Fabricating and Metalworking http://www.fabricatingandmetalworking.com The Business of Metal Manufacturing Wed, 24 Aug 2016 22:41:50 +0000 en-US hourly 1 https://wordpress.org/?v=4.6 What You Need to Know Right Now to Improve High-Volume Micro Manufacturing http://www.fabricatingandmetalworking.com/2016/08/need-know-right-now-improve-high-volume-micro-manufacturing/ http://www.fabricatingandmetalworking.com/2016/08/need-know-right-now-improve-high-volume-micro-manufacturing/#respond Wed, 24 Aug 2016 22:38:55 +0000 http://www.fabricatingandmetalworking.com/?p=98430 Opportunities abound for shops to cash in on the ever-growing micro machining market, but the differences between different types of micro tools vary from those found in standard tooling. Here are some insights into the extra care and know-how needed to achieve success and build a successful reputation as a reliable supplier of micro machined parts.

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The growing need for production of miniature parts and features in medical and dental applications – as well as mold making, fiber optics, automotive, and other industries – has taken us beyond more sluggish EDM and laser processes. Such tiny tooling and part features are, by nature, challenging to manage. And at production-level volumes, achieving consistent quality is even more difficult. If you’re looking for ways to improve productivity with micro cutting tools, here’s what you need to know about . . .

. . . WHAT MICRO TOOLS ARE
We consider tools with diameters under 3 mm to be micro tools. It’s important to note that these tools aren’t simply smaller versions of their macro counterparts. They have geometric considerations all their own and you must understand them. For example, our Ø1mm Sphinx drill can run at 80xD. But this is only possible because, by design, the cylindrical shaping extends further down the tool, closer to the tip, to facilitate pecking and maintain strength.

. . . CUTTING EDGE RADIUS
Edges on micro cutters are not proportional to those of macro cutters – it’s just not possible. Because of the duller edge, the energy required for micro cutters relative to the MMR can be up to 10x higher than their larger version. Because of this, we recommend using the shortest micro tool possible to avoid deflection.

. . . COATINGS ON MICRO TOOLS
With such miniscule features, even a coating can negatively affect performance. This is because the coating fills in valuable flute space for proper chip evacuation, which is absolutely critical in these applications.

. . . USING COOLANT
Use coolant only when absolutely needed and take special care when you do. These tiny tools are more sensitive than standard ones and even liquid flow can weaken their structure in the cut.

. . . FEED PER TOOTH WITH RESPECT TO MILLING
Often overlooked in micro milling, it’s critical that feed per tooth equals the cutting edge radius.

. . . THE EFFECTS OF CHIP EVACUATION ON FEED RATE AND RUN OUT
Chips and small tooling do not get along all that well. While trying to compensate for low spindle speeds with tools that have more flutes may help reach your ideal feed rate, chip evacuation will suffer. Determining the appropriate chip load – as close to the cutting edge as possible – allows you to operate at the highest possible spindle speed, speeding up the cycle improving surface finish and lessening the chances of built up edge.

. . . BUILT UP EDGE
Because such little stock is being removed, rubbing (instead of actual cutting) can occur which increases the chances of built up edge. This results in more required force and higher chances of deflection and/or early failure.

. . . THE IMPORTANCE OF THE RIGHT TOOL HOLDER
With requisite speeds for successful micro machining exceeding 60,000 rpm, quality micro cutting tools themselves are not enough to achieve success. You must also control important factors like dynamic runout and balance. You must have the appropriate holder, not only to ensure quality work, but also to preserve the life of your tools. When choosing a holder, for instance a micro collet chuck, keep in mind helpful attributes like a symmetrical design, a perfectly concentric collapse of the collet around the cutter, and a ball bearing raceway nut with precision-ground threads. Upfront costs may be higher, but preserving these specialized cutting tools will, without a doubt, save you money in the long run.

. . . TOOL WEAR
When runout occurs, the edge most affected takes over most of the cutting. The uneven wear leads the tool to failure much quicker than if the tool rotates about the centerline as intended. In one customer application, drilling into a steel workpiece 0.590 in deep with a 0.118 in diameter carbide drill in a holder with 0.00008 in runout accuracy produced 2,300 holes. A holder with 0.0006 in runout accuracy was only able to produce 800 holes. In this scenario, the shop could save hundreds of dollars a month in carbide costs – as well as labor costs due to less tool changing – by making one smart tool holder choice.

. . . HOW BALANCE CHANGES DURING A CUT
The balance itself does not change as speed increases, however, the forces it creates increase exponentially alongside speed. And at the high speeds required for micro machining, you’ll quickly see the impact.

Opportunities abound for shops to cash in on the seemingly ever-growing micro machining market. But it’s not as simple as increasing spindle speeds or using smaller tools. Miniature tooling is innately different than the more standard macro tools. The differences between the different types of micro tools vary from what you see in the standard tooling world. As such, the practice requires extra care and know-how in order to achieve success and build a reputation as a reliable supplier of micro machined parts. Whether you’re already a player in the micro game or are just starting to consider throwing your hat in the ring, hopefully these insights will help you grow and improve your work.

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Wildeck Launches New E-Commerce Website http://www.fabricatingandmetalworking.com/2016/08/wildeck-launches-new-e-commerce-website/ http://www.fabricatingandmetalworking.com/2016/08/wildeck-launches-new-e-commerce-website/#respond Wed, 24 Aug 2016 22:34:54 +0000 http://www.fabricatingandmetalworking.com/?p=98408 Online ordering of parts is now available 24/7 for the company's extensive line of VRC material lifts.

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Wildeck, Inc. (Waukesha, WI), a material handling equipment and safety products manufacturer has introduced a new e-commerce website, www.wildeckpartsnow.com to allow customers to view and purchase genuine repair and/or replacement parts for their extensive line of products with the initial focus being VRC parts (Vertical Reciprocating Conveyors).

“We are excited to introduce our new website,” stated Hubert Schlegel, the director of marketing for Wildeck. “It was designed to make it easier for our worldwide customers, dealers and installers to quickly find and purchase repair or replacement parts with a credit card and to keep our mechanical or hydraulic VRCs performing at their maximum potential. It’s part of our continuing commitment to helping our customers’ projects run smoothly while making their operations safer, more efficient and more profitable.”

The website contains a variety of more than 70 VRC parts grouped into eight categories for rapid identification and part selection. VRC part categories, include:

  • Bi-Parting Swing Gates
  • Carriage
  • Electrical
  • Hydraulic
  • Mechanical
  • Signs
  • Single Swing Gates
  • Vertical Gates

Benefits of the new website include:

  • Ability to select and order VRC parts online 24-7, without having to locate a company representative or communicate with the factory.
  • Secure ordering of VRC parts within minutes by providing a company credit card and billing information through PayPalR.
  • Clear visuals of each VRC part, as well as component drawings, that make it easy for customers to quickly identify what they need.
  • Future site expansion for Wildeck mezzanine and safety guarding product parts.
  • Intuitive, user-friendly website design for easy site navigation.
  • Automatic calculation of estimated Freight and Sales Tax.
  • Multiple shipping options, from UPS Ground to Next Day Air.
  • Option to save billing and shipping information, allowing for quicker form fill-in and purchasing during future visits.

Technical and VRC service support available at 800-325-6939.

According to Todd Canham, the product manager for Lifting Products, “Like our other products, VRCs represent a significant investment and in most facilities they are a critical material handling component allowing businesses to run smoothly, safely, and more efficiently. With proper inspection and maintenance our VRC will provide many years of reliable service, but if repairs are ever needed and discovered early through the company’s recommended Preventive Maintenance Program, the new website will make it easier to obtain the required repair and/or maintenance parts.”

Wildeck is a member of MHI (Material Handling Industry Association), MHEDA (Material Handling Equipment Distributors Association), and the NAEC (National Association of Elevator Contractors). The company is the largest manufacturer of manual and automated vertical lifts (VRCs), structural steel mezzanine platforms, safety guarding products in North America.

Their products and those of their subsidiary Ladder Industries Inc. (Goodyear, AZ), are sold through a dedicated and experienced network of customer-service-oriented dealers and systems integrators nationwide. They are used for the safe and efficient handling, storage, access, and protection of materials and personnel to improve supply chain efficiency and productivity. They are a subsidiary of Holden Industries, Inc. (Deerfield, IL), a 100 percent Employee-Owned Company.

www.wildeck.com

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External and Internal Thread Inspection Systems http://www.fabricatingandmetalworking.com/2016/08/external-internal-thread-inspection-systems/ http://www.fabricatingandmetalworking.com/2016/08/external-internal-thread-inspection-systems/#respond Wed, 24 Aug 2016 20:23:24 +0000 http://www.fabricatingandmetalworking.com/?p=98414 External and Internal Variables Inspection Systems from Johnson Gage are ideal for NPT, NPTF, ANPT, and NGT Threads that are in accordance with the new ASME B1.20 Specification.

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Recognized as the industry leader in thread inspection systems for dimensional conformance and verification, the Johnson Gage Company (Bloomfield, CT) will showcase a variety of new products in Booth E-5305, including their External and Internal Variables Inspection Systems for NPT, NPTF, ANPT, and NGT Threads that are in accordance with the new ASME B1.20 Specification.

Their new Indicating Systems are designed to replace L1 Thread Ring and Thread Plug Gages. Supplementary capabilities can assure conformance of all thread elements and characteristics to assure leak-free connections for all applications. In addition, on display will be the JCR Runout and Concentricity Inspection System for verification of cylindrical runout. The JCR can be used stand alone or with an optical comparator for verification of geometries in cutting tool product applications. The JCR incorporates precision datum rolls, a unique upper tension roll assembly, and integral axial stop pins to assure proper part staging and absolute gage accuracy. Also on display will be the time-tested Thread Inspection Systems for both conformance and process control.

The Johnson Gage Company, 534 Cottage Grove Road, Bloomfield, CT 06002, 800-245-4243, dbengston@JohnsonGage.comwww.johnsongage.com.

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EMI Installs Deep-Draw Press for Jet Engine Programs http://www.fabricatingandmetalworking.com/2016/08/emi-installs-deep-draw-press-jet-engine-programs/ http://www.fabricatingandmetalworking.com/2016/08/emi-installs-deep-draw-press-jet-engine-programs/#respond Wed, 24 Aug 2016 18:47:41 +0000 http://www.fabricatingandmetalworking.com/?p=98386 The new 11,600 psi Quintus deep-draw press will support the demand for fabrication of low-weight and very tough metal alloys required by jet engine designers seeking fabrication solutions for fuel-efficient aircrafts.

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Quintus Technologies (Lewis Center, OH) has delivered a hydroform deep-draw press to Electro-Methods, Inc. (EMI; South Windsor, Ct), a supplier of turbine engine components. In the face of robust demand from the jet engine industry, the new 4,000-ton press-force press will expand the company’s capabilities, further enabling the production of intricate shaped sheet metal parts and assemblies.

“We have a long history in the aerospace fabrication business, and with this new investment we are able offer additional capabilities to our customers, primarily General Electric and Honeywell,” stated the president of EMI, Randy Fries. “We are used to tough fabrication demands from our customers and are now well positioned and keen to support the expected ramp-up requirement in the aerospace industries.”

Along with excellent forming capabilities the press requires only a single rigid tool half, significantly reducing tool costs. The other half of the tool is a flexible rubber diaphragm under uniform hydrostatic pressure. Material draw ratios of up to 3:1 eliminate several forming operations, intermediate heat treatments, and operator dependencies. The high forming pressure ensures close-tolerance parts direct from the press, with little or no secondary hand work required.

“EMI has received many awards for its diverse capabilities which enable the manufacture of the most complex fabrications and assemblies, including flight safety-critical turbine engine components,” stated Jan Söderström, the chief executive officer of Quintus in Sweden. “The new family of deep-drawing fluid cell presses that our company has developed over recent years is specifically aimed at the versatility requirements within the jet engine industry, making this press a good fit for them.”

Ed Williams, the general manager of Quintus –Americas stated, “Their choice of the 11,600 psi deep-draw press will support the demand for fabrication of low-weight and very tough metal alloys required by jet engine designers seeking fabrication solutions for fuel-efficient aircraftsQuintus.”

Quintus Technologies is headquartered in Västerås, Sweden, and represented in 35 countries worldwide, the company is a world leader in high pressure technology and has delivered more than 1,800 systems to customers across the globe within industries such as aerospace, automotive, energy, and medical implants.

Since 1965 EMI has been a manufacturer of complex fabricated and machined aerospace assemblies and components. With a 140,000-square-foot campus encompassing five modern buildings they have long been considered a one-stop-shop by OEM customers due to the numerous special processes performed in-house.

electro-methods.com/, www.quintustechnologies.com

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The Largest Qualified 3D Metal Part for European Aerospace is Here http://www.fabricatingandmetalworking.com/2016/08/largest-qualified-3d-metal-part-european-aerospace/ http://www.fabricatingandmetalworking.com/2016/08/largest-qualified-3d-metal-part-european-aerospace/#respond Wed, 24 Aug 2016 18:21:47 +0000 http://www.fabricatingandmetalworking.com/?p=98380 How do you economically produce huge parts with intricate geometry that has a tendency to warp but must withstand critical applications in a demanding environment? Here’s the answer.

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Thales Alenia Space (Cannes, France), in collaboration with 3D printing service company Poly-Shape SAS (Salon de Provence, France), has additively manufactured parts for two new South Korean communications satellites, Koreasat-5A and Koreasat-7, that will launch into orbit in 2017 to provide coverage for South Korea, the Philippines, Indonesia, India, Japan, Indochina and the Middle East. The huge antenna supports on these two satellites each measure 447 x 204.5 x 391 cu mm and are the largest volume parts ever placed in orbit that were 3D printed by powder-bed-based laser melting of metals in Europe.

Aluminum is the most commonly used material for satellites due to its weight and thermal conductivity, high strength, rigidity and resistance to corrosion. Poly-Shape used an X line 1000R metal printing machine from Concept Laser (Lichtenfels, Germany) with a build envelope of 630 x 400 x 500 cu mm for 3D printing with aluminum and a closed system for reliable process and powder management in accordance with the ATEX directives. Its unique rotating mechanism allows two build modules to be used reciprocally to guarantee constant production with no downtime and simple and secure handling when arming and disarming the machine. The patented laser melting technology uses stochastic navigation to significantly reduce the stresses involved in processing the slice segments (or “islands”) of these very large parts and prevent warping to the maximum extent possible with balanced temperature regulation of the build envelope. Using this system, it took only a few days to print this large, bionic and intricate geometry.

In the following interview, Florence Montredon, the additive manufacturing technology development manager at Thales Alenia Space, and Stéphane Abed, the chief executive officer of Poly-Shape, discuss the manufacturing challenges associated with this project.

Which techniques and processes do you use to manufacture your products?
Montredon: Given the very low quantity of individual components for satellites and the small number of satellites in general, 3D printing is an ideal option for manufacturing. By comparison, cast parts (i.e. mold-based processes) tend to be more suitable for components that need to be manufactured in larger batches. By 3D printing the antenna supports of the Koreasat-5A and Koreasat-7 telecom satellites, we wanted to demonstrate how laser melting technology opens up numerous possibilities for our applications. The essential benefits are the short timeline from design and development through to the finished part, along with the high level of efficiency.

Abed: The X line 1000R machine is the only machine with a build envelope that is large enough for our 3D metal printing. There are currently no other alternatives, unless you use smaller build envelopes and then join the parts together – which carries the risk of weak points in the structure. One theoretical alternative would have been to print the parts in two halves and join them together, but we would have lost the benefit of reducing the amount of assembly work that is involved here. The joining process may also have revealed possible defects that can be ruled out with the one-shot option of laser melting. And by making only one part we can achieve our objective faster. Furthermore, on this machine we are also able to create not just aluminum parts that are customary in satellites, but also process reactive materials, such as titanium or titanium alloys, or also nickel-base alloys – all groups of materials that are vital in other areas of aircraft construction.

What were the particular challenges of building the biggest 3D metal part?
Montredon: The first challenge was that we needed two identical twin parts: one for Koreasat-5A and the other for Koreasat-7. But the principal challenge was the size. In comparison to our previous references and experiences, the dimensions of these parts were huge.

Abed: Examples of the issues involved were feasibility, the tendency to warp, geometry and the weight. Using CAE/CAD tools, the Thales Alenia Space designers managed to optimize the geometry to suit the process, save weight and meet the load requirements. They did a very good job. The final design was then further optimized and fine-tuned in numerous redesign stages, with close collaboration and interaction between Thales Alenia Space and Poly-Shape when it came to fabrication. What we have here is a bionically optimized design.

Montredon: Both antenna supports then underwent specific elementary ground tests. They will also be submitted to usual testing at satellite level, which includes a vibration test and high temperatures in a vacuum to simulate a required lifespan of 15 years in orbit.

What new experiences were you able to gain in this project?
Abed: Aerospace provides good training and practice to be at the forefront with additive strategies. 3D metal printing requires a design that suits the process so that the advantages of a digital approach can be fully exploited. The advantages in the freedom of geometry are huge and incomparable to anything offered by conventional manufacturing technologies: digital parts look different, do more, and tend to be lighter. Certain small and medium-sized batches are often the better alternative from an economic perspective, but the limits shift upward every year so this opens up more new horizons for AM.

Montredon: To deliver the high quality parts demanded by applications in space travel, there must be a strong partnership between the end user and the manufacturer – you must be able to rely on your partner. A close working relationship and mutual interaction, with teamwork and communication between our companies, was essential to meet the ambitious timetables.

Thales Alenia Space, 5 Allée des Gabians, 06150 Cannes, France, +33 4 9292 7000, www.thalesgroup.com.

Poly-Shape Espace Green Parc, Route de Villepecle, 91280 Salon de Provence, France, +33 1 6485 1310, www.poly-shape.com.

Concept Laser Inc., 1000 Texan Trail, Suite 150, Grapevine, TX 76051, 817-328-6500, info@conceptlaserinc.com, www.conceptlaserinc.com.

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Kirin Manufacturing Receives Aerospace Quality Certification http://www.fabricatingandmetalworking.com/2016/08/kirin-manufacturing-receives-aerospace-quality-certification/ http://www.fabricatingandmetalworking.com/2016/08/kirin-manufacturing-receives-aerospace-quality-certification/#respond Wed, 24 Aug 2016 17:53:30 +0000 http://www.fabricatingandmetalworking.com/?p=98360 With the quality standard AS9100C certification they can now bring sheet metal fabrication solutions to both the civil and military aviation and aerospace markets.

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Kirin Manufacturing (Tuscan, AZ) has announced they have received qualification as a certified aerospace supplier to the International Aerospace Quality Standard AS9100C. With this new certification the company is now certified to bring its high-quality precision sheet metal fabrication solutions to both the civil and military aviation and aerospace markets.

They officially received the certification by successfully passing the intensive auditing process developed in co-operation with and for the members of the aerospace industry. This new standard of the International Aerospace Quality Groups (I.A.Q.G.) builds on the well-known ISO 9001:2008 standard with additional requirements necessary to respond to the unique regulatory, safety, quality and reliability requirements of the aviation and space sector. Their qualification scores can be reviewed at the Online Aerospace Supplier Information System (OASIS).

“This international certification and the listing on the OASIS database for certified aerospace suppliers is a significant milestone for our company. As part of the aerospace industry supply chain, quality is critical and our products are now officially approved to reliably meet industry requirements,” stated Earl Williams, the company’s vice president of operations.

Kirin Manufacturing is a minority owned, vertically integrated precision custom sheet metal fabricator specializing in “quick-turn” high-mix, low to medium volume production.  Their work can be found in products throughout the world serving customers in the aerospace, defense, medical and industrial electronics industries.

www.kirinmfg.com

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How Clean is Clean Enough? Evaluating Air Quality http://www.fabricatingandmetalworking.com/2016/08/clean-clean-enough-evaluating-air-quality/ http://www.fabricatingandmetalworking.com/2016/08/clean-clean-enough-evaluating-air-quality/#respond Wed, 24 Aug 2016 17:52:00 +0000 http://www.fabricatingandmetalworking.com/?p=98363 Is your shop clean enough to fabricate components for medical devices? A proper diagnosis is necessary to solving an OSHA or FDA particulate problem. But before installing an air quality remedy, it helps to know your current particulate levels, exposure profile and airflow patterns. Let’s take a closer look at this evaluation process.

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Is your air clean enough? Of course, the real question is: clean enough for what?

Meeting minimum OSHA regulations for indoor air quality (IAQ) is a must for every manufacturing facility. However, there are many reasons that companies may decide to go above and beyond these minimum standards. In addition to the obvious benefits for worker health, cleaner air pays dividends in worker productivity, morale, retention and recruiting. It also has another benefit: a clean facility that makes a great first impression. That can be especially important for companies fabricating components for the medical industry. If your facility isn’t making the right impression, it’s probably time to take a closer look at your air quality systems. The first step to solving a particulate problem is proper diagnosis. Before installing an air quality remedy, it helps to know your current particulate levels, exposure profile and airflow patterns. Here is a closer look at the evaluation process.

MEASURING THE PROBLEM
Visible dust on surfaces is a key indicator of air quality problems. However, to get a more accurate diagnosis of indoor air quality, you need to take some measurements. Measuring your current state will help you determine what kind of remediation is needed. Evaluation starts with measurement of dust concentrations at different points in your facility. Dust concentration meters will help to quantify your exposure risks by providing accurate measures of total particulate levels in their immediate vicinity.

If your processes generate a consistent amount of particulate at all times, it may be enough to take a few “snapshot” readings and average the result. However, if your processes are variable, you may want a unit that takes incremental measurements over a period of time to see how air quality changes over time as your industrial processes cycle. This type of analysis allows plant managers to see both “peak” measurements and total particulate exposure over the time period. Meters should be set up at breathing-zone height (roughly 5 ft off the ground) at key points around the facility, including next to the fume-generating processes and in other areas in the facility where people congregate such as workstations and aisleways. Taking measurements in a grid pattern throughout the building will help you see how fumes are propagating and where they tend to collect.

CLEANER AIR, CLEANER FACILITIES
A clean, pleasant environment is a plus for any industry, but it is especially important when the FDA knocks on your door once or twice a year. Randy B., a facilities coordinator at a medical product manufacturing company, explains: “We give frequent tours to buyers coming from hospital systems and they appreciate a clean, orderly environment. It also matters for our annual FDA audits. Ultimately, they are looking at the quality of the finished product, but if the manufacturing side looks dirty, it sends a red flag.”

As weld fumes and particulates cool, they settle out of the air and onto horizontal surfaces, leaving a thin layer of visible grime throughout the facility. This is especially problematic when particulate impacts the finishing line for medical products. Before installing their current air quality system, Randy’s plant had a problem with particulate from the welding stations contaminating their powder coat line. The particulate ruined the finish, and affected components ultimately had to be scrapped. Cleaning up the facility air fixed the problem.

CALCULATING COMPOSITION
Understanding total particulate exposure is a good first step, but composition matters, too. Exposure risks depend on the size and chemical composition of the particles generated. For example, medical parts are often made of chrome alloys, titanium or stainless steel, each of which has their own exposure profile. To ensure that you are staying under safe exposure limits for dangerous contaminants such as hexavalent chromium, manganese or beryllium, you may want to conduct additional analysis.

Air quality engineers can approximate exposure levels for specific elements by analyzing the processes and materials being used and the total particulate levels. Total exposure levels to different elements can be extrapolated from the total particulate measurements if the composition of base metals, coatings and lubricants, and consumables is well understood. If these estimates show that you are close to exposure limits on one or more elements, you may want to consider further analysis to get precise measurements. Dust samples can be collected on special filters inside the dust concentration meter. Samples are sent away to a lab for chemical analysis, a process that generally takes about two to three weeks.

UNDERSTANDING AIR FLOW
A third crucial component that air quality engineers will evaluate is how air moves through the building. Every facility has its own unique airflow patterns that influence how weld fumes propagate through the facility, where they end up, and where they linger. The dust concentration meter readings at different locations will provide important data. But designing an effective remedy also requires a more in-depth evaluation of the current airflow patterns. The type and location of existing ventilation and HVAC equipment, location of windows and doors, equipment position, temperature variations, and other factors influence airflow currents throughout the building. These currents can have a great deal of impact on the efficacy of dust capture and filtration equipment.

If you try to work against the currents, you will need a much higher capture velocity for your air filtration equipment, resulting in significantly higher energy use. Capture velocity needs are also impacted by the processes themselves. Processes that aggressively “push” particulates into the air will require much higher capture velocities than those that allow them to simply waft into the air, such as fumes rising from freshly welded parts in a cooling bin.

A CLEANER FACILITY THROUGH SCIENCE
The evaluation process allows system engineers to take a more scientific approach to air quality system design. By understanding the volume, composition and movement of particulate throughout the facility, we can make better recommendations for mitigation and select the most cost effective solution to help you reach your goals. For example, we use a computer modeling program called Ventmapping™ to analyze data gathered during evaluation, model the facility layout and airflow patterns, and try out remedy options virtually.

So, is your facility clean enough? Sometimes you need more than your eyes to know for sure. Evaluation is the first step to creating a clean, healthy facility that will impress your employees, your customers and your OSHA or FDA inspectors.

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Linear AMS Expands Tooling and Manufacturing Business http://www.fabricatingandmetalworking.com/2016/08/linear-ams-expands-tooling-manufacturing-business/ http://www.fabricatingandmetalworking.com/2016/08/linear-ams-expands-tooling-manufacturing-business/#respond Wed, 24 Aug 2016 17:05:32 +0000 http://www.fabricatingandmetalworking.com/?p=98339 They have appointed company veteran Lou Young as the director over the expansion.

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With their acquisition by Moog Inc. (East Aurora, NY) only months ago, Linear AMS (Livonia, MI), formerly Linear Mold & Engineering, is announcing new investment in the molding and tooling side of its business with company veteran Lou Young heading the effort.

“We are a one-stop partner for everything from mold and part design through process qualification, and it remains critical that every employee knows that every task is about adding value to the customer,” Young stated. “With specialties including prototyping, mold building, and low-volume production for automotive and non-automotive companies, our 3D printing and metal AM capabilities are rewriting the manufacturing rules book. Tooling, however, remains the heart of production success. No one is bringing a stronger focus and solutions set, including 3D printing, than we are.”

The company is in the midst of adding two new account management experts for tooling and molding, in addition to new capital equipment at its Livonia, MI injection-molding facility. This is all aimed at supporting an already strong, customer-centric culture, according to Young. “We’re at our most effective establishing collaborative problem-solving and custom solutions with our customers centered on design, engineering, prototyping, and low-volume production,” he states.

“General interest in 3D printing and additive manufacturing is white-hot right now,” Young adds. “The ability to incorporate 3D printing with traditional tooling allows us to offer established companies innovative solutions for their existing manufacturing processes (e.g. molds and castings) together with new 3D metal-printed components that can make those existing tools much better. For companies making millions of parts, a cycle time reduction of 25 to 30 percent can be pretty disruptive, both from the part design side and from the production side.”

What do such companies want to know about? “Mainly design techniques for cooling channels, water lines, and how we could optimize inserts for particular parts,” Young answers. “With our knowledge and experience both on the 3D side printing metal inserts and our mold manufacturing expertise, we can go further and simulate how those optimized designs not only work better, but maybe in 30 percent less time. We can’t mention names, but we are able to present testimonials from customers who not only used the concepts, but showed we were able to hit the improvement marks we predicted. We consider large companies that mold millions of plastic parts annually leaders because they have their molding systems down to a science. Being a part of introducing them to a disruptive technology that can drastically change their core business, is profound to see and something we intend to continue.”

Production molds with 3D printed conformal cooling lines are a company specialty. “As opposed to drilled holes, 3D printed heating or cooling lines are designed to follow the contours of the part,” Young stated. “Placing them an optimal distance from the part surface means the mold can maintain a constant temperature and avoid warps and sinks. Testing these cooling lines with finite element analysis means we can fine-tune conformal cooling lines to accurately predict optimum mold performance and improved cycle times.”

Linear AMS has qualified cycle-time reductions from 15 percent up to as much as 45 percent. This not only means reduced energy output, but also extra capacity for a customer. Other tangible benefits include less scrap, improved final part quality, and much more flexibility when it comes to part features and the mold components necessary to make them.

www.linearams.com, www.moog.com

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PFERD Appoints New VP Sales http://www.fabricatingandmetalworking.com/2016/08/pferd-appoints-new-vp-sales/ http://www.fabricatingandmetalworking.com/2016/08/pferd-appoints-new-vp-sales/#respond Wed, 24 Aug 2016 15:36:06 +0000 http://www.fabricatingandmetalworking.com/?p=98317 Jon-Michael Raymond now manages their U.S. sales in the welding, industrial and STAFDA sectors.

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PFERD Inc. (Milwaukee, WI), a global manufacturer and distributor of abrasives, brushes and power tools, has announced the appointment of Jon-Michael Raymond to the position of vice president of sales. He is will now manage their U.S. sales force and is responsible for the welding, industrial and STAFDA channels.

The announcement was made by Gene Huegin, the president of the company. “We are pleased to have Jon-Michael join our staff. He brings a wealth of knowledge and experience in the industrial market and will provide a strong addition to our sales management team,” said Huegin. “His appointment is but another step in the continued growth that we are realizing as a company.”

Prior to joining the company, Raymond was the manager of private brand and retail of the U.S. and Canada for Osborn Manufacturing (Richmond, IN). He also held several positions with Saint-Gobain-Norton (Worcester, MA), the latest being their market manager of MRO for the U.S. and Canada. “I’m very excited about this opportunity. This is a world-class company with great products and a loyal customer base. I look forward to developing and increasing that base,” added Raymond.

PFERD is the U.S. subsidiary of August Rüggeberg GmbH & Co. (Marienheide, Germany).

www.pferdusa.com

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Met-L-Flo Increases Inspection Services and Capabilities http://www.fabricatingandmetalworking.com/2016/08/met-l-flo-increases-inspection-services-capabilities/ http://www.fabricatingandmetalworking.com/2016/08/met-l-flo-increases-inspection-services-capabilities/#respond Tue, 23 Aug 2016 23:51:46 +0000 http://www.fabricatingandmetalworking.com/?p=98297 Their new ROMER Absolute Arm provides 3D scanning that measures any type of part with minimal alterations, regardless of the material or shape.

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Met-L-Flo, Inc. (Sugar Grove, IL) has acquired a new 3D scanning arm, the ROMER Absolute Arm from Hexagon Manufacturing Intelligence (North Kingstown, RI), for accurate measuring and performing multiple inspection services that will increase their quality, response time and accuracy. This equipment advances the way they can their apply additive manufacturing, 3D printing and bridge tooling technologies for applications in variety of industries, including aerospace, defense, consumer products, agriculture, and industrial equipment.

Met-L-Flo has ISO 9001:2008, AS 9100C:2009-01, and ITAR #M34307 Certifications, and their expanded capabilities with this 3D scanning arm are in compliance and support of these certifications, which also include compliance with D6-51991 Digital Product Definition and related Model Based Definition.

This scanning device retrieves precise measurements with less user error. The arm can measure any type of part with minimal alterations regardless of the material or shape. The touch probe component of the arm provides exacting CMM measurements from two points on a part based on where it makes contact. The PolyWorks software option of the arm is one of the best on the market and makes reading the measurements easy and time efficient.

www.metlflo.comwww.hexagonmi.com

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