Unplanned downtime and production loss due to equipment failure is one of the leading losses for manufacturers. Most shops perform maintenance on a fixed schedule or on failure. This means a machine will be maintained regardless of how often it is used and unexpected breakdowns will stop production.
Mazak Corp. (Florence, KY) continues its steady advance toward the complete factory digitization of all its manufacturing operations with the recent transformation of its Oguchi, Japan, facility into yet another Mazak iSMART Factory.
Even though it’s been around since the 1950s, when engineering-grade resins were first introduced, many manufacturers still are not familiar with the many benefits that metal-to-plastic conversion provides.
Simulation tools are making it much easier for manufacturers to optimize their processes, visualizing the entire path of production from NC metalcutting simulations through 3D design and factory-floor imaging.
As additive manufacturing emerges from a long infancy, the industry is grappling with a key challenge: A file format and design tools from the 20th century are being asked to do 21st century jobs.
The challenges to manufacturing as it evolves into the 21st century are now familiar, and impact how metrology must contribute. Manufacturers face uncertain production volumes with roller-coaster demand, shorter production runs and faster product development cycles. Automation, while alluring as a way to reduce cost, needs to adjust.
Why use a metrology device on or near a machine tool? It isn’t just useful for making sure a tool is present or monitoring tools for wear or breakage. On-machine measurement technologies can save time and money, by speeding up processes and eliminating extra personnel, and they are a critical step in the movement towards “lights-out” manufacturing.
When you walk into the Redeye On Demand facility in Eden Prairie, MN, you enter into one version of the factory of the future. There you will see a bank of 100 high-end Fortus fused-deposition modeling (FDM) machines from Stratasys that provide the capacity to build real, functional parts with production-grade thermoplastics directly from CAD data.
Micro components continue to shrink in size, demanding ever-greater precision and improved handling of parts with sub-micron-sized features. New approaches in micro machining technology include higher-precision systems from traditional micro machining developers, as well as techniques using additive manufacturing processes and semiconductor wafer-scale technology on the smallest of micro parts.
For Dale Mickelson, Yasda product manager at Methods Machine Tools Inc. (Sudbury, MA) and author of several books on hard milling, tackling heat-resistant superalloys (HRSAs) requires the perfect combination of machine, workholding, tooling, tool paths and coolant.
