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On race day, everybody sees the race on TV, but behind the scenes there’s a competition going on between shops where time is everything, according to Matt Gimbel, Team Penske’s production manager.

Sunnen Products Company has acquired BTA Heller Incorporated, a US-based manufacturer of deep hole tooling and systems for primary hole generation. This move aims to expand Sunnen’s honing expertise to include tooling for initial hole creation and other complementary bore sizing and finishing processes.

The University of Illinois at Urbana-Champaign (UIUC; Urbana, IL) has a long, distinguished history and tradition in mechanical and applied engineering sciences, and the university will soon celebrate the opening of a long-planned, multi-million-dollar expansion to its Mechanical Science and Engineering (MechSE) building.

Thread milling, a fundamental metalworking process to create threads, is often the operation of choice when working with difficult-to-machine materials, such as titanium, tool steels, stainless steels, hardened steels and other superalloys.

The devices quickly become less costly, sophisticated and independent, gaining wider influence.

At Flexco Inc. (Downers Grove, IL), finding a solution to speed up slot-milling with Chip-Surfer replaceable tip solid-carbide cutting tool from Ingersoll Cutting Tools (Rockford, IL) has led to benefits in a host of other operations as well. Flexco, a manufacturer of belt conveyor components, estimates that retooling with Chip-Surfer replaceable solid-carbide tip cutting tools has saved about $200,000 a year overall on slotting operations and the company expects to save as much again on mill-turn operations.

While cameras and motion control have worked in tandem for at least 15 years, their integration has improved because networks have gotten faster, more reliable, and more deterministic (i.e., nothing will interfere with a function that’s a priority).

New systems, software and processes are replacing so-called islands of automation with seamless, automated manufacturing lines that boost overall equipment effectiveness (OEE) from 30 to 80% or more. Like a chess master, these systems think multiple moves ahead on the factory floor to ensure continuing production when circumstances change.

The next “dynamic duo” may not involve humans at all. “Machine vision and robots make for a perfect marriage,” stated Klas Bengtsson, global product manager, vision systems for ABB Robotics (Auburn Hills, MI). This is not new. Vision and robotics have gone hand in hand for years.

A key success factor for Industry 4.0 and IIoT (Industrial Internet of Things) initiatives is the emergence of more and better sensors in machining centers, and even in the cutting tools themselves. These sensors provide the data and connectivity that are the foundation for the “factory of the future.”