November-December 2012

Experts

High Speed Cutting Process Optimization: How to Cut Even Faster

3D laser cutting with a multi-axis machine. New functions such as gas purging while positioning, piercing on the fly, controlling machine dynamics, additional fast axes in tool direction and automatic adoption of the laser power to the actual cutting speed in the tool center point help reduce the time required for the machine to process the part, outside of the time when the laser is actually cutting.
New functions have helped to reduce the cycle times required for 3D laser cutting, outside of the time when the laser is actually cutting. But even with these new technologies, applying the established best practices and tricks can often reduce those times even more.

How to Avoid Messing Up Your Marketing

There is no place to hide: In today's world, all of your marketing, advertising, social media and public relations messages are fully exposed and claims are challenged. John Graham of Graham Communications examines six ways to avoid embarrassing and harmful marketing actions that can menace your company.

What Happened?

During the chaos that often follows a workplace injury, poor incident investigation can often leave us scratching our heads. To improve incident investigation, Phil La Duke of Rockford Greene International explains how to address the five most alarmingly common mistakes that people make under the pressure of the moment.

Using 95/5 Shielding Gas During Low-Alloy Filler Rod Conformance Testing

In filler metal qualification tests where argon/oxygen shielding gas mixtures are used, Regis Geisler of Lincoln Electric explains why and how to leave some wiggle room in contracts to make adjustments as the situation warrants, instead of stipulating how welding will take place with a particular blend.

A Look Back, A Look Ahead

Randy Pearson of Siemens Industry reflects on IMTS 2012, one of the best shows he’s ever attended (and he doesn’t exaggerate) . . . and how it points to the future for CNC and its use at your shop.

The Comeback Player of the Year: Manufacturing

Anne Goyer of the Chemical Coaters Association International explains why now is the time to sustain the momentum.

Spindle Repair: The New Way to Save Money

The humid atmosphere created in many machines, especially closed-type ones, further contributes to contamination. When the spindle is operating, its temperature is hot, and when the spindle is stopped it begins to cool, causing a “chimney effect” to occur that wants to suck in all the warm humid air into the spindle and bearings. (first view)
If a spindle on one of your machines fails tomorrow, what’s your backup plan? Can you afford to wait several weeks to receive a new spindle? Spindle repair is another option that many companies are now considering.
Metal Forming & Fabricating

Heat Treating Business Gains Competitive Edge with Polymer Quenchants

One job that took two weeks at Complete Heat Treating due to reworks is now done in two days by using a polymer quenchant from Tenaxol with anti-foaming agent and greater concentration consistency.

Advanced Laser Cutting Systems

New systems from MC Machinery Systems Inc./Mitsubishi include the revolutionary 3015 NX-F Fiber Laser with a fiber laser oscillator, a Z-axis linear drive, head preset auto-focus processing, a 64-bit NC with 15 in touch screen NC-panel and more.

Portable Marking for Flats & Rounds

Versatility moves beyond standard column-mounted systems with the hand-held electromagnetic dot peen marking technology from SIC Marking that is ideal for marking flat and round work pieces such as plate, pipe and fabricated vessels with heavy weight.

Custom Modular Hydraulic Presses

Hydraulic presses built by Beckwood Press are ideal for compression molding, heated platen, forming, drawing, powder compacting and those requiring off-center loading.

Direct Drive Servo Former Presses

80 ton through 3,000 ton Direct Drive Servo Former servo presses from AIDA-America are available in large size transfer and tandem lines, high precision and fine blanking, mid-size progressive die and transfer, general purpose gap frame and straightside styles.

Custom Hydraulic Press Applications

Greenerd Press builds hydraulic presses to specific user applications and press requirements, ranging from gap frame and straight-side to die-spotting and forging presses.

Cut-to-Length Lines

CTL lines from COE Press Equipment can process coil from 18 in to 72 in wide, .020 in to .375 in material thickness, and 6,000 lb to 60,000 lb coil weights in cold rolled steel, hot rolled steel, galvanized, stainless, and aluminum.

Automatic Punching of Flat Bar, Angle and Channel

The Sunrise ANC Punching System from Trilogy Machinery uses a fully automatic single-axis CNC in-feed system to combine an ironworker or punching machine with capacity up to 220 tons to punch flat bar, angle and channel web lengths up to a 20 ft.

Automatic Vertical Bandsaw

This new system from HE&M Saw miters to 60 deg and features a flat panel touch screen that controls saw data, including total motor hours, hydraulic pump hours, system parameters, time of day and up to 999 individual jobs.

Ironworkers with Electric Stroke Control

50-ton 50514CM and 5014TM ironworkers from Scotchman now come with a 50-ton Electric Stroke Control with a Remote Electric Foot Pedal option for more accuracy and consistent repeatability.
Welding

Top Ten Things to Teach Novice Welders

New welders should always install their diffusers, nozzles, contact tips and collet bodies according to the manufacturer’s recommendation, making sure that each component is securely tightened. Good connections help prevent weld defects, support consistent productivity and reduce the risk of premature consumable failure due to overheating.
Training must go beyond creating quality welds. This primer shows why instilling good habits early on is important to ensure that these individuals are prepared to contribute positively to the overall welding operation and gain the confidence they need to become increasingly proficient.

Pipe Welding Solutions

Bug-O Systems answers many medium-to-large diameter pipe welding challenges with The Piper Plus, a self contained, digitally controlled, mechanized pipe welding system that produces high deposition rates with excellent weld quality to reduce pipe welding costs.

Robotic 3D Cutting Combined with Welding

Flexible systems from Wolf Robotics switch between arc welding, plasma cutting, oxyfuel bevel cutting, pre-heating, etc. using precision tool changers to automate complex parts that once required multiple robots or systems.
Metal Cutting

Horizontal Machining Takes Center Stage

The NHX4000 from DMG/Mori Seiki is a heavy-duty horizontal machining center that is ideal for machining workpieces of up to 24.8 in x 35.4 in with a loading capacity up to 880 lb.

Statistically Capable Machining

In a manufacturing age of limited resources and rising costs, machining decisions made on probabilities, as opposed to limits, can offer a significant benefit. By implementing modern statistical process control, this primer from Makino shows how machinists can ultimately improve quality and reliability, and reduce operating costs.
Tooling & Workholding

Boiler Tube Membrane and Overlay Removal

The Membrane and Overlay Removal Head from ESCO Tool uses proprietary long-life inserts shaped like golf tees, rather than screws, to remove boiler tube membrane and overlay plus bevel all at the same time, with minimum vibration and reduced heat.

All-in-One Hole Sheet Metal Hole Cutting Packages

RotaCut Sheet Metal Hole Cutter Master Kits from Hougen Manufacturing have 16 different sizes of cutters for drilling holes in materials up to ¼ in thick for metal fabrication, maintenance and electrical applications, spot weld removal, plug holes for welding, and production environments.
Measurement & Inspection

Enhanced Portable CMM Laser Measurement

Portable 3D laser tracker measuring arms from Hexagon Metrology are ideal for inspection and tool building of oversized components in the aerospace, rail and heavy transportation, nuclear, solar and wind energy, and related industries.
Maintenance

Magnetic Filter Puts a Brake on Fines

This magnetic separator Magnetic Products removes fines from a drilling operation and automatically feeds the fluids back into the integrated reservoir tank for fewer messy, oily pools around machinery, improved coolant recovery and reduced fluid replacement costs.
Environmental Health & Safety

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