October 17, 2019
Insufficient grip that causes slipping parts, pushback in chuck jaws and collets wearing out prematurely are issues well known to CNC turning machine tool operators. The resultant production downtime, operator idle time, and expense of new or re-worked jaws is a significant problem. Dimac has recently launched a new service designed to eliminate such issues, using a new form of carbide application equipment called Rocklinizer from the USA. The application process improves clamping force by as much as 50% - thereby providing significant extra grip on workholding equipment such as jaws and collets, while wear is accordingly reduced. The new service uses the proven spark deposition process called Rocklinizing to easily and quickly boost the grip coefficient of workholding jaws and collets. The unit electronically applies a hard and wear-resistant surface of Tungsten Carbide, Titanium Carbide or Rockhard electrode material to workholding tools. Material is impregnated both underneath and on top of the workpiece surface. Unlike welding or metal spraying, no appreciable heat is…
October 17, 2019
A hand-held device to predict heart failure based on saliva could help millions of potential victims take preventative steps to avoid their fate. Nano-sensors on the tip of the diagnostic stick measure heart disease biomarkers from saliva to accurately predict the risk of heart disease, failure or heart attack, then warn users via a simple app. Now a multi-partner deal has just been signed to bring the life-saving technology to market by 2021. The collaboration is being led by an Australian start-up based in Melbourne called ESN Cleer, with RMIT University and the IMCRC now researching and developing the device for pilot manufacture. ESN Cleer CEO Leopoldt de Bruin says the collaboration represents some of the best minds in medical device innovation, design and manufacture. “We’re really pleased to be able to bring these strands together in addressing such a major global health challenge,” De Bruin said. “Of the 400 million people who suffer from…
October 17, 2019
I often remark to my children or anyone who will listen at trade events that there are only two kinds of people in the world: cutting tool people and everyone else. In the case of my kids (and our Marketing Manager, for that matter), they issue a despairing groan and roll their eyes. This is not a trivial proposition – and it goes deeper! Even amongst the broader Cutting Tool Community, it’s my long-held opinion that it’s us Tap People who are the crème de la crème. On further investigation, the logic behind this highly reasonable position is both obvious and compelling (to me, at least). Once upon a time… My love affair with taps began in my schooldays, while working at the Sutton Tools factory during the summer holidays. That passion continues to this day, based on the philosophical concept of “value add”. I am a confirmed Tap Person. To the…
October 17, 2019
‘Pultrusion’ is the next big thing in manufacturing, and Wagners Composite Fibre Technologies (CFT) has teamed up with the University of Southern Queensland (USQ) and Allnex to redefine what the manufacturing process is capable of. According to USQ Polymer Composites researcher Dr Xuesen Zeng, pultrusion creates continuous lengths of composite material, ‘pulling’ fibre-reinforced profiles through a cross-section of die, resin and heating and cooling zones. “It has been the manufacturing method of choice due to its ability to produce large sections in volume which are economical and consistent in quality,” Dr Zeng said. “We’re increasing the productivity of the process, incorporating additives such as fire retardants, integrating braiding process with pultrusion, optimising injectable tools, and more.” USQ, Wagners CFT and Allnex have embarked on a $10m project that recently received a $3m funding boost from Federal Government’s Cooperative Research Centres (CRC) program. Together they are creating advanced structures expected to capture new high value markets in the oil & gas and transport industries both in Australia and internationally. Wagners CFT…
October 10, 2019
Australia’s industry growth centre for the med-tech, biotech and pharmaceuticals sector, MTPConnect is offering BioMedTech Horizons (BMTH) grants of up to $1m to support development and commercialisation of cutting-edge new medical technologies. The BMTH program forms part of the Federal Government’s Medical Research Future Fund and is administered by MTPConnect. “Following a highly competitive Round 2, we have Round 3 of BMTH opening later this year,” says Dr Dan Grant, CEO and MD of MTPConnect. “These grants can provide eligible SMEs (small and medium-sized enterprises) with up to $1m of funding over a two-year period to progress medical technologies and devices through to proof-of-concept stage. This is a fully funded grant program that encourages, but does not require, matching funding by the applicant.” The proof-of-concept stage is the point where the idea for a new device is technologically feasible and it has the potential to secure further venture capital to assist in its commercialisation. Dr Grant…
October 10, 2019
In the last few years, the concept and implementation of cooling solutions for cutting tools has enjoyed such a surge in popularity and enthusiasm it is almost as if it had never existed before. CNC machine manufacturers throughout the world have invested time and resources to develop solutions that can supply coolant at high pressures, and all new machine tools today are supplied with a high-pressure coolant option. Manufacturers from industries such as aerospace, automotive and large part production appreciate the immense advantage of supplying coolant directly to the cutting edge and are only ordering machines for milling centres or turning centres with high-pressure coolant capabilities – offering a minimum of 70 bar and up to as much as 300 bar. Mass production manufacturers are also benefiting from the integration of Iscar’s JetCut tools into their processes. Keeping temperature at bay One of the most serious enemies of carbide inserts is the high temperature of the materials that results from…
October 10, 2019
Digitisation is a tsunami of unprecedented proportions sweeping relentlessly across the business landscape with no respect for geographical borders, your loyal team or the blood sweat and tears you’ve put into building your organisation. Being big or established doesn’t give you the automatic clout it once did. Consumers can now effortlessly choose from a multitude of competitors and follow trends with a few swipes of their thumb. An expensive property in a prime location no longer ensures passing trade will come in the door. And in the B2B world you are increasingly judged by the strength and consistency of your digital brand and footprint. Digital assets are appearing on balance sheets across every industry. ERP systems that drastically improve performance and productivity are now essential for anyone who wants to have a hope of staying competitive. And effective websites, social media channels and email communications are the minimum required to compete in the marketplace. As business owners we are staring down the barrel…
October 10, 2019
The ProtoLAB supports students in design, engineering and architecture and meets the needs of academic research, testing and industry partnered work. “In research, it supports conversations with research partners,” says Dean of Design, Professor Jane Burry. “We also now have the space and large-scale robotics to undertake prototyping, fabrication and assembly at architectural scale.” The lab is equipped with a new high-speed HP Jet Fusion 3D Printer that allows students to print complex geometry without needing to remove support material. Also in constant use are a new Okuma CNC turn mill; seven laser cutters; a Biesse CNC router; a Multicam router; two KUKA collaborative robots designed to work with humans; and a new larger KUKA KR120 robot. “The KUKA KR120 runs on a 7.9m linear track, and reaches out to 3m,” says Andrew Tarlington, Manager of Technical Services, Architecture and Design. “It has a sync table at one end and a horizontal positioner along one side for multi-axis machining. Computer programs, and the students tethered to them are…
October 10, 2019
From cures for cancer to fusion power and driverless cars, almost every technology seems to be perpetually five to 10 years away. For researchers, “five to 10 years away” means we’ve been working on it for quite a while and it seems feasible, we just haven’t got there yet. We understand people’s scepticism when we say “in five to 10 years we’ll be 3D printing organs”. Sceptical? Don’t believe us? Consider this: Over the last decade, there has been a paradigm shift in stem cell research. Since the mid-1800s, researchers have been growing cells in sheets layered on top of glass and plastic dishes. This method is the cornerstone of biological research and its impact has been immeasurable – it’s responsible for the development of vaccines for polio, measles and smallpox, as well as the insulin that’s used daily by millions of diabetics worldwide. That’s why it’s surprising that stem cell biologists have stopped using this method. Why? It’s…
October 3, 2019
The high temperature resistance of nickel-based alloys often presents process managers with challenges during machining, not least because there is still relatively little experience to draw on compared to other materials. If heat-resistant super alloys are milled with carbide indexable inserts, the cutting speed is only around 45 metres/min. Milling cutters with ceramic cutting tool materials achieve cutting values that are approximately 20 times higher during roughing: with cutting speeds of up to 1,000 metres/min, they achieve a much higher metal removal rate. The higher feed rate easily compensates for the depth of cut, which is generally lower for ceramic cutting edges than for carbide edges: In specific applications, the metal removal rate of Inconel 718 with ceramic cutting edges…
October 3, 2019
The phrase “all is number”, attributed to Pythagoras, is more pertinent now than ever before. Numbers enable us to capture and process physical magnitudes, be they positions, temperatures, flow rates, field strengths and many other quantities. A vast inventory of ingenious methods exists for measuring – or describing – the physical world using numbers. The age of computing has added a new, highly versatile tool: simulation. Simulation permits the inference of data that is not directly available for measurement. It is possible, for example, to gauge the temperature deep inside an object from measurements of the surface temperature combined with physical understanding of what is happening inside the object. The inaccessibility of a measurement point must not be strictly spatial. The data of interest can also be in the future, or even in a system that has not physically been built. Compared to physical testing, simulation can deliver huge savings in time and costs, as well as avoiding waste and potentially…
October 3, 2019
Industry 4.0 refers to advanced manufacturing technologies including the Internet of Things (IoT) and artificial intelligence (AI). It also facilitates new ways to apply old concepts such as automation and robotics, both of which have long been used in manufacturing (with outstanding results). Embracing emerging, intelligent technology is essential for Australian manufacturers to compete effectively in a tough globalised environment. While the manufacturing industry in Australia has recently returned to growth, strong competition from overseas manufacturers remains a concern for local firms. Manufacturers in this country tend to have higher costs in terms of energy, labour, materials and logistics, compared with overseas competitors. One of the ways to potentially overcome this disadvantage is to embrace smarter technology, such as IoT or AI. For example, one manufacturer has used cloud-based analytics and IoT to reduce equipment inspection times by 100%. This helped the company avoid a potential cost of $361 per second for downtime caused by manual inspections. This illustrates the enormity of savings that could be delivered…
October 3, 2019
Mapal already offers a wide range of innovative machining solutions for manufacturing individual parts and components in electric vehicles. However, the challenge is an ongoing one that Mapal is continuing to meet. High precision for large diameters using ultralight tools One of the core challenges in electrified automotive powertrains is the high-precision machining of the main bore in the stator housing. Presenting a challenge for the tool and machine, all other steps in the production of the stator housing can be carried out on machines with a HSK A63 spindle configuration. However, in most instances the main stator bore requires machining with HSK A100 spindle. This is down to two factors: firstly, the high cutting torque requirements of up to 500Nm; and secondly, the maximum permissible tool weight and tilting moment. Cost-effective manufacturing with short cycle-times calls for a solution whereby complete machining can be carried out on a single machine with small spindle connections. This is because these machines are characterised by their high spindle speeds, lower investment and operating…
