Month: November 2016

K-TIG not only leads the way for environmental sustainability within the welding industry – its state-of-the-art technology and process is proven to reduce welding and fabricating costs by an average of 80%. Developed by the CSIRO, K-TIG is a high speed, single-pass, full-penetration welding technology that eliminates the need for wire, edge-bevelling or skilled operators. K-TIG, or Keyhole TIG (tungsten inert gas), is a variant of gas tungsten arc welding (GTAW). K-TIG operates exceptionally well across a large array of applications, demonstrating working speeds up to 100 times faster than conventional welding technologies like TIG/GTAW. K-TIG’s stable keyhole penetrates materials up to 16mm in thickness with a fraction of the maintenance requirement of other processes. The technology has eclipsed past technologies through massive reductions in gas and power usage, and through single-pass welds, which eliminate, or significantly reduce, grinding and reworking at a faction of the price of laser systems. According to…

Since the day some ingenious machine tool engineer first mounted a metal tube on an engine lathe, machinists have been looking for a better way to cut off parts. From hand-ground bits to high speed steel blades to indexable carbide inserts, cut-off tool technology has continued to improve over the years, increasing metal-cutting efficiency and lowering operational expenses along the way. One large step in that evolution came with the development in recent years of multi-purpose cut-off tools able to switch hit as grooving, turning, and profiling tools, giving manufacturing companies the ability to simplify setups and shorten production cycles, and in some cases keep fewer tools in the crib. One such company is EMC Precision, a family-owned and operated precision machining job shop headquartered in Elyria, Ohio. Since 1925, EMC has provided prototype to production machining and value-added services to a range of industries including fluid management, hydraulic fluid & power, automotive, recreational, and other OEMs. Ian Dotson, manufacturing engineer at EMC’s facility in Sheridan, Indiana, says…

Renishaw recently collaborated with a customer to redesign a hydraulic block manifold with additive manufacturing in mind. The main goal of the project was to reduce the mass of the existing component while retaining its robustness. Due to the increased design freedom associated with additive manufacturing, an opportunity to increase the efficiency of the flow paths was also identified. A hydraulic block manifold directs the flow of fluid in a hydraulic system, linking valves, pumps and actuators. It enables the design engineer to manage the operation of a hydraulic circuit while combining the components in a compact unit. Traditionally, hydraulic block manifolds are manufactured from an aluminium alloy or stainless steel billet which has been cut and machined to size, followed by drilling to create the flow pathways. Specialised tooling is often needed due to the complex drilling that is required. Passages require blanking plugs to properly direct flow through the system. The nature of the manufacturing process results in abrupt angled junctions between flow paths, which can cause flow separation and/or…

In workshops with turning machines such as lathes and machine centres, one of the most dangerous risks is that the workpiece may not be firmly held by the chuck. Worldwide, there have been a number of horrendous accidents because the grip of the chuck was not checked before machining commenced. “We are glad – and relieved – to see that this century-old problem has now been overcome,” says Cliff Purser, Asia-Pacific Managing Director of Sydney-based 600 Machine Tools. “Our parent company in the UK, the 600 Group, has launched yet another innovative product that underscores its global reputation for safety.” Suitable for use on all makes of chuck, the Gripsafe gripmeter has been developed to help customers comply with health and safety legislation, enabling them to ensure that their chucks remain fit…

Modern technology and processes for the manufacturing industry now commonly include ‘steam vapour technology’. This is the number-one cleaning method for sectors such as healthcare and accommodation, and the manufacturing sector is now beginning to follow suit. The following are key elements of what makes up a best-practice cleaning process for the manufacturing industry, the use of steam vapour as a leading manufacturing cleaning method and common cleaning applications. Ensuring best-practice OH&S                                                                                                                                             The type of cleaning processes used can impact on occupational health and safety (OH&S). The cleaning of dirt and oils off industrial floors is vital to the manufacturing cleaning process to prevent slips and falls. However, when processes such as water and chemicals are used, it only “wipes” dirt, transferring the grime from one surface to another.…

Now the Managing Director and co-owner of Andrew Donald Design Engineering (ADDE), Hendy recalls: “After that job, Andrew and I went our own separate ways. I worked for several companies globally, among which were Kodak and ANCA, in business development and marketing. Andrew started ADDE 20 years ago and built up the business to what it is today.” Headquartered in Bayswater, in Melbourne’s eastern suburbs, ADDE designs and builds turnkey industrial automation solutions. The company’s team of engineers, industrial designers and robotics experts work on projects for clients across a wide range of industries, ranging from pharmaceuticals, food, aviation, defence, automotive to general manufacturing. It has 30 employees, including 15 engineers covering mechanical, electrical, control system, robot and programmable logic controller (PLC) programming. “When Andrew wanted to retire around six…

Moveable factories can bring efficient, flexible production to many sectors and any location. For example, mobile crop-processing factories are used in Africa to maximise yields; mobile abattoirs are used in northern Europe to reduce transportation of live animals; mobile factories are widely used for packaging. Mobile factories are used to bring production processes such as roll-forming to construction sites, and mobile factories are used to bring the most advanced CNC manufacturing to remote locations in challenging environments such as Afghanistan. This article explains how movable factories add value, and how they can be used to meet some big Australian challenges, such as the tyranny of distance and creating manufacturing jobs outside metropolitan areas. The article is based on 10 years of international research and a preliminary study recently carried out in Australia. Making value Moveable factories add value when it is counterproductive to centralise production. For example, when mangos and other bulky crops are collected and transported to a distant factory,…

Green power is a term for electricity generated from renewable energy sources rather than through the burning of fossil fuels such as coal and petroleum. Australia’s electricity-related emissions are high due to the fact that we rely on non-renewable sources for 88% of our electricity generation, with coal being the most greenhouse-intensive fuel. Green power provides an opportunity to mitigate greenhouse gases associated with electricity generation and promote natural energetic processes such as hydropower, solar energy and wind energy. Collectively these technologies make up the remaining 12% of electricity generation. Hydropower – The largest source of renewable energy, contributing 60% of all renewable generation. The Snowy Mountains Hydro-electric Scheme is the country’s largest hydropower generator contributing to almost half of the country’s total hydro output. Solar energy – Australia has the highest average solar radiation per square metre of any continent in the world and is a largely untapped resource. However, solar power cannot be…

Additive manufacturing has moved beyond prototyping. The current state of 3D printing systems, materials and parts-on-demand providers makes 3D printing jigs and fixtures and other manufacturing applications practical and accessible to manufacturers. Mainstream manufacturers are wise to seize on the economic and efficiency advantages offered by this technology, as well as the new possibilities it opens. New possibilities are born of new capabilities. The ability to dramatically lower production times and costs on complex, low-volume components, often while increasing functionality, is a game changer. What’s at stake for manufacturers are the prospects to improve current operational efficiencies and reduce costs, as well as capitalise on new product and market opportunities. Ultimately, 3D printing may enable strategic initiatives that change manufacturing and business models, and provide disruptive competitive advantages. Underlying the operational value of 3D printing are new ways to mitigate risks inherent in traditional manufacturing: Product and production risk due to imperfectly designed parts. Missed opportunities to supply new products to customers due to delays using traditional processes. Missed opportunities to innovate parts and Products using new design…

Safety and ergonomics are inextricably linked with productivity. The Oxford English Dictionary defines ergonomics as “the study of people’s efficiency in their working environment”. The use of press brakes is still a predominantly manual operation and global manufacturers are applying their safety and Ergonomic principles especially in markets where compulsory safety regulations apply. Light guards Some machinery manufacturers are being inventive and have integrated light guard systems into the machine’s control. This enables the light guard operation to be “programmed”, which can result in productivity benefits. The primary function of a light guard is to inform the machine when an operator is in the danger zone. It is therefore evident that the machine can also know when the operator is out of the danger zone and can use this information intelligently. An integrated light guard system can actually increase productivity by acting as a switch to ensure the machine is always ahead of the operator while maintaining a safe…

Melbourne-based Amaero Engineering – a spin-out company from Monash’s innovation cluster – has signed an agreement to print turbojet components for Safran, the French-based global aerospace and defence company. The collaborative agreement is between Monash, Amaero and Safran Power Units. “Our new facility will be embedded within the Safran Power Units factory in Toulouse and will make components for Safran’s auxiliary power units and turbojet engines,” said Barrie Finnin, CEO of Amaero. The world’s first 3D-printed jet engine was revealed at the 2015 Melbourne International Airshow. Safran, Monash University and Amaero, in collaboration with Deakin University and the CSIRO, took a Safran gas turbine power unit from a Falcon executive jet, scanned it and created two copies using customised 3D metal printers, as part of a project supported by the Science and Industry Endowment Fund (SIEF). This research is now being extended through the support of Australian Research Council’s (ARC) strategic initiative ‘Industry Transformation Research Hub’ and industrial partners including Safran and Amaero. “We proved that our team were world-leaders,”…

“We first invested in Okuma in 2007 and since then we have increased the size of our purchases each time,” said Managing Director Brad Byrne. “To remain competitive you have to have the best world-class equipment. “The reason behind getting the MB-56VA was to strengthen our standard engineering output and to diversify into other areas of work to meet the needs of new customers. We have seven- and nine-axis Okuma multi-tasking machines for the complex tasks and this takes care of mainstream jobs for our customers in Australia and overseas.” The Okuma MB-56VA is a three-axis vertical machining centre with a high-speed, 40-taper, 15,000rpm spindle and 22kW VAC integral motor. It has a work area of 1300mm by 560mm. The compact (2,500m x 3,100mm footprint) mill features Okuma’s Thermo Friendly Concept (TFC) and Collision Avoidance System (CAS). TFC accounts for the amount of heat generated in and around the machine space and uses sensors and feed axis position data to control against thermal deformation during machining to maintain cutting…

Micromet – Gearing up for mass production Staff from Adelaide company Micromet spent much of August in the major port and industrial city of Ningbo in China testing the company’s Generation 3 water treatment machine, which uses electrolysis to remove pollutants from contaminated water such as sewage, grey water, and industrial effluents. The in-situ tests are a pre-cursor to the establishment of a mass production model in Adelaide. Micromet Engineering Sales Director Andrew Townsend said the Gen 3 device could treat the desired two litres of water a second, adding that its one-tank design enabled mass manufacturing at a relatively low cost. According to Townsend, Australian products have a good reputation in the water treatment space in China. “They are very happy with ‘Made in Australia’,” he says. Micromet’s process uses continuous flow electrolysis methods with special anti-passivation technology that has eluded such systems in the past. The Micromet equipment is also very energy-efficient,…