Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Increasing demands made on precision and the push for the decrease of price of modern components is pushing traditional manufacturing processes. EMAG offers three production technologies that complement or replace traditional processes such as turning, milling and grinding.
PECM for nickel- and titanium-based alloys
The ECM process is used to deburr components only at the points where material needs to be removed, and without it having any mechanical or thermal impact on the workpiece.
With its PECM technology (Precision Electro-Chemical Machining) EMAG presents a production process that opens up completely new fields of application. PECM is a process for the machining of high-alloyed materials, such as nickel- and titanium-based alloys. The disadvantages of traditional metal cutting – tool wear, mechanical stresses, micro-fissuring caused by heat, oxidization layering and the need for subsequent deburring operations – are eliminated, because this process is a non-contact one without heat input. All electro-chemical machining processes are characterized by stress-free material removal, smooth transition points and surfaces without ridge formations.
The ECM process is used to deburr components only at the points where material needs to be removed, and without it having any mechanical or thermal impact on the workpiece.
The advantages that the PECM process provides for different branches of industry are best shown with the example of a turbocharger for the automotive industry. The electro-chemical process is one that can be used to effectively in the machining of many high-alloy components, especially those in the high-temperature sector of the turbocharger – it also offers a much shorter and very efficient process chain. The typical clean-up operations necessary when traditional machining processes are used – such as deburring after milling – are no longer necessary. PECM machining operations are burr-free. And there is hardly any tool wear. The result: downtimes are minimal, when compared to milling (which requires regular tool changes). The process as a whole is sturdier and less prone to errors. And another important factor that our example of the turbocharger shows: the superb surface finish of the PECM process, where Rz-values of 0.3 micron can be achieved.
Will camshafts ever again be made of a single piece?
Heat-shrink assembly of camshafts for small-power and passenger car engines.
Another highlight is EMAG’s heat-shrink assembly technology, a process that scores particularly well in camshaft production. The high degree of precision achieved with the joining process drastically reduces the number of cam profile grinding operations or – with the use of precision cams – avoids them altogether. Another benefit of the process is the ability to combine different materials in the construction of the shaft, such as forged cams (e.g. in 100Cr6) and sintered cams, which do not require regrinding. Accessory components, such as plugs and end pieces, can – like the shaft itself – also be made of better materials. This allows for the camshaft to be adapted to the requirements of the engine and to be optimized in load bearing capacity and manufacturing costs.
Operating costs reduced by 50 %
Operating costs are cut in half with the fiber laser on the new ELC 160 laser welding machine.
Production laser welding is already a highly productive process in the manufacturing of gearwheels. The use of diode-pumped solid-state lasers – such as disc or fiber lasers –reduces operating costs by up to 50%. EMAG has been involved with the use of solid-state lasers in the welding of powertrain components from an early stage and is considered a pioneer in the technology. EMAG again has fulfilled a promise to their users offering them the lowest possible cost-per-piece, by coming up with an innovative technology that brings true cost benefits.
For many applications, solid-state lasers allow welding without shielding gas. This not only reduces operating costs, it also avoids having to follow the annoying logistics imposed by the use of shielding and laser operating gasses. In many cases, the welding process can also be sped up considerably. This increases productivity and – through a reduction in energy input per unit length – reduces welding distortion, resulting in better component quality.
For more information:
Kristal Kilgore
EMAG LLC
38800 Grand River Avenue
Farmington Hills, MI 48335
Tel: (248) 875-0313
Fax: (248) 477-7784
E-mail: kkilgore@emag.com
Web: www.emag.com
A walking tour of Rattunde’s unique tubemaking machinery, provided by company president for North America, Rick Stadler.
Click here to view the video.
Check out all the machining functions it can perform! Rattunde delivers ready to install products to the assembly line for its customers.
For more information, please contact:
Alec Banish
Vice-President / Business Development
Rattunde Corporation
4980 Kendrick St. SE
Grand Rapids, MI 49512
(616) 940-3340 x202
www.rattunde-corp.com
OR
Richard Stadler
President
Rattunde Corporation
(616) 940-3340
No. 893 is an 850ºF, electrically-heated walk-in oven from Grieve, currently used for heat treating parts on rollout shelves at the customer’s facility. Workspace dimensions of this oven measure 54” W x 72” D x 78” H. 80KW are installed in Incoloy-sheathed tubular elements to heat the oven chamber, while a 6000 CFM, 5-HP recirculating blower provides combination airflow to the workload.
This Grieve oven has 8” insulated walls comprising 2” of 1900ºF block and 6” of 10 lb/cf density rockwool insulation, plus an aluminized steel interior and exterior, top-mounted heat chamber and three rollout shelves, each 48” wide by 60” long and rated at 200 lbs.
Controls on No. 893 include a digital programming and recording temperature controller, manual reset excess temperature controller with separate contactors, recirculating blower airflow safety switch, SCR power controller and fused disconnect switch.
For more information, please contact: THE GRIEVE CORPORATION, 500 Hart
Road, Round Lake, Illinois 60073-2835 USA. Phone: (847) 546-8225. Fax: (847) 546-
9210. Web: www.grievecorp.com. Email: sales@grievecorp.com. Attention: Frank
Calabrese.
Continue readingCrown Equipment in Mexico bought one of the MAE straightening presses from the GMTA booth at IMTS. Crown is a world leader in forklift trucks.
The expansion of the GMTA facility in Ann Arbor, Michigan is underway and targeted for completion in several months. When completed, the new facility will house a new machine demo and training center, plus additional sales and service personnel. GMTA continues to grow steadily, representing numerous high-quality German machine tool builders in North America.
Siemens in Mexico bought a Pittler PV630 ValueLine vertical turning machine for motor manufacturing. Take a look at video of this machine in action!
For more information:
GMTA (German Machine Tools of America)
4630 Freedom Drive
Ann Arbor, MI 48108
Phone: 734-973-7800
Fax: 734-973-3053
Web: www.gmtamerica.com
Email: sales@gmtamerica.com
Attention: Scott Knoy, VP
Connect with GMTA online: 
No. 1026 is a 550ºF, electrically-heated universal style oven from Grieve, currently used for preheating acrylic and polycarbonate sheets prior to forming at the customer’s facility. Workspace dimensions of this oven measure 34” W x 120” D x 48” H. 60KW are installed in Incoloy-sheathed tubular elements to heat the oven chamber, while a 4200 CFM, 3-HP recirculating blower provides horizontal, front to rear airflow to the workload.
This Grieve oven has 6” insulated walls, aluminized steel exterior, Type 304, 2B finish stainless steel interior and four front access doors with automatic door switches to shut off the heat and blower when a door is opened. Four structural steel slide beds are provided to support the plastic sheets during processing.
Controls on No. 1026 include a digital indicating temperature controller, manual reset excess temperature controller with separate contactors, recirculating blower airflow safety switch, SCR power controller and eight auxiliary thermocouples connected to a selector switch and temperature indicator.
For more information, please contact: THE GRIEVE CORPORATION, 500 Hart
Road, Round Lake, Illinois 60073-2835 USA. Phone: (847) 546-8225. Fax: (847) 546-
9210. Web: www.grievecorp.com. Email: sales@grievecorp.com. Attention: Frank
Calabrese.
Continue readingBill Hunter raises company-supported endowment to Foundry Educational Foundation; $25,000 in memory of Al Hunter will provide scholarships to students involved in metalcasting
Bill Hunter, left, president of Hunter Automated Machinery, presented a check to Bill Sorensen, executive director of the Foundry Educational Foundation, on August 9, 2012 at Hunter headquarters in Schaumburg, Illinois, near Chicago. The check raised the amount of money in the FEF Scholarship Fund to $25,000, in honor of Al Hunter, founder of the company.
Schaumburg, Illinois (USA)-Hunter Automated Machinery today announced a donation to the Foundry Educational Foundation (FEF), raising the current endowment to $25,000, in memory of Al Hunter, founder of the company and father of current owner Bill Hunter. Bill made this donation on August 9, presenting a check to the FEF Executive Director, Bill Sorensen.
Hunter Automated has been a contributor to the FEF for many years. Upon the death of Al Hunter in 2011, the family asked that donations be made to the foundation in honor of him. Once the contributions were collected, the Hunter family asked that FEF establish an endowment to honor Al’s memory, with scholarships provided at selected schools. The first school chosen was the University of Alabama. It provides a deserving student a scholarship in Al Hunter’s name.
FEF is a non-profit organization and the foundry industry’s first link to the college campus. The foundation uses funds contributed from the foundry industry to encourage the pursuit of metalcasting as an academic endeavor at schools across the country. Hunter has pledged to donate $500 every year to FEF, going forward.
As Sorensen explained, “Students will benefit not only from the scholarship monies, but also from getting to know the contributions Al Hunter made to the industry and the substantial legacy he left behind.” Al Hunter held over 80 patents in his lifetime and was chiefly responsible for the development and implementation of automatic matchplate molding machine technology in the North American and ultimately the global foundry market.
Bill Hunter presented the check to Bill Sorensen at Hunter headquarters in Schaumburg, Illinois (Chicago) on August 9, 2012. “It is our privilege to help fund this scholarship program that both encourages young people to enter the foundry industry and continues to honor the technological contributions made by Al Hunter,” Bill remarked.
Sorensen further noted that approximately 90% of the students who have received FEF scholarships continue to pursue their careers in metalcasting.
For further information on this announcement, interested parties may contact:
HUNTER AUTOMATED MACHINERY CORPORATION
2222 Hammond Drive Schaumburg, IL 60196
Phone: (847) 397-5110
Fax: (847) 397-8254
Email: info@hunterfoundry.com
Attention: Bill Hunter, CEO
Web: www.hunterfoundry.com
Connect with Hunter Foundry online: 
Schaumburg, Illinois (Chicago) – With MAGMA5 5.2, MAGMA Foundry Technologies has recently released the latest version of its leading casting process simulation software with significant new and improved functionality. More than 160 improvements were implemented for the user in this new release of version 5.2. The main focus of the development efforts was on increasing the efficiency in evaluating simulation results.
MAGMA5 5.2 now allows the direct comparison of up to four different project versions in the result perspective. Filling, solidification and stress results can be animated in a synchronized mode. A special highlight is the option to display the geometry and all MAGMA5 results in 3D stereo, using shutter or red/cyan 3D glasses and to store them as 3D images or movies. Various new tools facilitate a standardized result evaluation. 
New result criteria allow for a more effective evaluation of metal cooling and critical metal speeds during filling. The progress of feeding and porosity formation can be monitored and displayed continuously during the entire solidification process. A new criterion to predict cold cracks allows the user to find stress-related casting quality problems more quickly.
The implementation of user results further offers a powerful tool to compile user-specific criteria based on any MAGMA5 results. User results can easily be defined and created automatically during a simulation or subsequently in the result perspective.
Die casting users will appreciate an improved visualization of the process time line and extended consideration of the heat transfer conditions between die casting and die as a function of the local feeding conditions. Additionally, the MAGMAhpdc module now supports the assessment of the real casting temperature as a function of the current shot sleeve conditions.
All users will benefit from the new “resume point” capability, which allows flexibility in re-starting the simulation with modified die casting process conditions, based on the previous or next-to-last casting cycle. Sand casting processes can be resumed with different conditions at the end of any process stage. The automatic enmeshment of complex geometries is now further simplified by new enmeshment criteria and procedures.
Stress simulation results can be prepared for faster post-processing. For the quantitative assessment of casting distortion in the measurement perspective, it is now possible to compare the virtual measurement with the real part geometry.
Finally, with MAGMA5 5.2, a new database of riser sleeves, which was generated by ASK Chemicals, is now available.
About MAGMA
MAGMA offers comprehensive solutions to the metal casting industry, casting buyers and casting designers worldwide. MAGMA’s product and service portfolio includes the powerful, modular simulation software MAGMASOFT®,with the newest release MAGMA5 as well as engineering services for casting design and optimization.
Today, MAGMASOFT® is used throughout the global metal casting industry, especially for the optimization of cast components in automotive and heavy industry applications.
MAGMA Giessereitechnologie GmbH was founded in 1988 and is headquartered in Aachen, Germany. A global presence and support are guaranteed by offices and subsidiaries in the USA, Singapore, Brazil, Korea, Turkey, India and China. Additionally, more than 30 qualified partners represent MAGMA around the world.
For more information on this release, please contact:
Christof Heisser
President
MAGMA Foundry Technologies, Inc.
10 N. Martingale Road, Suite 425
Schaumburg, IL 60173
Phone 847-969-1001 ext. 225
Email cheisser@magmasoft.com
Continue readingNo. 873 is a 650ºF, electrically-heated inert atmosphere cabinet oven from Grieve, currently used for processing corrosive materials at the customer’s facility. Workspace dimensions of this oven measure 38” W x 50” D x 38” H. 40KW are installed in Incoloy-sheathed tubular elements to heat the oven chamber, while a 2000 CFM, 2-HP recirculating blower provides horizontal airflow to the workload.
This Grieve cabinet oven has 6” insulated walls, aluminized steel exterior, Inconel 600 interior with continuously backwelded seams and special exterior paint. The oven also features full inert atmosphere construction, including pressure regulator, flow meter, pressure gauge, internal high-temperature gasket, all-welded expansion connection in the doorway throat, air jacket on inner oven for cooling, ½” thick cellular silicone rubber atmosphere seal, blower shaft seal, positive latching door hardware, adjustable offset door hinges, outlet with pressure relief, interior seams welded gas-tight and all wall penetrations fitted with compression fittings.
No. 873 has a 650 CFM blower to pull air through the air jacket on the inner oven for cooling, plus automatic dampers. A hinged door jacket with 4” diameter connector to allow the jacket to be ventilated is also provided.
Sixteen pairs of shelf supports to support thirty-two Inconel 600 pans, with two pans on each level, plus loading truck tracks on the floor of the workspace, are built into this Grieve oven.
Controls on this inert atmosphere cabinet oven include a programming temperature controller, manual reset excess temperature controller, SCR power controller and fused disconnect switch.
For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road, Round Lake, Illinois 60073-2835 USA
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com – Attention: Frank Calabrese
Continue readingBesides predicting the filling process, the process simulation software SIGMASOFT® can also predict the curing reaction of elastomers and the thermal performance of mold tempering systems. A major advantage is that not only the cavity is simulated, but the complete mold including all details is considered in the calculation. Therefore, the interaction between heating elements, elastomer, inserts and mold can be accurately predicted.
Schaumburg, September 7, 2012 – In the elastomer processing industry, it is common for companies to rely on trial-and-error methods to solve production problems. Without process simulation, operators suggest a mold configuration which “should work” for a specific part geometry, based on experience. Factors such as tempering or processing times are defined later during the first production trials. It is not uncommon to find molds which require several rework stages, as well as parts with quality issues where the causes for this issues are not well understood.
Simulation technology can help avoid all these typical processing problems while saving significant time and effort during the development of a new mold. When utilizing the approach of “Process Simulation”, provided by SIGMA® with its software SIGMASOFT®, all the elements of the mold can be included. This allows the molder to run a “virtual production”, including all the process stages (preheating of the mold, injection, curing), not only over one cycle, but over several production cycles. With this process, the performance of a mold design can be evaluated completely before the steel is even cut.
“Historically, elastomer molders have relied on conventional injection molding tools to predict the filling of the cavity. Many processors still think this is all simulation can do for them. However, simulation tools available nowadays are far more powerful. Besides filling, the curing reaction can be accurately predicted, and the thermal behavior can be exactly anticipated”, explains Dr. Marco Thornagel, executive director of SIGMA Engineering GmbH/Germany. “Simulation can make a company achieve its production goals faster, being more profitable”.
Simulation can analyze different variables of the design of a new mold. After determining the desired geometry, the process starts with the selection of the injection point or gate type. Understanding the flow behavior, as well as quality issues related to weld lines, air gaps or jetting, the runner geometry can be defined. In this stage, different aspects including cavity balance or the pressure requirement can be predicted.
Once the part and runner are defined, the tempering of the mold can be designed. In the simulation the tempering elements can be precisely included: it is possible to define their exact location in the mold, as well as the material and the electric power. Even the control system can be defined. Instead of assuming a mold temperature in the simulation, the exact thermal condition of the mold is predicted, including the way it fluctuates over time.
After the effect of the desired tempering system is simulated, factors in the mold which can compromise part quality can be identified. Cold spots in the mold where the material cures too late or irregular temperature distributions, which can produce different curing degrees for parts produced in different cavities, are some examples of the virtual “troubleshooting” that can be achieved with Process Simulation.
For more information:
Christof Heisser or Matt Proske
SIGMA Plastic Services, Inc.
10 N. Martingale Road, Suite 425
Schaumburg, IL 60173
Phone: 847-558-5600
Email: contact@3dsigma.com
Web: www.3dsigma.com
Continue readingThe process-oriented approach of SIGMASOFT® makes it possible to use injection molding simulation of elastomer applications not only for filling or cooling times, but also the non-productive times between each process phase. When the process is simulated considering the influence of operational times occurring between the main process stages, the accuracy of the simulation is dramatically improved.
Temperature distribution in a metallic component overmolded with elastomer. Left: without consideration of the mold opening time; right: considering a mold opening time of 60s.
Schaumburg, IL, September 7, 2012 – Even though it is not necessary to include them to complete an injection molding simulation, the non-productive times have a major influence on the process and on part quality. Process Simulation Software SIGMASOFT®, from SIGMA®, can include non-productive times in the simulation enabling substantial improvement in the accuracy of the results to be achieved.
Taking into consideration the times in which the mold opens and closes, the times in which it is heated up or cleaned, as well as handling times when the inserts are placed simulation makes it possible to accurately analyze the process cycle. The interaction between all mold components has to be considered and cycle times have to be predicted accurately. That way even factors that influence the part quality, such as the curing degree, can be predicted by the simulation.
An example is presented in Figure 1. In this case the mold temperature decreases during the time period when the mold stays open. If this time is not considered in the simulation, the prediction of the whole cycle time, as well as the prediction of the cooling time or curing degree, will be erroneous. Besides, the predicted quality of the parts produced can deviate from reality.
In SIGMASOFT®, such non-productive times can be defined and varied separately in the simulation. Therefore, besides calculating the whole cycle, it is also possible to perform trouble-shooting of problems at each of the production stages. Through the utilization of simulation it is possible to decide if changes in the process definition are enough to solve production problems, or if the mold has to be reworked to achieve the desired quality and productivity goals.
—
SIGMA® (www.sigmasoft.de) is 100% owned by MAGMA® (www.magmasoft.de), the world market leader in casting process simulation technology based in Aachen, Germany. Our SIGMASOFT® process simulation solution optimizes the manufacturing process for injection molded plastic components. SIGMASOFT® combines the 3D geometry of the parts and runners with the complete mold assembly and temperature control system and incorporates the actual production process to develop a turnkey injection mold with an optimized process.
At SIGMA® and MAGMA®, our goal is to help our customers achieve required part quality during the first trial. The two product lines – injection molded polymers and metal castings – share the same 3D simulation technologies focused on the simultaneous optimization of design and process. SIGMASOFT® thus includes a variety of process-specific models and 3D simulation methods developed, validated and constantly improved for over 25 years. A process-driven simulation tool, SIGMASOFT®, with its comprehensive simulation approach, provides a tremendous benefit to production facilities. Imagine your business when every mold you build produces required quality the first time, every time. That is our goal. This technology cannot be compared to any other conventional “Design” simulation approach employed in plastics injection molding.
New product success requires a different communication between designs, materials, and processes that design simulation is not meant for. SIGMASOFT® provides this communication. SIGMA® support engineers, with 450 years of combined technical education and practical experience, can support your engineering goals with applications specific solutions. SIGMA® offers direct sales, engineering, training, implementation, and support, by plastics engineers worldwide.
For more information:
Christof Heisser or Matt Proske
SIGMA Plastic Services, Inc.
10 N. Martingale Road, Suite 425
Schaumburg, IL 60173
Phone: 847-558-5600
Email: contact@3dsigma.com
Web: www.3dsigma.com
Continue reading
