NOV/DEC 2018 Winner
John Hutton, Calibration Technician, Carlisle Interconnect Technologies, St. Augustine, Florida
How long have you been in the aerospace business? Including the U.S. Marines, 46 years.
How did you become interested in aircraft? Uncle Sam opened my eyes to aircraft.
What is your favorite aircraft and why? My all-time favorite aircraft is and will always be the F-4 Phantom. It is proof that with powerful enough engines, even a brick can fly at Mach 2.
Director of Maintenance,
Banyan Air Services Inc.
Fort Lauderdale, Florida
Sikorsky Aircraft Corp.
To enter the contest, visit www.AerospaceManufacturingAndDesign.com/Form/NameThatPlane and fill out the provided entry form. Only completed forms will qualify. A full set of rules is provided.
The entry deadline for this issue’s contest is April 5, 2019. Winners will be announced in the May 2019 issue.
Have fun, and good luck!
Look what John won!
Enter today to win your own high-quality desktop aircraft replica!
1) How can the KYOCERA SGS Tech Hub provide an optimal solution to each unique customer challenge?
Like a fingerprint, every machining application is unique. Therefore, making blanket predictions for each customer is challenging. With such a complex series of engineering relationships working together simultaneously to machine a component, there are far too many variables impacting the overall outcome of an application. An optimized solution, tailored to unique machining events in specific facilities with their own set of specific variables, requires a specialized approach.
2) What are some examples of the unique complexities that your customers are facing?
These would include (but are not limited to): toolholding, part fixturing, coolant (pressure, flow, position, concentration), material, processing, spindle (interface, rigidity), substrate, geometry, coating, programming (paths, parameters, engagements), temperatures, air pressure/quality, maintenance, and torques on various assembly points.
Each unique application must be diagnosed and treated on an individual basis using available resources, education, technology, and experience. Just as a doctor individualizes treatment for each patient, the same philosophy should be applied to completely optimize each application. This is how the most cost-effective, highest performing solutions are realized.
3) How has the ever-changing cutting tool industry impacted your organization?
This has been witnessed through the evolution of our product portfolio. For many years our industry had a one-size-fits-all mentality of a standard 30° helix, standard rake and clearance configuration. This was your geometry for steel, aluminum, titanium, or every other material encountered. As often occurs, the industry matured, forcing aspects of the complex engineering relationships within machining to reinvent themselves. This has a domino effect on all the associated variables forcing us to evolve our designs.
4) In what ways has this shifted the mindset of how KYOCERA SGS Precision Tools designs cutting tools?
As technology evolves, so must our processes. Cutting tools are no different. This is a new way of thinking for KYOCERA SGS and can be of tremendous benefit to the industry. Like a race team engineers race tires to optimize performance, the same mindset must be applied to win in a machining environment. While manufacturing tools on a large scale is effective, it has presented an opportunity to treat each customer’s challenge with the individual attention it requires.
5) How can the KYOCERA SGS Tech hub ultimately advance the future of the tooling industry?
The market is more sophisticated, technologies improve, global competition is constantly evolving. The analysis of each application recognizes the unique variables that can impact that application, and applying a customized tooling solution is a vital competitive advantage that KYOCERA SGS Tech Hub provides. KYOCERA SGS is taking advantage of this unprecedented technology to deliver a tool and a well thought out, unique solution. We strive to strengthen the chain of engineering relationships and apply our knowledge to dynamically address each challenge. We are evolving from a one-size-fits all approach to a multi-dimensional solution-based approach. Today’s special tools help inspire the evolution to the standard tool of tomorrow. https://www.kyocera-sgstool.com/tech-hub
Uncertainty may be slowing the economy, according to a recent analysis. Tariffs, consumer debt, tax changes, stagnating foreign economies, and politics are playing a part. In December 2018, all but one of the Federal Reserve Banks indicated signs of a recession coming. It could just be the arc of the business cycle, and if you are in aerospace manufacturing, any slowdowns you are experiencing may be due more to supply-chain disruptions than decreasing demand for your products.
Ned Hill, professor of economic development in the Ohio State University’s John Glenn College of Public Affairs and member of the College of Engineering’s Ohio Manufacturing Institute, has focused on coping with adversity in lectures and a recent book. He shared his economic analysis at the rollout of a state-of-manufacturing survey of nearly 500 respondents, keyed to Northeast Ohio, but his advice is more far-reaching.
If the economy pauses, Hill argues that’s the perfect time to consider your strategy for when the rebound comes, as history shows it will. Companies that learn from disruption in their business will be the ones that survive. “Companies investing in the future will win,” Hill says. New markets, new products, and innovation are the way to the future, he adds, but companies still need to do operations well. Increasingly, that means applying technology such as automation/robotics; smart, connected machines (Industrial Internet of Things/Industry 4.0); predictive analytics; virtual reality; and 3D printing.
In response to a skilled labor shortage, manufacturers of all sizes are turning to automation, regardless of whether their revenues were up, flat, or down slightly. Although larger companies can afford to embrace automation more than companies with revenues less than $5 million, nearly half that report it applies to them say they use automation to augment their workforce. Automation to replace workers represents only 6% of replies. Slightly fewer than 1 in 4 companies reported they are just starting to use robots, with 1 in 10 maximizing their use. For collaborative robots designed to help workers directly, the figures show 21% just starting to use them and 3% maximizing use. Ohio manufacturers may lag nationally in adopting automation, but even the broader picture reveals growth opportunity.
Similarly small numbers show up in adopters of other leading-edge technologies. Barely more than half of Ohio manufacturers say they are using smart, connected machines – 38% just starting, 13% maximizing results. Companies using predictive analytics: 30% are just starting, 5% report obtaining maximum benefit. Virtual reality barely registers, with only 7% of companies just starting and none reaching maximum use.
Companies are embracing 3D printing for prototyping, with 33% starting to adopt the basic technology and 7% claiming to maximize its use. Advanced 3D printing for tooling and mold-making is a little further behind, with 16% starting to use and 2% maximizing.
The lesson was twofold: despite the attention editors may give advanced manufacturing technology, it is still low on the growth curve, poised to make its impact with more widespread adoption. And companies that are succeeding, and likely to continue to do so, invest in technology. – Eric
The G420 turn-mill center features identical 3,500rpm twin spindles with 315mm (400mm optional) chucks and a 5-axis milling spindle that provides up to 12,000rpm with an HSK-T63 interface or 18,000rpm with a Capto C6 interface. The machine’s stability and high dynamic response make it suitable for working with difficult-to-machine materials, especially for completing large, complex parts in a single setup.
The main and counter spindles accommodate bar stock up to 102mm diameter, while the work area provides space for part lengths up to 1,600mm. An optional workpiece handling system can load, unload, and transfer parts up to 20kg and 120mm diameter.
The milling spindle offers 26kW, 150N·m, and 12,000rpm with an HSK-t63 interface or 27.5kW, 100N·m and 18,000rpm for the Capto C6 option. Optimized Y/B quill kinematics allow simultaneous 5-axis milling operations to tackle complex geometries.
The unit can accommodate up to three tool carriers in its workspace, each equipped with a Y-axis. Turret steady rests are available for maximum stability when machining long or shaft-shaped parts.
Ergonomic design optimizes accessibility to operating and maintenance personnel. A chip conveyor can be mounted on either side of the machine, and automation solutions, including conveyor belts and robot handling units, can be integrated.
The iXpanel operating system is Industry 4.0 ready, offering a direct connection between the machine control and the company operations department.