The CoolSpeed mini ultra-high-speed spindle rotates at speeds up to 75,000rpm for micromachining applications. The spindle turbine is driven by coolant, cutting oil, or air mist. It fits in standard tool holders for cylindrical tools, and is compatible with milling centers, turning centers, and Swiss-type lathes.
The cutting tool shank serves as the spindle shaft, so dynamic runout is 4µm or better. Bearings can be replaced by the customer with each cutting tool change.
An existing compressed air source can be used to convert older equipment into a high-speed machining center.
A year ago, I wrote about a boost in middle-market manufacturing executives’ adoption of Industry 4.0 technologies. Back then, a survey from professional services firm BDO USA LLP showed 31% were implementing an Industry 4.0 strategy, up from a dismal 5% the year before. Results are now in for BDO’s 2021 Industry 4.0 Survey, again polling 100 C-suite executives at U.S. manufacturing organizations about current and planned Industry 4.0 efforts.
This survey divides manufacturers into those born – or reborn – in digital, who are implementing Industry 4.0 (24%) and legacy manufacturers (76%) that haven’t. The legacy companies that aren’t yet implementing, are in the process of developing, haven’t started developing, or don’t have plans to develop an Industry 4.0 strategy risk business failure.
Of those identified as digital manufacturers, 33% report they are thriving (profitable and growing), 54% are surviving (stable, breaking even), and 13% are struggling (unprofitable or losing market share). Compare those numbers to legacy manufacturers, where 18% are thriving, 54% are surviving, and 28% are struggling.
“The gulf in Industry 4.0 maturity and overall business performance is widening between manufacturers who embraced Industry 4.0 prior to the pandemic and those who have either just begun to implement an Industry 4.0 strategy or are still skeptical of its benefits,” the survey authors report. “Those that adopted Industry 4.0 strategies prior to the pandemic were better equipped to navigate its disruptive impacts and are now positioned to reenter growth mode ahead of their less digitally advanced peers.”
BDO’s experts warn the technology stragglers, “It is imperative that legacy manufacturers reassess their outlook about Industry 4.0 to ensure their future growth.” If those manufacturers didn’t succeed with previous Industry 4.0 initiatives, the survey authors suggest bringing in new leadership or a third party that has proven Industry 4.0 expertise. A successful pilot project may help convince doubting company management to commit to a long-term initiative.
Among the technologies enabling the digital thread, about two-thirds of manufacturers report they are currently using data analytics, cloud computing, and enterprise resource planning (ERP) software. Technologies leading the list for planned deployments are robotics/automation, artificial intelligence (AI)/machine learning, virtual/augmented reality (VR/AR), blockchain/digital ledgers, Internet of Things (IoT), and 5G. The number of manufacturers with plans to implement these digital tools ranges from 43% to 61%.
The COVID-19 pandemic accelerated use of digital tools and solutions, allowing early Industry 4.0 adopters to achieve breakaway performance. “These organizations are more agile, connected, and resilient than their less digitally advanced peers, who will be challenged to keep up,” the survey’s authors note. But manufacturers shouldn’t rest on their laurels. BDO’s experts agree: “Manufacturers that recognize that Industry 4.0 is about continuous improvement will be most successful in the long run.” – Eric
The ATOS 5 Airfoil enables fast, accurate digitization of complex parts, capturing high-quality data for accelerated inspection and production capabilities and digital twin strategies for quality control.
High-tech measurement cameras and a speckle-free bright blue LED light source can collect 12 million points per scan in 0.2 seconds. Full-field data collection supports comprehensive process and quality control required to inspect critical airfoil components – including turbine blades, nozzle guide vanes, and blisks.
By comparing 3D measurement data against a CAD model or the part’s previous measurement data, manufacturers can verify the dimensional accuracy of the just produced, maintained, or repaired component.
With industrial housing to protect against dust and water, the unit safely integrates into production to quickly scan difficult parts, including reflective surfaces and objects with complicated geometries and surface anomalies. Turbine blades can be digitized entirely in three minutes, producing a digital twin with complete, high-resolution measurement data.
Replaceable drill tip for aluminum
The SMDT-NAL replaceable drill tip – featuring diamond-like carbon DLC Aurora coating – offers high efficiency when machining aluminum alloys and non-ferrous materials. SMD holders include deep hole drilling up to 12xD standard, in diameters ranging from 15/32" to 1-1/4".
DLC Aurora coating is an amorphous film, composed mainly of carbon, with lubricity and chemical stability. It features high hardness for superior abrasion resistance, superior tribology properties, and excellent adhesion resistance for stable chip evacuation.
Increased penetration rates (feed rate/drill diameter = penetration rate) from its low friction coefficient allow machining with 2x to 3x higher feed rates than uncoated drills, reducing cycle time and cost per unit.
Guide actuator with right/left ball screw
The Type KR-RL LM guide actuator features a driving element that uses right/left threads and enables symmetrical movements with a single motor.
The actuator integrates an LM guide and a ball screw. Because the single shaft is capable of simultaneous right and left drive, it eliminates complexity and several components from the design. A right- and left-handed ball screw and an integrated body also make a compact design, instead of using two separate ball screws and two separate LM guides.
An electric actuator, gripping force can be regulated according to the fragility of the object being transferred. It can handle loads in radial, reverse-radial, and horizontal directions, making it possible to install in any mounting orientation, such as robot arm end effectors. Speed control, longer life resulting from heat-treated steel, and energy savings are additional benefits. It’s available in nine sizes from 15mm to 65mm with long or short blocks.
Materialise has been qualified by Airbus to manufacture flight-ready parts using laser sintering technology. The material used in the process, produced by EOS, is a flame-retardant polyamide (PA 2241 FR) meeting strict quality standards required of flight-ready parts.
The qualification is valid across Airbus and marks a significant milestone for wider adoption of polymer 3D printing in aerospace. PA 2241 FR offers a cost-effective complement to the initially validated 3D printing material Ultem 9085. In addition to the PA 2241 FR material, qualification also encompasses the respective processes for 3D printing iton EOS systems. Materialise will use EOS systems including the EOS P 770 to manufacture PA 2241 FR parts for Airbus.
Applications include aircraft interior air ducts and brackets. The material is suitable for parts which must fulfill fire, smoke, and toxicity (FST) requirements, without using a primer and top coating.
Trilantic North America acquires 3D Systems’ On-Demand Manufacturing
Trilantic North America, a middle market private equity firm, is acquiring 3D Systems’ On-Demand Manufacturing business in partnership with industry executives and Ziad Abou, the division’s senior vice president and general manager for nearly a decade. The company will operate under the name QuickParts with Abou as CEO, providing on-demand 3D printing and custom manufacturing services. An installed base of approximately 200 in-house 3D printers and global network of manufacturing partners offer rapid prototyping, functional prototyping, low-volume manufacturing, and appearance model manufacturing services.