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Proprietary hybrid PLASMA coated brass wire from GIP

Clippard Uses GIP Hybrid Plasma Coated Brass Wire for EDM Operations, Realizes 15 to 20% Improvement in Speed

Market leader in high-precision pneumatic valves and other components machines 316SS and other materials, achieving better finish in less time with reduced power and less wire breakage, due to proprietary product from Global Innovative Products

Clippard EDM GIP

Trevor McCoy, CNC/EDM programmer at Clippard, runs a FANUC wire EDM with the GIP proprietary PLASMA coated brass wire. McCoy states he achieves better finish with 15 to 20% improvement in run time. (machine hood open only for photo purpose)

Clippard (Cincinnati, Ohio) is a world leader in fluid control products and other high-precision components, and the company prides itself on having been vertically integrated for decades, since its founding in 1941. The company operates two ISO certified manufacturing locations in Ohio and does advanced machining of all types to produce its extensive catalog of standard and custom product solutions for a myriad of markets worldwide. At the heart of its machining capabilities are 12-axis CNC Swiss machines, CNC milling centers and CNC wire EDM’s, plus numerous post-finishing operations, including anodizing, EN plating and thermal deburring. Various metal and thermoplastic materials are machined.

Recently, after extensive discussions with a local EDM supply distributor, a proprietary hybrid coated brass wire was presented to the Clippard Director of Operations, Robin Rutschilling and his CNC/EDM Programmer, Trevor McCoy by Barry Ramsay of Global Innovative Products (hereafter GIP), a Mason, Ohio supplier of consumables for EDM shops through their GIP distributor network, who also produces a variety of its own products for need-specific operations in electrical discharge machining. One such product is a PLASMA hybrid coated brass wire, comprising of a gamma-phase intermetallic zinc alloy coated wire with brass core. This proprietary GIP innovation had proven out in numerous lab testings but needed “real world” production validation. Barry Ramsay and GIP application engineer Brad Hansard approached the team at Clippard.

Clippard Wire EDM

Clippard uses wire EDM for the production of many components, including the tooling used in its conventional machine shops. All EDM work at Clippard is performed for internal production purposes, so one-offs are common, making speed a critical factor for the department.

As the product had been found suitable for all types of wire machines, with excellent auto-threading capability and increased performance, even at conventional brass wire settings, Ramsay felt confident the product would outperform what Clippard was currently using in its EDM shop, including other GIP wire. This new product was being offered in 0.008”, 0.010” and 0.012” (20mm, 25mm and 30mm) diameters, so Ramsay proposed giving the Clippard EDM department a supply for testing on one of its Fanuc wire machines.

Gamma phase brass is a brittle intermetallic alloy (Cu5Zn8) with a high zinc content (approximately 65% Zn) which can also be synthesized by a diffusion anneal. However, when such coatings are wire drawn subsequent to the diffusion anneal, the coating will fracture due to its brittleness and redistribute around the wire circumference creating a discontinuous layer sometimes described as a “porous layer”, which promotes turbulent flow enhancing the flushing of debris. However, it is zinc enrichment created at the surface combined with the elevated melting point of CuZn gamma phase (approximately 800ºC/1472ºF) which are the biggest factors contributing to the performance of Gamma Phase Brass coated wire.

The arrangement between the two companies actually began in a somewhat unconventional manner, as Trevor McCoy relates. “We have an Ocean hole popper (electrode/sinker EDM) and the circuit boards needed repair. Brad was able to do that kind of work, which I knew from previous experiences with him. So, he proposed exchanging the board servicing for the opportunity to test the GIP hybrid PLASMA wire. Seemed reasonable to us, so we agreed.” The FANUC wire EDM in the shop at Clippard seemed an ideal candidate for GIP, as well, as Barry Ramsay notes, “We knew they were running all types of materials and some very high-precision tooling used in their own machine shop for the production of various pneumatic components with very tight tolerances. It seemed a very good place to test our new wire, which had been proven out on our own EDM’s at GIP.” He further says it was a handshake deal, a “classic collaboration between two companies for their mutual benefit,” adding that application engineering supplied by GIP further enhanced the use of the product at Clippard, as the test learning process information was shared without reservation, so both companies benefited.

In this test case, many of the components were being run for the production of special parts being produced by Clippard for robotic arm articulation.

The testing immediately yielded positive results, as McCoy notes they were holding tolerances under a tenth, with a microfinish that was very important for the application. “We do a lot of custom work for our own use, over 50% of my production in EDM. Some of the hard tool steels are difficult to drill and we also run various others. The jobs require a lot of setup time and fixturing, so run time, finish and wire breaks all are critical for us.”

The goals for this proprietary wire testing were three, according to Barry Ramsay. “The characteristics of the PLASMA wire in production on the FANUC machine at Clippard were important, as the flushing of their precision components directly impacts quality. Further, we had our own test results galore but needed an outside house to validate what we were seeing. Lastly, we just wanted to help our friends at Clippard, who had been so cooperative and, in this case, needed our help with those circuit boards. It was a classic win-win for both of us, as all three goals were met.”

Multiple parts were EDM’d during the testing of this PLASMA wire, with full comparative data tracked on the test wire vs. conventional brass. One tool for a medical part was produced, for example, in :56 vs. 1:05 with five skim passes, a 16% improvement in overall production. McCoy notes, “We could apply more power to run faster. The GIP product consistently outperforms premium brass, based on my experience with both now.” He also cited a very practical advantage. “The PLASMA wire is as clean as conventional brass.” Ramsay adds the price point is also competitive, so there’s less of a premium to achieve these enhanced results.

Clippard is a third-generation, family-owned and operated company that has developed many pneumatic components for a variety of applications in industry, commercial and even fun applications. Clippard’s Chief Marketing Officer, Rob Clippard, developed this “air guitar” that operates with the company’s pneumatic valves and cylinders. See it in performance of the classic Pachelbel Canon in D below. A wonderful intersection of music’s magic with the technology of one very creative company!

Chris Agricola, Advertising Manager at Clippard, also contributed to this story.

 

For more information, please contact:

Robin Rutschilling
Director of Operations
CLIPPARD
7390 Colerain Avenue
Cincinnati, OH 45239
Phone:  513-521-4261
www.clippard.com
r.rutschilling@clippard.com

Or

Barry Ramsay
General Manager
GLOBAL INNOVATIVE PRODUCTS
7697 Innovation Way
Suite 200
Mason, OH 45050
Phone:  513-701-0441
www.gipintl.com
bramsay@gipintl.com

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Grieve Bench Oven 1050

400°F Large Capacity Bench Oven from Grieve

Grieve Bench Oven 1050No. 1050 is a 400°F (204°C), large capacity bench oven from Grieve, currently used for vacuum bagging at the customer’s facility. Workspace dimensions of this oven measure 36” W x 48” D x 36” H. 6.6 kW are installed in Incoloy sheathed tubular heating elements, while a 400 CFM, 1/3-HP recirculating blower provides airflow to the workload.

This Grieve oven features 2” insulated walls, six (6) point vacuum manifold with individual shut-off valves, vacuum gauge and quick disconnect. Additional features include an aluminized steel exterior, Type 304, 2B finish stainless steel interior and an 80 CFM powered forced exhauster.

Controls on the No. 1050 include a digital programming temperature controller, manual reset excess temperature interlock with separate contactors and a recirculating blower airflow safety switch.


For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road
Round Lake, Illinois 60073-2835
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com
Attention: Frank Calabrese

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Grieve Clean Room Oven #1048

350°F Clean Room Oven from Grieve

Grieve Clean Room Oven #1048No. 1048 is a 350°F (177°C), clean room oven from Grieve, currently used for final cure of hardcoated optical lenses at the customer’s facility. Workspace dimensions of this oven measure 54” W x 63” D x 72” H. 60 KW are installed in Incoloy sheathed tubular heating elements, while a 6000 CFM, 5-HP recirculating blower provides horizontal airflow to the workload.

The Grieve clean room oven features 6” insulated walls, Type 304, 2B finish stainless steel interior with continuously backwelded seams and an aluminized steel exterior which is finished with white epoxy paint and a #4 brushed finish stainless steel door cover. The oven is humidity controlled, including dew point sensor and steam humidifier.

Additional features include a motorized damper on exhaust for accelerated cooling, 24” x 24” x 6” thick HEPA fresh air filter with 2” prefilter, four (4) 30” x 24” x 12” thick stainless steel high temperature HEPA recirculating filters and minihelic pressure gauge across recirculation filters, as well as an 8” x 10” double pane window, interior oven light and a circuit breaker disconnect switch. The oven includes all safety equipment for handling flammable solvents (including explosion venting door hardware and 325 CFM powered forced exhauster) and NFPA 79 electrical construction (including NEMA 12 control panel and rigid conduit.)

Controls on the No. 1048 include a digital programming temperature controller to control temperature and humidity, manual reset excess temperature interlock with separate contactors and an SCR power controller.


For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road
Round Lake, Illinois 60073-2835
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com
Attention: Frank Calabrese

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Grieve Universal Oven

650°F Universal Oven from Grieve

Grieve Universal OvenNo. 841 is a 650°F (343°C), universal oven from Grieve, currently used for a variety of heat treatments at the customer’s facility. Workspace dimensions of this oven measure 36” W x 36” D x 36” H. 9 KW are installed in Incoloy sheathed tubular heating elements, while a 600 CFM, 1/2 HP recirculating blower provides universal airflow to the workload.

This Grieve universal oven features 6” insulated walls, aluminized steel exterior and Type 430 stainless steel interior with double doors. Additional features include a workspace floor reinforced for 500 lbs loading at removable subway grate and an integral leg stand.

Controls on the No. 841 include a digital programming temperature controller, manual reset excess temperature controller with separate contactors and a recirculating blower airflow safety switch.


For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road
Round Lake, Illinois 60073-2835
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com
Attention: Frank Calabrese

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Grieve Bench Oven No. 1047

350°F Bench Oven with Eight (8) Drawers from Grieve

Grieve Bench Oven No. 1047No. 1047 is a 350°F (177°C), bench oven from Grieve, currently used for curing plugs on the ends of cords at the customer’s facility. This bench oven has eight (8) drawers with dimensions of 6” W x 13” D x 6” H with removable insert to close around cord. 2 KW are installed in Incoloy sheathed tubular heating elements, while a 300 CFM, 1/3-HP recirculating blower provides horizontal airflow to the workload.

This Grieve bench oven features 2” insulated walls, Type 304, 2B finish stainless steel interior and stainless steel exterior with #4 brushed finish. Features include eight (8) digital batch timers with common alarm; one timer positioned above each drawer to individually time process in each drawer. Additional features include an integral leg stand.

Controls on the No. 1047 include a digital indicating temperature controller, manual reset excess temperature interlock with separate contactors and recirculating blower airflow safety switch. Additional controls include a circuit breaker disconnect switch and SCR power controller.


For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road
Round Lake, Illinois 60073-2835
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com
Attention: Frank Calabrese

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Exact Metrology Helps Create Red Stockings Pavilion Sculptures

Red Stockings Pavilion SculpturesThe Cincinnati Reds celebrated their 150th anniversary as the nation’s first all-professional baseball team by dedicating a pavilion outside the ballpark on May 5, 2019.

Local Cincinnati artist, Tom Tsuchiya, created relief figures of the members of the 1869 team that adorn a gazebo highlighting the site. It includes 12 bronze busts of 10 players, the club president and secretary. Tom also designed the player statues around the Great American Ball Park. The figures enshrined include Asa Brainard, pitcher/outfield; Doug Allison, catcher; Charlie Gould, first base; Charlie Sweasy, second base; Fred Waterman, third base; George Wright, shortstop; Andy Leonard, left field; Harry Wright, center field/pitcher (team captain);  Cal McVey, right field; William “Dick” Hurley, substitute; Aaron Champion, club president and John Joyce, secretary.

Exact Metrology scanning the sculpture

Exact Metrology, distributor of the GOM CT Scanner, used the GOM ATOS Triple Scan for each sculpture. The GOM ATOS Triple Scan is a high resolution, optical digitizer that delivers rapid and precise 3D measuring data for the optimization of design processes. Precise fringe patterns are projected onto the surface of the object and are recorded by two cameras, based on the stereo camera principle. As the beam paths of both the camera and the projector are calibrated in advance, 3D surface points from three different ray intersections can be calculated. The projection unit of the ATOS Triple Scan is based on Blue Light Technology. Since the sensor works with narrow-band blue light, interfering ambient light can be filtered during image acquisition. Short measuring times are possible because of the powerful light source.

Then, the data was processed in Exact’s Geomagic, the company’s 3D software for digital models of physical objects. Next, the data from the software was used to create a Styrofoam negative with a CNC machine. Lastly, the negative was taken to a foundry to be poured in the final sculpture.

The pavilion is located in the former rose garden, next to the Hall of Fame and Museum, along Joe Nuxhall Way on the first base/right field side of the Great American Ballpark. This pavilion is the first permanent recognition of the original Red Stockings.


For more information, please contact:

Steve Young
Exact Metrology, Inc.
11575 Goldcost Drive
Cincinnati, OH 45249
Phone: 614-264-8587
Local: 513-831-6620
www.exactmetrology.com
stevey@exactmetrology.com

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Grieve 824 Modified Universal Oven from Grieve

500°F Modified Universal Oven from Grieve

Grieve 824 Modified Universal Oven from GrieveNo. 824 is a 500°F (260°C), modified universal oven from Grieve, currently used for housing a vertical conveyor system at the customer’s facility. 9 KW installed in Nichrome wire heating elements, while a 600 CFM, 1/2 HP recirculating blower provides universal airflow to the workload.

This Grieve modified universal oven features 4” insulated walls, aluminum steel exterior, Type 430 stainless steel interior and two (2) 20” wide x 5-1/2” high conveyor access doors installed in oven door. Additional features include safety equipment for handling flammable solvents, including explosion venting door hardware. The oven also features an integral leg stand.

Controls on the No. 824 include a digital indicating temperature controller, manual reset excess temperature controller with separate contactors and recirculating blower airflow safety switch.


For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road
Round Lake, Illinois 60073-2835
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com
Attention: Frank Calabrese

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Grieve 797 Clean Room Cabinet

260°F Clean Room Cabinet Oven from Grieve

Grieve 797 Clean Room CabinetNo. 797 is a 260°F (127°C), clean room cabinet oven from Grieve, currently used for drying coating on printed circuit boards at the customer’s facility. Workspace dimensions of this oven measure 36” W x 36” D x 39” H. 20 KW installed in Incoloy sheathed tubular heating elements, while a 1000 CFM, 1-1/2 HP recirculating blower provides horizontal airflow to the workload.

This Grieve clean room cabinet oven features 4” insulated walls, Type 304, 2B finish stainless steel interior with continuously backwelded seams and exterior finished with white epoxy paint. Oven features include #4 brushed stainless steel door cover and control panel face. Additional features include safety equipment for handling flammable solvent including explosion venting door hardware and 30” x 24” x 6” thick stainless steel high temperature HEPA recirculating filter.

Controls on the No. 797 include a digital indicating, programming temperature controller and SCR power controller.


For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road
Round Lake, Illinois 60073-2835
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com
Attention: Frank Calabrese

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Grieve 879 Shelf Oven

350°F Modified Shelf Oven from Grieve

Grieve 879 Shelf OvenNo. 879 is a 350°F (177°C), modified shelf oven from Grieve, currently used for pre-heating bulk friction material in trays at the customer’s facility. Workspace dimensions of this oven measure 68” W x 30” D x 36” H. A 1000 CFM, 1-HP recirculating blower provides horizontal airflow to the workload.

This Grieve modified shelf oven has 4” insulated walls, an aluminized steel exterior and Type 430 stainless steel interior. Features include two (2) shelf trucks with supports on 9” centers to correspond to wheel supports in oven and two (2) tiers of wheel tray supports to aid in loading trays from oven to trucks. Additional features include 350,000 BTU/HR installed in a modulating natural gas burner.

This Grieve oven includes all safety equipment required by IRI, FM and National Fire Protection Association Standard 86 for gas-heated equipment, including a 325 CFM 1/3-HP powered forced exhauster.

Controls on the No. 879 include adjustable, thermocouple actuated, manual reset excess temperature interlock, electronic flame safeguard protection, exhauster airflow safety switch, recirculating blower airflow safety switch and purge timer.


For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road
Round Lake, Illinois 60073-2835
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com
Attention: Frank Calabrese

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Cooling Chamber from Grieve

Grieve Cooling Chamber 807No. 807 is a cooling chamber from Grieve, currently used for cooling oven trucks of steel parts at the customer’s facility. Workspace dimensions of this cooling chamber measure 84” W x 96” D x 72” H. 7000 CFM, 7 1/2-HP remote mounted exhaust blower to pull room air through load and exhaust.

This Grieve cooling chamber has aluminized steel construction, ¼” plate floor and is sectioned to pass through a 72” wide doorway.

No. 807 has twelve (12) 24” x 24” x 6” thick HEPA filters installed at top of workspace to filter exhausted air.


For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road
Round Lake, Illinois 60073-2835
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com
Attention: Frank Calabrese

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