Techni WaterJet: Leading the Industry with Innovation and Customer Service
With Jim Fields — VP of Techni WaterJet
Digital Technologies Are (Finally) Reinventing Machinery
In War Against Industrial Corrosion, Clean Lasers Prove Very Effective
Kaiser Tool Company Celebrates 60th Anniversary
The Use of Automated Storage and Retrieval Systems (ASRS) for Just-in-Time Inventory Management in Manufacturing Warehouses
Embracing the Future: Preparing Your Workforce for AI Integration in Industrial Machinery
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Welcome to the latest issue of Industrial Machinery Digest this edition is packed with insightful articles and features that highlight the transformative advancements reshaping the industrial landscape.
Digital technologies are finally revolutionizing the machinery industry.
Adrien Bron and Neil Malik examine the profound impact of digital solutions on traditional business models and market dynamics, noting the industrial sector's growing consumption of semiconductor and Iot technology.
We had the pleasure of interviewing Jim Fields, Vice President of techni WaterJet, who shared the company's commitment to innovation and customer service. Fields offers a comprehensive overview of techni WaterJet's evolution and technological advancements in the water jet fabrication market.
Del Williams presents an in-depth look at the effectiveness of clean technology lasers in fighting industrial corrosion. With the global cost of corrosion reaching staggering figures, these lasers offer a cost-effective and efficient solution for maintaining industrial infrastructure.
We also celebrate Kaiser tool Company’s 60th anniversary, honoring William (Bill) Kaiser's journey from a job shop operator to a pioneer in grooving tools. His ingenuity and perseverance mark a significant milestone in the industry.
As AI continues to revolutionize the industrial machinery sector, preparing your workforce for this transformation is crucial. We provide actionable strategies to equip your team with the skills and knowledge needed to leverage AI effectively, enhancing productivity and innovation.
We are excited to introduce VERICut Version 9.5 by Cgtech, a leading solution in CNC machine simulation, verification, and optimization. this latest release focuses on maximizing production efficiencies and minimizing downtime, ensuring manufacturers stay competitive.
Our spotlight on NWI Aerostructures highlights their collaboration with Fives Machining systems and sINuMERIK ONE. this partnership propels NWI’s capabilities in manufacturing complex structural components and showcases their expansion into new markets, including military aerostructures and space launch vehicles.
Finally, we delve into the precision and efficiency of advanced rotary surface grinders in producing high-performance magnetic seals. these grinders provide the necessary flatness, parallelism, and finish for industrial parts subjected to high pressure and rotation, optimizing production at reduced costs and cycle times.
We hope you find this issue both informative and inspiring. thank you for your continued support and readership.
Warm regards,
William Strickland
William strickland Publisher, IMD
INDUSTRY NEWS
A3D Manufacturing Opens New Phoenix Headquarters, tripling Capacity for Advanced Additive Manufacturing and Multi-Jet Fusion Printing
A3D Manufacturing celebrated the grand opening of its new headquarters in Phoenix, Arizona, with a ribboncutting ceremony attended by nearly 200 people, including local dignitaries and industry leaders. the new 9,000 sq. ft. facility, located at 15220 south 50th street, significantly expands A3D’s production capabilities, tripling their capacity for advanced additive manufacturing and Multi-Jet Fusion printing. senior Vice President Jon toews emphasized the transformative impact of the new headquarters on their ability to deliver high-quality manufacturing solutions throughout the product lifecycle, from prototyping to full-scale production. the company, which rebranded from Athena Manufacturing in 2023, has produced over 200,000 parts for nearly 2,300 customers over the past five years. this expansion supports A3D’s mission of transforming innovative ideas into tangible products and solutions, reinforcing their commitment to meeting the growing demand for fast, reliable manufacturing services. For more information, visit their website at www.a3dmfg.com.
10% growth for global Precision gears Market in 2025 After Recent slump
the global precision gearbox and geared motors market is projected to grow by 10.2% in 2025, recovering from the economic downturn experienced in 2023-24. According to Interact Analysis, the market will expand from $3.29 billion to $4.8 billion by 2028, driven by a compound annual growth rate (CAgR) of 7.9%. Despite challenges like inflation and high interest rates, the market shows resilience, particularly in the Americas and APAC regions. Innovations in automation and emerging industries such as battery manufacturing and humanoid robots are expected to drive demand. the mobile robot segment, with a forecasted CAgR of 45.9%, and battery manufacturing, with a 13% CAgR, are poised for significant growth. the market for precision gearboxes in industrial and collaborative robots, valued at over $1 billion in 2023, is also set to grow, reaching $1.33 billion by 2028. this growth reflects a broader optimism in the robotics and manufacturing sectors as interest rates stabilize and investments in automation increase.
BIg DAIsHOWA Opens state-of-the-Art Facility to Increase Manufacturing Capacity
BIg DAIsHOWA seiki Co., Ltd. has inaugurated its ninth production plant in Awaji, Japan, to meet current production demands and future growth. the 49,500-square-meter facility, operational since January 2024, features 21 multitasking machines and 23 automatic lathes, targeting an initial output of 20,000 tools per month, with potential for doubling. the plant focuses on producing BBt and Bt tool holders in various taper sizes. Automation, including robots and Automated guided Forklifts, enhances material handling efficiency and quality consistency. the
facility also emphasizes environmental sustainability with a central filtration system for coolant recycling and advanced air purification to minimize emissions. BIg DAIsHOWA, a global tooling provider, reinforces its commitment to innovation and sustainable manufacturing with this new facility. For more information, contact BIg DAIsHOWA or visit their website at www.us.bigdaishowa.com.
Cosen saws to Exhibit solutions at IMts CHICAgO 2024
Cosen saws, a leading band saw manufacturer, will showcase its top saw models and latest cutting solutions at the IMts 2024 in Chicago, Illinois. the event, held from september 9-14 at McCormick Place, is one of the world's largest manufacturing showcases, attracting over 86,000 attendees from more than 110 countries. Cosen, recognized as the number one sawing manufacturer by end-users in Metal Center News’ top-10 equipment brands survey, will exhibit six saw models, including the g320, NC-510Mg , C2, sV t-6070s, V-1822, and sH-500M. these models are designed to enhance productivity, accuracy, and safety. Visitors can experience these machines firsthand at booth 236931, where experts will be available to provide insights and answer questions. Cosen will also introduce new advancements in sawing automation, aimed at improving operator efficiency and production flow. For more information, visit www. cosensaws.com or contact them at info@cosensaws.com.
comparable products offering excellent performance, tool longevity, and quality at similar price levels. the upgrade will enhance Dormer Pramet's development of ANsI standard threading tools and expand its comprehensive product portfolio available in North America. By December 31, 2024, all uB products will be retired, with existing stock available until March 30, 2025. this strategic move aligns with Dormer Pramet’s goal to achieve sustainable growth and better serve its customers by consolidating product offerings under one unified brand. Eduardo Martin, President of Dormer Pramet, emphasized that this transition would strengthen their market position and benefit both the business and its customers. For more information, visit www.dormerpramet.com.
EXAIR and BEtE Announce strategic Merger
EXAIR, a leader in engineered compressed air solutions, and BE tE, a manufacturer of engineered spray nozzles and spraying systems, have announced a strategic merger. this merger aims to enhance product offerings and customer engagement by combining the strengths of both companies. the collaboration will drive innovation and product value for a global network of customers, distributors, resellers, and OEMs. the merger enables a diversified portfolio by integrating BE tE’s technologies with EXAIR’s expertise in compressed air products. this synergy will address broader market demands and foster a new era of invention. Presidents of both companies, Kirk Edwards (EXAIR) and tom Fitch (BE tE), highlighted the improved service, new products, and competitive prices resulting from the merger. the companies are committed to a seamless integration process, focusing on quality, advanced engineering, and customer service. For more information, visit www.EXAIR.com or www.BE tE.com.
CERAtIZIt Announces New sales Engineer for Cutting tools
CERAtIZIt usA has appointed Bryan Miller as the new Midwest territory sales Engineer for Cutting tools, serving Western Michigan. With 11 years of sales and application experience in automotive production, aerospace, and military manufacturing, Miller brings a wealth of expertise to the role. He aims to help manufacturers improve their machining and quality control methods by providing access to CERAtIZIt ’s advanced cutting solutions. Midwest National sales Manager troy Wilt praised Miller’s skillset and talent, highlighting his value to the team. Miller holds a bachelor’s degree in manufacturing engineering from Ferris state university and is proficient in various CAD/ CAM software tools, including Mastercam, suRFCAM, sOLIDWORKs, and CAtIA. For more information, visit www. Cuttingtools.CERAtIZIt.com or call 1-800-783-2280.
union Butterfield Family of Products to be upgraded to Dormer Pramet Brand
Dormer Pramet has announced the integration of the union Butterfield (uB) family of products into the Dormer Pramet brand. this transition aims to provide customers with
FANuC America unveils New $110 Million Robotics and Automation Campus
FANuC America has opened its new 650,000 square foot West Campus facility in Auburn Hills, Michigan, as part of a $110 million investment to support and advance industrial automation in North America. this expansion increases FANuC’s footprint in Michigan to over 2 million square feet and has created over 400 jobs since 2019. the West Campus provides advanced product manufacturing, customized automation systems, and warehouse space
for over 6,000 quick delivery robots and tens of thousands of parts. the facility also includes the FANuC Academy, an advanced automation customer training center, set to become the largest corporate robotics and industrial automation training facility in the u s. FANuC’s continued investment in North America, totaling over $250 million, underscores its commitment to driving efficiency across industries and supporting the future of the automation and robotics sector. For more information, visit FANuC America’s website.
Fixtureworks to Feature Expanded and Extensive Product Line at IMts 2024
Fixtureworks, a leading supplier of clamps, fixturing accessories, machine tools, and material handling products, will showcase its extensive product line at IMts 2024. the event will be held from september 9-14 at McCormick Place in Chicago. Fixtureworks will highlight new additions to its lineup, including retractable ball lock fasteners, heavy-duty push lock clamps, flat-style clamping fasteners, and a larger module for 5-axis modular clamping systems for large workpieces. the company will also feature a wide range of workholding products, such as pneumatic clamps, nutrunner clamps, One-touch Fasteners, Flex Locators, and various fixture clamps and locating systems. Visitors can expect hands-on demonstrations of these products at booth 432377 in the West Building Level 3. Fixtureworks’ booth will also feature Fairlane Products, offering workholding and positioning solutions, bumpers, rollers, clamping mechanisms, and more. For more information, visit www.fixtureworks.com.
Hexagon and Paperless Parts slash Quoting times for America’s Precision Manufacturers with Advanced software solutions
Hexagon’s Manufacturing Intelligence division and Paperless Parts have announced a strategic partnership aimed at modernizing quoting software for custom part manufacturers. the collaboration, announced at Paperless Parts' annual user conference, POWER, seeks to accelerate the adoption of advanced quoting technologies. Hexagon’s comprehensive portfolio of manufacturing solutions, combined with Paperless Parts’ innovative quoting software, will enhance operational efficiency and revenue for manufacturers. the partnership integrates Paperless Parts’ geometric interrogations, automated pricing, and AI-powered workflow technology with Hexagon’s Nexus Digital Reality Platform. this integration will streamline quoting processes, improve consistency in costing and pricing, and facilitate better collaboration and data visibility. Hexagon has also launched an online technology Benchmark tool for machine shops to support their digital transformation journey. this partnership underscores Hexagon’s commitment to supporting custom part manufacturers and small to mid-sized machine shops. For more information, visit www.HexagonMI.com and www. paperlessparts.com.
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Digital Technologies Are (Finally) Reinventing Machinery
By Adrien Bron and Neil Malik
Digital solutions are revamping traditional machinery business models, profit pools and market dynamics (see Figure 1). the shift comes years after digital revolutions overhauled other sectors, but the transformation will be no less profound.
A key indicator of the pace of change is the industry’s voracious consumption of semiconductor chips and Internet of things (Iot ) technology. the industrial sector is now a bigger consumer of chips and Iot technology than any other business sector. And industrial companies’ spending on Iot is growing at a rapid clip (see Figure 2). the push to develop solutions has prompted leading machinery companies to redefine their markets. Many are developing customer solutions tailored to specific industries instead of producing standard products for a global market. that pivot means focusing on a smaller number of customers in specific vertical industry segments, but it increases the scope of what these leaders can offer those customers—it also means less fragmented supply chains.
For many machinery executives, the shift to digital solutions is the most sweeping change to the industry in a lifetime. However, the payoff is significant for firms that get it right. Digital solutions leaders outperform the industry on total shareholder return by 100%. Customers are seeking these solutions as part of their strategic evolution. Machinery companies that are among the first to meet that demand will generate higher revenue, bigger margins, improved customer loyalty, and software-like valuation multiples (see Figure 3).
Adrien Bron
Neil Malik
Adrien Bron and Neil Malik are partners in Bain & Company’s Advanced Manufacturing and Services practice.
the Pitfalls
In our experience, several common errors hinder machinery companies’ efforts to develop digital solutions. the first is failure to clarify the company’s ambition in digital solutions. In short, why invest? As they rush to join the race, many design digital products and services to sell more hardware and equipment instead of solving customer problems. As a result, their solutions are less competitive. Worse, these companies continue to focus on traditional products while rivals reshape the market.
A second pitfall is a lack of focus. One of the biggest challenges leadership teams face in the transition to digital solutions is selecting a few target markets. Companies that engineer digital solutions for a broad market will be overwhelmed by the heterogenous demands of multiple industries. unable to scale their solutions, they will have to redesign or reengineer solutions from one customer to the next and won’t be profitable.
the Customer Mindset
Leaders scale digital solutions successfully by focusing on two questions: For which customers are we among the most relevant suppliers, and what solutions would solve the problems these customers face? software companies excel at this customer-centric market approach and it has propelled their success over the past 20 years. Machinery companies that lead the digital solutions shift will do the same over the next two decades.
John Deere, for example, has invested billions of dollars over the past decade to pivot from a tractor manufacturer to a provider of solutions for precision
agriculture, including machines combined with digital technology that make farming more efficient. In 2022, the company introduced self-driving tractors and sprayers that distinguish weeds from crops. the company plans to connect 1.5 million machines in service and use its cloudbased operations center to store crop data, hoping to sell farmers subscriptions to software that will help yield higher profit margins.
In our experience, machinery companies that have built successful digital solutions follow five guidelines:
» target a few customer segments. Address customer pain points in select vertical markets. thermostat maker Danfoss provides solutions to food supermarkets that depend on reliable refrigeration. In addition to selling systems that monitor the temperature of refrigerated storage areas and shelves, the company’s connected thermostats also offer solutions for energy management, usage analytics, and predictive maintenance.
» Become a digitalization partner. Digital solutions, such as software, change the way a company works. software companies use teams of expert advisers to help customers adapt their ways of working and ensure that they get the full benefits of the technology they install. Machinery companies will also need to provide such services.
» Embrace customer unit economics. Machinery and equipment companies build business plans based on product unit economics, ensuring that the price of a machine covers the costs of building it. Digital solutions, such as software, require a different approach as the most significant cost is not building the product but
acquiring customers. Leading machinery companies create a business case for digital solutions based on customer unit economics, including customer customer acquisition cost and lifetime value. ( the bad news: It’s not a fast payback).
» Invest in an Engine 2 business. Machinery companies can use organic investments and acquisitions to build a substantial technology-based business to complement hardware sales. Partnerships offer the greatest value in back-end operations (including solution development and delivery). Leaders avoid outsourcing customerfacing parts of the business. the reason is that sectorspecific knowledge and customer relations are key in winning sales and retaining core customers.
» use open technology architecture. Digital solutions built on flexible technology architecture have a big advantage in the market: seamless integration and interoperability with leading It systems and operations technology (Ot ). Open technology architecture also complies with security standards.
the digital transformation of machinery is well underway. successful OEMs are forging deeper relationships with their best industrial customers and developing solutions for the industry segments in which they are a leader. Future winners will scale solutions that can be used repeatedly in the same sector with minor adaptations from one customer to the next. As that process accelerates, it will change the competitive boundaries of the industry: Future markets will be defined by customer segments, not products. In this new era, machinery companies that have scaled digital solutions for a targeted set of customers will have a competitive advantage that is difficult to challenge.
FEATURING:
TALKING SHOP WITH: Jim Fields — VP of Techni WaterJet
Techni WaterJet: Leading the Industry with Innovation and Customer Service
In a recent interview with Industrial Machinery Digest, Jim Fields, Vice President of techni WaterJet, shared insights into the company’s commitment to innovation, customer service, and the technological advancements that set them apart in the water jet fabrication market. With decades of experience in the industry, Fields provides a comprehensive overview of techni WaterJet's evolution, unique features, and future prospects.
A History of Excellence
techni WaterJet, born in Australia in 1989, has been a prominent player in the water jet industry for over three decades. the company expanded to the united states in 2005, rapidly growing its presence and reputation. Fields, who has been in the water jet industry since 1993, emphasizes the high-end quality and intelligence of techni’s products. “We offer a high-end quality product with the most intelligence on the market,” he notes, highlighting the company's focus on innovation and customer-centric design.
Customer service: A Core Value
Customer service is at the heart of techni WaterJet’s operations. Fields underscores the importance of proactive support, stating, “Customer service is paramount. It's paramount to techni, but even in our own lives, what is the most frustrating thing that we experience today is poor customer service.” techni WaterJet ensures ease of operation and maintenance for their customers, aiming to minimize downtime and maximize productivity.
Proactivity in customer service is a key differentiator for techni WaterJet. t heir systems are designed to be unmanned, allowing for lights-out operation. t his requires comprehensive monitoring of the machine’s parameters, including heat, torque, amp draw, and stroke rate. By predicting maintenance needs, techni WaterJet helps customers avoid unexpected downtime. “Our system is designed to be unmanned... We use the term predictive when it comes to the tools on the machine,” Fields explains.
techConnect: Advanced Monitoring and Control
One of techni WaterJet’s standout innovations is the techConnect app. this intuitive tool, compatible with smart devices, allows users to monitor machine parameters in real-time. “It's a very advanced tool,” Fields says. “It gives us a great deal of confidence to be unmanned. set it and forget it.” the app alerts users to potential issues, enabling timely interventions and maintaining optimal performance. the techConnect app offers significant benefits for operators, maintenance personnel, and operations managers. It monitors critical indicators such as water pressure, oil flow rate, and temperatures, providing a comprehensive overview of the machine's status. Fields adds, “It's powerful across the spectrum. the ultimate is having us do the monitoring as well.”
Innovation at the Core
techni WaterJet’s commitment to innovation is evident in their development of the electric servo pump, a patented technology that offers greater efficiency than traditional hydraulic intensifiers. “We hold the patent. We were the first to the market with an electric servo pump,” Fields states proudly. this technology, initially inspired by NA sA's use of electric actuators, exemplifies techni WaterJet’s problemsolving approach and dedication to advancing the industry. Another notable innovation is the abrasive transfer pump, which allows for continuous loading of the hopper without
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LOW SPEED HIGH-TORQUE MOTORS… The Char-Lynn motor range consists of three major types based on the valving used to distribute fluid through the Orbit gear set (geroler or gerotor), Spool Valve, Disc Valve and VIS (Valve-in-Star). A variety of displacement sizes are available in each of the three motor types to provide a wide range of speeds and torques.
interrupting the cutting process. this non-pressurized vessel eliminates the need for depressurizing, streamlining operations and reducing downtime. Fields emphasizes, “We've always been driven by efficiency. How can we do it better, cheaper, with more reliability?”
Versatility and Efficiency
techni WaterJet’s machines stand out for their versatility and efficiency. they can cut a wide range of materials, from titanium and composites to glass and stone, without imparting heat or distorting the metal. “ the versatility of it... It can cut anything from titanium to composite to plastic,” Fields elaborates. this cold-cutting process preserves the integrity of the parent metal, eliminating the need for secondary processing and allowing for immediate assembly or welding.
Comprehensive support Programs
techni WaterJet’s commitment to customer success extends beyond the sale. t heir goal is to make customers independent through extensive training on maintenance, servicing, and software. For those who prefer not to handle maintenance themselves, techni offers various levels of service contracts, from periodic check-ins to full monitoring and maintenance. Fields explains, “We want to be the same person after the sale as well. Promise less, deliver more.”
• Complete isolation of load forces from the control station.
• Continuous, unlimited control action with low output torque.
• Wide selection of control circuits and meter sizes.
• Works with many kinds of power steering pumps or fluid supply.
GEAR PUMPS… Eaton Series 26 gear pumps with 13-tooth gears minimizes flow ripple to reduce noise and vibration. Bearing lubrication system uses inlet oil rather than high pressure oil, improving volumetric efficiency and power output. The 13 available displacements and many mounting configurations provide for an easy retrofit. Other series available.
HIGH PRESSURE
CHECKBALL PISTON PUMPS… Dynex high pressure hydraulic pumps with positive-seating checkball valves provide better wear and high volumetric efficiency. Pumps operate at pressures to 20,000 psi. Checkball pumps are ideal for hydraulic systems with demanding conditions and accommodate more force in a smaller package. At lower pressures, they provide the life and performance margin essential in critical environments. Checkball fixed displacement pumps offer flows from 0.22
gpm at 1800 rpm.
DIRECTIONAL CONTROL VALVES…
• HP Pattern Spool Valves — Simple spool valves eliminate complex valve circuits for fourway control in high pressure systems. HP03 pattern valves are rated for 15 U.S. gpm at 10,000 psi, HP05 pattern rated from 5 to 25 U.S. gpm at 8000 psi.
• NFPA/ISO Pattern Valves — Smooth spool movement with four-land design offers low pressure drop with large internal flow passages. 5000 psi valves rated to 165 U.S. gpm.
• VST Series Seated Valves — High pressure with low leakage. Reliable shifting with non-silting ball-on-seat design.
• Explosion Proof Option — Solenoids with special enclosures designed for use in hazardous locations. UL and CSA approved.
• Accessory Sandwich Valves — Mounts under directional valves, saves space, reduces weight and provides flexibility locating valves.
the true measure of success for techni WaterJet’s customer service is repeat business. “ the ultimate outcome and measure of whether we're doing our job is the purchase of that second machine or a good testimonial,” Fields asserts. this focus on long-term relationships and customer satisfaction drives the company's approach to service and support.
Personal Values and Professional Integrity
On a personal note, Fields emphasizes the importance of honesty and integrity in his work. “ the ultimate, I guess, being honest and integrity, that's key and foremost for me,” he shares. Fields believes in staying calm in chaotic situations and addressing customer concerns with a levelheaded approach. this philosophy has guided his career
and contributed to techni WaterJet’s reputation for reliable, customer-focused service.
Looking Ahead
techni WaterJet continues to lead the industry with cutting-edge technology and exceptional customer service. For those interested in learning more about their innovative products and services, Fields encourages visiting their website or reaching out directly. “We're always welcome to answer your questions and help out in any way we can,” he assures. techni WaterJet exemplifies the fusion of innovation and customer service, setting new standards in the water jet fabrication market. With a commitment to efficiency, reliability, and proactive support, they are poised to remain industry leaders for years to come.
In War Against Industrial Corrosion, Clean Lasers Prove Very Effective
Clean technology lasers offer superior industrial corrosion removal in myriad applications, helps solve some of industry’s most costly corrosion problems
By Del Williams
Industries have been fighting a war against corrosion in metal infrastructure, equipment, and products at great expense for generations. “ t he global cost of corrosion is estimated to be us $2.5 trillion, which is equivalent to 3.4% of the global g ross Domestic Product ( g DP) (2013), according to a NACE International IMPAC t study to examine the current role of corrosion management in industry and government and to establish best practices.
given the massive industrial outlay, proactively controlling corrosion is imperative and can have an equally impressive ROI.
“By using available corrosion control practices, it is estimated that savings of between 15 and 35% of the cost of corrosion could be realized, i.e., between us$375 and $875 billion annually on a global basis…the fact that corrosion control provides a cost benefit is a lesson learned over and over again by industry, often too late and following catastrophic events,” continues the NACE International IMPAC t study.
However, traditional methods of removing corrosion can be messy, laborious, time consuming, and can even pose serious health hazards.
today, one of the easiest to use and most effective alternatives in the war against corrosion is the
increasingly important category of industrial-grade, clean technology lasers.
With this approach, precision laser-based systems are used to remove corrosion, contaminants, paint, and residues with a high-energy laser beam that leaves the substrate unaffected. Preparation and cleanup time are minimal, and the low-maintenance equipment can last decades. the technology minimizes operator exposure to potential environmental health hazards. In addition, no consumables are necessary.
Corrosion and the Limits of Conventional Control
Any industry with metal infrastructure, processing equipment, or products exposed to water, fluids, moisture, or atmospheric humidity continually fights corrosion, which causes the deterioration and loss of a material and its critical properties due to chemical, electrochemical reactions of the exposed surface with the surrounding environment. Corrosion affects the microstructure, mechanical properties, and physical appearance of the materials. the direct cost of corrosion includes a loss of materials, equipment, and production, plus the cost of repair, maintenance, and replacement. Additional losses can result from accidents, injuries, and even loss of life as well as payments to repair environmental damage.
Preparation and cleanup time are minimal, and the low-maintenance equipment can last decades.
Within the continual struggle against industrial corrosion, one important niche area of corrosion control involves the pretreating of metal surfaces to remove corrosion and contaminants before coating or welding.
Although metal surface pretreatment is a small portion of industrial corrosion control, it is crucial to ensure the safety, performance, and longevity of products and structures.
Insufficient coating pretreatment can lead to inadequate protection from the environment, leading to potential coating failure, moisture entry, and accelerated corrosion as well as increased maintenance, early replacement, and warranty issues. similarly, insufficient weld pretreatment to remove corrosion and contaminants can lead to weakened or failed welds and necessary rework as well as substantial safety, liability, and litigation risk.
The technology minimizes operator exposure to potential environmental health hazards and no consumables are necessary.
toward this end, laser-based systems have significant advantages over traditional methods, starting with ease of use.
A More Effective Weapon to Eliminate Corrosion
In many industries, it is necessary to remove corrosion, residue, oil, grease, or paint before coating a product or
“With laser-based systems, an operator simply points and clicks a high-energy laser beam at the surface. the substrate is not affected by the laser, and the systems do
• Cost savings (up to 90%)
• High load threads - stronger joints
• High process reliability
• Faster production cycles
• No special machinery required
• Small investment
not create any mess or byproducts. the approach is eco-friendly, energy-efficient, and completes the job in approximately half the time of traditional methods when preparation and cleanup are considered. Also, no consumables are required,” says Wayne tupuola, CEO, Orlando, Floridabased Laser Photonics, a leading provider of patented industrial grade Cleantech® lasers for cleaning and surface conditioning. the company’s systems function either as mobile standalone units or can be integrated into production lines.
In the case of Laser Photonics, the laser systems are available in portable and stationary models ranging from 50 to 3,000-watts (a 4,000-watt version is in development) with chamber sizes from 3’ x 3’ in size to 6’ x 12’. the systems can also be installed in manufacturing lines in cabinets or operated by a robotic arm.
In industry, the laser pre-treatment of metal surfaces can be used to streamline various manufacturing processes. For instance, it has been used to remove rust from hundreds of automotive transmissions per day. It has also been utilized to eliminate corrosion from conveying system components.
the Cleantech lasers are also used to refurbish industrial infrastructure, such as when removing a previous coating along with any corrosion to facilitate the new coating’s adhesion to the surface.
Another common laser application involves pre-weld treatment to remove corrosion, mill scale, residue, and any impurities on the surface of the base material that would compromise the weld’s effectiveness. It is essential to avoid any such contamination on a weld’s surface, which could otherwise lead to a weakening of the weld’s mechanical properties, requiring rework.
Clean technology lasers offer superior industrial corrosion removal in myriad applications, helping solve some of industry’s most costly corrosion problems.
Laser treatment is also used for post-weld cleaning to increase the life expectancy and corrosion resistance of a welded joint. Post-weld cleaning is important for stainless steel as well. Welding can cause a “heat tint,” a discolored, thickened top layer on the stainless steel around the weld bead within the heat affected zone that compromises corrosion resistance. Removing the heat tinted top layer is necessary to restore stainless steel’s full corrosion resistance and aesthetic value.
A further benefit of the laser systems is that some of the most advanced units are designed to last for decades. For example, Cleantech laser systems can last for 50,000 to 100,000 hours. In addition, virtually no maintenance is needed after purchase and no consumables are required.
g iven the devastating cost of corrosion to industry and the inherent limitations of typical control methods, lasers are becoming a best practice technique to combat it in facilities and in the field. Laser treatment effectively removes corrosion for many industrial applications, minimizes cleanup time and operator exposure to potential environmental health hazards, lasts for decades, and requires no consumables.
For more information on laser cleaning solutions for surface preparation, contact Laser Photonics at (407) 804-1000 or visit www.laserphotonics.com.
ABOUT THE AUTHOR:
Del Williams is a technical writer based in torrance, California.
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Kaiser Tool Company Celebrates 60th Anniversary
In the 1950s, William (Bill) Kaiser operated a job shop and took in jobs that other manufacturers did not want to do in house. Most of the time, these jobs were difficult and he was expected to do them quickly and for very little money.
Bill found that he continuously had to make his own tools to cut small grooves for O-rings or snap rings. Hand grinding consistent grooving tools took too long and when a tool became dull, he had to start all over again.
He had an idea. If he could make grooving tools in .001” increments with standardized bodies that could be replaced in a toolholder, he would solve his problem and have a marketable product.
It took Bill almost seven years of working at night (when he wasn’t doing his job shop work) to develop and test the design of the inserts and the toolholders. He perfected the design and was awarded patent 3,296,683.
Bill and his wife, Hazel, started Kaiser tool Company (K tC) in 1964 with the purpose of supplying small lathe cutting tools. Lathe tools were known as bits and the tools were thin. tHINBIt® was chosen as the product name. the first tHINBIt® tools were insert sizes .010” through .050” in .001” increments made from high-speed steel with a 1/4”, 5/16” and 3/8” toolholders.
From 1964 until 1980, the production and sales of tHINBIt® tooling was done at the family home on Weisser Park Avenue in Fort Wayne, Indiana. Manufacturing took place in the garage. the employees used the bathroom and kitchen of the house. the sales office was in the attic and was accessed via a set of pull down stairs. the raw material was purchased at a local hardware store.
Bill continued to innovate and expand tHINBIt® products. Hazel designed the advertising, packed and shipped the tools, took orders, typed the invoices and juggled the money (or lack thereof) to pay the bills. their daughter Lenore, our President, grew up with tHINBIt® in every corner of the house.
sales were very slow in the beginning as there was little money for advertising tHINBIt® products. All revenue generated by tHINBIt® was used to pay the company’s bills and the few employees. Bill still had to do job shop work and Hazel worked at an accounting firm to generate their income. After a decade, tHINBIt® sales were sufficient to allow Bill to drop his job shop work and Hazel to leave her accounting job.
In 1980, K tC outgrew the garage and a new facility was built on sherman Boulevard. the site was located along
the st Mary’s river and terrible flooding in 1982 threatened to destroy the business. the extraordinary efforts of the employees and a few sand bags from President Ronald Regan saved the company.
Lenore took over K tC from her parents in 1982. she increased tHINBIt® product offerings, digitized the shop and office operating systems, expanded
HazelKaiser
Bill Kaiser
Kaiser Tool Company Westec 1992
advertising and modernized the manufacturing processes.
tHINBIt® sales took off and more employees and equipment were added. Lenore’s husband, Doug, was brought on board in 1987. Doug utilized some of the first laser marking systems to engrave tHINBIt® products with indelible identification codes and began the Laser Images division.
K tC outgrew the sherman street location in 1994 and built a new manufacturing facility on Centennial Drive. the land purchased was large enough for a new building, future expansion and nature. the design of the manufacturing area was ahead of its time with painted floors, bright lighting and climate control. Windows let in natural light and views of animals and trees.
In the 1990’s, Kaiser recognized the advantages of CNC equipment and automation which allowed continued expansion of product lines and a focus on custom tools.
Machines, work cells, inspection equipment and material storage were added and processes upgraded until the manufacturing floor was too cramped to function efficiently. In 2018, an addition was built to significantly expand the manufacturing space.
UNLOCK EVERY INCH OF YOUR STORAGE SPACE!
Industries served include: aerospace, medical, semiconductor, automotive, research, protective seals, jewelry, racing and those job shop innovators working out of their garages on the next big thing.
today, tHINBIt® is an industry leader in precision cutting tools. tHINBIt® stocks over 100,000 tools and offers millions of standard tools with fast delivery. Custom tooling is available for all products. Real people answer the phones and provide excellent service.
Bill and Hazel’s premise, during the early days, was always “customer service, quality product and fast shipment”. these are the foundations of Kaiser tool Company and what has allowed the company to grow from an unknown entity to its respected place in the industry today.
thank you for supporting tHINBIt® for 60 years.
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Kaiser Tool Company Fall 2023
The Use of Automated Storage and Retrieval Systems (ASRS) for Just-in-Time Inventory Management in Manufacturing Warehouses
In the evolving landscape of industrial automation, Automated storage and Retrieval systems (A sRs) have become a cornerstone technology for optimizing inventory management. Particularly within the context of Just-in-time (JIt ) inventory strategies, A sRs plays a pivotal role in ensuring ef ficient, timely, and precise storage and retrieval of materials. JIt inventory management aims to reduce waste and enhance ef ficiency by aligning inventory levels closely with production needs, receiving goods only as they are required. the integration of AsRs into JIt strategies not only enhances operational ef ficiency but
also minimizes costs and errors, making it an essential component of modern manufacturing warehouses.
understanding AsRs technology
Automated storage and Retrieval systems are sophisticated, high-density warehouse solutions designed to automate the handling of inventory. these systems consist of several key components, including storage racks, retrieval machines (such as cranes or shuttles), and a warehouse control system. there are various types of A sRs, each suited to different warehouse requirements and product sizes:
» unit-Load A sRs: Designed for handling large items or pallet-sized loads.
» Mini-Load A sRs: suitable for smaller items, typically stored in totes or bins.
» Micro-Load A sRs: used for handling very small items, often integrated into parts-picking operations.
» Carousel-Based A sRs: utilizes rotating shelves to deliver items to a picking station.
the integration of advanced robotics, sensors, and control software allows these systems to operate with minimal human intervention, ensuring precision and reliability in inventory handling.
Role of AsRs in JIt Inventory Management
the implementation of A sRs is crucial for the effective execution of JIt inventory management in manufacturing warehouses. By automating the storage and retrieval processes, AsRs ensures that materials are available exactly when needed, thus synchronizing seamlessly with production schedules. this real-time capability eliminates delays and reduces the necessity for large inventory buffers, which is a fundamental aspect of JIt principles. A sRs can swiftly and accurately store incoming materials and retrieve them for production, maintaining a continuous flow of inventory that supports ongoing manufacturing processes.
Benefits of using AsRs for JIt
Management
the adoption of A sRs within JIt inventory management brings several substantial benefits:
» Increased Ef ficiency and Reduced Lead times: A sRs systems significantly speed up storage and retrieval processes, thereby reducing lead times and ensuring materials are available for production without delay.
» Minimization of Inventory Holding Costs: By closely aligning inventory levels with production needs, AsRs helps minimize costs associated with holding excess inventory, such as storage costs, insurance, and obsolescence.
» Enhanced Accuracy in Inventory tracking and Movement: A sRs provides precise tracking of inventory locations and movements, reducing errors and ensuring the right materials are available at the right time.
» Flexibility in Adapting to
Changing Production
Demands: A sRs can be easily reconfigured to adapt to changing production schedules and inventory requirements, providing the flexibility needed in dynamic manufacturing environments.
» Reduction in Labor Costs and Human Error: Automation reduces reliance on manual labor for storage and retrieval tasks, lowering labor costs and minimizing the risk of human errors.
Implementation Challenges
Despite its advantages, implementing A sRs in JIt inventory management does present certain challenges:
» High Initial Investment and Cost Considerations:
the initial cost of purchasing and installing A sRs can be substantial, requiring careful financial planning and justification.
» Integration with Existing Warehouse Management and ERP systems: successful implementation requires seamless integration with existing warehouse management systems (WMs) and enterprise resource planning (ERP) systems to ensure smooth operations.
» training and Adaptation of Workforce: Employees need to be trained to work with the new automated systems, which can involve a learning curve and adaptation period.
» Maintenance and Operational Downtime: Regular maintenance is crucial to keep A sRs running smoothly, and any downtime can disrupt the JIt inventory flow, impacting production.
technological Innovations Enhancing AsRs
Ongoing technological advancements continue to enhance the capabilities of A sRs, making them even more valuable for JIt inventory management:
» Advances in Robotics and Automation: Improvements in robotic technology and automation have increased the speed, precision, and reliability of A sRs, enabling faster and more accurate inventory handling.
» Integration with Iot and Real-time Data Analytics: the integration of Internet of things (Iot ) devices and
real-time data analytics allows for better monitoring, control, and optimization of A sRs operations, improving ef ficiency and reducing downtime.
» Development of More Robust and scalable systems: New A sRs designs are more robust and scalable, allowing them to handle a wider range of products and adapt to growing warehouse needs.
» use of AI and Machine Learning for Predictive Maintenance and Optimization: AI and machine learning algorithms are being used to predict maintenance needs and optimize AsRs performance, reducing downtime and extending the lifespan of the systems.
Case studies of AsRs in JIt Inventory Management
In a global marketplace where ef ficiency and precision are paramount, many manufacturing companies have successfully implemented A sRs to enhance their JIt inventory management processes. While we won't dive into specific case studies, it's worth noting that companies across various sectors, including automotive, electronics, and consumer goods, have reported significant improvements in operational ef ficiency, cost savings, and product quality through the integration of A sRs these real-world applications underscore the transformative potential of A sRs in modern warehouse and supply chain management.
Future trends and Outlook
the future of A sRs in JIt inventory management looks promising, with several trends and innovations on the horizon:
» Emerging technologies in A sRs Development: Continued advancements in robotics, AI, and Iot are expected to further enhance the capabilities and ef ficiency of A sRs, making them even more integral to JIt inventory management.
» Potential for Increased Adoption in Various Industries: As the benefits of A sRs become more widely recognized, their adoption is likely to increase across a variety of industries, from manufacturing to retail and logistics.
» Impact of A sRs on the Future of Warehouse and supply
Chain Management: A sRs is set to play a key role in the evolution of warehouse and supply chain management, driving greater ef ficiency, accuracy, and responsiveness in inventory management.
» Development of Modular and Flexible A sRs solutions: Future A sRs designs may focus on modularity and flexibility, allowing for easier customization and scalability to meet the specific needs of different warehouses and inventory types.
» Integration with Advanced Data Analytics and AI: the integration of advanced data analytics and AI technologies will enable more sophisticated inventory management strategies, including predictive analytics for demand forecasting and real-time optimization of storage and retrieval operations.
Conclusion
the integration of Automated storage and Retrieval systems (AsRs) with Just-in-time (JIt ) inventory management offers a powerful solution for manufacturing warehouses. By automating the storage and retrieval processes, AsRs ensures timely, accurate, and efficient inventory handling, aligning perfectly with JIt principles. Despite the challenges involved in implementation, the benefits of increased efficiency, reduced costs, enhanced accuracy, and greater flexibility make AsRs an invaluable tool for modern warehouse and supply chain management. As technological advancements continue to enhance the capabilities of AsRs, their role in JIt inventory management is set to grow, driving further improvements in operational efficiency and productivity. the evolving landscape of warehouse automation, bolstered by innovations in robotics, AI, and Iot, promises a future where A sRs not only supports but revolutionizes the principles of JIt inventory management. As industries continue to seek greater ef ficiency and cost-effectiveness, the adoption of A sRs will likely become more widespread, heralding a new era of precision and agility in inventory management. By embracing these technologies, manufacturing warehouses can achieve a competitive edge, ensuring they are well-positioned to meet the demands of a fast-paced, dynamic market.
Embracing the Future: Preparing Your Workforce for AI Integration in Industrial Machinery
In the evolving landscape of industrial machinery, artificial intelligence (AI) is no longer a distant concept but a tangible reality revolutionizing the sector. As AI continues to permeate every facet of industrial operations, it’s crucial for companies to prepare their workforce for this transformation. t he integration of AI not only enhances productivity but also opens up new avenues for innovation and efficiency. t his article explores the growing use of AI in the industrial machinery sector and provides actionable strategies for companies to equip their workforce with the necessary skills and knowledge to leverage these advanced tools effectively.
t he Rise of AI in Industrial Machinery
AI technologies such as machine learning, predictive analytics, and robotic process automation are rapidly becoming integral components of industrial machinery. t hese technologies enable machines to perform tasks with greater precision, efficiency, and adaptability. For instance, AI-driven predictive maintenance can foresee
equipment failures before they occur, reducing downtime and maintenance costs. s imilarly, AI-powered robots can handle repetitive and dangerous tasks, enhancing worker safety and productivity.
t he Imperative for Workforce Development
While AI promises significant benefits, its successful implementation hinges on the readiness of the workforce to embrace and utilize these technologies. t he shift towards AI necessitates a comprehensive approach to workforce development, encompassing training, education, and a cultural shift within organizations.
1. A ss E ss IN g s KILL g AP s
t he first step in preparing the workforce for AI integration is to assess the existing skill gaps. t his involves evaluating the current capabilities of employees and identifying areas where AI knowledge and skills are lacking. Companies can conduct surveys, interviews, and assessments to gauge the readiness of their workforce and pinpoint specific training needs.
2. PROVIDINg tARgEtED tRAININg PROgRAMs
Once skill gaps are identified, companies should develop targeted training programs tailored to their workforce's needs. these programs should cover a range of topics, from basic AI concepts to advanced applications in industrial machinery. training can be delivered through various formats, including online courses, workshops, and hands-on sessions.
For instance, basic training might include an introduction to AI, its applications, and its potential impact on the industry. More advanced training could delve into specific AI tools and techniques, such as machine learning algorithms, data analysis, and the use of AI in predictive maintenance and quality control.
3. FOstERINg A CuLtuRE OF CONtINuOus LEARNINg
AI and related technologies are continually evolving, making it essential for companies to foster a culture of continuous learning. Encouraging employees to stay updated with the latest advancements in AI can be achieved by providing access to ongoing training opportunities, industry conferences, and professional development courses.
Creating an environment where continuous learning is valued and supported not only enhances the workforce's capabilities but also fosters innovation and adaptability. Employees who are well-versed in the latest AI technologies can contribute to the company's growth and competitiveness in the rapidly changing industrial landscape.
4. ENCOuRAgINg COLLABORAtION AND KNOWLEDgE sHARINg
Collaboration and knowledge sharing are key components of effective workforce development. Companies should create platforms and opportunities for employees to collaborate, share insights, and learn from each other. this can be facilitated through internal forums, cross-functional teams, and mentorship programs.
By fostering a collaborative environment, companies can ensure that knowledge and skills related to AI are disseminated throughout the organization. this collective intelligence can drive innovation and problem-solving, enabling the company to maximize the benefits of AI integration.
5. PARtNERINg WItH EDuCAtIONAL
INstItutIONs
Collaborating with educational institutions can provide companies with access to cutting-edge research and training resources. Partnerships with universities, technical schools, and industry associations can help bridge the gap between academic knowledge and practical application.
these partnerships can take various forms, such as sponsoring research projects, offering internships, and participating in advisory boards. By engaging with educational institutions, companies can ensure that their workforce development programs are aligned with the latest industry trends and technological advancements.
the Role of Leadership in AI Integration
Leadership plays a pivotal role in the successful integration of AI into the workforce. Leaders must champion the adoption of AI technologies and communicate the benefits and opportunities they present. Clear and transparent communication can alleviate concerns and resistance among employees, fostering a positive attitude towards AI adoption.
Leaders should also lead by example, demonstrating a commitment to continuous learning and professional development. By prioritizing workforce development and investing in training programs, leaders can create a culture that embraces innovation and technological advancement.
Conclusion
the integration of AI in industrial machinery is reshaping the industry, offering unprecedented opportunities for efficiency, innovation, and growth. However, the successful adoption of AI hinges on the readiness and capability of the workforce. By assessing skill gaps, providing targeted training, fostering a culture of continuous learning, encouraging collaboration, and partnering with educational institutions, companies can prepare their workforce to harness the power of AI effectively.
Leadership plays a crucial role in this transformation, guiding the organization through the transition and ensuring that employees are equipped with the necessary skills and knowledge. As AI continues to evolve, companies that invest in workforce development will be well-positioned to thrive in the new era of industrial machinery. Embracing AI is not just about adopting new technologies; it's about empowering the workforce to drive innovation and achieve excellence in the industrial landscape.
VERICUT Version 9.5
Maximize Efficiency, Minimize Downtime
Cgtech is proud to announce the latest release of VERICut, Version 9.5. VERICut leads the industry in CNC machine simulation, verification, and optimization across processes like metal cutting, additive manufacturing, hybrid manufacturing, and composites. It is an independent, standalone software that seamlessly integrates with all major CAM and tool management systems, as well as existing NC programseven those that have been edited, or created by means other than CAM.
In addition to improvements within the core product, VERICut 9.5 focuses on improving the user experience, practically automating NC program optimization, while maximizing production efficiencies across multiple processes, and minimizing downtime.
"We’re excited to unveil VERICut 9.5, featuring cutting-edge innovations like the new tool summary with Heat Map display showing tool wear with tool life analytics, and real-time CNC machine connectivity. this release underscores our commitment to enhancing precision and efficiency in manufacturing processes, ensuring our users stay ahead in an increasingly competitive market,” says Director of Product Management, gene granata.
VERICUT 9.5 Highlights
tool summary and tool Wear use the new Heat Map display (in VERICut ’s tool summary window) to see the wear pattern on your milling and drilling tools. A combination of colors and messages can be used to understand how each tool was used, and the effects of each cut on the tool.
track tool life by assigning wear limits to cutters for a variety of machining factors, such as cutting time, material removal volume or cutting distance, to get notified when a tool is nearing expiration. Different values can be specified for machining different stock materials. this is useful to better predict when a tool change will be required, and to improve tool inventory management.
CNC Machine Connectivity
CNC Machine Connectivity allows VERICut to connect directly to your machine to see real-time data in VERICut before, during and after machining has taken place. the new Postcheck capability within the CNC Machine Monitoring module enables users to review monitored data that was archived from the NC machine, within a VERICut simulation. this feature allows users to observe how well the machine ran, as well as identify when and where and spindle or feedrate override adjustments were applied, machining was paused, or if the Emergency stop was used during machining of a specific part.
VERICut 9.5 also introduces Connectivity support for NC machines with OKuMA, siemens and Heidenhain controls.
Interactive CsYs and Model transformations
VERICut 9.5 provides better tools for working with coordinate systems. New interactive transform menus enable you to interactively translate and rotate coordinate systems, components and models faster and easier, with fewer steps and less work. Visual cues show how pending transformations will be applied, giving users confidence to know the moved object will arrive at the desired location.
Enhancements to Interfaces
VERICut 9.5 continues Cgtech’s trend of adding support for the latest released CAM versions, as well as bringing a number of enhancements and capabilities to our CAM interfaces, to automate as many picks as possible from within the interface. In order to leverage all of the latest tools and tooling capabilities that VERICut has to offer, the CAM interfaces are also being updated to support more advanced types of tools for simulation.
the Mastercam-to-VERICut interface joins the CAtIA5to-VERICut interface, as the next CAM interface to include such enhancements, with a new look and feel, plus added functionality to automatically define the Fixture, stock and Design if they are defined in Mastercam’s stock setup. users can now change the interface language and other settings from within the interface, without the need to exit and restart.
“smarter” Learn Mode for Optimizing
VERICut ’s “Learn” mode evaluates machining performed by each cutting tool, then auto-configures optimization to increase cutting performance and efficiency. VERICut 9.5 has a “smarter” learn mode, with ability to learn from cutting tools used multiple times (e.g. roughing, semi-finishing, finishing, etc.), then use the learned information to optimize those tools uniquely, per each machining operation it performed.
Interactive simulation timeline
the simulation timeline (in the tool use window) is now interactive with the NC program viewer and NC Program Review. It has been enhanced to account for all time used by the machine as commanded by NC programs used to make the part. New color-coded markers show when errors (Red), warnings (Orange) and other events occurred during the simulation. Click the NC Program Review icon and then click directly on a marker in the timeline to review the error in the simulation, and investigate exactly where it occurred in the program.
New simulation Notifications
the VERICut 9.5 Preferences panel has a new Notifications tab where users can configure VERICut to send notices, via Email or Microsoft teams messages, to stay informed about their simulations. Notifications can be sent regarding when a simulation is completed, as well as how many errors or warnings were detected (if any).
Other new features:
» tether a Fanuc control simulator to a digital twin in VERICut to see the impact on the actual CNC machine in a simulation environment. Other controls are planned in future releases.
» Drag and drop a file summary ZIP file directly into
changes directly back into the ZIP file.
» EDM Die sinking can now be simulated by machines that carry a new "Electrode" tool type to perform EDM burning operations, including 5-axis burning.
» Ongoing enhancements to the stock Material Catalog and tool Performance Data containing valuable cutting feed and speed recommendations from the world’s largest cutting tool manufacturers.
» simplified guI panels for cutting conditions and Force graphs, tool Manager, component configuration in VERICut ’s Project tree, and more.
» Improved configuration of machine Collision tables for excluding certain sub-components.
» simplified configuration for interpolated turning.
ABOUT CGTECH
Cgtech specializes in numerical control (NC/CNC) post-processing, simulation, verification, optimization, and analysis software for manufacturing. Cgtech also offers programming and simulation software for composites automated fiber-placement, tape-laying, and drilling/fastening CNC machines. VERICut software is used by companies of different sizes in all industries. Established in 1988, and headquartered in Irvine, California; Cgtech has offices worldwide. For more information: visit the Cgtech website at cgtech.com, call (949) 753-1050, or email
Prepare For Takeoff
NWI Aerostructures thrusts forward with Fives Machining Systems and SINUMERIK ONE
the aerospace industry is in an era of profound innovation. Airplanes and air travel are transforming in response to the needs of the global economy, necessitating the building of aircraft at an accelerated pace.
With over 50 years of long-bed machining expertise, NWI is a contract manufacturer of complex structural components, sub-assemblies, and complete major assemblies of wing structures. the company supports leading OEMs producing commercial, business, and general aviation aircraft. NWI is now marketing its capabilities into military aerostructures, space launch vehicles, and ship building. the company is growing rapidly. Revenue was up 20% from 2021 to 2022, up 36% from 2022 to 2023, and up another 15% from 2023 to 2024, all on current contracted business.
Core competencies of this quiet powerhouse include precision machining of long and large aircraft components, forming of long and large parts, including autoclave age forming, large-scale processing, automated fastening of structural components, and integrated assembly of major aerospace structures.
NWI specializes in manufacturing some of the longest skins, stringers, and spars in the industry. state-of-the-art 5-axis machining technology allows the NWI team to produce large, monolithic, complex components. the company has made strategic investments in advanced
long-bed machining equipment to meet the demands of rising production rates and high-quality surface finishes, adding 10 additional spindles since 2021.
“We are a focused factory for long and large aluminum machining for structural components upward of 100 feet long and 20 feet wide for the world’s leading aerospace companies,” says Brannon Pfeffer, NWI senior Manufacturing Engineer. “Our niche in the market is long and large aluminum structures.”
trusted by top names in aerospace
NWI continually evolves, keeping up with advancements to best serve top-tier aerospace companies. “We’ve produced wing and empennage assemblies, and detail parts like skins, spars, and other components for the past 80 years. the precision, the surface finish, and the speed at which we produce them today is dramatically different than it was 20 years ago. that’s due to the cutters, equipment, programming, and the controls,” CNC Programming Manager steve Freeman explains.
With the continued growth in air travel, NWI Aerostructures has been receiving increased orders for more parts as program rates increase. to capitalize on this opportunity, NWI saw a need to standardize its machining capabilities. After exploring purchasing new equipment, the NWI team determined that retrofitted Cincinnati gantry machines, complete with sINuMERIK ONE CNC controls
from siemens, were the best option to meet the growing and evolving demands of their customers.
“We looked at new equipment, but with the solid foundations of the machines we have a robust history of experience with, it’s a more-efficient and cost-effective process to refurbish them into great shape for the needs of today,” Pfeffer says. “We do the mechanical refurbishment work, adjust the alignment, and then add our tooling and chip collection systems. Our capital investment and lead time is about one-third of what new equipment would be. We have refurbished all of our equipment over the past 10 years.”
Economical solutions from Fives group
Fives group is an international industrial engineering leader offering innovative solutions and products focused on boosting the performance of major industry leaders worldwide. Fives designs and supplies high-precision CNC machines, process equipment and production lines for various industries, including aerospace, automotive, and other complex manufacturing applications. through its Machine tool services and solutions group, Fives offers complete life-cycle solutions for machine tools around the globe. this suite of services is aimed at maximizing performance — ensuring customers’ machines will continue to deliver to their full potential year after year.
supported products encompass the Fives family of brands, including the Cincinnati machines that are integral to the success of NWI.
As the original equipment manufacturer of the Cincinnati machines, Fives understands the fleet like no other company. It is a major benefit to have Fives servicing the equipment on a regular basis and a huge check in the pro column to have the OEM refurbish these machines. to maximize investments made on precisionmachining equipment, Fives brings more than 40 years of experience and expertise to upgrading and retrofitting existing machines with the latest controls, drives, motors, and spindles. sINuMERIK ONE from siemens is integral to this process.
Retrofitting is the most cost-effective and sustainable full life-cycle solution Fives offers for its high-precision machines. the company believes in improving the productivity of in-use machines with retrofits resulting in nearly new machines capable of machining large aluminum parts with close tolerances.
Fives refurbished several machines at NWI, some with 30-plus years of successful service. Originally manufactured between 1985 and 1998, each machine has undergone a multi-stage refurbishing process. At the heart of each successful refresh, Fives relies on siemens mastery of 5-axis CNC control.
Pictured left to right, alongside very long and large wing components, are Robert Stiefel from Siemens; Brannon Pfeffer and Jacob Benton from NWI Aerostructures; and Gregory Mihalovich and Buddy Schoch from Fives.
Once installed, the new control package is commissioned and tested to ensure it delivers the operational performance levels desired. Fives also provides specialized training needed to ensure its customers get the most out of their new equipment.
game changing productivity increases switching to sINuMERIK ONE can result in a 30% increase in productivity for 5-axis machining. For 3-axis machines, you can achieve 20% faster results,” says Robert stiefel, Head of siemens Aerospace Vertical Market, u s gregory Mihalovich, technical sales manager at Fives Machining systems, sums up the benefits.
“With the pioneering sINuMERIK ONE now powering its 10,000-rpm Cincinnati gantries, NWI will be even more efficient, helping the company increase its value to customers by focusing on innovation,” he says.
sINuMERIK ONE is based upon a multi-core architecture comprising state-of-the-art micro-processors, delivering faster CNC cycle times. By working in combination with our s7-1500 PLC, the sINuMERIK ONE control delivers the best productivity and security in the industry. “In the case of NWI, the biggest technology change is the CNC. You get the biggest bang for your buck by focusing on retrofitting the electronic components,” stiefel says.
stiefel also emphasizes the time-savings of a retrofit, which typically takes only 14 to 16 weeks (about 3-anda-half months) and limits downtime. “A new machine purchase might take between six months and two years depending upon the size and complexity of the machine tool. It could be over two years between when you order the machine and when you machine your first part,” he says. “With a retrofit focused on a new control system, not only do you save money, but you also save time, and you benefit from measurable productivity improvements to help serve your customers better.”
stepping up to sINuMERIK ONE
NWI programmers and machine operators are finding the digital-native sINuMERIK ONE control a familiar tool for precision machining control. the functional characteristics of sINuMERIK ONE are similar to sINuMERIK 840D, but in terms of performance, the sINuMERIK ONE is lightyears ahead, allowing the operator to achieve maximum machining speeds and improve the path precision for complex surfaces.
In addition to improving the first part yield and productivity of a machine, retrofitting improves the user experience, capitalizing on the synergy between the capabilities of the machines and the skills of the people, always a goal for Fives.
“ staying with siemens CNCs has helped us be consistent,” says Jacob Benton, manufacturing engineer at NWI. “Both long-term employees and new hires have current experience running siemens-equipped CNC machines. Every person who touches a siemens sINuMERIK ONE is blown away by its processing speed, and our teams are quickly making the most of the increased functionality. standardization across the factory is very important for NWI, with all of their CNC milling machines running a siemens control. this decreases training requirements, improves flexibility, and standardizes maintenance and repair of parts.”
With its digital twin, the sINuMERIK ONE is a digitalnative CNC and provides the basis for future-oriented production with machine tools. Capacity utilization is optimized, with tasks being consistently moved from the machine tool to the work preparation phase.
“ using the digital twin, you can run an actual program and get an exact example of how the program will run on the machine — even before making the first cut on the real machine,” says Robert Varney, Fives after-market engineering director. “In some cases, it’s troubleshooting before there’s trouble.”
Helping to serve their highly-specialized niche in long and large machining for aerospace OEMs are long-bed, multi-spindle gantry machines refurbished by Fives Machining Systems and retrofitted with the SINUMERIK ONE control from Siemens.
Additionally, the advanced sINuMERIK ONE cybersecurity features, which are designed to meet coming requirements for government contracts, are ever more important to NWI and its customers.
t he Fives approach to agile innovation, using still-viable equipment upgraded to the cutting-edge performance of
companies looking to maximize production. together, Fives Machining systems and siemens are moving aerospace manufacturing forward in ways that are
The large touch-screen interface of the SINUMERIK ONE control was quickly embraced by the operators who found it highly intuitive and easy to move from machine to machine.
Precision Grinder Speeds Production of High-Performance Magnetic Seals
Advanced rotary surface grinders provide the precise flatness, parallelism, and finish needed for industrial parts subjected to high pressure and rotation, all at a reduced cost and cycle time
By Del Williams
In manufacturing, it is often necessary to grind metal and alloy parts to very precise specifications in thickness, parallelism, and surface finish. t his is particularly important when the parts are subjected to extreme rotational forces and must mate face-to-face, or parallel, to other surfaces.
Rotary shaft seals are a perfect example. t hese crucial components seal the rotating parts of machinery, prevent lubricant leakage, and ensure impurities do not infiltrate the inner workings of engines, gearboxes, and pumps. Mechanical seals, specifically, are utilized for high pressure applications demanding robust sealing capabilities. Consequently, the seal assembly components must be ground to exceptionally precise levels of flatness and parallelism to operate as effective leak-proof seals.
u nfortunately, the grinding process can be lengthy, labor intensive, and costly with conventional methods. s o, when production requirements increase, manufacturers frequently turn to more advanced, automated rotary surface grinders that can achieve the precise specifications in much less time, with less operator intervention and skill.
Exceptional seal Fit and Performance
For rotary shaft seals, various factors affect seal selection, such as shaft speed, pressure, temperature, lubricant type, and environmental conditions.
traditional designs typically involve three main elements: a metal case that provides rigidity and structural support; a rubber sealing lip that creates a tight seal around the rotating shaft; and a spring that ensures constant pressure is maintained by the sealing lip against the shaft. However, these seals may not perform as expected at very high pressure or RPMs, where traditional seals can begin to struggle to maintain contact with the shaft (track) due to radial runout. In these cases, the spring is often unable to maintain a tight seal with the shaft.
“ t he seals may be rotating at 40,000 RPM and if there is an imbalance because a part was not ground to size or
parallel, then it is going to throw off the whole system. t he seal can become compromised, and eventually it will begin to leak,” says Jared Desrosiers, Manufacturing Process and technology Manager, MAgsEAL, LLC, a supplier of specialty magnetic seals for critical systems that is celebrating its 70th anniversary this year.
In this type of scenario, magnetic seals create a strong attraction that eliminates the need for a spring in face seal designs.
“Magnetic seals are engineered to perform in high speed, high vibration, high altitude conditions and are excellent replacements for seals that are subjected to high torque, runout, and axial movement,” says Desrosiers.
t he OEM’s magnetic seals, called MAgsEALs, provide 100% positive face to face sealing and are designed to operate in air, gases, water, steam, refrigerants, lubricants, fuels, and hydraulic fluids. t he MAgsEALs are typically custom designed in a variety of sizes from a quarter inch to over 6 inches.
According to Desrosiers, MAgsEALs are comprised of a magnet (stator) and a seal case (rotor). When fully assembled, the attraction force of the magnet pulls the seal case assembly into itself to create a tight seal.
t he magnet is made from Cast Alnico V, a combination of aluminum, nickel, cobalt, and iron, to create the seal. t he seal case is made from a ferromagnetic material, 416 or 410 stainless steel, 17-4PH for maximum corrosion protection, or 42 Alloy steel for low thermal expansion. A carbon graphite ring is installed in the seal case to complete the assembly. t he carbon ring purposely protrudes out of the seal case to a specified nose height which is meant to interface with the magnet.
Each of these components – the magnet, seal case, and graphite ring – requires precise grinding to specific dimensions, parallelism, and surface finish.
Although the seal case does not have to be as precise, the carbon rings that are pressed into it are ground,
lapped, and polished to achieve the specified nose height. t he carbon seal ring surface flatness should be within two helium light bands, 0.0000232 in. [0.000589 mm] prior to use, according to John Westgate, MAgsEAL Manufacturing Engineering technician.
For the magnet, MAgsEAL starts with a rough casting and grinds all the sides and surfaces. secondary lapping steps are required to achieve the necessary surface finish. Currently, the OEM estimates it grinds 1,500 to 2,000 magnets each week.
In the past, the OEM utilized conventional reciprocating grinders on the magnets. Although reciprocating table grinders can be precise, the material removal rate is slow since the workpiece travels back and forth under the grinding wheel, so many grind passes are required.
However, as production requirements increased, the OEM decided to replace a slow, aging reciprocating rotary surface grinder that often needed to be repaired with advanced rotary surface grinders from Winona, MN-based DCM tech.
“We were able to achieve the precision and surface finish that we were looking for with the conventional method, but it took significantly longer to grind the same number of parts,” says Desrosiers. “With the [DCM] rotary surface grinder, we knew we could achieve significant time and efficiency gains.”
today, rotary surface grinders are designed with much more advanced sensors and controls that automatically maintain very tight tolerances, removing material down to within one ten-thousandth of an inch of the final thickness. Digital technology allows for an interface with easy-to-use touchscreen controls.
to expedite the grinding and finishing process for the magnet line, the OEM recently upgraded from a conventional rotary surface grinder to a more automated, Ig 282 sD grinder from DCM tech with a 24” variable speed table and 20HP variable speed spindle.
“We have found that nothing achieves the necessary flatness, height, and parallelism as fast as the DCM tech rotary surface grinders. t he required parallelism is particularly important to prevent vibration at high speeds of rotation,” says Desrosiers.
t he new model includes advanced features that automate the initial contact between the abrasive wheel and the part. With this updated option, advanced sensor technology detects vibration and can automatically fine-tune not only the pressure of the spindle motor but how quickly it moves the wheel down onto the part. When the machine senses the abrasive wheel has contacted the part, it automatically begins the grind cycle.
Automatic part detection eliminates the need for the operator to do time consuming, error-prone ‘manual touch offs,’ where they would manually feed the grinding machine until it just touches the surface of the part before backing off and restarting it.
“ t he DCM tech grinder simplifies the skillset needed and makes training a new operator a lot easier,” says MAgsEAL Manufacturing Engineering technician Westgate.
One of the reasons advanced rotary surface grinders are much faster than conventional reciprocating grinders is because the units can get much closer to the required dimensions before any finishing steps. In some cases, secondary steps can even be eliminated.
According to Desrosiers, the increased automation and ease of use has helped to dramatically improve magnet production.
“We increased manufacturing capacity with reduced setup, loading/unloading, and cycle time. We decreased the cycle time by more than 300%” says Desrosiers, adding that by reducing or eliminating the need for subsequent finishing processes, the company was able to achieve ROI in about three months.
MAgsEAL also appreciated the rotary surface grinder’s enhanced safety and cleanliness features.
Automated grinders contribute to a cleaner shop environment because the grinding is accomplished inside an enclosed shroud that contains the debris and prevents it from entering the work area. t he shroud, which is a sliding door with a built-in window for viewing the process, encloses the grinding area. t his has the added benefit of reducing the noise produced by the machine.
In addition to a shroud, grinders like the DCM Ig series provide an integral air mist collection system that draws particulate matter from the air and moves it away from the operator to enhance the cleanliness and safety of the work environment.
“For us, safety is paramount. t he advanced rotary surface grinder is a fully enclosed machine with door interlocks. t his configuration is significantly safer and cleaner than a conventional service grinder,” says Desrosiers.
He notes that MAgsEAL has already ordered another advanced rotary surface grinder to replace an aging reciprocal grinder used for the initial “rough” grind of the magnets.
When manufacturers need high-performance components that reliably operate in the most rigorous conditions, precise grinding is often necessary to meet the exact dimensions, flat, parallel surfaces, and finishes. In these cases, utilizing advanced, automated grinders that precisely and efficiently hone the component parts will help ensure that the required quality, reliability, and production goals are met.
For more information, call (800) 533-5339, email info@dcm-tech. com , visit www.dcm-tech.com , or write to DCM tech at 4455 theurer Blvd, Winona, MN 55987.
ABOUT THE AUTHOR:
Del Williams is a technical writer based in torrance, California.
PRODUCT SHOWCASE
COSEN SAWS
Cosen NC-510MG
Cosen SVT-6070S
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High-speed Vertical Plate saw
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E-Z LOK Finserts: Robust Threaded Inserts for Wood
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