New Machining Technologies and Processes - Productivity Engineering Applications

Lesson 103 of Industrial Engineering ONLINE Course.

Refer to Industrial Engineering Case Studies Collection for case studies and productivity engineering applications

Industrial Engineering

Industrial engineering redesigns and installs engineering systems primarily. It also examines and redesigns managerial processes that impact productivity in engineering systems. Machine tools and other machines are important components of engineering systems. Industrial engineers have to analyze the currently available machine tools in the market and the existing machine tools being used in the factory, plant and processes to identify more productive and profitable replacement of new machine acquisition opportunities.

This collection offers you information on new machine processes and applications  to increase productivity to help you in giving ideas and directions in searching for new machining processes. 

Process Improvement - Productivity Analysis and Productivity Engineering.

Industrial engineer analyzes each process into its ultimate, simple elements, and compares each of these simplest steps or processes with an ideal or perfect condition and modifies the element appropriately. - F.W. Taylor - Hugo Diemer.

Prof. Hugo Diemer  - Taylor's Industrial Engineering

https://nraoiekc.blogspot.com/2020/05/prof-hugo-diemer-taylors-industrial.html

Case Study 14 of  Industrial Engineering ONLINE Course

This note is an illustration of productivity improvement by adopting an alternative process. This particular process is new process and Lockheed martin even participated in its development.

2016 News
Creare’s Breakthrough Cryogenic Machining Process Significantly Reduces F-35 Titanium Manufacturing Costs in Lockheed Martin

Creare Incorporated has developed a breakthrough high-speed titanium machining process that will significantly reduce the manufacturing cost of critical titanium parts on multiple aircrafts, including Lockheed Martin’s F-35.

Though the high strength-to-weight ratio of titanium alloys make them attractive for use in military aircraft, their high strength and low thermal conductivity concentrate heat at the cutting edge during machining. This heating limits the attainable processing speed due to accelerated tool wear, which in turn results in increased part costs. These excessive machining costs have limited the applications of titanium to specialized applications, such as high tech aircraft. Creare’s innovation is the development of an internal cooling approach for cutting tools using small flows of liquid cryogens, which enables increased processing speeds and extends tool life by up to a factor of 10, markedly reducing the manufacturing cost of critical titanium parts.

Creare began developing this technology in 2004 when the company received its initial Phase I Navy SBIR contract. Lockheed Martin became interested in the Creare cooling technology for its F-35 production challenges and helped secure funding as part of a larger F-35 initiative to enable the Phase III program. As a result of this Phase III work, the combined team of Creare, Lockheed Martin, and MAG Industrial Automation Systems has successfully validated this technology for the production of F-35 titanium parts and integrated the approach on production machine tools. In addition, the technology has been featured in several key manufacturing publications and demonstrated world-wide at numerous high-visibility manufacturing industry events, setting the stage for the commercial introduction of the technology in late-2011- early-2012.

https://www.lockheedmartin.com/en-us/suppliers/news/whos-knocking/2016/creare.html


 Hartwig customer and leading aerospace OEM Lockheed Martin acquired an MA-600H II horizontal machining center from Okuma America Corporation (Charlotte, NC) that is equipped with a patented cryogenic machining system from 5ME (Cincinnati, OH).

According to Lockheed, the cryogenic technology will help lower the cost of large titanium parts by an estimated 30%.
https://www.hartwiginc.com/newsletter-archives/cryogenic-machining-efficiency-reigns-supreme


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https://youtu.be/EH0nVwpKczw



5ME Video
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Case Study 39 of Industrial Engineering ONLINE Course

PrimeTurning™ triples productivity in turning at Godrej Aerospace

21 May 2018
Sandvik Coromant

When faced with a large order and a difficult-to-machine steel grade, Godrej Aerospace, an Indian aerospace component manufacturer found their answer in PrimeTurning™. Find out how PrimeTurning™ helped increase productivity and reduce cycle time.
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Read the story in text.
https://www.sandvik.coromant.com/en-gb/mww/Pages/IM_Godrej.aspx

PrimeTurning™ delivers a huge cost saving for Riedl

29 Mar 2019
Sandvik Coromant
Passionate about cutting-edge technology, fast-growing Slovenian metal company Riedl CNC introduced Sandvik Coromant’s new Prime Turning solution in 2018. When the company applied it to KTM motorcycle components, the cycle time and production costs have never been better. Find out how PrimeTurning™ helped increase productivity and reduce production costs substantially.

Slovenian metal company Riedl CNC introduced Sandvik Coromant’s new PrimeTurning™ solution in 2018. When the company applied it to KTM motorcycle components, productivity increased 40 percent and costs declined by more than 50,000 euros a year.
Read the full story in text
https://www.sandvik.coromant.com/en-gb/mww/pages/im_riedl.aspx
Productivity Science

8 New Machining Technologies You Should Know

This week's most eye-catching new products and technologies for machine shops and manufacturers.

Updated KBM Library, User Interface, Milling Improvements

Better ‘associativity’ for more efficient set-up, selection, program storage

SmartCAMcnc released of SmartCAM® v2016 — the latest version of its CAM platform for software toolpath modeling and CNC programming (milling, turning, fabrication and wire EDM), for prismatic production work through to complex molds, dies, and prototypes. SmartCAM v2016 delivers a “substantially updated Knowledge-Base Machining (KBM) Library,” as well as improvements to the user interface and to the core milling functionality.

Evenly Spaced Radial-Force Vectors for Superior Gripping

Get-A-Grip multi-axis workholding will not distort, deform the workpiece

AMT INNOVATIONS’ new workholding product, Get-A-Grip® has a “cutting-edge triangular dovetail” design that will not distort or deform the workpiece. The dovetail provides three, evenly spaced radial-force vectors for superior gripping. Through carefully developed triangular contact geometry, it reportedly eliminates the need for an indexing pen. The novel internal clamping geometry reduces material preparation area and can be strategically placed where the finished part may have a pocket which greatly reduces secondary operations.

Get-A-Grip “revolutionizes traditional workholding products for multi-axis CNC machining,” according to the developer. Stainless steel materials and innovative design elements bring flexibility and time-saving advantages that will result in a dramatic increase in production and profits.

https://www.americanmachinist.com/machining-cutting/media-gallery/21901481/8-new-machining-technologies-you-should-know/slideshow?slide=2

120,000-RPM Air Power Spindle

Upgrade CNC machines for high-speed high-speed micro-machining, cost effectively

BIG KAISER introduced its RBX12 Air Power Spindle, a high-speed air-driven spindle that achieves variable rotational speed of 100,000-120,000 RPM. It makes it possible for machines to be upgraded cost-effectively to perform high-speed micro-machining in a normal machining center because the tool is driven by air supplied through a stop block, or through the machine spindle. Since there is no rotation of the machining center spindle required, your expensive machine tool spindle can be used without wear.

https://www.americanmachinist.com/machining-cutting/media-gallery/21901481/8-new-machining-technologies-you-should-know/slideshow?slide=5

Mastercam X9 Mill Brings Speed, Efficiency, Automation

Expanded machining flexibility; increased emphasis on speed and automation

MASTERCAM X9 Mill offers expanded machining flexibility and an increased emphasis on speed and automation. 2D High Speed Toolpaths, 3D enhancements, and Multiaxis features combine with dozens of additional new enhancements in a package intended to improve shop floor productivity.

https://www.americanmachinist.com/machining-cutting/media-gallery/21901481/8-new-machining-technologies-you-should-know/slideshow?slide=6

Solid Carbide Milling Tools for Universal Application

An ideal balance of hardness and toughness, plus tool life increases of up to 50%

WALTER introduced its Prototyp Advance line of solid carbide milling tools for universal application, consisting of six cutter types and 250 line items, each providing an ideal balance of hardness and toughness for the widest possible application, plus long tool life (increases of up to 50%) thanks to the Advance line’s new high-performance WJ30TF grade and Walter’s own TiAIN coating.

https://www.americanmachinist.com/machining-cutting/media-gallery/21901481/8-new-machining-technologies-you-should-know/slideshow?slide=7

 Wireless 5-Axis Workholding

Upgrade Existing Equipment … no drive cards necessary

KME CNC's workholding tombstones are designed to help machine shops increase productivity by accomplishing five-axis work on their existing equipment. The five-axis wireless tombstone is designed to convert four-axis horizontal machines to five-axis operation by allowing the operator to present multiple five-axis parts to the spindle — in a single set-up. The workholding tombstone is cast in meehanite with billet aluminum covers. It connects wirelessly to the CNC controls via RF frequency.

https://www.americanmachinist.com/machining-cutting/media-gallery/21901481/8-new-machining-technologies-you-should-know/slideshow?slide=8

Automatic Bar Feeder … At-a-Glance Position Check

External LED provides visual status of pusher position, amount of bar remaining, more

The new Tracer Vs-105XL bar feeder available from CNC INDEXING & FEEDING TECHNOLOGIES is designed for heavy bars: It can handle bars up to 4-1/8 in. (105 mm) diameter, up to 72 in. long.  The magazine rack has a maximum capacity of five bars.

The patented external LED light bar provides a visual status of pusher position, amount of bar remaining, notification of last bar, and flashing notification of machine or bar feeder alarms.

https://www.americanmachinist.com/machining-cutting/media-gallery/21901481/8-new-machining-technologies-you-should-know/slideshow?slide=9

Robert Brooks

JAN 21, 2016

https://www.americanmachinist.com/machining-cutting/media-gallery/21901481/8-new-machining-technologies-you-should-know

2020

TWI has recently invented a highly disruptive, new sub-surface machining technique called CoreFlow™. This solid state process is a development of friction stir welding (FSW) and friction stir channelling (FSC) which allows for sub-surface networks of channels to be integrated into two-dimensional or three-dimensional monolithic parts in a single manufacturing step. These channels could then be used for heat exchange or other applications.

Figure 1 shows a cooling plate demonstrator recently produced in aluminium (AA6082-T6) and infrared thermal imaging evidencing the circulation of liquid coolant.

https://www.twi-global.com/media-and-events/insights/coreflow-a-sub-surface-machining-process

Metal Machining—Recent Advances, Applications

by FJG Silva · 2021

https://www.mdpi.com/2075-4701/11/4/580/pdf

A Review on Advanced Manufacturing Techniques 

by AJ Patel · 2021 

https://www.intechopen.com/chapters/76653

(PDF) Improvement of Machining Processes: A Case Study

29-Apr-2021 

https://www.researchgate.net/publication/337699161_Improvement_of_Machining_Processes_A_Case_Study

24 August 2022

14 Most Significant Technology Trends by McKinsey

Billions are invested in many of them. As industrial engineer, assess them for adopting them for productivity benefit in your organization's processes.

https://www.mckinsey.com/capabilities/mckinsey-digital/our-insights/the-top-trends-in-tech

ud. 16.9.2022

pub. 8.9.2021