Industrial Machinery Digest Quarter 1, 2012

Quarter 1, 2012 Digital Edition — Expanded Editorial Issue! — Table of Contents page 4

Reinventing the way you buy saw blades.

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Quarter 1, 2012 table of contents www.industrialmachinerydigest.com

Productivity Profiles

12 Investing in U.S.-Based Manufacturing Pays Off 30 How to Choose the Right Plate or Sheet Rolling Machine 44 Hypertherm Releases Corporate Social Responsibility Report 46 MacroAir Transforms Brand Identity to Further Showcase 54 62 74 93 100 108

Product Efficiency and Reliability Transfixed By The Flame Tool Management System Provides Efficiencies, Mfg. Cost Reduction at Rousch CNC Router Helps Shipping Case Producer Reduce Lead Time from 10 to 4 Weeks Morgan Technical Ceramics’ Diamonex Diamond-Like Carbon Coatings Extend Aerospace Component Life Military Strength in Motion: Nook’s Electric Cylinder Series Delivers Rugged Actuation for Harsh Environments Deburring Solutions for Any Application

54

Fabricating News

14 Scotchman Industries Now Installing New 14 16 16 17 18 20 22 24 24 24 25 26 28 29 32 32 34 35 4

and Improved Hydraulic System in Dual Operator Ironworkers C Marshall Fabrication Machinery, Inc. Welcomes 2012!

GEKA Model PUMA S2 DP Hydraulic Double End Punching Machine New Marvel Control Allows Fully Automatic Cutting of Complex Multi-Angle Cuts MAE Straightening and Wheel Set Presses to be Represented by American Wera Water Injection Plasma Cutting Now Standard at Jacquet Facilities ROUNDO AB of Sweden Announces Merger Betenbender Manufacturing, Inc. Rollblocks for Stamping Presses Fit Variety of Needs Hydrapower Awarded Press Brake Contract Scotchman Introduces the AL100U-02 Pipe Notcher by Almi Water Jet Contractor Helps Move Temporary Pier Piles at Audubon Bridge Construction Site Following Record Floods Heavy Duty Shop Fabrication Tools from Edwards Manufacturing Company HACO KOMPAKT CNC Plasma Systems Hyd-Mech Launches Redesigned S-23A Band Saw AMERICOR Hydraulic Plate Bending Rolls from COMEQ, Inc. New Electric Coil Form Machine Cosen Saws, USA - The Pinnacle of Cutting Performance ESAB Introduces Vision T5C Control for Retrofits

Industrial Machinery Digest — Quarter 1, 2012

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Publisher: William C. Strickland, william.strickland@indmacdig.com, 866-833-5346, fax: 205-216-0593 Associate Publisher: Adrienne Gallender, adrienne.gallender@indmacdig.com, 888-407-7737, fax: 847-559-2909 Sales Consultant: Denise Rimmer, denise@indmacdig.com, 920-568-8720 Sales Consultant: Lisa Hanschu, lisa@indmacdig.com, 800-366-0676, ext. 114 Sales Consultant: Tonya L. Browning, 800-366-0676, ext. 115, tonya.browning@tipscd.com Sales Consultant: Kevin Bergeron, kevin@fandmmag.com, 608-359-3028 Art Director / Print Production Manager: Amy Boelk, amy@indmacdig.com, 800-366-0676 ext. 105 Interactive Product Manager: i nteractive@indmacdig.com, 800-366-0676 Audience Development Manager: Jamie Willett, jamie.willett@indmacdig.com Sales and Production Office: 262 Yeager Parkway, Suite C, Pelham, AL 35124 Circulation & Subscriptions: IMD, Hwy 31 S. #233, Pelham, AL 35124, Fax: 877-476-4995, jamie.willett@indmacdig.com Mailing List Rental: Jamie Willett, jamie.willett@indmacdig.com Reprints: To purchase article reprints please call 800-366-0676 ext. 103 or email reprints@morethanonesolution.com

INDUSTRIAL MACHINERY DIGEST (ISSN 1542-5223) is published 12x per year by Source 360 Media, 262 Yeager Parkway Suite C, Pelham, AL 35124.

POSTMASTER: Please send change of address to INDUSTRIAL MACHINERY DIGEST, 3584 US Hwy 31 South PMB #233, Pelham, AL 35124. Printed in the U.S.A. SUBSCRIPTION POLICY: Individual subscriptions are available without charge in the U.S. to qualified individuals. Publisher reserves the right to reject nonqualified subscribers. One-year subscription to nonqualified individuals in the United States: $60.00.

Single copies available (prepaid only) $10.00 each.

36 Introducing the Grizzly Models G0736 & G0737

15" & 18" Variable-Speed Vertical Metal Bandsaws

36 Carell Introduces New 305HV Angle Rolling Machine 36 Scotchman Features 6509-24M Ironworker 38 Trilogy Machinery Introduces Newly Designed Trilogy for iPad App! 38 Hydraulic and Magnetic Die Change Systems 38 Scotchman Features their Semi-Automatic Cold Saw with Electric Power Down Feed

48

metalworking news

49 59

48 CGTech to Preview Vericut 7.2 at WESTEC in Booth #2801 48 The Lion Advantage 49 Walter, 60 Years of Surface Treatment Technologies 50 Documenting a Rebuild 52 W/Z Zero Tracking Maintains Constant Zero, Helps Operators Avoid Collisions 52 Keep Your Equipment Running 56 Introducing the York 4-14 HD 56 Bridgeport Milling Machine Shields 56 RAS Machine Tool Technologies, Inc. 58 CML USA, Inc. Ercolina Announces Kris Herbst as Inside Sales Manager 58 Tormach Announces New Automatic Tool Changer for PCNC 1100 CNC Mill 59 Why Combination Sanders Don’t Spark Our Interest 60 Florida Job Shop Nears 100 Percent Machine Uptime

contract manufacturing news 70

64 Gearing Up For Process Improvement 66 High Precision Gear Products for Highly Specialized Projects

material handling news

68 Ergonomically Designed Material Handling Solutions 68 Actek Manufacturing is Your #1 Lift Ring Source 70 VersaLift Magnet Offers Horizontal and Vertical Lift Capability, Test Mode & RFID Chip

70 EnKon’s Heavy Duty Lifts Solve Ergonomic Problems for Commercial Tractor Company 72 Kanetec Gives You the Edge You Need to Outperform Your Competition www.industrialmachinerydigest.com

Quarter 1, 2012 — Industrial Machinery Digest

5

Quarter 1, 2012 table of contents www.industrialmachinerydigest.com

industrial & tooling news

76 WD-40 Brand Launches First Ever Product Line Extension, 78 80 80 81 82 82 83 83 84 86 87 88 88 89 90 90 91 91 91 92 92

Introduces New WD-40 Specialist Line of Products Comprehensive Compressed Air Audits: The 5-Step Process All World Machinery Supply Inc. - Industrial Solutions Through Personalized Care Power Plant Services Choose Lucifer Furnaces Homak Safety Cabinets Strong Hold Products: The Strongest Storage Cabinets Available!

Carmex Presentation at WESTEC to Focus on Defense and Aerospace BESSEY Introduces the DMT Multi-Function Tool Loosens Frozen Metal Parts Magnalight Announces Release of Industrial Grade LED Light Tripod Determining Drawer Needs High Quality Tools Introduces New Aluminum Body 6’’, 8’’, & 10’’ Shell Mills EXSYS Tool, Inc. Introducing New Additions to its PRECI-FLEX System at WESTEC Hold-It: Never Lose that “Little Red Straw” Again!

Cord Reel Selection Hi-Temp Inert Atmosphere Cabinet Oven from Grieve Representing the Hydraulic Industry with Responsive Experienced Service New Carmex DMT - 3 in 1, Drills, Threads and Chamfers in a Single Operation BESSEY Introduces the D15A Compact Aviation Snip The Scientific Cutting Tools Success Story Metabo’s New Pipe & Tube Belt Sander Ideal for Burnishing, Finishing & Reconditioning Durable Technologies Names Matt Martin to Director Position

electrical news

94 Need 3-Phase Power?

96 Get Complete System Protection with the ICM450 Three-Phase Voltage Monitor 98 3 Phase Power Anywhere!

trade show & event news

76 88

89 96

102 IMTS 2012, September 10-15: Experience First-Hand 104 104 104 106 6

the Technologies that will Help You Leave Your Competition in the Dust 2012 International Woodworking Fair Launches August 22 AmCon: The Cost-Effective Way to Find Suppliers One Voice Legislative Conference, May 8-9, 2012 Design-2-Part Shows Announce 2012 Schedule

Industrial Machinery Digest — Quarter 1, 2012

www.industrialmachinerydigest.com

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• Heavy duty clutched headstock with 5-7/16" spindle bores • 10" and 14" spindle bores on hollow spindle models • Precision SKF spindle bearings • Cuts inch and metric threads without change of gear • 4-way rapid traverse and 2-speed tailstocks standard • Heavy duty bed construction with extra wide bedways and heavy machine weights

20" 20" 20" 20"

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Heavy duty clutched headstock Precision SKF spindle bearings 4-way rapid traverse 2-speed tailstock

• Heavy duty clutched headstock with 4" spindle bores • Precision SKF spindle bearings • Cuts inch and metric threads without change of gear • 4-way rapid traverse and 2-speed tailstocks standard • Heavy duty bed construction with extra wide bedways and heavy machine weights

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Quarter 1, 2012 — Industrial Machinery Digest

9

band saws

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for LeSS Co sen Ban d S aw A d va nta g e s: U.S. availability of parts Local Service

Fast ROI

Model choices & Pricing User friendly fe atures

The V_Drive gives us the capability of cutting difficult-to-cut, high machinability index materials at a much faster rate. This piece of equipment typically will give me a productivity increase of a minimum of 25 to 50 percent more pieces on the floor in the same amount of time. In addition to productivity increases we get significantly longer tool life, on the order of 30 percent or higher. In productivity, we’re doubling our piece count.

— Allen Goddu, President imPAct Alloys, inc., Pembroke, mAssAchusetts

www.cosen.com 11626-B Wilmar Blvd., Charlotte, NC 28273 Phone: 704.943.1030 • Toll Free: 1-877-SAWING 1 Fax: 704.943.1031

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Micro Drill Presses a division of Treat Enterprises, Inc. 19401 Rawhide Road • Sonora, CA 95370 • Phone: 209-532-7201 • Fax: 209-532-1211

Cameron Micro CNC Micro Machining Center MODEL-TC • FOUR POSITION AUTOMATIC TOOL CHANGER • 3-Axis X-6" Y-4" Z- 5-1/2" (150mm X 100mm X 134mm) • Fourth Axis Wiring and integrated control module • Repeatability: .0002" • Travel Speed: 80ipm • Spindle Speed: up to 50,000rpm • Complete with Laptop Computer • FlashCut Controller with G-code Software • Nema 23 Servo motors on each axis (155oz/in peak torque) • 350 W brushless DC Motor on the Spindle • Precision Collet System (either 2mm, 3mm, 1/8", or 4mm included) • Process Inspection Camera • Video Edge Finder • Granite Surface Plate • Safety Enclosure

Manual Micro Drill Presses • For Small-hole drilling from .002" to 5/32" • Spindle Speeds of 9,500 - 17,000 - 30,000 RPM A Variable Speed Control is available.

• Spindle, pulley, and motor dynamically balanced • Spindle taper Run out is within .0001" Cameron Series 164 Micro Drill Press

MD 70 X Programmable Z- axis available

Cameron CNC Micro Machining Center MODEL-S is also available!

• 3 Axis: X-6" Y-4" Z-7" • Many of the same features and specifications of the Model TC, but NO Tool Changer • Choice of 40K, 50K, or 60K rpm Spindle Cameron Micro Max MD 90 Milling Machine Adapter Unit

Cameron Deep Throat Micro Drill Press MD 70

Leasing/Financing Available

“MADE IN THE USA SINCE 1964” 1-800-369-7769 • www.cameronmicrodrillpress.com • E-mail: camerondp@mlode.com www.industrialmachinerydigest.com

Quarter 1, 2012 — Industrial Machinery Digest

11

productivity profile

inveSting in U.S.-baSed manUfactUring payS off Minimize impact from shifts in global supply chain

By Kevin Jobsky, Director of Marketing, ICM Controls

U.S.-based manufacturers are increasingly finding themselves reacting to shifts in the global supply chain that are increasing prices and delivery lead times. Rather than rolling over and crying uncle, vertically integrated companies are playing on their strengths, which include faster times to market for new, updated, or custom-built products.

Such companies have better control over their inventories and can therefore minimize exposure to risks that plague companies that need to make overseas bulk purchases of preassembled products. This enhanced manufacturing flexibility allows a vertically integrated company to be much more responsive to critical needs and requirements of the customer, and often translates into a higher level of service and support.

In addition, a resurgence of consumer patriotism positions US manufacturing companies to leverage opportunities and capture market share for substantial bottom-line gains.

Shift in world marketS increaSing priceS and lead timeS China, and to a lesser extent India, has dominated world markets during the past few years. These self-sustaining economies now have the luxury of being both the biggest buyers and suppliers in the global supply chain. They are consuming vast amounts of raw materials, and are putting a strain on the rest of the supply chain. The upshot is a dramatic shift from the age of a buyer’s market to that of a seller’s market.

As a result, the rest of the world is experiencing increased pressures in the form of higher pricing and drastically increased lead times. What used to take a few weeks to receive may now take as much as six months to a year.

Vertically integrated companies are best able to mitigate these pressures. Those least reliant on others to conduct their business can be more adept at navigating around supply chain obstacles. Vertically integrated companies are more flexible and able to react to market fluctuations much faster than those heavily exposed or anchored to outsourcing. made in the USa - brand loyalty SweetenS the pot China (and to a lesser extent India) are being viewed in a similar way to how we viewed Japan in the 1980’s. As the world economy evolves, and new economic powerhouses emerge, we are also witnessing an upsurge in pride for American-made goods.

In the United States, the slow recovery following the recent downturn in the economy has fueled a resurgence of consumer patriotism among U.S. distributors, contractors and consumers alike. The sentiment is aided by U.S. government-backed stimulus programs that promote buying American-made products.

12

Industrial Machinery Digest — Quarter 1, 2012

Manufacturers that can brand themselves and their products as being truly Made in the USA, and can deliver the products, are best able to take advantage of these market opportunities. icm controlS leverageS made in the US benefitS ICM Controls, a leading manufacturer of electronic controls for the HVACR industry, is an example of a vertically Kevin Jobsky is the integrated U.S. manufacturer that is Director of Marketing poised to meet head for ICM Controls, on and successfully overcome the new where he has worked challenges in the global supply chain. since 2006.

The North Syracuse, NY-based He has 20 years company houses three core of professional manufacturing processes under one marketing/writing roof. From fabricating its own printed experience, and circuit boards, to populating these holds a BA in boards using dozens of high-speed Communication surface-mount machines, to the Arts from Hofstra molding of its own product casings and University. accessories, ICM Controls realizes the value of doing everything in-house, and prefers to operate this way.

By continuing to reinvest in its vertical integration strategy and world class manufacturing capabilities, ICM Controls can offer customers faster times to market from concept to delivery for new products and for product updates and/or custom refinements. The company can react to ever-changing market trends faster, better positioning itself to capture market share and maximize gain.

While it must still navigate the murky waters of buying some components overseas, ICM Controls does not “order” preassembled product overseas. Therefore, ICM Controls can better control its inventory levels and more easily and quickly liquidate any product it may need to. This becomes especially important for OEMs and for aftermarket products with revisions, for which ICM Controls can perform running changes. This leads to improved quality and higher levels of service and support.

The company’s Made in the USA product pledge is

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productivity profile

attractive to all segments of the market, including distributors, contractors, and homeowners.

For example, Waltham, MA-based distributor Johnstone Supply’s Rena Langley estimates that about half of the equipment she handles is made in the US, and wishes that proportion were higher. “I hope that we can have more domestic products coming in, because I know we have had quality issues with some of the foreign products we handle.” She adds, “I’ve got contractors saying that even though there may be savings up front in some of the foreign-made equipment, they have to change out parts more frequently, making it more costly in the long run.” She concluded by stating that she has observed much higher quality in American-made products and said if the prices could be brought closer to foreign prices, the industry would benefit more.

From a contractor’s point of view, energy efficiency is the number one driver in the HVACR business and efficiency innovations are absolutely key. “We know that innovation in industry still begins in the US. This is where patents are held and ideas are formulated,” said David Kagan, manager of Texas Central Air, a leading residential and commercial HVAC company in Houston, Texas.

Kagan notes that innovative and durable controls are a critical part of his business, where every product is relying on bringing clean electrical power to it. Electrical brown outs experienced in his service area have a tendency to affect equipment and reduce its life expectancy. Controls to reduce brownouts are one of the more critical components he adds to systems he installs to help the units last longer.

“As a contractor, we are selling durable goods with an assumed life expectancy. When we sell and then service a product, we are taking on customers whose business we want to earn down the road. We are always asking ourselves what we as contractors can do to help this equipment reach its life expectancy.”

And one key answer is to purchase American-made products. According to Kagan, “I’m well aware of how many manufacturing jobs have gone overseas and feel we owe our allegiance to the country in which we live. However, I also believe we produce a better product here.”

He explained that he has some experience with Chinese

products brought in by the largest distributor of a major HVAC equipment manufacturer. They purchased and installed a large number of these motors and found the brand was noisy and prone to frequent breakdown. “Once bitten, twice shy,” he says.

Kagan agrees that there is a price threshold, noting that he is running a business and must remain profitable. However, he affirms that price is not the sole determinant in what product he uses, stating that doing a quality job using quality products is likely to benefit the company in the long run. His company takes the initiative to educate customers on quality versus price issues, recognizing that the tough business environment may leave them out of certain jobs. “We don’t sell a Cadillac to someone in the market for a Chevrolet, but we want to promote a product we think will last longest. Since our goal is to earn business not just today or tomorrow but for years to come, we speak out to explain that American-made products in the HVACR industry are far higher quality.”

One reason he sees even more of an incentive to use higher quality, higher priced American-made products is a recent trend in the industry to offer greatly extended equipment warrantees. “We have to ask ourselves, what product do we want to put out there that’s going to meet this warranty?” He notes that the trend has them seeking not the cheapest, but the longest wearing components so they will not be out fixing and replacing equipment constantly. The challenge has been to find as many American-made products as they can, with the next best alternative products assembled in Mexico.

Contractor, Anthony Ragusa of Montz, LA-based Authentic Air, LLC agrees, saying, “I feel HVAC parts that are made in America are more reliable, and are also easier to work with, from the point of view of diagnosing issues and then getting parts for repairs. There is just that connotation of quality, reliability and good workmanship. I will always use made in America products first when I can.”

According to Ragusa, many people in his service area are looking for the best price due to the economy and are not clamoring for American-made products. However, they frequently will go along with his recommendations, and Ragusa usually recommends a product made in America.

“With an overseas product, it would have to be much, much cheaper for the same thing. I’d also have to see some reviews or testing on it first before recommending it.”

The final link in the HVAC chain is the homeowner, whose main concern is usually how well the heat or air conditioning is working in the home. For Robert Hall of Pensacola, FL, health issues make even mild humidity levels really uncomfortable, so the results he realized after installing a CC750 Comfort Control Center from ICM Controls onto his air conditioning system carried even more significance. “I was very pleased to learn that it was made in America. I would always go for an Americanmade product where possible because of its quality.” final thoUghtS In response to global shifts in the supply chain, U.S. based manufacturers that opt to reinvest in themselves versus outsourcing will be in a better position to minimize the impact of the paradigmatic shift in the global supply chain, and also leverage U.S. consumer patriotism that has resurfaced for the first time since the 1980’s.

For further information about ICM Controls and its products, call 800-365-5525 or visit www.icmcontrols.com, or follow us onTwitter, Facebook, and LinkedIn.

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Quarter 1, 2012 — Industrial Machinery Digest

13

fabricating news

Scotchman InduStrIeS now InStallIng new and Improved hydraulIc SyStem In dual operator IronworkerS Scotchman Industries reaffirms its position as a proven leader in the metal machinery and fabrication equipment industry by announcing their recent improvements to three models of ironworkers. The new hydraulic system that is being installed in several of the Scotchman Dual Operator ironworkers has increased the machine’s cycle time by over 40%. The change now makes the DO machines even more efficient.

The hydraulic system for these machines is designed to assure full hydraulic pressure and speed to both operators, meaning one worker can be operating the punching station while another worker runs a different tooling station without delay.

“Our goal is to provide the best machinery for our customers and help them find profitable solutions for their shop needs,” explains Scotchman owner Jerry

Kroetch. “We had concerns that our dual operator machines were simply not fast enough. Our old hydraulic system pumped 6.42 gallons per minute—now, our new pumps have increased to 9.06 GPM.” Dual Operator Ironworkers are generally more expensive and may require more floor space than single operator units, but the price difference is quickly diminished with the higher productivity achieved. Since more than one worker can be operating multiple stations at the same time, both production capacity and efficiency can increase simultaneously.

Scotchman’s Dual Operator 120 ton, 135 ton, and 150 ton machines have all received the improved hydraulic system and are now capable of achieving a 41% increase in cycle time. Cycle time is measured from the moment the foot pedal is pressed to start making a punch until

the punch is complete and the machine returns to its resting state.

Each machine features a versatile tool table design with standard punch, angle shear, flat bar shear, and notcher. In addition to providing a superior hydraulic system, Scotchman Industries has numerous accessories available including custommade tooling and punches and dies.

For more information, please contact Scotchman Industries: www.scotchman.com • info@scotchman.com • 1-800-843-8844 • 1-605-859-2542

C MARShALL FAbRiCATiOn MAChinERy, inC. wELCOMES 2012!

So far in 2012, there has been an increased interest in machines, more quotes being sent out and more sales. Those who understand the market’s up-and-downs are cautiously but steadily providing optimistic information about the strengthening economy — and best of all, are calling manufacturing ”the shining star of the recovery”.

C Marshall Fabrication has an extensive product line from brakes, shears and rebar equipment to laser cutting and plasma burning machines. And last but not least our great MG plate roll line.

As of January 1, 2012, C Marshall Fabrication Machinery is the authorized supplier of BNC rebar bending and cutting lines. These machines are made in Busan, Korea, by Taeyeon, which is one of the leading manufacturers of rebar machinery in the world.

MG PLATE ROLLS C Marshall Fabrication Machinery is going to dedicate 2012 to their flagship machines: MG Plate Rolls, made in Italy. Since 1981 MG has been supplying customers with plate rolls ranging in size from .020” to 10” thickness and 20” to 30’ in length.

MG gives customers real advantages on every large and small industrial application of boilers and heat exchangers; tanks and containers for alimentary sectors, agriculture and buildings; tanktrucks for oils and foods, road and heavy transportation; turbines and reactors; off-shore and land windmill towers; light and heavy

steel structural works, excavator buckets and any other application in the field of automotive, naval, railway and aero-spatial. Every one of these sectors is carefully studied by our staff in order to give our clients the best machine, system or service.

The machines are built to follow each customer’s specific bending requirements, expressly studied and projected for the task the customer needs to perform.

On December 16, 2011 MG was awarded the Quality Certificate ISO9001-2008. ISO 9001:2008.

View more on page 39 For more information contact C Marshall Fabrication Machinery, Inc.: 2281 Oakdale Circle, Simi Valley, CA 93063 • 866-399-2323 • Cary@cmarshallfab.com • www.cmarshallfab.com

14

Industrial Machinery Digest — Quarter 1, 2012

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MADE IN THE USA WITH PRIDE AND DURABILITY SINCE 1972

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Quarter 1, 2012 — Industrial Machinery Digest

15

fabricating news

GEKA ModEl puMA s2 dp hydrAulic doublE End punchinG MAchinE

Station one

Station two

COMEQ, Inc. is the Exclusive US Distributor for GEKA Ironworkers (Single cylinder and dual cylinder Models), Automated Ironworkers, SingleEnd Punches and automated processing systems. COMEQ, Inc. is pleased to announce that GEKA has introduced the Model PUMA S2 DP Hydraulic Double End Punching Machine w/CNC X-Y Positioning Table. This machine offers double features: Two independent punching heads, great flexibility and CNC positioning & manual punching versatility combination.

Station one is a 120 ton punch with Model Semi-Paxy CNC X-Y Positioning Table with Single or Triple punch capabilities.

Punching capacity is 1-1/4” hole thru 1” thick material or 1-1/2” hole thru 3/4” thick material. Touch screen control is a Windows based industrial/ military grade CPU featuring: Offline software, Importation of DXF and DSTV files, Networking via Ethernet, USB supported.

Station two is a 120 ton punch with a punching capacity of 1-1/4” hole thru 1” thick material or 1-1/2” hole thru 3/4” thick material.

Optional accessories include: Triple Punch, 78” Flip stop gauge rail, 4” Oversize Punching Attachment, 6” Oversize Punching Attachment and a Press Brake Attachment.

Triple Punch

Touch Screen Control View more on page 19

For more information, please contact COMEQ, Inc.: Phone: 410-933-8500 • Fax: 410-933-1600 • E-mail: sales@comeq.com • Internet: www.comeq.com

New Marvel coNtrol allows fully autoMatic cuttiNg of coMplex Multi-aNgle cuts.

The newest control from Marvel Mfg. Co. is available with an optional feature that will automatically cut multiple angles on the end of an incoming work piece. The multiple angle or “bullet nose” feature is available on Marvel’s Series 2000 machines that are equipped with servo controlled automatic bar feed tables. The desired angles are easily programmed into the Marvel PC3S control using our intuitive graphical interface. The control determines the most efficient sequence in which to make the various miter cuts.

Following the initial cut in a multi-angle program, the bar feed table advances the work piece far enough to clear the cutoff piece from the work area. It then repositions the work piece as required for the subsequent cuts. The ability to program and run these types of parts automatically saves time by eliminating the need for additional handling and secondary set ups. This new feature is just the latest example of how Marvel is using advanced technology to provide new capabilities and increase productivity.

MANUFACTURING COMPANY, INC.

View more on page 33

For more information, please contact Marvel Mfg. Co.: 3501 Marvel Drive, Oshkosh, WI 54902 • 1-800-4SAWING • sales@marvelsaws.com • www.marvelsaws.com

16

Industrial Machinery Digest — Quarter 1, 2012

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fabricating news

MAE STRAIGHTENING AND WHEEL SET PRESSES TO BE REPRESENTED

BY AMERICAN WERA North American sales to automotive, heavy equipment, steel, rail, OCTG and other metal fab markets to be handled by leading supplier of machine tools Effective October 1, 2011, an agreement was reached by American Wera, Inc. here and MAE Götzen GmbH of Erkrath, Germany for representation of the MAE line of straightening presses, wheel set presses and hydraulic presses in the North American market, comprising Canada, Mexico and the U.S. For MAE, American Wera will supply equipment, application engineering, onsite commissioning, training and all

after-sale service, operating from its headquarters in Ann Arbor, Michigan and sales & service center in Queretaro, Mexico. The company’s existing network of sales representatives will handle this new line, under the direction of Product Manager for MAE, Joseph Kemple.

MAE offers a broad line of manual, semi-automatic and automatic straightening equipment with press forces to 25,000 kN, used particularly in the automotive, heavy equipment, steel, rail and OCTG markets on round, profiled and complex shaped workpieces in lengths up to 100 feet.

MAE machines possess the high accuracy and repeatability necessary for extremely tight straightening tolerances on such large workpieces.

Depending upon the workpiece, the type of machine may be electromechanical or hydraulic. All hydraulic presses are equipped with the

MAE patented BiPAC hydraulic control systems for large energy savings.

Finally, MAE also offers special application presses in C-frame, as well as four-column styles with press forces to 10,000 kN. These special application presses are typically used in forming and calibration.

Scott Knoy, vice president of sales for American Wera, states, “We believe the MAE line will complement our existing equipment, making us a greater value adder to current customers, plus it will open new markets where our expertise can be helpful to a variety of end product manufacturers.”

Executing the agreement were American Wera President Walter Friedrich and MAE Managing Director Ruediger Goetzen.

For more information, please contact AMERICAN WERA, INC. - MAE: 4630 Freedom Drive • Ann Arbor, MI 48108 • Phone: 734-973-7800 • Fax: 734-973-3053 Web: www.american-wera.com • Email: joseph@american-wera.com • Attention: Scott Knoy or Joseph Kemple

www.industrialmachinerydigest.com

Quarter 1, 2012 — Industrial Machinery Digest

17

fabricating news

Water InjectIon Plasma cuttIng noW standard at jacquet FacIlItIes As a leading provider of stainless steel and nickel alloy plates and parts, Jacquet Metals knows that faster, cleaner cuts is the way to keep customers coming back. That is why they recently purchased upgrades to four plasma cutting machines.

Jacquet provides stainless steel and nickel alloy plates and cut parts to metal distributors, fabricators in the chemical and petrochemical processing industries, the power generation industry (including nuclear and coal-fired power), and water waste treatment facilities. In these corrosive environments, customers need materials that are heat- and corrosion resistant, such as stainless steel and nickel alloy.

“We cut a lot of rings, discs, and shapes,” says Ryan Hendrix, Jacquet Southeast Facility Manager. “We use the Sabre DX with an m3 plasma system featuring water injection capability from ESAB Cutting Systems because we need clean cuts with high edge quality.”

Jacquet installed 5 new ESAB cutting machines from 2006 through 2008, and installed a 6th machine at its new location in Charlotte, NC in 2010. The Charlotte location was the first to use the water injection plasma system.

“We were so pleased with water injection – it absolutely gives the best results,” says Terry Engle, Jacquet CEO. “We jumped on it pretty fast and ordered 4 for all of our North American facilities. We didn’t order one at a time – we immediately retrofitted our cutting heads.”

Water injection capability is designed to reduce the cost of cutting stainless steel and aluminum while improving edge quality and reducing dross formation.

Water injection cutting offers cutting speeds up to 100% faster than gasshielded systems. The ESAB m3 system allows the torch to switch automatically

between standard dual-gas cutting and water-injected plasma cutting.

Each of Jacquet’s 6 ESAB cutting machines features a 600 Amp m3 plasma system, which gives them the capability to cut through stainless steel up to 6 inches thick. Water injection yields the best cut quality on materials up to 3 inches thick.

But the system is so flexible it can easily handle precision plasma cutting all the way down to 10 gauge.

Thick plasma cutting of stainless steel and aluminum has traditionally been done using H-35 gas, a mixture of 65% argon and 35% hydrogen. Because water injection plasma uses only nitrogen gas and water, it is less expensive than plasma cutting with H-35.

“We have definitely seen a decrease in our costs,” commented Hendrix.

“We are impressed with the cut quality, reduced gas consumption, and tolerance of the ESAB m3 plasma system,” stated Engle.

“The water injection cutting system provides a nicer finish on stainless steel plate than ordinary plasma cutting with a smaller heat affected zone (HAZ). Having less HAZ on the edges of the cuts is key to getting the clean finish customers want,” continued Hendrix.

“The bulk of our production goes across those machines,” stated Engle.

“The ESAB machines are a critical part of our business, and we have been completely impressed with the results – that’s why every Jacquet facility in North America uses ESAB. We’re switching over to the water injection plasma head in every facility.”

For more information, please contact ESAB Welding & Cutting Products: www.esab-cutting.com • 1-800-ESAB-123

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Industrial Machinery Digest — Quarter 1, 2012

www.industrialmachinerydigest.com

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fabricating news

roundo ab of sweden announces merger ROUNDO AB, the world’s undisputed bending roll leader for more than 40 years, has announced they have joined a group of family-owned metal fabricating companies in southern Sweden.

This exciting change will enable ROUNDO to grow exponentially with increased product research and development, provide quicker delivery times as well as increased machine production.

Mats Nilstoft, the managing director of the group says “ROUNDO is a very fine company with a portfolio of quality products. We are eager to have them join our team and continue their tremendous success with our immense resources.”

ROUNDO will now have direct access to multiple Trumpf laser machines, Amada and Trumpf CNC press brakes as well a high-speed plasma burning machine with 2.5” plate cutting capacity. This new equipment will enhance ROUNDO’s inhouse production capabilities, allow for quicker machine frame production and share resources with a team of over 250 people.

“Everyone at ROUNDO is very excited to join this larger group of well respected manufacturing companies,” exclaims Åsa Kajrup, “We are eager to further enhance the ROUNDO products and it was important to find a company to continue the lifetime achievement of Göran Kajrup, the founder of ROUNDO”.

Furthermore, ROUNDO parts and service will see an immediate benefit with the expansion of a dedicated team for after-sales support, including prompter response times for custom tooling and accessories, increased access to CNC machining centers and CAD computer design.

“We are very excited and confident in the continued development and growth of the ROUNDO brand”, says Peter Nilsson, ROUNDO Manager of Technical Services.

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Industrial Machinery Digest — Quarter 1, 2012

Allan Flamholz, President of Trilogy Machinery, the exclusive North American agent for ROUNDO, adds, “We believe this new partnership will solidify ROUNDO as the preeminent brand of bending rolls around the world.”

In the field of Angle and Section Bending Machines, ROUNDO has been the undisputed leader for more than 40 years. The technology and know-how at ROUNDO is a result of the experience gained building larger and larger section and plate bending machines over many years, based on their close working relationship with the leading bending companies around the world.

ROUNDO bending rolls from Sweden are distributed

by Trilogy Machinery, Inc., their exclusive North American agent. Trilogy personnel have over 100 years of experience working with ROUNDO bending rolls, and are responsible for supporting and servicing almost 4,000 ROUNDO rolls currently in use throughout the United States, Canada, Mexico and the Caribbean. The web site for ROUNDO is www.roundo.com and the Trilogy web site is www.trilogymachinery.com

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fabricating news

betenbender manufacturing, inc.

Made in the Heartland of the USA since 1972.

If you’re not already a customer of Betenbender Manufacturing, Inc. we welcome you as a future owner of an American made Betenbender Hydraulic Shear or Hydraulic Press Brake. If you’ve bought one before, we welcome you back. We are very proud of the fact that our customers come back again and again as they grow and need more equipment.

In addition to a full range of Hydraulic Shears and Hydraulic Press Brakes -- all easy to operate and engineered for simplicity, we have an national and international sales and service team ready to serve you.

Since 1972 we have continually updated our designs and equipment to meet our customers’ needs.

HISTORY The Betenbender Family of American Hydraulic Shears and Hydraulic Press Brakes are manufactured by Betenbender Manufacturing, Inc. from Coggon, Iowa, U.S.A. Now celebrating 39 years in business, this Midwestern company continues to produce, what we think, is America’s best-built Shears and Press Brakes. Glen Betenbender began as a blacksmith in Coggon during the 1930s. During WWII, he ran a small fabrication and repair shop. In 1948 he and his wife moved their growing business into their current location as a repair and manufacturing facility. Their son, Max, joined the company in 1967 after serving in the United States Army. In 1972, Glen and Max built their first shear -- then for their own use, but demand from other local businesses for their shear prompted the Betenbender’s to begin producing shears for nationwide and international resale. In 1984 Betenbender Manufacturing, Inc. got its first contract to produce shears for a major company.

Today, there are over 3,500 Betenbender machines in use with very few on the used market. We have always said, “If it says Betenbender on the nameplate, you’ve got a machine that will do the job.”

Betenbender Manufacturing, Inc. continues to be a family owned business. Today, Max Betenbender, President, handles the operation of the manufacturing facility which includes customer service and fabrication. He is joined by his wife Donna, who is the corporation’s Asst. Secretary-Treasurer, and daughter, Teresa - Treasurer/ Marketing Director. Long-time employee and family friend, Kyle Rawson is Vice President.

This Betenbender Hydraulic Shear, (one of the first machines made in 1972) is still in operation today.

Over the years the Betenbender machines have progressed as the manufacturing needs have changed. Pictured below is one of the current High Profile Hydraulic Shears.

View more on page 15

For more information, please contact Betenbender Manufacturing, Inc.: 5806 Quality Ridge Road, Coggon, Iowa 52218 • 319-435-2378 • sales@betenbender.com • www.betenbender.com

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Industrial Machinery Digest — Quarter 1, 2012

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Quarter 1, 2012 — Industrial Machinery Digest

23

fabricating news

Rollblocks foR stamping pResses fit VaRiety of needs A variety of die lifters are available from Hilma Div. of Carr Lane Roemheld for easy, safe movement of dies on stamping presses.

Variations include hydraulic or mechnical, roller or ball-type lifters, in line or transverse, cartridge inserts or rollblock bar, and standard or high temp die lifters, with four metric sizes and two ASA sizes.

Consult with Hilma’s engineering staff to determine the best option for your presses and your needs.

More information is available in the online catalog at http://www.clrh.com/hilma/products or contact the Hilma Div. of Carr Lane Roemheld Mfg. Co., 16345 Westwoods Business Park Dr., Ellisville, MO 63021, 1-800-827-2526, engr@clrh.com.

hydrapower awarded press brake contract Hydrapower International Inc. with world headquarters in Marco Island, FL has been awarded a contract to manufacture a 3000 tons x 44’ Press Brake for SMGT Ltd., an investment group based in Singapore.

The machine will be built in Hydrapower’s North American facility and shipped to the SMGT new Joint Venture Company located on the Mississippi River in Northern LA. SMGT Ltd has interests in developing technology in Energy, Transportation and Logistics. They have developed a new method of efficiently shipping LNG in easy to transport Energy Modules to undeveloped regions of the world. Specific details of their product will remain confidential until worldwide patent protection is in place. They have designed a special tooling system which will also remain confidential.

Hydrapower, a Licensee of Global Brands Group Inc., manufactures the world’s biggest Press Brakes and exports more than 75% of its products . Hydrapower made North America’s first CNC Press Brake and during the past 40 years has introduced advanced design features that were later adopted by competitors.

The Hydrapower Product Line has continually grown and it’s Automation Systems represent a major part of revenues.

For more information, please contact Hydrapower at 239-642-5379, hydrapower@aol.com, or www.hydrapower-intl.com.

Scotchman introduceS the aL100u-02 PiPe notcher by aLmi Scotchman Metal Fabricating Solutions introduces the Scotchman AL100U-02 Pipe Notcher/Grinder. This pipe notcher is top quality, economical and great for high production, and is an efficient abrasive pipe grinder for the notching of gas pipes, steam pipes, stainless steel pipes, and many other types of pipes. Wherever pipes need to be welded together at an angle, Scotchman pipe notching machines ensure that the correct cope is made quickly and accurately and are ideal for double corner joints.

The construction quality of a welded tube depends largely on correct preparation. With the Scotchman abrasive pipe notcher/grinder, quality is easily achieved. Just place a pipe in the clamp, which is mounted on a compound carriage, and grind a diameter and/or any shape of pipe accurately and efficiently to the desired angle. The abrasive grinders are sturdy, precise machines which operate at high speeds so stainless-steel sections can be machined problem free without grinding burrs or heat discoloration. These machines are constructed so the grinding roller and the grinding belt can be changed easily and quickly without tools, saving you time and money.

The Scotchman Pipe Notchers by Almi are quick, easy,

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Industrial Machinery Digest — Quarter 1, 2012

inexpensive cost savers that are accurate on all material thicknesses and all types of material. They are easy to operate and are ideal for tubes and sections.

The grinding rollers are easy to change; the grinding belt is quickly tightened and easily adjusted. Once the sections of pipe have been ground they can be deburred using the handy deburring table on top of the machine. Scotchman Pipe Notchers are backed with Scotchman’s Best-in-the Business, 3 Year Warranty.

Scotchman Industries was founded in 1967, and has been providing quality materials and construction, dependable performance, competitive pricing, and service to its consumers ever since. As the world and its markets change and expand, Scotchman Industries continues to grow and adapt.

Contact Scotchman Industries, a leader in tool technologies, for more information about their Metal Fabricating Solutions.

Visit www.scotchman.com, info@scotchman.com, or call TOLL FREE at 1-800-843-8844 or DIRECT at 1-605-859-2542.

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Water Jet ContraCtor Helps remove temporary pier piles at audubon bridge ConstruCtion site FolloWing reCord Floods Midwest Mobile Waterjet developed unique waterjet cutter that was dropped 20-40 feet inside the piles to cut them off 3 feet below the riverbed.

The John James Audubon Bridge is the longest cable-stayed bridge in the Western Hemisphere. Located in south-central Louisiana, the bridge crosses the Mississippi River between Pointe Coupee and West Feliciana parishes. Photo courtesy of Midwest Mobile Waterjet

Normally most of the steel piles would have been on dry land and easily dug up, cut with a torch and removed with a crane, but the flood waters left them deep in the water, inaccessible with standard equipment.

The bridge contractors challenged Midwest feed. Midwest Mobile Waterjet has nine Jet Mobile Waterjet to rapidly develop a first-of-itsEdge waterjet pumps, including five diesel kind abrasive waterjet cutting system that could pumps and four electric pumps. be dropped 20-40 feet inside of the piles and “We pumped the water out of the pile prior cut them off three feet below the riverbed. The to the cutting operation,” Gleeson recalled. tool needed to be light, compact “It would leak in slightly during the cut, but and adjustable for different pipe the mud kept it from gushing in, otherwise it diameters, 24” to 48”, and it would have filled all the way to the top of the needed to maintain balance to pile. I had to get it done quickly. The Jet Edge keep the cut line at the same pump was ideal for the project because it has height all the way around. It hydraulic and air auxiliary power on the pump, also had to be operable in making set up much faster.” muddy water 25 feet below the waterline with little visibility.

Visibility was a huge challenge, Gleeson noted.

“To my knowledge, this had His crew used reflectors, spotlights and air movers never been done before,” said to help them with visibility during the process.

Brian Gleeson, Midwest Mobile “We were cutting from 50 feet away and could Waterjet vice president. “We’ve not see what we were cutting,” he recalled. “You’re done a lot of cutting, but this looking down the pipe and all you see is steam.” was definitely one of the more The crew cut each pile in about 20 minutes, After the cuts were challenging operations.” cutting through the 5/8” thick steel using 2 complete, a crane Working off a barge, the ½ gpm of 35,000 psi water and two pounds lifted the upper waterjet contractor pumped of abrasive per minute. After the cuts were portion of the piles the river water out of each pile, complete, a special cement mix was pumped and loaded them then dropped their waterjet into the pile to act as a “plug,” then the top on a waiting flatbed cutting device inside the pile. portions of the piles were lifted out and hauled truck. Photo courtesy Their ingenious system utilized away. Plugging the holes quickly and completely of Midwest Mobile two high flow cutting heads was critical because the piles were driven Waterjet that were powered hydraulically into man-made Mississippi River levy and the from a motion device positioned integrity of the levy could not be jeopardized. slightly above the cutting heads to allow for “We cut the piles that were in the deepest better visibility in case the pile began filling with water and would never be accessible with water during the cutting process. The cutting standard excavating equipment,” Gleeson said.

Midwest Mobile Waterjet designed and head speed, direction, high pressure water and ‘We ended up cutting out 10 of the piles. It was built a waterjet cutting tool that was abrasive feed were controlled from a remote very fast and easy to set up and much safer and used to cut out piles from a temporary console on the barge. They used a 36,000 psi more efficient than using divers. The cut quality work pier at the John James Audubon Jet Edge iP36-250DX diesel-powered waterjet and steel separation was also much better with Bridge construction site in Louisiana. intensifier pump to create the ultra-high the waterjet as divers were hand cutting with The cutting tool was lowered down pressure water, hydraulically power the cutting no visibility and were trying to cut with soft mud the inside of the piles and cut them at tool and pneumatically power the abrasive behind the steel…which can be a challenge.” the required depth. Photo courtesy of Midwest Mobile Waterjet For more information, please contact: Midwest Mobile Waterjet • 651-755-7089 • http://mmwaterjet.com Jet Edge • 1-800-JET-EDGE (538-3343) • www.jetedge.com When record spring floods made it impossible for the Audubon Bridge’s contractors to remove their construction pier piles using conventional methods, they turned to Midwest Mobile Waterjet, a Minnesota-based waterjet contractor whose motto is “if it is possible, we can do it.”

The bridge contractors had just finished constructing the longest cable-stayed bridge in the Western Hemisphere, the John James Audubon Bridge, north of Baton Rouge, La., and they faced hefty penalties if they did not meet their deadline for removing the temporary piles from the Mississippi River.

www.industrialmachinerydigest.com

Quarter 1, 2012 — Industrial Machinery Digest

25

fabricating news

heavy duty shop fabrication tools from edwards manufacturing company You asked for it and we delivered.

Edwards introduces a new line of HYDRAULIC ACCESSORY TOOLS designed specifically for the Shop Fabricator. Quick connect these tools to your Ironworker for instant fabricator gratification!

Powered by the 40 to 120 Ton (A) Ironworker models, or our Porta Power, 5-HP, 3000 psi, hydraulic power unit, Edwards Hydraulic Accessories are instant “plug and play” tools that expand your shop without breaking your bank.

The Edwards 10 Ton Bender powers through 2” ID Sch40 pipe, 2.5” OD tube and 2.5” square tube fast and accurately. Features hand jog operation, auto-stop controls for repeatability and a heavy duty rolling frame with rotating yoke for both horizontal and vertical bending operations.

The Edwards 40 Ton Shop Press offers premium features at a standard price. Heavy duty ½” plate table and frame construction, an adjustable 30” x 48” working area with 12 ½” stroke from an oversized 4” ram gives you the layout flexibility you need. Hand jog controls speed the ram to your work but allow for fine adjustment for those delicate projects. Set-up your press with standard or custom tooling to handle any job in your shop. Compact 20 Ton Shop Press also available, a perfect addition to the garage or shop with limited space.

BUY AMERICAN !

BUIld YoUR NExt pRojECt wIth AN EdwARds!

View more on page 21

For more information, please contact Edwards Inronworkers: 1107 Sykes St., Albert Lea, MN 56007 • 1-800-373-8206 • www.edwardsironworkers.com

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Industrial Machinery Digest — Quarter 1, 2012

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Miters from 90° to 30°in both manual & automatic Faster cycle times with ball screw & vector motor

16”H x 20”W capacity New design features cool recessed work lights & laser cut line!

5.5 HP AC frequency inverter drive

Standard PLC stores 1000 jobs with 100 in queue.

Features multi-indexing, job queue loops, multiple languages...

Green Machine!!! Save $$$ with on demand hydraulics

Need to visit: www.Hydmech.com

fabricating news

hACO kOmPACT CNC PlASmA SySTEmS The design of the HACO KOMPAKT is based on a long experience in the field of CNC Plasma Cutting Machines.

The large range of table sizes and Plasma Cutting Sources (conventional as well as high-definition), means that we can offer you the perfect machine for your specific application.

With its macro-based graphical programming system and easily accessible working area, the KOMPAKT is a user-friendly CNC Plasma Cutting Machine.

The Haco KOMPAKT is manufactured to the highest manufacturing standards and Craftsmanship. The optimum price/quality ratio of the Haco KOMPAKT translates itself into a profitable investment.

The KOMPAKT plasma range of machines are available with the well-recognized Hypertherm® cutting source. The Conventionally and High definition cutting sources are offer you a superior cut quality and consistency and maximizes your production at a minimum operating cost. True Hole Technology is available on all Hypertherm® High Definition XD models.

STANDARD EXECUTION • Mecano-welded monobloc frame with integrated fume extraction chambers • Dual-side driven gantry with AC servo motor and rackand-pinion system (X-axis) • Y-axis with AC servo motor and rack-and-pinion system

• Cutting head rest with integrated Z-axis for arc voltage height control to minimize bevel on cutting edge • Well-designed collision system to stop immediately the cutting operation • Cutting table made of easily replaceable steel fins • Graphical CNC control based on 2 Intel Pentium 3 processors, with stand-alone 15” TFT colour graphics screen and keyboard • Macro-based programming system with manual grid nesting • Conventional or High-Definition Plasma System and cutting head APC59-T gRAPhICAl CONTROl The APC59-T Graphical Controlhas a 15” TFT color display and comes standard with automatic cutting condition settings. Driven by high-performance, PC- based hardware, the APC59-T allows very fast processing of data and highly accurate calculation of plasma burning operations. The control has a high level plasma torch height control and communicates with the plasma torch during cutting for optimized ignition control. The cutting time is also improved by our rapid torch lifting and ignition height setting.

View more on page 37

For more information on this story, please contact Haco-Atlantic, Inc.: 11629 N. Houston Rosslyn Rd. • Houston, TX 77086 Phone: 281-445-3985 • Web: www.hacoatlantic.com • Email: sales.tx@hacoatlantic.com

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Industrial Machinery Digest — Quarter 1, 2012

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fabricating news

Hyd-MecH LauncHes Redesigned s-23a Band saw Hyd-Mech Group Ltd.’s high quality saws are unmatched in providing the best cost-per-cut in the industry.

Simply put: our saws are built to last.

The new S-23A band saw from HydMech has been completely redesigned.

This new saw features a larger 16” H x 20” W capacity and the increased ability to miter from 90 to 30 degrees in both manual and automatic.

Its automatic, programmable control features storage for 1,000 jobs and the ability to run 100 jobs in queue.

Job information, such as part length and quantity, is entered through the interface keypad.

The operator is able to choose from four different machine behaviors in automatic cycle when executing jobs from queue. Continuous cycle progresses from job to job without stopping. Pause sequence cycle pauses between jobs in queue allowing the operator to change a discharge bin preventing parts from being mixed. Sequence cycle pauses after the first cut between jobs in queue in order to allow for a first off inspection prior to proceeding with the rest of the job.

The loop cycle will execute a single cut from multiple jobs – helpful when cutting a complete set of parts for an order. This S-23A automatically returns to manual mode when has run out of stock.

This standard PLC can be set to run in a variety of languages and it’s digital display shows: blade tension, blade speed, blade feed rate, head height, time of cut, total time the machine has run since new, maximum blade motor current consumption, and actual blade motor current consumption (which is useful in determining how hard the machine is working).

Acquire quicker cycle times. The S-23A shuttle vise assembly provides material indexing of up to 29” in a single stroke. Powered by a ball screw and vector motor, the S-23A length measurement is precise and extremely accurate. This machine features 16” H capacity full stroke hydraulic vises.

Unique only to Hyd-Mech, the S-23A features “green” on demand hydraulics. Saving you money by reducing energy consumption, the hydraulic system operates only when required. Another “green” feature designed to save you money is the machines ‘Power Down Timer’ which shuts down both electric and hydraulic systems when the machine is not in use.

The S23A features a heavy duty 5.5 HP AC frequency inverter drive. No more dealing with Belts and pulleys. Mechanical blade

www.industrialmachinerydigest.com

View more on page 27

tensioning with LED display digitally confirms that the saw blade is tensioned to factory specifications.

Another unique feature is its hydraulic positive down feed which increases cutting rates when cutting larger solid cross sections or tough-to-cut materials. A cast iron guide arm is attached to a dovetail way for quick and easy adjustment.

The S-23As standard laser light allows for fast measurements and assures accurate angle cuts to a scribe line. Distinctive recessed work lights illuminate the band and discharge area for improved safety.

Additional standard features are its blade breakage switch with motion detector, coolant pump with wash down hose, discharge table, and blade brush which prevents chip welding of the blade and extends blade life.

Hyd-Mech’s unique and powerful saws are ideal for making the most out of your production time through accurate cuts and consistent reliable operation.

For a quote or more information, please visit us on the web at www.hydmech.com or call toll free 877-276-7297.

Quarter 1, 2012 — Industrial Machinery Digest

29

productivity profile

how to choose the right plate or sheet rolling machine

by David Donnell, President, Carell Corporation We have compiled some general, basic educational information regarding plate rolls and their use. It is our hope that this information will assist you in properly sizing and selecting a machine to fit your particular application. For further, in-depth information and application engineering please contact us directly.

Plate or Sheet Bending Rolls are offered in 2 distinct categories.

They are single and double pinch, but they may vary in geometry or style. Matching the most appropriate machine style to the application is important. General machine styles are: 3 Roll Initial Pinch (fig 4A), 3 Roll Double Pinch (fig. 1A), 4 Roll Double Pinch (fig 3A), 3 Roll Variable Translating (fig 2A), 3 Roll Pyramid (fig 5A), and 2 Roll Systems (fig 6A).

Plate rolls are also built in a vertical format for special applications.

Machine capacity is equally if not more important than style. Plate roll manufacturers commonly rate their machines according to baseline material yield strengths of 36,000 to 38,000 psi, but steel mills are producing materials with ever increasingly higher yields. When choosing a machine, you must refer to your mill certificates and verify the average yield strength of the plate you are buying. It will not be uncommon to find that the “mild steel” you are rolling will have actual yields in the 48,000 to 58,000 psi range.

Remember, machine capacity must match your material, and most plate roll manufacturers can provide detailed capacity vs. yield tables to assist you.

You will often see capacities for both pre-bending and rolling for any given size Plate Roll. Pre-bending is performed on the plate roll at the leading and trailing edge of the sheet (fig 7A) (eventually the seam - (fig 8A). A sheet cannot physically be bent right to the edge and thus there remains what is referred to as the ‘un-bent flat’ (fig 12A). The minimum flat you could expect is 1.5 times material thickness and often 2.5 to 3.5 times the material thickness for heavier plate. It is the pre-bending operation, in attempting to minimize the unbent flat that takes the most power; and why pre-bending ratings are lower than rolling capacities for any given machine. You must be mindful when reviewing machine capacities that the maximum rolling capacity is usually expressed with the basic requirement of multiple rolling passes and very long un-bent flats. Un-bent flat lengths for any given sheet are a function of thickness, width, cylinder diameter, machine type, yield, rolls diameter and operator proficiency, among other factors. NC - (fig 9A) and CNC- (fig 10A) Controls are becoming more common in the workplace, and most all NC/ CNC machines are 4 roll types. Automated controls are recommended for high volume cylinder or shell production and to roll complex shapes that are not easily reproduced using standard manual controls. Multiple bends, variable radius bends and ovals are common examples.

1a

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2a

Industrial Machinery Digest — Quarter 1, 2012

3a

Three Roll Initial Pinch or Single Initial Pinch Plate Rolls are generally for lighter capacity applications and may be electro-mechanical or hydraulic.

They work by “pinching” the flat sheet between two vertically opposed rolls while the third offset roll or ‘bending roll’ moves upward to contact and then bend the sheet. When rotation of the rollers is activated, the sheet exits at a given radius. With the sheet cut to the developed length and the bending roll properly positioned, the part is rolled into a cylindrical shape that can then be welded at the seam to produce a closed cylinder. To remove a rolled cylinder, it must be extracted from the top roll. Machines are generally equipped with some type of top roll release mechanism to allow extraction of the cylinder. Typical methods are either a forward tilting or releasing top roll, or a removable end yoke. In most applications, these machines require removal and re-insertion of the sheet in order to pre-bend both ends. They are cost effective but in contrast may be more labor intensive in a production setting. There were many large, mechanical, initial pinch machines built through the 1950’s and may occasionally be found on the used market. All will have cast frames, as modern alloys and welding techniques had yet to be invented.

Double Pinch Plate Rolls are available in light to very heavy capacities and may have three or four rolls. The terminology can be confusing as these units may also be referred to as ‘double pinch pyramid plate rolls’ or ‘double initial pinch plate rolls’. Both three and four roll styles have fixed position top rolls and two offset or ‘lateral rolls’, one on each side.

The 4 Roll styles have an additional roller underneath the top roll, which constantly pinches the plate during rolling. Double Pinch Rolls can prebend both ends of the plate without removal as required with single pinch rolls. Three Roll machines generally require pre-bending the leading end, running the sheet through the machine to pre-bend the trailing end then switching roll rotation direction to roll the cylinder body. Four Roll Plate Rolls have a slight advantage in cycle time since they permit pre-bending of the leading edge, rolling the cylinder body and finishing off the trailing pre-bend, all while rolling in the same direction. Smaller machines can be mechanical but most are hydraulic and include drop end yokes (fig 11A) for easy extraction of the work-piece.

Automatic NC or CNC Controls and Four Roll Plate Rolls: Automatic cycle systems are generally used only on four roll plate rolls because of the minimal chance for slippage thanks to the constant pinching action of the forth roll. Automatic controls use an encoder to track movement of the plate through the machine. If the plate slips, the bending roll movements will be out of synch with the rolling movement.

Variable Geometry Three Roll Plate Rolls are not new, but are gaining

4a

5a

6a

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productivity profile in popularity around the world. They are built for medium up to extremely heavy plate rolling applications. The top roll moves up and down while the lower two rolls each move horizontally. This lower roll movement increases the offset distance from the top roll, and in so doing delivers a distinct mechanical advantage in bending. A machine of this type works well over a wide range of material thickness. By varying the geometry, they can be used like a single pinch, double pinch or pyramid style machine and require minimal sheet movement during pre-bending.

In the past, these machines were commonly found in shipyards, but are now being placed in general job shop and manufacturing applications.

True Pyramid Machines are rarely used in modern industry. They may be found on the used market and are common in developing countries. They have three rolls, with both lower rolls fixed in position and the top or bending roll moving up and down. In general they leave a very long un-bent flat and have several other disadvantages.

Two Roll Machines are designed for thin gauge material rolled to reasonably small diameters. They use a large diameter, urethane coated pinch roller which moves up with extreme pressure against a small diameter steel top roll. A mandrel or drum, very close in OD to the desired ID of the finished part is fitted over the top roll. Two roll sheet rolls are extremely fast and will roll round parts even if the blank has cutouts or holes. Since they require a mandrel for each part diameter and material thickness, they are not as versatile as some other machines, but for dedicated high speed production, they are often the absolute best choice.

Optional Equipment can be found listed on most proposals for plate rolling machines: The most important items to consider are hardened roll surfaces and cone rolling devices. With today’s harder materials and laser/plasma cutting techniques, it is ever more important to have very hard outer roll surfaces. Look for a hardness rating from 50 to 55 Rockwell C Scale. Hardness in this range will have a reasonable penetration depth and provide long lasting protection against roll surface wear. Hardness exceeding 60 will have a shallow penetration and result in cracking or crazing of the roll surface. Cone rolling devices permit the operator to roll a conical shape and are standard on some machines.

Lateral material supports and overhead supports are also optional, but less frequently requested. Overhead supports prevent lighter materials from collapsing when rolled to large diameters. A side support can

also assist in preventing lighter materials from re-curving toward the floor if the radius is very large.

Some machines have extended roll shafts that protrude through the machine frame. Section or pipe dies can be fitted on these ‘stub shafts’, but it is not practical to roll angle iron on a plate roll. Angle tends to twist when rolled, and plate rolls do not have outboard, adjustable, lateral material guides to prevent this twist. You should consider using a section rolling machine or angle roll. In general, section dies on plate rolls are good for bending flat bar the hard way, rods or small pipe.

General Note: Most New Roll Bending Machines are equipped with modern safety devices such as emergency stop buttons, safety trip wires, 24VAC low voltage control circuitry and detached operator control consoles. However it remains the responsibility of the owner to ensure the installation and proper use of point of operation safety guards or devices.

You can reach our Sales dept through sales@carellcorp.com as well as by phone at (251)937-0947 or directly to david@carellcorp.com

View more on page 23

www.industrialmachinerydigest.com

Quarter 1, 2012 — Industrial Machinery Digest

31

fabricating news

americor hydraulic plate bending rolls from comeq, inc.

COMEQ, Inc. now distributes a New generation of AMERICOR Hydraulic Plate Bending Rolls. Available in 3-Roll Single Intial-Pinch and 4-Roll Double-Pinch Models.

These rolls are available with capacities ranging from 3’ to 10 lengths and 16 ga. to 9/16” thickness.

Standard features generally include: hydraulic roll adjustment for bending and prebending operation, hydraulic pinch/clamping roll, hydraulic drop-end, digital readout for bending rolls positions, cone bending attachment, inductionhardened rolls, roller bearings on all roll shafts, emergency stop cable at front and rear of machine, easy tilt of bending rolls for cone bending, extra large openings between top and bottom rolls, hydraulic oil and machine manual.

These New Generation Models are packaged with productive features and refinements including: rolling control console (to allow for optimum operator convenience), hardened gears, lineal-guided roll adjustment for the bending rolls, an enhanced drive system (to allow rolling thickness within the machines opening between the top and clamping rolls) with NO BELTS, CHAINS OR EXTRA GEAR-DRIVING

SYSTEMS, rolls are SAE 1050 high strength steel heat treated and induction hardened to 56-60 RC, high quality international electric and hydraulic components, more rigid frame and drop-end arrangement, enhanced cone bending device, corrosion and abrasive resistant paint finish, European design & manufacture and built & certified to CE standards.

Now with more available options including: interchangeable small diameter top roll, side and overhead support devices, variable rolling speeds, hydraulic drive and programmable controls.

View more on page 19

More information can be obtained by contacting COMEQ, Inc.: Phone: 410-933-8500, Fax 410-933-1600, E-mail: sales@comeq.com, www.comeq.com

NEW ELECTRIC COIL FORM MACHINE Burr Oak Tool Inc. offers the Electric Coil Form machine for producing bends in single row coils or multiple singlerow coils joined at one end. This machine handles round and flat-tube coils up to 60” wide and 3 meters long for large commercial HVAC/R applications. A single, vertically-oriented bend arbor produces one, two or three 90° bends, creating L-, U- or box-shaped coils.

This coil form machine is all electric, offering lower energy consumption, greater precision and lower maintenance than hydraulic machines. RFID matches part data to the arbor cover to avoid forming the wrong radius and to prevent scrapping of expensive coils. Options available include slip sheets, coil length measurement, inside coil pusher, bar code scanner and coil staging table.

For over 65 years Burr Oak Tool Inc. has designed and customized production machinery for the heat transfer and tube processing industries. OAK machines are installed and successfully operating in over 70 countries. Providing quality machines, service and parts to customers worldwide reinforces Burr Oak’s slogan, “Global Experience...Local Solutions.”

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Industrial Machinery Digest — Quarter 1, 2012

For more information contact Burr Oak Tool Inc., 405 West South Street, Sturgis, MI 49091. Telephone: 269-6519393, Fax: 269-651-4324. Website: www.burroak.com.

www.industrialmachinerydigest.com

MANUFACTURING COMPANY, INC.

2125 A-PC3-60

NEW PC3 Touch Screen Control 60 Degrees Left and Right Capacity: 20”x 25” (508 mm x 635 mm) Blade Speed: 30-650 FPM (9-200 m/min) Feed: 0-350 lbs. (0-1516 N) Motor: 7.5 H.P. (5.6 kW) Blade: 1.25 x 0. 042 x 17’6” long

2150 A-PC3s-60 IrONWOrkerS 50 - 180 Ton Capacity 11 Models to choose from One and Two Cylinder Machines 4 & 5 Stations Punching, Notching, Shearing 2 Simultaneous Work Stations (D Series) Rapid Tool Change Over Work Light 24 Volt Control

60 Degrees Left and Right Capacity: 20” x 25” (508 mm x 635 mm) Servo Drive Auto Bar Feed up to 18' Blade Speed: 30-650 FPM (9-200m/min) Feed: 0-350 lbs. (0-1516 N) Motor: 7.5 HP (5.6 Kw) Blade: 1.50 x 0.050 x 18’2” long Also Available in 1.25” Blade

ISO 9001:2000 registered

OVER 100 YEARs OF QUALITY Marvel Manufacturing Company, Inc. • 3501 Marvel Dr. • Oshkosh, WI 54902 1-800-4SAWING • Phone: 920-236-7200 • Fax: 920-236-7209 • email: sales.imd@marvelsaws.com

www.marvelsaws.com

fabricating news

cosen saws, usa — the pinnacle of cutting performance 36 Years of Continuous Growth Make Cosen an industrY Leader Since its establishment in 1976, Cosen has grown into one of the world’s largest Manufacturers of band sawing machines and systems.

Today Cosen manufacturers over 100 standard models, including manual, semi-automatic, automatic, and Programmable (HMI Mitsubithshi Touch Screen) Control. Machines are available in capacities from 200mm (8”) to 2000mm (80”). With more than 50,000 band saws sold to over 70 countries, Cosen provides sales and service through an extensive network of authorized distributors.

Cosen prides itself on being able to provide multiple answers to any customer’s sawing need, including the ability to manufacture special or ‘one of’ machines.

Proven assuranCe of absoLute QuaLitY and reLiabiLitY Cosen has spent more than 36 years maximizing efficiency and quality in every step of design, engineering and manufacturing.

Thisensures customers the longest-lasting, highest performing, best designed band saws available. Cosen utilizes world brand parts (such as Siemens of Germany, Telemecanique of France, NOK of Japan and Square D of the United States) to guarantee that each and every component that goes into a Cosen saw is high quality. As an added side benefit, Cosen’s use of these universal branded components allows for a local supply of repair parts.

ProduCts: 1. Programmable Production: SNC, NC Series 2. Automatic Production: AH Series 3. CNC Carbide Sawing Systems: KTC Series 4. Swivel Head Miter Series 5. Manual Series 6. Heavy-duty Straight Cut-off: Billet Series 7. Heavy-duty Traversing Head Vertical Saw: Plate/Block Series

Cosen's C-2 equipped with V_Drive new froM Cosen Cosen Saws is proud to announce the newest in vector drive blade control. SNC saws can be fitted with Velocity Drive Technology to improve cutting speed on harder-to-cut material. The optional Drive not only significantly improves metal cutting rate, but prolongs blade life in the process, making it the economical choice for its superior cutting speed in mass production and providing endusers the fastest ROI. about Cosen Quality, dependability, performance and reliability are all words that can be used to describe Cosen saws. Cosen has earned ISO-9001 certification as well as CE designation and EMC to assure customers around the globe of absolute quality and reliability. “We make every effort to meet or exceed our customers’ expectations. Cosen Saws is continually updating and meeting new certification requirements to prove Cosen’s commitment to providing a world class machine,” says Peng Huang Vice President of Cosen Saws, USA.

View more on page 10

For more information, please contact Cosen Saws, USA: 11626-B Wilmar Blvd., Charlotte, NC 28273 • Phone: 704-943-1030 • Fax: 704-943-1031 • info@cosen.com • www.cosen.com

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Industrial Machinery Digest — Quarter 1, 2012

www.industrialmachinerydigest.com

fabricating news

ESAB IntroducES VISIon t5c control for rEtrofItS ESAB Cutting Systems introduces the Vision T5c Control for retrofit onto cutting gantries. This updated version of ESAB’s Vision T5 CNC is re-packaged for quick and easy installation in place of existing Vision controls on ESAB cutting gantries.

Designed for ease of use and improved productivity, the Vision T5c features an ergonomic, wide-screen layout and an advanced touch-screen interface that offers twice the display area of other CNC controls, as well as unique process control features designed to simplify operation and boost productivity.

The large, bright 18.5” wide-format touch-screen features an ergonomic layout with controls positioned for easy access to reduce vertical arm motion and improve operator comfort. Simple up/down toggle switches provide intuitive operation of station lifters.

These are easily serviced or added in the field. Dual USB ports are positioned to prevent interference with the operator.

The five-wire resistive touch display panel offers unmatched durability, reliability and performance.

The touchable, graphical user interface provides more information and feedback to the operator than typical controls.

Important information is always visible, and operating steps are clear and intuitive, guiding the operator every step of the way for enhanced productivity.

The new Operating Wizard guides users with clear, step-by-step instructions, providing simple prompts with limited choices that lead from file selection to starting the cut.

This allows even new operators to become productive more quickly. This

unique system starts at power-up, simplifying control start-up and machine referencing, and includes steps for torch setup and positioning the machine. The built-in shape library also uses a wizard to simplify part programming of complex shapes and maximize cut quality on small holes and inner contours.

Vision T5c controls from 1 to 12 stations without additional panels and controls numerous axes for variable beveling and rotating tools. Automatic machine referencing makes machine startup quick and easy. Program parking allows cutting of rush jobs without losing your place in a nest. Remote diagnostics using a live connection between ESAB service and your control speeds up trouble-shooting or training.

Designed for retrofitting, with matching mounting holes and all electronics built into the operator console, the Vision T5c is quickly mounted in place of older Vision controls, including the Vision 1000, Vision 2000, and Vision PC. Depending on the original machine’s electrical systems, the Vision T5c is capable of fully integrating all process controls for every cutting or marking tool, making operation quicker and easier for every machine. The Built-In Process Database can simplify cutting tool setup by automatically setting parameters such as cutting speed, kerf offset, and timers based on material thickness, material type and cut quality desired. The operator sees a picture and part number for the torch parts that are needed for both plasma and oxy-fuel torches. All cutting and marking tools can be controlled directly on the touch-screen.

With more than 100 years of

experience, ESAB Welding & Cutting Products is one of the world’s largest and most skilled manufacturers of welding and cutting equipment and welding filler metals. Recognized as the technological leader in the industry, ESAB is committed to providing customized solutions for their customers. For more information, visit www.esabna.com, www.esabcutting. com or call 1-800-ESAB123.

For more information, please contact ESAB Welding & Cutting Products: www.esab-cutting.com • 1-800-ESAB-123

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Quarter 1, 2012 — Industrial Machinery Digest

35

fabricating news

IntroducIng the grIzzly Models g0736 & g0737 15” & 18” VarIable-speed VertIcal Metal bandsaws • Variable-speed cutting from 75–385 FPM, using Reeves-drive pulley system • Built-in 2.4 KVA blade welding station makes this saw perfect for jobs requiring internal cuts • Included air blower and work lamp make it easier to follow cut lines and ensure accurate cuts • Also features digital blade speed display, rack-and-pinion blade guide adjustment, and precisionground, cast iron table • The 15” model G0736 has a 1 1⁄2 HP, 220V, single-phase motor and is available for $2595 • The 18” model G0737 has a 2 HP, 220V, single-phase motor and is available for $2995 As with all Grizzly products, these machines are covered by a one-year warranty. For more information call 1-800-523-4777 or visit www.grizzly.com.

Carell IntroduCes new 305HV angle rollIng MaCHIne Carell Corporation introduces the new 305HV ( shown with optional CNC control panel ) to its Angle rolling machine lineup The CARELL 305HV is a 3 roll, double initial pinch universal bending machine with independent hydraulic adjustment of both lateral bending rolls and powered rotation of all three bending rolls. These versatile units are ideal for rolling standard/special sections plus tube/pipe in mild-structural-stainless steels, aluminum, brass, copper as well as other materials. Machines are furnished with a set of standard universal rolls.

The 305HV includes Dual LED Digital Displays to monitor bending roll positions, Double Pinch Geometry which permits pre-bending of leading & trailing ends of the profile without removal from the machine, Telescoping modular Multi-Component roll set specifically designed to bend standard sections including angle Leg-In/Out and Square Rectangular Tube as well as other shapes in a variety of material types, Tri-Directional Lateral Guides with cam rollers for correcting inherent twist when rolling angle leg-in, and it Operates in both Horizontal AND Vertical positions.

For more detailed information visit www. carellcorp.com or call directly to Carell Corporation at 251-937-0948 View more on page 23

SCOTCHMAN® FeATureS 6509-24M IrONwOrker More Versatility and Flexibility than Any Other Ironworker on the Market If you are in the metal working industry, this machine is a must have.

Scotchman® Industries 65-ton hydraulic ironworker, Model 6509-24M, offers more versatility and flexibility than any other ironworker on the market. It also offers the largest flat bar shear capacity (1"x 6", 1/2" x 12" and 1/4" x 24") and the largest angle shear capacity (5" x 5" x 1/2") for a 65-ton machine. This high quality machine now comes with an outstanding 3-Year Warranty!

Other additional standard features include: 9" throat depth, keyed punch ram to insure safe alignment of shaped punches, punch gauging table

with fence and scale, electric stroke controls, jog control, electric foot pedal, emergency stop button, lock-out tag out switch and fork lift accommodations.

Numerous optional tooling is available for additional fabricating functions.

American-made products are in high demand these days. Scotchman offers a wide selection of high quality American-made machines at an affordable price. Let Scotchman be your Metal Fabricating Solution!

Scotchman Industries was founded in 1967, and has been providing quality materials and construction, dependable performance, competitive pricing, and

service to its consumers for over 40 years. As the world and its markets change and expand, Scotchman Industries continues to grow and adapt.

For more information, please contact Scotchman Industries: www.scotchman.com • info@scotchman.com • 1-800-843-8844 • 1-605-859-2542

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Industrial Machinery Digest — Quarter 1, 2012

www.industrialmachinerydigest.com

ImpressIve performances.

ImpressIve solutIons.

More than 46 years of experience building state of the art fabricating equipment make us a leading manufacturer of fabricating machinery worldwide.

We offer a solution for every metal fabricating need with our complete line of machine tools.

PuNCHING

PRESS BRAKES

dRIllING lINES

CNC MACHINING CENTERS SHEARS

Haco-Atlantic, Inc. 11629 N. Houston Rosslyn Rd. Houston, TX 77086

281-445-3985 www.hacoatlantic.com

PlASMA CuTTING

fabricating news

Trilogy Machinery inTroduces newly designed Trilogy for iPad aPP! Trilogy Machinery, the Exclusive North American Distributor for ROUNDO Plate and Angle Bending Rolls; United States Distributor for SUNRISE Ironworkers and United States Distributor for LEMAS 4-Roll and 3-Roll Plate Bending rolls has introduced their newly designed Trilogy for Apple iPad App for all customers and dealers.

The Trilogy Machinery app will allow customers and dealers inside access to Trilogy Machinery including machine pictures, PDF’s, parts inquiries, support, sales assistance and much more. The newly designed iPad app is now available from the Apple iTunes store.

Hydraulic and Magnetic die cHange SySteMS Hilma provides both hydraulic and magnetic quick die change. Experience less downtime with Hilma’s die clamps, which permit safe, rapid change-over to new production lots. And new magnetic systems clamp existing dies without retooling, in just 2 to 3 seconds.

For more information contact the Hilma Div. of Carr Lane Roemheld Mfg. Co., 16345 Westwoods Business Park Dr., Ellisville, MO 63021, 1-800-827-2526, or learn more at http://www.clrh.com/hilma/hyd-magn-qdc.html

For more information, please visit: www.trilogymachinery.com

SCOTCHMAN® feATureS THeir SeMi-AuTOMATiC COld SAw wiTH eleCTriC POwer dOwN feed Scotchman® CPO 350 PKPD, semiautomatic circular cold saw with electric power down feed can miter up to 135°; 45º to the right and 90º to the left. With its double clamping and self-centering vise, it produces burr-free, high-quality, high volume parts.

This semi-automatic circular cold saw features electric controls, electric valves, and an electric remote foot pedal. The CPO 350 PKPD is built with dependability and versatility in mind and is backed by our outstanding 3-Year Warranty!

For all your cold sawing needs look to Scotchman. They offer a wide selection of high quality American-made machines at an affordable price. Let Scotchman be your Metal Fabricating Solution!

Scotchman Industries was founded in 1967, and has been providing quality materials and construction, dependable performance, competitive pricing, and service to its consumers ever since. As the world and its markets change and expand, Scotchman Industries continues to grow and adapt.

For more information, please contact Scotchman Industries: www.scotchman.com • info@scotchman.com • 1-800-843-8844 • 1-605-859-2542

38

Industrial Machinery Digest — Quarter 1, 2012

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The revolutionary Fiessler AKAS II-F is the most sophisticated form of press brake protection on the market today. Utilizing the latest in laser technology, the AKAS II-F allows the operator to bend even the smallest parts safely and easily without interrupting production. Change over from one punch size to another is minimized by the use of an exclusive “self aligning” feature for the laser beams.

This allows the operator to perform other set up functions during the 30 seconds it takes for the beams to align themselves, versus the 5-10 minute manual laser alignment.

200,000 lb. Capacity Hydraulic Press

• 4-Wheel Steer, 4-Wheel Drive • 26" from Floor to Deck • LP Engines with 4 Hydraulic Motors • PC & Remote Control • 8 Cylinders for Lifting • 200 Ft. per Minute

Red Stag Engineering & Automation, Inc.

Advanced Manufacturing Solutions, LLC Ph: 941.637.6660 • Fax: 941.637.8036 • E-mail: dboyer1@earthlink.net or visit us on the web: www.pressbrakesafety.com For press brake off-line software, visit www.pressbrakesoftware.com

N2548 Meadow View Court, Waupaca, WI 54981 Phone: 715-258-5074, Fax: 715-258-5242 Email: Redstag@waupacaonline.net Red Stag has transporters operating today that are over 25 years old

www.redstag.com

quick deliveries on mg plate rolls Wind Towers, Pressure Vessels, Petrochemical — Nobody beats MG quality!

c marshall fabrication machinery, inc.

Make CMF your place to go when you look into serious rolling.

Used MH365I 4-roll w CNC Control etc.

Available in 7 weeks. 2-3/8” x 10’. $421,300.00 NET.

New MH314C 4-roll.

10’ x 9/16”. Available in 6 weeks.

Call for price.

New MH2522 4-roll.

Available in 7 weeks. 8’ x 7/8’’. $120,500.00 NET incl. vertical and side supports etc.

New AK325 3-roll.

Available in 7 weeks. 10’ x 1”. $124,050.00 NET

www.cmarshallfab.com 2281 Oakdale Circle, Simi Valley, CA 93063 • 866-399-2323 • Cary@cmarshallfab.com www.industrialmachinerydigest.com

Quarter 1, 2012 — Industrial Machinery Digest

39

North Americaʼs largest plate rolling, brake forming, structural rolling and fabrication facility.

6” thick

8” thick

100ksi yield For all of your rolling, forming and bending needs, please call

175lb rail

Toll Free 1-800-263-2547 40

Industrial Machinery Digest — Quarter 1, 2012

Fax 1-905-356-6025 Email info@hcrsteel.com

www.hcrsteel.com www.industrialmachinerydigest.com

PLATE ROLLING • 8 Plate Rolls • Roll up to 10” thick • Roll up to 12ʼ wide • Small to Large Diameters • Heavy Walled

STRUCTURAL ROLLING

• 4 Rolling Machines • Angles • Channels • Beams • Flat Bar • Pipe • HSS

www.hcrsteel.com www.industrialmachinerydigest.com

Quarter 1, 2012 — Industrial Machinery Digest

41

BRAKE FORMING • 6 Brake Presses • Up to 6,000T capacity • Form up to 20” thick • Form up to 14ʼ wide

7 3/4” thick

SERVICES 80” x 80” saw cutting capacity

• Spiral and Curved Stair Stringers • Welding • Split and Straightening Beams to Tʼs • Stress Relieving up to 1,8000F • Flattening and Straightening • Architectural and Artistic Projects • CTPAT Secured Warehousing

Toll Free 1-800-263-2547 42

Industrial Machinery Digest — Quarter 1, 2012

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We are the answer when it comes to your rolling, forming and bending requirements.

Some of the industries we serve...

Transportation

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M.P.O. Box 1526, Niagara Falls, NY, USA 14302-1526 5580 Kalar Rd., Niagara Falls, ON, Canada L2H 3L1 Email info@hcrsteel.com Fax 1-905-356-6025

www.hcrsteel.com www.industrialmachinerydigest.com

Toll Free 1-800-263-2547 Quarter 1, 2012 — Industrial Machinery Digest

43

productivity profile

hypertherm releases corporate social responsibility report Hypertherm, a U.S. based manufacturer of advanced metal cutting systems, is releasing its first public Corporate Social Responsibility (CSR) report. The report, which tracks the company’s philanthropic and environmental initiatives, is available at www. hypertherm.com/csr/report. A few highlights from the report follow.

• Two-thirds of Hypertherm associates volunteered in the community last year, donating more than 7,000 volunteer hours to dozens of nonprofit organizations, a 22 percent increase from 2009.

• More than 60 nonprofit organizations received funding and other support from the Hypertherm Owners’ Philanthropic Endeavors (HOPE) Foundation in 2010.

• A new Environmental Scorecard outlines progress and goals such as zero waste and a 50 percent reduction in carbon by 2020.

“This inaugural report is a comprehensive overview of Hypertherm’s CSR initiatives and the progress we have made toward our goals,” said Barbara Couch, vice-president of CSR for Hypertherm. “Our journey is far from complete, but we are serious about becoming the best community partner, environmental steward, and responsible employer that we can be. This report is

44

one way we can share our progress.”

Hypertherm designs and manufactures advanced metal cutting systems for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair. Its product line includes handheld and mechanized plasma and laser systems, consumables, as well as CNC motion and height controls and cutting software.

Hypertherm systems are trusted for performance and reliability that results in increased productivity and profitability for tens of thousands of businesses.

The New Hampshire based company’s reputation for metal cutting innovation dates back more than 40 years, to 1968, with Hypertherm’s invention of water

Industrial Machinery Digest — Quarter 1, 2012

injection plasma cutting. The company, consistently named one of the best places to work in America, has more than 1,000 associates along with operations and partner representation worldwide.

For more information, please isit www.hypertherm.com.

www.industrialmachinerydigest.com

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productivity profile

MAcroAir trANSForMS brAND iDENtitY to FurtHEr SHoWcASE ProDuct EFFiciENcY AND rELiAbiLitY Originators of The HVLS Fan Industry, MacroAir Experts Are The ‘Engineers of Air’ In an effort to better communicate its position as the leader of the High Volume Low Speed (HVLS) industry, MacroAir is transforming its company brand identity to showcase its solutionoriented technologies that lead clients to more efficient HVAC operations and savings.

MacroAir, manufacturer of commercial ceiling fans in sizes up to 24 feet in diameter, has revamped its company messaging platform and voice, logo, and branding elements to highlight its expertise of the precision movement of air.

Elements of MacroAir’s new brand identity, including a new video demonstration, can be seen at www.macroairfans.com.

“We truly believe we are the ‘Engineers of Air’ with our origination of the industry category and constant innovation,” said Eddie Boyd, president of MacroAir. “Now is the time for us to increase our communication of the superiority of our product design and engineering philosophies to the marketplace, and I think what you’ll hear and see from the new MacroAir is an invigorated commitment. Our products are engineered to perform and outshine our competitors through efficiency and reliability.”

Company innovations, including its patented 6ixBlade technology, showcase MacroAir’s commitment to scientific advancement and evolving product efficiency. While most other HVLS fans have 10 blades, MacroAir engineers reduced its fan blades to six in 2010, creating the 6ixBlade technology that uses a NASA-engineered wing design and advanced blade-angle pattern to move the same amount of air with 40 percent less power. MacroAir fans are proven to reduce room temperature by 10 degrees and lower heating and cooling cost by as much as 20 percent.

Originator of the HVLS industry category in 1998, MacroAir fans use high volume and low speed to gently circulate air and create a more comforting environment. For more than a decade, the company has placed an emphasis on innovation and engineering superiority to create a business culture

46

Industrial Machinery Digest — Quarter 1, 2012

cultivating industry advancement, efficiency and reliability throughout all its products and design features.

With the most functional and durable high-volume, low-speed fans in the industry, MacroAir is committed to customer service and satisfaction, and offers a 12-year warranty on all products.

For more information on the extensive line of MacroAir’s HVLS fans and applications, and announcements on new product lines throughout 2012, visit www.macroairfans.com.

About MAcroAir Since developing the first HVLS prototype in 1998, MacroAir has continually refined the design of the most durable and cost-effective commercial ceiling fan on the market. The company’s energy-efficient, long-lasting HVLS fans are utilized by companies such as Coca-Cola and can be found in barns, warehouses, manufacturing plants, air hangers and retail establishments across the U.S. and around the world. To learn more, visit www.macroairfans.com or call 866/668-3247.

MacroAir can also be found on Facebook and Twitter.

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SINCE 1978

Complete parts in one cycle up to 10X faster than traditional two-axis CNC lathes

CNC BAR & CHUCKER AUTOMATICS LNT-3T model: 8+2 axis with 3 turrets, live tools on front & back ends

LNT-S model: 8+2 axis with up to 4 tools in the cut at the same time, back-working with live tools

LND-D model: Twin-spindle 2 Y-axis with a power turret and a power tool tower

LIPOCO ENTERPRISES, INC. / LICO MACHINE WAREHOUSE Toll-Free: 1-800-364-1641, Fax: 310-329-6073, Email: sales@lipoco.com

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Quarter 1, 2012 — Industrial Machinery Digest

47

Metalworking news

CGTECh To PREVIEw VERICUT 7.2 aT wESTEC In booTh #2801.

VERICUT 7.2 features many enhancements to improve speed, thereby reducing the time required for manufacturing engineers to develop, analyze, inspect and document the CNC programming and machining process. Along with proactively adding new features, CGTech developers and engineers are focusing on implementing hundreds of customer-driven enhancements.

VERICUT PRodUCT/FUnCTIon oVERVIEw: VERICUT is CNC machine simulation, verification and optimization software that enables users to eliminate the process of manually proving-out NC programs. It reduces scrap loss and rework. The program also optimizes NC programs in order to both save time and produce higher quality surface finish. VERICUT simulates all types of CNC machine tools, including those from leading manufacturers such as Mori Seiki, Mazak, Makino, Matsuura, Hermle, DMG, DIXI, and Chiron. VERICUT runs standalone, but can also be integrated with leading CAM systems such as Catia, NX, Creo Parametric (Pro/E), MasterCAM, EdgeCAM, hyperMILL, Esprit and GibbsCAM. “For VERICUT 7.2 we continue to focus on the customer’s use of VERICUT and how we can improve the simulation process effectiveness,” said Bill Hasenjaeger, Product Marketing Manager.

“We added features to the user interface to simplify the most common user actions and invested significant developer hours to increase speed by more thoroughly taking advantage of multiple processors and background processing.”

Another new feature is the ability to optimize an NC program from a saved simulation. Users can adjust and re-optimize without rerunning the simulation. A new interactive panel displays cutting conditions immediately anywhere in the machining process. The user can navigate the NC program to evaluate cutting conditions and quickly see the results of adjustments to optimization settings.

CGTech will also be demonstrating VERICUT Composite Applications at WESTEC. VERICUT Composite Applications are machine-independent off-line programming and simulation software solutions for automated composite tape and fiber-placement CNC machines. There are two separate applications: VERICUT Composite Programming (VCP) & VERICUT Composite Simulation (VCS).

For more information, visit the CGTech website at cgtech.com, call (949) 753-1050, or email info@cgtech.com

THE LION ADVANTAGE European built to high quality standards, LION Lathes are designed to provide a perfect combination of heavy construction, rigidity, accuracy, simplicity, and reliability.

32" x 120" (6" Spindle Bore) Most models feature heavy duty monoblock construction with extra wide bedways and heavy machine rapid traverse, inch & metric threading without change weights. All LION lathes feature clutched headstocks of gear, an exceptionally wide variety of threads and with hardened and ground steel gears which make for feeds, and large 4” to 6” spindle bores. ample rigidity and effortless cutting.

LION offers all these features and more Spindles feature SKF bearings, resulting at affordable prices, making it the best in high accuracy. In addition, LION lathe value on the market for over 30 years.

Lathes provide versatility with a wide Sizes range from 16” to 40” swings, array of standard features such as 4-way with 60” to 200” centers.

For more information contact International Machinery: 1-800-638-0770 • www.lionlathes.com

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Industrial Machinery Digest — Quarter 1, 2012

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Metalworking news

wAlter, 60 yeArs of surfAce treAtment technologies Its evolution of knowledge and methods has led to productivity increases in Canada, the Americas and Europe A preferred industriAl pArtner for 60 yeArs Contributing to their customers’ success by helping them work better, indifferent to short-term trends, unwavering when facing challenging times. Without a doubt, therein lies the secret to Walter’s success. once upon A time, there wAs A young mAn nAmed wAlter…

When Walter J. Somers and a few colleagues opened the first office in the Montreal region in 1952, they took the first steps on a new and unfamiliar path. the three mAjor phAses wof trAnsformAtion And growth: • Performance Walter J. Somers laid the company foundation during the 1950s and ‘60s.

Emphasizing ‘’total performance’’, Walter concentrated on bringing the best tools to Canada, the ones offering the best productivity - first by importing them from Europe, then developing and manufacturing their own brand throughout the years.

• Safety During the 1970s and ‘80s, Walter added another dimension to its company philosophy: work safety, for both its employees and its customers.

This idea provided the grounds to establish new objectives for product development: Walter must create products that would not only improve productivity, but improve health and safety in the workplace as well.

• Globalization and sustainable development The 1990s and 2000s witnessed an ambitious international expansion program which began in 1989, when Pierre Somers succeeded his father as director of the company. The Walter Company quickly made an impact in the South American and European markets, as illustrated by notable increases in sales and profitability. The first environmentally-

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friendly “green products” (branded as Bio-Circle Environmental Solutions) were also launched at this time, long before the phrase “sustainable development” found its way into popular business usage. reAdy for tomorrow, todAy Walter faithfully fosters its core corporate values. Increasing efficiency, accelerating cost reduction, and improving processes that favor the well-being of workers will drive all future technical innovations.

Sustainable development is more than a priority – it clearly is an integral part of the company’s DNA – and will continue to guide Research & Development in the coming years.

Walter’s new international headquarters and industrial center in Pointe-Claire, Quebec visually and in every sense exemplifies this. Built according to LEED standards, the complex is the ultimate expression of Walter’s commitment to sustainable development. This center was designed to follow the best engineering and management practices: optimized energy efficiency, ideal working conditions that favor the health and well-being of employees along with ultra-efficient logistics and warehouse systems. The new building serves as the world center for management and research. This is where Walter’s future will take shape – one innovation at a time.

innovAtion At the core of wAlter Innovation is at the heart of Walter’s business - it drives the introduction of truly ground-breaking products and services as well as enabling swift responses to market requirements.

Many Walter products are the fastest and most efficient in the market (Zipcut, Combo Zip, Coolcut XX, Enduro-Flex Turbo, Air Force, Bio-Rust, etc.) and are all designed to improve productivity and help Walter customers work better.

About wAlter Walter Surface Technologies a privately held company with its US headquarters in Windsor, Connecticut has been a leader in surface treatment technologies for 60 years, and has been providing high productivity abrasives, power tools, tooling, chemical tools and environmental solutions for the metal working industry. Founded in Montreal in 1952, Walter Surface Technologies is now established in 7 countries in North America, South America and Europe.

For additional information: www.walter.com

Quarter 1, 2012 — Industrial Machinery Digest

49

Metalworking news

Documenting a rebuilD Without documenting exactly what goes into a machine rebuild, what is the user paying for, and what is the rebuilder guaranteeing?

Say you’re shopping for a pre-owned Lexus. Being the car that it is, having everything in good working order is paramount. Checking the sticker, you see it’s “certified” to have met Lexus’ high quality standards.

Well, that’s fine, but how can you be sure without the right documentiaton?

The same thinking goes for a quality machine rebuild. It is for this reason that documentation, both written and visual, rules the day during any rebuilding process, says Sid LaMonica, president of Infinity Rebuild (www.infinityrebuild. com), the Exclusive Okuma Rebuilder based in Charlotte, N.C. “Without proper documentation, what is the rebuilder warranting?”

The Unload and Tear-down Documentation should start as soon as the truck hauling the machine pulls up to the rebuilder’s loading dock. Photos showing the machine on the truck itself record its condition upon arrival, detecting any damage due to shipment.

Next comes documentation of tear-down—removing the sheet metal, headstock, turrets, saddles, cross slides, ball screws, lubrication and hydraulic systems, electrical cabinets and the rest, until finally rebuilders reach the base casting. That casting and each element before it, says LaMonica, can be individually documented and photographed.

The pre-job inspection involves all mechanical and electrical machine elements. A rebuilder checks all axes for proper motion (on a four-axis machine, XA, XB, ZA, ZB), and document which functions work properly and which do not. What is the condition of the hydraulic unit, chiller unit, machine ways, sheet-metal covers, or the interlocking between manual and auto modes? Are push-buttons on the operator panel broken or missing? Do way covers need to be repaired? Is the spindle noisy, and what is the condition of the spindle gears?

The tear-down helps answer this and more, says LaMonica, and each element can be recorded, written and, for many elements, photographed.

The inspection creates a list of machine elements that require attention. Most usually are already included in a base rebuild scope-of-work. Those that aren’t can be grouped into one of three categories: make, buy or repair.

Part condition isn’t the only factor that determines whether to make, buy or repair an item (or do nothing). Delivery time weighs heavily into the decision.

“For example, we have the ability to reverse engineered parts,” LaMonica says.

Many elements of a machine could go in several categories, depending on need. Mounting brackets or gibs can often be made or purchased, as can labyrinths and spacers for spindles—either way would produce about the same quality, depending on the application requirements.

In making the make-buy-repair decision, the delivery, cost and application is considered. Regardless of the decision, the final choices should be welldocumented before the process begins. docUmenTing The rebUild Rebuilders aim to return the machine to OEM spec or better, which is impossible without taking accurate measurements before the process and documenting Before

After

Photos courtesy of Infinity Rebuild.

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Industrial Machinery Digest — Quarter 1, 2012

rebUild docUmenTaTion lisT

oK

#1. machine arrival photo gallery a) Photograph the machines four sides on the truck as it arrives b) Document any damaged during shipment (protect customer investment) c) Document any covers that... #2. electrical start-up checklist a) Document axis motor loads and spindle motor loads b) Document control communication and back-up memory c) Check Control for... #3. mechanical start-up checklist a) Document backlash on all axis ballscrews b) Document wear on all way surfaces c) Check hydraulic system for any... #4. machine functionality test a) Check headstock for rotation b) Check turrets for indexing and rotation c) Check machine options for... #5. document missing and damaged parts list a) Are any covers missing? b) Are the stainless covers damaged? c) Is the door glass... #6. Pre-teardown alignment checks a) Mount test bar in spindle check parrallel bed ways b) Document current axial, radial run-out of spindle c) Document turret alignments for..... #7. stock loss check sheet a) Document bed ways prior to regrind b) Document crosslide and saddle ways... #8. Final alignment specification sheet a) Check turret squareness b) Check axis repeatability c) Check final accuracy of... #9. Pre-shipment documentation a) Anti-rust all ways surfaces b) All machine documentation is in electrical cabinet c) All slide ways are... #10. Finish photo gallery a) Photos four sides of the complete machine b) Photo machine on truck c) Photo of machine....

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them, LaMonica explains. This includes measurements of the way surfaces prior to and after grinding, to reestablish center line (e.g., the height requirement for new turret liners determines where to return the tool exactly to its original position).

Beyond mechanical components, rebuilders may retrofit controls and electronics and send them to the OEMs themselves for recertification, he says— and, of course, provide documentation for it. docUmenTing reassembly LaMonica does say the most extensive documentation comes during tear-down.

Yet important elements remain to be documented during reassembly. This gives a comparison from the earlier photos and documentation taken showing what the machine had then versus what the machine has now. Pictures of the machine completely reassembled, sheet metal and all, complete the photo journal.

With the machine reassembled, next comes the geometric tolerance and alignment check to “demonstrate that the machine meets or exceeds the alignment specification for when the machine was new,” LaMonica explains. This includes putting a test bar in the spindle and positioning turrets back and forth along the axis travel to show the actual Z travel is within the allowed tolerance specification. Repeatability of all travels is checked (XA, ZA, XB, ZB, etc.), along with spindle axial and radial run-out. And each check is documented.

“People like to read and see exactly what is done to their machine,” says LaMonica, “and they can’t be here every day during the rebuild process.”

Complete written and visual documentation, he concludes, helps fill that need, assuring users do indeed get what they pay for.

For more information on this story, please contact Infinity Rebuild Inc.: 10721 John Price Road, Charlotte, NC 28273; Phone: 704-588-4995; Fax: 704-5885268; Web: www.infinityrebuild.com; Attn: Sid or Tony.

View more on page 57

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Metalworking news

W/Z Zero trAckinG MAintAins constAnt Zero, helps operAtors Avoid collisions MAG’s exclusive W/Z zero tracking feature maintains constant zero position between collinear axes, now available new or as retrofit to Siemens 840D controls on MAG horizontal boring mills and machining centers.

MAG IAS introduces exclusive W/Z zero tracking capability for its horizontal boring mills and HMCs with the Siemens 840D control, bringing a favorite operatorfriendly feature to machinists programming collinear axes. Previously available only on the NumeriPath 8000 control, W/Z zero tracking for up to three collinear axes can be retrofitted to existing MAG machines with 840D controls or added to new machines.

W/Z tracking accounts for changes in machine geometry when one of the axes in a collinear set is repositioned in the part program.

It electronically tracks each axis of the collinear set to calculate and maintain the correct part reference coordinate when one of the axes is repositioned. For example, the Z-axis reference point is typically the spindle gage line, while the W-axis reference point is a surface on the workpiece. After the W/Z relationship is established through part referencing, the control tracks all Z and W axis moves, displays their relationship, and moves one of the two axes to maintain the correct gap position.

W/Z tracking is especially useful when the machine operator modifies the part program at the CNC to account for interferences, better visual access to the cutting zone, etc.

W/Z Tracking is available on MAG horizontal machines, including floor-type (FT/FTR series) and table-type (RT, PT and MC series) boring mills.

About MAG MAG is a leading machine tool and systems company serving the durable goods industry worldwide with complete manufacturing solutions for metal cutting and composites applications. With a strong foundation based upon renowned brands such as Boehringer, Cincinnati, Cross & Trecker, Ex-Cell-O, Fadal, Forest Liné, Giddings & Lewis, Hessapp, Honsberg, Hüller Hille, Lamb, Modul and Witzig & Frank, MAG is recognized as the preeminent provider of tailored production solutions based on state-of-the-art technology.

Key industrial markets served include aerospace, automotive and truck, heavy

equipment, oil and gas, rail, solar energy, wind turbine production and general machining.

With manufacturing and support operations strategically located worldwide, MAG offers comprehensive lines of equipment and technologies including turning, milling, hobbing, grinding, honing, systems integration, composites processing, maintenance, automation and software, tooling and fluids, and core components.

For more information about MAG, please visit: www.mag-ias.com

keeping your equipment running Repair Parts, Inc. has been in the business of selling new, used and reconditioned parts and service for Sundstrand lathes, mills and Omnimils, as well as Barber Colman Hobbing, Shaping, and Hob Sharpening machines, Van Norman Milling machines, and Atlantic Jig Bore for over 20 years. We also sell used and reconditioned machines.

Most of the machines can be seen under power in our 83,000 square foot facility.

Repair Parts, Inc. is most proud of its reputation as a quality supplier to users of these machines, parts, and service. Repair Parts, Inc. employ’s personnel factory trained on the equipment that they deal in and prides itself on being able to help it’s customers resolve any difficulties they experience with the equipment they specialize in.

They carry in stock a large variety of the equipment of all of these manufacturers and offer machines anywhere from “as-is” condition to complete turn-key packages setup and qualified for the customer’s parts as well as training on the proper use of the equipment.

Repair Parts, Inc. is the OEM supplier of parts and

accessories for the Van Norman Milling Machines and the Atlantic Jig Bore and while not currently manufacturing machines supplies parts for the complete line. Repair Parts, Inc. is the U.S. distributor for parts and service on the Manhurin Swiss Screw type machines.

Repair Parts is also interested in purchasing your excess equipment, including machines, tooling, hobs, shaper cutters, and other accessories -- just fax or e-mail your list.

complete machines and parts for: Sundstrand Automatic Lathes, Sundstrand RigidMils, Sundstrand Omnimils, Van Norman Milling Machines, Atlantic Jig Bores, Manurhin Swiss Type Screw Machines, Barber-Colman Hobbing Machines, Barber-Colman Hob Sharpening Machines

View more on page 61

repair parts, inc.

Machine Tool RepaiR paRTs

For more information, please contact Repair Parts, Inc.: 2415 Kishwaukee St., Rockford, IL 61104 • Phone: 815-968-4499 • rpi@repair-parts-inc.com • www.repair-parts-inc.com

52

Industrial Machinery Digest — Quarter 1, 2012

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Tormach PCNC Mills Looking to fulfill your need for an additional piece of equipment without blowing your budget? With unprecedented affordability and high quality, a new Tormach PCNC 1100 Series 3 is the best value in the CNC market.

$8480 (plus shipping)

Tormach PCNC mills are perfect for small shops, custom manufacturing, hobbyists and R&D. But they aren’t just for the little guys...

Don’t let a dirty job like electrode machining take time and life out of your equipment - a PCNC can do the same job at a fraction of the cost.

Or set up a PCNC for secondary operations like CNC drilling to free up your other machines for increased productivity.

Sure, you could buy used, but why? With a rock-bottom cost of ownership and no-cost tech support by email or phone, a PCNC mill is an easy choice and avoids the hidden pitfalls of used equipment.

Every PCNC 1100 Series 3 features: • Table size 34” x 9.5” • R8 Spindle 1.5 hp variable speed 5000 RPM and 90 IPM axes motion • Computer controlled spindle speed and direction • Standard G code compatibility • Composition bonded slideways (similar to Turcite®) When compared to the risk and headaches of used equipment, the decision is easy.

Product information and online ordering at

The Tormach PCNC 1100 offers professional grade accessories like quick change tooling and optional Automatic Tool Changer.

Shown here with optional stand, LCD monitor, machine arms, 4th axis, and accessories.

www.tormach.com

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Quarter 1, 2012 — Industrial Machinery1/16/2012 Digest 1:14:22 PM 53

productivity profile

Transfixed

by The flame The Wonder of EDM Meets the Magic of ESPRIT CAM at the Maroney Company

By Stacey Wiebe and Ann Mazakas

It’s without the tell-tale Bunsen burners and beakers spouting frothy, mysterious liquids, but make no mistake: Maroney Company is a place where real science happens.

It just happens to be the science of machining.

Here, not-so-mad scientists push the envelope on tough jobs that no one else can or will do.

“We specialize in the complex machining of materials that are hard to machine,” says John Cameron “J.C.” Maroney, president and general manager of the 56-year-old business that bears his family name.

If you ask J.C., whose face pays imitative tribute to that of his father, John Maroney (as well as a passing resemblance to classic rocker Don Henley), he’ll tell you it’s the pioneering spirit of the company — and the brainiacs at work within it — that makes the house a success.

“We have an aggressive philosophy of maintaining the most modern workplace with the most talented workers,” he says from behind his desk. “A deep foundation built on this philosophy allows us to do things other people can’t.”

One of the things that the Northridge, Calif.-based company does is make precision wire and sinker EDM components for the defense, aerospace and medical industries. Though the custom house specializes in prototype and development work, it performs some assembly and production, as well.

Fig. 2: Ed Valadez, Maroney’s resident mad scientist and EDM supervisor, hard at work in his machining laboratory.

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Industrial Machinery Digest — Quarter 1, 2012

Fig. 1: The transfixing flame of a turn-and-burn EDM operation in ESPRIT on the shop floor of the Maroney Company.

Success at Maroney, as its founders will tell you, started early on.

The “one-man, one-machine” shop that began with John Maroney in 1955 was selected by now-defunct-company TRW, Inc., as the “sole supplier for E-ring and valve assemblies” for the LEM descent engine that went to the moon on Apollo 11.

It was this major coup that cemented the company’s reputation for delivering precision components.

“We have a passion for the application — for the diversified and the unique,” J.C. Maroney says.

It was the diversified and unique, in fact, that inspired the brains behind the precision parts to go right up to the cutting edge of EDM machining.

The company, which has programmed with ESPRIT® computeraided-manufacturing (CAM) software, by DP Technology, for nearly 30 years, used the software for its basic programming needs and for the kind of wire EDM maneuvers that make the shop one-of-a-kind. Maroney was, in fact, one of DP Technology’s very first customers.

In the way of groundbreaking behavior, the guys in the shop put on their thinking caps to take on non-traditional EDM machining long before it officially existed.

It was nigh on a decade ago that Maroney, with the aid of ESPRIT, began performing “spin-and-burn” EDM machining. In a nutshell, spin-and-burn EDM allows the work-piece to spin around the rotary axis while the wire cuts a 2-axis profile.

Each machine in Maroney’s shop, including the sinker EDMs, is armed with a servo-controlled rotary table or indexer of one variety or another.

But let’s press the pause button here to talk about why this trait sets Maroney apart — starting with the basics of traditional wire EDM machining: Traditional wire EDM machines have what’s called an X-Y-UV-Z control. With this configuration, the X and Y axes relate to the movement of the lower head in the X and Y directions, while the U and V axes relate to the movement of the upper head in the U and V directions.

Finally, the Z-axis moves the upper head up or down before X-Y-U-V movement starts. With standard wire EDM cutting, the

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Fig. 3 and Fig. 4: Parts, parts and more parts: Maroney Company is in the business of delivering the goods.

part is held stationary while the upper and lower heads move the wire as it erodes the material.

Wire EDM machining is widely used in the medical, aerospace, and injection-mold industries to produce parts in complex shapes that cannot be achieved with traditional cutting tools.

Hence its significance at the Maroney Company.

With rotational, or non-traditional, EDM, submersible rotary tables for wire EDM allow the programming of continuous variable high-speed rotation and indexing. Instead of clamping a part to the work table, it is held in a chuck mounted on a rotary table.

The rotary table then allows for the rotation and cutting of the part without the need to unclamp and reposition the part between cutting operations.

But Ed Valadez, Maroney’s resident mad scientist and EDM supervisor, is no stranger to these emerging EDM concepts.

A non-stop wellspring of machining information, Valadez, who has been with Maroney for six years, explains the intricacies of his world in the kind of matter-of-fact shop-talk that’s only matter-offact if you’re smart enough to understand what he’s saying.

In short, the man knows what he’s doing — and he figured out how to program Maroney’s wire EDM machines to work rotational wonders before there was software that could do it for him.

ESPRIT is now equipped with the ability to program spin-andburn, turn-and-burn and turn-while-burn operations, and to create profiles and index automatically. With indexed EDM, or turnand-burn, the rotary axis is used for positioning between each machining cycle. With turn-while-burn, or synchronized EDM, the work piece is rotated during the burn.

While Maroney was performing spin-and-burn wonders long before its peers, it also had a six-year jump on turn-and-burn operations. With the addition of the new operations in ESPRIT, however, the indexing for Valadez is now done automatically.

“In the past, we would create a profile, manually index, and then create another profile,” Valadez says. “The software is enabling us to get jobs that we couldn’t do in the past and to do our current jobs faster and with less handling. ESPRIT makes us look good — and is enabling us to go to another level.”

So, just what is that next level?

Well, for Maroney, it’s being able to more quickly and easily program multi-axis machines, in part due to the feature recognition capabilities within ESPRIT — which allow programmers to automatically capture manufacturing shapes specific to any given part. The software’s ability to recognize those features saves time programming complex parts, and time is, of course, money.

It’s no secret that jobs become more demanding as tolerances

tighten and parts grow more complex, so maximizing CAM that can maximize machine tools is part of staying ahead of the game.

“Tolerances are always more demanding, parts are getting smaller and materials are becoming more exotic and harder to cut by conventional means,” Valadez says.

Not surprisingly, advancements in wire EDM programming — and machining technology in general — influence the types of parts that can be made and the methods by which they can be machined. “We can educate our customers and the engineers to design better components around the technology,” Valadez says.

“ESPRIT has allowed us to do that.”

Also upping the complexity quotient is the habit of many customers to supply solid models as opposed to the prints, wireframe and surface models supplied in the past.

The ability to seamlessly import a solid model into ESPRIT is an element that makes the software’s ease of use a valuable component, Valadez says.

Ever the scientists, Valadez and his crew have always looked and will continue to find the means of maximizing the tools at their disposal.

“The bottom line with us is trial and error,” he says. “There isn’t a job in here that I don’t ask, ‘What happens if you double the feed rate?’ It all comes down to time.”

And if time is money, so are materials.

Among the range of materials machined at Maroney are rhenium, inconel, titanium, hastelloy, waspaloy and carbides.

When machining a material such as rhenium, which runs a whopping $3,500 to $5,000 a pound, saving as much material as possible is a critical move.

Since the material used for EDM turning operations is typically expensive, the initial roughing operation in ESPRIT is designed to remove the stock material in pieces large enough to allow for the easy recovery and recycling of unused material.

The rough turning operation uses multiple indexing moves to remove as much material as possible with each rough pass while also balancing the index moves for optimal performance and material recovery.

“By coupling turn-and-burn with spinning EDM, we’re able to save 50 percent of the material,” Valadez says, adding that, when that material is rhenium, that savings is up to $2,500 a pound.

But for Valadez, who remains “transfixed by the flame” of the EDM after years on the shop floor, the magic of his machining science never ends.

“I never get tired of watching it,” he says, heading back to the shop floor. It’s there that he will be on to the next big thing, on to the next great discovery.

For further information, contact DP Technology Corp., 1150 Avenida Acaso, Camarillo, California 93012. Telephone: 805-388-6000, Fax: 805-388-3085.

E-mail: esprit@dptechnology.com, Website: www.dptechnology.com

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Quarter 1, 2012 — Industrial Machinery Digest

55

Metalworking news

introducing the york 4-14 hd

bridgeport milling machine shields

With up to 351ft. lbs. of torque at the bar and a feed motor that delivers 30 ft. lbs. of torque, heavy cuts are made easy. York has two options available to suit every users need, the manual control machine with a 5hp hydraulic power unit and the remote control machine with a 10hp hydraulic power unit.

Let one of our factory trained field representative show you more of the features that will save you time and make you more money!

Rockford Systems, Inc. has specially designed, qualityconstructed chip shields ideal for Bridgeport milling machines.

These shields place a barrier between flying chips (swarf), sparks, coolant from the machine, and the operators or other employees in the area.

They can be easily moved in or out of position to provide quick tool and part changes.

These Bridgeport milling machine shields are constructed of high impactresistant, transparent polycarbonate material. Attached at the bottom of each section of the shield is durable, flexible neoprene material to keep flying chips and swarf contained as the bed moves up and down.

These shields are quick and easy to install. They attach directly to existing head machine bolts so no additional drilling or tapping is required. Both front and rear shields are available.

For more information, please contact York Portable Machine Tools: 1-888-783-YORK (9675), sales@yorkmachine.com, www.yorkmachine.com

For more information, contact Rockford Systems, Inc.: PO Box 5525, Rockford, IL 61125 • Phone: 1-800-922-7533 sales@rockfordsystems.com • www.rockfordsystems.com

View more on page 53

ras machine tool technologies, inc.

RAS Machine Tool Technologies was established in 1997

by Richard and Susan Staples. Richard had, by 1997, 12 years experience working for Matsuura and Kuraki distributors in the USA. RAS began as a machine repair service and an aftermarket importer and reseller of Japanese CNC replacement parts and accessories. They have since expanded to include Taiwanese and Korean brands as well, and added several full and part time employees to help maintain their high standard of service to their growing list of customers.

RAS customers for sales and service include machine shops, large

manufacturers, repair services, other distributors and machine tool OEMs. RAS service is local, and sales are worldwide.

RAS Machine Tool Technologies is the Metrol Co. Ltd. North American distributor, the Daikin Northeast stocking distributor, the Azbil North America’s (Yamatake) Northeast distributor, the Jarrer Co. Ltd. North American distributor, the Habor Precise Industry’s East Coast distributor, and the Tokyo Keiki/Tokimec distributor. RAS also receives distribution pricing from Yuken, Takigen, Igus, Graymills, Orion Fans, Future Life Technology, Inc. and many other manufacturers.

RAS carries a full line of bearings and machine tool accessories to meet your needs.

Introduces

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For more information, please contact RAS Machine Tool Technologies, Inc.: 30 Business Technology Drive, Belchertown, MA 01007 Phone: 413-323-9041 • Fax: 413-323-9595 • sales@rasmachinetool.com • www.rasmachinetool.com

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Industrial Machinery Digest — Quarter 1, 2012

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Quarter 1, 2012 — Industrial Machinery Digest

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Metalworking news

CML USA, InC. ErCoLInA AnnoUnCES KrIS HErbSt AS InSIdE SALES MAnAgEr CML USA, Inc., manufacturer of tube, pipe and profile bending and metalworking machinery, has appointed Kris Herbst to the position of Inside Sales Manager.

Kris holds a M.A. degree from Western Illinois University in Macomb, IL and a B.A. degree from Augustana College in Rock Island, IL. She has spent the past 9 years helping to establish Ercolina as one of the largest and most respected manufacturers of tube and pipe benders and metal fabricating machines in the world.

As Inside Sales Manager, Kris will be responsible for overseeing customer service, sales, delivery times and warranty issues. She will innovate and improve the sales process and promote Ercolina brand recognition. Kris is available to offer positive application solutions for your bending and fabricating needs.

Contact CML USA, Inc. today to discuss your next bending application, request a catalog, speak with your regional Ercolina representative or arrange a demonstration of Ercolina products.

For more information, please contact CML USA: 3100 Research Parkway, Davenport, IA 52806 Phone: 563-391-7700, Fax: 563-391-7710 Email: info@ercolina-usa.com, Website: www.ercolina-usa.com NC and CNC mandrel website: www.ercolinacnc.com.

Tormach announces new auTomaTic Tool changer for Pcnc 1100 cnc mill Tormach has announced the release of the Tormach Tooling System® Automatic Tool Changer (ATC), for use with Tormach PCNC 1100 CNC mills. The 10 tool carousel-style TTS tool changer expands Tormach’s mission in providing professional designs for CNC at affordable prices for prototyping, smallscale manufacturing, education, and hobby needs.

The ATC design features a retractable carousel cover for chip protection, an automated air-blast to clear chips from the tool taper and a double-acting pneumatic cylinder to slide the carousel into place. In addition, the ATC boasts capability for multiple virtual tool trays that can be stored in the control software, reducing setup time by assigning each project to a new tray and eliminating the need to retouch tools after the initial setup.

Features Include: • 10 position tool tray • Slide activation via double acting pneumatic cylinder with cushion • Mach3 control software with graphical screen set • Air blast • Virtual tool trays for multi-job setup • Integrated touch-off routine (requires electronic tool setter) • Swappable and configurable tool designations. Any tool number can be assigned to any slot and requires no program change • Carousel position feedback • Automatic crash detection and warning

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Industrial Machinery Digest — Quarter 1, 2012

about tormach The people at Tormach are dedicated to delivering tools, accessories, and components of unprecedented value in the world of CNC and motion control. Whether you are involved in R&D, education, short-run production, or simply entrepreneurs with new ideas, Tormach products allow you to make what you need easier, quicker, and more affordable.

Tormach is headquartered in Waunakee, Wisconsin. For more information about ‘personal CNC’ mills and accessories, please visit www.tormach.com or contact Tormach directly at info@tormach.com View more on page 53

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Metalworking news

Why Combination SanderS don’t Spark our intereSt So What’s The Difference?

Every tradeshow that Burr King does we are asked for a combination belt sander and disc sander. Several times a day we get asked this question when we work a tradeshow. The simple solution may be for Burr King to produce a combination unit, but the real answer may better help you understand why Burr King has elected to not have a similar machine in their product line.

So what is the difference? Everyone is selling a combination unit, why doesn’t Burr King?

There are three things that are important in selecting the proper machine for your application: (1) Belt Speed, (2) Horse Power, and (3) The ability to apply force. If you take away any one of these three things you are no longer grinding, you are sanding.

1. Belt Speed The combination belt and disc sanders are just that, they are sanders.

And one difference between a belt sander and a belt grinder is speed.

A “sander” is not well suited for metal applications. Most often the combination unit runs only a few thousand surface feet per minute.

A grinder will run upwards of 8,000 surface feet per minute. Abrasive manufactures like 3M and Norton understand this and are constantly engineering belts that perform to their full potential at the higher S.F.P.M. There are several factors why the combination units don’t operate their belts at the proper speed.

A. For a belt to run at the proper speed for grinding you need to have a motor and spindle speed that will exceed 3,500 rpm. If you try to turn a disc at anywhere near this speed, you have created a machine that far exceeds a safe recommended rpm. So the solution is to place a 1725 rpm or slower motor on the machine to allow the user to safely use the disc. Doing this makes the belt S.F.P.M. less then optimal.

B. Poor quality construction of the major components of the sanders produces vibration when a combination unit runs at higher rpm. Burr King’s contact wheels are balance and machined out of heat treated billet aluminum. Most combination units don’t even offer a contact wheel.

2. HorSe power The combination units also typically feature a smaller horsepower motor. You already know that horsepower is one of the functions to effectively remove material. Manufactures of combination units often use low quality motors that do not have sufficient horsepower.

These motors are inexpensive and use lesser quality components and produce less torque. For this reason Burr King uses high quality industrial grade motors from manufactures like Baldor and Leeson.

3. tHe ABility to Apply force Grinding or sanding against a hard platen is great if you need to square an edge, but grinding against a rubber contact wheel, is something Burr King calls the “Velvet Touch.” Grinding against a platen requires even more horsepower since you are pinching the belt between the platen and the work piece. There are several different contact wheel options that are available for a Burr King grinder, choose a soft wheel for delicate grinding or polishing, or a hard serrated contact wheel that will remove metal quickly producing less heat. Grinding against the contact wheel also allows the operator to apply more pressure to remove material. A platen will produce chatter and affect the overall quality. And if you are using a combination sander as soon as you touch a sharp surface to the belt working against the platen and apply force, you run the risk of tearing the belt. This too is a function of speed. When your abrasive belt runs at the proper speed you reduce the risk of damage to the belt and yourself.

Safety is another factor when choosing your machine. The combination units need to be guarded in such a way that if someone is using the belt the disc is covered completely and vise-versa. Units that are produced with similar guarding are often modified to defeat the safety intent. Doing this in an industrial environment may lead to fines and injury.

There are many reasons that Burr King does not produce a combination unit. We have only outlined a few of the reasons. Burr King offers disc grinders and belt grinders, the combination units we will leave for others that are less concerned with the overall quality of their machines.

ABout Burr King MAnufActuring: Founded in 1951, Burr King Manufacturing provides industrial grade machines, intended for use on metals, woods, composites, plastic, rubber, stone, fiberglass and other materials. Burr King’s headquarters are located in Warsaw, MO. View more on page 51

For more information, please contact Burr King Manufacturing Co., Inc.: 1220 Tamara Lane, Warsaw, MO 65350 • 800-621-2748 • info@burrking.com • www.burrking.com

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Quarter 1, 2012 — Industrial Machinery Digest

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Metalworking news

Florida Job Shop NearS 100 perceNt MachiNe UptiMe At its general industry job shop in Odessa, Florida, Alan Manufacturing Inc., now part of Model Screw Products, has been serving a variety of the local manufacturers with quality components since this production CNC turning shop opened in 1976. These components include parts used in the production of high-accuracy flow instruments, high-pressure hydraulic gear, surgical equipment, marine engines and military ordnance. The shop machines various bar stock using various machine tools to perform turning, threading, boring, drilling, crossdrilling and milling. Post-heat treat operations are also performed in this shop, including grinding, honing and hard machining to 0.000050” roundness, as required by Alan Manufacturing’s demanding customers.

While this might seem like any normal shop, what’s unique here is that the two operators, Al Feldman and Geoff Giner, both trained in G-code programming basics, are consistently achieving nearly 100 percent machine utilization, with the exceptions of cycle, workpiece and insert changes.

“We’ve targeted a customer product range and a production strategy that allow us to utilize the machine tools we have in-house in the most efficient manner,” says Al Feldman “For example, we can use a 1/16 groove tool for almost every job, performing single or multiple cuts. The set-ups are a lot easier and with a fresh insert each time, we’re ready to go.”

At Alan Manufacturing, the machine tools currently in use include a Landis grinder, Sunnen honing machine, Hardinge machining center for hard machining, plus the main workhorses,

The Lico turning center has three independent slides, separate from the turret, with a back spindle and can run up to four live tools.

as Feldman calls them, an Emco Maier 332MC turning center and the newest acquisition, a Lico LNT 36 turning center with three independent slides, separate from the turret, with a back spindle, so up to four live tools can be utilized simultaneously. The Lico machine runs its main and back spindles simultaneously, with full OD/ ID machining and an 8-position toolchanger.

Both the Emco Maier and Lico machines have Siemens SINUMERIK 840D CNCs onboard, which, according to Feldman, is a key factor for the shop’s efficiency,.

“We bought the Emco machine about 3-1/2 years ago and the Lico machine in early 2006.

Our first impression, lacking statistical data, was that the Siemens-controlled equipment seemed to run continually. Now, with over three years of production data to document the facts, I can say without reservation that our net production rates are approaching 100 percent on most jobs, stopping only to change inserts.” He adds that set-up data is easily captured for each job, as the data are downloaded via RS232 serial communication from the machine controls to the host computer for statistical analysis. “Further, with the large storage capacity on the CNC, all the jobs run can be stored for immediate recall, though each program is also backed up offline on the company’s computers.”

When programming a job, Feldman observes, “It’s a piece of cake. We can do it directly on the machine, using a customersupplied print or DXF file. The control has straightforward capabilities for cut, copy and paste. Plus, there are many helpful sub-routines and self-help graphics for threading, turning, boring and grooving. Almost every aspect of the cycle is accomplished on the machine control while the previous job is still running.”

The shop has been able to duplicate programs between the Emco Maier and Lico machines, so that it can run up to 75 percent of its jobs on either machine. The multi-channel controls are the same, as are the motors and drive packages. On the Lico machine, a custom, but transparent, front end to the Siemens CNC was developed by the machine builder. Feldman credits Jimmy Cheng, a Lico engineer from the factory in Taiwan, for getting the machine into action quickly at Alan Manufacturing. Working with its local dealer, this Lico engineer spent four days at the shop, helping the operators learn the system specifics.

Operator Geoff Giner at the Lico turning center.

Additionally, Feldman notes that both the machine builders and Siemens have been very responsive on service, whether the issue involves machine maintenance or programming issues. “With our CNC supplier, the ball starts rolling within minutes after any call or e-mail to the support center,” Feldman says. “Without fail, they stay with us until the issue is resolved and we’re satisfied.”

Alan Manufacturing typically machines 1141 and naval brass, 12L14, an extremely fast machining steel bar stock, 316 and 303 stainless, plus 6061 aluminum. Production output ranges from 5,000-10,000 pieces annually on most jobs.

According to Feldman, the near 100 percent machine efficiency, coupled with the large number of jobs stored on the machining centers and diversity of customers currently served, makes the future outlook for this company as secure as is possible in the present market conditions.

Alan Manufacturing produces high-accuracy components used for flowmeters, marine, surgical and military applications.

View more on page 47

For more information on Lico, please contact: Phone: 1-800-364-1641, Fax: 310-329-6073, sales@lipoco.com, www.lipoco.com For more information on Model Screw Products, please contact: Phone: 727-443-5764, Fax: 727-442-8423, sales@modelscrewproducts.com For more information on Siemens Energy & Automation Machine Tool Business, please contact: Phone: 847-640-1595, www.SiemensCNC.com

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Industrial Machinery Digest — Quarter 1, 2012

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Quarter 1, 2012 — Industrial Machinery Digest

61

productivity profile

Tool ManageMenT SySTeM ProvideS efficiencieS, Mfg. coST reducTion aT rouSh Inventory management made easy by Guhring Managing inventory and reducing costs within the manufacturing environment is the goal of any effective tool management system. The automotive racing specialist and product development company Roush has been working with their local distributor, Bennett Tooling Solutions to implement a tool management system at their manufacturing facility in Livonia, MI. Using Guhring’s tool vending machines and tool management software has led to increased efficiencies and reductions in manufacturing costs.

For over 30 years, Roush has provided precision machined parts to the racing industry. Using a wide variety of CNC machining centers, EDM and laser cutting machines, Roush manufactures short run, precision prototype parts using a wide array of tooling. Controlling tooling costs and managing inventory is always a challenge in a job shop environment and Bennett Tooling Solutions has joined with Roush to help improve their tool management systems. Working with Guhring’s Tool Management specialists, Bennett Tooling Solutions installed three vending units on the shop floor and implemented a tool management software package that allows operators to dispense tooling as needed throughout the shop.

Using Guhring’s Eco vending machine unit in conjunction with two slave units, Bennett Tooling Solutions was able to decentralize the tooling crib and move the higher consumption items closer

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to the manufacturing cells. In addition, using Guhring’s Tool Management Software, Bennett Tooling Solutions is able to remotely track consumption and manage inventory electronically. The tool management software provides automatic order processing, continuous reporting on all tool movement data, and reduced storage and administrative costs. Bennett Tooling Solutions replenishes the vending cabinets 2 to 3 times per week using the data from the tool management system.

In addition, Guhring installed additional software on 5 external PCs in order to manage inventory from the desks of the design engineers. This allows the engineers to look at real time tooling data when processing parts, and to choose tooling that is in stock, reducing new tooling lead times. Roush is also able to manage the inventory in the master tool crib itself via the tool management software in their TM Vending system.

Industrial Machinery Digest — Quarter 1, 2012

Guhring provides custom built and stocked vending machines to suit our customer’s needs. The six drawer Eco Unit used at Roush is designed specifically for carbide insert packages while the two 12 drawer slave units dispense a variety of round shank tools such as drills, taps and end mills. The installation and training for the units was one week and it has been a six month process to convert some 3,500 SKUs into the tool management software of which approximately 2,500 SKUs are stored in the vending units.

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DO YOU WANT TO BE PART OF THE SOLUTION? THE PROBLEMS FACING U.S. SMALL MANUFACTURING ARE NOT JUST IN ONE SECTOR OR IN ONE REGION OF THE COUNTRY. OWNERS AND MANAGERS IN ALL THE U.S. MUST WORK TOGETHER TO SOLVE THEIR COMMON PROBLEMS: — Do you need skilled workers to fill your needs now and in the near future?

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JOIN THE NATIONAL TOOLING AND MACHINING ASSOCIATION TODAY AND START GETTING THE HELP YOU NEED. SINCE 1943, THE NTMA HAS BEEN LEADING THE WAY HELPING MEMBERS TO SOLVE COMMON PROBLEMS AND GET MORE OUT OF THEIR BUSINESS.

Contact us today by going to www.ntma.org and filling out an online application.

MANUFACTURING AMERICA’S FUTURE

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Quarter 1, 2012 — Industrial Machinery Digest

63

contract manufacturing news

gearing up for process improvement

by Lee V. Mason

At age 57, many entities, (persons or institutions), begin the often predictable process of slowing down, disinvesting or retiring. Clarke Gear Co., a small, precision gear business in North Hollywood CA, has instead continued an upward trend of improving capabilities by setting its sites on achieving aerospace QMS 9100 Rev C certification in record time. As an aerospace gear supplier since 1954, and compliant to AS9100 since 2000, Clarke had not gone through the rigorous third-party audit process until 2011.

In the spring of 2011, the company’s management was endeavoring to upgrade many aspects of the production and documentation systems in order to correct internal audit findings.

The 2010 year end ‘internal audit’ had been carried out by a consultant whom the firm had engaged for over a decade. The phrase ’everything old is new again’ came to mind as déjà vu acronyms reappeared: OTD, ASL, QMS, VOC, PLM, CIP, MDM. Clarke’s team even developed a few of their own: TIP, PAR, and QII. OTD: On-Time Delivery (customer focused) ASL: Approved Supplier List(s) (vendor focused) QMS: Quality Management System (international standard-based) VOC: Voice of the customer (customer focused) PLM: Product lifecycle management (product focused) CIP: Continuous Improvement Process (could mean anything) MDM: Master Data Mining (data driven initiatives) TIP: Total Improvement Process (Clarke’s overall program focus) PAR: Parts Activity Reporting (operator productivity) PEAR: Process Effectiveness Assessment Reporting (AS9100C) QII: Quality Improvement Initiatives (catch-all term) ROI: Return on Investment (bottom-line driven) How could these competing initiatives be presented to employees in an understandable context? Where was a small firm to begin in meeting the same QMS requirements as its global customers? A 90 day timeline was established and by mid-June 2011, the firm had not only completed the entire Rev C process but had passed its first third-party audit with minimal findings.

Everyone on the shop floor and in management was deeply involved in the process through identification of ‘need’ areas, risk assessment

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Industrial Machinery Digest — Quarter 1, 2012

training, Kaizen events and a commitment to Clarke’s long – standing reputation of customer-driven processes.

With meetings and training sessions held several times a week, the path became clear. Selection of a CB (certifying body) and target audit dates were set. Resources were allocated and the ‘team’ concept began. Saturdays and overtime ‘Kaizen’ events were held with colored team shirts, prizes being awarded and feedback sessions scheduled. The Kaizen concept was new to Clarke despite lean principles and training being presented annually. This time it was different: the employee teams scored each other. 5 teams of 2 persons (who normally do not work together) were given unique colored shirts and an area to ‘Kaizen’, normally a noun meaning “Continuous Improvement” but which quickly became a verb inside Clarke meaning ‘Sort, Sweep, Scrub, Sustain’.

Each team ended up with four scores from the other teams, based on the ‘S’ criteria. The team with the highest composite score won the large first prize and each team ended up with some level of prize. Feedback sessions were held in conjunction with Risk Assessment training.

The main result was that long-lost items were found and the employees got to know one another’s skills better.

Management continued to work on reconciling the extensive requirements of maintaining improvements with internal assets, finding that the extra hours and resources required paid greater dividends than anticipated. The work force has a new vocabulary and employee meetings have revealed a continuing process of mature employees learning new concepts and applying them to documentation and ‘product realization’ tools already in place.

After discussions with the QA consultant, Clarke arranged for a summer intern from MIT, an engineering student whose eyes were opened to the intricacies of manufacturing in the US while assisting in implementing Discus AS9102 software, reviewing tool calibration and initiating a Coefficient of Efficiency model for Clarke’s shop floor.

Going forward, the tasks of sustaining improvements, reconciling competing requirements of regulatory agencies, older employees, and increasing customer demands will be the challenge which Clarke is tackling with a continued ‘Team Clarke’ spirit.

More information on Clarke’s Rev C protocol may be obtained by emailing Lee Mason at worldclassgears@yahoo.com, or by visiting Clarke Gear’s website at clarkegear.com.

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Clarke Gear Co. 58 Years of Gears… One Gear at a Time!

Precision Gears for Aerospace and Commercial Applications • Complete Gear Manufacture • CNC Gear Hobbing • CNC Gear Shaping • CNC Gear Grinding • CNC Inspection & Analysis • CNC Machining • CNC Hob Sharpening • BAC Coolants • Splines • Serrations • Spur • Worms • Internal & External to 12" Dia.

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www.ClarkeGear.com Phone: 888-827-GEAR or 818-768-0690 • Fax: 818-767-5577 • clarkegear@earthlink.net

contract manufacturing news

high precision gear products for highly specialized projects Buffalo Gear has been serving the Industrial Community with gear manufacturing and other machining services for over 50 years.

The majority of Buffalo Gear’s customers are in the Continental United States, however they do also supply clients worldwide.

Customers include pump manufacturers and compressor manufacturers, machine builders, all-terrain vehicle companies, food and implement packaging plants, aerospace, the military as well as the marine trade, automotive parts distributors, and suppliers of the textile trades, among others. Buffalo Gear’s specialty lies in gear manufacturing including the production of spur gears, helical gears, worm gears and pinion gears. custom precision gears and commercial gearing: Buffalo gear specializes in hobbed and shaped gears. Gear manufacturing capabilities include: • internal and external gear cutting • cutting to standard, metric and to special specs available • vast hob and gear cutter inventory on hand • state of the art CNC Hobber enables Buffalo Gear to manufacture high quantities of very accurate precision gears Buffalo Gear also manufactures worm gears, clusters, sectors, sprockets to 1-1/2” C.P., shafts, pinion gears, knurling/crimping wheels, timing pulleys, and various other machined parts. cnc machining In order to manufacture high quality precision gear blanks for gears such as spur gears, helical gears, worm gears and pinion gears as well as non-gear related cnc machined products, Buffalo Gear offers an In-House state of the art cnc turning facility with bar-feed capabilities. Also, In-House CNC milling with 4th Axis capability.

Bar-feeding on this machining equipment is ideal for high quality production runs, which allows them to offer you competitive pricing along with a precision machined product.

far beyond standard gear manufacturing: • internal and external gearing • shaping up to 18” O.D. • hobbing up to 40” O.D. • spur Gears / Helical Gears • worms & worm gears • splines / shafts • sprockets to 1-1/2" C.P. • clusters • timing pulleys • sectors • ring gears • pinion gears • CNC gear hobbing • CNC turning • CNC milling • broaching • key seating • precision honing • thread grinding • O.D. & I.D. grinding • gear tooth flame hardening • standard / metric / special • climate controlled inspection facilities id honing High precision Sunnen manual hones and High Speed Automatic hones provide precision bores with repeatable accuracy; prototype to production. broaching and Keyseating Broaching and keyseating are used in creating the keyways inside of a gear. By offering both gear manufacturing operations, Buffalo Gear is able to select the best method for an individual production run.

Hydraulic pull style broaching is used for short runs and production. Buffalo Gear has many standard keyway broaches in stock. Internal splines: hex, square and various irregular shapes can be produced with this method.

Keyseating for larger keyways is also available.

machining capabilities Buffalo Gear’s machining capabilities extend

custom pacKaging Buffalo Gear is proud of (y)our machined parts, and takes great care in their packaging. In using an Ampak shrinkwrap machine to package many products, Buffalo Gear has the ability to provide customers with machined product that not only maintains its integrity during shipping, but can be used to safely inventory their parts.

They can also package assemblies to initiate ease in receiving and distribution. climate controlled gear inspection A climate controlled Gear Inspection Facility is a vital part of Quality Control. It is essential for gauging accuracy needed to maintain and assure quality for CNC machined parts. Buffalo Gear’s facility also provides a clean environment for Certified Gear Testing equipment used to chart gears. They are capable of identifying gear forms using reverse engineering through the use of gear testing equipment and computer generated gear programs. stocKing program By taking advantage of Buffalo Gear’s stocking program, you can be assured to have needed parts on hand.

• machined parts stocking programs can keep customer’s costs lower • machined parts can be pre-packaged or binned to provide fast shipping when released • program can be customized to fit your requirements In manufacturing larger quantities and stocking machined parts, customers realize the price savings. Reducing machining set-ups and taking advantage of quantity material costs result in having stock ready for shipment on short notice, easing purchasing projection for customers who place annual blanket orders.

This can give Buffalo Gear and the customer the competitive edge needed in today’s market.

1962

50 years!

2012

For more information, please contact Buffalo Gear Inc.: 3635 Lockport Rd., Sanborn, NY 14132-9704 • Phone: 716-731-2100 • Toll-Free: 1-888-BUFF-GEAR (283-3423) Fax: 716-731-2553 • Email: info@BuffaloGear.com • Web: www.BuffaloGear.com

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Industrial Machinery Digest — Quarter 1, 2012

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PRECISION and COMMERCIAL 3D.P. - 120D.P. - 1” to 40” DIA.

MANUFACTURED TO YOUR SPECIFICATIONS! Complete Machining, ALL MATERIALS ANY QUANTITY Inspection Facilities, Custom Packaging, Prompt Quotations

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Stocking Program Available

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• C.N.C. TURNING • C.N.C. MILLING • C.N.C. O.D. GRINDING • BROACHING • KEY SEATING • THREAD GRINDING • GEAR TOOTH FLAME HARDENING • CLIMATE CONTROLLED INSPECTION FACILITIES

• RING GEARS 1962

50

2012

years!

✴ STANDARD ✴ METRIC ✴ SPECIAL

BUFFALO GEAR INC. 3635 LOCKPORT RD. - SANBORN, NY 14132-9704 (716)731-2100 Toll-free: 1-888-BUFF-GEAR • Email: info@BuffaloGear.com • Web: www.BuffaloGear.com 1-888-283-3432

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Quarter 1, 2012 — Industrial Machinery Digest

67

material handling news

ergonomically designed material handling solutions eepos US, LLC is a German designed overhead aluminum crane company which provides aluminum crane systems for the material handling and automotive industries. eepos US is a division of eepos GmbH and has a new facility located in Northeast Mississippi.

The comprehensive modular Aluminum Crane System allows eepos to solve a wide range of problems regarding the flow of material and load handling, thus relieving the burden placed upon the user. It allows you to tailor your transport system individually to suit your requirements. eepos aluminum crane systems are high-quality, lightweight, innovative,

View more on page 71

competitively priced and flexible.

The trained sales and service partners eepos customers include BMW, at eepos assist customers in planning the Mercedes-Benz, Volkswagen, Rolls optimum crane system for their purpose, Royce, Porsche, Audi, Fiat, and thus ensuring customer satisfaction. many more.

For more information, please contact Paul Comer, sales manager, eepos: 662-365-8880 • 964 Hwy 45 N, Baldwyn, MS 38824 • p.comer@eepos-us.com • www.eepos-us.com

Your #1 lift ring source Actek Manufacturing, established in 1989, is your #1 lift ring source. We use the best AISI 4140 Aircraft Grade Chrome-Moly available. All of our 4140 material is metallurgically analyzed and certified. All of our hoist rings are heat treated to MIL-H-6875 and 100% magnetic particle inspected to accordance with ASME Section 5, Article 7. Actek hoist rings meet or exceed all the requirements of ASME B30.26.

Our hoist rings are individually proof-load tested, serialized and come with a Certificate of Conformance. These test reports are also available on request. We are an approved supplier and are selling hoist rings to General Motors, Chrysler, Ford, Boeing, General Electric, Westinghouse, Lockheed, and many public utilities including nuclear power generating facilities.

We are ISO 9001:2008 Certified and we have a large inventory to facilitate same day shipping. The relationships we have built have helped us grow to where we are today and as we continue to grow, so does our commitment to you.

For more information, please contact Actek Manufacturing & Engineering: 1110 Fullerton Rd, City of Industry, CA 91748 • Toll Free: 800-752-7229 • Phone: 626-581-3424 • Fax: 626-581-3423 • www.actekmfg.com.

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Industrial Machinery Digest — Quarter 1, 2012

www.industrialmachinerydigest.com

Precision Drilling DemanDs

firm footing Easty-to-use Kanetec Magbore Drill Guides offer sure, positive, firm footing for your next precision drill jobs. It has the portability of a hand held drill, with the accuracy and stability of a drill press. It gives you a portable machine shop for in-house or on-site projects. Plus, it is easy to maneuver and position into areas of restricted accessibility; and, once it is set, it will magnetically hold to the most precise drilling position even on plates as thin as 1/5 inch.

Model KDC-MN1 (Drill not included)

CompaCt • Lightweight • hoLds positiveLy magnetiCaLLy attraCts or reLeases

140 W. Devon Avenue • Bensenville, IL 60106 Phone: 630-860-1545 • Fax: 630-860-9443 • Email: kanetec@kanetec.com

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Quarter 1, 2012 — Industrial Machinery Digest

69

material handling news

VersaLift™ Magnet Offers HOrizOntaL and VerticaL Lift capabiLity, test MOde & rfid cHip Industrial Magnetics, Inc.s’ VersaLift™ Lift magnet offers both horizontal and vertical lifting ability and is one of the only lift magnets on the market to feature a RFID chip for maintenance tracking.

Powerful, yet compact, the USA manufactured VersaLift™ supports extremely high lifting values in relation to its lightweight design and features a sleek, industrial grade, stainless steel housing.

The VersaLift™ can be used on flat or round, non- flexing steel in a horizontal lifting orientation and has a built-in lift capacity “test” function, which assists the user in determining whether or not a load is safe to lift.

The optional, bolt-on lift bracket also allows the user to lift flat parts in vertical orientation without the need of an extra piece of equipment, such as a vertical lift adapter.

Also worth noting is the lift magnet’s embedded RFID (Radio Frequency Identification) chip. RFID is used to identify each unique magnet as it relates to the recorded documentation of any maintenance and/or scheduled calibration performed on the unit, giving you an electronic history of the product.

For more information on the VersaLift™ lift magnet, contact IMI’s product specialists at 888.582.0823.

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EnKon’s HEavy Duty Lifts soLvE Ergonomic ProbLEm for commErciaL tractor comPany EnKon Systems, Herkules Equipment Corporation’s brand name of lift systems solved a tractor manufacturer’s ergonomic lifting problem by designing two heavy duty pneumatic scissor lifts that maintain a surface flatness of +/- ½” with minimal deflection, and providing a closed lift height of 8.5” enabling the tractor to be pushed onto the lift from an 8.5” height platform. All this while still providing 25” of travel. To enable the operators to effortlessly move the massive lifts (8 foot by 8 foot) down an in-ground track, EnKon utilized an air bearing system which was incorporated into the design of the heavy duty lifts.

EnKon’s custom-made lifts utilized two sets of scissor arms.

Each heavy duty lift was designed to support 6000 lbs. which would accommodate any future heavier tractor model additions. And the lowprofile characteristics of the EnKon lift design enable the customer to accommodate the 8.5” high platform.

The customer was impressed with how stable the tractor-loaded lift was when in the raised position. And they appreciated the fact that the use of the air bearing system would turn a back-breaking burden into an easily

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Industrial Machinery Digest — Quarter 1, 2012

accomplished task. The original lifting problem began when the manufacturer introduced a new model whose weight exceeded the capacity of the lifts being used. The new tractor weighed 3000 pounds, and since the existing lifts were designed to accommodate only 2000 lbs. they began to tip under the excessive weight.

EnKon Systems is the brand name for Herkules Equipment Corporation’s electric, hydraulic and air powered scissor lift table systems. Herkules has been manufacturing lifting equipment close to 30 years, building a solid reputation specifically for designing & manufacturing air operated lift systems for a variety of applications. Standard and custom lift systems include; Electric Belt Drive Lifts, Electric Ball Screw Lifts, Air Lifts, Hydraulic Lifts, Lift Tables, Lift & Rotates, Lift & Tilts, Operator Lifts, Power Rotate Systems, Cart Positioners, Pallet Positioners, Post Lifts, and Lifts for Integration.

For more product information, please contact EnKon Systems at 800-444-4351, or at info@ herkules.us or visit our website at www.herkules.us. Check out our newest website, www.enkon.pro.

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Total Industrial Plant Solutions (TIPS) is the only stand alone card deck with its own unique MAy 2011 circulation providing quality sales leads throughout every area of the manufacturing industry. TIPS is designed to cover all industrial OEMs and suppliers, ranging from high-end machinery and capital equipment to the industrial MRO consumables, accessories and other related commodities.TIPS reduces a dedicated audience of over 100,000 through integrated marketing opportunities via our direct mail, online e-deck, and trade show audiences. Stay connected with a highly targeted audience in real-time, 24/7, 365 days a year in print, online, electronically and in-person. TIPS is truly your one-stop marketing resource.

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crane systems

• High quality • Lightweight • Innovative • Competitively priced • Flexible • Customizable • Smooth Running • Cutting Edge • Versatile • Durable • Single Rail & Double Rail Girders • 3,000 lb load capacity • German Design

Double Girder Crane (ZTK) is the answer to blanket coverage transportation of heavy loads. A more even load distribution and increased hook height is achieved by using two crane beams arranged in parallel, with the chain hoist support fitted between them.

Double Girder Elevated Crane (ZTKA) combines the advantages of an elevated system with those of the double girder crane.

www.eepos-us.com www.industrialmachinerydigest.com

Our clients include: • BMW • Mercedes-Benz • Volkswagen • Rolls Royce • Porsche • Audi • Fiat • and many more!

Quarter 1, 2012 — Industrial Machinery Digest

71

material handling news

kanetec gives you the edge you need to outperform your competition Kanetec has been at the forefront of magnetic tools and equipment since 1959.

Kanetec is synonymous with quality and accuracy worldwide.

From the very beginning, we have adhered to the same basic principle and goals…

Quality Kanetec does more than manufacture magnetics. We research and develop solutions that make our products easy to use, efficient and reliable.

Kanetec stands behind each and every product with an unwavering commitment to quality and dependability. When you buy Kanetec, you receive the fruits of relentless persuit for perfection, from the most dedicated team in the business. innovation Keeping up with today’s exhilarating and demanding pace of technology, Kanetec gives you the most vital edge you need to outperform your competition.

Thriving on meeting new challenges,

we have earned the reputation of being the leader in magentic toolings for just one reason - our innovative approach to real world problem solving.

From small magnetic dial indicator stands to gigantic magnetic chucks, Kanetec’s research and production teams have always delivered the right magnetics for each application.

Why Kanetec?

If you think all magnetic tools are created equal, think again!

Above and beyond manufacturing the best known magnetics in the world, Kanetec now offers so much more!

• Chucks • Magnetic Blocks • Measuring Tools • Measuring Tool Holders • Magnetic Holders • Magnetic Tools • Lifting Magnets • Magbores • Chip & Sludge Transporters • Magnetizers & Demagnetizers • Magnetic Separators • Magnetic Bases

Model KDC-MN1 (Drill not included)

The newest additions to the line, Magcleans, feature a Magnetic Coolant Separator. When mounted to your grinding machine, the Magclean eliminates the grinding waste and other impurities from the coolant and keeps it clean at all times.

Kanetec has also expanded their Magnetic Bases, Tools, and Chuck lines with the latest technology and electronic controls. And, more than ever, they have aggressively priced products so they remain your No. 1 choice in industrial magnetics.

View more on page 69

For more information, please contact Kanetec: 140 W. Devon Avenue, Bensenville, IL 60106 • Phone: 630-860-1545 • Fax: 630-860-9443 Email: kanetec@kanetec.com • Web: www.kanetec.com

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Industrial Machinery Digest — Quarter 1, 2012

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Quarter 1, 2012 — Industrial Machinery Digest

73

productivity profile

cnc router helps shipping cAse producer reduce leAd time From 10 to 4 weeks Don Holcombe started producing shipping cases because he had a large telescope and no way to transport it. Friends in his astronomy club began asking him to build cases for them and he eventually quit his job and started a business to produce them. Holcombe soon discovered that he had orders for more cases than he could produce using a table saw, router and common woodworking machinery. He looked for a way to increase production through automation and discovered the Techno LC series computer numerical control (CNC) router. “The Techno router has reduced the time needed to cut out the shell of a case from 30 minutes to 6 minutes while at the same time greatly improving accuracy,” Holcombe said. “Reducing the time required to produce our cases has helped to grow the business by satisfying our customers’ desire to receive their cases quickly and freeing up my time to create more innovative designs. Shorter production times have also lowered the cost of manufacturing, increasing profit margins.”

Astronomy has become an increasingly popular hobby.

Amateur astronomers frequently buy large, bulky telescopes and accessories and are then faced with the challenge of how to transport them. Holcombe first got interested in astronomy when he was in the military doing artillery survey. When he had time, he used the surveying equipment to look at the planets and got hooked on astronomy. Some time after getting out of the military he bought a large Meade telescope and discovered he had no way to transport it. The company that he worked for at the time had a large projector and the case seemed like it would work well for transporting telescopes although it was the wrong dimensions.

Holcombe visited the local distributor for the projector case who told him that he was not aware of any companies that were building cases for telescopes.

cases direct. Holcombe gave the name ScopeGuard to his cases and opened a website: www.scopeguard.com. Soon his sales had risen to the point that he was able to quit his job and concentrate on building cases. “This business is like a hobby that went wrong,” Holcombe jokes.

During this period, Holcombe built his cases by hand using a table saw. He cut out the top, bottom, front, back and end panels with the table saw and then used a drill press and hand router to cut holes for the rivets that hold the panels together as well as locks and latches. The material is normally ABS plywood which consists of ¼ inch birch plywood with a 0.040 inch ABS plastic coating on one side. Holcombe had to measure and mark each panel before cutting. Then he attached a template to the panel and used it to drill holes and route openings. He typically cut out 10 cases at a time in about 6 hours. This job required the continuous attention of a highly skilled individual. The accuracy that could be achieved was limited by the skill and attention of The ScopeGuard shipping case.

“A hobby thAt went wrong” Holcombe built a case for the Meade telescope and took it to his local astronomy club. The case was designed for protecting the telescope while it is shipped as checked luggage on an airplane and includes corner casters for ease of movement. This case, as with all the others that Holcombe has built since, was designed to fit a specific model of telescope. A number of other members asked him to build cases for them. One of his customers posted a picture of the case on his web site. The second largest distributor of astronomy equipment in the US saw it. The company contacted Holcombe and asked for a one-year exclusive agreement to sell his cases. Holcombe agreed on the condition that he also be allowed to continue selling the

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Industrial Machinery Digest — Quarter 1, 2012

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the person doing the job. Even when panels were cut by the most experienced craftsman it was possible to see dimensional variations with the naked eye.

AutomAting the production process As the company’s business increased, Holcombe found it became more and more difficult to meet demand for the cases. “We began getting calls on a daily basis from people looking for cases for specific models of telescopes,” he said. “Customers were anxious to get the cases but since each one had to be designed and built from scratch it took a considerable amount of time to deliver. We often lost jobs because the prospect found another source that could provide a case faster. Also, I had to spend most of my time cutting out panels which limited the number of cases we could produce and in turn limited our revenues. I began to consider alternatives for automating our production process. Some machines would have done a great job but were very expensive.

Others were less expensive but did not seem to be accurate and rugged enough for use day after day in a production environment.”

“Then I stumbled onto the Techno web site,” Holcombe continued. “It was clear from a glance that the Techno LC router had some significant differences from the other machines I had looked at. The other machines use stepper motors which produce a serrated pattern when you cut an arc. The Techno machine has a servo motors which provides a much smoother cut.” The LC series machine is built on a heavy steel base and incorporates a closed loop servo control system that provides constant position feedback, high power and smooth continuous motion. Ball screws are provided on all three axes, offering smooth motion, a high level of accuracy and repeatability, and minimal maintenance.

Freeing up the owner For higher level Activities Holcombe designs new cases in Corel Draw then exports the design to the EnRoute computer aided manufacturing (CAM) software that he purchased with the CNC router. He uses EnRoute to create the CNC toolpath and nest the parts onto a 4 by 8 foot sheet of ABS plywood. The CAM software positions the parts onto the workpiece to minimize material costs. The Techno router produces all of the panels required for a single case in only 6 minutes, including not only the outside dimensions but also the holes and openings for the hardware. “Instead of being tied up continuously, I can turn the machine on and walk away while it cuts out the parts,” Holcombe said. “The only effort that is required to make additional panels is to load sheets of plywood and attach them to the table with the vacuum clamp. This can be done of course by a less experienced person so a considerable amount of my time has been freed up for higher level activities such as designing new cases and marketing.”

The operator simply loads the sheet onto the machine and turns on the vacuum pump to secure the workpiece. Then he selects the program for the model of enclosure that is being produced from the machines control software and pushes the start button. The CNC router then does all of the machining required to produce the enclosure in 20 minutes. The machine operates unattended while the operator is free to move to another task such as assembling the cases. Holcombe says that a key advantage of the Techno machine is that it has made it possible to use less skilled workers to produce the parts. “This makes it easier and less costly to find workers and the quality of the results is independent of the worker, making for a more consistent and higher quality product. I really like the accuracy of the cut. I no longer have worry about aligning the table saw. Every piece is identical because the machine cuts to a high degree of repeatability.”

These images show some stages of the production of shipping cases.

Holcombe uses EnRoute to create the CNC toolpath and nest the parts onto a 4 by 8 foot sheet of ABS plywood. The CAM software positions the parts onto the workpiece to minimize material costs. The operator loads the sheet onto the machine and turns on the vacuum pump to secure the workpiece. Then he selects the program for the model of enclosure that is being produced from the machines control software and pushes the start button. The CNC router then does all of the machining required to produce the enclosure in 20 minutes.

“Some of our customers have waited for five years for a particular model of telescope to be built,” Holcombe concluded.

“When they are about to receive the telescope they realize that they need a case to transport it and call us. Naturally, they do not want to wait another three months. The Techno machine has helped us substantially reduce the leadtime required to build their cases. We have noticed that we have won a higher percentage of our quotes since we began using the Techno router and we believe that shorter lead times and better fit and finish are the reasons why. The ScopeGuard website concludes that: “Our case components have a more precise initial cut resulting in an end product that compliments the telescope or mount stored in the case. We have already shortened the lead time of our orders significantly since the purchase of the Techno LC4896. As we become more familiar with the operation and capabilities of the router we will continue to decrease lead times.”

For more information on the CNC Machine described in this article, contact Techno Inc.: 2101 Jericho Turnpike, New Hyde Park, NY 11040. Phone: 1.800.819.3366/1.516.328.3970 Fax: 1.516.358.2576, E-mail: support@technocnc.com, Web site: www.technocnc.com

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Quarter 1, 2012 — Industrial Machinery Digest

75

industrial and tooling news

WD-40 bRAND LAuNCHES FIRSt EVER PRoDuCt LINE EXtENSIoN, INtRoDuCES NEW WD-40 SPECIALISt LINE oF PRoDuCtS Line of Five Specialty Maintenance Products Now Available

WD-40 Company, maker of the trusted and versatile WD-40® Multi-Use Product, is introducing WD-40 Specialist™ – a new line of best-in-class specialty products formulated to give trade professionals the performance they need to get their specific jobs done right.

The new WD-40 Specialist line consists of five products: Rust Release Penetrant Spray; Water Resistant Silicone Lubricant; Protective White Lithium Grease; Long-Term Corrosion Inhibitor; and Rust Remover Soak.

“Trade professionals need products that work for specialized jobs and the WD-40 Specialist product line is a great arsenal to help them do their jobs better,” said Dr. Ernest Bernarducci, vice president of research and technology at WD-40 Company.

“Of course, with jobs that aren’t so specialized, you can always trust the product that’s been used for nearly 60 years for thousands of tasks – WD-40 Multi-Use Product.”

Developed at the WD-40 Company Research and Development Center, all of the new WD-40 Specialist products are 50-state VOC compliant and have proven more effective in key performance areas than leading competitors in ASTM and other industry accepted test methods: • Rust Release Penetrant Spray – With Blu Torch™ Technology, it penetrates rust 50 percent faster than the leading competitor and also helps prevent rust and corrosion.

• Water Resistant Silicone Lubricant – Dries fast and doesn’t leave a mess – it even waterproofs and protects moving parts better than leading competitors.

• Protective White Lithium Grease – Ideal for metal-tometal applications and provides long-lasting lubrication and unbeatable, superior protection.

• Long-Term Corrosion Inhibitor – Outperforms the competition and protects metal from corrosion for up to one year outdoors and two years indoors.

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Industrial Machinery Digest — Quarter 1, 2012

Rust Remover Soak – Made with biodegradable ingredients and a non-toxic formula, it restores rusted metal parts back to bare metal.

WD-40 Specialist products are now available nationwide.

For more information about the new product line, visit WD40Specialist.com.

•

About WD-40 WD-40 Company, with headquarters in San Diego, is a global consumer products company dedicated to delivering unique, high-value and easy-to-use solutions for a wide variety of maintenance needs of “doer” and “on-the-job” users by leveraging and building the brand fortress of the company. The company markets multi-purpose maintenance products, which include the WD-40® Multi-Use Product, 3-IN-ONE®, BLUE WORKS® and WD-40® Specialist™ product lines. The ompany also markets homecare and cleaning brands X-14® mildew stain remover and automatic toilet bowl cleaners, 2000 Flushes® automatic toilet bowl cleaners, Carpet Fresh® and No Vac® rug and room deodorizers, Spot Shot® aerosol and liquid carpet stain removers, 1001® household cleaners and rug and room deodorizers, and Lava® and Solvol® heavy-duty hand cleaners.

WD-40 Company markets its products in more than 160 countries worldwide and recorded sales of $336 million in fiscal year 2011.

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industrial and tooling news

ComprehenSive CompreSSed air auditS: the 5-Step proCeSS

By Neil Mehltretter, System Engineering Supervisor, Kaeser Compressors

The U.S. Department of Energy estimates that air compressors use as much as 10% of all electricity generated in the United States. Further, the DOE calculates that as much as 50% of this energy is wasted. Compressed air leaks alone account for 25-30% of compressed air use.

Consequently, many industrial companies are identifying ways to lower their compressed air system energy consumption. One of the most popular methods to do so is a comprehensive compressed air audit, or “air demand analysis.” The objective of this paper is to define the five steps required in a compressed air audit. We will use a realworld example with system information from a magnetic materials manufacturer to clearly illustrate each step. In the following case, the user achieved a 42% reduction in annual energy costs.

Step 1: ConduCt a Site Survey It is important to list and understand all the equipment in a compressed air system before installing any measurement devices so that 1) the devices are properly placed, and 2) system dynamics are properly understood. The person responsible for collecting information should note: environmental conditions, physical layout, details on all air system components including clean air treatment, piping, storage and controls. Processes at the facility should also be documented. Many auditors will have a questionnaire which they will complete to compile the details into one document.

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Step ove kW ur dr ig ed hensive Compressed n nf ed pr llo co ress Air Audits 40 ga comp to Im 3. Re air leaks. mpress th a 10 ing co rough the and te ge wi by fix th propria d stora ks or “inap crease air lea 4. In tion of ssed na mi re COMPRESSORS eli of comp ed air 55 kW in a g uses” g engineer to lin e, in Instal uld result kW Description air. Us for exampl pe VFD wo ated 13.54 . , Proposal Estimate pi cfm tim Verification nozzles perforated an es per 100 Annual flow (cf/year) gs tions e 128,010,406 savin replac -off applica ed 130,600,422 stem’s Existing ss Energy sy ow Consump re the tion 685,792 kWh/yr for bl comp d 699,668 kWh/yr control, y not be duce ze Proposed Energy stem ma will re per sy umption be reali s Consumption 395,942 kWh/yr ns ut pro ONLY these gain ll 404,822 Witho energy co d. wi kWh/yr ll quency wever, ize on Annual Energy Savings overa cantly lowere gs, ho can capital variable fre rols 289,850 kWh/yr savin a signifi s 294,846 kWh/yr nt Energy Cost or co energy ressor use of 0.065 $/kWh oper . Real e air comp mpress dulating 0.065 $/kWh des pr mand ng co mo Existing Energy Cost air de ntrols on th this inclu th adjusti ns. Many $44,577 / yr of te co $45,478 / yr lved wi I calculatio me amount (cfm).

Proposed Energy Cost if the propria vo in ap sa $25,736 / yr en sts ws e RO $26, 313 / yr e the air flo air and wh FD). The co ded in th Annual Energy Savings consum mpressed mpressed clu (V $18,840 / yr ver in co co $19,165 /yr drive inue to ost ne ll cont d ranges of p between are alm ressors wi oa Original System Specific nshi 32.14 kW/100 cfm mp thin br ear relatio Power KPI air co ty (kW) wi (This KPI is assumed 32.14 kW/100 cfm lin me a ici based on the slightly Without reconfiguring the n. electr nnot assu io compressed air piping umpt ca (blue higher flow profile.) may have not have met Specific Power KPI the energy savings required pipe in image), the facility Users power cons 18.56 kW/100 cfm for the utility rebate. d 18.60 kW/100 cfm use an The piping was a critical component in the system’s optimization.

Creating a closed loop Offline Conclusion allowed for the proper sor #1 system pressure es downstre am, pr but required less work of the m It is critical to focus on compressor. With the 55 2: Co improving the specific unit capable of providin kW KPI of kW/100 cfm. g 389 cfm at 100 psig Figure Compressed air users and sized to operate in can ensure return on investme its most efficient range between 40-85% load, nts (based upon energy savings) on the new specific power KPI was estimated to be air system audits by working 18.6 kW / 100 cfm. This with firms who measure at least power, KPI would meet the recommendation to be flow, and pressure over below 21 kW / 100 cfm, a period long enough to obtain and an accurate system snapsho represented a significant improvement t, often 10 days. Further, over the existing systems’ the data obtained from specific the KPI of 32.14 kW/100 cfm. power audit must be thorough ly analyzed and recommendations should be made based on conserva tive estimates of power reduction.

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er.com

of kW/100 cfm

When implementing an Utility rebate programs optimization plan, it is sometimes require energy important to remember savings be verified that without proper system by an additional compres control, the system’s overall sed air audit performed after the air system is energy consumption may not be optimized. In cases where significantly lowered. In utility rebates do not require the case described, adding a VFD unit allowed such a degree of verification, facilities the system to generate should still consider impleme compressed air at the lowest acceptable pressure nting some form of a post-optimization , thereby reducing energy assessment. All systems can be enhanced – even cost. In many cases, consumption and systems designed using a master system controlle air audit data and that r is the best solution as are newly installed. The master controllers use additional assessment compressors at their most should verify the compres efficient design point sed air audit findings, or turn them off. as well as assist in identifyin g additional areas of improvem system controllers actually ent. Some track and store ongoing energy consumption Finally, users that complete a compressed data, so for many, a review air audit and optimize their with a master system controlle systems will surely reduce r provides enough information for energy consump tion and see lower operating internal evaluation and costs. However, even the can be used to verify improvement metrics. best, newly optimized systems can always be further improved. Facilities should be advised that additional savings can be determined by completi Case: A follow-up compres ng a leak detection audit sed air audit was performe in conjunction with a full evaluation of d for this manufacturer. The verificati the demand-side of the on results showed that facility for appropriate although the overall use of compressed air. air demand in the factory Facilities should determin had gone up (from 244 e which services are to 289 cfm), the 55 best suited for them (leak kW VFD efficiency was detection, supply-side well within the target zone compressed air audit, of 18.6 kW /100 and/or demand-side compres cfm KPI. Average operating sed air audit), and develop pressure had also been reduced by 3 psig. a plan for how often those services should Eliminating the water-co be performed. oling requirement provided a bonus potential savings of $1,208 per year (based upon $0.20 For more information please per 1,000 gallons cost of cooling water). The contact Kaeser Compres annual energy savings sors, tel: 877-586-2691, email: were verified per year – a whopping at $19,165 ada.us@kaeser.com, www.kae 42% reduction in energy ser.com/ada cost and slightly higher than what was estimate d.

Kaeser Compressors,

Inc. • 877-586-2691 • www.kaeser.com

CliCk here to view the rest of this study! http://www.kaeser.com/whitepapers?utm_source=industrialmachinedigest&utm_ medium=electronicmagazine&utm_campaign=adawhitepaper

Kaeser Compressors, Inc. • 877-586-2691 • www.kaeser.com View more on page 83

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Industrial Machinery Digest — Quarter 1, 2012

www.industrialmachinerydigest.com

WE ADD “SMART” AND “SIMPLE” TO THE “FIVE S” SYSTEM

N

obody understands organization like Strong Hold. If you are currently implementing the “Five S” System at your workplace… you’ll appreciate the built-in efficiencies our cabinets, shop desks, tables and work stations possess. Features like storage bins, drawer inserts, pegboards, and shelves instantly add order to your work area.

Take a look at all the efficient products we have to offer.

Call today for a Product Guide or visit us on-line.

LOUISVILLE, KY

www.industrialmachinerydigest.com

800-880-2625

www.strong-hold.com

Quarter 1, 2012 — Industrial Machinery Digest

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industrial and tooling news

all worlD macHinery supply inc. — inDustrial solutions tHrougH personalizeD care Founded in 1993, All World Machinery Supply Inc. was created on the belief that customers in the industrial marketplace need a dependable and reliable alternative source from which to purchase machine tool parts and components.

Combining a steady growth strategy with excellent customer service, All World Machinery Supply is rapidly becoming the preferred alternative for machine tool parts and services, supporting customers throughout the United States, Canada, and Mexico.

The key component in All World’s success is its business philosophy: it’s simply not enough to provide quality brand name products and good service to its customers; we must also strive to provide a virtually hassle-free, pleasant buying experience with a personal touch.

All World Machinery is focused on direct customer service response. It is our philosophy not to use a voice mail system. People call us

because they need help now and need to talk to a responsive person and not a machine.

Today, All World Machinery Supply employs an ever-growing staff of qualified sales and service personnel in order to fulfill your important requirements.

Included in our product line is the Daikin Hybrid hydraulic and cooling units. We carry a full line of bearings and accessories and offer repair services.

We provide industrial solutions through personalized care. Visit our website at www.allworldmachinery.com for more information.

View more on page 3

power plant services choose lucifer furnaces Lucifer Furnaces, Inc. recently delivered a single chamber bench model box furnace to Power Plant Services, an ISO 9001certified provider of parts and repairs for the power generation and steel mill industries. Model RD7-KHE24 is part of the Red Devil Series of furnaces built with economy, energy efficiency and ease of use in mind. The 12”H x 14”W x 24”L heating chamber is lined with 4.5” of multilayer firebrick and mineral wool insulation. Heating elements on the side walls provide 7 KW of power capable of heating to 2200°F. Heating element coils are equally spaced and fully supported in easyto-replace element holders to provide uniform heat and long life. Element lead wires are insulated by ceramic tubes through the rear wall brick for protection from electrical shorting and contamination. The box furnace frame is manufactured with heavy gauge sheet steel reinforced and welded to form a rigid unit with a heavy gauge front faceplace designed to withstand warping and distortion from the chamber heat. A rear mounted type K thermocouple assembly is located through the rear wall

of the chamber for rapid sensing of the chamber heat. The Red Devil bench model comes standard with a horizontal swing door insulated with multilayered ceramic fiber insulation with heavy duty hinges and a cam lock to insure a tight seal as well as a safety microswitch to automatically shut off power to the heating elements whenever the door is opened. The chamber of the unit is fitted with a ceramic hearth plate to support a workload of 25 lbs. per square foot of hearth area. A digital time proportioning temperature controller and all other instrumentation are mounted in a separate control panel on the side of the furnace away from the heat and loading of the chamber.

For more information, please contact Lucifer Furnaces, Inc.: 2048 Bunnell Rd. • Warrington, PA 18976 • 800-378-0095 • www.luciferfurnaces.com

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Industrial Machinery Digest — Quarter 1, 2012

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industrial and tooling news

homak Safety CabinetS Industries that deal with flammable liquids on a day-to-day basis know the importance of keeping them safe. That’s why Homak has produced a line of highquality Safety Cabinets that outperform the Industry Standards. Proudly manufactured right here in the United States, our cabinets are Factory Mutual (FM) tested and approved. Compliant with NFPA Code 30 and OSHA Specifications, these products are designed to protect contained flammable liquids for a period of up to ten (10) minutes. A 3-point, flat key locking system with button latches ensures all contents are securely stored.

Two 2” vents with fire baffles and caps, as well as welded double-wall construction with 1 ½” airspace, are offered on all models. Other standard features include adjustable galvanized steel shelves, fulllength piano door hinges, and a 2” raised leak proof sill. All models offer manualclosing doors, however, our 45 Gallon Cabinet can be ordered to include selfclosing doors. Your company deserves the safety and peace of mind offered through our line of Safety Cabinets!

Spill Containment SyStemS Hazardous chemical spills can (and will) happen.

When they do; will you be ready? Let Homak help your facility handle these issues and receive the peace of mind that comes from being prepared. Our new line of Spill Containment products offer components that work together (modular construction) to trap accidental leaks and spills, allowing for safer cleanup. Individual units are highly compatible, allowing you to create setups that are customized to the particular needs of your facility. All units are made with high performance engineered plastic for excellent chemical resistance. Removable, flat top grating allows for easy cleaning

View more on page 2

Homak Spill Containment Platforms & Pallets: Offering modular construction for ultimate customization.

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and access to spilled chemicals. Select models come equipped with sump drain plug and fork lift pockets. If expense is an issue, consider investing in our 2 or 4 drum basins: they offer spill containment solutions at a low cost.

Platform models are EPA 40 CFR 264 certified. Pallet models are both EPA and SPCC compliant.

The best part: They’re all proudly made right here in the United States.

For more information, please contact Homak: 1-800-874-6625 • www.homak.com

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industrial and tooling news

strong holD proDucts The strongest storage cabinets available!

Durability in the workplace Strong Hold’s production team is dedicated to providing the most durable cabinet available today. 12-gauge steel is sheared, formed, welded, steam-cleaned and then painted to produce a solid, strong and dependable cabinet. Our product is designed to withstand years of industrial abuse and tough treatment.

safe anD secure Our three point locking system is designed for a heavy padlock.

This feature, along with our cast handle and 8-gauge hinge, compliments the 12-gauge welded body design.

easy to buy Our production methods allow us to pass savings on to you. Strong Hold cabinets are comparably priced to competing “light gauge” steel cabinets, yet provide a far superior, lasting product.

There are no minimum order quantities at Strong Hold.

knowleDgeable service team If you should have a question, our staff of sales professionals will be glad to assist you. Call 800-880-2625.

fully assembleD Our products are shipped completely assembled and ready to use. There is no lost time for shelf installation or setup.

quality policy Strong Hold Products is committed to achieving total customer satisfaction. Implementing and maintaining an efficient, effective quality management system can aide us in achieving this goal. This can be accomplished through the continuous improvement of our manufacturing process, ongoing training of our employees and dedication to understanding our customers’ needs.

For more information, please contact Strong Hold: 800-880-2625 • www.strong-hold.com View more on page 79

Carmex presentation at WesteC to foCus on defense and aerospaCe Carmex Precision Tools, LLC, of Richfield, Wisconsin, will feature an extensive display of thread milling and other capabilities at Booth #2500 at WesteC 2012. Additionally, qualified applications specialists will be on hand to answer attendees’ questions regarding specific cases.

According to Jeff Dei, President of Carmex USA, “Defense and aerospace have always been important markets to us. Because of the high value of the parts involved and the very hard strength of the alloys and materials used, thread milling has long been a standard practice. Our line includes tooling capable of threading extremely small holes with high precision and delivering an excellent surface finish. Our new DMT line, with our Helical Advantage™, has been expanded to include multiple sizes and enables customers to drill, thread and chamfer in a single operation. We invite our visitors to challenge us with both conventional and specialty applications and look forward to helping them meet their production goals in the most effective and efficient

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Industrial Machinery Digest — Quarter 1, 2012

manner possible.”

For further information, contact your Carmex representative or Carmex Precision Tools, LLC, at 1-888-628-5030, or visit our website at www.carmexusa.com.

Carmex Precision Tools, LLC, is the North American product service center for tooling manufactured

by Carmex Precision Tools Ltd., an international manufacturer. For over 25 years, Carmex has pioneered the development of advanced thread cutting technologies for improved productivity, better product quality, and longer tool life. Carmex tooling is available in all standard sizes or by special order for unique applications.

®

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industrial and tooling news

BESSEY® IntroducES thE dmt multI-functIon tool The new DMT Multi-Function tool by BESSEY offers a new twist on the typical multi-function tool. Instead of pliers, the main tool is a cutting shear.

With an overall length of 7 Inches and 6 other tools folded conveniently inside this product is a go-anywhere tool for the professional.

In addition to the shears (with 2-1/8 Inch cutting edge length), the DMT also includes a flat blade, saw, file, a Phillips head screwdriver, a large and small slotted screwdriver and…it comes standard with a belt pouch. For those that do a lot of multi-purpose cutting this is a great tool for work in the field.

Competitive DifferenCe: 1. Cutting shears as the main tool.

2. 7 tool options included in the fold up tool.

3. Overall length of 4 Inches when folded and 7 Inches when open 4. Belt pouch included 5. Retail pricing in the $19.99 - 21.99 range.

BESSEY® has been a market leader in clamps and cutting tools since 1936. If you know BESSEY®, you know our reputation for quality and reliability; you know we’re 130 years of German engineering backed by the strength of our product and our reputation. BESSEY®.

Simply better.

For more information, e-mail info@besseytools.com or call 1-800-828-1004. ®

loosens frozen metal parts

Based on scientific discoveries at Kano Laboratories, Kroil creeps into millionth inch spaces, dissolves rust and lubricates to loosen frozen metal parts. Kroil’s unique molecular structure facilitates penetration while maintaining a structure that breaks bonds due to either corrosion or compression.

Kroil is now available in 8 sizes including a new 16.5oz.economical industrial size.

Guaranteed to meet your expectations whatever they may be. Kroil is available in aerosol and bulk. No minimum order. Call 1-866-458-9112 or order from the website at Kanolaboratories.com

View more on page 79

SmartPipe

™

Aluminum Compressed Air Piping Fast installation Low pressure drop Won’t rust Six sizes from ½ to 4 inches

Scan this QR code with your smart phone to see our SmartPipe video.

(866) 516-6888 • info.usa@kaeser.com • www.kaeser.com/smartpipe www.industrialmachinerydigest.com

Quarter 1, 2012 — Industrial Machinery Digest

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industrial and tooling news

Magnalight announces Release of industRial gRade led light tRipod Larson Electronics’ Magnalight. com has released a ruggedly designed LED light tripod built to provide a reliable and durable source of powerful illumination for industrial environments.

Designed with dual LED light heads and a high quality wheeled tripod, the WALTP-2XWP400MCE Industrial LED Light Tripod provides an easily deployed light source that is as economical as it is powerful. Rivaling more expensive to operate metal halide tripods in total coverage and light quality, this light tower runs cooler, uses less energy, and offers the long operational life and durability of LED technology.

The WALTP-2XWP400MCE Industrial LED Light Tripod from Magnalight.com provides brilliant illumination capable of covering as much work area as comparable metal halide lamp equipped tripods, yet costs less to purchase and operate. This industrial light tower is tripod mounted and includes a set of no-flat rubber wheels to make moving the tripod from one location to another easier for one person to manage. The dual LED light heads on this unit each produce illumination comparable to a 250 watt metal halide lamp, yet use less energy, run cooler, and have a far longer service life rated at 50,000 hours versus the 10-20,000 hour average ratings for metal halides. The waterproof and vapor proof LED light emitters used on the WALTP-2XWP400MCE also suffer none of the problems with slow warm up times and reduced lamp life from frequent on and off cycling associated with metal halide lamps, making them

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more reliable and effective in the workspace. The extendable tripod tower on this unit allows the light heads to be extended anywhere from 7 feet to 13 feet in height to provide the best coverage of large areas. The tripod itself is constructed of heavy duty aluminum and coated with a durable yellow finish for added durability and resistance to corrosion and includes no flat tires for easy maneuvering around the work space. The entire light head assembly can be removed from the tripod by loosening the locking hand knob and simply sliding the assembly off the tower. The legs can then be folded and the entire assembly easily loaded for transport or storage. This LED light tripod works with standard 120VAC and requires no additional transformers or hardware to operate.

The LED light heads can be operated independently of each other, allowing operators to produce as much or as little light as they need. The construction of the unit is industrial grade, including a heavy duty aluminum tripod, waterproof and vapor proof LED light heads with powder coated aluminum housings and unbreakable polycarbonate lenses, and 50 feet of abrasive and oil resistant SOOW cord ending in a heavy duty straight blade plug. This LED light tower is ideal for plant turnarounds, tank cleaning, construction sites, and even outdoor events where a reliable and powerful yet economical alternative to hot running and expensive halogen or metal halide lights is preferred.

“The WALTP-2XWP400MCE LED light

Industrial Machinery Digest — Quarter 1, 2012

tower adds to our growing number of ruggedly designed portable lighting towers,” said Rob Bresnahan with Larson Electronics’ Magnalight.com. “This is our most heavy duty aluminum tripod, equipped with the newest LED technology. Operators will benefit from the bright white light, with lower amp draw, more vibration tolerance and reduced maintenance costs. These portable lights are rated for wet areas and are easily deployed for temporary maintenance operations where general area lighting is not available.”

Larson Electronics’ Magnalight offers a wide selection of LED light towers, Led work lights, explosion proof LED lights, LED flashlights, intrinsically safe LEDs and LED spotlights. Visit Magnalight.com to learn more or call them at 1-800-369-6671 or 1-214-6166180 for international inquiries.

www.industrialmachinerydigest.com

agro-hytos

STRUCTURAL STEEL CO., INC.

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.

Essex Provides: • Pre-Engineered Buildings Built To Withstand The Rugged Northeast Winters.

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.

• Commercial, Industrial & Agricultural Buildings Built To Satisfy Your Building Needs.

• Steel Structure Sub-Structure, & Sheeting

Call For A Quote On Your Next Project

STRUCTURAL STEEL CO., INC.

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

607 Route 13, Cortland, NY 13045

National: 800-323-7739

Phone: 847-676-2910 Fax: 847-676-0365

607-753-9384 • FAX: 607-753-6272

www.essexstructuralsteel.com

www.macmhydraulic.com

THE CUTTING EDGE s c t a d va n ta g e i n d e x a b l e cut ting tool system

We use Premium Micro-Grain Solid Carbide For Longer Tool Life And Increased Feeds And Speeds

neW!

Tools are stocked uncoated and ALTiN coated Solid carbide Boring, Grooving and Threading Tools

Micrograin carbide shank with a hardened steel head

Threadmills

Pocket designed for maximum chip clearance keeps chips away from surface being machined

Port Tools

Low Profile screw keeps chips flowing for better tool performance Bars stocked with or without locating flat Tools will fit into our standard QHC coolant tool holders giving you coolant where you need it Available in right hand and left hand versions Inserts are lapped and ground to a fine finish Minimum bore diameter starting at .220”

scientiFic cutting tools, inc.

110 W. Easy Street / Simi Valley, CA 93065 / 800-383-2244 / 805-584-9629 [fax] info@sct-usa.com / www.sct-usa.com

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Quarter 1, 2012 — Industrial Machinery Digest

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industrial and tooling news

determining drawer needs Establishing a systEm First you must establish a method of organization.There are three basic options available: 1. Random Storage. This method provides extremely high density storage and a high degree of storage flexibility. It may, however, limit the speed and efficiency of item location when storing or retrieving.

2. Organization by Family. Items can be grouped according to use or function. Facilitates easy location and efficient storage/retrieval. Less effective utilization of the cube than the first method.

3. Organization by Part Number Sequence. Parts can be located with maximum efficiency. However, this method provides the least efficient utilization of the cube.

Random oRganization by sizE 1. Organize items into groupings based on height.

2. Determine the number of square feet needed for eachheight group, based on average inventory levels.

3. Divide the number of square feet needed for each size group by 4.0

4.

5.

6.

(the area of a standard drawer) to determine the number of drawers needed For example: If 16 sq. ft. are needed to accommodate height group A: 16/4 = 4. Thus, four drawers will be required.

Allow for expansion. It is generally a good practice to allow yourself 10-25 percent for future expansion. If you are aware of planned growth or expansion, add that to the standard expansion factor.

Select drawers based on the heights of items to be stored. For example: If your part heights range from 2-1/2”to 3-1/2”, a Model 120 drawer would be your best choice. It is always better to allow for greater clearance while selecting drawer height.

Select cabinet sizes to meet your needs.

nEEds analysis suRvEy Your STOR-LOC representative will survey your present storage system, listen to your requirements for future growth and expansion and provide

layouts of suggested solutions -- all at no cost or obligation to you. He also ensures every detail is considered when estimating ordering and installing your new storage system.

Stor-Loc is a manufacturer of quality, US made modular storage systems for tools, parts and inventory since 1989, providing dependability, durability and versatility to industry around the world.

®

Modular Drawer System

View more on page 77

For more information contact: STOR-LOC Modular Drawer System, a Division of Ryan Metal Products • 880 N. Washington Avenue, Kankakee, IL 60901 800-STORLOC (800-786-7562) • Phone: 815-936-0700 • Fax: 815-936-0767 • www.storloc.com

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Industrial Machinery Digest — Quarter 1, 2012

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industrial and tooling news

high quality tools introduces new aluminum body 6", 8", & 10" shell mills The automotive repair industry has long had a need to machine heads(and blocks) for proper gasket sealing when re-assembling. The equipment specifically designed for this application is both expensive and single purpose. Many shops have a milling machine, but the only tools available are single point - usually with a very expensive CBN insert. The problem with single point tooling is the “bounce” the tool makes as it engages the part and again as it passes over every chamber or passage and again hits the other side as it re-engages the work piece. High Quality Tools put together a cutter with 8 to 10 “standard” inserts around the diameter of a solid bodied head so that there is always 2 to 3 inserts engaged in the cut. The shell mill is made from aircraft aluminum to be strong, yet light weight enough to be used comfortably in a typical Bridgeport type mill.

High Quality Tools, Inc. was started in 1983 making & supplying replacement parts and accessories for milling machines. Over the ensuing 29 years, the business has expanded to include tooling and workholding for every aspect of today’s manufacturing and machining industries.

Everything from sanding discs to coolant are now part of High Quality Tools Available in 6", 8", product line. and 10" sizes. Custom While displaying at design also available.

High Quality Tools lightweight 10" aluminum shell mill is ideal for milling big block heads

the Performance Racing Industry show, we realized there was a need for a cutter of this design that would work on the machines that people already have, would be economical to buy and use, and result in the mirror like finish required by high performance engine builders. High performance engines using metal gaskets require a very smooth, mirror like finish with no discernable tool marks. This cutter excels in this application.

The shell mills use APKT inserts(available everywhere) with different grades to specifically cut aluminum, cast iron, steel, stainless steel, etc. They also use standard 1-1/2” shell mill arbors for R8 milling machines as well as CAT40 machining centers or any machine using R8, 30,and 40 taper spindles. They are finished in hard coat anodizing for durabililty.

View more on page 9

A servo Products Partner Company For more information, please contact High Quality Tools, Inc.: Ohio: 34940 Lakeland Blvd., Eastlake, OH 44095, 800-521-7359, Ph: 440-975-9684, Fax: 440-975-9685 Florida: 8950 131st Avenue, Largo, FL 33773, Ph: 727-585-8555, Fax: 727-585-6555 California: 14254 Valley Blvd., Unit A , City of Industry, CA 91746, Ph: 626-961-7800, Fax: 626-961-2444 www.industrialmachinerydigest.com

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industrial and tooling news

EXSYS Tool, Inc. InTroducIng nEw AddITIonS To ITS PrEcI-FlEX® SYSTEm AT wESTEc The EXSYS/EPPINGER PRECI-FLEX® Adapter System is continuously expanding to meet the toolholding needs of today’s manufacturers, and EXSYS Tool will feature two of the system’s latest innovate additions in booth 2108 at the WESTEC 2012 show scheduled for March 27 - 29 in Los Angeles, California.

Joining the industry-leading PRECI-FLEX line of high-precision modular tooling systems are the new Type 02 extended adapters and new Shrink-Fit adapters.

Type 02 extended adaptors within the PRECI-FLEX system feature extended collet chucks that allow tooling to be positioned closer into a machine spindle or chuck; because of their extended lengths, the adaptors eliminate any tool interference issues.

As part of the many different types of PRECI-FLEX adapters that adhere to the front face of the collet pocket, the Type 02 adaptors permit the use of smaller size collet diameters closer to those of the cutting tool to be used. This option provides more secure tool holding and the ability to clamp tooling at greater distances from the chuck, yet with the same rigidity as if using a standard toolholder.

EXSYS/EPPINGER adds all the benefits of shrink-fit tool holding technology to its PRECIFLEX system with the development of the company’s new Shrink-Fit adapters. The adapters deliver 100% clamping and connectivity around a tool’s entire shank diameter, while providing the holding power, rigidity and accuracy associated with shrink-fit tool holding.

Unparalleled in performance, the EXSYS/ EPPINGER PRECI-FLEX modular tooling system was the first of its kind on the market to offer a single base holder and multiple tooling adapters that utilize the ER collet pocket, making lathe tooling changeovers quick, accurate and costeffective.

The product’s compact design ensures maximum torque transmission and rigidity, resulting in increased machining accuracy and improved productivity. Available in a range of sizes and styles, PRECI-FLEX provides unsurpassed repeatability, with every toolholder offering repeatability within 3 microns. The system also virtually eliminates machine downtime, and allows tooling adapters to be interchanged between fixed and rotary base holders for fast, economical machining.

The new Type 02 extended PRECI-FLEX adapters from EXSYS/EPPINGER.

AbouT EXSYS Tool, Inc.

EXSYS Tool, Inc. provides high precision rotary and fixed tool holder solutions for CNC turning centers. For more information on EXSYS Tool, Inc.’s products and services, For more information on EXSYS Tool, Inc.’s products and services, please contact Scott Leitch at sleitch@exsys-tool.com or at 11654 Corporate Lake Blvd, San Antonio, FL 33576.

HOLD-it:

never LOse tHat “LittLe reD straw” again!

NEW “One of a Kind Product” that will make sure you always have that straw for pin-point accuracy on ALL your aerosol cans that require a straw!! HOLD-IT’s are made of an extremely durable rubber/elastic polymer that stretched to fit just about any size can. Therefore, HOLD-IT is adaptable to numerous products such as; Lubricants, Choke Cleaners, Computer Cleaners, Electrical Contact Cleaner, Degreasers, Carburetor Cleaners, Rust Proofers, Contact Cleaners, Pesticides, Key/ Lock Lubricants, Anti-Chillers and Compressed Air Sprayers just to name a few.

MSRP $1.29 per Blister Pack (contains 2 HOLD-IT’s) Available at Lowe’s & ACE Hardware Stores For more information, please visit Hold-It.net or call 281-440-1655

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Industrial Machinery Digest — Quarter 1, 2012

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industrial and tooling news

CoRD Reel SeleCtion General Duty – Series LD Heavy Duty Industrial – Series L

Light Industrial - Series LG

In addition to a reset-able circuit breaker, this series features a detachable wall mount and swing bracket.

Has the endless hand winding, constant tripping hazards and added expense due to premature wear and tear of power/light cords have you contemplating the purchase of a cord reel? Correctly assessing your needs is the first step and is crucial to the selection process. It is very important that you identify the following prior to purchasing: 1. Cord Requirements a. number of conductors b. wire gauge (AWG) c. jacket type d. desired amps and volts e. working length of cable f. accessory 2. Application a. frequency of use (low, medium, high or constant) b. environment c. appliance(s) being powered 3. Price Reelcraft offers the most complete line of general duty, light industrial

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and heavy duty industrial cord reels.

We endeavor to meet your cord reel needs, regardless of application. To further elaborate on the differences and similarities between the lines, read the following descriptions: GeneRAl Duty, SeRieS lD These reels are for general use in lighter duty applications. They feature a pancake style slip ring and lighter gauge cord. They are the most economic of price, but may not be well suited for industrial applications.

These reels feature a reset-able circuit breaker, so that if too much amperage is drawn, it will cut power so that no permanent damage is done to the reel or the implement itself.

heAvy Duty inDuStRiAl, SeRieS l The Series L are all steel constructed and made in the USA. They feature a heavier duty radial slip ring design that can withstand constant use in heavy industrial applications. These reels are available with a wide variety of cord gauges, jackets, number of conductors and a GFCI option. Customers can choose from numerous end accessories or completely customize a cord reel for their specific application.

Series L reels are serviceable and parts are easily obtained.

Installing a cord reel can greatly improve safety in the work place, worker efficiency and protect expensive cables.

The correct reel selection is crucial and regardless of the type of reel you select for your application, Reelcraft would welcome the opportunity to serve you.

For a full line catalog visit us online at www.reelcraft.com or follow us on Facebook for the newest product information.

liGht inDuStRiAl, SeRieS lG The next step up from general duty reels, the light industrial series features longer lengths of thicker gauged cable.

Quarter 1, 2012 — Industrial Machinery Digest

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industrial and tooling news

HI-TEMP INERT ATMOSPHERE CABINET OVEN FROM GRIEVE No. 855 is a 1250ºF electrically-heated, inert atmosphere cabinet oven from Grieve, currently used for heat treating at the customer’s facility. Workspace dimensions on this oven measure 38” W x 26” D x 38” H. 40KW are installed in Incoloy-sheathed tubular elements to heat the oven chamber, while a 1500 CFM, 1-1/2 HP recirculating blower provides horizontal airflow to the workload.

This Grieve cabinet oven features 10” insulated walls comprising 2” of 1900ºF block and 8” of 10 lb/cf density rockwool insulation, Type 304, 2B finish stainless steel interior with continuously backwelded seams, plus inner and outer door gaskets with the inner gasket sealing directly against the door plug while the outer gasket seals directly against the face of the oven.

Full inert atmosphere construction further includes a pressure regulator, flow meter, pressure gauge, internal high-temperature gasket, all welded expansion connection in doorway throat, air jacket on inner oven for cooling, ½” thick silicone rubber atmosphere seal, blower shaft seal, positive latching door hardware, adjustable offset door hinges, outlet with pressure relief, interior seams welded gas-tight and all wall penetrations fitted with compression fittings. A 325 CFM blower pulls air through the air jacket on the inner oven for cooling.

Controls on No. 855 include a special heating/cooling temperature controller to control heating elements for heating and modulating damper on cooling blower for cooling. The oven also has

an SCR power controller and circular chart recorder onboard.

For more information, please contact: THE GRIEVE CORPORATION, 500 Hart Road, Round Lake, Illinois 60073-2835 USA. Phone: (847) 546-8225. Fax: (847) 546-9210. Web: www.grievecorp. com. Email: sales@grievecorp.com.

Attention: Frank Calabrese.

rePresenting tHe Hydraulic industry WitH resPonsive exPerienced service Engineering expertise is essential for the production of efficient, economical hydraulic power units and manifolds.

As hydraulic specialists, we offer prompt professional response to your needs from concept to start-up. We will design and build power units and Circuit Blok® manifolds to your system requirements and physical needs.

Quality assurance At MacMillin we test every power unit and circuit block we build. We set pressure and flow, and test for system performance. You can rely on MacMillin’s proven engineering.

MacMillin offers factory parts and service on components and accessories. In addition, MacMillin has

been selected as an Eaton authorized service center for Char-Lynn products. “circuit Blok®” Manifolds eliMinate trouBlesoMe Hydraulic PluMBing With MacMillin “Circuit Bloks”, numerous valves and controls can be plugged into a single space-saving manifold. It eliminates troublesome pluming problems, such as leaking or broken hose and pipe connections, that can cause system failure.

We are a factory autHorized distriButor of: Argo-Hytos, Auburn Gear, Char Lyn, Dynex, Oilgear, Sheffer.

View more on page 85

Contact MacMillin Hydraulic Engineering Corporation: 7355 N. Lawndale Ave., PO Box 6, Skokie, IL 60076 • Phone: 847-676-2910 • www.macmhydraulic.com

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industrial and tooling news

New Carmex DmT – 3 iN 1, Drills, ThreaDs aND Chamfers iN a siNgle operaTioN

Manufacturers can now save time, tooling, and money thanks to the recently introduced Carmex DMT — 3 in 1. Constructed of solid carbide coated with TiAlN, the tool’s rotation creates the thread hole, the thread, and the chamfer in a single operation. The expanded product line offers thread mills with smaller diameter for a thread depth of up to 2.5 x Diameter.

For further information, contact your Carmex representative or Carmex Precision Tools, LLC, at 1-888-628-5030, or visit our website at www.carmexusa.com. ®

BESSEY® IntroducES thE d15A compAct AvIAtIon SnIp The new D15 snip family by BESSEY® offers aviation snip applications with compounded leverage but, in a more unique and compact shape. The D15 snip comes in left (D15AL-BE), right (D15A-BE) and straight versions (D15S-BE) and, is 25% smaller than a standard-sized aviation snip. The smaller size does not blunt performance as the snip delivers 100% of the cutting capabilities compared to other aviation snips.

The drop forged cutting heads have a European engineered shape which uses distinctive angles for the left and right versions to create a flow-through cutting head design. This allows sheet metal, once cut, to move along the cutting head and beneath the hand. As a result, the D15 snip permits longer continuous cuts and, provides greater productivity with fewer injuries. The straight version bears a closer resemblance to North American styles and, for those that prefer this, they can still get it in the more compact straight version.

Competitive DifferenCe: 1. Cuts smaller radii because of the more compact cutting head.

2. Permits cutting in confined spaces because of a shorter overall length.

3. Enhanced comfort with an ergonomic two-part handle construction.

4. Full-size cutting performance in a compact shape.

5. Retail pricing in the $12-15 range for top value.

BESSEY® has been a market leader in clamps and cutting tools since 1936. If you know BESSEY®, you know our reputation for quality and reliability; you know we’re 130 years of German engineering backed by the strength of our product and our reputation.

BESSEY®. Simply better.

For more information, e-mail info@besseytools.com or call 1-800-828-1004.

View more on page 79

the Scientific cutting toolS SucceSS Story PeoPle Making the Difference More than 50 years ago, Scientific Cutting Tools, Inc. was established as an innovative tool business based upon the simple marketing concept of providing customers with superior products, competitive prices and uncompromising service. The owners and employees started SCT with a fresh perspective in tool design techniques and an inspired ambition to succeed. SCT entered the tool business with one product, one customer, and one driving goal - to be number one in the cutting tool industry.

Over the years, SCT has developed new tool lines, and refined existing ones. SCT’s aggressive research and development department also has the capability of developing specialized customer tools designed for specific projects. SCT tool designers can also modify existing stock tools to meet individual customer needs.

Although more than 50 years has passed since SCT first opened its doors, the company’s fundamental reasons for being in business have not changed from those that were first established by company founder Stan Christopher. Today’s commitment to quality control, unparalleled craftsmanship, and customer satisfaction are the attributes that set the people of Scientific Cutting Tools above the competition.

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the Sct guarantee “Our pride in workmanship assures product superiority every time.” Adopting a company philosophy of “pride in our people means pride in workmanship,” has proven to be the spark that has ignited Scientific Cutting Tool’s phenomenal growth over the past 50 years. By continually out-pacing the competition, responding to rapidly changing tool design technology, and meeting customer demand for high quality, precision cutting, threading, and boring bars, SCT has been able to keep this pledge to its customers: • Each tool is 100% guaranteed • Premium Sub-Micron Carbide provides for a tough tool with improved finishes • Guaranteed concentricity • Unparalleled craftsmanship • Care and attention to detail • Closely monitored quality control • Off-the-shelf-stock for immediate delivery • Meet or exceed customer’s design expectations • Each tool triple checked before customer receives it • 100% customer satisfaction SCT has built an excellent reputation as a manufacturer of an extensive line of cutting tools including carbide thread mills both coated and uncoated. SCT’s cutting edge technology in the tool processing industry has allowed the

forward-thinking company to produce top-end cutting tools at competitive market prices. a SteP into the future Where Price, Quality, anD cuStoMer Service Will Still count In the years to come, Scientific Cutting Tools will continue to position itself to be at the cutting edge of tomorrow’s product design and development which will be guided by a renewed sense of commitment to the customers it serves. SCT will still offer competitively priced products at or below the industry average and deliver superior quality tools backed by a 100% customer satisfaction guarantee. SCT extends this challenge to any manufacturer who uses cutting, boring, or threading tools: “Just try any one of SCT’s quality crafted tools on your next job and see what a difference it will make.”

For more information please contact Scientific Cutting Tools at 800-383-2244 or visit their website at www.sct-usa.com.

View more on page 85

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industrial and tooling news

Metabo’s New PiPe aNd tube belt saNder ideal for burNishiNg, fiNishiNg aNd recoNditioNiNg Used on pipe and tube fabrications Metabo Corporation, a leading international manufacturer of professional grade portable electric power tools and abrasives for industrial, construction and welding applications, now offers an electronic pipe and tube belt sander for burnishing, finishing and reconditioning steel, stainless steel, non-ferrous pipe and tube. The RBE12-180 Pipe and Tube Belt Sander is a flexible tool that adapts to every contour and is easy to handle. This versatile tool can render weld seams invisible and can give stainless steel a mirror finish.

The RBE12-180 features Metabo’s Marathon motor with 1,200 W and 10 A of power, double gear reduction for a high rate of material removal, an exact sanding belt guidance feature for even grinding results and a 270° maximum wrap angle that allows the tool operator to work more efficiently.

The new pipe and tube finisher includes Metabo’s VTC (Vario Tacho Constamatic) electronic speed stabilization for increased productivity under the heaviest operating

conditions, electronic soft start and thumbwheel to preselect the tool’s speed. The RBE12-180 features a toolless sanding belt exchange that helps to increase operator efficiency and safety.

Additional safety features include overload protection, power interruption protection, Metabo’s winding protection grid and long life auto-stop carbon brushes.

The RBE12-180 has an extensive range of accessories for various materials and can be used to take metals from a welded or mill finish to mirror finishes.

For more information, please visit www.metabo.comor contact Terry Tuerk, Metabo Corporation, 1231 Wilson Drive, West Chester, Pa. 19380. Tel: 800/ 638-2264; Fax: 800/ 638-2261; Email: ttuerk@metabousa.com; Web: www.metabousa.com

Durable Technologies names maTT marTin To DirecTor PosiTion Durable Technologies, the leader in marking and identification solutions, recently announced that Matt Martin has been promoted to Director of Sales and Marketing.

Martin will be responsible for the design and implementation of sales and marketing programs and initiatives corporatewide. He also will evaluate and align the business development and marketing communications programs for each of Durable Technologies independent divisions — VisiMark, Inc., Durable Mecco, and Durable Machine — in support of the overall mission and vision of the organization.

“When Matt joined VisiMark five years ago, I knew he would be a vital contributor to our future plans,” said Kari Lunden, President & CEO of Durable Technologies. “By streamlining the sales and marketing functions of our businesses, and appointing Matt to his new position, he will directly impact our growth strategies. I am confident that Matt will continue to be a valuable asset to our company and to our customers.”

Martin began his tenure at the company as a sales representative and rose to branch sales manager where he was responsible for sales and marketing at VisiMark,

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Inc. on a division level. A resident of Millbury, MA, Martin is a graduate of Framingham State University.

His promotion closely follows Durable’s announcement that the company altered its corporate infrastructure and its strategic direction by aligning its three marking companies —VisiMark, Inc., Durable Mecco, and Durable Machine — under the Durable Technologies umbrella to leverage their combined experience and expertise. abouT Durable Technologies The Durable Technologies companies, based in Worcester, MA and Chicago, IL, provide marking and identification products, systems, and solutions to a wide range of industries including automotive, metal fabrication, defense, aerospace, medical, pharmaceutical, jewelry, and electronics. For more information about Durable’s full line of marking capabilities, equipment, and technology, please visit www.durable-tech.com

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productivity profile

MorgAn technicAl cerAMics’ DiAMonex® DiAMonD-like cArbon coAtings extenD AerospAce coMponent life Morgan Technical Ceramics (MTC) announced that it continues to expand its range of superior, exceptionally wearresistant Diamonex® diamond-like carbon (DLC) coatings for use in the aerospace industry. The coatings can be applied to a variety of metals, plastics and glass, providing a significant improvement in both product life and operating efficiencies. For aircraft windshields, the DiamondShield® coating reduces the abrasion caused by desert sand environments. Other recent applications include a titanium landing gear bearing refurbishment program, landing lights, and wing tip lenses.

Under harsh environments, Diamonex coatings provide a robust and durable solution for bearings, actuators, gears, fasteners, control mechanisms and landing gear as well as a variety of transparent products.

In response to market demands for an environmentally friendly, corrosion protective coating, Diamonex developed its special Diamonex Crx coatings, which provide a far superior and environmentally friendly solution compared to existing hard chrome plating. These coatings are deposited using a low temperature (<250°C) plasma-enhanced chemical vapor deposition process, so the underlying substrate material is not affected. The coatings are also significantly thinner than hard chromium, and do not require any post process machining. They feature excellent

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adhesion and a low coefficient of friction.

Compared to chrome plating or titanium nitride (TiN), the Diamonex Crx coatings are significantly harder and provide additional wear resistance and reduced coefficient of friction.

MTC’s Diamonex Ti coating has been approved by a leading aerospace prime contractor as fully interchangeable with the existing Tiodize AMS 2488 Type II coating on one of its aircraft’s landing gear bearings. Through qualification testing, the Diamonex DLC coating has been shown to have improved wear- resistant characteristics compared to Tiodize. It is a super hard coating (>15 gigapascals (GPa), which prevents fretting, wear and galling, thus extending component life, extending service intervals, and increasing flight up-time. It also has a low coefficient of friction, acting as a dry lubricant on mating surfaces and reducing wear and tear on components. The coating is stable through thermal cycling, which maintains coating integrity.

“The aerospace Industry is constantly striving to extend aircraft service life by increasing maintenance intervals,

and improving operating efficiencies by minimizing operating costs and reducing aircraft weight,” said Neil Winterbottom, general manager of MTC Diamonex. “The Diamonex range of high performance coatings are providing aerospace manufacturers with significant opportunities to help meet both current and future demands.”

About MorgAn technicAl cerAMics Morgan Technical Ceramics manufactures components and sub-assemblies using an extensive range of materials, including structural and piezoelectric ceramics, dielectrics, braze alloys, and specialist coatings. It works with manufacturers’ design and R&D teams at local, national and international level on projects from concept and feasibility studies through prototype development to full production. The business employs some 2,500 people and has 23 manufacturing sites worldwide across Europe, the US, Mexico, China and Australia.

Morgan Technical Ceramics is a business within the Morgan Ceramics Division of The Morgan Crucible Company plc, one of the world’s leading advanced materials companies. The company specialises in the design, manufacture and marketing of ceramic and carbon products which are used in a wide range of applications, from transport and telecommunications to fire protection and medical instruments. Morgan Crucible is listed on the London Stock Exchange in the engineering sector.

For more information on Morgan Technical Ceramics visit www. morgantechnicalceramics.com or contact us at: Morgan Technical Ceramics, 26 Madison Road, Fairfield, NJ 07004, USA, Phone 1-800-433-0638, Fax 1-973-2277135, Email mtcussales@morganplc.com

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electrical news

need 3-phase power?

Superior Phase Converters are the best in rotary phase converters!

Convert 220v/440v Single Phase into 220V/440V 3-Phase Power. Superior Phase Converters, LLC specialize in CNC, 3-Phase Farm Equipment, EDM, Woodworking, and all other 3-Phase Equipment! Superior Phase Converters consistently strives to be proactive with customers, works to provide the most cost effective and quality assured phase converters available in the world today, and maintains a team of people who will develop and maintain a quality and service oriented attitude, providing reliable technical sales and support.

What is the superior phase Converter?

It is a high quality electrical rotating transformer that produces three phase power when single phase is only available. It manufacturers effecient and convenient three phase power and saves you from the hight expense of utility supplied three phase power. hoW does superior phase Converters Compare With utility three phase?

Performance of electric motors hooked to Superior Phase Converters compares very favorably to three phase power. Locked rotor, full load torque, breakdown torque and full horse power development are achieved as if connected to three phase. are all phase Converters ConstruCted equally?

No! In general, some units on the market are badly unbalanced with all electrical capacity loaded up on one phase of the internal winding. This generates excessive overheating and often leads to converter failure. Another consumer objection is the high amount of noise generated from this method of construction.

does superior phase balanCe every unit?

Yes! Superior Phase Converters’ manufacturing attention is very detailed. Every unit is balanced by technical staff resulting in outstanding performance for the consumer. The units have a very favorable reputation for running cool and quiet.

is it expensive to operate superior phase Converters?

No! Energy savings is the heart of the Superior Phase design. Customers often say they leave Roto-Master running during lunch hours and other periods of work stoppage, without a noticeable increase in their electric bill.

is there a Warranty?

Yes! Superior Phase Converters’ new units have a one year warranty on both the rotary and the control panel.

Can superior phase Converters idle at no load Without overheating?

Yes! Balancing the current on each winding allows this. Since some models on the market are unbalanced, you will need to constantly start and stop the unit to prevent overheating, resulting in additional power consumption and inconvenience.

What are some of the appliCations superior phase Converters run?

Machine shops, Small factories, Elevators, Compressors, Sawmills, Hoists, Pumps, Farms, Fire Sirens, CNC machines, Woodworking shops, Computers, Irrigation, Sewage plants, and Welders should superior phase Converters be started first?

Yes! When Superior Phase Converters are running, you may start and stop motors without any limitations or sequences. hoW is the CorreCt superior phase Converter determined?

Each model is rated in HP with given parameters.

As a rule we size by the largest motor and total HP of smaller motors to be operated. Once this information is obtained a sizing selection may be made. Other considerations are type of application, as various equipment operates differently. In short, it is best to consult one of Superior Phase Converts’ factory engineers as to your individual needs.

What is the life span of superior phase Converters?

Typically Superior Phase Converters will outlast the equipment that it operates. The converter is designed to run continuously at low amperage, so it stays cool. You can expect many years of trouble free service from these units.

does superior phase Converters require exCessive Consumption of poWer to start?

No! Balanced converters start instantly as power is generated on each phase, resulting in low inrush amperage. Some converters on the market use only one phase of the converter winding, resulting in longer starting time and high current draw on the utility lines. This often results in power drops and flickering for the customers and the utility companies. The Roto-Master starts in approximately 2-3 seconds.

What size should my eleCtriC serviCe be?

This will depend upon the total HP that runs at one time. Add all three phase current (amperage) and multiply by 2.15 to convert to single phase, this allows for service size, wiring, etc. Superior Phase Converters’ engineers are available to help you determine your service needs. are superior phase Converters diffiCult to install?

No! It is among the easiest to install because there is a terminal block connector inside the pre-wired control panel for added convenience.

For more information on this story, please contact Superior Phase Converters, LLC: PO Box 14045, 3021 Standridge Rd., Anderson, SC 29624 Phone: 864-261-7172 or 800-603-7636 • Web: www.superiorphase.com • Email: sales@superiorphase.com

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Industrial Machinery Digest — Quarter 1, 2012

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?

need 3-phase power

superior phase converters buy the best we provide the following services and support products: Repair and recondition of ALL other brand name Phase Converters Refurbished 3-phase motors from 1 HP to 100 HP • New electric motors Single phase motors from 1 HP to 100 HP • Used and new single phase transformers

sizes from 1 to 200 hp at 230 and 460 volts save up to 50% factory direct!

✓ We specialize in CNC, EDM, Phase Converters - for over 25 years! ✓ We Guarantee to run your CNC or EDM Machines the Right Way! ✓ Single or multi-motor operation ✓ Our units do not run hot! ✓ Voltage on our units is not sky high ✓ No voltage regulation required ✓ 1 year warranty on windings and rotor ✓ Motor-run capacitors ✓ Sizes from 1 to 200 HP

buy factory direct! consumers welcome! free voltage regulator and terminal block included for easy hook up! call for prices on refurbished units!

superior phase converters, llc PO Box 14045 • 3021 Standridge Rd. • Anderson, SC 29624 • Email: sales@superiorphase.com

(864) 261-7172 • (800) 603-7636

www.superiorphase.com

electrical news

GEt CoMplEtE sYstEM protECtIon WItH tHE ICM450 tHrEE-pHAsE VoltAGE MonItor Delivers Superior Line AND Load Side Protection ICM Controls, a leader in the manufacture and supply of electronic controls to the HVAC/R industry, readies your equipment for the extremes of the summer months with its ICM450 ThreePhase Voltage Monitor. The fully programmable ICM450 has an array of powerful features that combine to prevent premature motor failure and damage due to common voltage faults. By evaluating the power on both the Line and Load sides, the ICM450 can spot power disturbances caused by factors like a worn contactor, problems that might otherwise be overlooked.

ICM450 features an LCD display, which helps simplify both the installation and troubleshooting processes. It offers fast, 7-step push-button setup and simultaneous displays all 3 phases being monitored. The ICM450 also records up to 25 of the last faults for display on the LCD. The ICM450 protects against voltage unbalance, high and low voltages, phase loss, phase reversal, faulty power, incorrect sequencing and/or rapid short cycling. It includes a field-adjustable delay on break timer, allowing the installer to avoid nuisance trips. The independent high and low voltage settings are ideal for dual voltage compressor applications.

The ICM450 is part of a complete line of single-phase and 3-phase

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motor protection controls to fit every application and budget.

About ICM Controls CorporAtIon ICM Controls has been a leading manufacturer of electronic controls for the HVACR industry for more than 25 years, a position achieved through product and process innovation. Serving both the OEM and the aftermarket, ICM Controlsâ&#x20AC;&#x2122; goal is to provide its customers with the most technologically advanced products at the greatest value without compromise in quality. ICM Controls offers better command of the supply chain through true vertical integration. Its products are proudly made in the U.S.A.

Industrial Machinery Digest â&#x20AC;&#x201D; Quarter 1, 2012

For further information about ICM Controls and its products, call 800-365-5525 or visit www.icmcontrols.com, or follow us onTwitter, Facebook, and LinkedIn.

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Quarter 1, 2012 â&#x20AC;&#x201D; Industrial Machinery Digest

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electrical news

3 phase power anywhere!

Phase-A-Matic, Inc. Phase Converters are used when three-phase lines are not available or are cost prohibitive. The phase converter will run virtually any 3-phase machine at any single-phase location.

Advances in converter technology have resulted in low price, high performance and reliability closely resembling threephase line power. This enables us to provide the required power for CNC and other voltage-sensitive equipment.

RotaRy ConveRteR ReLIaBILIty – MtBF (Mean tIMe Between FaILuRe) Failure rate (MTBF) is so low it’s almost impossible to determine. We find that within the first 12 months approximately 1 in 150 might have a problem, and usually within a few weeks or months.

After the first 12 months, it might be one or less in 10,000 over a 35 year period. We continue to hear of our Rotary Converters that have been in service for 25 or 30 years or more, and which are still working flawlessly. It could go on to do another 25 or 30 years.

The reason for the reliability is fairly obvious. Phase-A-Matic, Inc. Rotary Converters do not have start capacitors or contactors or mechanical connections of any kind as most other converters do, which contributes to and is usually the most common cause of failure. All connections are soldered, which is not feasible with other designs. Even though some other manufacturers claim to use Baldor motors, they still have start capacitors and switch gear, which we have eliminated by working with Baldor for approx. 2 years to develop. It pays to buy Phase-A-Matic, Inc. for long life and high reliability. There is very little to go wrong with the Rotary Converter, and is

considered by our customers to be the quietest they have used. aPPLICatIonS Phase-A-Matic, Inc. Rotary Phase Converters run all common three-phase machine shop equipment, providing the power necessary to run all load types including CNC/PLC, transmitters, lasers, welders, battery chargers, heating elements, etc. Whatever the load type - motor, resistive, induction, or transformer load - our Rotary Converter will power it. PhaseA-Matic, Inc. has been providing phase conversion for the home shop machinist, the industrial machinist, the farmer in agricultural use, for food processing equipment, the woodworking industry, the metalworking industry, medical equipment, elevators, etc.

The Rotary Converter is designed to operate as modules with the ability to be connected in parallel to produce any required output, no matter how large. With fuel prices skyrocketing, diesel generators are now being replaced with Phase-A-Matic, Inc. Rotary Phase Converters. Bring your request to us and we will supply the right conversion for your application. aBout uS Product lines began over 46 years ago with the well-known StatIC ConveRteR, the workhorse for tens of thousands of regular shop machines, such as mills, lathes, etc. Phase-A-Matic, Inc. has been innovating new technologies in the production and function of the converters by developing new electronic sensing circuit board switching, replacing old style mechanical components. The RotaRy ConveRteR FuLL PoweR line is a true phase converter jointly developed with Baldor Electric and built to our stringent specifications for

high performance and proven long-term dependability, the best quality available anywhere. This converter produces true three-phase power, and is considered by our customers to be the quietest rotary converter they have used. It meets your concerns in delivering the critical uptime and reliability your operation requires. Phase-A-Matic, Inc. is currently developing a full power transformer style phase converter, the PhaseFormer, and will be available for purchase in the very near future as we continue to forge ahead with new product lines and innovations in technology.

CoMPany RePutatIon & BeneFItS Professional, available technical support for proper sizing and installation, consistent product reliability and immediate delivery from stock for most items are core components of the strength of the company and its esteemed reputation.

Phase-A-Matic, Inc. phase converters range from 1/3 to 500 HP or more. We have the right converter to meet your needs in delivering economical, reliable and true 3-phase power of the highest quality, thus providing the dependability and uptime you must have.

For more information, contact Phase-A-Matic Inc. at 800-962-6976 or visit www.phase-a-matic.com Español: www.phase-a-matic-es.com. Spanish speaking technicians available to help you.

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Industrial Machinery Digest — Quarter 1, 2012

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productivity profile

MILITARY STRENGTh IN MOTION: NOOK’S ELECTRIC CYLINDER SERIES DELIVERS RUGGED ACTUATION FOR hARSh ENVIRONMENTS. Nook Industries (Cleveland, OH), is the leading supplier of electric cylinders in the world. The Nook Electric Cylinder series is ruggedly designed and intended for use in harsh/dirty industrial applications as it features ground and hard-chrome plated actuator tubes that enclose Nook’s Precision Acme and Ball Screw system.

Nook Electric Cylinders are completely enclosed−making them ideal for outdoor/off-road industrial applications including military use. Nook can also accommodate any MIL-SPEC paints for specific Military applications.

Nook linear actuators are often “the heart of modern engineered applications” and it’s no question why the Nook Electric Cylinder is truly primed for military combat applications. In comparison to alternative actuation devices Nook Electric Cylinders offer the greatest level of control, reliability and precision. The advantages of the Nook Electric Cylinders over competitors are endless and include a direct power source, no hoses, no leakage, a smaller footprint, high repeatability, and precision.

Nook Electric Cylinders are perfect for applications where lives depend on timing and accuracy, one micrometer can alter the outcome of engagement.

NOOK ELECTRIC CYLINDER SERIES DESIGN CONFIGURATIONS: In-LIne ActuAtor “ILA”: ILA Electric Cylinders offer no reduction as they are designed to have a motor or gear reducer directly coupled to provide fast, precise operation and/or higher duty cycles.

• Load capacities range from 1/2 to 10 ton.

• Nook Precision Ball Screw actuated.

• Keyed or un-keyed actuator tubes.

• Standard trunnion pin mounting; easily adapted for use with servo motors and planetary gear reducers.

DIrect DrIve of “DD”: • Load capacities range from 1/2 to 20 ton.

• Nook Precision Ball Screw or Acme Screw actuated.

• Worm gear power train. rIght AngLe DrIve “rAD”: For applications that require reduced RPMs to move a lot of weight, Nook’s RAD Electric Cylinders incorporate the same features of the DD with a second stage of worm gear reduction that provides higher thrust at lower speeds. The reducer and motor can be mounted in eight possible positions for maximum flexibility.

NOOK ELECTRIC CYLINDER ACCESSORIES: • Servo motors.

• Hand wheels.

• Motor mounts−IEC/NEMA • Couplings.

• Bellow boots. ª Limit switches.

CORPORATE PROFILE: For over 40 years, Nook Industries, Inc. has been a leading manufacturer of linear motion components and linear motion control systems. Manufacturing one of

the most comprehensive selections of integrated linear motion systems in the world, Nook’s progressive growth has been achieved through its commitment to quality, continuous improvement, defect prevention, and the use of statistical methods and consistent training to ensure the quality of its products. Headquartered in Cleveland, Ohio, Nook Industries is an ISO 9001- 2008 Registered company that provides controlled motion solutions in a wide range of industries including; transportation, medical/diagnostics, paper, chemical, food/ beverage, solar/aerospace, entertainment and communications markets. Clients in these markets rely on the company’s products for tooling, product design and engineering flexibility to provide modified standard products to meet their respective application requirements. Whether the application requires an off-the-shelf linear motion component or an engineered solution tailored to fit your application−Nook provides comprehensive engineering, design and analysis to provide the highest quality linear motion solutions on the market today.

Detailed and downloadable specification data is available at: http://www.nookindustries.com/cylinder/Cylinderhome.cfm Or call Nook Industries: 1-800-321-7800

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Industrial Machinery Digest — Quarter 1, 2012

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MaChIneS. ToolS. SYSTeMS. Experience first-hand the technologies that will help you leave your competition in the dust.

To win jobs, you must know about and employ the latest technology available.

The demand for the best is met by IMTS, the International Manufacturing Technology Show—the largest display and demonstration of global manufacturing technology in the Western Hemisphere.

Breakthroughs are everywhere on the show floor. You’ll find solutions you need from more than 1,100 IMTS exhibitors— the best the world has to offer—nearly a half million square feet of machine tools alone… plus tooling and workholding.

IMTS: Where Your TeaM BelongS More than 82,000 decision-makers, many of them your toughest competitors, attend IMTS to get ideas and find answers to their manufacturing problems.

At IMTS, they find ways to cut costs, increase productivity, improve quality and get more business. Your team should be there, too.

IMTS WIll ProvIde The anSWerS You need Show after show, we ask manufacturers like you, and they tell us…

• 92% find new products or ideas to use • 82% find specific solutions to manufacturing problems • 90% visit booths of companies not currently calling on them • 82% will buy from IMTS exhibitors At IMTS, you will find new sources, new solutions and you will make them yours.

The IMTS 2012 ConferenCe IMTS brings together industry experts to provide information and answers you need in a dynamic learning environment: • 92% Sessions complement what you see on the exhibit floor • 82% Gain insight that help you profit today and prepare for tomorrow • 90% Learn from professionals with solutions to your manufacturing challenges • Learn More IMTS WIll oPTIMIze Your ShoW floor ProduCTIvITY IMTS is organized to help you and your team navigate the show and find the answers you need efficiently.

IMTS features 10 industry pavilions, 18 major product groups and more than 350 product categories, all searchable and each with a list of exhibitors. Every list is in alpha order to facilitate your search. You can search directly by exhibitor name, too.

You can start your search here.

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This website features the ultimate planning tool, MyShow Planner. Use MyShow Planner to map your visit, contact exhibitors and set up productive meetings at the show.

You’ll compare technologies and get first-hand answers from the world’s leading manufacturing technology providers.

IMTS: The ManufaCTurIng evenT of The Year!

IMTS is the largest manufacturing technology show in the Western Hemisphere. You can see and compare technologies from around the world. Get the answers you need to stay competitive. Be there! regISTraTIon InforMaTIon Registration details can be found here. Registration for IMTS is currently open. Be sure to sign-up for the IMTS Insider.

SePTeMBer 10-15, 2012 MccorMick Place • chicago, illinois www.industrialmachinerydigest.com

When I hand my son the keys to this shop, I want him prepared to succeed.

Building a shop is hard work, long hours, solutions under pressure.

Building a legacy is guidance, experience, preparation. Which is why I’ll be getting him off the shop floor and onto the floor of the biggest manufacturing classroom in the Western Hemisphere.

Industry trends. New technology.

Suppliers. Purchasing.

Competitor demos and exhibits.

He’ll be exposed to it all, face to face, in one place.

Because someday, all too soon, this will be his place.

Dominate the competition.

Attend IMTS 2012. Register at IMTS.com

be there.

.com I N T E R N A T I O N A L

M A N U F A C T U R I N G

T E C H N O L O G Y

S H O W

Sept. 10-15 2012 · McCormick Place · Chicago

trade show and event news

2012 INTERNATIONAL WOODWORKING FAIR LAUNCHES AUGUST 22 IWF gears up For upcomIng attendees Mark your calendar for the 2012 International Woodworking Fair (IWF) this August at the Georgia World Congress Center in Atlanta. Industry exhibitors from all over the world will gather once again to participate in the largest woodworking technology tradeshow in the Western hemisphere.

“Registration for IWF starts now and the advantages for exhibitors go beyond just saving money.” says Michael Burdis, IWF 2012 chairman and president of James L. Taylor Manufacturing Company, “Exhibitors can get a head start on networking and marketing their products for the show.”

Those who attend IWF 2012 will meet with the industry’s technology experts to receive advice on how to profit in today’s marketplace. Attendees will also be able to test, compare and evaluate the latest technology from all over the world. Whether it is design, supply or machinery, if it’s wood-related, exhibitors and consumers can find it at IWF. For more information, or to register for the International Woodworking Fair, visit www. iwfatlanta.com. For up-to-date company news and industry updates, connect with IWF on Facebook and Twitter.

the cost-effective way to find suppliers Save the time and expense of traveling to prospective suppliers or national trade shows.

Find suppliers of hundreds of services under one roof. Save the time and expense of traveling to prospective suppliers or national trade shows.

AmCon regional expos are the cost-effective way to find suppliers of contract manufacturing and job shop services. Feel free to pre register to attend at our website: www.amconshows.com, or call us at 800-829-7467.

View more on page 105

One VOice LegisLatiVe cOnference, May 8-9, 2012 Have Your Voice Heard on Capitol Hill!

Please mark your calendar and make plans to attend the fourth-annual NTMA/PMA One Voice Legislative Conference in Washington, D.C., May 8-9, 2012.

With the Bush tax cuts set to expire at the end of the year, tax issues will be front and center. It is incredibly important for us to weigh in on tax reform as the action Congress takes could last a decade or more and impact our ability to compete globally. Congress also will address health care, workforce development and labor issues in 2012—all important issues to manufacturers. Because of the significance of these issues, extra emphasis is being placed on Capitol Hill visits this year, allowing more time to discuss the issues that matter most to your business with those who hold power in Washington.

The program kicks off on Tuesday, May 8 with lunch and a political insider’s analysis of what to expect in the 2012 elections, followed by a briefing from One Voice lobbyists on the latest developments related to key legislation. We’ll then head to Capitol Hill for a few hours of meetings before

enjoying a networking reception that evening. The entire day on Wednesday, May 9 will be spent on Capitol Hill.

Finally, as an added benefit, a pre-conference webinar is being planned for first-time attendees plus any others who would like a refresher on what to expect during the congressional visits.

More than 100 PMA and NTMA members convened in Washington, D.C., for last year’s conference, where we spread our message to 100 congressional offices. We want to build on that momentum and have an even more successful event this year, so please plan to join us May 8-9 in Washington!

Visit www.metalworkingadvocate.org for more information!

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View more on page 63

www.industrialmachinerydigest.com

Denver Colorado Convention Center Denver, CO Monday, May 7, 9:30am-3:30pm Tuesday, May 8, 9:30am-3:00pm Meet with top quality Suppliers from throughout the USA

trade show and event news

DeSign-2-ParT ShowS announce 2012 ScheDule Design-2-Part (D2P) Shows, America’s largest design and contract manufacturing tradeshows, have released their 2012 show schedule. The 11 show slate includes six annual events, four semi-annual shows and a highly anticipated return to the Pacific Northwest.

The schedule is highlighted by Design-2-Part Shows’ third ever appearance, and first since 2009, in Portland, Oregon with the Northwest Design-2-Part Show, on October 23 & 24, 2012 at the Metropolitan Exposition Center.

As usual, the schedule is anchored by six annual shows.

D2P will hold these events in Grapevine (Dallas), TX, Santa Clara, CA, Atlanta, GA, Schaumburg, IL, Long Beach, CA, and Marlborough (Boston), MA. The Southern California Design-2-Part Show actually rotates between Long Beach and Pasadena giving Greater Los Angeles area manufacturers two convenient, every-other-year options.

The D2P schedule is rounded out with four events that revolve semi-annually. These shows will be held in Secaucus, NJ, St. Charles (St. Louis), MO, Akron, OH, and Raleigh, NC. Design-2-Part Shows provide design engineers, manufacturing engineers and managers, and purchasers an excellent opportunity to meet local and national job shops and contract manufacturers to source custom parts, components, services, and design. Exhibiting companies will be showcasing their design-through-manufacturing services featuring more than 300 product categories for the metal, plastics, rubber and electronics industries. The shows are working shows and visitors are encouraged to bring sample parts and drawings.

D2P Shows exclusively feature exhibiting job shops and contract manufacturers with manufacturing operations in the United States. Companies that do not have facilities in the U.S. are not permitted to exhibit.

For more information about exhibiting or attending any Design-2-Part Show, visit www.D2P.com. abouT DeSign-2-ParT ShowS Design-2-Part Shows are America’s largest and longest running contract manufacturing shows for the sourcing of custom parts, components, services and design. Regional tradeshows covering the USA provide OEMs the opportunity to meet local and national job shops and contract manufacturers face-toface to find new suppliers, learn new technologies, compare processes, and reduce manufacturing costs.

The 2012 D2P Show ScheDule: TexaS DeSign-2-ParT Show

February 21 & 22 Gaylord Texan Convention Center, Grapevine, TX

norThern california DeSign-2-ParT Show March 21 & 22 Santa Clara Convention Center, Santa Clara, CA

SouTheaST DeSign-2-ParT Show March 28 & 29 Cobb Galleria Centre, Atlanta, GA

MiD-aTlanTic DeSign-2-ParT Show

April 11 & 12 Meadowlands Exposition Center, Secaucus, NJ

greaTer chicago DeSign-2-ParT Show May 1 & 2 Schaumburg Convention Center, Schaumburg, IL

MiDweST DeSign-2-ParT Show

June 13 & 14 Saint Charles Convention Center, St. Charles, MO

greaTer ohio DeSign-2-ParT Show September 19 & 20 John S. Knight Center, Akron, OH

SouThern california DeSign-2-ParT Show October 2 & 3 Long Beach Convention Center, Long Beach, CA

norThweST DeSign-2-ParT Show

October 23 & 24 Metropolitan Exposition Center, Portland, OR

new englanD DeSign-2-ParT Show October 31 & November 1 Royal Plaza Trade Center, Marlborough, MA

SouTheaST DeSign-2-ParT Show November 14 & 15 State Fair Exposition Center, Raleigh, NC

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www.industrialmachinerydigest.com

productivity profile

deburring soluTions For Any AppliCATion Deburring is a common metalworking problem and is important for quality, aesthetics, functionality and smooth operation of working parts. It is also an important safety consideration. Even a small burr can cause moving parts to catch, cut o-rings and seals during assembly or break off in the final assembly creating the potential for accident, injury or component failure. Rough edges can also cause injury when individuals are required to handle parts during processing. Each of these preventable problems can cost companies a great deal of money. “Burr removal meant a great deal of hand work in the past”, states Michael Miller, Brush Research Manufacturing’s VP of Sales. “A greater emphasis is now being placed on automating the deburring process and bringing the deburring tools into the manufacturing cycle.” Automated deburring provides more consistent results and eliminates many of the repetitive motion injuries associated with hand deburring. Burrs and poor finish affect parts of many shapes and sizes and specific tools have been developed for each case.

Flex-Hone® Tools — For Any Type or size oF Cylinder The Flex-Hone tool is recommended for internal surface finishing and cross hole deburring in cylinders. The Flex-Hone Tool is a resilient, flexible honing tool with a soft cutting action.

“Whether it’s deburring a hole, blending an edge or just improving the finish, the FlexHone provides consistent results from part to part”, Miller adds. The Flex-Hone produces a plateau surface finish with a non-directional or crosshatched pattern that greatly increases the surface’s ability to hold oil. This results in improved product performance and longer product life. The Flex-Hone is used in a variety of automotive, hydraulic, pneumatic and industrial applications. The tool fits holes from 4 millimeters to 36 inches. “A real advantage to using the Flex-Hone in a machining center is that parts can be deburred and finished in a single step,” Miller continues. “Parts can be dropped off complete”.

For the tool to work well in all materials, a variety of abrasive types are needed. The

Flex-Hone is available in 8 different abrasive types including silicon carbide, aluminum oxide and was recently introduced in diamond. To meet the widest variety of finish specifications, the tool must be available in different grit sizes. The FlexHone is produced in 12 grit sizes from as coarse as 20 grit to as fine as 800 grit.

AbrAsive nylon disC brusHes Abrasive nylon disc brushes are used for deburring and removing tool marks from flat milled surfaces, deburring gears and machined parts and fine blanked or punch press parts.

They are often used in robotic systems and in automated in line finishing systems producing parts for the automotive, appliance and aerospace industries. Machine cycle times and available machine spindles require the brushing tool to be as versatile as possible.

Brush Research has recently introduced

Nampower™ Disc Brushes, a line of abrasive nylon disc brushes with a combination of filament material that deburr and finish at the same time. These revolutionary brushes contain a unique combination of both ceramic filaments that provides maximum burr removal rates with silicon carbide filament that produces an optimum surface finish. The brushes are manufactured using a molded fiber reinforced thermoplastic base which provides greater stability and balance overcoming problems associated with other disc type brushes. To suite a variety of parts and deburring requirements, the brushes are available in 2 different styles: Dot Style for general purpose deburring and surface finishing applications and the Turbine Style brush for medium and heavy deburring applications. The brushes come in a variety of grit sizes and are designed to be used with the company’s unique flow-thru tool holder which provides better lubrication distribution resulting in faster cut rates and longer tool life.

“These high-performance tools create reliable, consistent and cost effective results”, says Miller, “Nampower™ Disc Brushes are easily integrated into today’s automated machinery, CNC machining

centers, transfer lines and robotic cells”.

AbrAsive nylon WHeel brusHes Abrasive nylon wheel brushes are used in the production of turbine blades, steel gears, machine parts, cam shafts and cutting tool inserts and are often used as an alternative to wire wheels and non-woven abrasive brushes. Brush Research’s NamPower™ composite hub wheel brushes are abrasive nylon brushing tools designed for machine-based and off-hand deburring, surface finishing and edge radiusing. A unique feature of these brushes is their composite hub construction.

Composite hub construction allows for greater and more uniform filament density that produces a brush with more cutting points. Higher filament density means more abrasive cutting points on the workpiece resulting in faster material removal rates and longer tool life. Composite hub construction also results in a more balanced brush that produces less vibration and greater process repeatability. NamPower composite hub wheel brushes are available in a variety of grit selections to provide maximum burr removal and optimum surface finish. The wheels are available in 6” and 8” diameters and either ½” or 1” face widths. deburring smAll Holes — THe miniATure brusH soluTion Miniature deburring brushes are used to finish and deburr holes as small as .024 inches. Miller states, “While we recommend the Flex-Hone tool for holes of 4mm and larger, miniature deburring brushes provide a viable solution for small cross holes and intersecting holes”.

Miller adds, “Removing burrs and producing an edge radius on small diameter holes is an expensive finishing problem that involves a great deal of hand work. Miniature deburring brushes can automate this process saving time and money while improving product quality and consistency”. Filament choices include carbon steel, stainless steel, brass, abrasive nylon, nylon and natural to provide the optimum finish on a variety of base materials. Miniature abrasive nylon deburring brushes are now also available in Diamond impregnated filament which is perfect for finishing ceramic, glass, aerospace alloys and hardened tool steel. BRM also offers a complete range of inch sizes from .024 and metric sizes starting at 1mm.

For more information, contact Brush Research Manufacturing: Brush Research Mfg. Co., Inc., 4642 Floral Drive, Los Angeles, CA 90022; Phone: (323) 261-2193; Fax: (323) 268-6587 email: info@brushresearch.com or visit the web site: www.brushresearch.com

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www.industrialmachinerydigest.com

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In the world of rapidly changing technologies and a shifting marketplace, find answers here.

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Quarter 1, 2012 advertisersâ&#x20AC;&#x2122; index www.industrialmachinerydigest.com

Actek Manufacturing and Engineering Inc.......... 73

Cosen Saws.......................................................... 10

Advanced Manufacturing Solutions LLC............ 39

Design & Manufacturing New England............. 110

All World Machinery Supply Inc............................. 3

Design-2-Part Shows......................................... 107

AmCon Design & Contract Mfg Expo............... 105

Eagle Bending...................................................... 23

Attica Hydraulic Exchange..................................... 7

Edwards Mfg Co................................................... 21

BESSEY Tools North America............................. 79

eepos.................................................................... 71

Betenbender Manufacturing Inc.......................... 15

Essex Structural Steel Co.................................... 85

Buffalo Gear.......................................................... 67

Fabricating & Metalworking................................. 45

Burr King Mfg Co.................................................. 51

Haco-Atlantic, Inc................................................. 37

C Marshall Fabrication Machinery, Inc................ 39

High Quality Tools/Servo Products........................ 9

Cameron Micro Drill Presses............................... 11

Hodgson Custom Rolling................................40-43

Carell Corporation................................................ 23

Homak Manufacturing Co...................................... 2

Clarke Gear Co..................................................... 65

Hyd-Mech Group Limited.................................... 27

COMEQ, Inc......................................................... 19

Industrial Magnetics, Inc...................................... 73

www.actekmfg.com

www.pressbrakesafety.com

www.allworldmachiner y.com www.amconshows.com www.ahx1.com

www.besseytools.com

www.betenbender.com www.buffalogear.com www.burrking.com

www.cmarshallfab.com

www.cameronmicrodrillpress.com www.carellcorp.com

www.clarkegear.com www.comeq.com

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www.cosen.com

www.DM-NewEngland.com www.d2p.com

www.eaglebendingmachines.com www.edwardsinronworkers.com www.eepos-us.com

www.essexstructuralsteel.com

www.fabricatingandmetalworking.com www.hacoatlantic.com www.hqtinc.com

www.hodgsoncustomrolling.com www.homak.com

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www.industrialmachinerydigest.com

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Infinity Rebuild...................................................... 57

RAS Machine Tool Technologies Inc................... 61

www.infinityrebuild.com

www.rasmachinetool.com

International Machinery.......................................... 8

Red Stag Engineering & Automation................... 39

www.lionlathes.com

International Manufacturing Technology Show (IMTS)................................... 103 www.imts.com

Kaeser Compressors............................................ 83 www.kaeser.com

Kanetec USA Corp............................................... 69 www.kanetec.com

Lipoco Enterprises............................................... 47 www.lipoco.com

MacMillin Hydraulic Engineering Corporation...... 85 www.macmhydraulic.com

Manufacturing 4 the Future (MFG4).................. 111 www.mfg4event.com

Marvel Manufacturing Company, Inc.................. 33

www.redstag.com

Repair Parts Inc.................................................... 61 www.repair-parts-inc.com

SawBlade.com.................................................... FC www.sawblade.com

Scientific Cutting Tools Inc................................... 85 www.sct-usa.com

Sprinter Marking, Inc............................................ 53 www.sprintermarking.com

Stor-Loc................................................................ 77 www.storloc.com

Strong Hold Products........................................... 79 www.strong-hold.com

Superior Phase Converters LLC.......................... 95

www.mar velsaws.com

www.superiorphase.com

Melmor Associates............................................... 71

Tormach, LLC....................................................... 53

www.melmor.com

www.tormach.com

National Tooling & Machining Association (NTMA)......................................63, 109

Total Industrial Plant Solutions (TIPS) Card Deck.................................................. 71

www.ntma.org

www.tipscd.com

Noren Products Incorporated.............................. 97

WESTEC 2012.................................................... 101

www.norenproducts.com

www.westeconline.com

Phase-A-Matic...................................................... 99

York Portable Machine......................................... 53

www.phase-a-matic.com

www.yorkmachine.com

www.industrialmachinerydigest.com

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