West Manufacturing News June 2017 : Page 1
M ANUFACTURING N EWS WEST Vol. 6 No. 6 June 2017 Serving Since 2012 Arizona, California, Colorado, Idaho, Montana, Nevada, Oregon, Utah, Washington & Wyoming Feature Editorial Finishing/ Grinding/Abrasives Flap Discs for Grinding All Metals Grinding discs developed for grinding stainless steel, aluminum, titanium and more. See Page 12 See Online DIGITAL EDITIONS at www.mfgnewsweb.com Advancements for Aerospace Manufacturing Chemeketa, DMG MORI Makino offers its latest T1 HMC developments for the Enter Educational manufacture of aero-space engine and struc-Partnership tural components, includ-ing titanium, steel and alu-minum milling, blade and vane grind-ing and EDM drilling of film cooling holes and diffuser shapes. “Production demands in the aero-space market remain incredibly strong, and with continuous advancements being made in machine technology, manufacturers have more reason than ever to expand capacity and seize growth opportuni-ties,” said David Ward, Makino Prod-u c t M a r k e t i n g M a n a g e r. “ O u r expansive portfolio of equipment built specifically for the aerospace industry has undergone many software and hardware-based optimizations over the last two years, and we are excited to share how these developments are Continued on Page 32 Furthering educational opportuni-ties for students through technology was the intent when Chemeketa Com-munity College recently signed an agreement for an educational partner-ship between itself, the college’s ma-chining technology program and DMG MORI at the Salem, OR, campus. “We are partnering with a world-class company,” said Johnny Mack, Chemeketa’s Executive Dean of Career And Technical Education. Sheldon Schnider, Machining Continued on Page 92 Aerospace/Defense Laser-Based Composite Manufacturing Laser projection software simplifies and accelerates manual composite lay-up for a variety of industries. See Page 28 Applying Technology AM enhances part design, increases production efficiency. See Page 48 Manufacturing Technology Orders Make a Jump in March Manufacturing technology orders continued to make gains in March, ac-cording to the latest U.S. Manufactur-ing Technology Orders report from AMT – The Association For Manufac-turing Technology. Orders were up 34.8 % compared to February, and up 3.3 % compared to March 2016. “An increase for the month was ex-pected, since it marked the end of the fiscal year for many companies, but it Continued on Page 92 Reduce Manifold Weight with AM Metal 3-D Printing Pushes the Boundaries in Moto2 cutting edge metal additive manufactur-ing (3-D printing) technology in an un-conventional front suspension system to gain a competitive advantage. Motorcycles ridden in the MotoGP Wo r l d C h a m p i -onships are special; the general public cannot buy them and they cannot be used on a public road. As prototype racing bikes they are cus-tom-built to outdo their rivals and maximize performance on the track. Continued on Page 92 Controls Enhanced control series features increased number of paths and axes that can be controlled. See Page 58 Increased Speed, Precision HxGN LIVE 2017 June 13-16 Hexagon Manufacturing Intelli-gence’s international conference, HxGN LIVE 2017, will take place at the Venetian Resort Hotel, Las Vegas, NV, June 13-16, 2017. This four-day event will showcase the latest data-driven developments enabled by Hexagon’s newest metrology and manufacturing solutions for the smart factory. This year’s theme “the Shape of Potential” sets the stage for attendees looking to re-engineer product development from concept to reality in a connected world where data informs the process every step of the way. The conference’s Continued on Page 92 Plant Maintenance Industrial LED light provides an alternative to gas burning luminaires. See Page 64 High Bay Light In the high-octane world of Mo-toGP motorcycle racing, technical en-hancements can have a big impact. Moto2 team TransFIORmers is using Retrofit/ Remanufacture/Repair Carbide Application Tool Using electronic spark deposition, the process extends the useful life of machinery. Subscription Changes: To make name, address subscription changes contact: • Phone: 800-375-8488 • Fax: 817-488-7813 • E-mail: firstname.lastname@example.org • www.mfgnewsweb.com CHANGE SERVICE REQUESTED Gross Publications, Inc. WEST MANUFACTURING NEWS P.O. Box 847 Grapevine, Texas 76099-0847 U.S.A. DALLAS, TX PERMIT 4245 See Page 80 Advertiser Index Page 71 PRSRT STD U.S. POSTAGE PAID
Advancements For Aerospace Manufacturing
Makino offers its latest developments for the manufacture of aerospace engine and structural components , including titanium, steel and aluminum milling, blade and vane grinding and EDM drilling of film cooling holes and diffuser shapes.
“Production demands in the aerospace market remain incredibly strong, and with continuous advancements being made in machine technology, manufacturers have more reason than ever to expand capacity and seize growth opportunities,” said David Ward, Makino Product Marketing Manager. “ Our expansive portfolio of equipment built specifically for the aerospace industry has undergone many software and hardware-based optimizations over the last two years, and we are excited to share how these developments are enabling manufacturers to boost productivity, improve quality and generate the greatest profitability.”
Several key technologies that Makino offers include the newly updated MAG3.EX, DA300, a61nx-5E, TSeries, G-Series and EDBV-Series machining centers and electrical discharge machines.
Advancements in Machining Technologies
• NextGen MAG3.EX: Makino’s MAGSeries 5-axis horizontal machining centers ( HMC s ) a redesigned for the aerospace industry to produce large aluminum structural parts. The NextGen MAG3.EX is an evolution in this platform design that provides advanced spindle capabilities, improved axial positioning and movement and enhanced motion control to eliminate non-cut times for aluminum structural part productivity.
• DA300: The DA300 5-axis vertical machining center (VMC) turns complexity into an advantage with rapid part positioning, dynamic motion control and high material removal rates in five-face machining applications. Optional workpiece pallet systems and expanded tool magazines provide expandable capacity for future growth.
• a61nx-5E: “Equipped with a 24,000 RPM, 80-kW duty-rated spindle, the a61nx-5E 5-axis HMC is a compact power house for productivity in small aluminum structural components,” said a company spokesperson. When combined with the newly updated MMC2 automated pallet handling system, the a 61 n x - 5 E can achieve utilization rates of up to 95%.
• T-Series HMC: Built for titanium, yet flexibly designed to support a variety of additional materials, the T1, T2 and T4 5-axis horizontal machining centers provide aerospace manufacturers with a balance between productivity and tool life for low cost per part.
• G-Series: For high-nickel-alloy blade and vane production, Makino offers the G5 and G7 5-axis HMCs. Their combined flexibility and capability enable manufacturers to perform grinding , milling and drilling in one machine platform, in a single set-up.
• EDBV-Series: Makino’s EDBV3 and EDBV8 EDM hole-drilling machines are purpose-built for the production of film cooling holes and diffuser shapes in aerospace blades and vanes. With the ability to produce a wide range of hole shapes and sizes in one set-up, the EDBV-Series machines help manufacturers save on tooling and cycle times.
For more information contact:
7680 Innovation Way
Mason, OH 45040
Metal 3-D Printing Pushes The Boundaries In Moto2
In the high-octane world of MotoGP motorcycle racing, technical enhancements can have a big impact. Moto2 team TransFIORmers is using cutting edge metal additive manufacturi n g ( 3 - D printing ) technology in an unconventional front suspension system to gain a competitive advantage.
Motorcycles ridden in the MotoGP World Championships are special; the general public cannot buy them and they cannot be used on a public road. As prototype racing bikes they are custom- built to outdo their rivals and maximize performance on the track.
Moto2, the second of the three MotoGP classes, was created in 2010, and its official engine is a 600cc four-stroke production engine, currently supplied by Honda.
The French Moto 2 team TransFIORmers, based in Perigueux, South West France, is revolutionizing front suspension design in order to stay ahead of the pack. Christian Boudinout, a former 250cc World Championship rider, lead’s the team, and the unconventional suspension system was inspired by the seminal work of the legendary French motor bike designer Claude Fior. Boudinot’s former friend and mentor, Fior, recognized the gains to be made from isolating the front suspension from steering forces. Resolving issues of ‘brake dive,’ the design enables later braking into a corner and faster acceleration out.
Instead of the more traditional telescopic front fork suspension, the TransFIORmers motorcycle employs a rigid front fork suspension system separated from the chassis using two wishbones. “To further advance the development of its new design, TransFIORmers approached I3D Concept, a world-class expert in metal additive design and manufacturing techniques,” said a Renishaw spokesperson.
Using Renishaw’s AM 250 additive manufacturing system, I3D Concept worked in partnership with the Trans- FIORmers team to optimize the design of its upper wishbone component, one of two attaching the front fork to the chassis and critical to the bike’s steering.
In the development of new components in the Moto2 bike design, achieving a weight reduction is a priority. In particular, reducing the unsprung mass of the bike is a key consideration. The lower the unsprung mass, the better the suspension is in terms of vibration management and responsiveness to both braking and acceleration. Of equal importance is the speed with which the design of a new component can be modified, and how long it takes to remanufacture. “Achieving perfection in a highly competitive environment demands fast and accurate component iteration,” said a spokesperson.
In a high reliability environment, mechanical strength is a further prime consideration. The TransFIORmers’ wishbone component needs to assure best possible rigidity, while handling significant levels of dynamic steering force. “To improve overall motorcycle performance, reducing the weight of all components located behind the shock absorbers is absolutely vital. Failure to optimize component weights can have an adverse effect on vibration, braking and acceleration, so weight reduction is a really high priority,” said Jérôme Aldeguer, Mechanical Engineer, TransFIORmers.
TransFIORmers’ original wishbone component was hand-fabricated in steel; with the assembly comprising twelve separately machined and welded parts. I3D Concept consolidated the design into a single-piece component, greatly reducing assembly time. The company produced the metal 3-D printed wishbone using a Renishaw AM 250 additive manufacturing system, initially prototyping in stainless steel (inox) and finally manufacturing a lighter weight part in titanium.
Key to the new 3-D component design was an iterative process of topological optimization, whereby the wishbone layout was successively rationalized in software within tight space constraints to withstand a set of predefined front fork loading conditions. Once the final component design was validated using digital CAD software, the build preparation file was prepared offline prior to export to the additive manufacturing system.
Within the CAD software, I3D Concept was able to assess whether the parameters were effectively predetermined or whether they required tweaking to match the specific metal powder characteristics and the complex target geometries of the TransFIORmers wishbone.
Importantly, using the AM 250’s dedicated Optical Control System (OCS) software, I3D Concept was able to very accurately control laser steering which helped to enhance precision, definition of features and surface finish. By taking an additive manufacturing approach to Moto2 bike design, TransFIORmers succeeded in dramatically reducing the weight of its critical wishbone front suspension component by 40%. Comparing the one-piece titanium component with the original welded steel component, a weight savings of 600 g was achieved.
Metal 3-D printing has also provided TransFIORmers with much finer control over component tolerances and the flexibility to very quickly iterate wishbone geometries to match specific chassis and kinematic requirements.
“The weight reduction that metal 3-D printing has achieved for us in our wishbone component has enabled us to bypass traditional weight transfer phenomenon and the problems associated with brake dive. More than that, it has allowed us to design a part that is not only lighter, but far more rigid at the same time,” said Jérôme Aldeguer, Mechanical Engineer, TransFIORmers.
“With an ultimate tensile strength in excess of 1,100 MPa when processed using additive manufacturing, and near perfect 99.7% densities, the titanium Ti6AI4V alloy used has delivered a radical new wishbone offering far greater rigidity than the original multi-part, hand-assembled steel component.”
“Due to additive manufacturing, TransFIORmers’ prototype wishbone development has become a highly efficient and cost effective process. Extensive part machining and assembly time overheads have been removed and design iterations and manufacturing have been made many times faster. In June 2016 the team won its first ever Moto2 GP race at the F IM CEV event i n Barcelona,” said the spokesperson.
For more information contact:
1001 Wesemann Drive
West Dundee, IL 60118
Chemeketa, DMG MORI Enter Educational Partnership
Furthering educational opportunities for students through technology was the intent when Chemeketa Community College recently signed an agreement for an educational partnership between itself, the college’s machining technology program and DMG MORI at the Salem, OR, campus.
“We are partnering with a worldclass company,” said Johnny Mack, Chemeketa’s Executive Dean of Career And Technical Education.
Sheldon Schnider, Machining Instructor, said that in conjunction with the partnership, Chemeketa has been recognized by DMG MORI as one of only five regional education centers of excellence in the country.
The excellence of Chemeketa’s program and the workers it is turning out was recognized during the ceremony by Marlow Knabach, DMG MORI’s Chief Technology Officer. “What you have through these doors is what drew me into the industry,” Knabach said of Chemeketa’s machining labs.
President Julie Huckestein said one of the proudest moments for the college, outside of graduation, is when partnerships like the one with DMG MORI can be celebrated.
For more information contact:
Chemeketa Community College
4000 Lancaster Dr. NE
Salem, OR 97305
DMG MORI -
2400 Huntington Blvd.
Hoffman Estates, IL 60192
Manufacturing Technology Orders Make A Jump In March
Manufacturing technology orders continued to make gains in March, according to the latest U.S. Manufacturing Technology Orders report from AMT – The Association For Manufacturing Technology. Orders were up 34.8 % compared to February, and up 3.3 % compared to March 2016.
“An increase for the month was expected, since it marked the end of the fiscal year for many companies, but it is encouraging to see the last two months outpacing their 2016 levels – the possible start of an upward market trend,” said AMT President Douglas K. Woods. “When manufacturers make investments to boost their capacity and productivity, it is a good sign for a strengthening manufacturing economy.”
Leading indicators show that promising gains for manufacturing are likely to continue. Consumer sentiment is on the rise, which will lead to more purchases of durable goods like cars, appliances, electronics and housing. Cutting tool shipments have grown, a marker of increased productivity. Machine shop spending for capital equipment has also been on the rise, indicating that manufacturers are using their services for excess capacity.
Orders for March 2017 totaled $407.53 million, up from $302.27 million in February. Year-to-date orders total $961.13 million, down 1.4 percent from the same point in 2016. USMTO is a reliable leading economic indicator as manufacturing companies invest in capital metalworking equipment to increase capacity and improve productivity.
For more information contact:
7901 Westpark Drive
McLean, VA 22102-4206
703-893-2900 / 800-524-0475
HxGN LIVE 2017 June 13-16
Hexagon Manufacturing Intelligence’s international conference, HxGN LIVE 2017, will take place at the Venetian Resort Hotel, Las Vegas, NV, June 13-16, 2017. This four-day event will showcase the latest data-driven developments enabled by Hexagon’s newest metrology and manufacturing solutions for the smart factory. This year’s theme “the Shape of Potential” sets the stage for attendees looking to re-engineer product development from concept to reality in a connected world where data informs the process every step of the way. The conference’s centerpiece is The Zone, which displays more than 50,000 sq. ft. of Hexagon technologies and more than 60 exhibiting sponsors.
The Manufacturing Intelligence track will address the most pressing questions for manufacturers who want to leverage the benefits of smart factory practices, such as: How can factories become more connected and work smarter? What is data-driven manufacturing? The speaker line-up of Hexagon customers, partners, special guests and in-house experts will answer those questions and present stories about automation, process control, closed loop manufacturing, Internet of Things ( IoT ) and other successful data-driven applications addressing all aspects of industrial manufacturing. Attendees will have access to Hexagon’s metrology, statistical process control, sheet metal design and costing and CAD/CAM solution portfolios and experience live demonstrations with knowledgeable product developers and application engineers.
“HxGN LIVE has become a standout industry event showcasing how leading manufacturers are enabling the digital thread through metrology,” said Norbert Hanke, President of Hexagon Manufacturing Intelligence. “At this conference, our valued customers and guests step into our world and discover how quality-driven productivity can have a major impact on their bottom line. HxGN LIVE attendees get to see firsthand the important touchpoints across the production lifecycle, where smart factory principles and the power of connected data, upstream and downstream, ensure speed and confidence in everyday manufacturing operations across many industrial applications.”
For more information contact:
HxGN LIVE 2017
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