Morden Machine Shop PDF

DIE/MOLD MACHINE CUTTING TOOL
MANUFACTURING MONITORING TECHNOLOGY

Laser welding for AI predicts spindle Tips for programming
mold repair pg. 60 lifespan pg. 66 ceramic tools pg. 72
mmsonline.com
Trusting
Machine
Vision pg. 80
JUNE 2019 A property of Gardner Business Media

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advanced the replaceable parts concept and 3D printing, robotics and high-speed precision
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more than 50 years, their former factory has manufacturing technology and processes that,
housed the American Precision Museum. in turn, led to profound changes in people’s lives.
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FEATURES
JUNE 2019
VOLUME 92
NUMBER 1
80 AUTOMATION
Unguarded Automation
Can vision and AI make every robot collaborative? MOLDING INDUSTRY

That is the aim of this Boston-area startup. This year, 60 Pulsed Laser Welding
it will come to market with technology to make even Speeds Mold Repair
fast and powerful robots safe to approach,
eliminating the need for fences around them.
BY PETER ZELINSKI
CUTTING TOOLS TRADE SHOW REPORT
72 76
MACHINE MONITORING
66 Using AI to Predict
Spindle Issues Before
They Are Issues
7 Tips for A Virtual Visit
Programming to TIMTOS
Ceramic It is possible you will never
Cutting Tools get the chance to visit the
Taipei International Machine
Ceramic tools require
Tool Show, let alone Taiwan.
different thinking and a
This story and a series of
willingness to tweak tool
tweets with video give you a
paths developed with
flavor for what I encountered
carbide in mind.
at the show in March.
BY MATT DANFORD
BY DEREK KORN
8 MMS JUNE 2019 mmsonline.com

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CONTENTS JUNE 2019
From the MMS Editors

18 The Z Axis | Peter Zelinski
20 One-Off | Derek Korn
22 Data Matters | Matt Danford
38 Technical Perspectives
26 Competing Ideas | Frequently Asked Questions Regarding Lean Manufacturing
30 Quality Gaging Tips | Air Gage System Maintenance
34 CNC Tech Talk | Monitoring Time for Preventive Maintenance Tasks
38 Additive Insights | AM for Hard Tooling
42 The View from My Shop | Decisions, Decisions
The Metalworking Industry

14 MMS Connect
16 Digital Extras Products
46 Shop Talk
58 Events | Conferences | Meetings 114 Tooling and Workholding
144 Metalworking Indexes
94 Better Production
86 Grind to Finish: A Postprocessing
Solution for Additive Manufacturing
94 Integrated CAD and CAM Boosts

Job Shop’s Efficiency through
Collaboration 122 Systems and Software
106 With 3D Printing, Fixture Making

132 Modern Equipment Review
Goes from the Tool Room to the
Spotlight: EDM
CAD Room
Advertisers
140 Business Opportunities
142 Index of Advertisers
| ABOUT OUR COVER | Trusting Machine Vision

Creative director Jeff Norgord took a quick series of photos at Veo Robotics that he and
graphic designer Claudean Wheeler combined into this image showing the motion of a
robot before a safety system using machine vision and AI stopped it from making contact
with Veo’s Gwenn Ellerby. Reliable, fast-responding machine vision promises to reduce
the need for guarding and make powerful robots collaborative. Read more on page 80.

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Bryce Ellis • Additive Manufacturing
bellis@gardnerweb.com • Modern Machine Shop
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EDITOR-IN-CHIEF • MoldMaking Technology
Peter Zelinski • Production Machining
pzelinski@mmsonline.com
• TechSpex
COMPOSITES & PL ASTICS
EXECUTIVE EDITOR • CompositesWorld
Derek Korn • Plastics Technology
dkorn@mmsonline.com • Plastics Technology Mexico
SENIOR EDITOR AUTOMOTIVE
Matt Danford • AutoBeat Daily
mdanford@mmsonline.com • Automotive Design & Production
FINISHING
SENIOR EDITOR
• Products Finishing
Brent Donaldson • Products Finishing Mexico
bdonaldson@mmsonline.com
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Emily Probst
eprobst@mmsonline.com Richard G. Kline . . . . . . . . Chairman
Richard G. Kline, Jr. . . . . . President
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Jedd Cole Steve Kline, Jr. . . . . . . . . . Chief Data Officer
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ASSISTANT EDITOR Dave Necessary . . . . . . . . Director of Strategic Engagement
Eli Plaskett Jeff Norgord . . . . . . . . . . . Marketing and Creative Director
eplaskett@mmsonline.com Jan Schafer . . . . . . . . . . . Director of Market Research
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EDITOR EMERITUS
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malbert@mmsonline.com INDUSTRY PARTNERS
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MMS CONNECT
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The Importance of
We Want to Write About You
People in Automation
What’s the latest in #CNC grinding technol-
Our March cover story about ogy that machine shops should be aware of?
succeeding with robotic machine What’s a misunderstood aspect of existing
tending featured Alexandria grinding technology? @MMS_Derek is on
Industries’ Jackie Rechtzigel. the hunt for a good grinding story. gbm.
Here, CEO Tom Schabel presents media/story-lead. (Learn more about how
her with a framed cover. gbm. we select magazine content on page 20.)
media/rechtzigel
AM Needs an Executive’s Eye

The potential impact of #Additive-
Manufacturing extends beyond how
parts are made, touching five distinct
parts of the enterprise. Why the CEO
must be the one to evaluate and
implement AM: gbm.media/ceo-am

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DIGITAL EXTRAS mmsonline.com
12
LONGFORM
MIN.
The Evolution of Camshaft Grinding
By improving its CNC grinding processes and adding a
new Micro Surface Enhancement (MSE) finishing
technology, Comp Cams not only improved the look of
its camshafts, but more importantly, their longevity.
READ: gbm.media/compcams
3
MIN.
REPORT | Studer Expands Universal Cylindrical
Grinder Series
Our European correspondent, Barbara Schultz, was able to attend a
Studer press event at the Hagerbach Test Gallery, an R&D facility in
Switzerland for underground mining tunnel construction.
READ: gbm.media/mining
VIDEO | On the Shoulders of a Giant

1
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installation process of the Emco Mecof PowerMill, one of the largest
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Peter Zelinski
EDITOR-IN-CHIEF
A new facility for five-axis machining lets a small team @Z_Axis_MMS

oversee significant capability. The way of the future?
There was a time when machine shops were machining is performed on two integrated pallet
routinely organized by operation. There were cells consisting of six Makino Mag 3 machining
separate departments for turning, milling, grind- centers apiece. The cells each require one operator
ing and so on. The arrangement was meant to per shift, for a total of six operators, with three
bring together people who were alike in their more providing buffer. Therefore, nine operators
specialization by equipment type. By contrast, are enough to staff the two cells’ 12 machines
cross-training and diverse equipment are more around the clock. Suffice it to say, of the 1,000 new
valued in shops today. Though similar machines hires, few or none will be needed on these cells.
might locate near one another, a variety of The center of excellence concept creates capac-
machines fill the shop and employees are valued ity, most basically in floor space. Concentrating
for their ability to engage across that variety. five-axis into one place is more space-efficient
Yet Spirit AeroSystems is going a different way, than the previous arrangement of dispersed five-
at least partially. axis capability. It also creates productive capacity
On a tour of the company’s manufacturing because the five-axis specialists assembled here
campus in Wichita, Kansas, I got to visit its newly now have an easier time coordinating to address
opened Five-Axis Machining Center of Excellence. challenges. Moreover, they can give their atten-
A similar center for three- and four-axis work is in tion to more machines apiece. There are many
Oklahoma. These facilities bring like machining more people here than just those on the pallet
capability together, along with people dedicated cells, but still, the team here is few but mighty.
to this capability. The sense of concentration at And Spirit AeroSystems is poised to capitalize on
the Witchita center was clear: It was just five-axis that might. One reason for increasing capacity is
and nothing else. Is this a step backward? the company’s hope to raise contract machining
Actually, no. It is an advance in line with ways alone into a $1 billion business.
machining technology is advancing. It may even Relatively few manufacturers will have the
offer a glimpse of the way machine shops will chance to invest in a six-machine cell on the order
routinely operate not far in the future. of what this site has, let alone more than one of
A striking contrast illustrates the center’s value. them. But increasingly automated systems are the
The Wichita site is expanding. It makes com- reality of almost any shop that is continuing to
mercial aircraft fuselages (among other aircraft update its technology. In a shop with ever more
systems), and though one major plane model has automation, the challenge is to see just how much
seen an unexpected decline in orders this year, machining capacity a knowledgeable operator
the trend overall for Spirit has been a challenge might be able to oversee and what arrangement
to increase production, and therefore increase will address this challenge best. The model of con-
personnel. The company had aimed to add 1,000 centrating capability is therefore liable to make
new employees this year (unknown whether a comeback, but no longer as much for the sake
recent events affect that plan). Yet here is the of bringing together people doing similar work.
contrast: The personnel needs of the new five-axis That’s part of it, but the benefit now is much more
center are slight by comparison. There are various about bringing all the equipment and capability
types of five-axis machines here, but much of the together around these people.

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SOLIDWORKS®
ONE-OFF
Balancing Act
There is a method to our madness when it comes to
determining what articles to present to our readers. dkorn@mmsonline.com
Derek Korn
EXECUTIVE EDITOR
@mms_derek
Choosing what topics to write about for this mag- write? Absolutely. Was I a smidgen uncomfort-
azine is all about maintaining balance. able that it was a cover story? Absolutely.
One reason is that Modern Machine Shop is a I certainly thought readers would find the
horizontal publication, not a vertical one. That story intriguing. At the same time, I secretly won-
means we have to cover a range (rather than a dered if this technology would ever be something
small niche) of machining technology, equipment that they would, at some point, leverage to their
and processes that shops might apply to grow advantage in a tangible, beneficial way. After all,
their businesses and become more efficient, capa- the company I profiled was not actually using it in
ble and profitable. To ensure we present such a a proven production process or in some way out-
well-balanced smorgasbord of stories, we create side of prototyping.
a yearly editorial calendar that identifies specific But flash-forward to today. Recent MMS issues
topics we must cover in each month’s issue. This have described machine shops benefiting from
discipline keeps us from writing about the same 3D printing beyond prototyping by creating fix-
few concepts over and over, and it enables us to turing, robot end effectors, parts trays and other
bring fresh ideas to your attention that could help shopfloor widgets. In fact, the story on page 106
your operation. In this way, our magazine con- of this issue describes a shop that 3D prints plas-
tinues to be a means for discovery, spurring you tic workpiece fixtures rather than having its tool-
to research topics you learned about that piqued room produce them out of metal.
your interest. That’s why I had to check myself when I
The other part of our balancing act is pre- noticed how often the promise of artificial intel-
senting the right mix of articles that introduce ligence (AI) was mentioned in this issue without
leading-edge, possibly unfamiliar technology citing real-world examples of it being applied
as well as those that highlight the real-world in an actual shop. Our cover story describes a
application of company’s efforts combining AI with sensor tech-
AI FOR AM new or known nology to enable industrial robots and humans
machining to interact collaboratively on the shop floor
Using AI to draw insights from data equipment and sans protective fencing. Another story describes
could help additive manufacturing
strategies. Both how AI is being used to predict when a machine
operations move beyond machine
monitoring: gbm.media ∕aimap. kinds of stories tool’s spindle will start to fail, while still another
are designed to explains how AI facial recognition technology
help you improve your manufacturing business, can ensure only certain operators are permitted
whether it is something you can implement now access to a machine’s CNC.
or consider for the future. AI is an example of new technology we have
Let’s first consider the former type of arti- recently come across in our travels, technology
cle. I believe I was the first MMS editor to write that is likely coming to a shop near you (or to
about the promise of additive manufacturing/3D yours) at some point. Who knows, maybe one day
printing in a production (not prototyping) sense we’ll describe how your shop is applying AI in a
back in 2011. That article described a manufac- way that you learned about in this issue.
turer’s experimental efforts printing contoured, Still, I wonder. What other new technology will
high-temperature-polymer aircraft duct compo- we be bringing to your attention in the years to
nents. Was it an interesting story to research and come? Time will tell.

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DATA MATTERS | Data-Driven and Data-Enabled Manufacturing
ERP Helps Forward-Thinking

Shops Look Back
mdanford@mmsonline.com
Enterprise-wide performance data and an
understanding of which metrics matter form a Matt Danford
SENIOR EDITOR
foundation for predictive analytics. @MMS_MattDanford
I recently used this space to report on a “factory division of software developer ECi, says the same
operating system” that developers describe as thing about many of the company’s JobBoss and
“Google Maps for manufacturing.” Driven by arti- M1 enterprise resource planning (ERP) system
ficial intelligence (AI), this computerized assistant users. “At first, a lot of companies just want to be
predicts how different options for, say, sequenc- able to get the information out of Steve’s spread-
ing manufacturing operations or scheduling jobs sheet when he goes on vacation,” he explains. With
might play out. Based on both user priorities and that accomplished, manufacturers tend to seek
historical data, the system suggests changes that insight about their businesses by using ERP data to
are implemented automatically once approved. “look in the rearview mirror,” he says. “They’re not
This predictive analytic capability — this use doing predictive anything.”
of simulated “what-if” scenarios to guide deci- However, manufacturers motivated to use the
sion-making and make manufacturing proactive mirror provided by an ERP system are likely farther
rather than reactive — is the kind of thing that along the path toward predictive analytics than
thought leaders envision when they describe the they realize, he says. Looking back is essential to
“smart” factories and shops of the future. However, looking forward, and ERP can provide a foundation
it seems to me that many shops are not yet ready to for both. By extension, it can help manufactur-
take full advantage of predictive analytics, regard- ers prepare for the inevitable, yet unpredictable
less of whether AI is involved. change that developing technologies like AI and
Jeff Ralyea, president of the manufacturing machine learning can bring.
For one, the primary function of ERP — stream-
lining day-to-day business management tasks
— makes the software a unified, organized
source of information about everything
from quoting and material management to
finances and logistics. Much of this data can
directly feed predictive analytics systems.
For instance, AI-driven scheduling can derive
critical assumptions for modeling different
scenarios directly from ERP data, including
orders of operations, processing times at
various workstations, the locations of poten-
tial bottlenecks and more. “The first step to
using data is to effectively collect it in the first
place,” Mr. Ralyea says.
For another, the latest ERP systems are
more tailored than ever to individual users’
Business intelligence visible on this dashboard from ECi’s
M1 manufacturing ERP software includes an overview of needs — users that increasingly crave capa-
key action items (such as shipments that need to be bility to leverage their data. “Manufacturers
invoiced); job data (including such information as needed are looking to us for insight,” he says.
resources and due dates); and sales and quoting data. “Probably the most important things they’re

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S i nc e 1 9 8 8
DATA MATTERS | Data-Driven and Data-Enabled Manufacturing
looking for are pre-built dashboards that explain sets of questions to inform their own “what-if”
how efficient and effective they are, as opposed to exercises. “If you’re the operations manager,” Mr.
just operational documents.” Ralyea explains, “we can help answer questions
Determining what these dashboards will look like, How efficient are my workers and machines?
like begins with determining which questions How many jobs can I get through? What kind of
need answering for the specific manufacturer in disruption will occur if I drop a hot-parachute
question. In ECi’s case, he says consultations with order into the factory?”
customers and prospects tend to be specific and Shop smarts likely require more than ERP. For
granular, digging into how specific business units instance, functionality required for predictive
have performed in the past, why they perform the maintenance, such as processing sensor feedback
way they do that indicates the health of a machine tool spindle,
and how their is generally outside the purview of shop-manage-
AI MAKES SHOP performance ment software. Nonetheless, ERP data — how
NETWORKS COUNT should be eval- many jobs are scheduled in the next month,
uated in the part-quality information and more — can be bene-
AI could help push data-driven
manufacturers beyond machine first place. ficial or necessary to predicting when maintenance
monitoring: gbm.media ∕aimap. With a cus- should occur and what might happen if it doesn’t.
tomized system Overall, shops should view ERP as a means to
in place, reflec- do more than streamline functions like accounting
tive analysis can morph into an elemental form of and inventory management. These systems also
predictive analysis. For instance, top decision-mak- can inform what additional data to collect, how
ers can predict the result of adding a three-axis to collect it and what to do with it in the future.
machining center instead of a five-axis, or going “Whatever other tools and technologies are avail-
without new equipment. People in other roles can able won’t be applicable unless you know what
use different dashboards developed from different really matters,” Mr. Ralyea says.
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Frequently Asked Questions

Regarding Lean Manufacturing
Here are my answers.
WAYNE S. CHANESKI | COLUMNIST
For as long as lean manufacturing concepts have makes more than is needed or makes something too
been around, there are some who still do not fast or soon.
understand what lean is and why it’s an important • Waiting happens when something goes wrong
part of a continuous-improvement strategy. Having or doesn’t go as planned in a prior process, creating
spent many years training and consulting on lean idle time. It generally refers to processes or prod-
concepts, I have responded to many questions. ucts rather than people who can usually find some-
Here are some of the most frequently asked ones: thing to keep them busy rather than stand idle.
• Non-value-added processing is taking more
What is lean manufacturing? action than necessary to meet a customer’s needs
In simple terms, lean manufacturing is a process when making a product or offering a service.
that operates effectively through the elimination • Transportation is excess movement of prod-
or reduction of waste. There are proven tools to ucts through the process. If the shortest distance
address waste, such as the 5S system to improve between two points (or processes) is a straight line,
workplace organization, quick change-over to a more circuitous path is considered to be excessive.
reduce • Inventory is needed to make any process func-
machine tional, yet anything more than is required to satisfy
REVISITING THE VALUE STREAM setup immediate needs can be considered excessive.
times, • Motion is a waste when people look for things,
Mapping all activities required to
total pro- rearrange items and reach for∕lift things frequently
produce goods and services, not
just some, will reveal more oppor- ductive during any process.
tunities for continuous improve- mainte- • Employee under-utilization includes not apply-
ment. gbm.media/vs-map nance to ing employee skills, knowledge and experience to
reduce their fullest potential. It can breed frustration or
equipment downtime, one-piece flow to keep complacency.
things moving until finished, standard work to
discover the best way to do a job and ensure How do you get rid of waste in a process?
everyone follows the same protocol, and more. Getting rid of process waste starts with recog-
nizing the waste and taking steps to address it.
What is waste? There are a few ways to recognize waste. One is a
Waste is any activity that does not add value from “waste walk” during which a team walks through
a customer’s perspective. Another way to think an entire process the way a product might, looking
about waste is that it is something a customer for the eight wastes described above. The wastes
does not want to pay for. Over the years, eight should be recorded when found and discussed
specific types of waste have been identified. An amongst the team. Another way to identify waste
easy way to remember them is through the acro- is value-stream mapping, a tool that depicts all
nym DOWNTIME: the steps used to produce a product or deliver a
• Defects include anything that was done service. Waste can be represented as the number of
wrong and needs to be fixed. days an inventory sits at each step. This inventory
• Overproduction happens when a manufacturer can include parts, orders, deliveries, responses

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COMPETING IDEAS Manufacturing Management
to customers and more. The number of days is When are we “lean enough?”
calculated by dividing the inventory by the daily If we believe in continuous improvement, we know
demand for that step in the process. So, if 10 wid- we are never really finished. Lean, like continuous
gets are available for a specific process step, and improvement, is a journey in which many small but
the average daily demand for widgets at that step sustaining gains are made. If we can say that what
is two, we have five days of demand. The more we are doing today is better than yesterday, we are
days of demand, the greater the amount of waste on the right path.
at that step. Elapsed time, or the time something
typically waits at a process before moving to the
next process, is another way to represent waste.
The longer the elapsed time, the greater the AUTHOR | Wayne S. Chaneski
waste inherent to that process. President, Smart Manufacturing Solutions
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QUALITY GAGING TIPS Measurement Tools
Air Gage System Maintenance

Tight, clean and dry: The requirements of air gaging
aren’t very different from mechanical gaging.
GEORGE SCHUETZ | COLUMNIST
While quite durable and reliable compared to Air main lines should be pitched down from the
mechanical gages, air gaging is not carefree. Accu- source, with a proper trap installed on the end.
rate air gaging requires proper tooling mainte- Feed lines should also be equipped with traps.
nance and air supply vigilance. Take air from the top rather than the bottom of
Let’s start with the foundation of air gaging: the the mains, so moisture doesn’t drain into the gage.
air supply. Shop air is difficult to keep clean and Bleed air lines before connecting them to gages.
dry. Air dryers are not entirely adequate. The very Operating gages must always have a filter in place,
act of compressing air produces moisture, and a which should be changed regularly.
compressor’s need for lubrication inevitably gen- Basic air-tool maintenance simply means keep-
erates some oil mist in the line. Oil and water mist ing the tool clean and dry inside and out. Contam-
can actually act as an abrasive and cause part wear inants such as chips, dirt, coolant and cutting fluid
over long periods of time. Air also can be costly, so may be picked up from workpieces, while water
don’t let it run unless needed. The goal is simply and oil are likely to come from the air source itself.
to prevent mist from entering the gage and fouling While air pressure may flush out most contamina-
the jets. To do this, we must employ proper air-line tion, the gage must be inspected and cleaned when
design to intercept it before it enters the meter. necessary. Repeated mastering that produces vary-
ing readings is a good indication of dirty jets.
With single master air gaging systems, the accu-
racy is built in to both the air tooling and display.
This means that the air pressure, jet diameters and
clearance between the jet and the part are manu-
factured to standards creating the same pressure
distance curve for the tooling and the display. Just
as gage blocks act as standards for mechanical or
electronic gaging systems, master restrictor kits
act as standards for air gage systems, providing
standards for the pneumatic zero and span of the
reference system.
To check for contaminated air tooling, the
zero-restrictor would be used to verify pneumatic
zero on the display unit, and then the tooling and
its master would be compared to this pneumatic
zero setting. Large variation would indicate con-
tamination or damage to the tool’s jetting.
Air gaging is often referred to as a non-con-
tact form of measurement. This is accurate, to
A proper air-line design prevents

mist from entering the gage.
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QUALITY GAGING TIPS Measurement Tools
the extent that there’s no metal-to-metal contact through the maximum diameter to another chord.
between a sensitive gage component and the work- Wear may be considered excessive if the reading
piece. Nevertheless, air gage tooling generally changes by 10% or more of the part tolerance.
does make contact with the workpiece, and like To check for balance error, the test is performed
any tooling, may show wear after several thousand as above but the tooling is rotated so that the jets
measurements or years of use. are mounted vertically. Now the master is placed
When the clearance between the gage and the on the plug by resting it on the top jets and noting
workpiece exceeds the design clearance due to the reading. Lift the master so that it restricts the
wear, centralization error results. The air jets then lower jet and note this reading. Normally, two-jet
measure a chord rather than the true diameter of air plugs automatically balance themselves when
the part. As the distance between the chord and one of the jets is closer to the workpiece than
the bore centerline increases, we begin to see mea- the other as is the case here, where the master is
surement inaccuracy. allowed to rest on the upper jet. However, if one
The amount of allowable centralization error jet or orifice is damaged or worn, this test will
depends on both the diameter of the workpiece demonstrate the gage’s inability to maintain that
and the dimensional tolerance specification. Obvi- balance.
ously, looser tolerances can “tolerate” more mea- Plug gages tend to be highly durable, because
surement error. But equal amounts of misalign- they contact the workpiece across a broad sur-
ment will cause a greater centralization error in a face area. But that doesn’t mean you can ignore
small bore than in a large one. the possibility of poor centralization or balance.
To inspect for wear, secure the gage with the Include these tests in the annual gage calibration
jets oriented horizontally. Place a master on the program.
plug, release it and note the reading. Carefully
raise the master until it contacts the lower surface
of the plug. If the plug is worn, the readout will AUTHOR | George Schuetz
change as the measurement moves from a chord Director of Precision Gages, Mahr Inc.
DEBURR
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32 MMS June 2019 mmsonline.com

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CNC TECH TALK Processes and Programming
Monitoring Time for Preventive

Maintenance Tasks
Not all maintenance tasks should be performed
based on a calendar date.
MIKE LYNCH | COLUMNIST
Machine builders recommend preventive mainte- PM Task: Interval: Started:

Current
Monitored by:
nance (PM) tasks that should be performed and Time:
the intervals at which to perform them. Common Battery change #521 #531 #541
Total elapsed
tasks include CNC and encoder backup-battery time
replacement, air/oil filter replacement, way lube Change coolant #522 #532 #542 Coolant-on time
replenishment, hydraulic system oil replacement,
coolant replenishment∕replacement, and inspec- Inspect spindle
#523 #533 #543 Spindle-on time
bearing
tion and cleaning of key machine components.
It doesn’t make sense to perform certain PM Machine in-cycle
Inspect way system #524 #534 #544
time
tasks based on calendar dates since machines can
often sit idle for long periods of time. A more logi-
cal approach is to monitor certain PM issues on an
individual basis, based on specific criteria related Specifying intervals
to the machine function requiring maintenance. This program can be run once to specify intervals
With spindle bearing inspection, for instance, spin- for PM tasks based on machine builder recom-
dle run time should be the determining factor. mendations:
Many modern CNCs have comprehensive • O0032
PM programs built in, and there are many soft- • #521=8736.0 (replace CNC battery)
ware-based machine monitoring systems that can • #522=3000.0 (change coolant)
provide PM data. Some may allow you to specify • #523=6000.0 (inspect spindle bearings)
intervals for the various tasks and even alert you • #524=5000.0 (inspect way system)
when the interval has elapsed. However, with • M30
older FANUC or FANUC-compatible CNCs, or if you
want to take full control of a given PM issue, you Initializing
can do so using custom macro. Another program is needed to initialize the
This example utilizes the custom macro pre- system and to reset the monitoring variable for
sented in my May column. It makes an excellent PM tasks when they have been completed. After
way to monitor the passage of time, converting performing maintenance, the operator must scan
date and time into the number of hours since the to the appropriate sequence number for the task
beginning of 2019. Consider this command that to reset. N1: Battery replacement, N2: Coolant
calls the date/time converting custom macro: change, N3: Spindle bearing inspection, N4: Way
• G65 P9060 D#3011 T#3012 H531.0 system inspection.
The current time in hours since the beginning • %
of 2019 will be placed in permanent common vari- • O0033
able #531. • N1 (Reset battery time)
Here are the variables used to track the four PM • G65 P9060 D#3011 T#3012 H531.0
tasks for our example, based upon four different • #541=0
criteria. • M30

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CNC TECH TALK Processes and Programming
• N2 (Reset coolant change time) • O9002 (Coolant start M08)

• G65 P9060 D#3011 T#3012 H532.0 • G65 P9060 D#3011 T#3012 H142.0
• #542=0 • M08
• M30 • M99
• N3 (Reset spindle bearing time) • O9003(Coolant stop M09)

• G65 P9060 D#3011 T#3012 H533.0 • G65 P9060 D#3011 T#3012 H143.0
• #543=0 • #542=#542+[#143-#142]
• M30 • M09
• M99
• N4 (Reset way system time)
• G65 P9060 D#3011 T#3012 H534.0 • O9004 (Spindle start M03 or M04)
• #544=0 • G65 P9060 D#3011 T#3012 H144.0
• M30 • M03 (or M04)
• % • M99
Updating • O9005 (Spindle stop M05 or M19 or M06)

Machine functions require different updating • G65 P9060 D#3011 T#3012 H145.0
methods. • #544=#544+[#145-#144]
Battery change: We can update total elapse time • M19 (or M05 or M06)
every time a program is run by using a user-de- • M99
fined M code for the end of program word: M30.
Coolant change: We can update coolant-on time Monitoring and testing
in user-defined M codes that turn the coolant on Finally, there must be a way to alert maintenance
and off (M08∕M09). personnel when a PM task is required. You could
Spindle bearing inspection: We can update spin- place the detection sequence in machining pro-
dle-on time in user-defined M codes that turn the grams, but to keep from disrupting a production
spindle on and off (M03∕M04∕M05∕M19∕M06). run, it may be better to create a separate pro-
Way system inspection: We can update in-cycle gram. The operator or a maintenance person will
time in user-defined G or M codes that are exe- run the detection program when they want to
cuted only at the beginning and end of the pro- find out if PM tasks are required.
gram, like G20∕G21 and M30. • O100 (Detection program)
• IF[#541LE#521] GOTO 5
User-defined G- and M-code programs • #3000=101(REPLACE BATTERY)
These programs will run when the designated • N5 [IF#542LE#522] GOTO 10
G or M code is executed. A parameter specifies • #3000=102(REPLACE COOLANT)
which G or M code is related to each program. • N10 IF[#543LE#523] GOTO 15
With current FANUC CNCs, parameter 6071 spec- • #3000=103(INSPECT SPINDLE BEARINGS)
ifies the value of the M code that will execute • N15 IF[#544LE#524] GOTO 20
program O9001. If you set parameter 6071 to 30, • #3000=104(INSPECT WAY SYSTEM)
for instance, the CNC will run program O9001 • N20 #3000=105(NO MAINTENANCE REQUIRED)
whenever an M30 is executed. • M30
• O9001 (M30)
• G65 P9060 D#3011 T#3012 H141.0
• #541=#141-#531 (Current total elapsed time)
• #544=#544+[#141-#140]
• M30
• M99
• O9011 (G20 or G21 at program start)

• G65 P9060 D#3011 T#3012 H140.0
• G20 (or G21)
• M99 AUTHOR | Mike Lynch
Founder and President, CNC Concepts Inc.

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ADDITIVE INSIGHTS Understanding Industrial 3D Printing
AM for Hard Tooling

Another form of hybrid manufacturing.
TIMOTHY W. SIMPSON | COLUMNIST
Last month I discussed the concept of hybrid

manufacturing—combining additive manu-
facturing (AM) and subtractive machining
together within a single machine to make parts
more efficiently. This month, I want to touch on
another form of hybrid manufacturing that AM is
enabling, namely, making the tooling to make the
part (versus making the part itself).
Numerous companies have been using polymer
3D printing for years to make fixtures and jigs
to aid production and fabrication with conven-
tional manufacturing methods. Some have even
been using polymer 3D printed parts to make soft
tooling. However, with metal AM, companies can
now make hard tooling for injection molding, for
instance, and that can be game changing.
Why use AM for hard tooling? The answer is
Additive manufacturing processes alone cannot achieve
simple: It provides design freedom, which is the a smooth, finished surface like this. It also needs to be
same reason we’d use AM for making complex machined. Photo: Timothy Simpson
and intricate features and parts. The same goes
for hard tool-
THE EUROPEAN VIEW ing. The design
freedom can be exploit its interactions with melt temperature
German companies are buying used to create of the plastic being injected into the mold can
molds and dies from the U.S. where features that reduce defects and lead to improved properties
conformal cooling is common. Yet
would be too and enhance part performance. Who wouldn’t
new developments and applications
are evolving in Europe: gbm.media/ expensive or want a faster process and better parts?
am-molds. impossible Unfortunately, it’s not that easy. In October, I
to make via discussed the issues that you will encounter with
conventional surface roughness when using AM, and the same
means like machining. The bigger bang for the applies here. Horizontal and vertical faces will
buck, though, is printing conformal cooling have different surface finishes, and conformal
channels inside the mold to help manage thermal cooling channels will not be smooth either—they
cycles during production. may even be filled with support structures if you
One of the factors that limits the speed of an aren’t careful in how you design and orient them.
injection molding process is mold temperature. I would go so far as to say that none of today’s
The ability to dissipate heat quicker from a mold AM processes will give you anything close to the
can lead to reductions of 10, 20 and even 40% surface finish you need for hard tooling. Laser
in cycle time based on some of the studies that I powder-bed fusion (PBF) may get you close in
have read. More importantly, the ability to con- rare cases, but you have no chance with directed
trol the mold temperature more accurately and energy deposition (DED) right now, regardless of

ADDITIVE INSIGHTS Understanding Industrial 3D Printing
the thermal energy source. meet a machining expert who can tell me how
Luckily, this is where some of the hybrid man- to machine the curvy internal conformal cooling
ufacturing systems that I talked about last time channels that are possible with this technology.
excel. In fact, the hybrid PBF and subtractive If you have any ideas that you want to share, I’m
systems offered by Matsuura and Sodick create all ears.
finished molds in a single machine, and now DMG Meanwhile, if you specialize in making hard
MORI is getting into the game. tooling for companies, I encourage you to keep an
I had the pleasure of meeting with the team eye on this hybrid use of additive manufacturing.
from Matsuura in our lab a couple of years ago, The molds that you can make with this technol-
and the parts ogy are relatively small thus far, but that will
they showed me change. Companies are actively working on larger
Who wouldn’t back then were PBF systems, and as hybrid machines get better,
want a faster impressive. As people will soon start targeting large molds and
you can see in the dies with DED given the cost and lead time associ-
process and image, there is no ated with that tooling as well.
better parts? way you are going
to get a smooth,
finished surface
like that from PBF alone. You can only do that
with machining, and that’s exactly what their
hybrid manufacturing system does. It adds a few
layers to the part (in this case, the mold), then
machines and finishes surfaces, then adds a few AUTHOR | Timothy Simpson
more layers, machines and repeats until the mold Professor of Engineering Design & Manufacturing
is done. It’s a sight to behold, and I have yet to Pennsylvania State University
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THE VIEW FROM MY SHOP A Metalworking Leader’s Perspective
Decisions, Decisions
Reflecting on past decisions will help you learn to make better
ones in the future.
ANTHONY STAUB | CONTRIBUTOR
How do you make decisions? What guides you? Do and I like all of them. As I’m sitting in my chair
you have a set of principles or a trusted team that rocking away, I like to reflect on my career and
you lean on? Ethics, cost, past experience, future the decisions I’ve made. Not every decision ages
expectations and many more factors can be a part the way we think it will — some decisions are
of every decision. Time is important too. Do we decidedly poor, others improve over time and still
need to get a job done as quickly as possible, or do others simply depend on how you look at them.
we need to prioritize the long-term impact over Experience has shown me that a good decision is
short-term gain? We all have a decision-making one that I can look back on with warm thoughts
process, whether we recognize it or not. My deci- many years later.
sion-making process has changed over the years, For example, I bought an expensive piece of
and I’ve embraced a strategy that I’d like to share equipment a few years ago, spending $1 million
with you. Reflecting on my past decisions has dollars on a five-axis machining center. It came
helped me learn how to make better ones in the with a robot-loading pallet system and was
future. new technology for us. I spent a lot of company
In my case, I use a variety of criteria to make money (really my money), and then I spent many
decisions. The final measure is deciding how I will evenings reflecting on that purchase, especially
feel about this decision once I get to my rocking as it sat idle without a single job for months. It
chair. I’m a big proponent of the “Rocking Chair was two years before we landed our first substan-
Theory.” There are different versions of this theory, tial contract. It gave me plenty of opportunity to
second-guess myself, and this one was bothering
me. During those two years I asked myself, “What
were you thinking?” Fast forward to today, three
plus years later, and that machine is at capacity.
Now when I sit in my rocking chair, I’m convinced
I made a good decision (although I tell myself I
never wavered). It just took some diligence to see
it through.
Personnel decisions can be the most difficult
of all. There is no such thing as a short-term
personnel decision. I care about my employees.
When I project forward to when I’m sitting in my
rocking chair in retirement, I ask myself, “How
did I do?” Let’s take a real example: Dave came to
work for me in the ‘80s after his former employer
The rocking chair theory is

a helpful tool that relies on
time and distance when
evaluating decisions.

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with aspirations to do exactly that.
The PUMA SMX ST is a twin-spindle

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a dedicated milling spindle and
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Learn more at DOOSANMACHINETOOLS.COM

THE VIEW FROM MY SHOP A Metalworking Leader’s Perspective
folded. He was young and married with no kids. been much fatter. I could have owned a giant RV
Now, after two kids and three decades, Dave is and a 50-foot yacht. Wouldn’t it be great to rub
talking retirement. He has social security to look elbows with the millionaires? The fact is that I
forward to, but he also has the benefit of a prof- neither need nor desire those things. I’m content
it-sharing plan that we started in 1990. Over the to rock away knowing that I took care of those
years, we were able to put away a lot of money. employees — my friends. Dave’s profit-sharing
This money was shared by every employee in the plan is still intact, and he can look forward to his
plan. It encouraged employees to remain at Staub retirement years with the benefit of hundreds of
during the vesting period and after. The contribu- thousands of dollars.
tions were based on total yearly salary and every The rocking chair is where I like to go to reflect.
employee received the same percentage. The I judge myself. The question I ask is, “Am I proud
contribution percentage was arbitrary. I decided of the decision I made years earlier?” I’ve learned
the amount of contribution based on how I felt a new skill. When I make decisions now, I look
that year. It was never tied to profits even though ahead. I ask myself “How will I feel five years from
it was called a profit-sharing plan. I’m proud to say now with the decision I’m making today?” Is it
that I contributed an average of 15% per year over good for the company and the employees? Does it
a 25-year span. reflect my values?
Only now can I sit back in my rocking chair and
reflect on these decisions. I made the five-axis
decision to continue to lead in our industry, with
ABOUT THE CONTRIBUTOR
an eye toward the future of our company. We’re
now specing out another five-axis mill that will Staub Machine started with a single lathe in
help our company continue to grow and support Mr. Staub’s garage. Some 40 years later, the
Western New York shop has grown to two
our employees and their families. I spent millions
facilities that provide precision machining for
of dollars in profit sharing because I felt it was a range of manufacturers.
the right thing to do. My bank account could have More at staubinc.com.
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SHOP TALK Industry News
Harry Moser, president of the

Reshoring Initiative, presents the
2019 National Metalworking
Reshoring Award to Greg Owens,
CEO of Sherrill Manufacturing at the
MFG Meeting.
Sherrill Manufacturing Recognized for

Success in Reshoring
Sherrill Manufacturing (Sherrill, New York) has received the 2019 National
Metalworking Reshoring Award. The award, given by the Reshoring Initia-
tive, the Precision Metalforming Association (PMA), AMT – The Association
For Manufacturing Technology, and the National Tooling and Machining
Association (NTMA), honors companies for effectively reshoring products,
parts or tooling made primarily by metalforming, fabricating, casting or
machining (including additive manufacturing).
Sherrill Manufacturing was chosen as the award winner this year
because, according to the Reshoring Initiative, its success demonstrates
that it is feasible to reshore whole product categories, including everyday
products such as dining flatware. When Oneida Ltd. ceased operations a few
years ago, U.S. flatware production became offshored, primarily to Asia.
Sherrill Manufacturing took over the Oneida flatware factory, launched its
own products under the Liberty Tabletop brand and found a more efficient
way to market those products. Sherrill is now growing consistently.
“We are very pleased that after many years of hard work our efforts to
reestablish the flatware industry in the United States are finally paying off.
This is a big win for our employees, who stuck with us through thick and
thin,” says Greg Owens, CEO. “I was honored to accept this award for them,
the dedicated silversmiths at Sherrill, and in recognition of our customers,
who have supported the comeback of flatware manufacturing in the USA.”
The award was presented in Tucson, Arizona, at the MFG Meeting, orga-
nized by the AMT and NTMA. A letter of congratulations was also presented
from Ian Steff, U.S. Commerce Department deputy assistant secretary for
manufacturing.

A bso lute
Deep Hole &
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reliAbility
Single & Multi-Spindle Gun Drills
Up to 4 Spindles
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• Solutions cover nearly 200 applications
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• Hole sizes of up to 16” and hole depths
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Industry Applications:
• Micro Gun Drilling Machines (Medical, Aerospace, Automotive)
• Multi Axis Gun Drilling Machines (Die & Mold, Energy)
• Vertical and Horizontal Honing Machines (NEW!) (Automotive, Firearm, Aerospace, Energy)
• Skiving & Roller Burnishing Machines (Hydraulic Cylinders)
• Complete Gun Barrel Manufacturing Machines
BVN Series
BTA Deep Hole Drills

S i nc e 1 9 8 8
The 2020 National Metalworking Reshoring | AMT - The Association For Manufacturing Technology
Award will be presented next fall during IMTS 800-524-0475 | amtonline.org
2020. | National Tooling and Machining Association
“Reshoring 2010 through 2018 totaled over 800-248-6862 | ntma.org
450,000 jobs, about 4% of total U.S. manufactur- | Precision Metalforming Association | 216-901-8800
ing employment,” says Harry Moser, founder and pma.org
president of the Reshoring Initiative. “Sherrill’s | Reshoring Initiative | 847-867-1144
success demonstrates that large categories of reshorenow.com
work considered to have been ‘lost forever’ are
eligible to be reshored. Our goal is to reshore Siemens PLM Invites Users and Non-Users to
millions more jobs.” Realize Live 2019
Previously available only to Siemens PLM Soft-
ware customers, Realize
Live 2019 will be open
to the public June 10-13
at Detroit, Michigan’s
Cobo Center. The edu-
cational conference will
be divided into several
tracks called Connec-
tions, with seminars as
well as hands-on train-
ing and what the com-
pany is calling Knowl-
edge Theaters.
The tracks include
additive manufacturing,
business process, man-
ufacturing operations
management, Mind-
sphere, NX CAM and
Tecnomatix, Solid Edge,
and others.
In addition, the event
will feature a Top Shops
benchmarking presenta-
tion from Steven Kline
Jr., chief data officer for
Gardner Business Media
(publisher of Modern
Machine Shop). Mr.
Kline’s presentation will
highlight some of the
significant differences
in key performance
metrics as well as the
various technologies
and strategies used at
leading U.S. shops.
Realize Live will also
feature several peer-to-
peer events. A first-timers
program will host net-
working opportunities

for those new to attending the conference. A Walter AG Appoints New President
Women’s Luncheon will provide time for further Walter AG, parent company of the Walter USA
networking and presentations. Finally, the Dig- LLC, has appointed Richard Harris its new pres-
ital Enterprise Society (formerly PLM World) ident. He succeeds Mirko Merlo, who had been
will be organizing its mentorship program with president of Walter AG since 2012.
attendees. Mr. Harris has held various management posi-
Those interested in attending can visit tions with Sandvik, the parent company to Walter
siemens.com/plm/realize-live to register. AG, since 2002. Most recently, he led the Powder
| Siemens PLM Software | 262-312-2720 and Blanks Technology division within Sandvik
plm.automation.siemens.com Machining Solutions. While there, he advanced
the strategic and operative development of supply
management.
“Walter has an outstanding
reputation in the machining
industry,” he says. “The company
is a pioneer for technology in
many areas. The digitalization
strategy, started by Mirko Merlo,
puts the company in an ideal
position for the future. Together
with the Walter Team, I want to
further develop this successful
business strategy so that we can
continue to grow globally in a
demanding and ever-changing
market environment.”
| Walter USA LLC | 262-347-2400
walter-tools.com/us
Mikko Nyman Appointed

Fastems CEO
Fastems Oy AB has appointed
Mikko Nyman as its new CEO.
The former CEO, Tomas
Hedenborg, will continue as an
advisor to the board of directors
and support Mr. Nyman in his
new role until the end of the
2019.
Mr. Nyman has worked at Fas-
tems as a business unit vice pres-
ident since the beginning of 2017
and as deputy CEO since the fall
of 2018. Prior to those posts, he
was the company’s CFO for three
years. Before joining Fastems,
Mr. Nyman worked in financial
management within interna-
tional industries and IT.
“Fastems has experienced
strong growth since 2016 and
has expanded its operations
from machine automation for
the metalcutting industries to

SUMMER SALE
Savings up to 30% OFF!
JUNE 3RD - SEPTEMBER 1ST, 2019
21" X 80" TURN-NADO GEARHEAD LATHE WITH DRO

• Swing over bed: 20.98" • Tailstock barrel diameter: 3"
• Distance between centers: 80" • Inch threads: (38) 2 to 72 TPI SINCE
• Swing over cross slide: 14.01" • Metric threads: (40) 0.4 to 14 mm 1906
• Swing over gap: 31.10" • Modular pitches: (18) 0.3 to 3.5 MP
• Cross slide travel: 10.7" • Diametral pitches: (21) 8 to 44 DP
• Compound travel: 5.39" • Longitudinal feed range: 0.0015" to 0.04"
• Spindle bore: 3.149" • Cross feed range: 0.00075" to 0.02
• Spindle taper: MT #7 • Spindle motor: 15 HP, TEFC induction
• Spindle speeds: (16), 20-1600 RPM • Voltage/Amps: 440V, 3-Phase
• Tailstock taper: MT #5 • Coolant motor: 1/8 HP, TEFC induction
• Tailstock travel: 6.5" • Approximate shipping weight: 5952 lbs.
$
3,400
SB1047F $24,500 shipping
lower 48 states
14" X 40" GUNSMITHING 9" X 48" HIGH PRECISION VARIABLE-

GEARHEAD LATHE SPEED VERTICAL MILL
• Motor: 2 HP, 220V, single-phase, 10 Amps, • Motor: 3 HP, 220V, 3-phase, 8.5 Amps
60 Hz, 1725 RPM • Motor RPM: 1725 • Power transfer: Cogged belt
• Swing over bed: 14" • Spindle taper: R-8 • Spindle travel: 5"
• Swing over gap: 193⁄4" • Table size: 9" x 48" • Table travel (longitudinal): 29"
• Swing over cross slide: 813⁄16" • Table travel (cross): 12" • Knee travel (vertical): 16"
• Distance between centers: 40" • Tram travel: 13" • Ram swivel: 360°
• Spindle bore: 1.57" (40mm) • Max. dist. spindle to table: 18"
• Spindle nose: D1-5 camlock • Head swivel: 90° left & right
• Spindle nose taper: MT#5 • T-slots: 3 on 21⁄2" centers, 5⁄8" wide • Spindle speeds:
• Cross slide travel: 611⁄16" Variable • Range of speeds: 60–5000 RPM
• Width of bed: 73⁄8" • Table size: 10" x 50" x 41⁄8" • Base footprint: 26" x 24"
• Approx. shipping weight: 1550 lbs. • Approximate shipping weight: 2352 lbs.
299
$ $
395
G0709 $579500 SALE $499500 shipping
lower 48 states
G0667X $995000 SALE $875000 shipping
lower 48 states
12" x 14" AUTO METAL-CUTTING 16" x 40" 3-PHASE GEARHEAD

BANDSAW GUNSMITH’S LATHE
• Number of spindle speeds: 16
• Motor: 4 HP/3 HP, 220V, • Speed range: 45–1800 RPM
• Motor: 3HP, 3-phase, 220V, 60Hz 3-phase, 2-speed
• Blade speeds: 92, 161, • Bed width: 10"
• Swing over bed: 16" • Approximate shipping weight:
236, 338 FPM • Swing over gap: 22"
• Saw blade (in): 3300 lbs.
• Swing over cross slide: 10"
13⁄8"W x .043"T x 155.5"L • Dist. between centers: 40"
• Cutting capacities: 90° round • Spindle nose: D1-6 camlock
1113⁄16", 90° rectangular 1113⁄16" x 14" • Spindle nose taper: MT#6
• Floor-to-table height: 27" • Spindle bore: 2.0625"
• Machine dimensions: • Tailstock barrel taper: MT#4
83"L x 43"W x 55"H • Tailstock barrel travel: 4¾"
• Base footprint: 56" x 28"
• Weight: 1800 lbs.
MADE IN
• Cross slide travel: 8½"
• Compound travel: 5½"
$
525shipping
$
295 AN ISO 9001 lower 48 states
FACTORY
G0886 ONLY $
975000
shipping
lower 48 states
G0509G 9995 SALE 899500
$ 00 $
14" X 40" 3-PHASE HIGH PRECISION 18" X 60" LATHE 440V

TOOLROOM METAL LATHE • Spindle motor: 10 HP, 3-phase, 440V • Approximate shipping
• Main motor: 10 HP, 220V, 3-phase • Approximate shipping • Coolant motor: 1/8 HP weight: 5424 lbs. SINCE
• Swing over bed: 14.17" weight: 2684 lbs. • Swing over bed: 18.11" 1906
• Swing over cross slide: 8.66" • Swing over gap: 27.95"
• Distance between centers: 40" • Distance between centers: 60"
• Swing over gap: 20.94" • Spindle bore: 3.125"
• Swing over saddle: 12" • Spindle nose: D1-8 camlock
• Spindle bore: 1.57" (40mm) • Spindle taper: MT #7
$
• Spindle nose taper: MT#5 • Cross slide travel: 11" 3,000
shipping
• Spindle nose: D1-5 camlock • Compound travel: 5.39" lower 48 states
• Cross slide travel: 7" • Carriage travel: 79"

• Spindle speeds: 116, 50–2570 RPM • Inch threads: (38) 2 to 72 TPI
• Bed width: 13 3⁄4" • Spindle speeds:Variable from 18 to
• Range of threads (metric): 39 @ 0.2–14mm 1800 RPM
$
375
G0740 $12,99500 SALE $10,397 shipping
lower 48 states
SB1036 $42,395 SALE $
24,995
Due to rapidly changing market conditions and tariffs, our advertised prices may be increased at any time without prior notice.
19MMS
TECHNICAL SERVICE: 570-546-9663 • FAX: 800-438-5901
2 GREAT SHOWROOMS!
20416 BELLINGHAM, WA • SPRINGFIELD, MO
intelligent factory automation software design,” these areas, he says. “The core of our competitive
says Kai Öistämö, chairman of the board. “In edge is in intelligent factory automation systems
recent years, Tomas and Mikko have worked that enable better optimization and scheduling
closely to lead Fastems and — together with the of manufacturing.”
staff — have set the company on a strong growth | Fastems LLC | 513-779-4614 | fastems.com
track.”
According to Mr. Nyman, the application of Tooling Tech Group Appoints New CEO
digitalization in the manufacturing industry is Tooling Tech Group (TTG), a provider of tools
still in its early stages. The future of industrial and assembly equipment, has announced that
manufacturing will be about small production Lee Childers, former TTG COO, has been named
batches and flexible automation that aims to company CEO. He will lead TTG’s operations
increase efficiency. Fastems is already strong in providing design, tooling solutions and automa-
tion equipment to the
company’s Tier 1 and
OEM customers and will
report directly to the
MARPOSS 4.0 board of directors.

Mr. Childers joined
THE SMART FACTORY TOGETHER TTG as COO in early
2018, bringing 33 years
of experience in devel-
SELF oping business plans,
ADJUSTING
PROCESS growth strategies and
OPTIMIZATION leading operations for
Tier 1 suppliers includ-
ing United Technologies,
Lear Corp., IAC Group
and Crowne Group.
BIG DATA
UNIVERSAL ANALYSIS Anthony C. Seger,
CONNECTIVITY founder and former CEO
of TTG, will be moving
into a board role to
continue advising and
supporting the manage-
ment team.
“With a lot of very
hard work, we have built
the largest tooling com-
pany in North America,
and I’m very proud of
all that we have accom-
plished,” says Mr. Seger.
“My decision to step
TOOL & into a new role has been
PROCESS MONITORING hard, but I feel greatly
Genior Modular can monitor real time and track
encouraged about the
quality from rough to finish part providing and future of Tooling Tech
using various sensors and acontrol information. Group and its leadership
This solution allows machines and components
to communicate and optimizes the manufacturing under Lee.”
process. | Tooling Technology Group
Marposs is the partner you need to make Industry
4.0 a working reality. 937-295-3672
toolingtechonline.com

Mazak to Open Technical Center Serving Mazak’s new Technical Center in the San Fran-
Florida Manufacturers cisco Bay/Silicon Valley area. Both the Florida
Mazak is opening a new Florida Technical Center and San Francisco facilities join Mazak’s network
centrally located in the Orlando area to serve of Technology Centers and Technical Centers
manufacturers throughout the state, including dedicated to localized training and education of
Florida’s so-called “space coast” of Tampa and customers on the continually changing manufac-
Jacksonville. The new facility will provide local turing technologies available to them.
and immediate access to machine technology “Our Technology Centers and Technical Cen-
demonstrations along with sales, service, appli- ters are designed with customer success in mind
cation and training support. and are built around the various manufacturing
With an expected third-quarter 2019 open- needs of each region,” says Dave Kennedy, gen-
ing date, this announcement comes soon after eral manager of Mazak’s Southeast Technology
Center located in nearby
Suwanee, Georgia. “Cus-
tomers not only want
innovative machine
technology but also a
partner that is close
by that will work with
them and provide the
means to help overcome
all their manufacturing
challenges whether tech-
Aviation & Aerospace • Automotive • Communications • Electronics • Hydraulics nology-, application- or
training-related.”
Current EDM machines now available | Mazak Corp.

800-231-1456
with Siemens MindSphere mazakusa.com
• Enables machine tool users to gather, prioritize and access data Acu-Rite Moves
in real-time using Edge technology and advanced analytics Production to
• Offers a variety of customizable software Heidenhain’s Chicago
platform and application options for the Headquarters
control and maintenance of machine tool Acu-Rite’s manufac-
and shop-floor operations turing facilities have
successfully moved from
• Application options include machine tool their long-time base in
predictive maintenance services, energy Jamestown, New York,
data management, resource optimization to larger facilities at the
development, and more North American head-
quarters of parent-
company Heidenhain in
Schaumburg, Illinois.
This centralized location
speeds the company’s
access to the industrial
Model FT300
manufacturing resources
in the Chicago area.
Current EDM, Inc. Technical Center “The production of
2577 Leghorn Street 9201 Penn Avenue South, Suite 40
Mountain View, CA 94043 Bloomington, MN 55431 the Acu-Rite products
Phone (650) 966-9676 Phone (763) 476-2290 is now going strong in
Illinois. At the same
WWW.CURRENTEDM.COM • email: INFO@CURRENTEDM.COM time, we continue to
invest in the Acu-Rite

UNITED. EXPERIENCED. METAL CUTTING.
The new Team Cutting Tools from the CERATIZIT Group.
The CERATIZIT Group is represented in the market by a number of competence brands:

Cutting Solutions By CERATIZIT, KOMET, WNT and KLENK. Four experts make a
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customer groups and cover a range of product categories. This means we can ensure
that our customers have access to the most comprehensive products and knowledge
in all areas of the metal cutting industry. Team Cutting Tools is a one stop shop.
CERATIZIT is a high-tech engineering group

specialized in tooling and hard material technologies.
Tooling the Future

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CERATIZIT USA, Inc. \ (877) 4-CERA-US \ (877) 423-7287

R&D department that remains in Jamestown, New place in Schaumburg to provide Acu-Rite techni-
York,” says John Parker, Heidenhain’s machine cal support as well as field service.
tool business development manager. Mr. Parker says, “With these changes and
Products currently on the Illinois manufactur- investments, we expect the brand to become even
ing lines include all the digital readouts (models stronger, and look forward to sharing that with
DRO10X, DRO203 and DRO30X) and DRO acces- all our distribution.”
sories such as IB2X and IOB610; all the encoder | Heidenhain Corp. | 800-233-0388
bracket kits such as those for SENC 150, SENC heidenhain.us
50; and the Millpwr G2 control and associated
components. Service and support of these Acu- Omax Promotes General Manager and
Rite products have also been a focus during this VP of Sales
operations transition. Dedicated staff are now in Omax Corp. has made two changes to its manage-
ment team. Previously
vice president of North
American sales, Mike
AutoFlex
Ruppenthal has been
promoted to general
manager. Steve Ulmer,
previously vice president
Auto Focus Inspection System of international sales,
has been promoted to
vice president of sales.
For the past seven
years, Mr. Ruppenthal
has been responsible for
developing sales strat-
stem
let e Sy egy across the United
omp . 30
154
C States and Canada. Prior
$ 2 , to coming to Omax, he
worked at Flow Inter-
national for 11 years in
both sales and market-
ing. In his new position
as general manager, he
will oversee Omax’s day-
to-day operations.
Mr. Ulmer has been
the VP of international
18” FlexArm sales for over 10 years.
• Achieve instant auto focus Before that, he worked
• 18” flexible arm: limitless positioning options five years in a variety of
• 360° ball joint: tilt and rotate the camera territories selling Omax
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• 3x-80x magnification at a 6” working distance regional sales manager.
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Advancing
AVEN
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aveninc.com | 734-973-0099 | sales@aveninc.com

From every perspective, the Kitamura SUPERCELL-300G
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[ SHOP FLOOR PRODUCTIVITY ]
MAKES [ ]
EASY. JOHN THERRIEN
CNC Mill Supervisor
JIM HAYSSEN
Owner Bradford
Machine Company
DAVID SQUIRES
Watch and Learn! CNC Milling Machinist
EVENTS | CONFERENCES | MEETINGS
WEBINARS
Find current listings and
archived webinars at
mmsonline.com/webinars
JUNE 12-13 AUGUST 27-29

JUNE 4, 2 P.M. EST Rosemont, Illinois Austin, TX
Data-Driven Machining: How to Optimize amerimoldexpo.com additiveconference.com
Your Machining Process With Minimum
Interruption to Production This annual tradeshow This conference and
TechSolve | gbm.media/datamac addresses the business expo focuses on
development, best industrial applications of
FROM THE ARCHIVE practices and networking additive technologies for
Technology Integration and its Profound interests of the plastic making functional
Impact for Manufacturers injection mold manufac- components and
Okuma | gbm.media/tecint turing industry. Amerimold end-use production
is owned and operated by parts. The dynamic
Gardner Business Media conference program will
and is presented by cover processes,
MoldMaking Technology, applications and
Plastics Technology and materials that deliver
Modern Machine Shop practical knowledge on
magazines. how to implement AM in
your facility.
EVENTS | CONFERENCES | MEETINGS
JUNE 5-6 JUNE 13 SEPTEMBER 11-12

Upper Midwest Design-2- Additive Manufacturing D19 Distribution Group
Part Show Workshop for Plastics at Conference
Minneapolis, Minnesota Amerimold 2019 Detroit, Michigan
d2p.com Rosemont, Illinois amtonline.com
additiveconference.com/plastics
JUNE 5-6 SEPTEMBER 16-21
Robotics Summit 2019 JUNE 18-20 EMO Hannover
Boston, Massachusetts MT360 Hannover, Germany
roboticssummit.com Santa Clara, California emo-hannover.de
mt360conference.com
JUNE 10-13 SEPTEMBER 23-26
Realize Live Detroit 2019 JUNE 27-28 CAMX
Detroit, Michigan Solutions Days With Anaheim, California
siemens.com/plm/realize-live GF Machining Solutions thecamx.org
Lincolnshire, Illinois
JUNE 11-13 gfms.com SEPTEMBER 24-26
Grand Opening of Mazak San WESTEC
Francisco Technical Center SEPTEMBER 9-12 Long Beach, California
Fremont, California Top Shops Conference westeconline.com
mazakusa.com Cincinnati, Ohio
topshopsevent.com
MOLDING INDUSTRY
Pulsed Laser Welding

Speeds Mold Repair
Compared to TIG welding, pulsed laser
welding technology is said to enable
faster overall mold repair time while
maintaining higher metal hardness.
DEREK KORN | EXECUTIVE EDITOR
Tungsten inert gas (TIG) welding has been the Using pulsed laser welding, repairs to injection molds can
traditional method for building-up worn or dam- be completed with the mold still installed in the press.
This saves time compared to TIG welding, which requires
aged mold and die surfaces prior to subsequent
the mold to be removed from the press, heated, welded
hand finishing or CNC machining to complete a and then hand-finished before being re-installed.
repair. However, pulsed laser welding technology,
which has been popular in Germany for decades,
is gaining acceptance here in the United States as
an option for mold repair (as well as other weld- 1. Shorter overall repair time.
ing applications). Prior to TIG welding a large mold component,
These welders fire a laser beam in 5- to 10- it must be heated slowly. After welding, cooling
millisecond pulses that melts the base workpiece must be gradual, too. This is necessary to prevent
metal and filler wire that is deposited and then the base metal from cracking. However, heating
re-solidifies the weld pool before the next pulse. and cooling can take hours, delaying the manual
It offers high peak power, but low heat input into bending or CNC machining work needed to
the base metal compared to continuous TIG and complete the repair. This controlled workpiece
other welding operations. In fact, most work- heating and cooling is not necessary with pulsed
pieces are said to be cool to the touch immedi- laser-welding equipment due to the low heat
ately after welding. input. In addition, it is not necessary to cut the
Blair Learn is president of Alpha Laser-US, the electrical power to a press when a mold remains
North American distributor for Germany-based installed during welding (as is common for very
Alpha Laser, which manufactures Nd:YAG and large molds). That is because pulsed laser weld-
fiber laser-welding, cladding and hardening ers do not require a ground wire to be attached
equipment. Mr. Learn says that while the pulsed to the mold as is necessary for TIG welding. The
laser-welding operation itself currently is not as laser welding process also provides the accuracy
fast as TIG welding, pulsed laser welding offers to weld small details and areas without acciden-
the following three advantages: tally hitting adjacent features or surfaces. Laser

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MOLDING INDUSTRY
welding can be done with welding wire as thin as 3. More repeatable results.
0.003 inch in diameter, which decreases machin- There is more art to manual TIG welding than
ing time afterward. pulsed laser welding. Depending on a TIG weld-
er’s skill level, the bead path can include peaks
2. Minimal workpiece hardness reduction. and valleys. Conversely, pulsed laser welding
Compared to pulsed laser welding, TIG welding enables users to start and stop the operation at
creates a deeper heat-affected zone (HAZ). The precise positions while depositing a more con-
HAZ is the portion between the melted metal sistent bead height. Pulsed laser welders such as
and unaffected base metal under it that under- Alpha Laser’s mobile Alflak and ALM units, which
goes adverse metallurgical changes, growing the are commonly used for mold repair, feature
grain structure and softening the metal. For TIG microscopes with crosshairs to enable operators
welding, the HAZ can be as deep as 0.15 inch, to precisely position the laser beam. In addition,
while the typical range for pulsed laser welding only four parameters must be adjusted for each
is 0.008 to 0.012 inch. The larger HAZ for TIG job—voltage, frequency, pulse time and spot size
welding means a greater reduction in hardness (laser beam diameter).
of the metal in that zone. For TIG welding, the These units can be operated manually, in
material in the HAZ is softened by 15 to 22 HRc semi-automatic mode or in full CNC mode,
points, compared to 2 to 4 points using pulsed although full CNC mode typically is used for
laser welding. This damage, when done to a production work, not mold repair. In semi-auto-
molding component, can decrease wear life. matic mode, operators can lock any or all axes
As a result, a subsequent heat-treating opera- during laser operation to rotate at a set speed,
tion might be required for a mold block that is weld in a straight line, or follow a complex
repaired via TIG welding. angle. Pulsed laser welders can also weld a spot
Pulsed laser welding also can be used to repair milling errors with the workpiece
still installed in the machine tool. Here, an Alflak 300 has been hoisted onto the bed
of a machine using a crane.

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Pulsed laser welders such as this ALM 300 can weld a spot as small as 0.004 inch compared
to 0.04 inch for a micro TIG unit, increasing weld location accuracy.
as small as 0.004 inch, compared to 0.04 inch floor rails used to move large molds, tooling
for a micro TIG unit. or parts. These are the company’s largest laser
Mr. Learn says new advances are making models, offering arm extension of almost 5 feet.
pulsed laser welders more capable. One is higher The laser head can rotate to face straight up or
power. In 2010, the highest power available for down to access various workpiece features, too.
an Nd:YAG pulsed laser welder was 200 watts Mr. Learn started Alpha Laser-US two years
(Nd:YAG lasers are more commonly used for ago, but has been owner of Phoenix Laser Solu-
mold repair than fiber lasers.) Since then, Alpha tions since 2008. This welding service company
Laser and other manufacturers have developed has four U.S. locations with a total of 20 pulsed
300-watt models. The company also offers 500- laser welders. In fact, its Meadville, Pennsylva-
watt models, which have twice the welding speed nia, location has a metallurgical lab that per-
of 300-watt models and can use larger-diameter forms weld testing and studies the effect of the
filler wire to further increase metal deposition HAZ in metals and explores different welding
rates. The maximum wire diameter for a 300-watt applications. He says this experience is helpful
model typically is 0.025 inch, while a 500-watt for providing training and assistance for custom-
model can use a wire as large as 0.0625 inch. ers’ specific welding needs.
Another advance is improved mobility.
Self-propelled Alflak models are available with
continuous, tank-like caterpillar tracks. Mr. Learn
says this enables the welding unit to easily drive | Alpha Laser-US | 814-336-9000
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MACHINE MONITORING
Using AI to Predict Spindle Issues

Before They Are Issues
A machine tool builder is using artificial intelligence technology
to predict when a spindle problem might occur, so shops can
better prepare for and schedule necessary maintenance.
An AI-based health system has

been developed to eliminate
unexpected downtime due to
damaged spindles or bearings.
It does this by predicting spindle
life so shops can better plan for
repair/replacement downtime.
Artificial intelligence (AI)

is poised to make industrial
equipment predictive maintenance
truly predictive.
One example I wrote about last
year is Cosen Saws’ cloud-based
predictive maintenance app that
not only monitors blade life for
the company’s CNC saws, but
also predicts blade failure well
before failure is immenent. A sim-
ilar example is Mazak’s AI-based
Spindle Health Monitoring System
(SHMS) that is currently an option
for its HCN horizontal machining
centers (HMCs).

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MACHINE MONITORING
Both systems were developed in conjunction Sanders, process development coordinator for
with the University of Cincinnati’s Industrial Mazak, says the key difference between the
AI Center (formerly the Center for Intelligent company’s AI-based system and other spindle
Maintenance Systems). Dr. Jay Lee, founder monitoring technology is that the SHMS is not
and director, researches prognostics and health based on threshold data. For example, an alert is
management with an eye toward ensuring not sent if a specific spindle vibration frequency
zero-break- suggests that damage is about to occur or has
down already. Instead, he says the SHMS can detect
START WITH SMART SAWING perfor- issues months before they happen, providing
This cloud-based predictive mainte- mance for time to schedule spindle repair or replacement
nance app monitors blade life and pre- industrial at the most convenient time.
dicts blade failure: gbm.media ∕cosen. equipment. Data crunched from one year of extensive
Today, the spindle destructive tests led to the creation of
Industrial the SHMS’s AI spindle neural network self-orga-
AI Center is a National Science Foundation nizing maps, spindle-specific signatures that can
industry/university collaborative that consists determine the difference between good vibra-
of the University of Cincinnati, the University of tions and bad ones. Algorithms created from
Michigan and the Missouri University of Science these maps predict how spindles will degrade
and Technology. Since 2001, the center has con- over time (barring a crash) while displaying
ducted more than 100 projects in partnership remaining lifespan as a percentage. “This dif-
with more than 100 international organizations, fers from estimating a timeline of a spindle’s
including Toyota, Boeing, Bosch, Caterpillar, life, because we don’t know if a machine will be
GE Aviation, Goodyear, Harley-Davidson and used for light-duty work, heaving cutting, 24 ∕ 7
Siemens. Its goal is to eliminate the risk of unex- operation or any other possible scenarios,” Mr.
pected industrial equipment breakdowns. Sanders explains.
Mazak’s SHMS was created to enable shops to The SHMS’s primary components include
take spindle maintenance measures long before vibration and current sensors, a data acquisition
spindle or spindle bearing damage occurs, mini- module, and an industrial computer to process
mizing downtime and enabling any maintenance the SHMS algorithm. Upon installation, a one-
tasks to be more conveniently scheduled. Joe hour modeling test maps that particular spindle’s
Users can call up 60-second SHMS tests to establish what percentage of life is in a
given machine’s spindle. (Mazak says this graphical user interface is being refined.)

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MACHINE MONITORING
Rather than estimating a timeline for remaining spindle life, the SHMS shows a spindle’s lifespan as a
percentage to account for the various ways a machine might be used (hogging work, light cutting, etc.).
operating signature. After that, users can perform and eliminate the need for 60-second tests. This
periodic 60-second tests that compare data to the active system also will be able to detect tool wear
spindle model. When cycle times are sufficiently and automatically reduce cutting parameters to
long, Mr. Sanders suggests performing a test after prevent breakage, Mr. Sanders says.
each part is completed. However, this likely is Displayed at the International Manufacturing
not necessary for parts with relatively short cycle Technology Show (IMTS) last September, SHMS
times, he notes. will be officially introduced at the compa-
The SHMS is available as an option on Mazak ny’s Discover event in October at its Florence,
HCN machines equipped with the the company’s Kentucky, headquarters.
Smooth CNC and as a retrofit for those machines
with Matrix CNCs. (The system’s graphical user
interface is currently being refined.)
The company soon plans to offer ballscrew
predictive monitoring as part of the SHMS
option, too. In fact, the Industrial AI Center has | Cosen Saws International | 877-729-4641
been gathering data to develop predictive wear cosensaws.com
algorithms for ballscrews for some time. The
next goal is to create an active SHMS technology | Mazak Corp. | 800-231-1456
that will continuously monitor spindle health mazakusa.com

mcmachinery.com
It’s not where you are, it’s where you’re going.
CUTTING TOOLS
7 Tips for Programming

Ceramic Cutting Tools
Ceramic tools require different thinking and a
willingness to tweak tool paths developed with
carbide in mind.
MATT DANFORD | SENIOR EDITOR
For some shops, the flexibility of inserted car- work,’” he says. “Most of the time it was because
bide cutting tools might be too much of a good they were making mistakes.”
thing. “Carbide is safe and easy to use,” says Ceramic tools require more care than their car-
Steven Howard, engineering and marketing bide cousins, Mr. Howard explains. They operate
manager for NTK Cutting Tools. The problem according to fundamentally different principles.
is that better-performing options can be easily And yet, CAM programs written by newcomers to
overlooked — or worse, dismissed for the wrong these tools often reveal no difference in approach
reasons. “I’ve heard so many people say, ‘We to plotting tool motion or selecting parameters
tried ceramic cutting tools, but they didn’t such as feeds, speeds and cutting depths. In these
cases, results tend to be
underwhelming.
Meanwhile, he says
applications for ceramic
insert cutters are expand-
ing. Once relegated
mostly to aerospace parts,
heat-resistant alloys
incorporating metals like
nickel, cobalt and tita-
nium are now increasingly
common in automotive
and energy industry appli-
cations. Such materials
are ideal for ceramic. In
one recent case, switching
away from carbide on an
oil-field pipe inlaid with
Inconel 718 reduced an
Ceramic insert cutters like the one

in this application run 8 to 10 times
faster than carbide.

Programming Ceramics
Fire spitting from the cutting zone does not

intimidate machinists used to working with
ceramic tools. Heat is not the enemy — in fact,
these cutters require it.
Running 8 to 10 times as fast as a

carbide tool may be frightening—par-
ticularly when the cutting zone spits
red- or even white-hot chips — but
maintaining speed is critical. Fail to
maintain adequate surface feet per
minute (sfm), or cautiously ramp up to
speed, and the cut becomes mechani-
cal. Cutting speed and tool life suffer.
2. Maintain Contact
Interrupted cuts are bad for ceramics
because disengaging from the work-
piece allows the tool to cool. When
NTK customer’s cycle time from an hour and a half interruptions can’t be avoided, programmers
to less than four minutes. Ceramic is also useful for should power through rather than approaching
materials like hardened steel and cast iron. with caution, as they likely would with carbide.
In short, there is good reason for many manu- In fact, programmers should strive to maintain
facturers to consider (or to reconsider) ceramic tool contact with the workpiece for as much of
cutting tools. However, if programmers continue the operation as possible, particularly when
to “think in carbide,” and to insist on blindly milling.
applying the same strategies they always have,
ceramic tools are not likely to perform at their full 3. Feed Fast
potential. Based on a recent conversation with High spindle speed is an obvious requirement to
Mr. Howard, here are seven tips for those consid- ensure sufficient sfm. Aggressive feed rates are
ering a trial or re-evaluation of ceramic tools: also desirable, although for a different, possibly
counterintuitive reason: preventing tool wear.
1. Prioritize Surface Speed “The fewer rotations an insert completes, the
“When you’re having problems, it’s human nature longer it’s going to last. You don’t want to back
to slow down,” Mr. Howard says. “Like when off to try and protect it,” Mr. Howard says. If
you’re driving on a bad road — we all do it. But the feed rate must be reduced for other reasons,
that’s a big mistake with ceramic tools.” such as a sharp corner, programmers should
These cutters crave surface speed. More specif- strive to keep spindle speed (and thus, sfm) as
ically, they crave heat. As opposed to the shearing high as possible.
action of carbide, ceramic melts the workpiece
material ahead of it. Rather than generating 4. Take Care in Corners
chips that carry heat away, the goal is to generate Ceramic’s hardness and resulting heat toler-
intense pressure at the cutting zone, where tem- ance comes with a price: brittleness. Even with
peratures can exceed 1,200ºF. a robust insert, a general rule is to reduce feed
Lacking a binder material like the cobalt in rates by half in corners. This strategy can protect
carbide inserts, ceramic inserts are designed against extra pressure when a larger portion of
specifically to withstand this heat-generating the insert engages the material.
pressure. Inserts are generally thick, and chip Sharper corners and diamond-shaped insert
breakers are mostly nonexistent. Large, rounded points require special care. Whereas a tool
corner radii are the preferred choice if the appli- path developed for carbide might simply drive
cation allows it. “We’re generally trying to drive the insert around a 90-degree turned corner,
the forces into the middle of the insert,” Mr. engaging a ceramic cutter to this extent is
Howard says. likely to break it, Mr. Howard says. Rather, the
Modern Machine Shop 73

CUTTING TOOLS
Ceramic inserts cut faster than carbide, but they require extra care, particularly in finishing operations that
do not lend themselves to stronger, more rounded shapes like the roughing and semi-finishing inserts on the
left. The selection of inserts on the right includes 55-degree and 90-degree geometries for finer cutting.
preferred approach (illustrated in the diagram round insert, the less your depth of cut, the more
on the next page) is to first cut along one wall, benefits you get from chip thinning,” Mr. Howard
pull away, then engage the other wall and feed explains. “When you exceed a certain depth of
in the opposite direction (in this case, remov- cut, the front of the insert is no longer thinning.
ing the tool from the material and allowing It is taking the full brunt of the full feed.”
it to cool slightly is preferable to subjecting
it to forces that may break it). The cut should 7. Vary Cutting Depths
remain below the 45-degree mark on the cutter Recommendations for other insert shapes differ.
radius to minimize notching and facilitate feed- For instance, a deeper cut may be advised for
ing in two directions. rough turning with a triangle or diamond insert.
Whatever the specifics of the application, pro-
5. Round Sharp Edges grammers should make sure to vary the cutting
Even when corners and other geometry dictate depth with each pass. The resulting change in
a thinner, more brittle insert, NTK often recom- the location of wear on the insert reduces the
mends a slight T-land or honed edge. Particularly chance of notching and premature tool failure.
with heat-resistant alloys, such features can Ramping cuts in the same direction provide the
reduce notching, flaking and built-up edge. same effect.
This advice goes for more than just inserts.
Programmers should also take care to round off The Work is Worthwhile
areas where the cutter will enter or exit the work- The list above is by no means comprehensive.
piece before machining begins. Otherwise, the However, it illustrates the extent to which pro-
insert might chip or break. grammers comfortable with carbide need to think
differently about how they use ceramic tools. And
6. Turn Shallow thinking differently is likely to lead programmers
Given the prevalence of large, rounded nose radii, to rely less on automated CAM software functions
machinists might be tempted to cut too deep with developed with carbide tools in mind.
this relatively brittle material. “They’ll break the Not all examples are as simple as adding a
insert and then say, ‘ceramic doesn’t work,’ but chamfer or ensuring the correct approach to
they’ve actually overtaxed it,” Mr. Howard says. a corner. Consider a part that requires milling
Such scenarios are particularly common in tower-like structures from the bottom of a cavity.
turning operations. A round insert can leverage With a modern CAM system, programming a rou-
chip thinning, a phenomenon that reduces cut- tine to mill out the cavity around these structures
ting pressure and is more common to milling with is a simple matter. However, the resulting tool
triangle- or diamond-shaped inserts. “With a path is likely to work better with a carbide tool

Programming Ceramics
FEED FEED
Varying the cutting depth (LEFT) and ramping (RIGHT) are effective strategies for reducing
the risk of notching by spreading wear across more of the insert surface.
With ceramic tools, corners

might require more of a
programmer’s attention than
carbide. In a case like this, NTK
recommends roughing away as
DEPTH OF CUT much material as possible, then
engaging no deeper than the the
45-degree mark of the finishing
insert’s corner radius. This
approach minimizes notching
and enables cutting in both
directions with the same insert.
than a ceramic one. “It would probably start carv- milled structures just like those in the previous
ing away material in passes like a snow shovel, example. “We went in and tweaked their pro-
but ceramic wants to act more like a snowblower gram, and ceramics went from being uneconom-
— you never want a snowblower to not have snow ical to doubling the amount of parts they could
in it,” Mr. Howard explains, referencing the need make,” Mr. Howard says. “After that, their cus-
to maintain heat by keeping the cutter engaged. tomer sent them twice as much work.”
In an application like this, he says, “You might
have to go through and plan every cutter path.”
Nonetheless, any extra thought and care can
be well worth it. As an example, he cites an aero-
space manufacturer that had become frustrated | NTK Cutting Tools | 866-900-9800
by the lack of improvement in work involving ntkcuttingtools.com

TRADE SHOW REPORT
A VIRTUAL VISIT TO
TIMTOS
It is possible you will never get the chance to visit the
Taipei International Machine Tool Show, let alone Taiwan.
This story and a series of tweets with video give you a
flavor for what I encountered at the show in March.

Highlights from TIMTOS 2019
Before leaving for a Taiwanese machine tool trade

show a few months ago, I forced my own @MMS_
Derek Twitter hand(le).
Knowing many of my Twitter followers might
never attend the Taipei International Machine Tool
Show (TIMTOS) — or visit Taiwan for that matter
— I tweeted prior to my trip that I would capture
some of my experiences (silly or otherwise) from
the time I left my house to when I returned home
one week later. My goal was to offer a taste of
what it is like to travel halfway around the world
seeking insight into the latest machining and
Come along with me on a visit to the Taipei
manufacturing technology. You can find all those
International Machine Tool Show in Taiwan.
tweets at gbm.media/timtos19.
In fact, this exercise in social media helped
shape this article. Here, I present five interesting year’s event to accommodate more than 7,000
booth demonstrations that I thought would draw booths, making TIMTOS the world’s third-largest
your attention had you been walking TIMTOS manufacturing trade show. So, the following five
with me, although there was plenty more to see. demonstrations (video of each included in the link
The addition of a fourth show hall enabled this above) offer just a taste of what I saw there.
FOLLOW ALONG PRESIDENT WAS PRESENT

More tweets from my trip and all Traditionally, the current president of
video in this article can be found at: Taiwan kicks off TIMTOS. Dr. Ing-Wen
gbm.media/timtos19. Tsai opened the 2019 event.
Unattended five-axis machining. systems (FMS). The company opened its U.S.
Quaser manufactures automation-friendly five- location in Rock Hill, South Carolina, in late
axis machines as well as vertical machining 2016 after using an importer for a number of
centers, horizontal machining centers (all with years. One of its booth demonstrations showed
hand-scraped ways) and flexible manufacturing technology to maximize the potential of unat-
tended five-axis machining on the
company’s UX500APC machine.
For example, the machine’s tilting
rotary table is not a trunnion design
supporting the table on two sides,
so it offers more open access for an
integrated pallet changing system
to swap pallets in 12 seconds. A
non-contact laser probe on the side
of the rotary table casting helped
detect tool breakage and track wear
through automated measurement of
the barrel cutters demonstrating how
the part would be cut. These tools
have a larger radius than ballnose end
The tilting rotary table on this Quaser five-axis machine mills, which reduces the cycle time
offers open access for an integrated pallet changing system by reducing the number of step-down
to swap pallets in 12 seconds. passes required down a part feature
to complete it.

TRADE SHOW REPORT
FUN FACT
It took 31 hours
from the time I left
my house to when
I walked through
the door of my
Taipei hotel room.
The Omron self-navigating autonomous intelligent vehicle (AIV) in this Campro

cell was topped with conveyor rollers to accept pallets of parts and deliver them
to machines and storage racks.
AIVs for part handling.

Campro offered its spin on smart flexible manufacturing systems with a
robotic cell incorporating the company’s U255C five-axis (4 + 1) machine
and NT208 turning center. An Omron self-navigating autonomous intelligent
vehicle (AIV) was topped with conveyor rollers to accept pallets of parts
KEEP IT SIMPLE
and part blanks. The AIV delivered fresh workpiece blanks to the five-axis
The name of machine, moved work in process from that machine to the turning center,
Taiwan’s best-
and delivered completed parts to a storage rack. AIVs such as the Omron unit
selling beer is
easy to remember. feature software and controls that enable intelligently navigating around
It’s called people and unplanned obstacles. In fact, these types of robotic-loading/AIV
Taiwan Beer. demonstrations are becoming more commonplace at manufacturing trade
shows such as TIMTOS.
Facial recognition for CNCs.

Artificial intelligence (AI) and data-driven manu-
facturing are common themes of manufacturing
trade shows. TIMTOS 2019 was no different. For
example, Hartford demonstrated facial-recog-
nition technology that ensures only authorized
operators can take control of a machine’s CNC.
A manager would have the new operator stand
in front of the CNC, select “operator” from an
onscreen menu, and then click to take a photo
for the facial-recognition app to process. From
that point on, the operator can access the CNC by
Hartford’s facial-recognition app for its control
ensures that only an authorized operator can take looking into the camera and pressing the “access”
control of a machine’s CNC button. This is one example of more than 40 other
apps the company offers for this control.

Highlights from TIMTOS 2019
The Soco cell featured an all-electric, eight-axis CNC tube

bender that can perform both left- and right-side bends to
produce U-shaped parts. It provides angular tube bending
accuracy ranging from ±0.05 to ±0.1 degree.
Automated tube bending and measurement.

Soco is well known in the United States for its CNC tube
sawing, bending and laser machining equipment. In fact,
the United States was the company’s first export target.
At TIMTOS, the company showed an automated cell to
BEST LINE
cut, bend and measure tubular frames for automotive
headrests. The cell featured an all-electric, eight-axis “Sir, you know this is the
SB-22x8A CNC tube bender that can perform both left- Asian breakfast buffet,
right? The Western buffet
and right-side bends to produce U-shaped parts. Its
is upstairs.”
Direct Gear Transmission (DGT) system, which features a (Ha, yes, I know)
gearbox with direct connection to the servomotor, offers
angular tube bending accuracy ranging from ±0.05 to
±0.1 degree. The critical dimensions for the headrest
frames in this demonstration are the diameters of the FREE SOUVENIR
tube ends where they insert into the seat and distance
My international
between the two vertical tube sections at the top inverted “souvenirs” are screen
“U.” After bending, the cell’s Yazkawa robot delivers each captures from the Map
frame to a gaging station for automated measurement. My Run app showing the
routes I took during
morning jogs.
On-machine probing.
A demonstration on Palmary ’s VIG-50 vertical
cylindrical grinding machine showed the value
of in-process probing, in this case to check the
inner diameter (ID) of a customer’s landing gear
component after grinding. The machine also had
a ground master artifact with known ID and made
from the same material as the part. The artifact,
mounted near the wheel dresser, would react in
the same way as the part to any temperature or
other environmental changes. The demonstration
showed how periodically probing the artifact and
After this Palmary machine grinds a landing gear
component’s ID, a probing routine ensures that the
comparing that measurement to the known ID
diameter was ground to specification. value enables adjusting the grinding process for
fluctuating environmental conditions.

AUTOMATION
Unguarded Automation
Can vision and AI make every robot collaborative? That is the
aim of this Boston-area startup. This year, it will come to market
with technology to make even fast and powerful robots safe to
approach, eliminating the need for fences around them.
PETER ZELINSKI | EDITOR-IN-CHIEF
Automated manufacturing facilities are full And the day when this is possible might arrive
of physical barriers — guarding and fences — yet this year.
because of our fears. Dr. Sobalvarro is one of the cofounders of
That is, because of our entirely legitimate Cambridge, Massachusetts-based Veo Robotics,
fears. Automated systems, industrial robots a company that has been working to develop a
in particular, are capable of moving fast and collaborative robot or “cobot” system based not
unexpectedly, imperiling a human who comes on force and speed limitation — typical of cobots
too close. A fence is a reasonable precaution. in use today — but instead on speed and separa-
However, Patrick Sobalvarro points out that tion monitoring achieved reliably using AI and
fences are far from fully effective as safety advanced vision technology. Veo’s “Freemove”
measures. People are quick and clever, and often system can make any robot collaborative, he says,
too effective at finding workarounds for phys- providing the robot with the ability to operate
ical barriers. He looks forward to the day when close to a person without threat to that person’s
people can work safely alongside even powerful safety. In fact, during my visit to Veo’s head-
robots without fences because vision technology quarters, I saw demonstrations involving stan-
and artificial intelligence (AI) provide for greater dard industrial robots from brands I recognize.
safety than a physical barrier can deliver. Existing robot safety standards, including ISO

Fast and Powerful Collaborative Robots
No employees were harmed in the

making of this photo. New technology
using vision and AI can make any
robot collaborative, its developers
say. Veo Robotics’ Gwenn Ellerby
stood close to the robot for this photo.

AUTOMATION
The Freemove system uses machine vision to locate objects it recognizes, such as the robot, as
well as occlusions that might represent the presence of a human. The system responds to the latter
by slowing or stopping the robot to avoid potential harm.
10218, ISO/TS R1506 and IEC 61508, all recog- is partial, redeployable automation safely oper-
nize this system’s approach to realizing operator ating alongside a human being. Collaborative
safety, and Veo expects to have a commercial automation is the way to achieve this.
version of Freemove for production facilities on Yet cobots typically realize this safety in part
the market by the end of the year. by operating at speed and force levels below what
The system answers what will soon be recog- might cause harm, thereby limiting the maximum
nized as a growing need for collaborative auto- payload to perhaps 10 kilograms including the
mation, he says, a need the most commonly used end effector. Dr. Sobalvarro points out that only
cobots available today cannot address alone. a sliver of industrial robot applications involve
Collaborative automation “gives you the loads this light. Veo’s system aims to allow robots
option to have a human in the cycle,” he says, and that are fast and powerful enough to seriously
this option — as injure a human to be controlled so as to become
opposed to full collaborative as well.
automation — is The vision technology enabling this possibility
becoming more arrived only within the last five years, he says.
ROBOT VS. COBOT valuable. Various One of its earliest uses was video games. Safety
trends in manu- is no game, of course, but the motion-tracking
The use and challenges of facturing make vision capability used by Veo is an industrial,
collaborative robots and some of
full automation longer-range version of the kind of motion
the history that made cobots pos-
sible. Visit gbm.media ∕cobot101. increasingly prob- sensing used by the Xbox Kinect game accessory.
lematic, including
mass customi- Observing Occlusions
zation, shorter product cycles and tightening Dr. Sobalvarro explains how the system relying on
quality demands. “For a growing number of this sensing technology works. Veo’s collaborative
manufactured products, you will never amortize automation employs four or more vision cameras
the cost of full, dedicated automation before you mounted high above the robot that have overlap-
have to change the process,” he says. Rather, the ping fields of view. Each camera repeatedly sends
option that makes economic sense in these cases infrared flashes to map every object in its view

Fast and Powerful Collaborative Robots
field by means of the IR reflection. The resolution human comes in contact with the robot, then the
of the cameras developed by Veo is fine enough robot is slowed down or brought to a stop.
to distinguish a human finger at 10 meters. Thirty Crucially, the system employs AI, but not
times per second, the collaborative system maps machine learning, Dr. Sobalvarro says. Machine
the vicinity of the robot by combining all the learning is probabilistic, where the relevant
cameras’ data. Within this combined field, he says, safety standards disallow statistical approaches
the system is looking for occlusions. for triggering safety measures. “Even very good
That is, the system is looking for every volume machine learning could have one fail in 10,000,
of space that it cannot see because something is which is too large where human safety in a manu-
blocking its view. Any occlusion a little larger than facturing environment is concerned,” he says.
a loaf of bread, or bigger, is assumed to be able The AI instead entails rapid computation for
to contain a human (meaning potentially a very occlusion analysis combined with classification
small human), and analysis of these occlusions is according to model recognition.
used to detect safety concerns. Phase transitions The latter component, classification, makes
logged through the 30 samples per second track the occlusion analysis more efficient. From the
the progress of any occlusion. If the course of vision data, the system is equipped to identify
movement of an occlusion can provide clearance the robot, fixturing and workpiece, ruling them
for a human to have entered the work zone and out as suspect occlusions. This classification also
come within range of the robot, then the space helps make the system quick to install—a valu-
is considered “infected” by the occlusion and the able side benefit. No precise locating of cameras
system responds accordingly. From this occlu- is required, because once the cameras are
sion’s current position, the Freemove software mounted, the system can “zero” itself by locating
then compares future states based on possible the base of the robot.
moves of the robot and possible moves of the
suspected human at a presumed (fast) speed of 2 Human Motives
meters per second. If the event horizons of these Why is this artificial intelligence system safer
two actors lead to any possible state in which the than a fence? Because fences are vulnerable to
human intelligence,
Dr. Sobalvarro says.
Humans follow
conflicting motives
that put them in
danger. “The career
of a person working
in manufacturing
involves a lot of
training in safety,
but it involves even
more training in
how important it is
to keep production
moving,” he says.
In an instant, these
two priorities can
come in conflict.
Patrick Sobalvarro
(background) discussed the
vision-based collaborative
technology with me, as did
Veo co-founder Clara Vu,
speaking with me here.

AUTOMATION
I broke away and tried to catch the robot by surprise myself. It was moving at normal
speed before this picture was taken, but quickly slowed to a stop as I drew this close.
The worker who dropped an item that fell behind prove injurious or deadly. By contrast, there is
the safety fence might resist interrupting produc- no similar way to defeat the vision and AI system
tion just to retrieve that item. That worker might with just a single moment’s poor impulse. If the
see how to compromise or move over or under worker tried to do so by covering the camera,
the fence — a move made in an instant that might then this would produce an occlusion that would
lead to a response from the system. With the
vision and AI system, there just isn’t a fence that
Veo Robotics and Modern Machine Shop can be jumped.
to Share Stage at MT360 There have been non-contact systems before
for speed and separation monitoring of robots.
A new manufacturing technology event aimed at Light curtains, for example. However, devices
bringing together manufacturing leaders and the such as these can only be conservative, keeping
tech community, MT360 will take place June 18-20 the barrier of triggering far away from the robot’s
in Santa Clara, California. Peter Zelinski of Modern reach. They don’t allow for collaboration, for the
Machine Shop will hold on-stage conversations with human and robot easily working together in close
Veo Robotics’ Patrick Sobalvarro, ThyssenKrupp proximity so that the automation does not have to
Bilstein CEO Fabian Schmal on his company’s adop- accomplish every detail.
tion of collaborative automation in manufacturing, Indeed, Dr. Sobalvarro notes there is nothing
EOS North America President Glynn Fletcher on about the Veo system that suits it specifically
the enterprise-wide transformations resulting from to a robot. The ultimate hope of the company is
additive manufacturing, and HP head of 3D metals that any automated industrial machinery might
Tim Weber on additive manufacturing for production. be governed by a system such as this, producing
Tech startups related to manufacturing and hands-on unguarded factory floors through which people
demonstrations of disruptive manufacturing tech- can move freely, in safety and without fear.
nology will be part of the event as well. Learn more at
gbm.media/mt360 and at mt360conference.com.
| Veo Robotics | veobot.com

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BETTER PRODUCTION POSTPROCESSING AM PARTS
Grind to Finish: A Postprocessing Solution

for Additive Manufacturing
CONTRIBUTED BY K. PHILIP VARGHESE, PHD., AND
JOHN HAGAN, NORTON | SAINT-GOBAIN ABRASIVES
COMPANY
Norton Abrasives
PROBLEM
How best to finish an
additively produced part
made of Inconel to tight
aerospace tolerances
SOLUTION
Grinding with fine-grain
abrasive wheels
RESULTS
Surface roughness
reduced by 94 percent
parallel to grind lines
and 34 percent perpen-
dicular to grind lines,
beneficial residual
surface stress levels
This is one of the test parts: an Inconel 718 workpiece made using direct metal
laser sintering (DMLS). These parts were then media-blasted and put through
stress relief, hot isostatic pressing, solution treatment/anneal and precipitation
hardening to 40 HRC.
The increased use of additive manufacturing AM specifically as it might apply to nickel-based

(AM) in the aerospace market (among others) superalloy components used in aerospace, engi-
fosters a growing need to finish the surfaces of neers at Norton | Saint-Gobain conducted a
additive parts to meet final application require- finish grinding study on additively produced
ments. Since the AM process is capable of produc- parts made of Inconel 718 (IN718). The engi-
ing components close to near-net shape, there is neers were seeking answers to three questions:
often little stock that remains for providing final
finish. This benefits the overall manufacturing •What is the minimum stock/volume that
process by reducing waste, but it also means that needs to be ground off an AM part?
subsequent finishing processes have limited room •What range of surface finishes can be obtained
for postprocessing errors and inconsistencies. from grinding an AM part with the latest gen-
Postprocessing, therefore, needs to be consistent eration of abrasive grinding wheels?
in achieving part tolerances and surface quality. •What, if any, is the impact of finish grinding
When compared with other traditional material on an AM part’s surface stresses?
removal processes such as milling and turning,
grinding typically offers the best surface quality To get answers, Norton received IN718
and surface integrity characteristics. parts that Stratasys Direct Manufacturing had
In order to gain more insight into finishing for made through direct metal laser sintering

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Grinding Conditions on a 3D-Printed Inconel 718 Part
Condition Peak MRR' Feed Rate Depth of Cut

# (mm 3/sec./mm) (mm/min.) (mm)
1 0.1 254 0.025
2 0.6 254 0.152

To get insight on the range of
surface finishes possible on 3 1.0 127 0.457
additively produced Inconel
parts, Norton Abrasions ran five 4 1.9 254 0.457
parts with increasing grinding 5 3.9 508 0.457
conditions as shown here.
(DMLS). These parts were then media-blasted increasing depths of cut to determine the mini-
and put through stress relief, hot isostatic mum stock that needs to be removed to clean up
pressing, solution treatment/anneal and an additively manufactured surface. After each
precipitation hardening. The hardness of the grind, the surfaces were checked for visual imper-
parts measured 40 HRC. The parts were then fections. The trial results showed that to elimi-
ground using a Norton NQX60E24VTX2 grind- nate any geometrical inconsistencies and surface
ing wheel on a Magerle MFP-125.50.65 creep- imperfections related to the AM process, about
feed grinder. 0.30 to 0.45 mm of stock needs to be removed
from the part.
1. How much stock needs to be removed For this test, the grind length was 50.8 mm,
from the part? and the wheel diameter was 462 mm, operating
First, several areas were ground at progressively at 23 m/sec. A total of five specific material
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removal rates (MRRs) Surface Finish Ra (µm) Before and After Grinding
were tested ranging (As Measured Perpendicular to the Grind Lines)
from 0.1 mm 3/sec./
3.5
mm to 3.9 mm 3/sec./
mm. The MRR was 3.0
Surface Finish Ra (µm)

adjusted by altering 2.5
2.1
the feed rate or the 2.0
depth of cut. While
1.5
nickel-based alloys 1.1
such as IN718 can 1.0 0.8
0.5 0.6 0.7
be ground at high 0.5
removal rates using 0.0
modern engineered Before 0.1 0.6 1.0 1.9 3.9
abrasives, the MRRs Grind
selected in this study Material Removal Rate (mm 3/sec./mm)
were lower, based on
more typical finishing
rates for this material. measured before and after grinding using a
Based on the grinding of non-AM work- Federal contact profilometer system 5000. An
pieces, the expected results were that as MRR evaluation of the surface finish before grinding
increased, surface finishes (Ra) of ground work- found it to be considerably different depending on
pieces would increase or get coarser as grinding the direction of measurement. When measured
power increased. lengthwise, the average finish was 3.3 microns Ra;
when measured widthwise, the average finish was
Peculiarities of Measuring the AM Part Surfaces 2.1 microns Ra. This large difference appears to be
The surface finishes of the workpieces were related to the 3D-printing method, but the exact
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Grind to Finish BETTER PRODUCTION
Surface Finish Ra (µm) Before and After Grinding to the grind lines,
(As Measured Parallel to the Grind Lines) the stylus travels
over their peaks and
3.5 3.3
valleys, whereas mea-
3.0 suring in the parallel
Surface Finish Ra (µm)
2.5 direction does not.

2.0 As expected, post-
grind perpendicular
1.5
measurements taken
1.0 in this study had
0.5 0.21 0.25 0.22 0.26 0.22 significantly higher
0.0 (coarser) surface
Before 0.1 0.6 1.0 1.9 3.9 finish results as com-
Grind pared to measure-
Material Removal Rate (mm 3/sec./mm) ments taken in the
parallel direction.
reason is unknown at this time. 2. What range of finishes can be achieved?

The conventional method for measuring a An evaluation of the surface finish before and
ground surface finish is to take the trace perpen- after grinding found that grinding improved
dicular to the grind lines rather than parallel to the surface finish significantly. This was true for
them. In this study, it was decided to measure in measurements in both the parallel and perpen-
both parallel and perpendicular directions to com- dicular directions. When measuring in a parallel
pare with the equivalent pre-grind measurements. direction, the average surface finish was 3.3
It is important to remember that when measur- microns Ra before grinding and 0.21 microns
ing a ground surface in a perpendicular direction Ra afterward. When measuring perpendicular
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to the grind direction, the surface finish was an residual stresses were negative/compressive
average of 2.1 microns Ra before grinding, and both before and after grinding, an effect that
as low as 0.5 micron Ra afterward. tends to help with fatigue by slowing the prop-
Grinding wheels with finer abrasive grains agation of surface crack. This is typical of parts
after finish grinding.
These tests successfully answered the initial
BACK TO THE DAILY GRIND starting questions and demonstrated that grind-
ing with fine-grain grinding wheels is an effective
For those in the market for a new grinding
machine, this multi-part series draws on method for finishing additively manufactured parts
Norton’s expertise to discuss the tech- made of superalloys like Inconel to standards typi-
nology in detail: gbm.media ∕dailygrind. cal of the aerospace industry, among others.
or other abrasive products, such as engineered AUTHORS

abrasive belts, can be used to reduce the lay lines K. Philip Varghese leads Saint-Gobain Abrasives’ Advanced
further and generate a super-finished surface if Application Group, providing grinding solutions to customers
that is a critical requirement to the component’s as well as education and training in grinding science and
performance and quality. technology.
John Hagan is a senior application engineer for Norton |
3. What is grinding’s impact on residual Saint-Gobain Abrasives, where he designs and completes
surface stresses? grinding projects focused on new process development and
In order to understand the impact of grinding the optimization of existing processes.
on the overall surface integrity of the part,
residual surface stresses were measured before
and after grinding using microdiffraction | Norton Abrasives | 800-446-1119 |
equipment. The test showed that near-surface sgabrasives.com
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BETTER PRODUCTION CAD/CAM
Integrated CAD and CAM Boosts Job Shop’s

Efficiency through Collaboration
EDITED BY JEDD COLE | ASSOCIATE EDITOR
COMPANY Like many other machine shops, Creations Unlimited (Morgan Hill,
Creations Unlimited California) faces increasing pressures from shrinking lead times. “Every
customer we have would take things in a week or two if we could do it,”
PROBLEM says owner Dennis Rathi. “Everyone wants everything tomorrow.”
Separate CAD and CAM To reduce lead times, the family-operated shop has invested heavily in
software hampered automation, equipping some of its 15 machine tools (including five-axis
efficiency in an otherwise machining centers) with machine-tending pallet changers with dozens
technologically sophisti- of pallets and large toolchangers. “We have a lot of equipment that can
cated machine shop run unattended,” Mr. Rathi says. “We can do large production batches or
one-piece prototypes without change-overs or lengthy setups.” These have
SOLUTION been the company’s advantages. “We focus on the more complex parts that
NX CAD/CAM software other job shops don’t want to make or don’t have the capability to make,”
from Siemens PLM Mr. Rathi says. “That’s how we have grown the company.”
To realize the best return on its investment in advanced equipment,
RESULTS Creations Unlimited has adopted NX software from Siemens PLM
50% shorter lead times, Software. Prior to NX, the shop used separate CAD and CAM systems
elimination of test runs, that were not only lacking in capabilities, but also required file transfers
increased efficiency and between the software solutions, which hampered overall efficiency. The
reliability integrated design and manufacturing capabilities of NX support a more
For Dennis Rathi,

Creations Unlimited’s
owner, having a “digital
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Creations Unlimited’s staff

program the shop’s 15 machine
tools using Siemens’ NX
software. This integrated CAD,
CAM, and CMM inspection
programming system facilitates
continuous end-to-end part
manufacturing. Previously, the
shop used multiple software
systems between design and
production, making the process
less efficient.
streamlined process that enables the company software system that Creations Unlimited takes
to go more quickly from CAD part model, to NC advantage of regularly:
programming, to simulation and verification, and
finally to finished part. 1. Design for Manufacturability
“Customers would send CAD models that we
The Value of Integrated CAD/CAM Software couldn’t machine: Faces were not tangent, or
Whereas the company made the switch to NX we had to put check surfaces in, etc.,” he says.
primarily because of its integrated modeling “With the modeling capabilities in NX, we can
capability, there are five advanced features of the easily fix bad geometry, remove features and do

Machining complex parts to tight tolerances,

as in the case of this surgical instrument, has
traditionally set Creations Unlimited apart from
its competitors. NX CAM provides advanced
five-axis machining capabilities, further
enabling the company to manufacture the
most challenging parts that come its way.
whatever else we need to optimize digital part

models for machining.”
NX supports a master model concept that
enables Creations Unlimited to prepare and opti-
mize part models for CAM while leaving the orig-
inal part intact. In many cases, the shop proposes
modifications to improve manufacturability — an
important service that improves collaboration with
customers and enables the shop to offer more com-
petitive quotes.
2. Machine Setup Modeling

Creations Unlimited also uses the assembly this approach, the company can create a fully
design capabilities of NX to model the com- detailed and accurate digital model of the
plete machine setup, including fixtures, tool- machining environment that streamlines the NC
ing, riser blocks, clamps and other items. With programming process.
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WEBINAR
Digital Machine Shop: How Automation
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Automation is key to achieving the goal of reduced time-to-delivery —
a top objective for 56% of surveyed machine shops.
Digitalizing part manufacturing, a prerequisite to effective

automation, can be applied to individual tasks, such as NC
programming or to end-to-end processes.
Learn how Siemens’ NX software for CAD, CAM, CMM, robotics, and
additive manufacturing transforms how you make parts, boosting
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• Control advanced robots, industrial 3D printers, and CMMs
• Opportunities for total automation
DATE AND TIME OF WEBINAR

Thursday, June 20, 2019 • 2:00 PM ET
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If you miss the live event, you can short.mmsonline.com/

view the recorded webinar at: Siemens620
The job shop makes extensive use of

high-speed machining (HSM) to cut
hard materials such as titanium.
Adaptive milling, an advanced HSM
roughing method in NX CAM, has not
only shortened machining times for
Creations Unlimited, but has also
contributed to extended tool life.
“When we first started, every time we got a

new job we had to start from scratch to build a
new riser block or a new fixture or clamp,” Mr.
Rathi says. “But with NX, we saved and orga-
nized all the components, so now we can pull in
complex fixture assemblies and reuse them for
other jobs. It’s very rare now to build specialized
tooling for a job.”
3. Five-Axis Machining
Creations Unlimited makes extensive use of the
advanced five-axis machining capabilities of NX is having an accurate representation — a digital
to deliver complex parts with quality surface fin- twin — of the entire machine setup and machin-
ishes. For parts with complicated geometry, the ing process. “For us, it was critical to have all
shop has found that the key to five-axis efficiency the models of all the fixtures — all the holders,
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019 C ATI, O
H
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I N PA RT N E R S H I P W I T H :
the part in its accurate location in the machine, shorten the cycle time using higher cutting speeds.
everything in NX matching everything on the But the main benefit is that we can extend tool life
machine,” Mr. Rathi by 200 percent. The longer and more predictable
says. “For the majority tool life helps us reduce the overall manufacturing
SIMILAR STROKES, of five-axis machining, time because we’re not changing tools as often,
DIFFERENT FOLKS
we use the automated and we’re not stopping the machines to check the
See how NX helped a
tilt tool axis capabil- tools. A lot of people undervalue that time.”
moldmaking shop stream-
line its processes from ity,” he says. “It’s easy
design through machining: to create a three-axis 5. Toolpath Simulation and Verification
gbm.media.com/nxmold. tool path and let NX The machining simulation and verification capa-
software tilt the tool so bilities of NX, used in conjunction with the dig-
we can easily machine difficult parts using five- ital twin of the machining setup, give Creations
axis machining.” Unlimited more confidence in its NC programs.
“Integrated simulation means we’re not having to
4. Adaptive Milling switch to another program to verify the G code,”
Adaptive milling is a high-speed machining Mr. Rathi says. “It’s all complete and all in one
strategy designed for hard materials like steel software, so if we make a change we can instantly
and titanium that are a focus for the company. verify it. Whatever we see in NX is exactly how
Adaptive milling uses a large axial depth and a the machine performs, all the way to how the
small radial depth of cut to maintain consistent machine rotates under certain conditions.”
chip thickness and reduce machining time. For all of its machines, Creations Unlimited uses
“We’re now using adaptive milling for all high- NX to output NC programs that are optimized for
speed machining,” Mr. Rathi says. “I can program the controllers. The NX simulations leverage every
an operation in one tenth the time compared to detail of the digital twin, including the machine
our previous software. These smooth tool paths controller code. “Having everything staged in the
A Must For Every Shop!
Dot Peen Marker

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IAL: 011 7
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TS
21
-17
ARC TEX
18:27
2D DATA MATRIX Impo rt Graphics
XT
MIRROR TEXT
R TE
LA
GU
REVERSE TEXT AN
REVERSE TEXT
ANGULAR TEXT
Type or teach positioning

r r r r r r
Compact flash card memory

Automatic serializing
Date/time shift coding
Mark virtually any material
The KM-64 True chipless engraving
info@kwikmark.com (815) 363-8268 www.kwikmark.com MADE IN USA

WEBINAR
Integrating NC Manufacturing Data to
Help Make Better Decisions
PRESENTED BY
PRESENTER
OVERVIEW
Manufacturers are attempting to understand and implement the
“digital twin.” With more NC manufacturing data available, choosing
the best data, using it efficiently, and optimizing processes are key
to reducing costs and improving efficiency. Software interoperability
connects CAD/CAM systems, PLM systems, Tooling databases, Cloud-
based downloadable resources, and CNC machines, providing realistic
and accurate data. Learn how companies can make better business
decisions by simulating CNC machines in a robust virtual environment
Jeff Voegele (versus in reality).
VERICUT
PRODUCT SPECIALIST
DURING THIS WEBINAR YOU WILL LEARN:

• Simulation software’s connectivity in the NC Manufacturing environment
• What data to seek, what to avoid, and why
• How simulation interoperability and “good” data help drive smart decisions
• How physics-based software tools help with optimization and analysis
DATE AND TIME OF WEBINAR

Tuesday, June 18, 2019 • 2:00 PM ET
DURATION: 1 HOUR
If you miss the live event, you can short.mmsonline.com/

view the recorded webinar at: CGTech618
Creations Unlimited has become an

established supplier of high-quality
parts to customers in many indus-
tries, including automotive, aero-
space and consumer electronics.
software saves up to 50% of the lead time, depend-

ing on the complexity of the job,” Mr. Rathi says.
“We have complete confidence in our programs
and have eliminated test runs.”
Manufacturing Efficiency Comes

from Collaboration
The shop has also taken advantage of the software
to facilitate reuse of machining expertise and best
practices. Process templates in NX enable program- using NX CAM.”
mers to reapply machining parameters from one To provide the shop floor with documenta-
job to the next. “We can create geometry groups tion such as setup sheets and tool lists, Creations
with a sequence of tool paths such as roughing, Unlimited relies on NCmatic, the product and
semi-finishing, finishing and chamfering. All you company name of a Siemens PLM partner that
have to do is select a feature and NX applies all specializes in workflow automation tools that are
the parameters — how to enter the pocket, how to then integrated with NX.
machine the corners... All the rest of the tool paths “We worked with Marek Pawlus, CEO of
are still there. We can program up to 90% faster NCmatic, to customize a work instruction template
INCONEL
MACHINING
MADE EASY Visit www.onsrud.com
for more information
800-234-1560
E n g i n eer ed t o m eet t h e t o u g h est ch a l l en g es o f LMT Onsrud LP

m a ch i n i n g i n co n el a n d o t h er su per a l l o y m a t er i a l s: 1081 S. Northpoint Blvd
t h e n ew M X R a n d H X R Ser i es f r o m L M T On sr u d. Waukegan, IL 60085
H ea v y pr o f i l i n g , H i g h E f f i ci en cy M a ch i n i n g (H E M ), Phone 800 234 1560
a n d r edu ced cy cl e t i m es - a l l w h i l e cr ea t i n g
su per i o r w o r k pi ece f i n i sh es.
T r u st L M T On sr u d t o pr o v i de cu t t i n g t o o l s t h a t
m eet y o u r ex a ct i n g st a n da r ds.

Efficiency Through Collaboration BETTER PRODUCTION
tailored to our workflow and to create NC reports program, we are able to review and influence the
based on my input,” Mr. Rathi says. “We can simply development of NX CAM software. For example, as
select a menu button to create a PDF of work a result of visiting our offices and regular discus-
instructions that are customized to our require- sions, Siemens has adopted elements of our feed-
ments.” NCmatic also supports the shop with post- back into new CAM functionality.”
processing and simulation tasks.
Creations Unlimited’s involvement with
Siemens PLM has even gone so far as to influence | Creations Unlimited | 408-776-0581
development of the software. “We notice that creationsultd.com
Siemens development has been implementing new
NC programming functions at a fast pace,” Mr. | Siemens PLM Software | 800-498-5351
Rathi says. “By joining the Siemens early adopter plm.automation.siemens.com
If you can think it, we can machine it.

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MODERN MACHINE SHOP 105

BETTER PRODUCTION 3D-PRINTED WORKHOLDING
The Rize One 3D printer is what IGI

uses for its ficturing and prototyp-
ing work. The system uses what
Rize calls augmented deposition, a
hybrid of extrusion and jetting. The
machine jets a release agent
between layers for cleaner removal
of support structures. Jetting also
enables the ink marking capabili-
ties that IGI takes advantage of for
printing work order numbers, line
numbers and pictures of the piece
on the fixtures for identification as
well as instructions for part use
and storage.
With 3D Printing, Fixture

Making Goes from the Tool
Room to the CAD Room
EDITED BY JEDD COLE | ASSOCIATE EDITOR
COMPANY Founded in 1943, Ira Green Inc. (IGI), headquartered in Providence,

Ira Green Inc. Rhode Island, is a full-service manufacturer and distributor of nearly
40,000 different accoutrements for military uniforms. IGI’s tool shop is
PROBLEM focused, therefore, on manufacturing coining and blanking dies. It also
Fixture iteration produces small fixtures for welding and polishing.
produced lead times of With high demand for IGI products, new fixtures are required every
days or weeks, with day. However, each job had to wait in a queue for several days before it
costs ranging to $300 could begin, resulting in bottlenecks. Lead times between job requests
per fixture and fixture delivery ranged from several days to weeks. Moreover, each
fixture required eight hours of CNC programming, either for setup of
SOLUTION pockets or contour electrodes for tool steel and wire EDM flat pockets.
Rize One 3D printer IGI was spending $300 for every fixture.
IGI’s manufacturing manager Bill Yehle argued that creating fixturing
RESULTS from 3D-printed plastic components instead of asking toolroom personnel
Printing of more accurate to machine metal fixturing components would reduce the toolroom back-
fixtures in hours rather log while maintaining headcount. He proposed that using a 3D printer
than days, and at $2 per from Rize Inc. to print fixture parts would enable IGI to move that work to
fixture on average the fast-response CAD group instead of the overburdened toolroom.
“Implementing Rize 3D printing as part of a strategic process shift has

FH630SX-i 5-Axis HORIZONTAL MACHINING CENTER
Developed best-in-class 5-axis machine, the FH630SX-i
5-axis is designed with a tilting spindle with a robust C-axis
drive train and an enlarged C-axis swivel range for wider
complex part machining.
www.toyoda.com/5-axis
Ira Green Inc. makes accoutrements

for military uniforms, such as
medals and pins. 3D-printed fixtures
ensure the accuracy of nail
placement while cutting down
significantly on both the time and
cost of designing and building
fixtures. The machine’s ink-marking
capability also adds three points of
verification to prevent errors.
Photo: Ira Green
completely transformed our production process,” From $300 per Fixture to $2

Mr. Yehle says. In short, the shift has added tool- Prior to using Rize, machine operators clamped
room skills to higher-skilled CAM and machine the piece down on the machine, which required
building tasks, so that fixture design can be accom- considerable trial and error to get the placement
plished at the time of product design, following right. They also tried melting the mold into
the design/manufacturing development process nylon to hold it in place, but this also required
along a parallel path. a time-consuming process of trial and error
Saving Thru Throughput

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June 12-13, 2019

“Everything for EDM” Booth 401
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IN BETWEEN — THAT’S WHY WE ARE EVERYTHING FOR EDM. 800.356.4811 • www.belmont4edm.com

CONFERENCE + EXPO
AUGUST
27-29, 2019
AUSTIN, TEXAS
The first and only event
focused exclusively on
additive technologies
for industrial part
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The AMC is expanding in 2019 to include
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and better networking opportunities.
Join hundreds of professionals from
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what’s working and what’s coming in
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PRESENTED BY
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COMMON CENTS — “turning and for welding and polishing. Using the Rize One,
DECISION-MAKING burning,” as Mr. IGI is able to standardize the molds and the nails,
What are the factors that make Yehle calls it — resulting in faster setup and change-over, repeat-
3D printing cost effective? Here and did not meet ability, and increased accuracy. Mr. Yehle says
are three from a part maker: IGI’s accuracy the shop has realized an 80 percent time savings
gbm.media ∕3dcost.
requirements. in setup and change-over times and has virtually
Precision is eliminated errors.
critical. The 3D-printed fixtures hold the piece Besides speed and accuracy in making fixtures,
while it is being nailed in the welder and ensure IGI’s designers have found use in the Rise One’s
the precision and accuracy of the nail placement. ink marking capability. They use it to print work
This speeds the process because it eliminates order numbers, line numbers and pictures of the
the need for repeated manual adjustment of the piece on the fixtures for identification as well as
fixtures. It also saves time from machine opera- instructions for part use and storage. These mark-
tors placing one nail at a time using traditional ings also serve as three points of verification for
machining. Using fixtures printed with the Rize machine operators to prevent errors.
One machine, IGI has been able to standardize When IGI has to fabricate steel fixtures to sus-
the center of the fixture for nailing the piece tain heavier workpiece loads, staff still use the 3D
without requiring adjustment. printer for functional prototypes. The designers
Since implementing 3D printing less than a iterate the prototypes until they get them right
year ago, IGI’s design team has printed approxi- and then turn to the toolroom for final steel fix-
mately 300 fixtures. It now uses the Rize One 3D ture manufacturing. Previously, the shop iterated
printer every day to reliably manufacture fix- fixture designs two or three times in steel at a
tures in 50 minutes at a cost of $2 per part. This cost of $300 and lead times of two days per iter-
enables IGI’s design team to produce seven differ- ation. Rize enables IGI to produce seven proto-
ent versions of fixtures per day that can be used types per day at $2 each.
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3D Printing on the Radar and to further enhance the standardization and

IGI had been thinking about implementing repeatability of the production process.
3D printing to improve its processes for some Some of these enhancements include print-
time before implementing the Rize One, ing fixtures within fixtures. In this situation,
which it chose after seeing it demonstrated the base fixture is a standard size while the
at an event and in consultation with Rize fixture insert is customized for the workpiece,
and Dassault Systèmes authorized reseller threading the molds for screws and print-
Caelynx. IGI was impressed with the part ing spacers that enable selected molds to fit
strength and industrial material properties securely on certain machines.
Rize was able to work with, which enable IGI is also considering using the 3D printer
fixtures to be drilled, polished and welded to manufacture service and spare parts on
without welding flash and without increasing demand for its machinery in order to reduce
part temperature during welding. the time and cost of sourcing and ordering
Equally important to IGI’s strategy of operat- machined parts, especially when parts are
ing 3D printers in its design office is that Rize obsolete or suppliers go out of business.
3D printers are easy enough to use that the “The process we are using with Rize gives
existing design staff could operate them. IGI’s us a unique competitive advantage,” Mr. Yehle
industrial designer, who had not used a 3D says. “And we are looking to expand the use of
printer since he was a college student, said he Rize technology to applications in other areas
was able to get up and running with Rize One of the company.”
quickly and easily.
IGI continually develops its use of the Rize
One for fabricating fixtures. The company reg- | Rize Inc. | 978-699-3085 | rize3d.com
ularly iterates its fixtures for easier removal
of the molds from nail and welding machines | Ira Green Inc. | 800-663-7487 | iragreen.com
THE EMAG GROUP TECHNOLOGIES

Turning Milling Grinding Gear Hobbing Power Skiving
Heat Shrink Assembly ECM / PECM Laser Welding Induction Hardening
The EMAG Group is one of the few manufacturing system suppliers that cover the entire process chain – from soft to hard machining.
Access to a wide range of technologies (turning, drilling, milling, gear cutting, grinding, laser welding, ECM/PECM machining,
induction hardening and automation) allows EMAG to implement complete process chains, not only for the production of gear box,
engine and chassis components, but also for components in the non-automotive sector including oil field, power generation,
aerospace and large equipment.
www.emag.com

ENGAGE
EXHIBIT. NETWORK. LEARN.
EXHIBIT HALL
featuring machine tools, mold components,
tooling, materials, software and more
BUSINESS DEVELOPMENT
OPPORTUNITIES
for mold builders and mold buyers
AMERIMOLD TECH TALKS

on designing, machining,
maintaining molds
BOOTH SALES ARE OPEN*

Reserve Early and Save! REGISTER NOW!
Sales@amerimold.com
* 70% of booths have already been sold! JUNE 12-13, 2019
Donald E. Stephens Convention Center
A M E R I M O L D E X P O . C O M R O S E M O N T, I L L I N O I S
PRESENTED BY:
JEDD COLE | EDITOR | jcole@mmsonline.com
Tooling and Workholding
Toolholder Mounts Directly to Star

Micronics Swiss-Type Lathes
Arno Werkzeuge’s AWL direct-mount toolholder for Star Micronics-brand Swiss-type
lathes is compatible with Star Micronics’ SR 20R II, III and IV machines currently.
When combined with the AFC quick-change system, users can increase productivity
for Swiss-type machines through reducing setup and non-productive times.
Designed for turning or grooving tools, the AWL toolholder has an inte-
grated adjustable high-pressure coolant supply ranging to 130 bar.
Two separate cooling channels can be selectively opened or
closed. The various connection options make it adaptable
to several machine types. Depending on the machine,
the new AWL direct mount can fit from two to six tools.
Each chamber has an integrated coolant supply to allow
the simultaneous use of several tools, whether they have
internal cooling or not. Since the direct mount is designed
with integrated cooling, it dispenses with the time-consuming
connection of external and cost-intensive tubing.
When turned, an integrated counter nut raises the wedge slightly
to speed tool removal and fitting. “The direct mount can also hold the
tools of other manufacturers. The freedom of tool choice is one of the
greatest benefits of our AWL direct mount,” says Werner Meditz, head of
technology at Arno.
“Users have the best benefits when they combine the AWL direct-mount with the
AFC quick-change system,” says Simon Storf, marketing manager, since to change
a tool, only the front part of the two-part holder needs to be removed and a new tool
is then fitted with a different holder. This combination dispenses with the need for
recalibration in many cases, according to Mr. Storf.
| Arno Werkzeuge USA | 800-943-4426 | arnousa.com
Insert Grade Stabilizes Grooving Tool System for Interrupted Cuts

Kyocera Precision Tools has expanded the insert lineup of the GBA grooving system
with the PR1625 grade designed for grooving steel and stainless steel. PR1625 is
designed to provide hardness and toughness during grooving operations, incorporat-
ing a stable carbide base material and Megacoat Nano coating for resistance to wear
when grooving light as well as heavily interrupted cuts.
The GBA grooving system features inserts with three usable cutting
edges. These inserts are available in three grades: PR1215 for
general-purpose grooving, TN620 for surface-finish-oriented
grooving and PR1625 for interrupted cuts. The tool’s GM chip-
breakers are designed to maintain smooth chip control and
provide a more stable groove in a range of shallow grooving
applications.
| Kyocera SGS Precision Tools Inc.
330-688-6667 | sgstool.com

ACCELERATED DRILLING
Deep hole drilling for Exceptional Straightness
MCTR... for machining centers (8xD, 10xD, 15xD and 25xD)
TRLG... for gundrill machines (up to 94" (2400 mm) length)
TOHT
Unique insert with 3 cutting edges,
chip splitter and built-in wiper
Tungaloy America | info@tungaloyamerica.com | 888.554.8394

www.tungaloy.com/us
TOOLING AND WORKHOLDING
Face Mill Performs

Roughing and Finishing
in One Operation
The M5F90 face-milling cutter from Sandvik Coromant radial and axial stepped cutting edges.
is designed for machining thin-walled aluminum auto- Such a configuration promotes burr-free
motive parts without burring, scratching or chipping. milling and good surface finish on thin-walled
The two-in-one cutter can perform roughing and finish- aluminum parts while enabling a close pitch to avoid
ing in a single operation for faster and more efficient cutting vibration, according to the company.
machining strategies. “The inherent flexibility of being able to rough- and
The M5F90 cutter body’s diameter (25 to 80 finish-mill makes it possible to machine different
mm/0.98" to 3.15") carries brazed PCD inserts that positions on the same part with just one cutter,” says
require no adjustment thanks to new production pro- Emmanuel David, global automotive product manager.
cesses and therefore enable higher feed rates with- Although designed for thin-wall milling operations on
out vibration. Scratches, burrs and breakages on the aluminum parts, such as gearbox cases and housings,
machined part are said to be eliminated with a com- the M5F90 is also able to handle other aluminum auto-
bination of optimal cutting angles, insert shape, edge motive part features, the company says.
preparation and cutting parameters. The M5F90 is described as completing Sandvik
In terms of roughing, the tool works as a conven- Coromant’s milling cutter offering for aluminum automo-
tional cutter, with all rough-cutting edges positioned on tive parts, complementing the M5B90, M5C90, CoroMill
the same diameter and height. The M5F90 can machine Century/590, M5Q90 and M5R90 tooling solutions.
to a depth of cut measuring 4 mm (0.157"). With | Sandvik Coromant Co. | 201-794-5000
regards to finishing, this portion of the tool consists of coromant.sandvik.com/us
YMW TAPS USA YMW HIGH PERFORMANCE TAPS
Quality.
ZELX SERIES
YMW
YAMAWA
Consistency.
Performance. 1507 E. McFadden Ave. Santa Ana, CA 92705

Customer Service 855-YMW-USA1 855-969-8721
Ph:714-782-0960 Fx:714-380-6324
www.ymwtapsusa.com

End Mills Engineered NEW
SOLUTIONS® USA
for Machining Inconel CNC Rotary Tables ...
LMT Onsrud LP’s MXR and
into the future with
HXR end mills are designed
to meet the challenges of
machining Inconel and other
nickel-based materials. Both
4th & 4th/5th axes
tool series are coated with for your machine
EnduraSpeed for better tool
life and performance.
The MXR series has been
engineered for heavy profil-
ing, allowing for 15% radial
engagement during machin-
ing. The optimized variable
geometry delivers high
material removal rates along 5-axis grinding in the aviation industry with the T1-507510.
with a quality surface finish.

Tools are available with four
or five flutes and with multi-
ple corner radii. A four-flute MXR HXR Modular
ballnose version for contour- construction.
ing is also available.
Configured in seven-, nine- or 11-flute options,
the HXR end mill line has been developed for lower
radial and higher axial engagement for high-efficiency
machining (HEM). Longer tool lengths incorporate
a chipbreaker design to enhance chip removal and For hundreds
of solutions.
thereby increase tool performance.
| LMT Onsrud LP | 800-234-1560 | onsrud.com
Your benefits
morespacefor PGD–backlash
Workholding System Provides workpiece. free & lifelong
Three-Sided Workpiece Access morefreeload preloaded gear.
capacity. IP67–nowallet
Kurt’s rotary table workholding system is designed
using the company’s DX6 CrossOver hydraulic vise with higher productivity. pLiBox4.3–
Strongclamping– predictive
a trunnion mounted onto a fourth-axis rotary table. The
higher precision maintenance.
system uses double-acting hydraulics for automated
part loading and unloading via a robotic system. The wideuserange. Excellentservice.
system can also be used for manual part loading and
unloading. This provides three-axis vertical machining ... for many applications
centers with three-sided access to a part in one
Milling / boring (drilling), grinding, engraving,
clamping.
laser machining, water jet drilling, measuring.
The DX6 CrossOver hydraulic vise is manufactured
with the flatness, parallelism and strength for critical
high-precision machining, according to the company.
High clamping force keeps workpieces rigid as they are
machined on each side. The hydraulic vise features a pL SOLUTIONS USA LLC
1
/4" jaw stroke. The vise body also provides chip evacu- www.us-pl-lehmann.net
ation at its sides and ends to prevent chip buildup.

HIGH VOLUME
HOLE DEBURRING
Perfected in Michigan
• For holes from 1.5 to 25.4 mm

• Customs available
• User friendly
• Proudly Made in the USA
Michigan Deburring tools work better, last longer

and lower your cost per hole!

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1,, 810-227-1000
/"" Brighton, Michigan
The rotary table system features complete integra-

tion of workholding, rotary table and mounting base. The
GRIPPERS. vise includes a GrooveLock jaw plate and workstop for

convenient part positioning as well as a larger bearing
PINS. pack to increase durability. A new brush seal design

eases removal or replacement in the nut.
| Kurt Manufacturing - Industrial Products
ROLLERS. 877-226-7823 | kurtworkholding.com
Expanded Turning,
Boring Line Features
Vibration Damping
Seco Tools has expanded its long-reach turning and boring
products with additions to its Steadyline vibration-damp-
ing turning/boring bars. The new additions include 1.00"
(25-mm) diameter Steadyline bars, GL25 turning heads
and 4.00" (100-mm) diameter Steadyline bars, along with
a range of rough- and fine-boring heads.
Steadyline tools are said to deliver accuracy in
long-overhang applications and boring operations
ranging in depth to 10×D for small or large holes. In
addition to the Steadyline’s internal damping system,
the short and compact GL heads are also said to max-
imize vibration absorption, making it possible to use
extended lengths without tool chatter. The GL connection
LOCATE YOUR
DEALER ONLINE!
www.fairlaneproducts.com
800.548.2935

is designed for quick change-out of turning and boring interfaces. The 16 new GL25 turning heads are designed
tool heads while providing centering accuracy and for applications like general turning, recessing and back
repeatability of 5 microns and 180-degree head reori- boring with DN..11, CC..09, DC..07, DC..11, TC..11 and
entation if required. VB..11 inserts. The larger 4.00" (100-mm) diameter bars
The 1.00" (25-mm) diameter bars with GL25 work- accommodate existing GL50 turning heads and incorpo-
piece-side connection for 6×D, 8×D and 10×D reach rate Jetstream Tooling high-pressure coolant technology
are carbide-reinforced to meet deep tool overhang for adapters BA through GL50.
challenges. These tools are also available with Seco- | Seco Tools LLC | 248-528-5200 | secotools.com/us
Capto, HSK-T/A and cylindrical shank machine-side
Deburring Blade Designed to Enable Automation

of Hand Processes
The pneumatically controlled, articulated design A simple mechanical design without high-speed
of ATI Industrial Automation’s Compliant Deburring moving parts makes the CDB ideal for collaborative
Blade (CDB) enables users to tune the contact force robotics processes, while axial and radial compliance
to accommodate specific applications by changing maintains constant force when deburring surface
the air pressure. The CDB is said to excel in light and irregularities. Integrating the CDB into a robotic
medium deburring, chamfering and scraping opera- material removal application not only reduces robotic
tions on materials such as plastic, aluminum, steel programming time, but also makes the programming
and brass. The robust collet accommodates a variety process easier, according to the company.
of blades and media used with hand deburring tools. | ATI Industrial Automation | 919-772-0115
The blades can be changed without the use of addi- ati-ia.com
tional tools.
• 100% SPINDLE CAPACITY WHILE ACHIEVING MAX SPEED & FEED RATE
• SHORT FLUTES FOR MAXIMUM RIGIDITY
• IDEAL FOR CYCLE TIME REDUCTION
• OPTIMAL CHIP EVACUATION AT HIGH SPEEDS
• OPTIMAL WORK PIECE FINISH
• VARIOUS END CONFIGURATIONS AVAILABLE
VISIT WWW.KYOCERA-SGSTOOL.COM
OR SCAN THE CODE FOR MORE
INFORMATION.

Drill Provides
Scientific Cutting Tools
Stability with Reliable
Our pride in workmanship assures product
Chip Removal
quality every time. That’s the SCT guarantee. Built for a variety of drilling applications, Walter USA’s
D3120 indexable-insert drill features square positive
Premium Submicron Carbide inserts with four cutting edges, reducing cost per edge.
Tools are Triple-Inspected Available in five diameter sizes ranging from 0.63" to
Made in America 1.654" (16 to 42 mm) and with lengths of 2×D, 3×D
Thread Mill Code Generator and 4×D, the drill is said to deliver process reliability
Guaranteed Concentricity with efficient chip removal. Two through-coolant chan-
nels and hardened and polished flutes and surfaces
protect against friction and improve coolant flow. The
D3120 is suitable for ISO material groups P (steels), M
(stainless steels), K (cast irons), N (nonferrous) and S
(super alloys).
www.sct-usa.com 1.805.584.9495
sales@sct-usa.com 1.800.383.2244
Single Point - Thread Mills - Port Tools - Indexable Tools - Specialty
RE-TAP-ER
SECOND OPERATION MACHINE
The drill has one indexable insert shape for both

Forward hand pressure
outer and inner seats and a measuring collar for easy
rotates spindle counterclockwise
diameter identification. Torx Plus screws provide
secure insert clamping and stability in all working
conditions, the company says.
Backward hand pressure
Walter says its Tiger-tec Silver grades increase the
rotates spindle clockwise drill’s wear resistance because of its aluminum oxide
layer with optimized microstructure. Grades available
Lowest Priced Rugged Construction
for the D3120 include:
Lightweight & Portable • WKP25S and WKP35S for ISO steels, cast irons,
Retap Threaded Parts • Inspect Threads • Counter-sinking and good or moderate machining conditions;
Chase Threads • Deburring • Reaming • WSP45S for steels, stainless steels, super alloys
and difficult machining conditions;
• WK10 for aluminum; and
• WXP40 primarily for central inserts.
PREMIER TOOLING FOR THE MANUFACTURING INDUSTRY | Walter USA LLC | 262-347-2400
109 Scott Road, Waterbury, CT 06705 walter-tools.com/us
PHONE (203) 753-2114 FAX (203) 756-5489
Call Today for Our Free Tooling Catalog
www.sommatool.com sales@sommatool.com

Boring Tools Make Larger Holes and

Eliminate Special Tooling
According to Big Kaiser, limitations of using milling tools
to prepare holes for finishing become apparent as hole
depth and volume increase. Designed to address these
limitations, the company’s 319SW Twin Cutter series of
boring heads can machine holes ranging in diameter
from 0.787" to 8.000" as well as perform rough boring
and semi-finishing operations. These tools can also
eliminate having to make multiple passes on the same
bore, the company says, and enable the use of existing
smaller tools to create a starting hole. Sometimes, for
example, cast parts have more material to remove than
was initially expected. Being able to balance- or step-
cut with the same boring head helps to minimize tooling
and cycle times, says Big Kaiser.
Accessory insert holders enable the Twin Cutter
series to perform auxiliary operations not normally
associated with this type of tooling. For example, some milling cutter. Back-boring holders can even eliminate
parts require several bores to be machined in line with the need for expensive dedicated special tools, and face
a blended angle in between. Insert holders with an grooving holders allow plunge cutting rather than mill-
adjustable insert cartridge allow completion of the bore ing, for a better surface finish, the company explains.
while producing the blend angle in one pass, thus elim- | Big Kaiser | 888-866-5776 | bigkaiser.com
inating the need for follow-up tooling such as an angled
lang-technovation.com

Systems and Software
CNC Meets the Accuracy Needs of Aerospace

Machine Shops
Fagor Automation has developed the 8065 CNC with features necessary for high speed and surface finish
quality while maintaining accuracy. The CNC is seen as a complement to aerospace machine shops and those
requiring extreme accuracy.
Each 8065 is offered with a 10", 15", 19" or 21" high-resolution LCD TFT color or touch screen. Also
included is Ethernet, USB and built-in touch sensitive mouse pad. The 8065 can control up to 28 axes and four
separate spindles with four different execution channels
with auto-tuning system setup capability. In addition,
the CNC includes block processing speeds of less than
0.5 ms while analyzing the tool path with high-speed
block look-ahead at nanometric resolution. Combined
with the Fagor Adaptive Real-time Feed & Speed control
(ARFS), the CNC analyzes machining conditions such as
spindle load, servo power and tool tip temperature, and
it adapts both the axis feed rate and the spindle speed
accordingly. The results include reduction in cycle times,
better part finish, extended spindle and servomotor life,
and improved tool utilization, the company says.
Equipped with the aerospace-specific HSSA (High
Speed Surface Accuracy) machining system, the
CNC is said to provide reduced mechanical stress on
the machine for smoother movement and the potential of higher feed rates. In addition, the On-Board Bode
Diagram tool enables measurement of the machine’s frequency response for filtering the machine vibrations
incurred by the various operating conditions and environment.
| Fagor Automation Corp. | 847-981-1500 | fagorautomation.com
Control HMI Handles Extreme Environmental Conditions

ABB has expanded upon the current CP600 control simplifies integration of products without network inter-
platform to provide a human-machine interface (HMI) faces, and USB ports and SD cards facilitate backups
for high-end applications and challenging installations. and system updates.
The CP600-Pro promotes reliable operation within an Like the other control panels in the CP600 platform,
environmental temperature range of -4 to 140°F and the CP600-Pro is fully compatible with ABB’s AC500 and
features a true glass touch screen for clear information AC500-eCo PLCs, and includes all standard HMI func-
display and easy operation. Strong aluminum front tions such as alarm management, schedulers, recipes,
frames ensure IP66 protection, and the all-black front trends, data acquisition, gateway function and user
design is appropriate for multiple applications either in management.
landscape or portrait format. The screen can be configured and programmed with
Available in 5", 7", 10.1", 15.6" and 21.5" screen Panel Builder 600, which eases the creation of graphical
sizes, the panels provide HMI functions with multi- HMI pages. It includes libraries of ready-to-use vector
touch operation. Three Ethernet interfaces — one with graphics and a set of widgets so that applications can
10/100/1000 Mbit — support up to three networks. be designed efficiently.
With an OPC UA server and client protocol, the CP600- | ABB Inc. | 800-435-7365 | abb.com/robotics
Pro is prepped for TSN connectivity. A serial port

Program
Griffo Brothers Inc. From
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Support for Mazak SMOOTH, Smart, Matrix, Fusion 640,
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SYSTEMS AND SOFTWARE
AUTOMATION . . . that pays for itself

Affordable Lights-Out Solutions. Built to Suit
Small Conveyors - Uni-Mate™

Accumulator Tables
800-586-4585
Ask for a quote.
www.mini-mover.com
www.mini-mover.com Mini-Mover Conveyors CAM Software Enables Programming
for Robotic Machining and Finishing
SprutCAM America, the official North American reseller
of the multi-axis CAM software of the same name, has
released SprutCAM 12, featuring a more user-friendly
interface and a 2D CAD editor integrated into the model
page. Other features include:
• Product and Manufacturing Information (PMI)
import
• Adaptive SC high-speed machining
CAM? Still satisfied? • Painting simulation
• Five-axis toolpath conversion
Explore the benefits of hyperMILL ®
The company’s SprutCAM 12 Robot version, a single

and switch to the CAM solution for
all of your 2.5D, 3D, 5-axis, mill-turn,
environment for the offline programming of industrial
HSC and HPC requirements. robots, supports milling with a robotic arm. Other fea-
tures are available through an optional module that
includes robotic cladding, plasma cutting, waterjet cut-
ting, welding and sawing. SprutCAM Robot supports pro-
gramming for various industrial robots, including FANUC,
Kuka, Staubli, Yaskawa Motoman, Toshiba, Mitsubishi,
Nachi, ABB and others.
| SprutCAM America | 608-849-4430
sprutcamamerica.com
Quality Control Dashboard

Software Integrates with
Machine Monitoring
© The helmet was programmed and produced by DAISHIN
The eNET QC Status Dashboard from eNetDNC is a

locally hosted software product that works in con-
junction with the company’s eNET Machine Monitoring
product to increase visibility and accountability for
the quality control department’s first-piece inspection
process. The dashboard is fully interactive with any
touchscreen and is designed for a large-screen display
in the QC department. If desired, QC managers can also
display a seat of the QC Dashboard on their desk com-
www.openmind-tech.com
puters for increased department visibility.
When the first piece is scanned at a machine, that

job will immediately be time-stamped and blink on to keep a machine waiting on a first-piece inspection
the QC Dashboard to catch the attention of any avail- locked in setup mode until the job’s status has been
able inspector. That job will remain in the first-piece changed to approved. Once an inspector changes the
status until the inspector interacts with the job on the job status to approved, all of the live eNET Machine
QC Dashboard and changes its status to in process. Monitoring dashboards will also change the job status
An automated email or text notification can be sent to to match, so that the operator knows they can begin
the QC manager from eNET Machine Monitoring if a running production for the job. The first cycle run by
machine remains in the first-piece status for a prede- the machine after a status change to approved will
termined length of time. Once the first-piece inspection automatically put that job into “production” mode in the
is completed, the inspector changes the status on the eNetDNC Machine Monitoring software and cause that
dashboard to approved or failed. job to be removed from the eNET QC Status Dashboard.
The machine monitoring software can also be setup | eNetDNC | 414-817-7070 | enetdnc.com
Machine Monitoring at Your Fingertips
Peace of mind anywhere, anytime.

Mitsubishi Electric proudly presents the IMA Mobile app.
IMA Mobile is an MTConnect® compliant application, which
works in conjunction with our IMA Adapter and any other controls
that use MTConnect. The IMA Mobile app gives you real-time
data of your machine shop and sends push notifications of status
changes to ensure you’re running at optimal levels. Whether you’re
in the shop or on the go, our IMA Mobile app is here to provide you
peace of mind 24/7.
For the fastest part processing, best finishes, and IIoT capability,
always choose Mitsubishi Electric CNCs
Automation Simplified.
us.mitsubishielectric.com/fa/en/support/services/imamobile

CAM Add-On Makes

Bulk Material Removal
More Efficient
NCCS Corp. has developed an add-on module to
NCL with VoluMill, its multi-axis machining software
commonly used in the aerospace, automotive and
turbo-machinery industries, to enable high-speed bulk
material removal rates. The add-on is said to shorten
cycle times compared to traditional milling with less
machine wear and better tool life.
For open shapes, the programmer can cut any com-

bination of part/stock boundaries; all open edges are
fully leveraged for efficient machining and to minimize
plunging into the material.
It's easy to say your tooling Intelligent slot and side milling options comprise
solves problems . another feature. For softer metals, the software deter-
It's harder to mines the fastest possible cycle time and intelligently
selects slot milling or side milling to maximize the
prove it. material removal rate. Feed rates and axial depths of
We prove it cut are automatically adjusted in slot milling to main-
every day. tain a constant material removal rate but can be over-
ridden by the programmer. For harder materials, users
can configure side milling over the entire tool path to
avoid burying the cutter. The software behaves simi-
larly to make small-pocket machining more efficient.
The software provides high-feed repositioning with
floor clearance, taking advantage of the machine’s
capabilities in order to move the tool as safely and as
quickly as possible when not engaged in material. It
Stuck on a tough tooling challenge? Let us help. ensures that the tool clears the floor by a small amount
Heimatec isn’t just a world leader in live tools, angle heads and when repositioning at the highest possible speed with-
multi-spindle drill heads; we’re your source for problem solving
and tooling application expertise. out dragging it across an already-machined floor.
With years of hands-on experience and the most innovative With automatic feed adjustment, the programmer
tooling, we are your TOTAL solution source. can maintain a more consistent load on the cutting tool
Put us to the test and send us your toughest tooling challenge. with no feed rate optimizer needed. VoluMill tool paths
16 E. Piper Lane, include precise and automatic feed rate optimization,
Prospect Heights, IL the company says.
Suite 128 847-749-0633
info@platinumtooling.com
www.platinumtooling.com
| Numerical Control Computer Sciences
949-852-3664 | nccs.com

CNC Can Now Import Solid 3D CAD Models

The Hurco Max5 control now includes a 3D Import fea- outputs, including splines. For example, with 3D DXF, the
ture with 3D DXF technology enabling the user to load user can select the bottom of a contour, and the Z-axis
the file they receive from their customer directly into depths will also be automatically input into the conver-
the Hurco control. sational block.
“3D Import eliminates extra steps and is a huge time Previous versions of DXF translators only displayed
saver,” says Mike Cope, product technical specialist for lines and arcs data, and were only useful in two dimen-
Hurco. He says that paper prints are growing obsolete sions, since no Z-axis data were translated, the com-
for many shops as it becomes more common for them pany says. The solid model portion of 3D Import auto-
to receive solid models of the parts they need to pro- matically creates the necessary Transform Plane data
duce. In response, he says, Hurco developed 3D Import, blocks in conversational programming for five-sided
which displays all geometry that the CAD system programs.
Your factory floor:

in the palm
of your hand.
Make data your competitive advantage with our
machine monitoring and predictive analytics platform. machinemetrics.com

Powered by WinMax, the Max5 control is designed

for flexibility and intuitive operation. It is equipped with
a 2.7-GHz dual-core processor, 4 GB RAM, a 128-GB
solid-state hard drive, 10,000-block lookahead, and a
graphical user interface that supports multiple machin-
ing strategies.
| Hurco Companies Inc. | 800-634-2416 | hurco.com
Machine Monitoring
System Accounts for
Planned Downtime
Version 2019.01.15 of Scytec’s DataXchange machine
LARGE-CAPACITY monitoring system, available from Shop Floor

Automations, incorporates new features based on user
BOX FURNACES
feedback.
Users wanting to properly track scheduled down-
time can now plan for specific downtime in the shop.
They can schedule holidays, plant shutdowns, planned
maintenance and more. These planned downtimes will
Temps to 2200ºF/
1204ºC
4-96 cu. ft. capacity
Gas & Electric
models
Lightweight ceramic
fiber insulation
Heavy-duty ceramic
hearth plate
www.grievecorp.com 847-546-8225

automatically be recorded and reported. These signals alert users if the machine is running or
Users can also now import the current part, ideal not.
times and work orders by using an import template. Other modifications have been made to Focas con-
Once that information is in the system, they can see nectivity, charts and reports, RTV screens, user events
real-time data regarding work orders as well as histori- and more.
cal information. | Shop Floor Automations | 619-461-4000
For shops with older equipment, the hardware can be shopfloorautomations.com
added to legacy machines to monitor electrical signals.
CNC System Incorporates Robot Control

Through a cooperative agreement, Siemens and is said to help improve path and positioning accuracy
Comau now offer a jointly engineered Sinumerik Run as well as reliability. It also yields enhanced dynamic
MyRobot DirectControl product. This product enables response during robot-aided machining tasks. As a
robot kinematics to be fully integrated into a CNC result, the companies claim, the robot is able to under-
system. The Sinumerik CNC controls the articulated take more challenging machining assignments, while
robot arm directly with the basis of complex algo- users receive the advantages of compact hardware,
rithms without the need for a separate robot con- simpler engineering and faster commissioning. Additive
troller, as the operations are entirely controlled on a manufacturing, fiber placement, machining, carbon fiber
second channel of the CNC. reinforced polymer and laser machining are among the
The Sinumerik Run MyRobot DirectControl solution sectors the company says this product can benefit.
allows the CNC both to control the robot arm drive | Comau Robotics spa | 39 01 10 04 9111
system and to contain safety functions typically per- comau.com
formed by the robot controller. | Siemens Industry Inc. | 800-879-8079
Integrating control of the robot arm into the CNC usa.siemens.com/cnc
Why you’ll love Tebis!

• Automate processes in 3 to 5 axis
NC programming
• High-end surface technology creates
best-in-class finish
• Integrated simulation capabilities allow
for stress-free, lights-out machining
Manufacture high-quality molds and dies faster.
Tebis America
HIGH-QUALITY 400 E. Big Beaver Rd., Troy, MI 48083
EFFICIENT 248.524.0430
RELIABLE Find out more at www.tebis.com
Follow us on:

Automated Titanium
Software Connects
Color Anodize Machine Tools Across
Equipment and Chemistry Brand for Shopfloor
Monitoring
Excellerant, a division of Macdac Engineering, is the
name of a system designed to simplify data-driven
manufacturing at the shopfloor level, connecting CNCs
across brands to send data to MES and ERP systems.
It builds on MTConnect, FANUC Focas, OPC-UA, Haas
MNET Q Codes, and other machine control connecting
protocols, even legacy CNC machines, the company
says. This allows companies to link across systems
while expanding and customizing the information they
receive.
716.763.4343 www.miraclean.com
Although some control systems offer the ability to

link devices of the same brand, manufacturing compa-
nies often have a variety of different control systems
and a combination of older and newer machines, thus
requiring a more universal solution. Excellerant is
branded as one such solution.
Designed with the knowledge that products like
Excellerant are only effective when staff are inclined
to use them, the system is engineered for ease of
use across work groups and operational levels. This
is achieved through a simple graphical user inter-
face, clear and logical functionality, and an array of
convenient output types, the company says. Machine
operators can communicate problems, request assis-
tance and report progress at the touch of a button.
Supervisors and managers can assess cycle time,
downtime, and process status by job, machine type,
operator and a host of other useful dimensions.
Executives can run reports in real time with continuous
and immediate feeds, from machine controllers to the
ERP system. These capabilities enable timely assess-
ments of progress, capacity and bottlenecks, fueling
more accurate forecasts and dynamic scheduling.
| Macdac Engineering Inc. | 860-749-5544
macdac.com

Software Increases Reliability of

NC Verification
Based on client/server scheduler architecture, the new
version of NCSIMUL’s machining module available from
Hexagon Manufacturing Intelligence includes automa-
tion functionality that gives the user wider control over
their jobs on other devices by communicating with
distant servers.
Philippe Legoupi, NCSIMUL technical director,
explains that a dedicated graphical user interface (GUI) program verification and simulation accurately follows
enables the performance of tasks such as simulation, requirements.
cut analysis and 3D movies on any device. “Users can The module also maximizes license usage. For exam-
follow the status of the job and receive a notification ple, if a manufacturer has just one license, they can use
when it’s complete,” he adds. this module to postpone tasks with the scheduler until
The Automation Module ensures that the entirety of lunchtimes or overnight.
the program sent to the workshop is validated by the The NCSIMUL Machine 2020.0, which detects NC
simulation, since “for most minor modifications in the programming errors and any potential collisions from
CAM system, such as the number of passes or changing the same NC code that drives the CNC machine, also
the cutting conditions, the end user won’t verify the contains enhancements to a variety of functions, includ-
program because it’s too tedious.” The system enables ing Probing and Optitool.
customers to implement their own automation rules The latest release of NCSIMUL’s flexible CNC pro-
according to constraints and production priorities. The gramming module, 4CAM, also includes a number of
tasks all feature in a command file, which also shows new and enhanced functionalities.
the parameters to use and allows for customization. | Hexagon Manufacturing Intelligence | 800-343-7933
These features are meant to assure users that all hexagonmetrology.us
MONITOR TODAY -
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•Rapid software deployment
Call us today at (877) 611-5825
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Modern Equipment Review

SPOTLIGHT EDM
Hole Drilling EDM Available

in Three- or Five-Axis
Configurations
Current EDM has released the CT400 CNC hole drilling machine
designed for toolroom and production drilling applications. The
machine is available in three- and five-axis configurations for appli-
cations requiring the drilling of holes at multiple angles. It features
a moving bridge designed for greater weight capacity and minimal
machine footprint. High-quality slides and ball screws optimize posi-
tioning accuracy, says the company. The granite worktable is said
to provide flatness and electrical insulation to improve machining
performance.
The CT400 is available with the company’s AEC24 automatic
electrode changer for production drilling applications.
| Current EDM Inc. | 650-966-9676 | currentedm.com
EDM Handles Larger Parts

MC Machinery’s MV2400-ST, a wire EDM, is specifically designed for
large-part production, capable of performing submerged cutting as
deep as 16.5". With an annealing length of over 21", its automatic
wire threading system can thread the maximum workpiece height
both at the start point and through the gap if needed for a broken wire
recovery, the company says.
The EDM also features Mitsubishi’s
M800-series control with a 19" touchscreen
providing easier user interface than previous
models. The control uses rotational and tilting
functionality while showing job monitoring and
other important information in a single view.
The new navigation interface is also said to
provide intuitive operation for users of different
expertise.
| MC Machinery Systems Inc.
888-297-9895 | mcmachinery.com

0.016" puts you
miles ahead
Double your cutting speed—not your wire
consumption—with 0.016" wire.
Makino’s new U6 EDMs are the first to use HEAT Extreme 0.016" wire
that cuts 2x faster than 0.010" wire in side-by-side tests. It’s also packed
with performance boosters that lead to more unattended reliability:
• (x2) High capacity digitally controlled flush pumps
• Simpler wire threader design
• Enhanced power generator
No other EDM wire can do what HEAT Extreme does. And no other
machine has as much power to transform your EDM production.
For a quick look at faster performance,

visit makino.com/extreme
MODERN EQUIPMENT REVIEW SPOTLIGHT | EDM
EDM’s Wire Feed

System Improves
Threading Capability
Available from Methods Machine Tools, the FANUC
Robocut C800iB-20 wire EDM offers features for
increased accuracy, efficiency and throughput.
This EDM is available with a larger Z-axis config-
uration and can accommodate workpieces with a
maximum size of 49.21" × 38.38" × 19.68" and
weighing as much as 6,613 lbs. The C800iB-20
is designed for a range of applications including
large molds and stamping dies as well as complex
aerospace parts. pulse control further improves straightness, corner
FANUC’s high-speed AWF3 automatic wire feed accuracy, surface finish and cutting speeds by keeping
system helps to thread wire within the machine’s max- the gap consistent according to discharge status and
imum 500-mm work thickness (submerged) with an cutting shape.
automatic wire recovery to 150 mm work thickness (sub- The FANUC core stitch slug retention feature pre-
merged) when cutting non-parallel-plane workpieces. vents slugs from dropping, saving time and increasing
Improved pitch error compensation over the entire efficiency. The core stitch function enables operators
cutting area, mapped by grid patterns to within ±2 to set stitch points for cases where long, unattended
microns, increases machining accuracy. According to the machining and multi-workpiece cutting are necessary.
company’s factory tests, the machine can consistently | FANUC America | 888-326-8287 | fanucamerica.com
achieve 0.0002" positioning accuracy and 0.0001" | Methods Machine Tools Inc. | 877-668-4262
repeatability, even during long burns. An iPulse2 flexible methodsmachine.com
Wire EDMs Offer Either Ballscrew or Linear Axis Models

AccuteX’s GE-SAi and GE-SAiL CNC wire EDM machines, Both models are part of AccuteX’s Great Economy
available from Absolute Machine Tools, feature ergo- (GE) series. The machines in this series are engineered
nomic enhancements and a choice of either traditional for reliable, economical production of small parts and
ballscrew (SAi) or AccuteX linear motion (SAiL) axis drive components.
systems. An ergonomic, space-saving design includes a | Absolute Machine Tools Inc. | 800-852-7825
drop door and three-sided table (back rail optional) as absolutemachine.com
well as fully annealing, automatic wire threading (AWT)
and the ability to perform submerged machining as deep
as 8" (195 mm).

SPOTLIGHT | EDM MODERN EQUIPMENT REVIEW
10-Foot-Wide Sinker EDM Applies

Linear Axes for High Precision
Sodick’s AG200L is its largest sinker EDM at nearly 10 well-suited for burning high-precision features such as
ft. wide with a worktank 15% larger than the AQ20L. The ribs and subgates into large molds, the company says.
AG200L is designed for simplified operability so that users Standard AG200L specifications include a worktank
of the smaller AG100L and AG80L models can more easily size of 118" × 70.8" × 37.4" and X-, Y- and Z-axis travels
add the AG200L to their capabilities. measuring 78.7" × 47.2" × 31.5". All axes are driven by
The AG200L’s cast iron construction improves stability Sodick’s rigid linear motors with glass scale positioning
and reduces deflection with heavy workpieces. As a large- feedback.
size sinker EDM with linear motor drives, the AG200L is | Sodick Inc. | 888-639-2325 | sodick.com
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STORE NEAR YOU 3744 Plaza Drive, Suite 1C • Ann Arbor, MI 48108 / U.S.A.
Tel.: (734) 761-9549 • Fax: (734) 761-1171 • e-mail: info@borriesusa.com

MODERN EQUIPMENT REVIEW SPOTLIGHT | EDM
Wire EDMs Deliver Cost-Effective Performance

GF Machining Solutions offers the AgieCharmilles Cut C measurements and machining. A low-maintenance
350 and Cut C 600 wire EDMs for U.S. manufacturers design reduces the number of components and con-
that want higher performance with lower operating sumable parts in order to lower operating costs. Along
costs. The company says the machines provide opti- with an integrated anti-collision protection system, the
mized cutting speeds and reliable accuracy, while their machines include linear glass scales and encoders for
AC Cut HMI 2 interfaces ease programming through high production accuracy.
efficient EDM expert modules. Easily accessible wire spool holders enable fast and
Both models offer manual-mode setup for access to easy changes, the company says. Automatic threading
main functions, enabling operators to perform manual systems thread hard, soft, coated or uncoated wire for
reliable lights-out manufacturing.
Both the Cut C 350 and Cut C 600 operate with
digital Intelligent Power Generators (IPG) for optimized
cutting speeds. With the IPG, the machines can gener-
ate surface finishes of 0.25 micron Ra in carbide and
0.30 micron Ra in steel. Additionally, several Expert
Intelligent technologies manage surface quality and part
precision while streamlining overall operation, according
to the company. For wire breakage prevention on vari-
able-height parts, the Power-Expert intelligent function
automatically selects power levels. Corner-cutting strat-
egies automatically adjust machining parameters during
changes of cutting direction to create accurate sharp
angles and small radii.
File and project management features enable
operators to configure and sequence jobs, follow job
progress, manage digital project documents and access
the AC CAM Easy programming system for autonomous
operation.
| GF Machining Solutions LLC | 800-282-1336
gfms.com/us
be progressive. be SW
W W W. S W - M A C H I N E S . C O M

SPOTLIGHT | EDM MODERN EQUIPMENT REVIEW
Mill-Turns Enable Six-Sided

Complex Machining
Stama, a member of Chiron Group, has introduced the
MT 733 series of vertical-spindle mill-turns for machin-
ing a range of complex parts complete in a single work
cycle. The machining centers are capable of six-sided/
simultaneous five-axis machining, including milling
and turning from barstock or from chucked parts. The
machines are designed to fit the needs of aerospace,
automotive and medical parts manufacturers.
Both the one- and two-spindle machine configura-
tions are equally capable of machining a range of
materials from aluminum to high-alloy steel bar with base frame in a thermo-symmetric structure with high
diameters ranging to 102 mm and lengths ranging to heat capacity and low heat conductivity. Adaptive soft-
1,020 mm. The machines accommodate workpieces as ware for active milling spindle compensation helps
long as 250 mm and chucked parts with diameters rang- reduce temperature-related variations in the Z axis. The
ing to 250 mm. Milling spindle speeds range to 20,000 process is aided by cooled linear guides, chip channels
rpm, turning spindles to 4,200 rpm, spindle acceleration and structural components throughout. Notably, the new
to 1.3 G and rapid traverse speeds to 56 m/min., mini- series includes a B-axis drive unit with zero backlash
mizing cycle times while processing parts complete. kinematics and high torsional rigidity, resulting in a
The MT series offers parallel complete machining in robust system with higher accuracy and repeatability,
two work zones on an MT 733 Two or MT 733 Two Plus according to the company.
for doubled process productivity. The automatic work- | Chiron America Inc. | 704-587-9526
piece in feed and output is a standard feature. chironamerica.com
The MT 733 is designed with a polymer-concrete
Wire EDM Boosts Productivity

without Sacrificing Accuracy Fast Hole EDM Provides
Manufactured in Taiwan and distributed throughout
the United States, the W-EDM S series of CNC wire
Accurate Axis Movement
EDMs from Kaast delivers surface quality combined The FH30 from Beaumont Machine is a fast-hole EDM
with technologies to help keep production efficient. with 16-axis capability, a rotary table with accuracy
Automatic corner control contributes to high geometric ranging from 3 to 5 arcseconds and repeatability
accuracy during production. Automatic wire tension ranging to 0.0002". With an electrode capacity of 24"
monitoring helps to ensure that tools are machined (diameters from 0.012" to 0.250"), this machine is
quickly without sac- useful for aerospace, medical, power generation and
rificing precision. The semiconductor applications. Onboard drive resolution
machine is equipped and absolute encoders provide high accuracy and
with a 64-bit CNC with rapid traverse speeds ranging to 400 ipm in the X,
2D/3D graphics for Y and Z axes, with 200-ipm rapid traverse speeds
six-axis machining of in the W axis. The X-, Y- and Z-axis travels measure
complex forms. 30" × 20" × 26", and the machine’s spindle speed is
The automatic wire 3,000 rpm.
threading (AWT) option The machine features an automatic electrode
(0.006" to 0.012" changer and robotic toolchangers. Siemens and other
copper wire with a CNCs are available.
waterjet 0.04" in diameter) further saves production | Beaumont Machine LLC | 513-701-0421
time. beaumontmachine.com
| Kaast Machine Tools, Inc. | 888-765-2278
kaast-usa.com

Modern Equipment Review

Benchtop CNC Router Mills Metal as
Well as Wood
The Spyder CNC milling machine from APSX cuts metal,
wood and plastic. The company says it designed the
machine to fill what a void in the CNC router market for
machines that cut specifically metals, not just wood. The
machine features a configured LinuxCNC, an embedded
PC, a monitor, a keyboard and a pendant. It uses a wall
outlet to power its control box and monitor.
The liquid-chilled spindle operates at speeds ranging
from 2,000 to 20,000 rpm and, according to the com-
pany, provides high torque at low speeds. A water-air
mixing system facilitates cooling of the workpiece and
the cutting tool. Steel shafts, hard anodized aluminum
blocks, lead screws and strong stepper motors are said
to contribute to the machine’s rigidity. A solid concrete The system monitors spindle stress and can stop motion
base is available as an option. before too much workpiece or cutting tool damage
The machine saves the X, Y and Z coordinates, occurs, the company says.
enabling users to machine without homing the spindle. | APSX | 513-716-5992 | apsx.com
Multi-Spindle Machines Accommodate Both

Large and Small Batches
Schütte’s PC-series multi-spindle automatics perform tapping, milling, polygon cutting and eccentric drilling
operations. The machines feature either six or eight work spindles. The endworking and cross slides can be con-
trolled independently of each other.
The machining centers in the PC series are
designed to be used whenever classic cam-con-
trolled automatics reach their limit. The machines
can remove material from geometrically sophis-
ticated parts made of hard solid materials. Rear-
side machining can apply as many as three tools.
Over 56 CNC axes can be programmed with
Schütte’s SICS 2000 system. The automatics are
said to produce ready-to-install precision parts
in large and small batch sizes, minimizing setup,
non-production and part production times.
These machines are used by automobile manu-
facturers and suppliers in the fittings, pneumatics
and hydraulics sectors, as well as in the produc-
tion of precision parts, according to the company.
| Schutte TGM LLC | 517-782-3600
schutteusa.com

MODERN EQUIPMENT REVIEW
Electronic Weld Head System

Extends Force Range
Amada Miyachi America has updated its Series 320
electronic weld head system to increase the maximum
weld force to 7.0 lbs (3,175 gm) with a maximum follow
up force of 7.75 lbs (3,520 gm). Now it can handle a
wider range of applications requiring precise position
and force control.
Series 320 meets the process demands of micro-
electronics manufacturing but is robust enough to
endure industrial environments. The system can be
configured with in-line or offset opposed electrodes
to tailor the weld head for specific applications. The
weld-to-displacement feature stops the weld precisely
during collapse.
Also offered is an initial part detection feature that
detects missing or extra parts. Displacement limits
facilitate monitoring of both initial and final part thick-
Surface Grinder’s
ness. The software now includes a low-force dress
mode for preparation and cleaning of electrodes. This Sealed Spindle
feature decreases the routine maintenance required to
get precise, repeatable results. Promotes Service
The system is available with linear motion or two-
level footswitch options. A user-friendly I/O module Longevity
eases integration with a programmable logic controller Kaast Machine Tools’ saddle-style F-Grind AH series
(PLC). Four programmable relay outputs facilitate pre- high precision surface grinder is said to accommodate
cise process control. workpieces ranging from 5.8" × 17.5" to 15.5" × 31",
The Series 320 is ideal for safety-critical applications depending on the model. It features hardened, ground
in the medical, aerospace, precision electronics and and PTFE-coated table guideways. It also features a
automotive markets. With the expanded force range, the double-V guide for transverse movements and combined
system is a good choice for fine wire welding like squib flat and V guides for longitudinal movements.
wires as well as hearing aid components, electronic Spindle motors are available with up to 7.5 hp and
components and implantable medical devices. speeds ranging to 2,900 rpm. The class-P4 high-preci-
| Amada Miyachi America Inc. | 626-303-5676 sion angular contact bearing is said to provide runout
amadamiyachi.com accuracy better than 2 microns. The cartridge-type
spindle is completely sealed and lubricated, providing
high-accuracy grinding and a long service life, says the
company. The vertical feed moves in 0.01-mm (0.0004")
increments. The transverse feed moves in 0.02-mm
(0.0008") increments. Automatic downfeed from 0.001
to 0.999 mm (0.00004" to 0.04") is said to ensure a
smooth finish.
Users can add an optional AD5 automatic downfeed
system to enable fully automated three-axis grinding.
The optional AD5 NC decreases vertical feed increments
to 0.005 mm (0.0002").
| Kaast Machine Tools Inc. | 888-765-2278
kaast-usa.com

BUSINESS OPPORTUNITIES
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we provide deep, rich, actionable insights about durable goods manufacturing.
GARDNER BUSINESS INDEX TOP SHOPS CUSTOM REPORTS

A business trends index measuring monthly changes Enables shops to benchmark operational and
in new orders, production, backlog, employment and financial performance, leverage strengths, and
other critical measures. identify opportunities.
CAPITAL SPENDING DATA CUSTOM RESEARCH

Capital Spending data collected annually, regarding Forecasting, consulting, benchmarking, modeling and
budgeted spending on machines, testing equipment, custom research that reveal insights on technology,
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513-527-8800 gardnerintelligence.com
AD INDEX
2L inc. . . . . . . . . . . . . . . . . . . . . . .140 Griffo Brothers Inc. . . . . . . . . . . . . . . . . 123

Grizzly Industrial, Inc. . . . . . . . . . . . . . . 51
A
Grob Systems Inc. . . . . . . . . . . . . . . . . 41
Absolute Machine Tools, Inc. . . . . . . 3, 23, 35, 47
Additive Manufacturing Conference . . .109, polybag* H
Advent Tool & Manufacturing Inc. . . . . . . . . . 110 Haimer USA . . . . . . . . . . . . . . . . . . . 44
Air-O-Filter Environment Systems, Inc. . . . . . .126 Hardinge Inc. . . . . . . . . . . . . . . . . . 37, 93
amerimold 2019 . . . . . . . . . . . . . . . . . 113 HELLER Machine Tools . . . . . . . . . . . . . . 65
Aven Inc. . . . . . . . . . . . . . . . . . . . . . 56 HORN USA . . . . . . . . . . . . . . . . . . . . . 9
Hurco North America . . . . . . . . . . . . . . . . 5
B
Hwacheon Machinery America Inc. . . . . . . . . 53
Beaumont Machine, LLC . . . . . . . . . . . 45, 140
Hyundai WIA . . . . . . . . . . . . . . . . . . . 61
Beijing Jingdiao Group Co., Ltd. . . . . . . . . . . 89
Belmont Equipment & Technologies . . . . . . . .108 I
Borries Marking Systems . . . . . . . . . . . . .135 Ingersoll Cutting Tools . . . . . . . Inside Back Cover
Bucci Industries USA, Inc. . . . . . . . . . . . . 128 Iscar Metals, Inc. . . . . . . . . Inside Front Cover, 1
C J
Campro Precision Machinery Co., Ltd.. . . . . . .136 J.W. Done Corp. . . . . . . . . . . . . . . . . . 32
CERATIZIT USA, Inc. . . . . . . . . . . . . . 55, 97 Jingdiao North America, Inc. . . . . . . . . . . . 89
CGS North America Inc.. . . . . . . . . . . . . . 127 Johnford . . . . . . . . . . . . . . . . . . . . . 35
CGTech . . . . . . . . . . . . . . . . . . . 50, 103 JTEKT Toyoda Americas Corp. . . . . . . . . . .107
Chevalier Machinery Inc. . . . . . . . . . . . . .105 K
Cogsdill Tool Products Inc. . . . . . . . . . . . . 92 Kennametal Inc. . . . . . . . . . . . . . . . . . 67
Current EDM Inc. . . . . . . . . . . . . . . . . . 54 Kitamura Machinery of USA Inc. . . . . . . . . . 57
D Koma Precision Inc. . . . . . . . . . . . . . . . 49
Digipas Technologies . . . . . . . . . . . . . . .135 Kurt Industrial Products Division . . . . . . . . . 85
Doosan Machine Tools America . . . . . . . . . . 43 Kwik Mark Inc. . . . . . . . . . . . . . . . . . .102
DP Technology . . . . . . . . . . . . . . . . . . 69 KYOCERA SGS Precision Tools . . . . . . . . . . 119
E L
EMAG L.L.C. . . . . . . . . . . . . . . . . . . . 112 LANG Technovation. . . . . . . . . . . . . . . . 121
EMO Hannover . . . . . . . . . . . . . . . . . . 24 LMT Onsrud LP . . . . . . . . . . . . . . . . . .104
Eriez Magnetics . . . . . . . . . . . . . . . . . 98 M
F MachineMetrics, Inc. . . . . . . . . . . . . . . . 127
Fairlane Products . . . . . . . . . . . . . . . . 118 Makino. . . . . . . . . . . . . . . . . . . . 39, 133
Fastems LLC . . . . . . . . . . . . . . . . . . .100 Marposs Corp. . . . . . . . . . . . . . . . . . . 52
Fresmak S.A.. . . . . . . . . . . . . . . . . . .130 Mastercam/CNC Software, Inc. . . . . . . . . . . 19
Fryer Machine Systems. . . . . . . . . . . . . . 11 Mazak Corp. . . . . . . . . . . . . . . . . . . . . 7
MC Machinery Systems, Inc. . . . . . . . . . . . 71
G
Metal Supermarkets . . . . . . . . . . . . . . .135
Gardner Business Intelligence . . . . . . . . . . 141
Methods Machine Tools, Inc. . . . . . . . . . . . 21
GF Machining Solutions. . . . . . . . . . . . . . 40
Michigan Deburring Tool . . . . . . . . . . . . . 118
Greenleaf Corp. . . . . . . . . . . . . . . . 58, 59
Milltronics USA, Inc. . . . . . . . . . . . . . . . 15
Grieve Corp. . . . . . . . . . . . . . . . . . . . 128
Mini-Mover Conveyors . . . . . . . . . . . . . . 124
*Regional insert/ad included in select copies only.

AD INDEX
Miraclean . . . . . . . . . . . . . . . . . . . .130 SW North America, Inc. . . . . . . . . . . . . . .136

Mitsubishi EDM . . . . . . . . . . . . . . . . . 71 SwiftCarb . . . . . . . . . . . . . . . . . . . . 48
Mitsubishi Electric Automation, Inc. . . . . . . . . 125
T
Mitsui Seiki (USA) Inc. . . . . . . . . . . . . . . 25
Takumi. . . . . . . . . . . . . . . . . . . . . . . 4
MMS Top Shops . . . . . . . . . . . . . . . . .101
Tebis America Inc. . . . . . . . . . . . . . . . .129
Modern Machine Shop . . . . . . . . . . . . . . 33
Techspex, Inc. . . . . . . . . . . . . . . . . . . 111
MT360 . . . . . . . . . . . . . . . . . . . . . . . 6
The Up! App . . . . . . . . . . . . . . . . . . . 31
N THINBIT . . . . . . . . . . . . . . . . . .17, 90, 91
Next-Generation Aerospace Supplement . . polybag* Tool-Flo Mfg., Inc. . . . . . . . . . . . . . . . . 13
Northfield Precision Instrument Corp. . . . . . . . 88 Tungaloy America, Inc. . . . . . . . . . . . . . . 115
O U
OPEN MIND Technologies USA Inc . . . . . . . . 124 UNISIG . . . . . . . . . . . . . . . . . . . . . . 29
P V
Peter Lehmann AG . . . . . . . . . . . . . . . . 117 VDW - Verein Deutscher
Platinum Tooling . . . . . . . . . . . . . . . . .126 Werkzeugmaschinenfabriken . . . . . . . . . 24
Precihole. . . . . . . . . . . . . . . . . . . . . 47 Y
Q YG-1 Tool Company. . . . . . . . . . . . . . . . 63
Q-Mark Manufacturing Inc. . . . . . . . . . . . .134 YMW Taps U.S.A. . . . . . . . . . . . . . . . . . 116
You Ji . . . . . . . . . . . . . . . . . . . . . . 23
R
Royal Products . . . . . . . . . . . . .33a, 33b, 140
S
Sandvik Coromant . . . . . . . . . . . . . . . . 27
SCHUNK Inc. . . . . . . . . . . . . . . . . . . . 95
Schwanog LLC . . . . . . . . . . . . . . . . . . 87
Scientific Cutting Tools . . . . . . . . . . . . . .120
Seco Tools Inc. . . . . . . . . . . . . . . Back Cover
Setco . . . . . . . . . . . . . . . . . . . . . . 28
Shear-Loc . . . . . . . . . . . . . . . . . . . .140
Shop Floor Automations, Inc. . . . . . . . . . . . 131
Siemens PLM Software, Inc. . . . . . . . . . . . 99
Somma Tool Co. Inc. . . . . . . . . . . . . . . .120
Sumitomo Electric Carbide Inc. . . . . . . . . . . . 2
Supertec USA . . . . . . . . . . . . . . . . . . 96
Modern Machine Shop (ISSN 0026-8003) is published monthly and The information presented in this edition of Modern Machine Shop is
copyright © 2019 All rights reserved by Gardner Business Media Inc. believed to be accurate. In applying recommendations, however, you
6915 Valley Ave., Cincinnati, OH 45244-3029. Telephone: (513) 527- should exercise care and normal precautions to prevent personal injury
8800. Printed in U.S.A. Periodicals postage paid at Cincinnati, OH and and damage to facilities or products. In no case can the authors or the
additional mailing offices. publisher accept responsibility for personal injury or damages which may
Postmaster: Send address changes to Modern Machine Shop Maga- occur in working with methods and/or materials presented herein, nor
zine, 6915 Valley Ave., Cincinnati, OH 45244-3029. If undeliverable, can the publisher assume responsibility for the validity of claims or per-
send Form 3579. formance of items appearing in editorial presentations or advertisements
Canada Post: Canada Returns to be sent to IMEX Global Solutions, in this publication. Contact information is provided to enable interested
P.O. Box 25542, London, ON N6C 6B2. Publications Mail Agreement parties to conduct further inquiry into specific products or services.
#40612608.

GARDNER BUSINESS INDEX
Metalworking Index Continues

Modest Growth Trend
Index posts identical readings over three-month period. mguckes@gardnerweb.com
A.C. Michael Guckes, MBA

April’s Gardner Business Index (GBI): Metalworking registered 53.6 for CHIEF ECONOMIST—
GARDNER INTELLIGENCE
a third month in a row, marking 2019 as atypically static. Index read-
ings above 50 indicate expanding business activity while those below 50 Michael has performed
indicate contracting activity. April’s value is 10.4% lower than last year’s economic analysis, modeling
and forecasting work for
reading. nearly 20 years. Gardner
Gardner Intelligence’s review of the underlying components observed Intelligence is a division of
Gardner Business Media,
that the Index — calculated as an average of its components — was
publisher of this magazine.
supported by increased supplier deliveries, production and employment
activity. Components including new orders, exports and backlogs lowered
the Index. Both backlogs and exports contracted in April.
April’s growth in new orders extended the volatile pattern first
experienced in late 2018. Since reaching a peak in February 2018, the
three-month moving-average trend in new orders activity has signaled
decelerating growth. However, individual month-to-month changes have
expressed a much more volatile seesaw motion. Throughout 2019, new
orders readings have been the most volatile among all business index
components.
METALWORKING BUSINESS INDEX April’s increased business activity in

65
supplier deliveries, production and
employment was offset by a sharp slowing
60 in new orders. New orders readings have
been very volatile on a month-to-month
55
53.6 basis.
50
45
40
7/13 1/14 7/14 1/15 7/15 1/16 7/16 1/17 7/17 1/18 7/18 1/19 7/19
METALWORKING — SUPPLIER DELIVERIES & EMPLOYMENT (3MMA)

65
60
Closely similar Metalworking Index
readings throughout 2019 belie the
55 volatility in new orders, which have been
50
offset by improving monthly readings in
other components, particularly supplier
45 deliveries and employment.
40
7/13 1/14 7/14 1/15 7/15 1/16 7/16 1/17 7/17 1/18 7/18 1/19 7/19
Supplier Deliveries Employment
PRESENTED BY
Stay ahead of the curve with Gardner Intelligence.
Visit Gardner Intelligence’s blog at gardnerintelligence.com/blog.

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