December 18, 2012 Volume 08 Issue 47

Mechanical News & Products

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New adhesive for aerospace manufacturers

AeroPaste is Solvay's new generation of epoxy-based structural paste adhesives that provide film-like property and performance, comparable or superior to leading film adhesives on the market. AeroPaste 1006, 1009, and 1100 are now available commercially. These products are suitable for both metal and composite bonding or repair in a variety of application requirements and are designed specifically to enable rapid assembly and automation. AeroPaste is aimed at increasing manufacturers' efficiency and output by enabling fast and easy application, and offering excellent tolerance to variations in bondline thickness.
Learn more.


Handle basic misalignments starting at 10 bucks

Automation-Direct has added SIM drive couplings to their line of mechanical power transmission products. SIM drive couplings are power transmission components used to couple the shafts of various mechanical devices, often of different sizes, and compensate for shaft misalignment. Four different styles of couplings are available: Jaw/Spider couplings provide a wide range of fitment and higher torque, Oldham couplings provide a higher speed rating and allow for a higher misalignment of mated shafts, servo beam-style couplings add a significant increase to speed rating and have zero backlash, while high-gain couplings offer the highest speed ratings, excellent vibration absorption, and zero backlash.
Learn more.


Round vs. square rails -- which are better for you?

Thomson invented the world's first anti-friction linear ball bushing bearings in 1946. For many years, these round-rail linear guides satisfied every linear motion control requirement. However, as machines required closer tolerances, the round rail didn't always fit the bill. Learn the pros and cons of each design type.
Read this informative Thomson blog.


New bearings reduce wear in heavy-duty applications

igus has introduced a new bearing with an improved iglide material, called TX2, that offers self-lubricating and maintenance-free properties for heavy-duty applications. TX2 increases wear resistance by a factor of 3.5 in load ranges with more than 100-MPa surface pressure. The material is ideal for components in machines that serve construction and agriculture, which can require more than 50 liters of lubricant annually. The material is also very resistant to temperature, chemicals, moisture, corrosion, and seawater, which opens up the applications base for its use substantially.
Learn more.


Aerospace fastener hole drilling and countersinking all in one step

Kennametal has introduced the HiPACS drilling and countersinking system for aerospace fastener holes. Designed to drill and chamfer holes in one operation, the high-precision tool meets the aerospace industry's stringent accuracy requirements while delivering increased tool life in machining composite, titanium, and aluminum aircraft skins. With an industry-standard interface, HiPACS can be utilized on any CNC machine. Three components eliminate the need for custom tooling: a reducer sleeve with a built-in high-precision pocket seat, a PCD countersinking insert, and two series of solid carbide drills.
Learn more.


Why precision metrology is critical for electric vehicle gearing

As the shift from internal combustion engines to electric motors in vehicles continues, the number of drivetrain components will dramatically lessen too. The remaining components will be even more critical to a vehicle's operation and longevity. One such area is the gear components necessary to convert the high-force torque from electric motors to the RPMs at the wheel.
By Michael Schmidt, Zygo Corporation
Read the full article.


Master CNC machining tolerances eBook

Need a refresher on the basics of applying tolerances to custom machined metal and plastic parts? In this ebook, Xometry provides some pointers on designing mating parts and parts for specific functions. Chapters include: general machining tolerances, clearance and interference fit, how to avoid over-tolerancing, CAD drawing prep and specs, and an inspection report cheat sheet.
Get this valuable resource from Xometry.


Specifying metal inserts for molded plastics

Teaming with insert manufacturers that offer engineering expertise throughout the design and manufacturing process can be worth its weight in gold. Learn how two OEMs overcame their metal insert challenges by using advice and products from Tri-Star Industries, including specialty stainless steel parts and modifying the knurling on some inserts.
Read the full article.


Posi-Lok keyless shaft bushings for secure shaft-to-hub connection

Zero-Max offers a variety of options within the Posi-Lok keyless shaft bushings (PSL) product line that allow users to rigidly and reliably secure shaft-mounted components into position for optimal operating results in their machines. Options include material choices, plating, and different mounting methods. Posi-Loks are a superior shaft-hub locking solution, eliminating the need for keyways that can weaken or cause excess wear to shaft components. All Posi-Lok models easily slide onto a shaft for mounting and provide reliable, zero-backlash performance.
Learn more.


Automation: ECONOmaster drilling units -- affordable, flexible, get the job done

Suhner's ECONO-master® is a low-cost, high-output automated drilling unit that puts holes in light metal, composite, thermoplastic, and even wood substrates at high speed with excellent accuracy. It features low power and air consumption. On a recent project for Mid-State Engineering, Suhner custom ECONOmaster drill units -- featuring selectable drill heads that can be used in combination or individually -- were used to automatically drill holes into fiberglass panels for truck trailer bodies.
Read the full article.


Great Resources: Ultimate Guide to Injection Molding

Xometry has put together a comprehensive resource for injection molding -- from the basic principles to applications, tooling, materials, design features, and more. Learn how to optimize your part designs and choose the right surface finishes, textures, and post-processing for your projects. A super-handy resource worth bookmarking.
Read the Xometry Ultimate Guide to Injection Molding.


Sealing fasteners may optimize your designs

Highly specialized sealing fasteners include sealing screws, sealing nuts, sealing bolts, and sealing washers. Unlike ordinary fasteners, sealing fasteners are configured with a rubber O-ring (or a rubber element) that, when squeezed, permanently seals out a wide range of contaminants from entering and damaging equipment while preventing leakage of toxins into the environment. ZAGO sealing fasteners are designed to withstand harsh weather and extreme temperatures and are vibration and pressure resistant.
Learn all about ZAGO's wide selection of sealing fasteners.


Spirit levels with adjustment and cross-measurement

They may seem like relics from the past, but spirit levels remain indispensable tools in everyday industrial operations. Two new types from JW Winco now offer even better and faster alignment. The cross spirit levels GN 2276 combine two perpendicular linear levels within a single, round aluminum housing to show the alignment in two planes at once, making installation and leveling easier and faster. The new screw-on spirit levels GN 2283 are used to check the horizontal position of jigs, machines, devices, appliances, and instruments. These are available in a directly mountable, flat version (AV) and as an adjustable version (JV) with an alignment cam.
Learn more.


New cast urethane materials and finishes

Xometry has added new urethane resins and finishes as options for quick and affordable low- to mid-volume production. Urethane casting is used to make end-use, highly durable parts with robust mechanical properties. It is considered a "soft-tooled" process, where a silicone mold is formed around a master pattern -- usually 3D printed. Xometry has materials in two main durometer classes, rigid (Shore D) and rubber-like (Shore A). Finishes include matte/frosted, semi-gloss, high-gloss, and custom.
Read this informative Xometry blog.
Get the Xometry Urethane Casting Design Guide.


New molded-in aluminum threaded inserts for plastics

SPIROL has introduced a new, high-performance series of Molded-In Inserts for plastics assemblies. The rugged design of the Series 63 Through Hole Inserts and Series 65 Blind End Inserts consists of multiple bands of helical knurls to maximize torque resistance, balanced with radial undercuts to achieve high pull-out (tensile) force. These Molded-In Inserts are designed to be placed in the mold cavity prior to plastic injection. They offer exceptional performance due to unrestricted plastic flow into the retention features on the outside diameter of the Inserts.
Learn more.


Ford and Dow team up to bring low-cost, high-volume carbon fiber composites to next-gen vehicles

Cutting the weight of new cars and trucks by up to 750 lb by the end of the decade is a key component of Ford's strategy to improve fuel efficiency. In order to help achieve that goal, Ford Motor Company is partnering with Dow Automotive Systems, a business unit of The Dow Chemical Company, to research the use of advanced carbon fiber composites in high-volume vehicles.

"There are two ways to reduce energy use in vehicles: improving the conversion efficiency of fuels to motion and reducing the amount of work that powertrains need to do," says Paul Mascarenas, Ford chief technical officer and vice president, Research and Innovation. "Ford is tackling the conversion problem primarily through downsizing engines with EcoBoost and electrification, while mass reduction and improved aerodynamics are keys to reducing the workload."

Ford is investigating a range of new materials, enhanced design processes, and new manufacturing techniques that would enable automotive structures to meet increasingly stringent safety and quality standards while cutting weight.

Carbon fiber composites have been used in aerospace and racing cars for decades due to their unique combination of high strength and low mass. Until recently, these materials have been far too costly for use in high-volume mainstream applications.

Dow Automotive Systems and Ford have signed a joint development agreement that will see researchers from the two companies collaborate on several fronts. The development teams will focus on establishing an economical source of automotive-grade carbon fiber and develop component manufacturing methods for high-volume automotive applications.

The partnership will seek to combine the best of Ford's capabilities and experience in design, engineering, and high-volume vehicle production with Dow Automotive's strengths in R&D, materials science, and high-volume polymer processing.

"Reducing weight will benefit the efficiency of every Ford vehicle," says Mascarenas. "However, it's particularly critical to improving the range of plug-in hybrid and battery electric vehicles."

The joint development effort will also leverage work that The Dow Chemical Company has already begun through partnerships with Turkish carbon fiber manufacturer AKSA and the U.S. Department of Energy Oak Ridge National Laboratory.

If the joint development effort is successful, carbon fiber components may begin appearing on new Ford vehicles in the latter part of this decade as product development teams work toward meeting new fuel-efficiency standards of more than 50 mpg and extending the range of plug-in vehicles.

Source: Ford Motor Co.

Published April 2012

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