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Sawing by the Numbers

An AMSAW S100SI carbide sawing machine with automated bar measuring systems is shown here cutting cylinder liners for automotive applications. The stumbling block for many buyers is the upfront cost for a carbide saw, which is two to three times more than for a band saw. But this study shows that just three carbide saws can handle the same volume of work that requires 18 band sawing machines.
On a cost per square foot of cutting basis, circular carbide saws come out on top.

Tell Them What You Saw

The APS-438 Universal Air-Powered Saw from ESCO Tool is ideal for onsite pipe cutting, erection of piping systems, and pipe fabrication in shops.
A review of some of the newest sawing systems and related accessories now on the market.

Control Plant Safety Functions from a PC

You configure the virtual I/O in the usual manner in the software tool, PNOZmulti Configurator. Instead of wiring, you simply configure your safety circuit on a PC. 
The PNOZmulti 2 open configurable control system from Pilz can be used for stand-alone or modular expansion of multiple safety functions throughout the plant, on machine tools and other equipment.

Automated Friction Stir Welding

The world’s largest spacecraft welding tool, the Vertical Assembly Center (VAC), is a giant circumferential welding system that uses FSW to precision weld the fuel tank structures for NASA's new heavy-lift rocket, the Space Launch System (SLS).
Because its low heat input and high strength provide opportunities to redesign structures with increased tensile strength, outstanding fatigue properties, improved corrosion resistance and minimal distortion and shrinkage, FSW could change the way trains, trucks, cars, aircraft and aerospace components, and other common aluminum structures are built.

Using Adaptive Grippers as Flexible Fixturing For Robotic Welding

The goal was to use a 3-Finger Adaptive Gripper as flexible fixturing instead of traditional jigs inside a complete robotic welding cell. Several tests were conducted to position a piece on a structure at ± 1 mm accuracy and weld it. Each step had to be reproduced numerous times with the same accuracy.
Using a traditional jig for every type of piece and assembly is complicated and expensive when welding small volumes or high mixes of parts. Why not use a robot with an adaptive gripper to feed a welding robot? This could replace most of the templates currently used by adapting to any part size and shape and holding them firmly while welding.

Welding Automation

As a digital system, the HELIX M85 weld head from Lincoln Electric calculates and controls travel time, weld speed and other variables to reduce complicated setup work on the front end. The track ring can be installed or removed in seconds, and it also eliminates binding and compensates for work surface heat expansion.
Here are some of the new automation solutions that are helping shops make their welding operations more productive and profitable.

Best Practices for Surface Preparation and Cleaning in Pipeline Applications

For most surface conditioning and cleaning jobs in pipeline welding applications, there are four common tools that are most often used: stringer bead brushes, aluminum-backed flap discs, bonded abrasive wheels and grinding wheels. 
Surface preparation and cleaning is just one part of the large process of oil and gas pipeline welding, but it’s a step that can have a significant impact on the productivity, quality and efficiency of the job. Proper preparation and cleaning in pipeline welding applications can help extend tool life, benefit operator safety and improve productivity and efficiency.

Finishing Welds in Stainless Steels

A non-woven disc removes grind lines left on the surface by a fiber disc. A premium unified wheel that is designed for light stock removal and is ideal for blending applications is recommended. 
Here are some tips and guidelines for selecting and using the best abrasives products to create the desired finish.

Grind It Out

The XCAVATOR ultra high removal grinding wheel from Walter Surface Technologies is ideal for the toughest, most demanding grinding jobs in metal fabrication, steel mills, mining, oil and gas, and shipbuilding.
Grinding represents a major part of shop costs. Take a look at the latest generation of flap discs, wheels, brushes and other tools that can help save time, reduce costs and improve the efficiency of your metal finishing operations.

Put On Hold

For precise serial production, the ROTA NCO lathe chuck from SCHUNK has the highest clamping force, lowest jaw stroke and lowest height of any chuck in its class, ensuring more space in the engine room, shorter cycle times, and higher versatility.
The increase in higher precision machining is creating demand for stronger, more durable, faster acting, closer tolerance chucks and collets that can grip and hold the parts and the tools being used. Here is a review of some of the latest chuck and collet solutions that meet that demand.