October 13, 2015 Volume 11 Issue 38

Mechanical News & Products

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SOLIDWORKS: FeatureManager tips for assemblies

Discover tools to make your SOLIDWORKS assembly Feature-Manager design tree display easier to view and use. Learn options to limit the amount of information in each component listing, combine multiple instances of a component into a single listing, and separate fasteners mates into a new folder. Lots more tips on the SOLIDWORKS YouTube channel.
View the video.

Top die casting design tips: Xometry

Optimize your die casting project's manufac-turability with these 23 top design tips from Xometry. Ensure your work is cost effective too, so you can hit the ground running and have the highest chance of success. Tips include: fillets and radii, wall thicknesses, ribs and metal savers, holes and windows, parting lines, finishes, and more.
Read the Xometry article.

8 top ways to wreck your coupling-driven system

Engineers at Ruland Manufacturing Co. have compiled the eight best ways to consistently sabotage or damage your coupling-driven system -- and how to avoid these pitfalls in the future. Misunderstanding performance criteria such as misalignment, torque, or rpm can be all it takes to cause a critical and costly failure.
Read the full article.

New washer tech for leak-free automotive sealing

Trelleborg Sealing Solutions has just launched the Rubore® Washer, a unique solution offering virtually leak-free sealing beneath screwheads to safeguard critical systems in vehicles, especially electric ones.
Read the full article.

How Reell electric wrap spring clutches work

Electric wrap spring clutches are ideally suited for critical timing applications requiring consistent, repeatable engagement and disengagement performance. Wrap spring technology used in Reell clutches provides the capability to transmit a large amount of torque in a small size -- package sizes smaller than other clutch technologies such as friction disk, tooth, or magnetic particle. Reell's technology has very positive engagement characteristics and also limits the effects of wear.
Read this informative Reell article.

New 'breathable' rupture disk tech provides overpressure and vacuum relief

To increase equipment safety and reliability, a new rupture disk technology activates at a set burst pressure, but it can also "breathe" to relieve minor pressure fluctuations. The patent-pending, dual-function device from BS&B Safety Systems is ideal for use on low-pressure vessels that are susceptible to ambient temperature changes.
Read the full article.

Engineer's Toolbox: 9 considerations for specifying a slewing ring bearing

In applications that require a bearing to support a structure while it rotates (e.g., cranes, radar, tank turrets), premature bearing failure can put people and equipment at risk. While slewing ring bearings have proven themselves countless times in such applications, designers must consider many factors when specifying them. According to engineers at Kaydon, the bearing's support structure, mounting (including bolt strength, tensioning, and hole patterns), installation, and even storage are all factors in a bearing's success or failure.
Read the full article.

ClampDisk micro fastener is new alternative for automotive and consumer electronics

Designed as a unique alternative in assemblies for the automotive and consumer electronics markets, the ClampDisk Press-on Fastener is a new offering from PennEngineering that delivers a fast, simple way to achieve sheet-to-sheet clamped fastening while replacing the use of standard screws, nuts, and adhesives. The most common challenges that can be eliminated or reduced by using ClampDisk include over installation, cross threading, stripped screw heads, broken screws, and damaged product. This fastener can be removed easily with a sharp-edged tool.
Learn more and see how ClampDisk works.

New nylon constant torque hinge

Southco has expanded its line of E6 Constant Torque Hinges with a compact, nylon version designed for small applications. The newest addition to the company's E6 50 Constant Torque Position Control Hinge series measures 45 mm with a torque range of 4 to 16 in./lb and is 65% lighter compared to the standard E6 50 Hinge. It provides constant resistance throughout the entire range of motion, enabling users to easily position doors, display screens, and other mounted components and hold them securely at any desired angle.
Learn more.

What injection molding material do I use?

How do you decide what type of plastic to use for your next injection molding project? Xometry can help you narrow your choices. Discover the different strengths and applications for materials that could be ideal for your application by learning about the most common plastic injection molding materials in detail.
Read this detailed Xometry article.

What are carbon composite bellows springs?

The Carbon Composite Bellows Spring (CCBS) from MW Components is a system of carbon fiber elements that combine to work as a high-performance, lightweight, and design-flexible compression spring meant to replace coil springs or metallic Belleville disc springs. A functional spring is made from several individual elements paired and joined to make a stack. The stack spring rate is determined by the number of elements, the base rate of each element, and their series or parallel orientation in the stack. Applications include motorsports, aerospace, and high-performance activities.
Learn more.

Conductive Brush Ring overcomes current leakage in EV powertrains

SKF's new Conductive Brush Ring paves the way to greater reliability and longer life in high-performance electric vehicle powertrain systems. Using pure carbon fiber bristles, it provides a reliable electrical connection between an EV eAxle rotor shaft and its housing. When used in combination with SKF Hybrid ceramic ball bearings, it helps to alleviate parasitic current effects that can lead to premature failure in bearings and other components. Available in different configurations for wet (oil-lubricated) motor designs -- and soon for dry (sealed) applications.
Learn more.

hyperMILL 2024 CAD/CAM software suite

OPEN MIND Technologies has introduced its latest hyperMILL 2024 CAD/CAM software suite, which includes a range of powerful enhancements to its core toolpath capabilities, as well as new functionality for increased NC programming efficiency in applications ranging from 2.5D machining to 5-axis milling. New and enhanced capabilities include: Optimized Deep Hole Drilling, a new algorithm for 3- and 5-axis Rest Machining, an enhanced path layout for the 3D Plane Machining cycle, better error detection, and much more.
Learn more.

One-part epoxy changes from red to clear under UV

Master Bond UV15RCL is a low-viscosity, cationic-type UV-curing system with a special color-changing feature. The red material changes to clear once exposed to UV light, indicating that there is UV light access across the adhesive material. Although this change in color from red to clear does not indicate a full cure, it does confirm that the UV light has reached the polymer. This epoxy is an excellent electrical insulator. UV15RCL adheres well to metals, glass, ceramics, and many plastics, including acrylics and polycarbonates.
Learn more.

SPIROL Press-N-Lok™ Pin for plastic housings

The Press-N-Lok™ Pin was designed to permanently retain two plastic components to each other. As the pin is inserted, the plastic backfills into the area around the two opposing barbs, resulting in maximum retention. Assembly time is quicker, and it requires lower assembly equipment costs compared to screws and adhesives -- just Press-N-Lok™!
Learn more about the new Press-N-Lok™ Pin.

'Off-the-shelf' semitrailer becomes Army missile launcher

By Jason B. Cutshaw, USASMDC/ARSTRAT

A tactical ballistic missile being launched off a 25,000-lb-capacity Transportable Target Launcher, or 25K TTL, designed by the U.S. Army Space and Missile Defense Command/Army Forces Strategic Command. [Photo Credit: U.S. Army photo]





In times of continuing budgetary constraints, the U.S. Army Space and Missile Defense Command/Army Forces Strategic Command, or USASMDC/ARSTRAT, is making an extended effort to save taxpayers by not only designing low-cost targets, but also by designing low-cost launch vehicles.

Members of the USASMDC/ARSTRAT Test Execution Support Division developed a transportable, mission-configurable, 25,000-lb-capacity Transportable Target Launcher, or 25K TTL, to support Department of Defense operational testing of theater-class tactical ballistic missile targets.

The Transportable Target Launcher (25K TTL) undergoes inspections before returning to the Naval Surface Warfare Center Crane in Indiana for maintenance prior to future test missions. The 25K TTL is designed to support Department of Defense operational testing of theater-class tactical ballistic missile targets. [Photo Credit: Jason B. Cutshaw.]





"The 25K TTL is a rapidly deployable (C-17 and C-5 transportable), treaty-compliant rail launch platform for theater-class tactical ballistic missile targets," says Bryon Manley, SMDC Technical Center Test Execution Support Division chief. "The 25K TTL is a cost-effective, transportable launcher that can expand the number of available launch sites, adding a more comprehensive selection of threat scenario geometries for tactical ballistic missile target testing on national ranges."

SMDC developed two 25K TTLs, at a cost of approximately $3 million, that are rapidly deployable. They were designed, analyzed, built, and tested using a modified commercial off-the-shelf semitrailer and hydraulic crane as a portable launch platform.

"Our division is about low cost, so we design things based on commercially off-the-shelf available items so that they are cost effective," says Stephanie Chrisley, SMDC general engineer.

Utilization of the TTL is a cost-effective means of presenting test scenarios in a threat-representative construct due to its ability to operate at both unimproved and improved range sites. Additionally, the launcher is transportable by air or land, permitting use at all ranges. The missile launcher can begin operating within 15 minutes of setting up.

"We can take it onto an unimproved launch site with one generator and a small crew and we launch ballistic missile targets with no problem," Chrisley says.

The TTL, which can hold a missile up to 48 ft long and handle up to 73,000 lb of rocket thrust, is undergoing inspections before returning to the Naval Surface Warfare Center Crane in Indiana for maintenance prior to future test missions.

"We brought it out of storage to have it inspected because we will be using it for a flight test in the spring of 2016," Chrisley says.

The 25K TTL is capable of being transported to a launch site, converted to a fixed installation before target loading and launch, reconfigured for transport after launch, and returned to storage or emplaced for a follow-on mission.

"This gives us the flexibility to launch in any area we want that does not necessarily have to be an improved area; it can be any open area where we can set it up with a small crew," says Kevin Creekmore, Test Execution Support Division acting director. "It does not need existing power, it does not need existing communication lines, and it does not need existing infrastructure. It gives us the flexibility to launch at just about any angle that we want using the adjustable boom.

"We use it to support many different tests for many different customers," he adds. "We have several tests upcoming in the next few years."

SMDC has also developed targets to be launched by the TTLs. Made from existing materials, the program was named Zombie. Zombie uses government-owned material components that have reached the end of their useful lives and are subject to consideration for demilitarization. Using this government hardware instead of demilitarizing it ultimately saves taxpayer dollars.

The command developed the Zombie targets that cut expenses from the around $30 million each for high-end targets to approximately $4 million for SMDC's low-cost Zombie.

"We look for unused rocket motors or some that are going to be demilitarized and just thrown away. The motors are generally still good, so we try to repurpose those with new avionics and new front-end sections and launch them as low-cost targets," Chrisley says.

Published October 2015

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