September 01, 2015 Volume 11 Issue 33

Mechanical News & Products

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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.


How to avoid premature linear screw actuator failure

At their core, electric linear screw actuators deploy mechanical technology such as ball bearings, ball screws, and roller screws that have a finite life. These components do not last forever -- even though that is the expectation of some customers. But how long will an actuator really last? Tolomatic engineers provide a way to calculate, estimate, and size the electric linear screw actuator to achieve the desired life for your applications.
Read this informative Tolomatic blog.


3D Printing: Desktop Metal qualifies 316L stainless steel for high-volume manufacturing -- thousands of parts per week

3D-printer machine maker Desktop Metal has qualified the use of 316L stainless steel for its additive manufacturing platform called the Production System, which provides some of the fastest build speeds in the market for mass production and can make thousands of parts per week. This article includes very useful cost-per-part and time-to-manufacture information using five different application examples.
Read the full article.


Glue for wet environs hardens when zapped with electricity, can be easily 'uncured'

Inspired by the limitations of biomimetic glues in wet environments, scientists from Nanyang Technological University, Singapore (NTU Singapore) have invented a glue that will harden when a voltage is applied to it. This opens a plethora of commercially promising advances such as:

  • Using the adhesive to glue metal panels underwater, for example, in underwater pipe repairs;
  • Replacing sutures when there is a need to join body tissues together during surgery; or
  • Tailoring the properties of the adhesive to be more gel-like or rubber-like, which would work well in vibrating or damp environments,

This innovative research was published mid-August in Nature Communications,* a peer-reviewed scientific journal under the Nature Publishing Group.

The new adhesive, nicknamed "Voltaglue," opens up a host of possible practical applications, from making underwater repair works for ships and pipes, to being a versatile tool for doctors performing surgery.

NTU Asst. Prof Terry Steele (right) with his researcher Gao Feng, who is holding the new Voltaglue. [Credit: NTU Singapore]

 

 

In the future, surgeons could use biocompatible glue patches to join two pieces of internal body tissue together in one or two minutes, instead of sutures that often require 15 to 20 minutes of careful stitching.

Assistant Professor Terry Steele, the lead scientist for this research project from NTU's School of Materials Science and Engineering, said it took them over a year to develop an adhesive that could work under wet conditions such as in the human body or underwater.

"Most glues in the market don't work under wet conditions, much like how sticky tapes won't work if the surface is wet, since the adhesive will stick to the water instead of the surface," said the American scientist, who graduated from the University of Minnesota before he moved to NTU Singapore.

Usually adhesives such as superglue harden upon contact with moisture in the air. Others like epoxy, often used in electronic mobile devices, have to be baked in high heat of about 150 deg C, or made using two different chemicals mixed together. These methods are unsuitable in wet environments.

"We had to find a way to make glue which cures (hardens) when we want it without being affected by the environmental conditions, so electricity was the best approach for us. The hardness of our glue can be adjusted by the amount of time we apply a voltage to it, which we call electrocuring."

This unique electrocuring property allows Voltaglue to be customized for different applications.

"For example, if we are gluing metal panels underwater, we want it hard enough to stick for a long time. However, for medical applications, we want the glue to be more rubber-like, so it wouldn't cause any damage to the surrounding soft tissues," Steele explained.

Voltaglue is developed using hydrogels consisting of carbon molecules called carbenes grafted onto tree-shaped plastic known as dendrimers.

Upon contact with electricity, the reactive carbenes, which are capable of hooking onto any surface nearby, are released. The amount of "hooks" created depends on how long electricity is applied and how many carbenes are present.

This technology is currently patented through NTUitive, the university's commercialization arm.

Strong but reversible
Another distinct feature of the new glue is that it could be made reversible, said Steele. He is now furthering research in this area, aided by a competitive research grant of almost U.S. $670,000 awarded by Singapore's Ministry of Education won earlier this month.

As the world becomes more concerned about sustainability, companies are looking to design "end-of-life" products that can be easily recycled, reused, or remanufactured into new parts and components in an aim to reduce waste and energy consumption.

Glues that can cure and be subsequently un-cured through electricity could provide something akin to an industry "holy grail," as automakers and shipyards could be able to assemble and dissemble parts with ease, minimizing the need for fixation by bolts, nuts, and screws.

Such reversible glue will also open up new possibilities in the global adhesive market in transportation applications, estimated to be worth over $3.3 billion in 2016 (Adhesives and Adhesive Applying Equipment, by BCC Research).

Moving forward, Steele and his team of 11 researchers are working to improve their new electrocuring glue so it can harden in just a few seconds, compared to about 30 seconds now. They are also working on a way to undo the process. They will also look for the best way to commercialize the technology through a new start-up or via industry partnerships.

* "Adhesive curing through low-voltage activation," Nature Communications, August 18, 2015. Jianfeng Ping, Feng Gao, Jian Lin Chen, Richard D. Webster & Terry W. J. Steele.

Source: Nanyang Technological University

Published September 2015

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