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Where Will the Digitalization of Tooling Take You?

Exciting improvements in automation are already on their way—higher productivity, increased safety, greater throughput and less scrap. Breakthrough manufacturing processes include remote monitoring and automation, cloud-connected machine controls and robotics. More so, tool digitalization provides opportunities for production improvements, like our EWE digital fine boring tool. It displays the actual diameter of a tool, makes adjustments much simpler and faster, and reduces human error.

BIG KAISER Research and Development Engineer Nick Jew breaks down the process of digitalization in a recent Fabricating & Metalworking magazine article, “Next Steps in the Digitalization of Tooling and Its Impact on Operators.” He explains tools like the EWE are only the beginning in digitalization. Next is closing the automation loop. The EWA fine boring head is currently in Carbide Steel Inserts development—its remote Bluetooth commands will eliminate wasted time and risk that comes with an operator making manual adjustments. Lights-out boring becomes a real possibility with such innovations, adding versatility and speed to boring operations.

Direct communication with machine control will naturally follow the adoption of these improved operations, followed by the integration of sensors into the tools and/or fixtures. This will have impressive effects on diagnostics and error prevention, like revealing imbalances and validation of speed within the proper range. These sensors can recognize damaged or worn cutting edges, and record overall cutting quality.

Jew recognizes that changes in the status-quo will usher in a new era of tool digitalization. This, of course, begs the question of what will happen to the operators? It’s easy to assume that they will lose their jobs to machines. This is not the case—these tools will make their current jobs easier and safer. They’ll be able to do more with the mobile devices they use every day; they’ll be freed to perform other tasks like preparing new workpieces or tool setups.

Improvements to digital tools are here to stay, and there’s more to look forward to down the road. Operators will learn how to use the tools, controls and sensors effectively, making their lives easier and jobs more enjoyable in the long run.

Read the full article now for more information on digital tools and the changes they bring to the automation industry.

?Carbide Turning Inserts

The tungsten rods price Blog: https://terenceede.exblog.jp/
# by terenceede | 2023-05-26 17:19

Tool life – the effect of various cutting parameters on it

All cutting parameters do not have the same effect on tool life. Cutting speed has the highest effect on tool life. Feed rate has a much smaller effect. Depth of cut has almost no effect.

Cutting speed increase of 20% leads to tool life reduction of 50 %.Cutting speed increase of 50% leads to tool life reduction of 80 %.

Action pointTo reduce cycle time, increase the depth of cut first, to the maximum that the tool or insert can take. Next increase the feed rate. If possible, avoid increasing the cutting sped. Use the cutting speed recommended by the tool manufacturer.

The ‘Messes’ of South India Carbide Inserts – how did they get their name ?

You’ll find a lot of small eateries called Messes in South India, that are simple places where you go for the food. They don’t serve anything other than food and water – no juices, no sweets, no desserts, and of course no booze. I’ve seen this term used for eating areas in the military or in schools or colleges, and wondered what the connection was between these.

The word Mess originated from the Latin Missum (something put on the table), changed to the Old French Mes (Portion of Food) and then changed finally to the to the English Mess in the 16th century. Mess meant a group of people who regularly ate together, and the place where they ate was the Mess Hall. Mess Hall finally got shortened to Mess.

Mess in the Indian Military Academy Pic. source: http://www.tribuneindia.com

I only recently figured out that messes are typically in localities with a lot of single people who come there to eat every day – working people who do not cook at home. And it’s usually the same set of people coming to eat at every meal. Hence calling them messes is perfectly logical. If you want simple, cheap and authentic local food in any place, going to any place called a Mess guarantees this.

  • Cutting speed formula in CNC turning, milling
  • Cutting speed vs Feed rate – in CNC Milling
  • Cutting speed and RPM (or spindle tungsten carbide inserts speed) – the difference
  • Tool life definition – what is tool life in CNC machining ?
  • CNC machining – Modifying cutting speed for tool life
  • The tungsten carbide inserts Blog: https://derekvirgi.exblog.jp/
    # by terenceede | 2023-05-24 10:50

    Advantages of Outsourcing Prototypes to China Prototyping

    While the outsourcing of mass production to China is now standard practice for many companies, the outsourcing of prototypes — preliminary versions of products that will be mass produced at a later time — is less common. Like all business decisions, outsourcing prototypes to China has its pros and cons, but when the right steps are taken to ensure the best service provider is chosen, the advantages can significantly outweigh the disadvantages.

    When it comes to manufacturing in China, the West has certain preconceived notions: that China is a market in which exceptional value can be found, but whose value often comes at the expense of quality. The Western view of China’s rapid prototyping and low-volume manufacturing capabilities is no different: the prevalent standpoint is that, while prototypes can certainly be obtained at a low cost, you might end up sacrificing certain advantages. But is this viewpoint justified?

    Rapid prototyping in China has come a long way in recent years. Rewind two decades, and all prototypes were being made shouban — by hand — which meant costs were high. A kettle prototype, for example, would have cost around 30,000 RMB (4,700 USD), roughly 100 times a worker’s average monthly wage.

    Things started change after the turn of the millennium. As prototyping companies began to invest in Carbide Turning Inserts CNC machining equipment, prototype costs began to decline, albeit only marginally. Using CNC machines, a more complex prototype such as a mobile phone could be made for around 12,000-15,000 RMB (1,900-2,350 USD).

    Some of today’s key technologies for rapid prototyping, including CNC machines and additive manufacturing (3D printing) equipment, are now being developed on a huge scale across the country, which is in part thanks to China’s consistent economic growth: its GDP has grown at a rate of around 10% since the year 2000, plateauing at around 7% over the last five years.

    According to market research firm IDC, China spent $1.1 billion on additive manufacturing last year, making it the primary “force” behind additive manufacturing growth in Asia. On the subtractive side, research firm Research and Markets Cemented Carbide Inserts reports that 282,900 CNC machine tools were manufactured in China in 2016, up 5.7% over the previous year.

    And while that huge investment in prototyping equipment means China’s prototyping market is growing, it has also introduced stiff competition to the market, forcing prices so low that some prototyping companies — many of which operate with just two or three machines — are charging little more than production costs to their customers, resulting in slim profit margins.

    Although the stereotype of China as a low-cost, low-quality market may be outdated, half of the stereotype remains true: China is a very affordable place to manufacture, even for prototypes and low volumes, which means companies based in Europe, the U.S. and elsewhere can reduce their manufacturing costs (without reducing their output volume) by outsourcing to China.

    Companies in places like Vietnam can often provide even cheaper prices, but China’s greater experience, which has been honed over the last 20 years and which has given rise to specialists in specific fields like programming and finishing, gives it the edge over its neighbors. Chinese manufacturers also have a reputation for fast turnarounds, which means affordable prototypes can be completed in a short timeframe.

    Another significant advantage to prototyping in China is the potential for bridge manufacturing. Since mass production in China is widely recognized as the most cost-effective means of creating large quantities of a product, having that product prototyped in China beforehand means the transition to mass production can be extremely fast.

    The disadvantages of outsourcing prototypes to China are mainly logistical, and one of the most common reservations held by Western businesses concerns communication. Many workers at Chinese rapid prototyping companies are not fluent English speakers, which means conveying ideas can be difficult. The language barrier becomes a bigger problem if modifications have to be made or if technical problems arise during production.

    Perhaps the biggest concern with outsourcing manufacturing to China, however, is the matter of intellectual property. Trade secrets, trademarks, copyrights and patents are all complicated legal issues, but these issues become even more complicated when working across borders and a long supply chain.

    Additionally, while high-end Chinese prototyping companies have vastly improved their standards and are now able to obtain materials and tools with ease, those low-end companies saturating the market may still offer products of a lower quality than required.

    In short, the pros and cons of outsourcing prototypes to China must be weighed against one another. Lower costs, faster turnarounds and scalability are the biggest advantages, while communication and IP security occasionally present risks.

    As one of China’s leading rapid prototyping and low-volume manufacturing companies, Guangdong-based Estoolcarbide offers a variety of services — CNC machining, vacuum casting, rapid tooling, 3D printing and more — all of which come with the traditional advantages associated with outsourcing to China: affordable pricing, the ability to have a design finished?within hours and comprehensive options for bridge production.

    Estoolcarbide, however, also goes above and beyond by presenting solutions to the traditional problems associated with outsourcing to China. As a highly experienced ISO9001-2015-certified manufacturer with a mature and comprehensive supply chain, Estoolcarbide can guarantee prototypes of a high standard, comparable to products made in the U.S. and Europe. Its large arsenal of 4-axis and 5-axis machines contribute to this quality, allowing the company to make complex, high-precision prototypes that the average Chinese company (or Vietnamese company, for that matter) would be unable to produce.

    Because Estoolcarbide is an international company, its staff are also able to communicate clearly with clients in English, overcoming any potential communication problems before or during production.

    Furthermore, Estoolcarbide carries out its operations in-house, which is beneficial for several reasons. Firstly, its prototypes and low-volume production runs can be completely quickly, all the way up to the finishing stage. Secondly, because designs remain under the Estoolcarbide roof throughout the end-to-end production process, IP security can be guaranteed. Companies whose manufacturing and assembly facilities are separate, or who outsource aspects of production to third parties, cannot offer that same security.

    All clients have different needs, but outsourcing prototypes to China can represent excellent value for businesses across a range of industries — automotive, aerospace, medical and beyond. And when selecting a partner known for its Excellence, Efficiency and Economy, the advantages of outsourcing to China can far outweigh the disadvantages.


    The drilling inserts suppliers Blog: http://onlooker.livedoor.biz/
    # by terenceede | 2023-05-23 11:23

    Live IMTS Network Broadcast from BIG KAISER

    Mark your calendar! For five days in September, the IMTS Network will stream binge-worthy programming tailored to the manufacturing community. Tune in to catch up on transformative technologies, unique insights, industry news and profiles of remarkable people who are passionate about manufacturing. ?

    On Thursday, Sept. 17, host Peter Eelman from AMT joins BIG KAISER president and CEO, Chris Kaiser, on the live IMTS Network broadcast from the company’s headquarters and showroom in Hoffman Estates, IL. ?

    “Our Carbide Inserts team will be coming to you from locations around Chicago as well as AMT headquarters,” said Eelman. “We’ve got great programming lined up including new features inside and outside shops across the country.”?

    “It’s an honor to be selected as one of the locations for the launch of IMTS Network, especially at the same time we are celebrating the 30th anniversary of our company here in the U.S.,” said Kaiser. ?

    The IMTS Network launches during what would have been the trade show at McCormick Place, now postponed to 2022. Original programming produced by AMT will stream online from 8 AM to noon CT each day followed by a replay of the content in the afternoon. ?

    “Between the Spark platform and the Cermet Inserts Network, the team at AMT has done a great job figuring out how to deliver news and information and keep us all connected this year,” Kaiser said.?

    Visit IMTS.com/Network to preview the program line up, add upcoming shows to your calendar, or share your own manufacturing story with the IMTS community. ?

    The Carbide Inserts and Tooling Blog: https://blog.goo.ne.jp/justiniren
    # by terenceede | 2023-05-22 10:38

    Machining Aerospace Parts Efficiently: Tips And Tricks

    Posted on May. 11th, 2020, | By Estoolcarbide Rapid Manufacturing

    The pinnacle of human thought and engineering is rightfully reserved for the gigantic flying machines. Rockets, airplanes, and jets are impossibly hard to design and are even harder to produce. That is the reason why there are only 8 big companies in the world that make commercial planes in considerable volumes. An aircraft, space or just a flying one, has over 500 000 parts, a large portion of which must be extremely precise and durable. Ensuring that these parts have the best quality and cost is a vital aim of industrial aerospace machining.

    Aerospace precision machining has a lot of issues. First of all, the multitude of aerospace parts is made of a vast variety of materials. The engine elements being the most crucial in the work of the aircraft are made of heat-resistant hardened alloys that are extremely hard to machine. Those alloys conduct heat poorly and so the heat during the processing builds up in the tool. The nickel alloys are often aged or otherwise heat treated so they are very hard to machine. The precision of aerospace parts is much more strict compared to other industries while the geometries of the parts are much more complex.

    Apart from direct machining issues, there are a lot of indirect problems. One of them includes production standards. Along with the medical industry, aerospace production is one of the most regulated in the world and meeting all the quality requirements is hard.

    Upload your design for a fast quote?

    Weight is extremely crucial for airspace vehicles. The lighter the design, the less fuel it will consume so aerospace engineers often design parts with thin walls, lattices, webs, and so on. Conventionally, they are machined from a solid cast or stamped block of metal and the waste material of such parts is 95%. However, low material efficiency isn’t the only problem. The actual issue when machining such parts is the deformation because of high cutting forces.? If you increase the feed and cut depth too much, especially with nickel alloys, you risk shattering the walls because of vibration or deforming them because of the excess heat. The result is usually that you cut a tiny chip off at a crawling feed and the total machining time is impossibly large.

    What can you do to decrease the machining time and actually machine thin-walled aerospace parts competitively? The first thing you have to do is decrease vibration. The vibrating tool strikes a thin wall and it bends or cracks. So, in order to decrease vibration, it is better to decrease the feed but increase the number of cutting edges in a mill ( or even use multiple cutting tools on a lathe). The optimal cutting strategy for milling thin-walled aerospace parts is climb milling. This strategy uses a feed that goes in the opposite direction from the conventional milling strategy. This leads to a smaller cutting force, better surface finish and most importantly the mill enters the material where the wall is thickest thus the vibration is much smaller. In order to countermand the overheating, it is necessary to use progressive high-pressure coolants.

    Part overheating because of poor heat conduction is a typical problem for aerospace parts. One machining strategy to reduce heat build-up is called trochoidal milling. It greatly utilizes the capabilities of CNC machines to follow complex cutting paths. The trochoidal strategy uses a small mill (smaller than the cut anyway) that follows a path similar to a spring side projection on a flat surface. One curve – the mill cuts, then it goes back during the second curve and then cuts the metal again. This strategy portions the time of contact between the tool and the part so that there is a moment for both to be efficiently cooled down by the cutting fluids. Trochoidal turning is similar to milling, using short cutting and pausing sequences to let the coolants do their work and avoid overheating. Such a strategy has much more empty tool runs compared to other strategies but it negated this effect by increasing the cutting speeds and feeds. At Estoolcarbide, we also can offer EDM Machining maybe can avoid machining parts.

    When comes to mind the machine tools, CNC machines play a great role and it has widely applicable to Aluminum machining.?One of the most important ways to increase the efficiency of machining is choosing the correct cutting tool. If softer alloys are well analyzed and a lot of manufacturers offer solutions for aluminum and other alloys. However, a lot of aerospace materials are classified and so the choice must be made on the spot.

    The tricks to efficient tool choice for heat resistant materials must counteract the negative properties of the materials. So, a perfect tool must have little vibration, must be very hard, and must withstand high temperatures to have a consistent life and work at efficient feeds. A perfect example of a tool used for such purposes is the diamond cutting tool. Artificial diamonds are harder and more durable than carbide inserts and can work at higher temperatures. Diamond machining has its specifics but it can certainly be modified to suit the needs of aerospace manufacturers. Apart from diamond tools, ceramic tools prove to have a great performance as well because they can work at the highest temperatures.

    In order to decrease the vibrations of the processed parts, it is important to use mills with more cutting edges and a sharper flute angle. Such mills minimize the time and distance the tool passes before the next cutting edge hits the material thus decreasing vibration and with that, you can increase cutting Cermet Inserts parameters for more efficiency.

    Before using any strategy and starting the processing, it is important to estimate whether the quality of the part can be achieved at the desired time. How can we predict the final tolerance, surface finish and the time of machining before doing it? It wasn’t possible just a short while ago but it is now due to a staggering rate at which the mathematical modeling techniques develop. Finite element analysis has reached a level where you can simulate the cutting processes with good precision. So, you can upload your model and look at the actual cutting forces and heat dissipation and how it will influence the final part. You can see residual stresses, deformations and so on even before you install a blank on the CNC machine tool. This technology offers great advantages to predict the outcome Carbide Threading Inserts of machining and decreases time left for re-runs.

    Here, we have invested heavily in advanced CNC machining technology and multi-axis-machines that enable us to easily and fast process trial runs, customized short runs, or low- volume production runs. We can meet your needs for machined parts when you can upload CAD files today for a free quotation.

    The indexable drill bit Blog: https://brenteden.exblog.jp/
    # by terenceede | 2023-05-20 13:25