Industrial Machinery Digest - August 2021

» Manufacturers: Creators Wanted! » Versatile Horizontal Hobbing and CNC Gear Deburring » Power Skiving For Electric Vehicles » Exposing the Myth that All Spindle Rebuilds are Equal

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August 2021

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Table of Contents

COLUMNS

10

BUSINESS 4.0 A Return to the Pre-Pandemic Trend US Manufacturing Technology Orders total $448 million in May 2021, an increase of 11% from April, pushing the 2021 total over the $2 billion mark

20 FEATURES:

20

14

TALKING SHOP

16

SAFETY & MAINTENANCE Exposing the Myth that All Spindle Rebuilds are Equal By: Del Williams

MANUFACTURING SHOWCASE Big Blue Saw

54

SURPLUS BUYING AND SELLING Integrated Rupture Disk Assemblies for OEM Hydraulic & Pneumatic Equipment

By: Russ Willcutt

22 24

WORKFORCE DEVELOPMENT Industry Concern Over Workforce Challenges Grows Despite Record Growth in Sector

NEW TECH

Versatile Horizontal Hobbing and CNC Gear Deburring

28 PROCESS 32

DEPARTMENTS

Manufacturers: Creators Wanted!

Power Skiving For Electric Vehicles

How manufacturers can achieve 90% machine use reduction with power skiving

INDUSTRY INSIGHTS

Bringing Advantages To The Growing E-Mobility Market EMAG develops a production line for rotor shaft manufacturing

6 EDITORIAL DIRECTIONS 8 INDUSTRY NEWS 36 ON EXHIBIT – NMTE 38 ON EXHIBIT – FABTECH 46 ON EXHIBIT – MOTION + POWER 48 ON EXHIBIT – WIMTS 50 PRODUCT SHOWCASE 61 CLASSIFIEDS 62 ADVERTISER INDEX

ON THE COVER

28 |

4 IMD AUGUST 2021

Since 1951 Burr King grinders, polishers, and mass finishing systems have been used by the world's leading companies. Burr King products use innovative designs of uncompromising quality, they are industrial grade, intended for use on metals, woods, composites, plastics, rubber, stone, fiberglass and other materials.

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Editorial Directions SERVING AMERICAN MANUFACTURERS FOR OVER

Yesterday was a good day. At the end of it I thought back over what had occurred to leave me with such a satisfied glow. I hadn’t raked in a pile of money, caught a big fish, or broken any world records.

I’d gone about my usual routine; working in the morning, and running errands in the afternoon.

Then I realized that, through some strange alignment, I’d lucked into a daylong chain of encounters in which everyone I dealt with had gone a little bit out of their way to be helpful and pleasant. Retrieving my car from the dealership after a maintenance check that morning, my escort had a few, quick questions; she wanted to make sure my seats had been returned to their original settings, as well as my audio system. On my way back home, I stopped by my favorite local café, where they included a free sample of a locally harvested honey because they know I support neighborhood small business. Later that day, a marcom professional resolved a glitch in an international call with the utmost calm, allowing me to keep mine before an important interview.

Small enough events on their own, but what they share is that somebody went out of their way to help me. They could’ve done the minimum required, or ignored me altogether, but each of them stepped in and delivered that little extra something that culminated in a more pleasant experience all around. And you know what else? I’ll go back, and I’ll look forward to doing it. And I will also refer friends on my community chat groups to these businesses, and others like them.

Looking at myself, I wonder if I can honestly say that I take this sort of “valueadd” approach to my own work? When I conduct an interview for an article I’m writing, do I always remember to ask the subject if there’s anything they’d care to add? Do I make sure to mention the many ways they’ll be able to use the article in their marketing efforts? A good experience might also leave the door open to future collaborations, as they often do. The list continues, And yet another benefit is that this close inspection of how you interact with customers and colleagues allows for continuous improvement, and a professional that only gets better with each passing year. So how about you?

35 YEARS

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Russ Willcutt Editorial Director, Industrial Machinery Digest

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Industry News Design-2-Part Trade Shows Returns with Three Successful Events Design-2-Part Shows (D2P) has returned to running live in-person events. So far this year, they have successfully completed three shows with limited restrictions in Atlanta (GA), Grapevine (TX), and Uncasville (CT), resulting in higher than expected attendance.

According to Jerry Schmidt, President of Design-2-Part Shows, “We felt the time was right to return to live trade shows, and our customers were anxious to be back offering their contract manufacturing services to OEMs.” said Jerry Schmidt, President of Design-2-Part Shows. “With so many manufacturers and OEMs still restricting vendor visits, the demand for a safe and controlled face-to-face sales environment was at an all-time high.”

D2P will wrap up their Spring/Summer show season in Schaumburg, IL on August 4th and 5th. Jerry Schmidt added “Schaumburg is one of our anchor shows, so we are looking forward to returning to such a critical manufacturing market. Exhibit space is in high demand this year and is selling out quickly”.

Following the Schaumburg show and a short break, Design2-Part returns with a full slate of shows in the Fall: Marlborough (MA); Akron (OH); Oaks (PA); Indianapolis (IN); and Raleigh (NC).

Tormach Now Offers Machine Assembly Services and On-Site Installation For CNC Mills and Lathes Tormach Inc. has announced it is now offering assembly services for its line of machines, including the 1100M/ MX & 770M/MX CNC Mills, the PCNC 440 Mill, and the Slant-PRO 15L. By default, Tormach ships its machines unassembled to its customers as a way to keep costs down. Now, for a reasonable fee, customers now have options. Assembly services are performed at Tormach’s facility and offered in a tiered system. An in-house Tormach professional will install, align, and test all pre-installed components (if partial assembly is chosen) and major systems to the machines for full assembly. This allows customers to speed up the time to commission their new machines quickly at their shop once they arrive.

“We heard from many customers that they would prefer it if we would provide our machines fully assembled or assist in installing

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8 IMD AUGUST 2021

major accessories, and the additional cost was well worth it to them,” said Lori Morrison Bufalo, Tormach’s Marketing Director. “We have decided to add this service as a way to make life easier for our customers and much like our philosophy with machine design, every customer has different needs, so you have the ability to pick and choose what you’d like installed by our technicians.”

Combilift’s 60,000th Truck Delivered

The Irish manufacturer Combilift recently marked a further milestone when it’s 60,000th unit came off the production lines at the company HQ in Monaghan and was shipped to the other side of the world. The customer taking delivery of this special forklift is Metroll, a leading Australian manufacturer and supplier of steel building products including roofing, cladding, rainwater, structural and fencing.

Combilift CEO and Co-Founder Martin McVicar commented: “This is a great achievement for Combilift, particularly as almost every truck we manufacture is a one-off, designed for specific and individual requirements. There are very few other companies, if any, that can offer this level of customization whilst manufacturing in such volume. The first half of this year has been by far the best in our 23 year history for the number of orders we have received – not just for Combi-CB models but across our complete product range.”

Mazak Appoints New Managers to Fulfill Increased Customer Demand in Southeast Region Travis Kirby is the new service manager and Jesse Jones was promoted to regional applications manager. In their new positions, Kirby and Jones will help further ensure the region’s manufacturers receive the expert applications and service support they need to keep pace with the industry’s surging production demands.

As the new service manager, Kirby will guide and grow the service group and streamline operations to effectively and efficiently support field service engineers and provide customers unmatched technical support. His qualifications for the new position include 21 years at Mazak, with five years as an application engineer and 16 years as a department manager in applications engineering.

Travis Kirby

Jesse Jones

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Jones joined Mazak in 2007 and brings a wealth of knowledge to his new position. The Southeast regional applications staff and the company’s Florida applications engineers will report directly to him.

Global Automation Leader FANUC Announces Production Of 750,000th Robot Currently, FANUC is capable of producing 11,000 robots per month in fully automated factories that use its own robots to make robots, controllers and machine tools that offer world-renowned reliability, precision, speed and easy operation.

FANUC’s customer base covers a wide range of industries including automotive, aerospace, food and beverage, consumer goods, medical and pharmaceutical, warehousing, and many more. “Now more than ever manufacturers are embracing automation and robotics to solve production challenges. I’m proud to say that FANUC is in a position to meet the growing demands for easy-to-use automation solutions that help our customers increase efficiencies, improve their competitive position, and realize a quick ROI. We look forward to helping as many companies as possible achieve their goals.”

In-Place Machining Company Acquires Exact Metrology

cutting and measurement services to customers, announced today that it has acquired Exact Metrology as of July 2, 2021.

As part of the In-Place Machining Company long term growth strategy, this acquisition will expand In-Place Machining Company’s service offerings to include 3D scanning, Industrial CT scanning, metrology equipment sales, and software solutions. This exciting addition provides In-Place Machining Company a strategic resource to bolster their growing measurement and alignment business. When talking about the benefits of acquiring Exact Metrology, President and CEO of IPM, Dean Flint said, “In-Place Machining could not be more excited about the strategic potential resulting from the combination of these two great organizations. Both have been built on solving their customer’s most challenging technical problems.”

Commenting on this new partnership, Dean Solberg, Vice President of Metrology Sales/Services, states “This opportunity to join forces with In-Place Machining Company is exactly what we were looking for. The ability to combine our metrology expertise and IPM’s expertise with on-site machining will push barriers in every industry. We look forward to combining our collective synergy as one team and taking on high-precision projects together, anywhere in the world.”

In-Place Machining Company, LLC (“IPM”), a globally recognized high acuity field machining company focused on providing highly technical, precision on-site machining, diamond wire

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IMD 9

Business 4.0

A Return to the Pre-Pandemic Trend

US Manufacturing Technology Orders total $448 million in May 2021, an increase of 11% from April, pushing the 2021 total over the $2 billion mark

I

n only three other years since 1998 have orders surpassed $2 billion by May. Manufacturers across the industry have expressed broadly positive sentiment, so we would expect the remainder of the year not only to return to the pre-pandemic trend.

U.S. Manufacturing Technology Orders totaled $448 million in May 2021, according to the latest U.S. Manufacturing Technology Orders report published by AMT – The Association For Manufacturing Technology. May 2021 orders increased 11% over April orders and were nearly double that of May 2020. Total orders for 2021 topped $2 billion two months before that milestone was reached in 2020.

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10 IMD AUGUST 2021

“Given the state of the economy last year, orders were expected to be up, but so far, 2021 is shaping up to be a historic year,” said Douglas K. Woods, president of AMT. “In only three other years since 1998 have orders surpassed $2 billion by May. Manufacturers across the industry have expressed broadly positive sentiment, so we would expect the remainder of the year not only to return to the pre-pandemic trend but also to exceed previous forecasts.

“Despite the general optimism felt across manufacturing sectors, one common impediment to growth is the inability to find sufficient labor. Manufacturing employment is still about half a million jobs below pre-pandemic levels, and the current number of open positions

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in the manufacturing industry is double the February 2020 level.

Growth with fewer employees occurs regularly during manufacturing recessions, according to work done by the Brookings Institution. Studies have found that manufacturers in a position to do so will leverage a slowdown to invest in greater automation and more sophisticated production equipment. The result is a more productive in-place workforce, but continued growth is dependent on a larger, more skilled manufacturing labor pool.

“Now, and during the recession, our members have reported that automation and new-tech sales continued to grow or barely saw a pause in order levels. Without these investments, growth in recovery would have been more susceptible to supply chain disruptions. We have seen industries with modest domestic capacity increase investments in production capacity by multiples of pre-2020 levels. Metal valve manufacturers, whose products are used as components in nearly every corner of manufacturing, increased orders by staggering margins in May 2021, suggesting that U.S. manufacturers are shoring up supply chain risks by looking to domestic sources.”

to speed the pace of innovation, increase global competitiveness, and develop manufacturing’s advanced workforce of tomorrow.

With extensive expertise in industry data and intelligence, as well as a full complement of international business operations, AMT offers its members an unparalleled level of support. AMT also produces IMTS – The International Manufacturing Technology Show, the premier

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The United States Manufacturing Technology Orders (USMTO) Report is

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based on the totals of actual data reported by companies participating in the USMTO program. This report, compiled by AMT – The Association

ABOUT IMTS

For Manufacturing Technology, provides regional and national U.S. orders data of domestic and imported machine tools and related

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attracts visitors from every level of industry and more than 117 countries.

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AMT – The Association For Manufacturing Technology represents

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exhibiting companies (2,563). IMTS is owned and managed by AMT-The

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12 IMD AUGUST 2021

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Talking Shop

FEATURING:

TALKING SHOP WITH: Paul Aiello — Director of CERT Sales and Operations, FANUC America Many consider FANUC to be a true pioneer in the development of education and certification programs in the United States. How did this all come about?

We have always been involved in strategic planning, working with our industry partners on projects that are one to five years out, so by reviewing various statistics we were able to see there would soon come a challenge in being able to acquire a trained, skilled workforce in the numbers that would be required. You can invest all the resources you’d like into developing new technologies, but if you don’t have the workers who know how to use it, then you haven’t quite met your goal. So that began a period of reevaluation.

First of all, FANUC has one of the largest training centers in the world here in Rochester Hills, Michigan where some 6,000-7,000 students pass through our doors each year. But we came to realize that the closer we could get to the companies in need of this training – as well as the students who could benefit – the more effective our efforts would be. We needed to move into the community, to somehow provide them

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with a pipeline of skilled workers right in their own back yard rather than requiring students to travel to spend time with us. So the first logical step involved working with community colleges and technical schools, which was met with a certain amount of success. Then we realized that most students make their fundamental career decision much earlier than that, meaning we needed to reach them at an earlier stage in their educational development, such as high school.

The goal was to give them a glimpse of what modern manufacturing is like like right in their own classroom so they could see that it’s primarily a clean industry dominated by technology these days instead of the dated image they and their parents may hold from the past. As it now stands, we have more than 1,400 educational partners around the country, and employers are clamoring for graduates possessing their particular skill sets.

Has the COVID pandemic altered your approach to thinking about these issues, or reaching out to students and educational systems in any way?

It definitely has. For instance, within industry, you can see three sectors in particular – food production, supply chain, and medical equipment – that had become vulnerable because they were located so far outside the United States. It quickly became apparent how important it was to bring these three production centers, and many more, back home, and for that to succeed we needed more qualified workers, which meshed perfectly into what we were trying to accomplish. We had learned there

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were three central areas that a student needed to focus on in order to meet current industry demands: automation, process control technology, and the digital thread. I remember one company coming to me and saying they currently has 200 job openings for graduates possessing knowledge in those skills, and another employer claiming as many as 2,000. These are the types of job opportunities that should be broadcast and communicated to high school students who are searching for a stable, good-paying jon where they can use their minds as well as their hands. Not everybody requires a four-year college degree, and these types of programs can allow students to get started down their career paths much more quickly than traditional means.

Any other accomplishments or accolades you’ve achieved along the way you’d care to share?

FANUC America has always been proud that we gift 25 copies of our Roboguide programming virtual software to each one of our 1,400 educational partners. And we also continue our education outreach by standing as a Standard Recognition Entity for the Department of Labor at their request, for which we gathered a robust industry coalition in order to gain a wide range of perspectives and insights.

It’s critical that all sectors of industry do their part in educating and recruiting the vibrant, skilled workforce we require to meet our potential as a country.

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IMD 15

Safety & Maintenance

Not all machine shops offer the same level of service when it comes to spindle repair work.

Exposing the Myth that All Spindle Rebuilds are Equal By: Del Williams

E

xpert spindle rebuilders that pay attention to the details and communicate throughout the process offer fast, reliable rebuilds that last For manufacturers, CNC machine tool spindles are critical to any drilling, milling, boring, grinding, routing, cutting, or sawing process. However, when these systems deteriorate and fail due to contaminants, human error, improper maintenance, lubrication issues, or poor spindle design, a quality rebuild is often required.

Despite the availability of spindle rebuilders nationwide, not every firm provides the same level of quality. Even if a rebuilder has the equipment, they may not have the experience, technical knowledge,

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or attention to detail necessary to rebuild a spindle that performs reliably for many years.

Even reputable rebuilders vary in the extent and quality of the initial inspection, accuracy of quotes, and level of communication with customers. Yet given the direct correlation between these factors and the ultimate quality and longevity of the rebuild, most machinist continue to believe that it makes little difference which shop they contact.

In actual practice, however, the difference can be significant and seriously impact shop productivity. As a result, most machinists can easily relate tales of failed spindle repairs that led to costly downtime.

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“After one spindle rebuild, I had to pull the machine out of production within a short time for additional repair,” says Tom Collins, maintenance supervisor at Edro’s Engineering’s Walnut, California facility. Edro Engineering, which serves North America and Europe, is a one stop tooling solution shop for machining services, special materials, custom mold bases, PVD/DLC coatings, and additive manufacturing.

“Any time these CNC machines are down it costs us money, so we never want them down,” explains Collins, who is responsible for more than 50 milling machines, jig borers, and surface grinders.

“Because we run our spindles often at high speeds and we do surface grinding of stainless steel and specialty materials, frequent rebuilds are necessary – even expected.”

“So, if we send out a spindle and it is not properly repaired, it has to be removed again for additional repairs and that is going to put the machine down for even more time – and that’s even more money,” he adds.

Morgan Stipp, who supervises a grinding operation for Embee Processing in Santa Ana, California, agrees that minimizing downtime is essential.

Stipp oversees about 20 precision grinders at Embee Processing’s 124,000 square foot metal finishing campus facility in Santa Ana, California. This includes Studer CNC grinders, Okamoto NC OD grinding machines, centerless grinders, and other equipment with thread, surface and superfinish grinding abilities.

Most part configurations require the chrome or HVOF surfaces to be ground, polished, honed, and deburred after plating to achieve the desired surface finish. These operations are performed to ensure a flawless finish with tolerances as low as 50 millionths of an inch, according to Stipp.

“We are extremely picky with our precision grinding because it has to be essentially perfect for our customers. Without the right equipment and properly maintained spindles, we would not be able to stay in business,” says Stipp.

In this regard, Stipp believes the thoroughness of the initial inspection performed by the repair/rebuild shop not only impacts the longevity of the spindle after it is rebuilt, but also the accuracy of the price quote.

“Having a machine down for unexpected extra maintenance because the inspection missed something can cost us a lot of money,” says Stipp. “We also do not want any surprise upcharges either, due to the original inspection and quote not being thorough enough.”

Both Stipp and Collins found the precision and attention to detail they required when they contacted MZI Precision of Huntington Beach, Calif., an experienced machine tool spindle rebuilder with a complete process to supply customers with a fast way back to maximum productivity.

While most spindle rebuilders only take minimal time to wipe parts before inspection, during disassembly the rebuilder cleans and polishes each component with emery cloth to clearly reveal even minute imperfections. Even the nuts are removed, polished, and then tested to ensure proper fit.

The next step is detailed measurement and documentation of every part of the spindle’s shaft and housing geometry. Micrometers

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are used to take detailed size measurements, runout is checked using 50 millionths of an inch dial indicators. The shaft bearing The quality of the initial inspection matters when spindle shoulders are then repair work is involved. checked to see that they are true and perpendicular. The housing bores are checked for size, alignment and shoulders squareness. MZI Precision also takes video, followed by digital photographs of each part during the disassembly process.

“If I have anything go wrong with our spindles, I will call them before the manufacturer. They will diagnose the spindle at no cost and send me a detailed quote, which has been down to the penny on everything. I have never had a surprise charge,” says Stipp.

According to Edro Engineering’s Tom Collins, the quality of the repair is also impacted by the expertise of the rebuilder and level of communication, traits he also found in MZI Precision.

“Communication is important, and it is a two-way conversation,” says Collins. “The company wants to understand how the spindle is run, the conditions, the types of parts being made, what metals are cut, the depths of cuts, etc. so the rebuild can be tailored to my application. Also, when I have a question, they answer it quickly.”

Collins also appreciates the spindle rebuilder’s use of only high-grade replacement components and bearings, which help to increase equipment reliability and lifespan. The rebuilder utilizes aerospace-grade bearings that are ABEC rated 7 or 9, the highest classification. Depending on the requirements, ceramic bearings are often recommended despite the nominal additional cost, due to longevity and higher running speeds.

“I have found their rebuilds to be as good as OEM and sometimes better. The spindles have run perfectly so I expect them to last a long time,” says Collins.

While spindle rebuild reliability and lifespan is essential, quick turnaround is also important since equipment downtime must be minimized. “The turnaround for our spindle rebuilds has to be timely to keep our production on track,” says Collins.

Although spindle rebuilds are available from various sources, for manufacturers that seek greater production reliability, uptime, and lifespan out of their CNC equipment, working with an expert spindle specialist is usually the best option.

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

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Manufacturing Showcase

Big Blue Saw

By Russ Willcutt

W

hile earning his keep as a freelance IT consultant, Simon Arthur began designing and building robotic war machines, or “battle bots,” and entering them in contests around the country. As he grew to know other enthusiasts he found they shared a problem he’d encountered himself: locating dependable suppliers of the custom-designed parts they required, with a reasonable lead time and cost for small-quantity orders.

Arthur recognized a market in terms of “need,” but no existing structure to support and define such an enterprise.

That’s when his IT training kicked in. Instead of focusing on the part, as an engineer probably would, he began by imagining the system that could make this happen – what types of services should be offered, and how would order specifications be submitted? Building a strong network of specialty service contractors – laser and water jet cutting, primarily, which the battle bots required most – would take time, and then the years of effort it would require, with no marketing budget, to build a customer

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20 IMD AUGUST 2021

base working the crowd at battle bot events. Arthur began developing the software for the company, which he’d decided to name Big Blue Saw, located near Atlanta, Georgia, in 2005, launching soon after.

Arthur graduated from his home into a small office space in 2014, going full-time with the company and soon hiring additional employees. The majority of their work was subcontracted, Customers were drawn to a website that organized and simplified their needs, allowing complete design prints to be uploaded and providing assistance to those requiring polishing, whether the order called for one or 10.000 parts. The company made its last significant move in 2019, gaining more production space and equipment for both its laser and water jet cutting divisions. He quickly found that equipment service was a primary concern in his line of work, “Rather than focusing on the brand to impress potential customers, I found it was more important to identify OEMs that took

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maintenance response seriously,” Arthur says. “If you’re looking at a water jet, for instance, the whole system is under extreme pressure, and something can blow at any time.

Expanded space was required because Big Blue Saw, as expected, had begun to pull in subcontracted work so they could begin performing as many operations on site as possible. Since that decision was made, 90-percent of production takes place under-roof, leaving only a small portion of specialty operations currently being subcontracted, The two processes allow for cutting a broad range of materials. Water jet cutting, for example, is ideal for aluminum, stainless steel, titanium, copper, and brass, while laser easily handles wood, rubber, and acrylic.

Nothing has been abandoned while these gains have been made, though, Arthur says: “All of our customers were hobbyists in the early years. They were just excited to find a site where they could get the custom parts they needed quickly, easily, and at a reasonable cost. So they remain a central part of our business, as they will.”

At the same time, Big Blue Saw has expanded its horizons, collaborating with NASA’s Jet Propulsion Laboratory (JPL) and Microsoft, for instance, leading a field of big-name enterprises attracted to the company’s business model and output. Its roots remain intact, however, as Big Blue Saw will be sponsoring four

teams at BattleBots 2021 in Las Vegas this August, which will be broadcast on The Discovery Channel.

It’s long been said that if you can find a way to make a living doing some you truly enjoy, then you’ve really accomplished something. And that can surely be said for Simon Arthur and his colleagues at Big Blue Saw. For more information go to bigbluesaw.com.

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IMD 21

Workforce Development

Manufacturers: CREATORS WANTED! Industry Concern Over Workforce Challenges Grows Despite Record Growth in Sector

T

he National Association of Manufacturers released its Manufacturers’ Outlook Survey for the second quarter of 2021. “Attracting and retaining a quality workforce” and “rising raw material costs” remain manufacturers’ biggest concerns for the second straight quarter. Despite those concerns, manufacturers predicted some of the highest expected growth rates in the survey’s history and the most positive outlook since the third quarter of 2018.

“Manufacturers see an incredible future on the horizon and are predicting growth numbers unheard of in the more than two-decade history of this survey,” said NAM President and CEO

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22 IMD AUGUST 2021

Jay Timmons. “But yet, a dark cloud still hangs over the industry.

Manufacturers face long-term workforce challenges, with a record-high 851,000 open manufacturing jobs right now and more than 4 million to be filled over the next decade. While a very serious concern, manufacturers are doing everything we can to meet this challenge. The NAM and The Manufacturing Institute’s Creators Wanted campaign, including a first-of-its-kind mobile manufacturing experience, will cover thousands of miles in the second half of this year tackling the top two issues facing this critical workforce challenge: a skills gap and misperceptions about modern manufacturing.

IMD – The Industry’s Most Extensive

“To keep this momentum going, elected leaders in Washington should advance policies that will enhance our competitiveness and strengthen our industry, starting with delivering bipartisan infrastructure investment. Failing to do so will rob generations to come of the opportunity to achieve their highest potential.

Conversely, moving forward with proposed tax increases, as our studies have shown, would mean 1 million jobs lost in just the first two years. Anti-worker laws like the forced unionization PRO Act would upend our workplaces. Whether today’s manufacturing optimism is a passing moment or a new normal has a lot to do with the choices our elected leaders make.”

Survey highlights: » 90.1% manufacturer optimism, highest since Q3 2018 » 3.7% expected growth in full-time employment, a record high » 6.1% expected growth in sales over the next 12 months, a record high » 5.9% expected growth in production over the next 12 months, a record high

Background on Creators Wanted The NAM, together with the MI, launched the Creators Wanted campaign, an unprecedented national effort to build the modern manufacturing workforce of tomorrow. By 2025, Creators Wanted aims to reduce the skills gap in the United States by 600,000, as well as increase the number of students enrolling in technical and vocational schools or reskilling programs by 25 percent and increase the positive perception of the industry among parents to 50 percent from 27 percent.

Creators Wanted is part of a digital campaign together with a first-of-its-kind mobile traveling manufacturing experience, and it is part of sustained initiatives at the MI targeting youth, veterans, women and other underrepresented communities.

ABOUT THE NATIONAL ASSOCIATION OF MANUFACTURERS The National Association of Manufacturers is the largest manufacturing association in the United States, representing small and large manufacturers in every industrial sector and in all 50 states.

Manufacturing employs more than 12.3 million men and women, contributes $2.35 trillion to the U.S. economy annually and has the largest economic multiplier of any major sector and accounts for 63 percent of private-sector research and development. The NAM is the powerful voice of the manufacturing community and the leading advocate for a policy agenda that helps manufacturers compete in the global economy and create jobs across the United States.

Industrial Publication

MI and NAM Honor Manufacturing Leader The Manufacturing Institute and the National Association of Manufacturers released a statement on the passing of Emily Stover DeRocco, former President of The Manufacturing Institute:

“Our industry has lost a true leader on workforce development,” said Manufacturing Institute Executive Director Carolyn Lee. “Under her leadership, the Institute developed a national portal of industry-recognized Manufacturing Skills Certifications that have influenced today’s secondary and post-secondary education efforts in 36 states. Emily’s efforts helped put a spotlight on the changing workforce needs in manufacturing and the policies needed to meet these greatest challenges.

As we remember and honor her many contributions, our thoughts and prayers are with the DeRocco family.”

“Emily was a true champion to our nation’s workforce and was passionate about manufacturing,” said NAM President and CEO and Chair of the MI Board of Directors Jay Timmons. “She served former President George W. Bush and U.S. Secretary of Labor Elaine Chao as well as many other political leaders on workforce development initiatives where her voice and leadership helped usher in a renewed focus in this country on matching education programs with the skills needed to build the modern manufacturing workforce. Although Emily will be sorely missed, there is much to celebrate in the life she lived and the example she set. She is an inspiration to us and to the Manufacturing Institute and manufacturing community which she was proud to serve.”

For more information about the NAM or to follow on Twitter and Facebook, please visit www.nam.org INDUSTRIAL MACHINERY DIGEST.COM

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IMD 23

New Technology

Versatile Horizontal Hobbing and CNC Gear Deburring

A new hobbing machine enables a job shop to take new opportunities, while Helios Gear Products new CNC gear chamfer-deburring machines increase profitability for job shops and high-mix manufacturing.

T

erry Roach, sales manager for Gear Master, said, “We saw market growth potential by adding hobbing ability for small-diameter parts and for long-shaft hobbing, meaning parts over 500 mm long,” recalling the challenge for the job shop’s growth in 2019. As all job shops consider expanding capabilities, Gear Master’s next step for growth appeared to be in smaller parts and longer parts, and the

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AUGUST 2021

company found an ideal solution that solved both needs. This machine, a Helios Hera 90-W horizontal CNC gear hobbing machine, provided a complete installed package within a few months: ability to hob small diameter parts, capacity for part lengths up to 600 mm, high-speed carbide hobbing, domestic support in the Midwest, and a price that ensured a profitable platform for the future.

Master. Together, Helios and Gear Master have forged a relationship for versatile horizontal gear manufacturing success. Helios equips the job shop with globally leading technology, fast deliveries, low prices, and domestic support. This combination empowers Gear Master to be an industry leader and more competitively serve its customers.

New CNC Gear Deburring “Gear manufacturers need a new level of gear chamferdeburring that offers quick and easy setups with repeatable high quality,” said Adam Gimpert, president of Helios Gear Products. To meet this demand, Helios announces new CNC advances to its line of Tecnomacchine chamferPictured from left: Kevin Geloge, William Abke, Kyle Dobbs, Richard Conger, Patrick Greer, Tim Hoban, Lon Parker deburring machine tools.

These CNC improvements offer manufacturers a machine platform with maximum flexibility setups of all tool and work positions and parameters. Changeovers for a high mix of part sizes and types including spur and helical can be accomplished in just a few minutes rather than the gears, bevel gears, bore- and shaft-type parts, and others. These traditional 30-45 minutes. abilities are driven by a new CNC system that programmatically For productive gear chamfer-deburring, the new series of controls all factors for the chamfer-deburring process. This equips Tecnomacchine equipment from Helios Gear Products offers manufactures with a process that is easy to set-up and change-over manufacturers an ideal machining solution. With complete CNC for reliable and consistent quality. functionality, these machines minimize changeover time, maximize Several factors impact successful chamfer-deburring with repeatable quality, are easily programmed, and minimize idle abrasive wheels and carbide end mills. These include the tool time. Consequently, gear manufacturers can achieve top levels of position (radial, axial, tangential, and inclination), tool pressure, tool productivity from their chamfer-deburring operations. rotation speed, tool rotation direction, workpiece rotation direction, and workpiece rotation speed. Traditional machine tool deburring ABOUT HELIOS GEAR PRODUCTS, LLC often requires manually setting several if not all these items. Today, Helios offers its gear chamfer-deburring machine tools with friendly Helios Gear Products, LLC specializes in the parallel axis gear industry dialog programming of all these items. This allows a setup technician and offers hobbing machines with optional automatic loading systems, to store a complete application to later be recalled by the CNC worm and thread milling machines, gear inspection equipment, with just a few software steps. Additionally, tool spindles can be deburring and chamfering machines, consumable tools (including hobs, configured with brushing units for CNC brushing within the same gear grinding and honing wheels), hob and shaper cutter sharpening chamfer-deburring cycle. machines, and expert services for hob sharpening and part inspection.

As one example, manufacturers use the Helios TM 250-CNC Helios products are used worldwide, and our experience gives us the machine for profitable gear chamfer-deburring. This machine edge in contributing to the productivity and efficiency of our customers. features a rotating table with two stations: one for loading/unloading Helios Gear Products, LLC services the North American market for parts by hand or integrated robot; the second for chamfer-deburring YG Tech, Monnier + Zahner / Lambert−Wahli, Tecnomacchine, and and brushing of the workpiece. This feature minimizes machine Tyrolit−MIRA. Helios also offers cooperative sales and service with Kapp idle team and drastically improves productivity of the solution.

Technologies and Penta Gear Metrology.

Moreover, the machine implements a complete CNC system for the abovementioned abilities: quick and easy changeovers from saved For more information, visit www.heliosgearproducts.com

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26 IMD AUGUST 2021

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Process

Power Skiving for Electric Vehicles How manufacturers can achieve 90% machine use reduction with power skiving

As more car manufacturers enter the electric vehicle (EV) market, a growing case is emerging for multiple gear ratios in EVs.

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28 IMD AUGUST 2021

IMD – The Industry’s Most Extensive Industrial Publication

T

esla’s automobiles are frequently cited as examples that electric vehicles (EVs) don’t need multiple gears or dual transmission. That is, except for all the models that do. As the multi-gear EV trend begins to pick up speed Mats Wennmo, Global Automotive Transmission Manager at Sandvik Coromant, the global leader in metal cutting, explains how a process known as power skiving can help EV manufacturers keep-up, but with greatly-reduced machining times.

Tesla’s Dual-motor Model S, Model X and Model 3 vehicles each have two different gears, one in the front and one in the back. The potential of EVs with multiple gears has also been explored by Porsche, which has confirmed its electric Taycan will have a two-speed gearbox. Electric vehicles by the likes of Polestar, Volvo, Lucid and Volkswagen all have transmissions, too, but not transmissions like cars have had in the past. New technologies include a two-speed EV transaxle drive unit announced by ZF, the manufacturer of technical systems for vehicles.

There are several performance advantages of multiple gear ratios in EVs, which we’ll explore in this article. But, if multi-gear EVs by the likes of Porsche and Tesla do prove successful, then how can other manufacturers follow suit while also keeping their production cost-effective?

Sandvik Coromant’s CoroMill® 180 is an indexable insert cutter used for power skiving.

There are two main reasons why EVs need to have transmissions, shown in Figure 1. First, the torque/revolutions per minute (rpm) ratio is not the same in an EV as in an internal combustion vehicle. In the EV, it is hard to achieve torque/ acceleration from the battery without a transmission. The high torque puts higher loads on the gear flanks and, together with

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IMD 29

In EVs, it’s hard to achieve torque/acceleration from the battery without a transmission. The higher rate of rpms in EVs also puts extra demands on the transmission.

high rpms, this brings noise reduction into focus since EVs don’t have an engine to cover the noise.

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So, what is the best way for manufacturers to produce these higher-quality transmission components? The answer lies in concept that’s been around for more than a century: power skiving.

The process combines shaping and hobbing — a machining process for gear cutting — into a single continuous cutting process.

Power skiving has several advantages over traditional machining methods, including higher productivity and flexibility. Using this method it’s possible to machine the complete component in a multi-task machine, or machining centre, with one single set-up.

This shortens production time, improves quality and reduces handling and logistics costs. The process also aids manageable and predictable component machining.

Because all machining can be carried out in a single set-up, this removes the need for several specialized machines and machine changes. For automotive manufacturers— for whom downtime is incredibly costly — reducing machine changes can have a significant impact on their bottom line.

One Sandvik Coromant customer, put power skiving to the

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30 IMD AUGUST 2021

Second, the higher rate of rpms in EVs puts higher quality demands on the transmission, which makes it increasingly difficult to use conventional machining methods. That includes when machines are standing in a line, adding deviations to the gears every time the gear component is moved to the next machine.

The EV transmissions are mainly planetary transmissions where the compact design also reduced weight and space needed for the transmission. Some transmissions are also called reduction transmissions since the task is to reduce torque and rpm at the start.

11/17/20 8:10 AM

test when it sought to shape main gear components made from low-alloy 16MnCr5 steel using the Sandvik Coromant CoroMill® 178 or the indexable CoroMill 180.

The workpiece would be subjected to roughing and finishing with CoroMill 178H PM-HSS solid power skiving cutter. Previously, the customer used a shape cutter for this process, run at cutting speeds of 40 m/min (131 ft/min) for the roughing stage and 50 m/ min (164 ft/min) for the finishing stage. Using this method, speeds could be increased to 250-300 m/min (820-980 ft/min) for both roughing and finishing.

Overall, the manufacturer applied the CoroMill 178H PM-HSS cutters to three-to-five steps for roughing and two steps of finishing.

The customer also reported a reduced tool set-up and indexing time, increased process stability and considerably-improved component quality. The improved quality came mainly from that there was no need moving the component between different machines/machining operations, adding center deviations, and run out deviations. The complete machining was made in one set-up.

What’s more, by replacing the time-consuming shaping process with power skiving, cutting time was reduced and tool life increased considerably. This equated to a 90% reduction in machining time, leaving the customer with a large amount of valuable free capacity.

metallurgical high speed steel (PM-HSS). They are designed for extremely high accuracy and performance and are available for module 0.5–6 (DP 50–5). Sandvik Coromant also offers CoroMill 180. This is an indexable insert cutters with railed insert seats, for excellent and repeatable accuracy in modules ranging from 2.5–8 (DP 10–3).

Although power skiving has been around for a long time, it has recently taken a new turn as machines become more robust and rigid and manufacturers seek new methods of machining. Power skiving works particularly well in mass production where short lead times are decisive, as well as industries in which downtime is costly, like the automotive and EV manufacturing market.

ABOUT SANDVIK COROMANT Part of global industrial engineering group Sandvik, Sandvik Coromant is at the forefront of manufacturing tools, machining solutions and knowledge that drive industry standards and innovations demanded by the metalworking industry now and into the next industrial era.

Educational support, extensive R&D investment and strong customer partnerships ensure the development of machining technologies that change, lead and drive the future of manufacturing. Sandvik Coromant owns over 3100 patents worldwide, employs over 7,900 staff, and is

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represented in 150 countries.

Sandvik Coromant offers a series of carbide cutters for power skiving, CoroMill 178S, and also CoroMill 178H made from powder

For more information visit www.sandvik.coromant.com

UNEXPECTED. IN A GOOD WAY. Prototyping. Second operations. Short-run production.

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IMD 31

Industry Insight

Fine turning of collar and seats of rotor shaft.

Bringing Advantages to the Growing E-Mobility Market EMAG develops a production line for rotor shaft manufacturing

B

y 2032 more alternative drive systems than pure combustion engines could be licensed in the passenger car market, according to a new study by Deloitte. It is easy to imagine what this development will mean for the automotive industry: The value-added share of combustion engine components is declining and the share of "electric" drive components is rising just

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32 IMD AUGUST 2021

as quickly - including many rotationally symmetrical parts for which mechanical engineering specialists such as EMAG are currently developing precisely tailored production solutions.

Currently, a fully automated and efficient complete solution for the production of rotor shafts as well as the high-precision overturning of the rotor-sheet package has been developed for a

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Green turning on two VTC 200. 4-axis machining of the shaft will reduce machining times significantly.

supplier group. With the flexible systems, the customer can cover a large portfolio of machining operations. Those responsible are highly satisfied with component quality and reproducibility.

The increasing quantities of e-motors are challenging production planners: In many application areas, they have to establish new solutions with which components, such as the e-motor drive shaft, can be manufactured faster and more efficiently - and with holistic production systems. A new and impressive example at a supplier company that produces components for e-mobility shows how a solution like this can look. How did the collaboration come about?

"Our contact partners were looking for a highly flexible system, including smart automation solutions and IoT integration, to cover a large number of machining operations around the rotor shaft.

When faced with such an issue, the customer has relied on EMAG for many years because we offer turnkey solutions from a single source and the EMAG Group masters almost all machining technologies," explains Andreas Bucher, Key Account Manager at EMAG. The collaboration began very early on: the customer even shared the design drawings of the component with EMAG in advance, in order to facilitate the subsequent mechanical engineering and enable the leanest and most reliable production process possible. The development of the entire line took place through close contact, as Michael Ihring of EMAG Systems confirms: "At EMAG, the principle of 'one face to the customer' always applies. An experienced contact person discusses the requirements of the entire production solution with the customer - this also includes, for example, the machines that do not come from EMAG. Therefore, we still take care of the complete production solution and define its specifications. The advantages are obvious: significantly fewer interface reconciliations shorten the delivery time and also lead to a more favorable and effective overall solution."

Reaching The Goal In Twelve Operations The end result now shows an impressive sequence around the rotor shaft - with no less than twelve main and various secondary operations. The automation and interlinking of the individual machines and stations will be carried out with robots, gantry systems and EMAG's own TrackMotion system.

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IMD 33

Induction hardening of bearing seats on a MIND L 1000 from EMAG eldec.

This process is laid out here, in detail: » After the operator has fed in the raw parts on buffer belts, rough turning starts on two VTC 200s from EMAG - a perfect solution for 4-axis shaft machining with reduced main times Blow-off and measuring processes follow. The measuring machine gives feedback to the lathes, which then carry out any corrections automatically. » After the internal gear cutting process the rotor shaft bearing seats are induction heated and hardened in OP 40 on a MIND L 1000 from EMAG eldec. » The next operations performed on two VTC 200 CD and two VTC 200 from EMAG are also interesting. Both processes are carried out in parallel on two machines in order to increase output. The rotor shaft is then blown off a second time, measured, and the good parts are described with a DMC. » In OP 70, two assembly processes take place, with a sleeve and a lid being joined.

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34 IMD AUGUST 2021

With twelve main and various secondary operations to the completely machined rotor shaft. The automation and interlinking of the individual machines and stations is carried out with robots, gantry systems and EMAG's own TrackMotion system."

ACTEK HOIST RINGS SAFE & EASY LIFTING SOLUTIONS Assembly of sleeve and a cover.

» A final turning operation by VTC 200 perfects the collar and seats of the rotor shaft. Blowing-off, measuring, and stacking complete the line.

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"We see our plans confirmed," sums up Michael Ihring. "The processes are very stable, which is reflected in the component quality. At the same time, the customer benefits from a flexible cell solution that could be expanded at any time to meet increasing capacity requirements. This flexibility is evident in every detail, right down to the automation. In addition, various intelligent mold change strategies ensure that there are very few downtimes."

Scroll-free turning ensures perfect sheet package surface finish However, this is not the end of EMAG's major e-mobility project for this customer, because the machine builders have also designed a solution for high-precision overturning of the rotor-sheet package using the VTC 200 machine. The so-called scroll-free turning process is used: here, a rolling motion of the tool takes place on the workpiece - an obliquely set CBN cutting edge moves over the rotating workpiece.

The cutting edge engagement point moves on continuously. The whole process is around five to six times faster than conventional hard turning and up to three times faster than grinding. Despite this, the result is excellent quality without twist. In other words, surfaces that previously had to be ground can thus be peel turned in the future. This is an ideal solution for the stack of sheets surrounding the shaft.

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These are enormous advantages that we intend to bring to the growing e-mobility market in the coming years," says Andreas Bucher. "Inquiries from the electric motor manufacturing sector are increasing significantly. At the same time, our technology is already in use in very many application areas in the industry today.

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IMD 35

On Exhibit – NWMT

NMTE SEPTEMBER 1 – 2 Oregon Convention Center | Portland, Oregon Northwest Machine Tool Expo is a unique regional event for the machining and manufacturing industries. This event features free educational sessions and an exhibit floor showcasing the latest products and services in the industry. You don’t want to miss this great opportunity. Come to the expo to see what’s new in the world of machining and manufacturing and to network with peers and key industry players.

Learn more at www.mtenw.machinetoolexpos.com

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

BOOTH: 732

Allied Machine Releases T-A Pro Drill High-Speed Steel Geometry As the most recent addition to the T-A Pro high-penetration drilling system, this insert demonstrates that the best just keeps getting better. Not only are the faster penetration rates maintained, but in using the redesigned body of the T-A Pro, maximum coolant flow and excellent rigidity are also present when utilizing the high-speed steel geometry. This offers machine shops and manufacturers a spade drill that operates at incredible speeds and a cost per hole that averages 25 percent less than other existing drills.

For more information, visit www.alliedmachine.com

BOOTH: 726

VERICUT Version 9.2 – Increase Productivity and Sustainability CGTech is pleased to announce the latest release of VERICUT software, Version 9.2. VERICUT CNC machine simulation, verification, and optimization software simulates all types of CNC machining, additive, and hybrid manufacturing processes. VERICUT 9.2 brings significant speed increases and improved accuracy to collision checking and overall performance. Users gain substantial speed increases for deep concave collision penetration, turning operations (especially inside diameter work on large parts), and collision checking between highly detailed models such as those having high triangle counts. Simulate material removal at tight cutting resolutions up to 30 percent faster.

For more information, visit www.cgtech.com

BOOTH: 627

ESPRIT CAM Improves Productivity For Long Part Machining By Automating Multi-Spindle Program Creation New computer-aided-manufacturing (CAM) technology has been introduced by ESPRIT CAM, part of Hexagon’s Manufacturing Intelligence division that provides manufacturers with the control and flexibility needed to use multi-spindle and multi-channel computer-numerical-control (CNC) machinery for the machining of long parts. More accurate simulation of spindle transfers and bar pulls enables manufacturers to exploit multi-tasking machinery with high productivity program creation of error-free toolpaths. ESPRIT TNG now also enables manufacturers to perform face-milling operations with a unique “roll-in” lead-in strategy recommended by Sandvik Coromant to improve surface quality, reduce cycle time, and extend tool life.

For more information, visit www.espiritcam.com

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36 IMD AUGUST 2021

IMD – The Industry’s Most Extensive Industrial Publication

BOOTH: 620

FANUC Expands Line of High-Performance Scara Robots FANUC’s family of 4-axis SCARA robots has grown to include the SR-3iA, SR-6iA, SR-12iA, and new SR-20iA models with 3kg, 6kg, 12kg and 20kg payload capacities, and a 400-1,100mm reach, respectively. The small SR-3iA and SR-6iA SCARAs have a compact footprint and space-saving design for maximum efficiency. In addition, the SR-3iA/H and SR-6iA/H are 3-axis variants that provide strong performance and an affordable alternative to small linear slide products. The higher-payload SR-12iA and SR-20iA provide flexibility with a large vertical stroke, and an environmental option for harsh conditions. All of FANUC’s SCARA robots include superior robot motion, high-speed operation and ultimate precision.

For more information, visit www.fanucamerica.com

BOOTH: 611

Save Time And Enhance Productivity With The KONTEC KSC Mini from SCHUNK Speed is the key to success – especially when it comes to handling of parts to be clamped.

Flexibility is also a factor that must not be neglected. The new SCHUNK KONTEC KSC mini small parts vise addresses both with easy handling and high clamping force. Its jaw quickchange system enables users to convert the compact vise efficiently and without tools in no time at all. Users can exchange the jaws by simply clicking in and out.The KONTEC KSC mini is the vise of choice for flexible use in efficient blank and finish part machining.

For more information, visit www.schunk.com

char-lynn

dynex

low speed high-torque motors… The Char-Lynn

high pressure checkball piston pumps… Dynex high

steering control units… offer these advantages: • Minimal steering linkage reduces cost, provides design flexibility.

• 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.

directional control valves…

hydraulic products

hydraulic products

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.

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.

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 to 60 U.S. gpm at 1800 rpm.

• 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 fourland 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.

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

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

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

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

www.macmhydraulic.com

www.macmhydraulic.com INDUSTRIAL MACHINERY DIGEST.COM

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IMD 37

On Exhibit – FABTECH

FABTECH SEPTEMBER 13 – 16 McCormick Place | Chicago, IL With emerging manufacturing trends and the introduction of disruptive technologies making their mark on the metal fabricating industry, FABTECH 2021 returns and will provide industry professionals with immediate access to the information, technology, and equipment they need to transform their businesses for success in the future.

For more information, visit www.fabtechexpo.com

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

BOOTH: A3381

The First 5-Axis Belt Surface Grinder from Burr King The 92110-SGX Surface Grinder from Burr King features precision surface grinding at an affordable price. Kit includes 1.5 HP 120v Variable Speed 960-250, 2.5 x 60 Belt Grinder, dynamically balanced serrated 90 Duro Contact Wheel, SG1200 Surface Grinder Base, X-Axis Slide on all models, and a choice of 12, 24, or 36-inch Mag Chuck. The SG120 features a built in sine bar for taper grinding. Burr King’s surface grinders are constructed from 6061T6 aluminum and are made in the USA. For more informatin, visit www.burrking.com

BOOTH: A5331

A Manual, Vertical Tilt-Frame Band Saw Cosen is proud to introduce the all new V-1824 Vertical Tilt-Frame Band Saw to our extensive product line, and to this year’s Fabtech line-up. In an ever changing and growing fabrication market, the need for cost effective cuttings solutions at different capacities and price points is evident. With vertical saw designs becoming more popular amongst fabricators, the 1824 takes Cosen's popular tilt-frame design and applies to a rigid yet small footprint. Developed to be a more affordable option for those in non-production settings, the saw is a manual design and allows for miter cuts ranging from 0-60 degrees, both left to right.

For more information, visit www.cosensaws.com

BOOTH: B25055

COXREELS® Product Enhancement for the 1¼” and 1½” SLPL Spring-Driven Models COXREELS has made a product enhancement to the spring-driven 1¼-inch and 1½-inch SLPL models. COXREELS eliminated the aluminum inline swivel on five SLPL models (725, 750, 825, 835, and 850) and incorporated a nickel-plated steel inline swivel (from the 1185-Series). This swivel increases the pressure rating of the inline plumbing from 250psi to 1500psi. The nickel plated steel is also far more rugged and durable than the aluminum swivel that it replaces. The new swivel includes COXREELS multi-lobe seals for much improved leak integrity. The inline swivel also boasts a more efficient, less restrictive flow path than the 90-degree swivel.

For more information, visit www.COXREELS.com

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38 IMD AUGUST 2021

NORTH AMERICA’S LARGEST METAL FORMING, FABRICATING, WELDING AND FINISHING EVENT

MAKE IT HERE SEPTEMBER 13–16 McCormick Place / Chicago, IL

2021

REGISTER TODAY fabtechexpo.com

EVENT PARTNERS

When it comes to metal forming, fabricating, welding, and finishing, there’s only one event that makes it possible to see it all together— FABTECH. This show of industrial force is where you’ll find the latest in manufacturing equipment.

Discover high-tech solutions by application and industry. And see the smart technology that brings new levels of productivity and efficiency to your operations.

BOOTH: B25060

Dynabrade Manufactured Orbital Sanding Pads Dynabrade was founded on a tradition of quality and is recognized as a leading manufacturer of air-powered abrasive tools worldwide. Tools like the Dynafile and the Dynorbital Extreme are the benchmark that competitors are measured against. Until now, Dynabrade supplied high-quality random orbital sanding pads known for their patented single-piece hub design, smooth operation, and superior finishes. Dynabrade is proud to now be the manufacturer, with the stated goal from Dynabrade President, Hardy Hamann of: “...utilizing state-of-the-art technology to manufacture the highest-quality, custom-built and precision engineered random orbital sanding pads in the world.”

For more information, visit www.dynabrade.com

BOOTH: A3525

Formdrill: Thermal Drilling Experts Thermal drilling is a process that uses friction to produce bushings in metal tubing and flat stock. The combined rotational and downward force of our special Thermal Drilling tool bit creates frictional heat. Temperatures can reach 900-degrees Celsius for the tool, and 700-degrees Celsius for the work piece. The material is transformed into a "super-plastic" state, allowing the tool to displace material and form a bushing. These bushings are ideal for threaded applications, as the number and strength of threads is significantly increased. It is an excellent alternative to weld nuts or threaded inserts.

For more information, visit www.formdrill-usa.com

BOOTH: A3526 & A3625

See Live, Working Demonstrations for Scotchman Cold Saws, Ironworkers, Pipe Notchers, And Hydraulic Presses.

Specific equipment to be shown at Fabtech include the CPO 350 AutoLoader circular cold saw with new, Clear Awareness Barrier with safety interlock switch. These new features provide extra safety for sawing while allowing the operator to visually monitor the saw in-action. The variable speed CPO 350 saw is semi-auto, but coupled with an auto loading material feed system it creates a fully automatic sawing system which can cut multiple lengths of tube (max 3-inch dia.).

For more information, visit www.scotchman.com

BOOTH: B23008

Suhner Technology at An Affordable Price - MADE IN AMERICA Suhner introduces the ECONOmaster® line of drilling units, affordably priced at under $3000 for the basic unit, in stock for immediate delivery or customizable to suit the particular operation. This economical solution is ideal for multiple materials such as light metal, wood, composite, plastic and foam. Because these units are entirely produced at the Suhner factory in Rome, Georgia, response times for delivery and customized construction are minimal, according to Division Manager Lee Coleman. “We recognized the need to bring our global technology to a local level, here in America, and the ECONOmaster® is a key step in that process.”

For more information, visit suhner-machining.com

BOOTH: A3362

Rubber Seals In-Stock and Ready to Ship With nearly 50 years of consistent growth Trim-Lok has proven to their customers that premier customer service and quality is theirr priority.

Trim-Lok has provided support to their customers by shipping on-time for both off-the-shelf and custom extruded parts. Trim-Lok offers

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40 IMD AUGUST 2021

hundreds of EPDM closed cellular sponge rubber seals in a variety of shapes and sizes are in-stock and ready to ship! From “D” and “P” profile seals to ribbed, triangle, flap seals, and more, all are available with your choice of standard or 3M tape attachment system. Use in static or dynamic applications for a long-lasting water-tight seal.

For more information, visit www.trimlok.com

BOOTH: B17012

New Solution For Flexible Machine Loading Automating machine loading traditionally means integrating conveyors, bowl feeders, custom trays, shaker tables or various other components and processes. These approaches can lead to a range of obstacles and challenges, including complex programming and setup, poorly-utilized manpower, inefficient machine utilization and decreased output. ActiNav changes all that, combining intelligent vision and sensor software with the autonomous motion control of Universal Robots’ world-leading cobots in one seamless Application Kit that solves the random bin picking challenge in machine tending applications.

For more information, visit www.universal-robots.com

BOOTH: B17038

ABB Robotics Advances Construction Industry Automation Robotic automation offers huge potential to enhance productivity, efficiency and manufacturing flexibility throughout the construction industry, including automating the fabrication of modular homes and building components off-site, robotic welding and material handling on building sites and robot 3D printing of houses and customized structures. Pilot projects include the automated fabrication of timber roof supports with Autovol in the United States, the robotic

INDUSTRIAL MACHINERY DIGEST.COM

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IMD 41

installation of elevators with Schindler Lifts and the robotic automation of Intelligent City’s production of prefabricated modular homes, which has increased production efficiency by 15 percent and speed by 38 percent, while reducing waste by 30 percent.

For more information, visit www.abb.com

BOOTH: B5378

AXYZ Announces the New Innovator CNC Router for Rapid-Prototyping & Educational Institutions This entry-level industrial CNC router replaces the legacy Z-Series model, offering a significant increase in performance while including a robust construction and high precision accuracy that AXYZ machines are known for, all at a cost-effective price. The AXYZ Innovator is available in two standard sizes, 4’ x 4’ (1.2m x 1.2m) and 5’ x 8’ (1.5m x 2.4m), with a gantry clearance of 6” (152mm). Compact in size, the machine is powerful enough to cut Aluminum, Plastics and Hardwoods creating higher quality finishes and short lead times.

For more information, visit www.axyz.com

BOOTH: A5945

One of the Most Advanced Barrel Fan Ever Created Built to deliver mobile comfort to virtually any space, Sidekick is your facility’s best choice for immediate airflow on the go. Its six-blade design and permanent-magnet motor move more air than any barrel fan on the market with class-leading energy efficiency and the quietest sound level. Lightweight and impactresistant, Sidekick offers optimum maneuverability with two locking swivel casters, a large handle, and convenient 12-foot power cord. At 4 feet wide, Sidekick is sized just right for the power you need and easy to store when not in use.

For more information, visit www.bigassfans.com

BOOTH: A2126

Discover the Bystronic World of Smart Manufacturing Solutions Bystronic will present a wide range of modular system solutions comprised of ‘world class’ laser cutting, bending, automation, and software to create a flexible network of intelligent components that allow you to stay ahead of your customers’ growing requirements. Bystronic will introduce the ByStar Fiber with NEW 20kW laser and ByTrans Extended material automation. BySmart Fiber with new 10kW laser will be shown with the ‘new’ ByTrans Modular automated loading and unloading with BySort. First time at FABTECH, the ByTube 130 laser tube processing with 3kW Fiber power will be presented, among other solutions.

For more information, visit www.bystronicusa.com

BOOTH: A5705

Cincinnati, Inc. Uses BAAM to Produce Monolithic Multi-Material 3D Printed Object Cincinnati Incorporated has used its Big Area Additive Manufacturing (BAAM) machine to demonstrate that recycled materials can be used for 3D printing by producing one of the largest monolithic multi-material objects to date. The demonstration successfully proved that large-scale multi-material printing can be done effectively and economically with recycled composite materials. The large-scale multi-material print was achieved by making modifications to the BAAM and including a new extruder design that accommodates a dual feed system.

For more information, visit www.e-ci.com

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42 IMD AUGUST 2021

BOOTH: D46527

Dallas Industries To Feature New Advanced Graphical Display Plc Control For Feed Lines The 15-inch new graphical display is designed to maximize productivity during start up and into production by providing an HMI touch and diagnostic screen for the entire feed line process. The new design features an intuitive and easy to follow graphical format that duplicates the machine in operation. The graphical display can reduce launch and set-up time, minimize changeover time and assist production by providing real time diagnostics for the entire machine. With the conventional feed line, personnel will be on hand to discuss ways to achieve smoother feed motion through ProfileSelect™ software.

For more information, visit www.dallasindustries.com

BOOTH: A3289

XPS-16+ CNC Drill Sharpener Designed for shops that demand precision, the XPS-16+ grinds complex geometries with the touch of a button quickly and accurately. The XPS-16+ Automatic 4-axis CNC Drill Sharpener and Grinder is an extremely accurate work horse for high tech applications. The XPS-16+ is for shops that demand the ultimate in precision, simplicity and productivity. The XPS-16+ can do it all - with the touch of a button. Assembled in the USA. Point styles sharpened include standard conic, 4-facet, standard and radius split point. Darex offers in-house training, and 60-grit and 320-grit diamond wheels, 120-grit hone brush, as available options. The XPS-16+ includes a one year warranty.

For more information, visit www.darex.com

BOOTH: A4449 & B17021

Hypertherm Inc. Highlights Fabricating and Welding Solutions In the Fabricating Hall, booth A4449, see the industry’s only X-Definition plasma, ProNest CAD/CAM part nesting software, AccuStream waterjet consumables and replacement parts. Visit Welding Hall, Booth B17021, to see Powermax air plasma technology and Robotmaster CAD/CAM robotic software. Metal artist and social media influencer, Rae Ripple, will appear at Booth B17021 on Monday, Tuesday, and Wednesday where she'll unveil metal art created for the show using a new plasma product from Hypertherm.

Product experts will also be on hand to discuss plasma, waterjet, Robotmaster and/or CAD/CAM software.

For more information, visit www.hypertherm.com

C-FRAME PRESSES MADE IN THE USA!

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

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

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

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

WE CAN BUILD A CUSTOM MACHINE FOR YOU!

HYDRAULIC MACHINES OF IOWA

A Division of Betenbender Mfg. Inc

Phone: 319.435.2378 | Fax: 319.435.2262

www.betenbender.com INDUSTRIAL MACHINERY DIGEST.COM

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IMD 43

BOOTH: A1100

Markforged Expanding Into Robust Production with New Printer Series While not debuting until FormNext in November, the FX20 will be the biggest, fastest and most sophisticated 3D printer Markforged has ever produced. Together with Markforged’s state-ofthe-art software and materials, the FX20 will transform the Digital Forge into a next generation additive manufacturing platform capable of printing high-temperature thermoplastics reinforced with continuous fiber at the click of a button. By printing high-strength, more accurate and higher performance parts, the FX20 will meet the needs of even the most demanding and regulated industries, such as aerospace, defense, automotive and oil & gas.

For more information, visit www.markforged.com

BOOTH: A3155

Mate Precision Technologies Showcases An Expanded Line Of Products For Punching, Bending And Laser Consumables The Mate QCT™ tool-less punch retention system expanded to include QCT Metric™, AMX QCT™ for Amada air blow systems and MXC QCT™ for Wilson Series 90 systems. Also see Mate’s full line of high-performance punch press tooling, special application forming applications for Thick Turret, Trumpf-style, Salvagnini, Murata systems. Mate expands its extensive Press Brake Tooling line with new Wila Trumpf Style punch and die profiles including punches with acute, sash, gooseneck and blade profiles. New dies including V-openings and angles at 30°, 80° and 86° with a 55mm height.

For more information, visit www.mate.com

BOOTH: A4968

Element 400 New Cutting Machine From Messer Cutting Systems Messer’s Applications Engineers will be running two cutting machines and demonstrating the latest in plasma bevel cutting and oxyfuel cutting techniques. They will be displaying the new globally designed Element 400 cutting machine, the latest innovation from Messer Cutting Systems where form follows function.

Included onboard is a new controller, the Global Connect, with redesigned HMI software and integrated OmniFab compatibility.

This configuration features improved real-time transparency on maintenance, downtime status, and production reports that are transmitted through the controller, via a PC, or tablet.

For more information, visit www.messer-cutting.com

BOOTH: A4454

ProtoMAX Abrasive Waterjet from OMAX The ProtoMAX is an excellent user-friendly machine to build a curriculum around advanced manufacturing technology. Compact, safe, and easy-to-use, the ProtoMAX is a perfect teaching tool. Several universities have elected to add ProtoMAX to their engineering, material sciences, robotics, and arts programs, allowing students to experience hands-on innovative technology. Featuring OMAX engineering in a space friendly package, the ProtoMAX delivers 30,000 psi cutting power with a 5 hp pump. Whether metal, glass, plastic, or wood, the ProtoMAX cuts virtually any material under 1 in. thick with a 12 in. by 12 in. cutting area.

For more information, visit www.omax.com

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44 IMD AUGUST 2021

BOOTH: B20034

Small, Versatile and Extremely Fast GP4 Robot Expands Capability of GP-series Line Highly flexible, the GP4 offers a wide work area for its size, making it a viable six-axis alternative to SCARA-style robots typically used in the electronics and small parcel sortation industries. The GP4 features a 1,008 mm vertical reach, 550 mm horizontal reach and ±0.01 mm repeatability. A high wrist allowable moment enables accurate and repeatable handling. A compact footprint and slim body design allow for minimum installation space and minimize interference with peripheral devices. This enables the GP4 to be placed in close proximity to workpieces and other robots to create flexible, high-density layouts.

For more information, visit www.motoman.com

BOOTH: B23036

ATI Industrial Automation’s QC-7 Robotic Tool Changer is a FeaturePacked Solution for Automatic End-Effector Exchange.

This lightweight yet durable tool changer offers a variety of configuration options with ATI’s Pass-Through Utility Modules and Tool Stand systems. An optional ML12 Electrical Module attaches easily to the QC-7 Tool Changer body, which also includes five pass-through air ports and lock/unlock air fittings. The QC-7 Robotic Tool Changer features a low stack height and mounts directly to ISO 9409-1-31.5-4-M5 robot wrists. The tool changer is compatible with ATI’s modular Tool Stands and has an optional tool storage hook to make robot programming easy.

For more information, visit www.ati-ia

BOOTH: A3543

LENOX® Announces New Technology to Improve Performance and Efficiency for Fabrication Shops and Steel Service Centers The LENOX 360™ System provides access to key insights, measurements, and the control of valuable sawing operations data. This new technology is ideal for steel service centers and fabrication shops as it is designed to improve decision making and maximize efficiency by capturing data in real time. Using a collection of sensors that are installed on the saw, performance data such as utilization and efficiency metrics are transferred into a LENOX 360™ System tower. The data is then transmitted to the cloud where it is analyzed and populated into customized dashboards to arm users with the information needed to help maximize production and profits for the facility.

quality matters. every time.

For more information, visit www.lenoxtools.com

PRO GRADE

HOSE, CORD, & CABLE

REELS

BOOTH # B25055

SOLUTIONS FOR:

AIR / WATER | HYDRAULIC | PNEUMATIC | VACUUM | WELDING | POWER AND MORE

TOLL FREE | 800.269.7335

FOLLOW US:

www.coxreels.com INDUSTRIAL MACHINERY DIGEST.COM

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IMD 45

On Exhibit – MPT

Motion+Power SEPTEMBER 14 – 16 St. Louis, Missouri The Motion + Power Technology Expo, produced by the American Gear Manufacturers Association, connects the top manufacturers, suppliers, buyers, and experts in the mechanical and gear power, electric power, and fluid power industries. Over three action-packed days in St. Louis, end-users can shop the latest technology, gear products, and services, and compare benefits side-by-side.

For more information, visit www.motionpowerexpo.com

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

BOOTH: 3637

The popular ANCA FX5 gets a power-boost with a new 12kW grinding spindle and an even stronger upgrade option CNC tool grinders strive to achieve the shortest possible cycle times - to keep the cost per tool produced at a minimum. Machine performance and grinding cycle time are linked to the power capabilities of the grinding spindle. To maximize material removal rate, a commonly accepted industry practice is limiting the spindle load to between 30 percent and 40 percent for fluting operations. Auto white-sticking becomes an important option as batch sizes increase.

For more information, visit www.anca.com

BOOTH: 2312

Power Skiving and Gear Shaping with Mytec HYDRACLAMP Skiving has been around for a long time, but recent advances in technology have improved the speed and effectiveness of this gear-making process making it a more viable manufacturing option for gear producers. Mytec HYDRACLAMP clamping tools are robust and rigid enough to minimize vibrations caused by the high spindle rpms and significant cutting forces generated by the new “Power Skiving” process. Today’s demands also include clamping very thin parts for the robotic gear boxes (flex spline gear box). Mytec HYDRACLAMP clamping tools are designed to clamp components the entire length of the clamping area. If the component is irregularly shaped, they clamp around it to achieve the highest accuracy.

For more information, visit www.eurotechcorp.com

BOOTH: 2925

At Gear Motions, The Future is in Motion Gear Motions recently added a trio of ultramodern gear grinding systems from Reishauer; two model RZ260s, and one RZ550, all equipped with advanced robotic automation systems from Felsomat. These high-performance grinders, paired with multi-pallet automation, have greatly improved gear grinding performance and efficiency. New capabilities include super finishing and polish grinding on parts ranging in size from 0.5 to 27.5 inches in diameter and accommodating a variety of part types including spur gears, helical gears, and assemblies.

This investment has allowed Gear Motions to take our precision gear grinding capabilities to the next level.

For more information, visit www.gearmotions.com

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46 IMD AUGUST 2021

BOOTH: 2607

Gear Calculator App from Gleason This free mobile app bundles simple calculation tools to make gear manufacturer’s daily work life more efficient and productive. The Gear Calculator toolbox includes calculations for gear inspection values like addendum modifications, base tangent lengths and measurement over balls, it provides a hardness converter including tensile strength, Rockwell, Brinell or Vickers, the calculation of rotational speeds, calculation of deviations within gear quality standards, feed rates and chip thickness when gear hobbing, and a twist calculator to determine the natural twist when threaded wheel grinding. Future updates are planned to make the app even more useful.

For more information, visit www.gleason.com

BOOTH: 3513

GMTA Presents Several Products at Motion + Power Show The company represents several high quality, high performance lines including Arnold, BvL, K+G, Profilator, Rasoma, Samag and its latest addition, Stiefelmayer.

Arnold laser technology provides a complete line of laser welding machines for the automotive, aerospace and other markets. BvL offers parts washing systems, equally suited as a one-off station for large castings/forged products or as a continuous washing and drying line. K+G are high-tech machine tools for internal or external grooving, turning and milling. Profilator is a world-renowned brand of machines for gear pointing, cutting, rounding, deburring, polygon slot facing and the SCUDDING® process.

For more information, visit www.gmtamerica.com

BOOTH: 3521

Helios Motion + Power Technology Expo 2021 Preview In the Helios show booth, manufacturers will see a Hera 90 CNC gear hobbing and thread (worm) milling machine with unified gantry automation. This machine offers a single platform for automatically hobbing and milling parts up to approximately 3.5” outside diameter.

With its 6,000 rpm cutter spindle, the machine productively handles small parts with small hobs by maximizing surface speeds.

This high-speed spindle also enables productive milling of worms. Moreover, this machine will demonstrate its versatile, easy-to-set-up automation system to prove its place as the industry-leading workhorse at an unbeatable price for fine-pitch gear manufacturing.

VISIT US – BOOTH #743

For more information, visit www.heliousgearproducts.com INDUSTRIAL MACHINERY DIGEST.COM

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IMD 47

On Exhibit – WIMTS

WIMTS OCTOBER 5 – 7 Exposition Center at Wisconsin State Fair Park | West Allis, Wisconsin The place for education, collaboration, innovation and job search. The Wisconsin Manufacturing & Technology Show (WIMTS) is Wisconsin’s largest manufacturing event, with nearly 5,000 in attendance at the last show. This year it’s back with more of everything—100,000 square feet full of exhibit displays, competitions, seminars and much more.

For more information, visit www.wimts.com

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

BOOTH: 743

Hypneumat Quill Stabilizer Option Hypneumat Inc. developed a quill stabilizer option for their auto-feed drilling units allowing for a rigid tool feed to offset high side load applications, as well as accurate and concentric tool feeding for tight tolerance drilling and reaming applications. This option can be provided on any series of Hypneumat quill feed units. The unit shown is a DQ46EHB unit with a side mounted 2 HP 1,200 RPM motor. Capabilities of the 400 series unit is 6-inch of stroke and 1,107 pounds of thrust at 100 psi air and built to order with a 1-3/8-inch straight bore spindle and spindle positive depth stop.

For more information, visit www.hypneumat.com

BOOTH: 338

Stor-Loc’s CNC Tool Caddy STOR-LOC® offers a variety of choices for organization and storage of CNC tools. Each STOR-LOC® CNC tool product provides protection and security, helping to get the most of your investment. When space is limited, the Stor-Loc Tool Caddy offers mobility and is equipped with your choice of six shelves and any taper. Stor-Loc® is one of the few companies that does not use nylon rollers in their support system. Only Steel Ball Bearings and heat-treated steel rollers are used providing consistent, lifetime drawer performance.

For more information, visit www.storloc.com

BOOTH: 804

Hastings Provides Innovative Solutions That Create Healthier Lives For Workers And Energy Savings For Employers.

Their energy management systems include benefits such as remote monitoring and control that keep workers healthy and save energy for employers. One of the more recent additions is a patented system supplied by IVEC Systems allowing Hastings to have a total solution in large weld bays. This solution has allowed the company to leverage that technology to competitively offer it to small-to-medium weld shops.

Hastings Air Energy Control designs, installs, commissions, and provides service and support for the lifecycle of their total solutions – not just selling the dust collector.

Having grown to a midsize family-run organization, the company embodies key core values that the company exhibits every day.

For more information, visit www.hastingsair.com

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48 IMD AUGUST 2021

BOOTH: 1205

ESPRIT CAM improves productivity for long part machining by automating multi-spindle program creation New computer-aided-manufacturing (CAM) technology has been introduced by ESPRIT CAM, part of Hexagon’s Manufacturing Intelligence division that provides manufacturers with the control and flexibility needed to use multi-spindle and multi-channel computer-numerical-control (CNC) machinery for the machining of long parts. More accurate simulation of spindle transfers and bar pulls enables manufacturers to exploit multi-tasking machinery with high productivity program creation of error-free toolpaths. ESPRIT TNG CAM software now automatically tracks the location of work offsets regardless of part position by enabling programmers to define the offset and offset translations, or the points at which offset changes occur.

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BOOTH: 600

New LX10 Ceramic Grade for Economical Hard Part Turning New LX10 ceramic grade is an aluminum oxide (Al2O3) based, with added TiCN for enhanced bending strength. LX10 offers insert cost advantage and demonstrates excellent wear resistance and long tool life that outperform CBN in hard part turning of up to 55 HRC in the medium speed range from 50 to 150 meters per minute (from 164 to 492 sfm). In combination with CBN grades that ensure hard part productivity at extremely elevated cutting speeds of over 200 meters per minute, Tungaloy offers comprehensive grade options to deliver optimum performance in all hard part turning applications.

For more information, visit www.tungaloy.com

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IMD 49

Product Showcase

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

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

First Truly Modular Mezzanine Allows Businesses to Quickly and Cost-Effectively CIP’s Modular Mezzanines are 10-foot X 10-foot solid steel raisedplatform sections that support up to 125 pounds per square foot L.L. Each section, or unit, can be used separately or bolted together in series to provide a flexible and scalable capacity solution ideal for space-constrained warehouses, factories, and distribution centers.

Since each unit can be combined and bolted to another unit there is no need for on-site welding, and you can configure the sections into a variety of shapes to meet your specific space. » For more information, visit www.customindprod.com

Caldwell Beams for Schneider Electric Paint Plant Rockford, Illinoisbased The Caldwell Group Inc. has customized two 500-pound capacity adjustable lifting beams for a Schneider Electric plant in Columbia, South Carolina. The beams, which measure 44 inches long, 5 inches wide, and 2 inches high, are used by the energy management and automation company to lift 300-lb. circuit breakers in and out of electric switchgear during the final stages of testing, prior to shipment. The circuit breakers are produced in a separate area of the paint plant from the switchgear. Once in the testing zone, the breakers must be lifted into the switchgear for testing, utilizing the beams. » For more information, visit caldwellinc.com

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50 IMD AUGUST 2021

KHK USA Inc. Announces Extensive Line of Spur Gears A large selection of off-the-shelf KHK Spur Gears are available in many materials, configurations, modules and numbers of teeth, and KHK quick customized products can ready within 5 business days. Spur gears are cylindrical disks which have involute shaped teeth cut into their face. The meshing of spur gears results in rolling contacts producing high efficiency of about 95 – 98 percent.

Secondary operations that can be performed include opening the bore, adding of keyways, adding of tapped holes, or reduction of the hub diameter. » For more information, visit www.khkgears.us

IMD – The Industry’s Most Extensive Industrial Publication

New EasySwitch HEPA Vac Simplifies the Process of Vacuuming Wet and Dry Materials EXAIR’s new EasySwitch® HEPA Wet-Dry Vac simplifies the filter change process when switching from vacuuming a dry material to a liquid or vice versa. Utilizing minimal compressed air, the EasySwitch is a powerful pneumatic vacuum that is ideal for any application - wet, dry, light and heavy. This EasySwitch vacuum uses a HEPA certified filter when vacuuming dry material. With EXAIR’s patent pending design the fast and tool-less conversion to vacuuming liquids is done by releasing one latch, removing the filter element and securing the latch. Simply reinstall the filter into the lid assembly for dry materials. » For more information, visit www.exair.com

Jergens Expands Its Range of True-Lok™ Toggle Clamps to Include Additional Locking Mechanisms for Maximum Clamping Security Four types of clamps are available with the locking mechanism including Vertical Handle, Horizontal Handle, Pull (Latch) Style and Push (Straight Line) Style toggle clamps. The added feature ensures that the toggle clamp will remain in the closed / hold down position for maximum security in workholding applications. Additionally, it also ensures that the clamps remain in the unclamped / open position to facilitate part change and operator convenience. True-Lok™ toggle clamps are available with flanged-base in either steel or stainless steel and are suitable for numerous applications in many industries. » For more information, visit www.jergensinc.com

Exact Metrology Showcases Its Long Range Scanning Capabilities Exact’s tool of choice for long range scanning is LIDAR (Light Detection and Ranging) scanners. Long range scanners are typically set up in multiple locations to collect very large data sets. The data set from each location generates a point cloud and each of the point clouds are stitched together to create a 3D space. The stitched point cloud data is then sent directly to the customer or 3D models of the areas are generated to work in any CAD environment. The ability to implement CAD modeling allows tasks to be completed in a fraction of the time as opposed to manual drafting. » For more information, visit www.exactmetrology.com

ESAB Rogue Es 130i Pro Compact Stick/Lift Tig Inverter Rogue’s next-level control technology produces a smooth welding arc with all types of Stick electrodes, including E70818, and it has a special mode for E6010. The Live TIG (DC TIG) function provides positive arc starts without the use of high frequency. It delivers a stable TIG arc down to 10 amps, giving welders the control they need to work on thin metal or delicate components. Users include mechanical contractors and those in general fabrication, maintenance and repair, rental, process pipe, food/beverage, farming and home workshops. » For more information, visit www.esab.com INDUSTRIAL MACHINERY DIGEST.COM

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IMD 51

Guill Offers Machining and Fabricating Manufacturing Services for Aerospace As part of this new merchant machining program, Guill offers 5-axis machining centers, high precision machining and full wire EDM capabilities, highlighted by a .008” hole popper. Guill machines super alloys and exotic metals to close tolerances. They offer state of the art precision machining of many materials including aluminum, aluminum bronze, HY-80, HY-100, Hastelloy, Inconel, K-Monel, nickel copper, stainless and carbon steel and titanium. Guill continues to invest in utilizing innovative machine tools with the most advanced automation controls and operated by experienced technicians. Guill Tool endeavors to be a cost efficient manufacturer while adhering to a continuous improvement quality program. » For more information, visit www.guill.com/aerospace

18-inch Gear Head Bench Drill Press from Palmgren Highly versatile, the 18-inch Gear Head Bench Drill from Palmgren is built for precision drilling applications and continuous use. Its all-gear head driven transmission delivers full power at any speed, driving the cutting tools at nearly 100% of the available horsepower. To ensure positive, quiet operation, the bench drill uses combined steel and reinforced fibers. The ground steel clutches enhance its performance and strength. The 100-year-old Palmgren is a C.H. Hanson brand. » For more information, visit www.palmgren.com

Bar Pulling Made Easy

www.accudyneproducts.com • ONE TIME SETUP • AUTO ADJUST BY CHANGING “X” VALUE IN PROGRAM • EZ-RANGE • .093” – 2.000” ROUND STOCK • .125” – 1.375” HEX STOCK • .125” – 1.000” SQUARE STOCK Your time is too valuable to

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Platinum Tooling Announces an Expansion to their Tool Program for Automatic Lathes Platinum Tooling Technologies, Inc. is excited to announce their extended product offering to the current Citizen tool program. In addition to the standard live and static tools, they will offer 1:4 speed increasers for the most current Citizen machine models. Designed to optimize the machine’s parameters, these precision tools are efficient and cost effective. Platinum Tooling and Heimatec’s goal during the development of this line was to construct a series of tools that would offer the greatest possible processing quality and longest service life, while additionally enhancing the machine’s capabilities with the use of speed increasers.

303-991-1500 » For more information, visit www.platinumtooling.com

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52 IMD AUGUST 2021

New SIMOTICS SD200 Frame Size 440 low-voltage, severe-duty AC motors now with 75-800 hp output

BIG KAISER expands Hydraulic Chuck offering for Swiss lathes

Providing high productivity and energy-efficient operation in all torque ranges, these new cast-iron NEMA motors are built to power pumps, fans, compressors, hoists, winders and similar equipment in harsh environments. With a three-year warranty, the SD200 motors offer 75-800 hp output and feature 444-5013 cast-iron frames for operation in 460V and 575V ranges. They meet or exceed NEMA Premium® MG1 Table 12-12 efficiencies. A wide selection of options is offered, including IP56 ingress protection, encoders, brakes, and blowers plus others to suit the applications presented.

BIG KAISER introduced Hydraulic Chucks for Swiss lathes in 2018, the first improvement to the technology in more than 30 years. This year, the program has expanded to include inch-size Standard Type chucks, as well as new F Type and R Type chucks. Standard Type Hydraulic Chucks with tool-side clamping are now available in inch sizes with the clamping range of ø1/8-inch, 3/16-inch and ¼-inch.

» For more information, visit usa.siemens.com/simotics-sd200

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

Once a Hydraulic Chuck is centered, the runout will not vary, even if a cutting tool is changed repeatedly. Runout of fewer than three microns at four times diameter can be achieved.

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• Provide reliable, low cost, ink code marking.

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IMD 53

Surplus Buying and Selling

Custom engineered, miniature rupture disk assemblies designed for low to high pressure and cycles are ideal for many OEM applications involving missiles, wheels, fuel storage and transport.

Integrated Rupture Disk Assemblies for OEM Hydraulic & Pneumatic Equipment

Custom engineered, miniature rupture disk assemblies designed for high cycling at low to high pressure are ideal for many OEM applications involving hydraulics and gases.

F

or more than 85 years, rupture disks have served as an effective passive safety mechanism to protect against overpressure or potentially damaging vacuum conditions. The disk, which is a one-time-use membrane made of various metals including exotic alloys, is designed to activate within milliseconds when a pre-determined differential pressure is achieved.

Equipment reliability in operation is essential for its owner, and this demands high integrity from the pressure relief technology used to protect low- and high-pressure OEM systems. As a

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54 IMD AUGUST 2021

result, OEMs are increasingly turning to integrated rupture disk assemblies with all components combined by the manufacturer, as opposed to loose rupture disk and holder devices that leave much to chance. These assemblies are being tailored to the application, miniaturized, and utilize a wide range of standard and exotic materials, as required. This approach ensures the rupture disk device performs as expected, enhancing equipment safety, reliability, and longevity while simplifying installation and replacement.

IMD – The Industry’s Most Extensive Industrial Publication

Separate Components Versus Integrated Assemblies Traditionally, rupture disks began as standalone components that are combined with the manufacturer's separate holder device at the point of use. The installation actions of the user contribute significantly to the function of the rupture disk device. When installed improperly, the rupture disk may not burst at the expected set pressure. There is a delicate balance between the rupture disk membrane, its supporting holder, and the flanged, threaded or other fastening arrangement used to locate the safety device on the protected equipment.

For this reason, an integrated rupture disk assembly is often a better choice than separable parts. Available ready-to-use and with no assembly required, integrated units are certified as a device to perform at the desired set pressure. The one-piece design allows for easier installation and quick removal if the rupture disk is activated.

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

There are additional advantages to this approach. Integrated assemblies prevent personnel from utilizing unsafe or jury-rigged solutions to replace an activated rupture disk to save a few dollars

or rush equipment back online. The physical characteristics of increasingly miniaturized rupture disks as small as 1/8” can also make it challenging for personnel to pick up the disk and place it into a separate holder.

“OEMs are driven to deliver the longest life and lowest cost of ownership to their customers, says Geof Brazier, Managing Director of BS&B Safety Systems Custom Engineered Products Division. “The use of an integral assembly maximizes the longevity, proper function and trouble-free service of the pressure relief technology.”

Hydraulic And Pneumatic Applications Benefit The integrated assembly is ideal for numerous hydraulic, pneumatic and other low, medium and high-pressure applications including pumps, piston & bladder accumulators, engines, pressure vessels and piping. Additional markets include OEM equipment for onshore/ offshore oil and gas applications, pressure washers, refrigeration systems, fire protection, and breathing equipment.

As one example, the oil and gas industry utilizes rupture disks on triplex pumps for many field applications including oil extraction and well servicing operations. Triplex pumps are positive-displacement pumps configured with three plungers. Commonly referred to as “mud pumps,” the devices typically can handle a wide range of fluid types, including corrosive fluids, abrasive fluids and slurries containing relatively large particulates.

The pressures the pump must endure depend on the depth of the drilling hole and the resistance of flushing fluid, as well as

INDUSTRIAL MACHINERY DIGEST.COM

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IMD 55

Surplus Buying and Selling the nature of the conveying drilling fluid, although application specific, hydraulic operating pressures are typically in the 5,000 to 20,000 psi range.

“A three-plunger pump is continuously cycling, so the disk must be able to withstand high pressures with 1,000,000 pressure cycles or more easily experienced,” says Brazier.

In oil and gas and other industries that depend on hydraulic systems to store energy and smooth out pulsations, standard system components like accumulators require rupture disks. By definition, accumulators hold hydraulic fluid under pressure. If the pressure spikes too high, there is a risk that without a rupture disk the system, or even accumulator, could experience a catastrophic failure.

Both medical devices and fire rescue breathing equipment depend on integrated application specific rupture disk solutions for critical life safety reliability. Medical devices in particular often must be very compact and low profile, and integral assemblies can help to provide such capability with streamlined design.

In aerospace, from satellites to aircraft to drones, tailoring integrated rupture With the availability of integrated, miniaturized rupture disk solutions tailored to the application in a variety of standard and exotic materials, OEMs like BS&B can significantly enhance equipment safety, compliance, and reliability even in extreme work conditions. disk applications for use with lightweight, compact materials like titanium and aluminum are also important, since it takes more energy to get as dictated by the codes and standards,” says Brazier. heavier vehicles off the ground.

Because user material selection can also determine the longevity When tremendous corrosion resistance is required as well in very of rupture disks, the devices can be manufactured from metals and aggressive conditions, titanium is often the material of choice. For such alloys such as stainless steel, nickel, Monel, Inconel, and Hastelloy. applications, BS&B can weld titanium rupture disks to titanium housings According to Brazier, for a wide range of industries it can be and provide a titanium assembly. Where light weight and economy are important for rupture disks to have a miniaturized reverse buckling required, an aluminum welded assembly may be the right solution. capability in both standard and exotic materials.

“Where economics is the driver, reverse buckling disks are typically made from materials such as nickel, aluminum, and Integrated Assemblies - Rupture Disk Design stainless steel. Where aggressive conditions are required, more According to Brazier, the most important considerations in rupture exotic materials like Monel, Inconel, Hastelloy, Titanium and even disk device design are having the right operating pressure and Tantalum can be used,” he says. temperature information along with the expected service life, which In almost all cases, “reverse buckling” rupture disks are utilized is often expressed as a number of cycles the device is expected because they outperform the alternatives to endure during its lifetime. Since The physical characteristics of increasingly miniaturized rupture disks as small as 1/8” can make it challenging for with respect to service life. pressure and cycling varies depending on personnel to pick up a disk and place it into a separate holder.

In a reverse buckling design, the dome the application, each requires a specific of the rupture disk is inverted toward engineering solution. the pressure source. Burst pressure is “Coming up with a good, high reliability, accurately controlled by a combination of cost-effective, and application specific material properties and the shape of the solution for an OEM involves selecting the domed structure. By loading the reverse right disk technology, the correct interface buckling disk in compression, it can resist (weld, screw threads, compression fittings, operating pressures up to 95% of minimum single machined part) and the right options

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56 IMD AUGUST 2021

IMD – The Industry’s Most Extensive Industrial Publication

burst pressure even under pressure cycling or pulsating conditions.

The result is greater longevity, accuracy, and reliability over time.

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

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

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

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

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

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

Because customers are often accustomed to certain types of fittings to integrate into a piping scheme, different connections can be used on the housing. Threading is popular, but BS&B is increasingly utilizing several other connection types to attach the rupture disk assembly to the application. Once the integral assembly leaves the factory, the goal is that the set pressure cannot be altered.

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

While OEMs have long relied on rupture disks in their hydraulic and pneumatic equipment, high-pressure, high-cycling environments have been particularly challenging. Fortunately, with the availability of integrated, miniaturized rupture disk solutions tailored to the application in a variety of standard and exotic materials, OEMs can significantly enhance equipment safety, compliance, and reliability even in extreme work conditions.

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

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sed. dness is determined by production condition. ted hardness value is informed in a quotation of gears.

r precision grade table : oned equivalent grades are for reference only. s completely match each other.

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