In most manufacturing facilities, there is substantial potential to reduce operating costs through improved energy efficiency. While some of these opportunities involve significant capital investments, many only require simple modifications to existing equipment or controls at little to no implementation cost. We will discuss how energy efficiency can benefit businesses, typical efficiency opportunities and best practices, how we can help eligible facilities get started with a free assessment through the U.S. Department of Energy’s Industrial Assessment Center program, and a case study of a facility that saved more than $100,000 a year based on our recommendations.
Reduce Operating Costs in Your Manufacturing Facility with Energy Efficiency
The aim of this presentation is to illustrate the application of X-ray computed tomography (CT) not only for non-destructive inspection but also for the metrological assessment of diverse manufactured parts, particularly by using dimensional metrology (part-to-CAD comparison, wall thickness analysis, size measurements) and for material inspection (voids and defect detection). The benefits of CT for the quality assessment and inspection of new manufacturing technologies such as additive manufacturing (or 3D Printing) will be considered.
Automation comes in many forms. We often think of robots when automation is mentioned. Many think we are taking jobs from workers when automation is used. In the search for skilled labor or any labor, companies are looking for innovative ways to automate processes.
This presentation will present other concepts of automation: reciprocators, X-Y Machines, indexing systems, automatic loading of ovens, and other specialized conveyor movements that add automation to a process.
To machine two metals in one detail, you must understand the physical properties and material characteristics that cause them to EDM differently. Through the study of these material characteristics and EDM testing, we have found that there are techniques that allow for efficient machining of different materials as one detail.
This session will discuss the effects of the EDM process with a bi-metal workpiece, and the detailed results of successfully machining across both materials simultaneously.
Regarded as the most versatile process in the world, waterjet systems allow fabricators to take on any manner of work. Waterjets complement other fabricating technologies and are becoming the process of choice for many fabricators and machine shops. You will hear how waterjet technology continues to benefit customers, using several smart approaches to maximize performance which includes productivity, cost, and accuracy driving significant gains in the manufacturing industry.
Robotic welding systems have evolved over the years and now have the ability to take on more jobs than ever before. With added pressures of labor shortages and global competition, robotic welding technologies are giving manufacturers the ability to maintain consistent throughput and quality without increasing costs.
In order to realize inefficiencies and to iterate more frequently in the plastic prototyping process, engineers are turning to 3D printed tooling as a fast and cost-effective replacement for aluminum tools. However, typical 3D printed plastics are unable to handle the pressures or temperatures of longer injection mold runs. In our study, we investigate how incorporating reinforcing-additives, such as engineering grade cermanics, to the 3D printing resin can extend tool life.
Among various extreme pressure (EP) agents, chlorinated paraffins (CPs) have been the most popular EP additive in metalworking fluids (MWFs) due to the numerous advantages including cost effectiveness, wide activation temperature, versatility in applications, easy formulation and stablility in water. But CPs have health and hazard issues. Thus, MWF manufacturers are seeking CP alternatives. Along this line, the present report describes new organic-inorganic hybrid systems as new EP and corrosion inhibitor technology for MWF application.
Tool wear in machining is difficult to predict due to large number of influencing variables and tool-to-tool performance variation. In this presentation, machine learning classification methods, Support Vector Machines, and Logistic, for modeling tool life using production shop-floor tool wear data will be presented. Results show good agreement with the ‘true’ tool life curve. A simplified method to generate synthetic data to augment sparse and unbalanced datasets is also presented.
In today’s marketplace where part mix is high and volumes are low, the ability for a shop to thrive requires flexibility with the ability to change at a moment’s notice, all while maintaining high part quality. Fixturing requirements are becoming more complex as workpiece complexity is increasing. We will look at how parts that have traditionally posed workholding challenges are being held rigidly and securely with modern-day solutions.
Engineering plastics have seen widespread use in demanding aerospace, military, and industrial applications. These materials have unique mechanical, electrical, and thermal properties that allow them to perform in conditions where other materials will rapidly fail. This presentation will include an overview of plastic material selection and plastic part design. A number of new plastics that offer quality improvements and cost savings compared with traditional plastics will be introduced.
You’re bound to encounter a few twists and turns when designing parts for sheet metal fabrication. In this presentation, we’ll briefly look at the multi-step manufacturing process involved in creating sheet metal parts and the various equipment used along the way. You’ll learn which part features increase production risks, the resulting design implications, and most importantly, how to reduce that risk through design iterations. We’ll also discuss tactics to reduce overall production costs.
Manufacturers are attempting to understand and implement the “digital twin.” With more NC manufacturing data available, choosing the best data, using it efficiently, and optimizing processes are key to reducing costs and improving efficiency. Software interoperability connects CAD/CAM systems, PLM systems, Tooling databases, Cloud-based downloadable resources, and CNC machines, providing realistic and accurate data. Learn how companies can make better business decisions by simulating CNC machines in a robust virtual environment (versus in reality).