Students in the Wood Center at IUP collaborated on the design and production of the 2017 Pennsylvania Governor’s Awards in the Arts.
This year, the awards were presented Thursday in Lancaster. There were five awards given out, and one given to the institution.
An advanced woodworking class, instructed by Artist-In-Residence, John Hallett, built the governor’s awards into its course curriculum.
The students involved in this project were Samson Andanje (fine arts), Nicholas Gemberling (graphic design), Jenn Milkey (graduate, ceramics), John Miller, Katie Ott (graduate, woodworking), Micaela Rodas (pre-dentistry), Jonathan Simkins (senior, communications media), Tyler Stanton (graduate, woodworking), Samuel Tyson (junior, studio art) and Jesse Wolfson (studio art).
Shops that decide to expand into new markets are often spurred to add new machining equipment or adopt new machining processes to support their efforts. In True Die’s case, the strides it has taken to diversify its product offerings by manufacturing precise round tooling for deep-draw sheet-metal-forming applications has led it to develop an effective strategy for hard turning. The goal was to eliminate the need for inner diameter (ID) and outer diameter (OD) grinding of (primarily) hardened powder metal round tooling ranging to 64 HRC, enabling it to achieve higher material removal rates while matching what grinding could achieve in terms of concentricity, surface finish and dimensional accuracy. That it has since done, establishing the capability to hard-turn diameters and radii to ±0.0002-inch accuracy.
In fact, two of the Zeeland, Michigan shop’s recent machine additions are turning centers that were purchased primarily for hard turning. Mitch Stahl is True Die’s technical specialist who, along with Chris McCleary, turning coordinator, led a team of machinists in establishing the shop’s hard-turning strategy. In short, he says the shop’s approach boils down to three interconnected concepts: establishing overall process rigidity, implementing the right types of cutting tools and applying the appropriate cut data.
The key word here is interconnected. Mr. Stahl maintains that implementing only one or two of these concepts would not work; all must be appropriately addressed for effective hard turning. “It is also just as important to mind the small details when putting a process such as this in place,” he notes.
Round Tooling Opportunities
True Die, formerly Contour Tool and Engineering before it acquired that company in 2015, has expertise in designing, machining and assembling plastic injection molds and progressive die sets. It has a diverse array of machining equipment in its 10,000-square-foot facility, including CNC mills, turning centers, grinding machines, and wire and sinker EDM equipment.
Brian Brown, True Die’s president, says the deep-draw metal-forming industry represented an opportunity for the shop to diversify into a new market that complements the others it serves. “Our expertise of the application of deep-drawn stamping positioned us uniquely as a tooling supplier, enabling us to bring tangible solutions and higher performing tools to the market,” Mr. Brown says. “With well over 100 years of combined experience in the design, development and production of drawn stampings, we were well prepared with a thorough understanding of the unique requirements of that industry.”
Cnc Machine Tools Market Analysis, Growth Forecast Analysis by Manufacturers, Regions, Type and Application to 2022
Cnc Machine Tools Market report gives a clear understanding of the current market situation which includes of antique and projected upcoming market size based on technological growth, value and volume, projecting cost-effective and leading fundamentals in the Cnc Machine Tools market.
According to the Cnc Machine Tools Market report, the global market is expected to witness a relatively higher growth rate during the forecast period. The report provides key statistics on the market status of Global and Chinese Cnc Machine Tools manufacturers and is a valuable source of guidance and direction for companies and individuals interested in the industry.
Major Key Contents Covered in Cnc Machine Tools Market:
- Introduction of Cnc Machine Tools with development and status.
- Manufacturing Technology of Cnc Machine Tools with analysis and trends.
- Analysis of Global Cnc Machine Tools market Key Manufacturers with Company Profile, Product Information,
- Production Information and Contact Information.
- Analysis of Global and Chinese Cnc Machine Tools market Capacity, Production, Production Value, Cost and Profit
- Analysis Cnc Machine Tools Market with Comparison, Supply, Consumption and Import and Export.
- Cnc Machine Tools market Analysis with Market Status and Market Competition by Companies and Countries.
- 2016-2021 Market Forecast of Global Cnc Machine Tools Market with Cost, Profit, Market Shares, Supply, Demands, Import and Export.
- Trending factors influencing the market shares of APAC, Europe, North America, and ROW?
- Cnc Machine Tools Market Analysis of Industry Chain Structure, Upstream Raw Materials, Downstream Industry.
Then, the report explores the international and Chinese major Cnc Machine Tools market players in detail. In this part, the report presents the company profile, product specifications, capacity, production value, and 2011-2016 market shares for each company.
After the basic information, the report sheds light on the production. Production plants, their capacities, global production and revenue are studied. Also, the Cnc Machine Tools Market Sales growth in various regions and R&D status are also covered.
Through the statistical analysis, the report depicts the global and Chinese total market of Cnc Machine Tools market including capacity, production, production value, cost/profit, supply/demand and Chinese import/export. The total market is further divided by company, by country, and by application/type for the competitive landscape analysis.
Producing functional parts via additive manufacturing (AM) enables us to design and manufacture products that we just can’t make any other way. With the flexibility of 3D printing, we can realize part-performance benefits such as lightweighting and thermal efficiency, we can integrate separate components into consolidated designs with complex forms, and we can do all this within a build process that is often highly automated and highly efficient it its use of materials, producing little waste.
AM has a dark side, however. The benefits above are offset against some very real and potentially painful challenges with postprocessing. Finish machining of AM parts can be challenging directly because of their light weight and their complex forms. Both attributes can lead to problems with workholding and vibration and can result in poor process yields. Furthermore, there is the additional problem of aligning complex components when they lack precise geometric datums in the as-built state.
This article will look at the challenge of making lightweight parts stiff enough for effective finish machining. We will explore how to realize effective workholding solutions to make non-rigid additive parts machinable. We will also demonstrate how machine tool probing can be used to perform sophisticated alignments of AM parts, enabling us to “find the good part” within the shape that we have built and produce the critical datum surfaces correctly.
The Need for Machining
As versatile as it is, an additive or 3D-printing-style process, particularly in metal, cannot produce features with very fine tolerances. Post-process machining is often needed to produce precise round holes and smooth, flat surfaces for interfacing with other parts. Yet lightweighting often has the effect of reducing the stiffness of AM parts, which can mean that they do not stand up well to the machining process. The complex forms of AM parts also make them hard to grip securely without causing damage. And finally, it is common to produce the datum features on additive parts after the build itself, so setting up components for finishing can be tricky.
There are a lot of similarities here to the challenges that manufacturers of composite and super-plastically formed parts face—namely, complex shapes that may have some distortion onto which precision features must be machined. Users of AM can learn from the best practices in these other sectors while adding an AM twist of their own.
Case Study: Microwave Guide
Among the machining challenges characteristic of AM, the first consideration is whether the part is likely to be stiff enough to cope with the loads it must bear during machining. Many questions arise from this. Will the part deflect away from the cutter, and will it vibrate such that we get tool chatter and poor finish on machined surfaces? If yes, what can we do about it? Can we design the part differently to make it stiffer? Or if that is not an option, how can we hold the part to support it sufficiently that it will not deflect or vibrate excessively? We will use a case study to explore these questions.
Roughly three and a half seconds, or maybe a hair more. That’s all it takes for a pair of dragsters to traverse a 1,000-foot Top Fuel circuit track, spewing flame and drowning out the din of cheering spectators as they blur past at speeds exceeding 330 mph.
In these moments, precisely how many onlookers fully appreciate the engineering that goes into these lightweight machines is anyone’s guess. And yet, three and a half seconds is all it takes for critical engine components to fail. That’s why the starting line isn’t really at the racetrack for National Hot Rod Association (NHRA) teams; it’s in the shop. In fact, keeping the cars running is demanding enough that the shop literally travels with the team during the 10-month race season, with the same kinds of trucks that house cars and crew also transporting mills, lathes and other equipment.
At more than 20 vehicles strong, the caravan of tractor trailers hauling Don Schumacher Racing (DSR) around the country is the largest in the NHRA. The home-base manufacturing operation in Brownsburg, Indiana, just outside Indianapolis, is more sizeable than most as well. Last year alone, DSR invested more than $7 million in new equipment and a 25,000-square-foot expansion, bringing the facility to a total of 145,000 square feet. At the time of this writing, engine blocks were the only significant components not produced in house, and plans were already in the works to start machining those parts, too. “We want to control our own technology and control our own costs,” says Tom Warga, one of 14 machinists and one of the lead strategists for improvements throughout the shop.
That goal is likely a familiar one to many North American manufacturing enterprises. Although winning titles is the primary aspiration of any race team, this 120-employee organization is a business like any other, and it faces similar pressures and challenges. Team owner and former driver Don “the Shoe” Schumacher certainly thinks this way, at least judging by his decision in 2013 to start selling parts to other teams as well. In keeping with Mr. Schumacher’s predictions (and contrary to the worries of some crew chiefs), selling itself as a parts supplier as well as a race team hasn’t detracted from DSR’s competitiveness, Mr. Warga says. (In fact, 2016 was the fourth year in which the team won two NHRA world championships in the same season.) Supplying parts does, however, provide extra revenue, not to mention a potential hedge against unexpected events off the strip.
As the volume and variety of work have grown, strategies for addressing the resulting pressures have also tracked closely with broader industry trends. These days, the steady hum of carbide on metal emerges from not just three-axis VMCs and lathes, but also five-axis, turn-mill and pallet-fed horizontal machining centers. From clamping to cutting tools to CAM software, processes are designed to maximize spindle access to the workpiece and minimize the need for manual intervention during the machining cycle.
This report analyzes the worldwide markets for Machine Tools in US$ Thousand by the following Product Groups/Segments: Metal Cutting Tools (Boring & Drilling Machines, Gear Cutting Machines, Grinding, Honing, Lapping, Polishing & Buffing Machines, Lathe Machines, Milling Machines, Machining Centers, Station Type Machines, & Other Metal Cutting Tools), Metal Forming Tools (Punching & Shearing Machines, Bending & Forming Machines, Metal Working Presses, & Other Metal Forming Tools), and Special Machine Tools (Waterjet Cutting Machines, High Power Laser Cutting Machines, Electrochemical Machines, & Electrical Discharge Machines).
The report also analyzes the worldwide markets by the following End-Use Segments: Automobile, erospace/Defense, Electronics/Electrical, and Others. The report provides separate comprehensive analytics for the US, Canada, Japan, Europe, Asia-Pacific, Middle East & Africa and Latin America.
Annual estimates and forecasts are provided for the period 2016 through 2024. Also, a five-year historic analysis is provided for these markets. Market data and analytics are derived from primary and secondary research. Company profiles are primarily based on public domain information including company URLs.
Read more: Global Machine Tools Industry
Despite a reputation for handcrafting and manual labor, many Amish businesses welcome computerized production and digital communications to improve productivity.
Operators of Amish Country Gazebos, a Manheim, Pennsylvania, manufacturer of gazebos, pergolas, and pavilions, aim to set the record straight on their corporate blog, debunking misconceptions about how the religious-centered communities operate farms and woodworking firms. They describe the role technology plays in Amish businesses:
Myth: The Amish don’t use any electricity or electronics: The Amish do not have electricity running into their houses like the average American does, true. However, most Amish families and businesses have generators which they use to power various appliances or devices in their homes. Also, though the Amish will not allow a phone in their homes, it is not uncommon for Amish to own cell phones for business purposes, or to have a landline phone in the barn or other outbuildings.
Amish Country Gazebos is a business of significant scale, selling directly to consumers, and commercially to the hospitality industry – where clients include Sheraton, Hilton, and Marriott. The firm, which maintains its own shipping fleet to deliver its structures across the country, was also featured in a recent New York Times article on the growing adoption of technology by “plain communities,” as the Amish are known.
The business was founded by the Beiler brothers – Leon, Tom, Chet and Mel – who grew up on an Amish farm. Amish Country Gazebos is among an estimated 2,000 Amish businesses in the Lancaster, Pennsylvania area. The population of Amish is running above the national average and has led to the formation of many new businesses over the past 25 years.
One of these is Knot & Ore, a Lancaster, Pennsylvania furniture start-up that is catering to the contemporary metal and wood designs favored by younger Millennial customers. Steve Riehl, who founded Knot & Ore with several partners, will describe the business model of the start-up during Wood Pro Expo in Lancaster October 20.
The Beiler brothers at Amish Country Gazebos describe the tradition of woodworking among the religious community:
The Amish use only real wood in their projects – no particle board will ever measure up to the exemplary standards of Amish craftsmanship. Their almost sole use of pneumatic tools, often run off of diesel generators, has also drawn attention to Amish handiwork.
Everyone is talking about 3D printing, additive manufacturing (AM), and generative multi-layer construction technologies. Nevertheless, this is a long way from meaning the classic machine tool is going to be sent away. EMO Hannover 2017 will be showcasing an array of production technology – including alternative processes.
Carl Fruth has long since achieved his goal of “transferring competences in the field of multi-layer technologies into product manufacturing,” and during a Technology Day featuring an in-house exhibition at FIT AG (Fruth Innovative Technologies) in Lupburg, Germany, in addition to inaugurating an office building, FIT also opened the first additive factory.
The “FIT factory is even on an international comparison unique in terms of manufacturing capacity and automation technology, and is intended to serve as a template for further additive manufacturing facilities of the FIT Group,” says Carl Fruth, founder and managing board chairman at FIT. Fruth is a pioneer of AM, who 10 years ago was certain the future multi-layer construction technology would be the norm in everyday production operations and the sale of milling machines or injection molding machines would inexorably decline.
However, we are still a long way off from the day where the traditional machine tool is numbered, confirmed by the innovations that will be highlighted by exhibitors at EMO Hannover 2017. One of the impediments to the widespread adoption of additive technology in individualized mass production was described several years go by Fruth as the “lack of production-suited manufacturing lines.”
Yet, this has changed in the meantime.
Fruth states that, “There are a large number of delicate seedlings: many of our customers would like to use additive technologies to manufacture replacements for existing components. But this is possible only in a very few cases. Usually, a new component has to be developed and very often the adjoining components of the system as well. First, many companies are deterred by the outlay involved, and second, of course, you need specialized development competence for this new production technology.”
The country needs new designer engineers
When traditional design guidelines no longer apply, a new generation of design engineers is needed, keen to embrace function-driven thinking.
According to Fruth, AM means that, “in the design phase not only the geometry, but also the material properties and the component costs are essentially specified in full. This complexity necessitates specialized training and experience. Moreover, up to now there is no software tool in existence that provides all the requisite functions. So, firms have to work with different, complex software tools. Very often, information is lost in transitioning from one tool to another. When you need up to eight iterations for developing a component, the substantial outlay involved is obvious.
“The competences required, moreover, are possessed not by a single design engineer, but only by a team. In traditional companies, the competences concerned are divided up among different departments – a situation exacerbated by squabbles about prerogatives and uncertainty. Innovative companies, however, also see this as an opportunity: ‘We support our customers in this process, and train them component by component to achieve maximized performance in AM design. That’s why we also call these products ADM – Additive Design and Manufacturing.’”
Global Surfacing Lathe Market 2017 KAAST Machine Tools, DMG MORI, echoENG, EMAG GmbH & Co. KG, FAIR FRIEND
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