January 14, 2020 Volume 16 Issue 02

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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.


Army develops cold spray technology to repair Bradley gun mounts

An Army M2 Bradley Fighting Vehicle stages out on a breaching range during a dry run of dismounted breach training conducted on a range in Poland, May 23, 2019. With funding from the Army's Manufacturing Technology Program, a team of scientists and engineers from the U.S. Army CCDC worked together to develop a cold spray process to repair costly turret gun mounts on the Army's M2 Bradley Fighting Vehicle. [Photo Credit: Jeremiah Woods]

 

 

 

 

By Argie Sarantinos-Perrin, CCDC, Aberdeen Proving Ground, MD

Repairing a 40-ton armored vehicle is a lot harder than having your car fixed at a neighborhood auto repair shop. Tactical armored vehicles require specialized repair procedures, which are very costly. What if repairing routine wear and tear on an Army vehicle was inexpensive and as easy as fixing your car?

With funding from the Army's Manufacturing Technology Program, a team of scientists and engineers from the U.S. Army Combat Capabilities Development Command (CCDC) Army Research Laboratory, Ground Vehicle Systems Center, and the Armaments Center, as well as Bradley Product Manager and Red River Army Depot (RRAD) worked together to develop a cold spray process to repair costly turret gun mounts on the Army's M2 Bradley Fighting Vehicle.

"This project demonstrated the ability to apply new manufacturing technologies to bring components back into service that would otherwise be scrapped during depot maintenance operations," said Gehn Ferguson, CCDC ARL materials engineer.

The project began in 2017 when CCDC ARL visited RRAD to view the inspection process and access the wear on the Bradley turret gun mounts. RRAD, the primary depot responsible for the Bradley vehicle, inspects gun mounts for excessive wear. In subsequent months, CCDC ARL developed and demonstrated a process for repairing the gun mounts using cold spray. Prior to developing the cold spray process, worn gun mounts that were inspected and identified as non-repairable were disposed of.

The 25-mm gun mount supports the gun barrel on the M2 Bradley Fighting Vehicle. When the mount begins to wear unevenly, the barrel becomes less stable. The Army is evaluating if a cold spray process can be used to repair the gun mount. [Photo Credit: U.S. Army]

 

 

 

 

"Cold spray is an emerging technology that will enable the Army to reclaim worn components that were previously replaced with new parts. This new technology reduces lifecycle cost and improves systems availability," Ferguson said.

While the cost of a new 25-mm gun mount is more than $25,000, a cold spray repair costs approximately $1,000. Additionally, the cold spray process improves readiness by reducing the time that a Bradley is out of service while lessening the burden on the supply chain by reducing the necessity for stockpiling new gun mounts.

Cold spray is a process where micron-sized particles are accelerated in a high-velocity gas stream through a nozzle and subsequently consolidated on a target surface. The accelerated particles impact and bond to the surface, resulting in a buildup of the sprayed material. Both the sprayed particles and the target surface remain solid during the process.

Using the cold spray process, CCDC Army Research Laboratory restored the internal diameter of the gun mount exit throat to its original drawing dimensions, demonstrating the ability to return worn gun mounts back into service. [Photo Credit: U.S. Army]

 

 

 

 

The Bradley turret gun mount was selected as a candidate for the cold spray repair process because CCDC ARL has extensive experience working with similar steels, and an established process to repair the worn gun mounts didn't exist. CCDC Armaments Center was responsible for designing and engineering the turret, and CCDC ARL developed and demonstrated the cold spray repair procedure. The Tank-Automotive and Armaments Command is reviewing the repair and overhaul instructions currently under development. The team plans to repair four or five gun mounts within the next six months.

While the project initially began as a way to repair gun mounts, the material used in the cold spray process is much more durable, which suggests it could even be used to extend the life of new gun mounts.

Cold spray is also being evaluated for use with other applications, including the ability to repair corrosion on combat vehicle surfaces and possibly to coat the interior of cannon barrels. For example, if the inside of a cannon barrel can be effectively coated with tantalum, which is a very durable material, its service life can be extended.

"As the command develops new weapon systems, there will be more opportunities to leverage the cold spray process to augment or repair components that may otherwise be labeled unusable. We're hoping this new manufacturing technology will lead to more success stories that will validate challenging requirements for improved readiness and reduce the lifecycle operation and sustainment costs of current and future tactical systems," Ferguson said.

Published September 2019

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