purchased the assets of the company in 2018, but that it has actually been in business for the past 34 years.

That’s right. We acquired the facility, the equipment, the accounts that were already on the books last November, and we retained key employees so that we could benefit from their long years of experience. It was quite an experience to able to hit the ground running so quickly. We are ISO 9001:2015 certified and currently finalizing our International Traffic in Arms Regulations (ITAR) compliance as well. Steve McDaniel is our principal owner, who provides seasoned corporate leadership and vision. He has quite the proven track record. US Metal Crafters is a sister company to US Duct, one of his other successful businesses.

Can you give us some idea of the markets you serve, and how you go about doing so?

We are involved in so many different industries that it’s somewhat difficult to pull together a comprehensive list, but we’re basically using roll forming, metal stamping, laser cutting, fabrication and assembly, among other methods, to produce component parts that are used by a variety of OEMs. Some examples are in the solar industry, commercial and hospitality furniture, and access control industry, etc. We can either work from our customer’s plans, or we can step in and provide prototype design service, including die manufacturing and maintenance. We have independent sales reps

located around the country to assist our customers, and we also have an in-house tool and die shop, which is pretty rare, and allows us to cut our lead time on manufacturing dies by weeks by handling the work ourselves. That’s a huge benefit for our customers, since it slashes the lead time for their orders. In addition, we are both a job shop for smaller orders and a production manufacturer for larger blanket orders involving periodic PO releases.

At this early stage of the company’s development, what do you and your colleagues most want it to be known for?

The fact is, it goes without saying that we have to deliver quality parts on time. So, we do that. We ensure this by relying on continued equipment upgrades and utilizing engineering tools including Autocad 2020 (CAD), Fusion 360 (CAD/CAM/CAE), Metacam (CAD/CAM), Profil (CAD), Radan (CAD/CAM), and E-2 Shop Tech (ERP). And our pricing must be competitive and lead times reasonable. Still, what truly sets us apart is our people – we care about our customer’s success deeply. So it becomes largely a matter of integrity. As we like to say, it’s a matter of “promises made, and promises kept.” We place a great emphasis on being dependable.

Please go online to us-metalcrafters.com for a complete list of equipment and capabilities.

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IMD 9

Business 4.0

The Importance of Networking By: Nick Boliek

W

hen it comes to manufacturing, due to the extensive range of applications, processes, and specialties, increasing your network of available resources is important. It can provide your business with a core focus and supports valuable relationships that often are mutually beneficial.

Whether it is another shop or the people you meet at trade shows and other networking events, as the old saying goes, it is often not what you know, but who you know.

Networking is important because it allows you to gain essential development of your business and can provide you with job opportunities that you may not have had access to. It can also provide insight on specific shortcomings that you, as a manufacturing professional, may realize are unique to your location. Maybe there is a need for a shop or facility specializing in heat treatment, additive manufacturing, fabrication or another specific process.

Our industry’s trade shows also provide an exclusive range of networking potential. These regional, national, and international events allow you to meet with not only product and service providers to find the best solutions, but also with fellow manufacturers, educators, and other like-minded individuals.

You can share your own personal insights and gain a wealth of information right from the trade show floor. Of course, networking shouldn’t come from these trade shows alone. Past employees, clients, personal friends, and even family members can provide a crucial initiation point for your next big job. A referral from a close mutual connection can dramatically increase the chance of speaking with decision-makers.

Digital networking cannot be ignored either. Social networking platforms such as LinkedIn, Twitter, Facebook, and even Instagram provide a public presence to not only build relationships on your own, but also for others to connect with you. Currently, LinkedIn, the more business-oriented social network, has over 645 million registered users alone. Almost acting as an online resume, users can connect and learn about others’ past and current professional experience. Many of these platforms provide groups focused on a particular subject to further develop networking relationships.

4 TIPS FOR NETWORKING 1. It’s Not All About You Focus on the person you are speaking with. Learn their background, and any commonalities you may share. You never know what you may learn speaking with someone.

2. Never Forget the Importance of Business Cards In a world that is increasingly digital, the benefit of a traditional business card may seem like it isn’t as important today as it was decades ago. In my experience, business cards provide a quick and easy reference point to who you talked to, what they do, and what company they work for.

3. Build Your Contact List After all the handshakes, information exchange, and generally getting to know a client or contact, it is especially important that you

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have a way to stay connected. Business cards can be scanned, or the information entered manually in your own contact lists.

4. Follow Up Whether it is a simple email, a phone call, or in-person, staying connected is just as important. Out of sight is often out of mind, staying present can strengthen your network.

A good networking relationship should never be a one-way street. Build on your relationship, follow up with your contacts.

Your network of contacts can be further strengthened by connecting others with the product and service providers you already trust. Building these key relationships can allow you to work far more efficiently and effectively.

Safety & Maintenance

Preventative Maintenance Strategies O perational assets are at the heart of business operations and failure can not only affect business critical processes and cause downtime but also endanger people and equipment.

A well-planned maintenance strategy is a key factor of an organisation’s asset management strategy that strongly lends towards mitigating the risk of asset failure. The results of an effective maintenance strategy are extensive for operations.

Maintenance staff responsible for the execution of an asset performance management program typically aim for strategies that produce reliable asset capacity whilst minimising operational and equipment lifecycle costs.

While maintenance approach depends on organisation’s unique requirements, financial capability, ability and culture, the following cover the most commonly used type:

Corrective or reactive maintenance Corrective maintenance, also referred as run-to-failure is carried out upon failure detection, whereas reactive maintenance is where

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equipment is repaired after wear, breakdown or malfunction to enable an asset to perform its intended function. Although these involve low short-term costs and require minimal planning, however, corrective and reactive maintenance actions result in unplanned additional costs, asset’s lifetime decrease and operational delays.

The proactive maintenance model combines intentional preventive and predictive interventions to maintain an asset in reliable and operable condition.

Preventative maintenance Time based proactive approach, involves performing periodic inspections, preventative maintenance prevents machine failures from occurring. This model keeps assets more efficient and extends their operable life, avoiding unforeseen breakdowns.

Preventive maintenance appears costly and time-consuming at the beginning, it most often proves to be a solid return on investment by reducing the number of major breakdowns as well as the asset’s downtime.

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Traditionally, maintenance teams relied on preventative maintenance schedules provided by the manufacturer, including regularly replacing asset components based on a suggested timeline. However, these timelines are only an estimate of when an equipment will require service, and the actual use of the equipment can significantly affect the reliability of OEM estimates.

A well-planned preventative maintenance strategy can provide visibility of routine maintenance and any statutory compliance requirements.

Predictive Maintenance Predictive maintenance involves a condition-based process, forecasting when a physical asset failure can occur and facilitate maintenance at the right time. This is achieved through monitoring the condition of the asset through data from machine sensors and smart technology to alert the maintenance team when a piece of equipment is at risk of failing.

Even though predictive maintenance can be carried out via visual inspections of equipment, but the effective way to establish a predictive maintenance strategy is by using an Enterprise Asset Management (EAM) to track sensor data or meter readings.

In the recent times, digitalization via the Internet of Things (IoT), has aided in the improvement of predictive maintenance routines.

Reliability-Centered Maintenance (RCM) The reliability-centered maintenance, a multi-factor approach is a

highly involved process that takes into account all the possible failure modes to derive a custom maintenance plan for each individual asset. The outcome of a successful RCM program is the definition and implementation of a specific maintenance strategy on the most critical assets of the facility.

Asset-intensive companies emphasize on reliability, availability and safety in order to achieve world class performance by replacing reactive maintenance strategies with proactive strategies such as RCM and total predictive maintenance.

Poor maintenance practices can lead to decreasing availability and productivity as the operational assets’ condition deteriorates thus escalating maintenance costs arising from incremental breakdown frequency. To address these challenges requires a shift from reactive maintenance to preventative maintenance paradigm. Enabling preventative strategies would produce a small delay in order to prevent possible larger delays.

Preventive maintenance allows the maintenance team to focus on high-level priorities. Elevating the maintenance planning from a tactical approach to strategic can help extend the life of critical assets. Once a reliability and maintenance policy and associated improvement strategy are in place, it requires constant refining to keep abreast of the dynamic demands of the industry and organization.

Furthermore, the following five step strategy will help your organisation establish a world-class preventive maintenance program and experience the resulting operational gains.

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Maintenance Strategy

Summary

Advantages

Corrective or Reactive

Maintenance after breakdown or failure has occurred

Low up-front cost and planning effort.

Ideal for low-priority equipment.

Preventative

Maintenance is scheduled before a defect occurs

Best strategy to implement without any required expertise

Predictive

Maintenance based on asset condition

Provides insights into asset behaviours through time-based condition monitoring

Reliability-Centered Maintenance

Monitor and analyse failure mode and consequences to derive the best strategy for each asset

Provides the most effective scheduled maintenance plan. Helps organisations to understand the criticality of an asset to facilitate informed decision making as to apply a break-fix, preventative or a condition-based maintenance (CBM) approach.

1. Review the Current Maintenance Strategy An insight into the current asset portfolio and maintenance programs will help understand key gaps and areas for improvement.

2. Determine Systemised Operating Procedures for Reactive and Preventative Maintenance Simple procedures outlining the types of tools to be used on particular maintenance requests and establishing standardized operating procedures across the board can greatly improve the outcomes from both reactive and preventative maintenance.

3. Set Up A Reliability and Maintenance Policy with An Improvement Plan Planning is the key to becoming more cost-effective with the asset maintenance

activities. Establish a sound reliability and maintenance policy that incorporates an improvement plan to prevent failure.

4. Attain Perfect Execution of Preventive Maintenance in Line With The Industry Rule Sporadic preventive maintenance practices can limit the effectiveness of the maintenance procedures.

Practise ten percent rule of preventative maintenance i.e., the task must be executed within a ten percent variation of the time frequency of the request.

Example, a 60-day preventative maintenance activity must be completed within three days on either side of the due date for optimal maintenance outcomes, therefore propelling into a world-class preventative maintenance organization.

5. Leverage Technology To Advance Your Preventative Maintenance Program Over the past decade, automation using the right technology has significantly helped assetintensive organizations reduce costs, both from an operational and people standpoint.

An Enterprise Asset Management solution can provide the key technology enabler for an organisation to realise these benefits through the implementation a preventative maintenance approach to managing its operational assets. An effective

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EAM will reduce breakdowns and improve availability and productivity of critical assets through a risk-based preventative maintenance approach aligned to service, cost and risk outcomes.

Leveraging business and asset intelligence via reporting capabilities offer maintenance departments the opportunity to showcase activities and the ways to obtaining key performance indicators.

Once a reliability and maintenance policy and associated improvement plans are in place, it requires constant refining to ensure it meets the dynamic demands of the industry and organization.

In fact, organizations with world-class preventative maintenance programs assess the current state of the program quarterly and how it can be improved.

Once established, it opens doors to extend an organisation’s maintenance program beyond that by integrating predictive maintenance techniques and technologies. Asset availability is directly correlated with the company’s maintenance strategy. Reactive maintenance generally yields lower asset availability than preventative models which is lower than predictive which is lower than Condition Based Maintenance approach.

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Manufacturing Showcase

Cleaning Technologies Group

By Russ Willcutt

C

leaning Technologies Group (CTG), headquartered in Cincinnati, Ohio, is made up of three divisions. Ransohoff, a manufacturer of aqueous parts washers, has been doing so for more than a century. Blackstone-NEY Ultrasonics designs and manufactures industrial and precision ultrasonic cleaning equipment, harnessing environmentally sound solutions for challenging parts cleaning applications. These technologies utilize multiple frequency and waveform ultrasonic generators. It is located in Jamestown, New York. Finally, CTG Asia, in Suzhou, China, was formed in 2007, building Ransohoff and Blackstone-NEY equipment for that market in its new, high-tech facility.

According to Dave Melton, marketing manager at CTG, so many factors must be taken into consideration when determining the best parts washing system for a particular operation that the vast majority of its systems are custom made. “These variables include the geometry of the part, the angles involved, the

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temperature of the solution being used — and the temperature of the part as it enters the washer — the degree of cleaning required, the material in use, and the number of change-outs that will be performed,” he says.”Even surface conditions must be taken into consideration, as lapped parts will need a longer ultrasonic bath to remove particulates from the grooves than would a smoother, less-striated finish.”

In metalworking, there are four basic methods to performing water-based cleaning operations: standard spray, total immersion, ultrasonics, and high-pressure spray. The two spray processes are called “line of sight,” as the spray will clean all features that can actually be seen with the naked eye. Immersion and ultrasonics are required for more complex geometries with angles and deep pockets that require a more cleaning penetration to get the job done. Total immersion can also be combined with the parts being spun or agitated, if need be.

A quick review of how these processes are performed, and how they differ, is useful, along with a look at the latest CTG advances available on the market. »» Standard spray is a simple, straightforward process that is ideal for a wide variety of manufacturers, providing flexibility among parts of different shapes, materials and sizes in general industry. Parts are positioned on a rotary table and sprayed with water containing different concentrations of surfactant to clean oil and other contaminants from the surface of the part. Remaining liquid is then blown off using compressed air. More acidic cleaners are used with soft metals such as copper, brass and bronze, while steel products require that attention be paid to the pH level. A solution with a pH of less than seven is considered acidic, while a solution with a pH higher than seven is referred to as basic, or alkaline. »» Total immersion is generally considered first when features or deep recesses on the part prevent direct line of sight inspection.

Cutting fluids, chips and other particulate matter can evade even high-pressure spraying, so some parts must be fully immersed in the cleaning solution. Parts can be loaded into a basket and then into the cleaning chamber and sprayed while the basket is rotated. The chamber is filled while the basket is plunged into the bath, agitated, and then withdrawn, penetrating the part’s

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recesses. Automation can be incorporated into any of these processes. »» Ultrasonics can be combined with the standard spray and total immersion processes, adding cavitation to the cleaning system. Once spraying has been completed to remove gross contaminants, the chamber is filled and high-intensity sound waves are introduced into the solution, forming vacuums within the crevasses of the parts being cleaned. Depending on the frequency of the sound waves, contaminants are removed at the lower end of the scale while material can actually be removed from the part surface at higher exposures. Ultrasonic cleaning is ideal for aerospace and medical markets that have the strictest requirements. »» High-pressure spray is primarily used for deburring applications, removing burrs without damaging the underlying substrate. With an upper range of 10,000 psi, the Ransohoff line of high-pressure washers generally operate in the 3,500-psi range for materials such as aluminum and approximately 5,000 psi for parts made of steel.

CTG offers laboratory testing to ensure that the final customer specifications for cleanliness are met. The company’s tech center houses a cleanroom rated at class 10,000 using gravimetric filters to conduct microscopic particle size analysis.

As is the case with any OEM, CTG has worked to incorporate new streamlining into its designs, bringing multitasking and robotics

into the process. The Rotosonic ultrasonic cleaning system is an automated, all-in-one machine that uses high-pressure spray, part rotation, and ultrasonic energy to clean parts within a single machine. It is ideal for automotive maintenance, rebuilding and restoration, as well as transmission and engine rebuilders and aerospace remanufacturing. The Ransobotic TT-180 combines robot-operated spray nozzles and a precision worktable to help users meet their complex parts washing requirements. A Fanuc LR-Mate robot and Siemens programmable controls make operation fast and efficient. The Robosonic is a robotic automated cleaning cell that features a four-tank system incorporating a spray wash, ultrasonic immersion wash, an ultrasonic rinse tank, and a dryer. Flexible part processing is provided by a Fanuc CR-7i robot or optional collaborative robot. This unit was designed for clean room and precision parts cleaning applications.

While this provides a mile-high view of CTG’s extensive product lineup, as well as the latest additions to its technological offerings — all detailed clearly and completely on its website — the real experience involves the attention paid to determining a customer’s needs at the front end, Melton says. “It’s critical that we ask all the right questions going in,” he says, “because that’s how we’ll get the right outcome on the other end from the very beginning.”

To learn more go online to ctgclean.com.

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IMD 17

Workforce Development

Dean Baker, instructor of Manufacturing Technology Machining, shows a student how to work on a Fryer machine with a SINUMERIK 828D controller during a class at the Francis Tuttle Technology Center’s Portland Campus in Oklahoma City.

CNC Education in America Why tech schools are taking the LEAP into Siemens’ advanced CNC training

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rapid advancement in technological development has changed and challenged industries around the world in recent years. In manufacturing, as new technologies permeate the industry, the demand for employees with advanced machining skills increases. Those that possess the latest skills will quickly rise to the top of the talent pool.

Progressive high schools and community colleges around the country that sense an opportunity to meet the growing needs of the industry are turning to the Siemens Lifelong Educational Advantage Program (LEAP) to equip their students with career-enabling, advanced machining skills. The LEAP curriculum features basic-toadvanced computer numerical control (CNC) machining, including 5-axis training, that puts students on a path to a career, not just a job.

“The manufacturing industry is investing heavily in and quickly

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moving to 5-axis machining, so 5-axis capabilities are becoming necessary for shops,” says Steve Holmes, CNC Education Manager at Siemens. “Students must learn 5-axis machining to obtain the best, highest-paying jobs at the best companies.”

LEAP-certified schools use the Siemens SinuTrain training system, which is PC-based simulator software replicating the SINUMERIK Operate interface of 828D and 840D controls. Siemens provides software and installation assistance as well as free instructor training, certification, and support.

The LEAP training program consists of three days each on Level 1 (conversational programming, ShopTurn and ShopMill), Level 2 (more complex machining, including 4-axis), and Level 3 (5-axis milling) for instructors. Upon completion of training, instructors are certified, and they in turn can certify students. Successful

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completion of each level of training and subsequent testing can provide students with up to five certificates to help them begin their careers in CNC machining.

Markus Puntigam, technical sales manager at EMCO Group USA in Wixom, Mich., has firsthand experience with LEAP. EMCO supplies many of the machines using Siemens controls to schools in the LEAP program. He says LEAP benefits not only the students, but also the schools.

“The LEAP program has real market value,” Puntigam says.

“The schools get—free of charge—three-levels of training, each level backed by three days of instructor training—that is a full nine days of training. Part of that training can be done at the school on site. Schools are getting a training service package in the range of $25,000 dollars for free.”

Many schools around the country already are part of the Siemens LEAP program, giving their students the game-changing capabilities employers seek. Program leaders at three of those schools in Fort Worth, Texas; Cupertino, Calif; and Oklahoma City say the program has elevated their curriculum—and they are ready for even more advanced machining training and certification.

“Schools must improve their programs to incorporate 5-axis because the market is going that way, otherwise, their programs won’t be in demand,” Holmes says.

Hollenstein Career and Technology Center—Fort Worth, Texas

De Anza College Design & Manufacturing Technologies department coordinator Mike Appio and a student look at a part produced on a CNC mill.

Demetrius “Coach” Anthony, a tool and die maker journeyman who served in the military, started the manufacturing/engineering program at Eagle Mountain-Saginaw ISD-Hollenstein Career & Technology Center in Fort Worth, Texas, eight years ago. He has seen increasing demand for employees with advanced CNC machining skills, and the Siemens LEAP program is helping Anthony train Hollenstein students with the latest technology. His classes feature several EMCO machines with a Siemens 840D emulator,

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IMD 19

Siemens SinuTrain training system turns PCs into an exact representation of the SINUMERIK Operate interface during one of instructor Demetrius Anthony’s classes.

which gives the students valuable experience that is attractive to high-tech companies.

“If any of our students ever wanted to go to an advanced manufacturing company using a Siemens controller, that’s the technology and skill set being used,” says Anthony, an instructor and former high school football coach. “I’m always looking at different things that I can teach the students to give them an extra tool in their bag.”

Holmes says that strategy will pay off for Hollenstein students.

“Graduates with experience in advanced technology are in great demand by the manufacturing industry,” he says. “These companies are asking for students that know the Siemens platform and that know 5-axis machining.”

In his classrooms, Anthony has seen students quickly improve using Siemens controls. He attributes that in part to the conversational programming feature.

“Once I brought Siemens in, those students who struggled with code got to see the conversational part of it, and they took off with it,” Anthony says. “When they can see it before they actually run their simulation, it helps them. It gives them that visual, because a lot of people are visual learners, like I was. You’ve got to show me. I want to see it, because if you just talk about it and tell me in theory, I don’t quite understand it.

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A Hollenstein Career and Technology Center student holds a part that he produced in one of instructor Demetrius Anthony’s classes.

“On our other control option, all they see is the line of code, and they’ll see a 2D line tracing the moves it made. That’s it. They don’t get the 3D visual like what they do with the machines with the Siemens controls we have now.”

Under his guidance and with hands-on experience with Siemens-controlled machines, students who complete the LEAP program at Hollenstein are ready to enter the workforce, Anthony

says. He shows local employers his students’ skills during open houses, where company representatives often tell him a variation of a common theme: It’s hard to believe high school students can machine.

“I’ll have one student, and I’ll say, ‘Here’s a student; he can draw up any part that you have in CAD (computer-aided design). … He can set it up. He can do the CAM (computer-aided manufacturing) or he can hand-program it. He can run the machine, set the machine up.

He can go over and help with the mech lab units, which is essentially lighting the POC (proof of concept)—controlling the conveyor, sensors, things like that—and then he can print up 3D models.’ This is all coming from one student,” Anthony says. “One of the guys who came out from a local large manufacturing company says, ‘We have four or five different people doing all those things.’ And I said, ‘Here you have a student who has the very basics for all of that, and he’s ready to go.’”

Puntigam of EMCO, which supplies machines to Hollenstein, says it is exactly that type of employee that is highly sought in the industry: “not a button-pusher, but somebody who really knows what they’re doing.”

Anthony’s students also rise above their peers in the state and national SkillsUSA competitions that showcase the best career and technical education students in the country. He says his students, using Siemens controls, often win their district and finish in the top three, if not win, in the state SkillsUSA competitions.

“We prepare for competitions and for the workforce at the same time,” says Anthony, whose program is so popular, students must enter a lottery for enrollment.

Hollenstein Career and Technology Center manufacturing engineering instructor Demetrius Anthony teaches more advanced machining on an EMCO machine with a Siemens 840D emulator.

question by pointing to their work learning Siemens’ Sinumerik 828D and 840D controls via the LEAP program training. He particularly covets training and certification on the 840D, a worldwide favorite because of its capabilities in high-end machining.

“We want to do certification on the 840D because there are larger companies around like Northrop Grumman and others that are using the 840D controller on not only DMG Mori Seiki but other machines,” he says. “That’s the direction we want to work toward,

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De Anza College—Cupertino, Calif.

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Appio, coordinator of De Anza’s Design & Manufacturing and Technologies department, wants his program to reflect those industry needs and “stay one step ahead of the rest of the community colleges.” He’s turning to the Siemens LEAP program to do that.

Appio, who’s been with De Anza for more than 13 years, has a DMG DMU 50 machine with a SINUMERIK 840D controller in his program. Students start their training with 3-axis machining on Haas equipment, then work up to multi-axis machining, automation, and Siemens NX. Many of the students that enter the design and manufacturing program at De Anza already have earned bachelor’s degrees, Appio says, but return to school because they need experience and training with advanced machining technology like the Siemens 840D. “There are a lot of companies in the Silicon Valley that want to know ‘Do you have any machining experience?’ It’s not like you need 20 years under your belt, it’s: ‘Have you run equipment? Are you familiar with equipment?’ ” Appio says.

Appio wants De Anza students to be able to answer that

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IMD 21

Manufacturing Technology Machining Instructor Dean Baker and his students explore the capabilities of the SinuTrain emulator during a class at De Anza College.

unlike other education approaches that use introductory level machines. You’ve got to expose students to various things.”

The SinuTrain software that teaches students those basic-toadvanced machining skills is very close to a real-world experience, Holmes says. It turns a PC screen into an exact representation of the SINUMERIK Operate interface; the numeric control kernel (NCK) that drives the software is the same NCK that drives Siemens 828D and 840D controls.

Among SinuTrain’s many features, collision-avoidance is especially beneficial for students, Holmes says.

“Collision-avoidance is not only going to find errors in the program, but it’s also going to prevent the machine from crashing, which can be very, very costly,” he says. “In a learning environment, having a tool like SinuTrain with collision-avoidance is incredibly beneficial.”

For Appio, the LEAP program certification is important for his students and De Anza in general. He says it will set both apart from the pack.

“A certification on a Siemens 840D, 828D, that’s going to put you in a whole different ballpark, a whole different arena,” he says. “These people thirst for something else to put on their résumé, another skill. In the whole Bay Area here, across several million people and 10 community colleges, no one is issuing these certificates. No one’s doing it all. So I’m giving them another avenue to get students jobs.”

Holmes says that is a route that will lead to success.

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“The students that successfully complete LEAP, especially the 5-axis program, will be in the biggest demand and command the highest salaries in the industry,” Holmes says.

Francis Tuttle Technology Center, Portland Campus— Oklahoma City “Please write.”

That’s all Dean Baker was told to do when he began writing G-code for machining controls in 1979. His instructor, a Japanese engineer with little command of the English language, would show Baker a blueprint and give that simple, two-word command. Baker would do his best to write the code, then the instructor would correct his work.

“That’s when it dawned on me—it’s what I tell my students now— that this is a different language,” Baker says. “Back then, G-code was a language by which we both could communicate, at least as far as manipulating a machine to do something for us.”

Now, Baker is the one doing the teaching. He is instructor of Manufacturing Technology Machining at the Francis Tuttle Technology Center’s Portland Campus in Oklahoma City. He’s using more than blueprints and “please write” to teach advanced machining, however. Baker’s students work with, among others, a Fryer machine powered by the Siemens SINUMERIK 828D control. Baker sees LEAP and the 828D training as the next step for his program.

“It’s just an awesome, awesome control,” he says. “I’ve barely scratched the surface with it—I’m real excited to get in there and get

A student does conversational programming on a DMU 50 machine using a SINUMERK 840D controller during class at De Anza College.

my hands on it and make some stuff.”

Baker, a self-proclaimed “G-code guy,” calls the conversational feature of the 828D “pretty cool.”

“I still teach G-code programming,” says Baker, who is also secretary of the SkillsUSA board of directors. “But with conversational, that enables students to see. Instead of just, ‘OK, I’m pushing this, and this is going to happen,’ conversational teaches what’s happening behind the scenes. I know what the machine’s doing.”

Similar to Anthony’s students at Hollenstein Career and Technology Center in Texas, Baker says the 828D’s conversational programming resonates in his classes.

“I’ve had students understand [G-code], but they’re just not as good with it,” he says. “Then they’ll get on a conversational control

and—bam—it seems to fit their personality or their skill set, and they do great on it.”

His classroom experience with the 828D control has pushed Baker to advocate for conversational programming supported by the Siemens SINUMERIK CNC platform in future SkillsUSA competitions.

“SkillsUSA is a very progressive organization. We always want our students to learn and our instructors and teachers to deliver the latest technology. To me, the 828D represents the latest in CNC machining technology,” Baker says. “Haas does a good job putting on the CNC G-code contest right now, but as an instructor, I think we should also have a CNC conversational contest. Two different controls.”

Being an instructor along with being a SkillsUSA board member gives Baker a unique and educated perspective on the organization’s mission. He sees conversational as a trend that will help shape a new generation of CNC professionals, and he doesn’t want any students left behind.

“You always have to be forward-looking,” he says. “Our SkillsUSA competitions drive behavior immediately, adapting new technologies out there, getting them more and more common.

“At competitions, students introduce these new technologies at the national level. From a board directive, we want to make sure that the greatest number of students possible are able to participate.”

To learn more, or to join the Siemens CNC LEAP program, visit usa. siemens.com/cnc-leap or email cnc-leap@siemens.com for information.

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New Technology

Companies need a welding operator or other employee skilled in robotic welding programming. This will likely involve additional training to upgrade his or her skill sets.

ROBOTIC WELDING: Taking the First Steps By: Ryan Lizotte, technical service manager, Tregaskiss

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n today’s marketplace, companies continue to automate portions, if not all of their welding operation. The reasons are many: to address a shortage of skilled labor, to improve quality, to decrease waste and rework, and/or to increase productivity — in short, to seek benefits that provide a competitive edge.

Not all companies, however, are successful in the process. Those beginning without a well-thought-out roadmap risk losing valuable time during implementation and operation and may miss the full benefits provided by a robotic welding system.

Conversely, companies that begin with a careful examination of their welding needs and existing processes — and develop a detailed plan with clearly established goals — are more likely to achieve success. Planning should include an accurate assessment of parts, workflow and the current facility, as well as an evaluation of the potential return on investment (ROI).

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Companies should not only look at current needs, but also consider future opportunities to determine the best robotic welding system to scale for potential growth or changes to products they may produce later.

Why Robotic Welding?

In an economy where orders are increasing and welding positions are hard to fill, robotic welding can help maintain or increase productivity. In a semi-automatic welding operation, labor accounts for approximately 70 to 85 percent of the total cost of welding a part. A robotic welding system can reduce that cost and increase throughput by completing the work of two to four people in the same amount of time — however, companies still require skilled welding operators to oversee the robotic cell.

In addition, the national and international marketplace has become

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increasingly competitive, with companies seeking contracts from any number and any size of business. Investing in welding automation can help set up a company on the path to compete at a global level.

Repeatability Is Key When considering an investment in a robotic welding cell, companies should have part blueprints, preferably in an electronic format.

Without a blueprint, the part likely won’t meet the basic criterion necessary to ensure repeatability during the manufacturing process.

A robotic welding system welds in the same place every time.

When a part’s tolerances are unable to hold its position — if there are gap and/or fit-up issues — the company will simply be automating a broken process. This can increase rework or scrap.

If a company currently relies on its welding operators to compensate for fit-up issues, it will need to look upstream in the manufacturing process to establish consistency. What processes need to change so these welding operators send uniform parts downstream?

Or, if vendors supply the parts, can they guarantee consistency?

Assess the Workflow A streamlined workflow is one of robotic welding’s benefits. To achieve it, companies need to look beyond the weld cell, making certain the facility can accommodate a smooth flow of materials.

It makes little sense, for example, to invest in a robotic welding system to increase productivity, but then place it in a corner where employees may have to handle each part multiple times.

There should be a consistent supply of parts to avoid moving a bottleneck from one area to another. It is also important to look at the expected cycle time of the robot. Can personnel supply parts to keep up with the demand of the robot’s cycle time? If not, the supply of parts, including where the company stores them and how it moves them, will need to be adjusted. Otherwise, a robot will sit idle waiting for components to come down the line.

Robotics or Fixed Automation?

There is no single welding automation solution that is best for every company. When a company is considering the investment, it should factor in the expected lifetime of the job, the cost of tooling and the flexibility the equipment offers.

Fixed automation is the most efficient and cost-effective way to weld parts with simple, repetitive, straight welds or round welds, where the part is rotated with a positioner. If a company wants to reuse the equipment when the current job ends, however, a robotic welding system offers more flexibility. A single robot can store programs for multiple jobs, so it may be able to handle the tasks of several fixed-automation systems.

There is a certain volume of parts that justify the investment of welding automation for each company. An accurate assessment of goals and workflow can help determine what that volume is. If a company makes only small runs of parts, robotic welding becomes more challenging. But, if a company can identify two or three components that can be automated, a robot can be programmed

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Additional Benefits of Robotic Welding Systems With the right robotic welding system, companies can improve first-pass weld quality and reduce the amount of rework or scrap parts. Depending on the welding wire and mode used, the system may also minimize or eliminate spatter, which reduces the need to apply anti-spatter compound or perform post-weld clean up.

A robotic welding system can reduce over-welding, a common and costly occurrence associated with the semi-automatic process. For example, if a company has welding operators who weld a bead that is 1/8-inch too large on every pass, it can potentially double the cost of welding (both for labour and for filler metals). Over-welding may also adversely affect the integrity of the part.

Companies can reallocate skilled employees to other production areas to fill open positions and gain additional productivity and efficiencies.

Welding automation can also provide a competitive advantage as it may be considered attractive to customers.

The improvement in quality may prompt new customers to place orders or lead existing customers to increase their orders with the objective of growing their own businesses.

Finally, robots are fast. They don’t have to weld all day to be profitable. That fact improves productivity and the bottom line by making the same number of parts as in a semi-automatic process in less time.

to manufacture those parts, offering greater versatility and boosting productivity. This may benefit even small companies that may not have significant volume of a single part.

Although a robot is more expensive than a fixed-automation system, it is important to consider the cost of the tooling before deciding between the two. Fixed automation systems can become quite expensive if they require extensive changes to retool a new part so it can be welded consistently.

Consider the Available Space The physical footprint for a robotic welding system and the area needed for parts to flow into the welding cell is typically greater than that of a semi-automatic welding operation. The available space needs to be adequate for the robot, welding power source and other equipment. This helps minimize the need to customize products, such as cables, nozzle cleaning stations (or reamers) or the robotic MIG gun to fit the work envelope.

A company with less space can still make welding automation work. One option is to purchase fewer pieces of robotic welding equipment that are capable of performing multiple tasks, such as material handling or vision/scanning systems.

A third-party integrator can help determine whether a facility suits the installation of a robotic welding system. System integrators are knowledgeable about facility modifications, including important safety regulations that apply in a company’s region, country or state — in addition to those specified by OSHA and RIA (Robotic Industries Association).

Integrators and Equipment Selection In addition to offering advice on facility modifications and helping a company select the right robot, a robotic systems integrator or welding automation specialist can: »» Help determine if parts are suitable for automation, and, if not, what is required to make them suitable »» Analyze the workflow and facility to identify potential roadblocks »» Analyze the true costs involved with the investment, including facility updates and tooling »» Determine the potential payback of the investment »» Help identify goals and develop a precise plan and timetable to achieve those goals »» Explain automation options and help select those that best fit the company’s needs »» Help select a welding equipment that has the flexibility to maximize travel speed, minimize spatter, eliminate over-welding, provide great arc stability and increase first-pass weld quality Integrators can also help select additional equipment for the robotic welding cell, including positioners, tooling, the robotic MIG gun, welding wire and peripherals. Each item serves a distinct function.

The positioner turns, rotates or otherwise moves the part into an optimal position for welding. In many cases, this involves moving the part so that the system can weld in a flat position for optimal deposition efficiency. A positioner can also allow for coordinated motion between the robot and weldment.

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26 IMD NOVEMBER 2019

A streamlined workflow is one of robotic welding’s benefits. To achieve it, companies need to look beyond the weld cell, making certain the facility can accommodate a smooth flow of materials.

The tooling holds the part in place during welding and is a critical component of a robotic welding system. The robot arm and robotic MIG gun travel a programmed path each cycle. If the weld joint is out of place because the part is misaligned, it can result in inadequate fusion or penetration and rework or scrap. It is important to design the tooling correctly upfront when investing in a robotic welding cell and monitor it for mechanical wear or heat distortion once it has been put into operation. This helps ensure consistent part fit up so that weld quality doesn’t suffer.

The robotic MIG gun should never be an afterthought when considering an investment in welding automation, nor should the welding wire. Both can have a significant impact on productivity and profitability. An integrator can help with the selection based on how the gun and wire perform in conjunction with the rest of the system’s components. The gun will be subject to intense heat and spatter, so it must be durable. It also needs to be the appropriate size to maneuver around the tooling and gain proper joint access.

Finally, peripherals, such as reamers, an anti-spatter sprayer and wire cutter are good options to discuss with an integrator prior to making the investment in welding automation. These devices can improve uptime and welding performance by keeping the welding gun consumables free of spatter, operators out of the weld cell and providing consistent wire stickout during welding.

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IMD 27

With the right robotic welding system, companies can improve first-pass weld quality and reduce the amount of rework or scrap parts.

skilled in robotic welding programming. This will likely involve additional training to upgrade his or her skill sets. The good news is, programming a robot today is much quicker than in the past.

Simplified teach pendants, along with the availability of desktop programming, help expedite the process and reduce downtime.

Despite the ease of programming, however, companies may need to alleviate some existing tasks to allow time for the employee to oversee the robotic welding cell without becoming overloaded with too many responsibilities.

Most robot OEMs offer a weeklong training course explaining how to operate the equipment. This course, followed by a week of advanced programming, is recommended when implementing welding automation.

Justifying the expense and calculating payback If the personnel investigating the prospect of robotic welding determine it’s a good fit, they will likely need to justify the investment to upper management or an owner. Calculating the potential payback is essential. There are several steps to consider.

First, determine whether the volume of parts the company needs to produce requires the speed of welding automation. Remember, the key benefit of a robotic welding system is the ability to produce high volumes of quality welds or in smaller facilities to offer the flexibility to weld smaller volumes of multiple parts.

Calculate payback by assessing the current volume of semi-automatic parts and cycle times. Compare these to the potential cycle times of a robotic welding system. Again, an integrator or welding automation specialist can help. Establishing the comparison is

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critical to estimating the potential return on investment.

That said, even if a company will produce the same number of parts with a robot, it could justify the investment by the amount of labour it can reallocate elsewhere in the operation for jobs that boost production, eliminate bottlenecks or increase quality. For example, a company could utilize the skills of semi-automatic welding operators to complete challenging welds that are too complicated for a robot to manage.

It's important to factor the bulk cost of shielding gas and welding wire when looking at the potential payback. While there is an initial cost for a shielding gas/manifold system, it can help optimize a company’s robotic welding capabilities in the long term by minimizing downtime for cylinder changeover. The same is true for welding wires. The larger drums — typically ranging from 500 to 1500 pounds — can further reduce costs in a robotic welding cell since they require fewer changeovers and often come with purchasing discounts.

Companies need to keep in mind that the benefits of robotic welding can be significant. However, those benefits come at an upfront price. Many companies, especially smaller ones or those that frequently change production lines, need a faster payback — no more than 12 to 15 months is common to justify the investment. If a company will have the same production needs for many years, it can typically justify a longer payback period. Management and owners should discuss their payback goals with a trusted robotic welding integrator as part of the assessment process.

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Process

Improving EDM Speed and Operations Market leader in high-precision pneumatic valves and other components machines 316SS and other materials, achieving better finish in less time with reduced power and less wire breakage, due to proprietary product from Global Innovative Products

C

lippard (Cincinnati, Ohio) is a world leader in fluid control products and other high-precision components, and the company prides itself on having been vertically integrated for decades, since its founding in 1941.

The company operates two ISO certified manufacturing locations in Ohio and does advanced machining of all types to produce its extensive catalog of standard and custom product solutions for a myriad of markets worldwide. At the heart

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IMD – The Industry’s Most Extensive Industrial Publication

Clippard uses wire EDM for the production of many components, including the tooling used in its conventional machine shops. All EDM work at Clippard is performed for internal production purposes, so one-offs are common, making speed a critical factor for the department.

of its machining capabilities are 12-axis CNC Swiss machines, CNC milling centers and CNC wire EDM’s, plus numerous post-finishing operations, including anodizing, EN plating and thermal deburring.

Various metal and thermoplastic materials are machined.

Recently, after extensive discussions with ia local EDM supply distributor, a proprietary hybrid coated brass wire was presented to the Clippard Director of Operations, Robin Rutschilling and his CNC/EDM Programmer, Trevor McCoy by Barry Ramsay of Global Innovative Products (hereafter GIP), a Mason, Ohio supplier of consumables for EDM shops through their GIP distributor network,

who also produces a variety of its own products for need-specific operations in electrical discharge machining. One such product is a PLASMA hybrid coated brass wire, comprising of a gamma-phase intermetallic zinc alloy coated wire with brass core. This proprietary GIP innovation had proven out in numerous lab testings but needed “real world” production validation. Barry Ramsay and GIP application engineer Brad Hansard approached the team at Clippard.

As the product had been found suitable for all types of wire machines, with excellent auto-threading capability and increased performance, even at conventional brass wire settings, Ramsay

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IMD 31

felt confident the product would outperform what Clippard was currently using in its EDM shop, including other GIP wire. This new product was being offered in 0.008”, 0.010” and 0.012” (20mm, 25mm and 30mm) diameters, so Ramsay proposed giving the Clippard EDM department a supply for testing on one of its Fanuc wire machines.

Gamma phase brass is a brittle intermetallic alloy (Cu5Zn8) with a high zinc content (approximately 65% Zn) which can also be synthesized by a diffusion anneal. However, when such coatings are wire drawn subsequent to the diffusion anneal, the coating will fracture due to its brittleness and redistribute around the wire circumference creating a discontinuous layer sometimes described as a “porous layer”, which promotes turbulent flow enhancing the flushing of debris. However, it is zinc enrichment created at the surface combined with the elevated melting point of CuZn gamma phase (approximately 800ºC/1472ºF) which are the biggest factors contributing to the performance of Gamma Phase Brass coated wire.

The arrangement between the two companies actually began in a somewhat unconventional manner, as Trevor McCoy relates.

“We have an Ocean hole popper (electrode/sinker EDM) and the circuit boards needed repair. Brad was able to do that kind of work, which I knew from previous experiences with him. So, he proposed exchanging the board servicing for the opportunity to test the GIP hybrid PLASMA wire. Seemed reasonable to us, so we agreed.”

The FANUC wire EDM in the shop at Clippard seemed an ideal candidate for GIP, as well, as Barry Ramsay notes, “We knew they were running all types of materials and some very high-precision tooling used in their own machine shop for the production of various pneumatic components with very tight tolerances. It seemed a very good place to test our new wire, which had been proven out on our own EDM’s at GIP.” He further says it was a handshake deal, a “classic collaboration between two companies for their mutual benefit,” adding that application engineering supplied by GIP further enhanced the use of the product at Clippard, as the test learning

Proprietary hybrid PLASMA coated brass wire from GIP

process information was shared without reservation, so both companies benefited.

In this test case, many of the components were being run for the production of special parts being produced by Clippard for robotic arm articulation.

The testing immediately yielded positive results, as McCoy notes they were holding tolerances under a tenth, with a microfinish that was very important for the application. “We do a lot of custom work for our own use, over 50% of my production in EDM. Some of the hard tool steels are difficult to drill and we also run various others.

The jobs require a lot of setup time and fixturing, so run time, finish and wire breaks all are critical for us.”

The goals for this proprietary wire testing were three, according to Barry Ramsay. “The characteristics of the PLASMA wire in production on the FANUC machine at Clippard were important, as the flushing of their precision components directly impacts quality.

Further, we had our own test results galore but needed an outside house to validate what we were seeing. Lastly, we just wanted to

Cross section and surface views of the PLASMA coated brass EDM wire shows the discontinuous layering, caused by fracturing during the diffusion annealing process. This surface formation actually enhances the flushing of the workpiece during machining.

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32 IMD NOVEMBER 2019

help our friends at Clippard, who had been so cooperative and, in this case, needed our help with those circuit boards. It was a classic win-win for both of us, as all three goals were met.”

Multiple parts were EDM’d during the testing of this PLASMA wire, with full comparative data tracked on the test wire vs. conventional brass. One tool for a medical part was produced, for example, in :56 vs. 1:05 with five skim passes, a 16% improvement in overall production. McCoy notes, “We could apply more power to run faster. The GIP product consistently outperforms premium brass, based on my experience with both now.” He also cited a very practical advantage. “The PLASMA wire is as clean as conventional brass.” Ramsay adds the price point is also competitive, so there’s less of a premium to achieve these enhanced results.

For more information, please contact:

GLOBAL INNOVATIVE PRODUCTS Barry Ramsay General Manager 7697 Innovation Way Suite 200 Mason, OH 45050 Phone: 513-701-0441 Trevor McCoy, CNC/EDM programmer at Clippard, runs a FANUC wire EDM with the GIP proprietary PLASMA coated brass wire. McCoy states he achieves better finish with 15 to 20% improvement in run time. (machine hood open only for photo purpose)

www.gipintl.com bramsay@gipintl.com

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Industry Insight

Dynamic Fixturing: The Secret Behind Precision Machined Parts

M

odern CNC equipment is the gift that keeps on giving to American Manufacturing; it’s allowed machine shops all over the country to produce high-quality parts in a fraction of the time it used to take our grandparents’ lathes.

However, even with the same high-tech equipment, not all machine shops are able to create the same results. That’s because the difference between an average machined part and a high tolerance component often comes down to fixturing.

Though the process of designing, selecting, and implementing the right fixturing requires extra time, talent, and technology, US manufacturers, and their customers are discovering that the additional investment pays serious dividends.

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How Custom, Dynamic Fixturing is a Game Changer in American Manufacturing For many major equipment brands, an inferior part can sabotage the performance of an entire machine, damaging both bottom lines and global reputations. In these cases, precision isn’t just an expectation, it’s a mandate. Thanks to today’s technology, improved surface finishes, and tighter tolerances are possible with the right people, tools, and strategies in place. One of the ways to achieve such superior levels of accuracy is by using specially designed fixturing for complex parts.

Fixturing or workholding devices are just as important to the production of precision parts as machining and tooling process.

IMD – The Industry’s Most Extensive Industrial Publication

They keep part after part in position so that each finished product falls within a few thousandths of an inch of the desired specs.

Fixturing selection also requires additional time and expertise that not every machine shop is cut out for -- and that’s why US-based complex part manufacturers like Allis Roller are able to make a name for themselves in the niche of high tolerance applications.

President and CEO of Allis Roller, Dave Dull, put it succinctly: “Anyone can order a CNC lathe or robotic welder. Not everyone wants to take things to the next level with custom fixturing.”

At Allis Roller, custom fixture design is developed in collaboration with a full bench of engineers, die makers, and research and development experts. To produce the kind of precision results Dull expects at his operation, highly skilled machinists use stand-alone fixturing for many parts. This has required a significant investment in people and technology, but for this manufacturer, it has more than paid off in their ability to maintain customer satisfaction. It’s common in custom machining and welding for materials to shift unexpectedly, and adjustments have to be made in real-time in order to preserve tolerance. To keep production moving, Allis Roller’s fixturing team is available on the spot to make any necessary changes and maintain standards.

This is how operations like Allis Roller have been able to earn the loyalty of Fortune 500 companies and has allowed Allis Roller to purchase three new CNC Machining Centers for delivery by the end of 2019.

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Anyone can order a CNC lathe or robotic welder. Not everyone wants to take things to the next level with custom fixturing.

Custom, Dynamic Fixturing is Scalable and Technologically Advanced Dynamic fixturing practices and methods are as diverse as the wide range of parts they serve. Depending on their specialty, some operations find it more cost-effective to provide a degree of customization without employing a full team of engineers. To streamline the manufacturing process, others will reuse custom fixturing for repeat orders once their customers have come to depend on a certain level of quality. The strategy used depends entirely on the needs of the application.

One method, known as modular fixturing, uses a system of interchangeable components designed to secure a given workpiece during a machining process. Modular fixturing is ideal for use in hole making equipment, such as horizontal or vertical machining centers.

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IMD 35

As CNC lathes become increasingly versatile machines, flexible solutions like modular fixturing also help to maintain quality from one unique part to the next.

This form of dynamic fixturing provides needed customization without creating custom workholdings for each new part. As long as the application doesn’t require a high level of custom engineering, modular fixturing systems can help streamline the process of machining precision parts. They can also be used for both high volume and low volume work to keep an operation moving from one job to the next with very little work stoppage or additional set up.

Using CNC equipment to fashion entirely custom fixturing

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can also streamline the machining process and improve accuracy because automated fixturings are able to produce exact tolerance per the customer’s specifications. The level of precision afforded by computerized fixturing also assures the customer that each new order will measure up to the same specs as the last. Consistent complex parts eventually power equally reliable machinery, allowing international brands to promise a high level of performance and longevity to their own customer base. For US-based machine shops carving out their own niche in a crowded manufacturing market, this benefit is key to their success with globally renowned equipment manufacturers.

Even with the benefit of the latest technology, some operations still rely heavily on people to produce the kinds of custom fixturing needed for more complex parts. For each new complex component, Allis Roller assembles a project team consisting of engineering, tool room, die making, and manufacturing departments. This team works together to ensure that the entire manufacturing process goes smoothly from start to finish, and that includes accounting for fixturing integration and adjustment. An individual welder’s skill is also imperative for achieving optimal penetration and a lack of inclusions in custom fixturing production. By combining the built-in adjustability and precision of CNC equipment with a high level of fixturing experience, complex parts manufacturers can maximize results, while keeping processes lean and cost-effective.

At the end of the day, the quality of the fixture dictates the manufacturer’s ability to reuse it down the road for renewed parts orders and directly impacts the customer’s bottom line. High tolerance parts machining forces manufacturers to strike a delicate balance between quality and speed, and the use of custom, dynamic fixturing is how it’s done.

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IMD 37

On Exhibit

FABTECH DATES: NOVEMBER 11TH - 14TH, 2019 Location: McCormick Place | Chicago, IL FABTECH 2019 is set to provide a wealth of knowledge this year in Chicago. Top industry experts, including C-level executives, owners, manufacturing engineers, plant managers and research and development professionals, have been selected as speakers to share their wealth of knowledge and experiences. These subject matter authorities are set to lead collaborative discussions and presentations to provide an exchange of best practices and explore the industry’s latest technology and advancements. Key tracks include 3D/Additive Manufacturing, Automation, Cutting, Finishing, Forming & Fabricating, Laser, Lean, Management, Marketing & Sales, Smart Manufacturing, Stamping, Welding & Welding Fabrication and Workforce Development. »» For more information, visit www.fabtechexpo.com

EXHIBITOR HIGHLIGHTS.............................................................

BOOTH: B10018

EXTREME Sanding In Any Application From Dynabrade Dynabrade proudly introduces their most refined random orbital sander to date. The Dynorbital® Extreme boasts the greatest power and most consistent speed of any palm-style orbital sander.

Power and speed combine quickly and reliably produce the desired finish, while ergonomic features keep operators safe and comfortable throughout their day. Symmetrical design allows left or right-handed operators to work comfortably, while the compact size of the Dynorbital® Extreme fits naturally in most operator’s hands. The Dynorbital Extreme is American-made from the highest grade materials ensuring long-life and high durability.

The new motor design has the highest power-to-weight ratio in the industry, with 0.3 hp at 1.8 lbs. The Dynorbital® Extreme features the most consistent speed under load in industry, running at 92 percent of rated tool speed. The ergonomic design provides an integrated comfort platform for more wrist support and overall operator comfort. A soft grip is co-molded to rigid composite base housing for maximum comfort and durability.

Combine the Dynorbital® Extreme with Dynabrade’s own Raptor Vac® Portable Vacuum Systems. These clean air solutions are designed to aggressively capture dust and debris fo ra cleaner, safer workplace. These top-quality vacuums may be utilized in a wide variety of industries such as auto body shops, wood shops, fabricators, and more. Raptor Vac vacuums meet North American and international safety standards, and are offered in electric and pneumatic models, each with an efficient HEPA filter. »» For more information, visit www.dynabrade.com BOOTH: A5325

Cosen’s AV-2026NC – A Fully Automatic Vertical Tilt Frame Band Saw Cosen's AV-2026NC band saw is our latest answer to the call for more automation in structural steel fabrication. The AV-2026NC combines Cosen’s vertical tilt frame saw with an automated feeder table for a fully automatic system. The end result is an advanced saw that allows operators to push a button and walk away until the job is completed.

With a capacity of 20” x 26” at 90 degrees, and the ability to feed up to 59” per single shuttle, the AV can be programmed to index up to 999” of material. The AV’s rigid tilt-frame saw head can easily cut angles between 60

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Fastest, Most Accurate Bar Puller On The Market Watch the video now at: ezpullerusa.com • NO MECHANICAL ADJUSTMENT NECESSARY (X axis end point gets changed in the program when changing bar diameters) • ONE TIME SETUP • NEVER NEEDS ADJUSTMENT •CHANGE BAR SIZE IN SECONDS (BY CHANGING “X” VALUE IN PROGRAM) • EXTREME REPEATABILITY RESULTS IN LESS MATERIAL WASTED PER PART • NO GRIPPING FINGERS TO ADJUST, LOSE OR BREAK • EZ-PULLER WORKS ON ROUND, HEX AND SQUARE STOCK. RANGE: .093″ – 1.750″ ROUND STOCK .125″ – 1.375″ HEX STOCK .125″ – 1.000″ SQUARE STOCK

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degrees in both directions, making this saw a perfect fit for steel fabrication and cutting complex shapes. All saws in the Tilt-Frame series also come standard with an automatic angle adjust built into the HMI to help make the cutting process simpler.

Cosen's Vertical Til-Frame saws are excellent options for any fabrication production shop looking to make a transition into the vertical saw market. Additional features include an adjustable flood coolant system, motor driven, and synchronized wire blade brush. The AV-2026NC’s carbide blade guides and bearing provides additional blade support, and is built with a rigid cast-iron guide arm. »» For more information, visit www.cosensaws.com BOOTH: A5743

Plate Roll Solutions from Carell Corporation.

Plate or Sheet Bending Rolls fall into two general categories, single or double pinch. However, they may have different geometries or operational features. Matching the most appropriate machine style to the application is of primary importance to the user in order to maximize the return on investment (ROI). Carell Corporation offers many two, three, and four roll machines available in a variety of styles.

Carell’s Variable Geometry Three Roll Plate Rolls are built for medium, heavy to extremely thick plate applications. The top roll moves up/down and the lower two rolls each move horizontally. This lower roll movement allows increasing the offset distance from the top roll and commensurately increasing mechanical advantage in bending. By adjusting the geometry, they can be used similar to single pinch, double pinch and pyramid style machines and require minimal sheet movement during the pre-bend operations.

Carell 4 Roll Double Pinch Plate Rolls are built tough for longer machine life and are designed to minimize maintenance. The VBH Series plate rolls are available in over 60 sizes with capacities from to 6” down to 20 gauge. Their unparalleled range of standard models provide unmatched flexibility and coverage of most any plate rolling requirement. Both four roll and three roll plate rolls can be designed and built to handle a wide range of specific rolling requirements to include shorter or longer lengths from 20 inches to 24 feet, custom roll cambers, slotted rolls for plate with flanges-lips-ribs, corrugated patterns for corrugated material, vertical rolling applications and more. »» For more information, visit www.carellcorp.com BOOTH: B32055

SUHNER’s Proven High Speed Machining Unit Type BEX15 Takes Off To Even Higher Speed Levels Chip producing machining operations with modern tools today demand progressively higher cutting speeds. Specifically, for metals with high cutting speed rates or small diameter hole drilling applications. The SUHNER machining unit type BEX15, proven in thousands of installations, provides new speed options, reliably up to the maximum speed limit. With an increase of 25% up to a permissible maximum spindle speed of 23,000rpm, operations requiring higher spindle speeds can be accomplished more easily. This improvement is the result of a complete redesign of drive and spindle bearing components. A new style timing belt drive multiplies the motor speed up to 13,050rpm spindle speed. An AC-inverter drive is used to increase the spindle speed up to 23'000rpm at 87Hz. The machining unit BEX15 can be applied in axial and radial orientation, directly mounted to a SUHNER slide assembly type UA15-PH or UA15-CNC. In this combination numerous machining operations like milling or demanding drilling cycles including jump or peck feed can be accomplished very easy. Four optional tool holder systems (Collet ER25, ISO30, HSK50 and Weldon) , standard air purge connections for spindle and belt housing including a number of additional options (for example: coolant

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40 IMD NOVEMBER 2019

through the spindle or automated tool change features) make this machining unit type BEX15 adaptable and an optimal choice for demanding and specific machining requirements. »» For more information, visit www.suhner.com/en BOOTH: B27056

Yaskawa Motoman Introduces AR-Series Robots for High-Speed Welding to Boost Productivity Designed specifically for arc welding applications, the new AR-series six-axis robots offer optimized acceleration/deceleration control for all robot axes, resulting in overall improved productivity. These high-performance robots are available with 8-25 kg payload capacity in order to support a wide variety of sensors and torches for welding application flexibility. The AR-series robots offer the highest payload, fastest speed and highest wrist allowable moment in their class.

Advanced, intuitive programming functions, such as High-Speed Search, maximize weld quality and speed without complicated programming. Preprogrammed welding processes allow users to select materials and weldment properties to automatically control supply settings. A digital interface on the robot programming pendant allows the user to remotely access and manipulate weld settings with all major brands of power supplies.

Each model offers high allowable moment of inertia ratings that provide substantial wrist rigidity and consistent weld quality. Installation is quick and efficient; a single cable is all that is needed to connect the manipulator to the controller, resulting in easy setup and reduced expenses for maintenance and spare parts inventory. »» For more information, visit www.motoman.com

INDUSTRIAL MACHINERY DIGEST.COM

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IMD 41

BOOTH: B17044

ABB Ability™ Allows Users to Apply Big Data and Predictive Analytics ABB has introduced a new augmented reality platform to improve the ability of ABB and its customers to speed response times, extend asset lifecycles, improve production performance and ensure operational excellence. ABB Ability™ Remote Insights for service uses commercially available headsets to assist field service technicians and expand the reach of ABB subject matter experts. The technology enables a field service technician to share his or her view of a situation using the device’s camera and receive guidance directly from an expert through on-screen annotations, chat, and document sharing. »» For more information, visit www.abb.com BOOTH: A3491

Allied Machine Promotes High-Penetration Insert for Structural Steel Allied Machine & Engineering will display their newest GEN3SYS XT Pro high-penetration insert While Allied’s entire XT Pro product line thrives in high-penetration drilling applications, this unique combination of carbide grade, geometry and high-temperature coating is designed to run at or beyond current O.E.M. rates in structural steel applications. The insert’s simplified setup and extended tool life reduces changeover and increases throughput. Their upgraded carbide insert has been completely redesigned to improve throughput and cut operational costs by extending life and increasing penetration rates. »» For more information, visit www.alliedmachine.com BOOTH: A5768

AXYZ Showcases Versatile Infinite Router for Multi-Purpose Routing The new Infinite Router process areas up to 128 inches (3251mm) wide and over 50 feet long (15.24m). Built in North America using the latest technology, the router has been redesigned from the ground up, making it the most configurable CNC router solution in the market. Key design features include a heavy-duty frame with a robust structure for high performance and high part-finish, new carriage design with easier access for service and a new dust extraction system which reduces clogging and allows for longer tables. »» For more information, visit www.axyzautomationgroup.com BOOTH: A3306

DCM Goes Big Introducing the new DCM IG 480 SD Rotary Surface Grinder. This brand-new machine offers the precision of a DCM style grinder with an extra-large 48” variable speed table and heavy hitting 50HP variable speed grinding spindle motor. Easy to use controls feature new programmable touch-screen technology, as well as manual handwheel for precise and effortless control of Z-axis spindle positioning. An integral mist collection and coolant filtration are other standard features that provide clean consistent grinding operations. The IG 480 SD removes stock fast and can create finishes that reduce or eliminate the need for subsequent lapping operations. »» For more information, visit www.dcm-tech.com

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42 IMD NOVEMBER 2019

TOP QUALITY HOIST RINGS AND RIGGING ACCESSORIES BOOTH: B37069

Pipeline Saw and Beveler Produce Precise Welds on Highly Alloyed Pipe A pneumatic saw that cuts all materials and pipe schedules up to 60” dia. to produce perfectly square cuts with no HAZ (heat affected zone) and a full line of precision bevelers are available from ESCO Tool. The Esco APS-438 Air Powered Saw and WrapTrack® pipe trolley lets operators rapidly cold cut pipe from 6” to 60” O.D. with ±1/16” accuracy and no HAZ to permit better end prep bevels for welding. Ideally suited for pipeline construction and repairs, users can use a variety of MILLHOG® end prep tools to perform any angle of prep and square the pipe ends simultaneously. »» For more information, visit www.escotool.com

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BOOTH: A5118

HOIST RINGS ARE:

Global Shop Solutions Simplifies and Optimizes Manufacturing with Cloud ERP Global Shop Solutions, an international producer of ERP software for the manufacturing industry, announced their continual efforts to promote efficiencies on the shop floor with top performance through the use of Cloud ERP. Designed to eliminate the need of on-premise servers and the costly IT support they demand, Global Shop Solutions’ cloud-based ERP software was specifically created with manufacturing customers in mind. Customers are now offered the same robust ERP software experience, but with increased accessibility, speed, and security.

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IMD 43

BOOTH: B2199

Airframe® – Fatigue Has New Enemy Levitate is the creator of the AIRFRAME, a lightweight wearable exoskeleton that relieves upper extremity muscle and joint strain and discomfort for skilled trade workers who are exposed to the repetitive elevation of the arms (think manufacturing, automotive, construction, etc.). The device lowers exertion levels by up to 80%, comfortably providing all-day ergonomic support, reducing muscle fatigue and supporting a healthier worker. A few of Levitate’s customers include Toyota, BMW and John Deere. Levitate’s exoskeleton also comes with fire-retardant technology, which can be used for hot work in open-flame settings such as welding, sanding and grinding. »» For more information, visit www.levitatetech.com BOOTH: A2923

MC Machinery’s Adds New All Electric Press Brake The BB all electric series adds the NEW BB306 to its lineup giving customers a new small footprint high precision all electric press brake to maximize productivity in a small size. With a broad spectrum of ultra-modern features, high performance requirements, accuracy you can measure, cost efficient operation to standard options our customers have requested including a foldable front table, 5 axis back gauge and user friendly tilting control. The BB306 has the potential to bring you profit through precision when the first part must be the right part. »» For more information, visit www.mcmachinery.com

BOOTH: A4950

agro-hytos hydraulic products

filtration… The range of filter solu-

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

fluid and motion control…

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

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

7355 N. Lawndale Ave., PO Box 6, Skokie, IL 60076

Phone: 847-676-2910 Fax: 847-676-0365 www.macmhydraulic.com

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44 IMD NOVEMBER 2019

Precision Cutting With A Compact Design from Messer Cutting Systems The new MetalMaster 2.0 provides superior cut quality at a low cost. This space saving, compact machine can be quickly installed and ready to use. Longitudinal drives with precision guiding system maintains accuracy to create quality cut parts. Positioning speeds up to 1300 ipm coupled with a fast, intelligent torch lifter helps minimize non-productive time. This table features elbows for an optional integrated smoke extraction unit with fan and filter system for your shop’s safety. With the user-friendly Global Control 2.0 touch-screen you are only a few clicks away to begin cutting. Virtual Service™ remote diagnostics puts applications and service help with one push button. »» For more information, visit www.messer-cs.com

BOOTH: B23054

Millermatic® 255 MIG welder Built for professionals in the light manufacturing or fabrication segments, this smaller, more versatile machine is capable of welding metals up to 1/2-inch thick with an output rating of 230 amps and 25.5 volts at a 60 percent duty cycle.

Built for professionals in the light manufacturing or fabrication segments, this smaller, more versatile machine is capable of welding metals up to 1/2-inch thick with an output rating of 230 amps and 25.5 volts at a 60 percent duty cycle. The Millermatic® 255 MIG welder provides versatility with multiprocess capabilities of MIG, Pulsed MIG, Stick (6010), DC Lift Arc TIG and DC Pulsed TIG. »» For more information, visit www.millerwelds.com BOOTH: D46541

Schwarze-Robitec Presents Highly Efficient Tube Bending Solutions Schwarze-Robitec has developed a fully electric tube bending machine in a new dimension, the CNC 25 E TB MR, which is capable of also bending tubes with diameters as small as 25mm particularly quickly thanks to its intelligent NxG control system.

For each bending sequence, the system automatically checks the interaction between all axes, operates them simultaneously and prepares the next sequences. This reduces production time by 20 to 40 percent depending on the component and the desired tube geometry – the more complex the sequence, the more time saved. »» For more information, visit www.schwarze-robitec.com BOOTH: A3650

Sinumerik Motion Control (MC) — The New Open, Industrial PC-Based CNC For Fabrication and Metal-Processing Machines Siemens is showcasing the new Sinumerik MC controller as a universal, open, industrial PC-based CNC system. Its optimized motion control, high-performance automation and integrated Windows 10 operating system makes it the ideal control, especially for fabrication and specialty machines. With an open operating concept, the control system is also suitable for additive manufacturing, metalforming, adhesive applications, plate cutting, grinding, and laser or waterjet cutting. The open operating concept and the extensive range of interfaces make it a universal, open control, which can be easily utilized in existing fabrication machine solutions. »» For more information, visit www.usa.siemens.com/motioncontrol

C-FRAME PRESSES

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

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

• Pump, motor, valve and reservoir are all easily accessible for maintenance.

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

WE CAN BUILD A CUSTOM MACHINE FOR YOU!

5806 Quality Ridge Rd | Coggon, IA 52218 Phone: 319.435.2378 | Fax: 319.435.2262

www.betenbender.com INDUSTRIAL MACHINERY DIGEST.COM

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IMD 45

BOOTH: A4184

Steel King to Showcase New ScrapHopper Industrial Steel Container Steel King’s new ScrapHopper boasts beefy, corrugated steel sides, making it a rugged and durable sidekick at any workstation. Ready to work right out of the gate, the new ScrapHopper features two-way entry tubes, fully rotatable heavy-duty casters, and a push handle that make it easy to maneuver. Fork tubes make dumping quick and easy to keep production rolling. Each unit features a 4,000 pound capacity. ScrapHopper is available in two standard sizes: 32” x 40” x 24” and 40” x 48” x 24” and comes in four standard colors – vista green, precaution blue, poppy and yellow. »» For more information, visit www.steelking.com BOOTH: B35038

Safely Lift, Move, & Place Heavy Gas Cylinders with the New Cylinder Cart Strong Hand Tools®, manufacturer of innovative Strong Hand Tools® Welding Clamps, Magnets, and Pliers, and BuildPro® Modular Welding Tables proudly announces the New Cylinder Cart for the safe handling of heavy gas cylinders.

The self-supporting 4-wheel base of the New Gas Cylinder Cart provides a safe and stable method for the transport, lifting, and placement of heavy gas cylinders while minimizing the effort required for heavy cylinder handling. Easily transport cylinders around the work area with smooth maneuverability, even in tight areas. »» For more information, visit www.stronghandtools.com BOOTH: A1212

THK’S New Type SHS-LE Combines LM Guide With Linear Encoder New from THK, the Type SHS-LE integrates the global standard THK Type SHS LM Guide with a THK linear encoder (linear position sensor). This combined model allows for compact machine designs that require less assembly time. THK’s Type SHS Caged Ball LM Guide performs with high speed and precision. The SHS features patented THK Caged Technology for smooth and quiet motion.

Caged Technology employs a synthetic resin cage with a patented curvature that cradles each ball and separates it from the next. The spaces between the rolling elements retain grease and act as a lubrication system for long-term maintenance-free operation. »» For more information, visit www.thk.com BOOTH: B35083

Universal Robots Powers Vectis Automation’s New Cobot Welding Tool The Vectis Cobot Welding Tool helps manufacturers boost productivity by reducing the learning curve, deployment time, risk, and cost of robotic welding. Powered by Universal Robots’ UR10e collaborative robot, the Vectis Cobot Welding Tool is a portable, safe, versatile, and extremely easy-to-use solution that is even available as a low-risk, no-capital rent-to-own option. FABTECH attendees will be the first to experience the new cobot welder as it debuts in Universal Robots’ FABTECH booth. Users of the Vectis Cobot Welding Tool are typically set up entirely by the customer within a few hours of system arrival and welding within 10 minutes of setup – with no programming experience necessary. »» For more information, visit www.universal-robots.com

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46 IMD NOVEMBER 2019

BOOTH: A3288

Automatic Tube Mill Line from ERS Engineering Corp.

SAFETY IS OUR BUSINESS ERS Engineering Corp. is presenting an automatic tube mill line for direct forming of electro-welded tubes. This line is capable of making square or rectangular shapes from 4x4x0.12 inches up to 10x10x0.31 inches, speeds up to 115 feet-per-minute for lighter gauges, and up to 49 feet-per-minute for heavier gauges without the need to produce preliminary round tubes. Complete automation and communication between the un-coiler, leveler, shear and edge welder and accumulator provides for efficient operation of the entire line. Tube section changeover takes just around 90 minutes. No roll changing is required for forming and calibration, and all changes in tube sections are automatically controlled by a PLC. This line is capable of finding the most economical solutions. This helps the user obtain considerable cost reduction and ensure competitive advantage by offering state-of the-art technology and supreme product quality. This product is available now. »» For more information, visit www.ersengine.com or email info@ersengine.com BOOTH: A3743 & D46355

Lincoln Electric Launches New Flextec® 350X PowerConnect® The new Flextec® 350X PowerConnect® with CrossLinc® technology has been designed to be a reliable and flexible multi-process electric welder that automatically connects to any power input worldwide from 200-600V input. This allows for the welder to be plugged in and used globally, as input powers are different based on power allowances. Compatible with acrossthe-wire portable wire feeders, analog wire feeders, digital wire feeders and CrossLinc wire feeders, Flextec 350X is lightweight and portable to offer maximum flexibility. It has basic pulsed MIG capabilities for smoother, more consistent welds.

Flextec 350X offers a streamlined and user-friendly operator panel with simple controls for ease of use.

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»» For more information, visit www.lincolenelectric.com INDUSTRIAL MACHINERY DIGEST.COM ADB Hoist Rings Ad_01 .indd 3

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IMD 47 8/13/19 11:31 PM

Product Showcase

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

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

Large No Drip Internal Mix Atomizing Nozzles Conserve Liquid EXAIR’s new 1/2 NPT No Drip Internal Mix Atomizing Spray Nozzles work in the same way our standard atomizing nozzles do, but have the added benefit of positively stopping liquid flow when compressed air is shut off. Internal Mix Atomizing Spray Nozzles mix liquid and air inside the nozzle and produce the finest atomization of liquids up to 300 centipoise. The patented No Drip design requires no additional air line to control the No Drip feature.

When spraying any type of liquid, post-spray liquid flow can cause big problems. Unwanted drips can ruin product function on sealing or mating surfaces and ruin the appearance of painted or coated finishes. In addition, excess liquid flow wastes precious resources such as expensive coatings, chemicals or water. No Drip Atomizing Nozzles are ideal where no post-spray drip is permissible. When the compressed air supply is shut off, the no drip nozzle positively seals off the flow of liquid eliminating the possibility of drips. EXAIR's 1/2 NPT No Drip Internal Mix Atomizing Nozzles are available in four patterns: narrow angle round, wide angle round, flat fan and 360 degree hollow circular pattern. They are for pressure fed applications that don't require independent air and liquid control. »» For more information, visit www.exair.com

400°F Large Capacity Bench Oven From Grieve No. 1050 is a 400°F (204°C), large capacity bench oven from Grieve, currently used for vacuum bagging at the customer’s facility. Workspace dimensions of this oven measure 36” W x 48” D x 36” H. 6.6 kW are installed in Incoloy sheathed tubular heating elements, while a 400 CFM, 1/3-HP recirculating blower provides airflow to the workload. This Grieve oven features 2” insulated walls, six (6) point vacuum manifold with individual shut-off valves, vacuum gauge and quick disconnect. Additional features include an aluminized steel exterior, Type 304, 2B finish stainless steel interior and an 80 CFM powered forced exhauster. Controls on the No. 1050 include a digital programming temperature controller, manual reset excess temperature interlock with separate contactors and a recirculating blower airflow safety switch. »» For more information, visit www.grievecorp.com

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48 IMD NOVEMBER 2019

IMD – The Industry’s Most Extensive Industrial Publication

BIG KAISER Expands BBT30 Tool Holder Offering, Adds Production in U.S.

DEWALT® Introduces Cordless Polishers

BIG KAISER has added inch standard sizes for the U.S. market to the production of its BIG-PLUS BBT30 basic arbors (shell mill holders, end mill holders, shrink fit and blanks). The first batch of products produced in the U.S. with inch standard sizes is now available. The expansion allows for enhancements to the BBT30 program that satisfy demands specific to the North American market. Custom tools can be ordered, produced and delivered more quickly. An inch-based BBT30 shrink fit series is being introduced to complement the 10 metric sizes currently offered. Standard items available in sizes 1/4", 3/8", 1/2", 5/8" and 3/4". A single blank size has been added to give customers the ability to make special tools on their own. Additional grinding services and custom manufacturing are available.

DEWALT has debuted two new polishers. The new tools include the 20V MAX* XR® 7 in. (180mm) Variable Speed Rotary Polisher (DCM849) and the 20V MAX* XR® 5 in. (125mm) Variable Speed Random Orbit Polisher (DCM848). Cordless automotive tools not only offer convenience both in the shop and in remote work areas, but they also help to prevent damage to work by not having power cords drag across surfaces. The 20V MAX* XR® 7 in. (180mm) Variable Speed Rotary Polisher features a high-efficiency brushless motor and achieves a no-load speed of 800-2200 RPM with a variable speed trigger and dial. Designed to be held either by its side or bail handle (both included with the tool), the tool can be held at a variety of angles and positions. Featuring rubber molding, it is also covered in key areas to protect worksurfaces. In addition, the battery housing is oriented horizontally so that the foot of the tool doesn’t interfere with polishing, and so that the user can get as close to the surface as possible. Its tool-only weight is 4.7 pounds and it’s 16 inches long.

»» For more information, visit www.bigkaiser.com

»» For more information, visit www.dewalt.com

INDUSTRIAL MACHINERY DIGEST.COM

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IMD 49

Signode’s unique Unitizing Solution For those looking to unitize corrugated pallet loads, Signode introduced its Octopus™ Twin Series automatic rotary ring stretch wrapper to the corrugated industry. Able to wrap up to 150 loads per hour, the Octopus™ Twin features the classic ring-type method of wrapping coupled with a unique dual film carriage design. Its robust construction and well-balanced design maximizes efficiency and reliability.

The machine’s ring design allows for unlimited wrap patterns due to its ability to begin and end film cycles at any vertical point on the load. This inherent feature increases flexibility and reduces film usage up to 25%. With dual film carriages, the Octopus™ Twin further reduces film roll changes by 50%, significantly increasing labor savings, uptime and overall machine efficiencies. In addition, the wrapper utilizes an “s” style film carriage. When compared to traditional wrap systems, the “s” wrap pattern improves pre-stretch levels, can better handle a variety of films, and significantly lowers the overall cost of ownership. This highly intuitive machine is also easy to operate and install. Loaded with benefits, the Octopus™ Twin Series can accommodate variable load sizes and features multiple machine options to meet varying packaging challenges. »» For more information, visit www.signode.com

UNISIG Unveils Next Generation of UNE Gundrilling Machines Ideal for manufacturers focused on high-volume/low-mix or low-volume/ high-mix production environments, UNISIG’s next generation of UNE Series gundrilling machines delivers operational flexibility, improved performance and effortless operation. Now available, the UNE Series is engineered and designed to simplify gundrilling for all those individuals involved in a facility’s manufacturing process. The UNE Series offers gundrilling solutions that are well-suited for various industries, including firearms, automotive, medical, energy, defense and aerospace.

With five models built from two frame sizes, the UNE Series can drill hole diameters from 1.4 mm to 40 mm and depths up to 3,000 mm. The compact frame construction saves valuable floor space as well. Each machine can fit in close proximity to a shop’s existing machining center, lathe or Swiss-style machine for efficient part-processing strategies. Built with quick and easy setup in mind, the machines are also small enough to be relocated when necessary.

For added flexibility to grow with future production needs, all UNE models are robot-ready, allowing shops to add a robot whenever it fits into their budgets and production schedules. »» For more information, visit www.unisig.com

IMI’s New Copper-plated Magnetic Welding Squares Resist Spatter Industrial Magnetics, Inc. recently announced a new line of copper-plated magnetic welding squares that resist corrosion and prevent weld spatter from sticking to its surface. Due to the highly conductive properties of copper, the heat from small particles of weld spatter that hit the face of the welding square are quickly conducted away, thereby preventing bonding of the materials. This keeps the sides and edges of the square clean, true, and free from spatter buildup, protecting the accuracy of its alignment. As copper is also naturally corrosion-resistant, the plated squares ensure a durable and long-lasting product lifespan. »» For additional product information, visit www.magnetics.com

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50 IMD NOVEMBER 2019

ERS Engineering Enters The North American Market With Roll Forming Equipment ERS Engineering Corporation is proud to announce their entrance into the North American market for sales of roll forming processing equipment.

Over the past 20 years, ERS has successfully implemented over 2000 pieces of equipment throughout Europe. Their equipment can process materials from 0.2 millimeter all the way up to 12 millimeters. Their products are made by the latest European technology and meet international criteria. ERS Engineering Corp. can design and build different types of roll forming machines, as well as special lines to meet your company needs. »» For more information, visit www.ersengine.com

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IMD 51

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52 IMD NOVEMBER 2019

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IMD 53

Surplus Buying and Selling

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54 IMD NOVEMBER 2019

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IMD 55

Surplus Buying and Selling

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IMD NOVEMBER 2019 56SelectEquipment_SBS0917_FP.indd

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IMD 57

Ad INdex Accudyne Products USA — www.ezpullerusa.com .........................................................................39 Actek Manufacturing and Engineering Inc. — www.actekmfg.com ............................................43 ADB Hoist Rings Mfg. — www.adbhoistrings.com ........................................................................... 47 Air-Vac Systems — www.air-vacsystems.com .................................................................................. 25 Amada Marvel, Inc. — www.marvelsaws.com .................................................................................... 5 ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com .........................................59 Betenbender Manufacturing, Inc — www.betenbender.com ....................................................... 15

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58 IMD NOVEMBER 2019 IMDdirectory-Listed-TV-01-2019.indd 1

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PRSRT STD U.S. POSTAGE PAID BOLINGBROOK, IL PERMIT NO. 467 3590-B Hwy 31 South PMB #233 Pelham, AL 35124

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Original Dynabrade Building, 1969

For 50 years, Dynabrade has earned a reputation and position of leadership in the innovative design and manufacturing of unique portable abrasive power tools, accessories and dust collection. With our total process solutions, we are able to meet the needs of many industries.

OUR HISTORY Dynabrade began in 1969 with one inspired idea. Walter Welsch, Dynabrade’s founder, developed the first Dynafile® Abrasive Belt Tool as a method of improving the task of hand filing metals and other hard surfaces. Thanks to his innovative, entrepreneurial spirit, Dynabrade thrives to this day. We are continuously upgrading the products offered, through extensive research and development based on market needs.

Early Photo of Walter Welsch, u Founder of Dynabrade

Evolution of the Dynafile® Abrasive Belt Tool q

PROUDLY DESIGNED, ENGINEERED, AND BUILT IN AMERICA SINCE 1969

OUR FUTURE Dynabrade is a local company with a global presence. Our tools are sold by hundreds of distributors worldwide in over 90 countries. We support our international efforts at our headquarters, as well as with subsidiaries in Europe (Luxembourg) and India (Mumbai). We help supply many industries like automotive manufacturing, aerospace, woodworking, metalworking and wind energy to name just a few. With salesmen worldwide and no-obligation demonstrations on any product in our line, we truly strive to listen, to observe, and to optimize.

Dynabrade, Inc. | 8989 Sheridan Drive | Clarence, NY 14031 | 1.800.828.7333 | dynabrade.com