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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.

Why hybrid bearings are becoming the new industry standard

A combination of steel outer and inner rings with ceramic balls or rollers is giving hybrid bearings unique properties, making them suitable for use in a wide range of modern applications. SKF hybrid bearings make use of silicon nitride (twice as hard as bearing steel) rolling elements and are available as ball bearings, cylindrical roller bearings, and in custom designs. From electric erosion prevention to friction reduction and extended maintenance intervals, learn all about next-gen hybrid bearings.
Read the SKF technical article.

3M and Ansys train engineers on simulating adhesives

Ansys and 3M have created an advanced simulation training program enabling engineers to enhance the design and sustainability of their products when using tapes and adhesives as part of the design. Simulation enables engineers to validate engineering decisions when analyzing advanced polymeric materials -- especially when bonding components made of different materials. Understand the behavior of adhesives under real-world conditions for accurate modeling and design.
Read this informative Ansys blog.

New FATH T-slotted rail components in black from AutomationDirect

Automation-Direct has added a wide assortment of black-colored FATH T-slotted hardware components to match their SureFrame black anodized T-slotted rails, including: cube connectors (2D and 3D) and angle connectors, joining plates of many types, brackets, and pivot joints. Also included are foot consoles, linear bearings in silver and black, cam lever brakes, and L-handle brakes. FATH T-slotted hardware components are easy to install, allow for numerous T-slotted structure configurations, and have a 1-year warranty against defects.
Learn more.

Weird stuff: Moon dust simulant for 3D printing

Crafted from a lunar regolith simulant, Basalt Moon Dust Filamet™ (not a typo) available from The Virtual Foundry closely mirrors the makeup of lunar regolith found in mare regions of the Moon. It enables users with standard fused filament fabrication (FFF) 3D printers to print with unparalleled realism. Try out your ideas before you go for that big space contract, or help your kid get an A on that special science project.
Learn more.

Break the mold with custom injection molding by Rogan

With 90 years of industry experience, Rogan Corporation possesses the expertise to deliver custom injection molding solutions that set businesses apart. As a low-cost, high-volume solution, injection molding is the most widely used plastics manufacturing process. Rogan processes include single-shot, two-shot, overmolding, and assembly. Elevate your parts with secondary operations: drilling and tapping, hot stamping, special finishes, punch press, gluing, painting, and more.
Learn more.

World's first current-carrying fastening technology

PEM^® eConnect™ current-carrying pins from Penn-Engineering provide superior electrical connections in applications that demand high performance from internal components, such as automotive electronics. This first-to-market tech provides repeatable, consistent electrical joints and superior installation unmatched by traditional fastening methods. Features include quick and secure automated installation, no hot spots or poor conductivity, and captivation options that include self-clinching and broaching styles.
Learn more about eConnect pins.

New interactive digital catalog from EXAIR

EXAIR's latest catalog offers readers an incredible source of innovative solutions for common industrial problems like conveying, cooling, cleaning, blowoff, drying, coating, and static buildup. This fully digital and interactive version of Catalog 35 is designed for easy browsing and added accessibility. Customers can view, download, print, and save either the full catalog or specific pages and sections. EXAIR products are designed to conserve compressed air and increase personnel safety in the process. Loaded with useful information.
Check out EXAIR's online catalog.

5 cost-saving design tips for CNC machining

Make sure your parts meet expectations the first time around. Xometry's director of application engineering, Greg Paulsen, presents five expert tips for cutting costs when designing custom CNC machined parts. This video covers corners and radii, designing for deep pockets, thread depths, thin walls, and more. Always excellent info from Paulsen at Xometry.
View the video.

What can you secure with a retaining ring? 20 examples

From the watch dial on your wrist to a wind turbine, no application is too small or too big for a Smalley retaining ring to secure. Light to heavy-duty loads? Carbon steel to exotic materials? No problem. See how retaining rings are used in slip clutches, bike locks, hip replacements, and even the Louvre Pyramid.
See the Smalley design applications.

Load fasteners with integrated RFID

A crane, rope, or chain may be required when something needs lifting -- plus anchoring points on the load. JW Winco offers a wide range of solutions to fasten the load securely, including: lifting eye bolts and rings (with or without rotation), eye rings with ball bearings, threaded lifting pins, shackles, lifting points for welding, and more. Some, such as the GN 581 Safety Swivel Lifting Eye Bolts, even have integrated RFID tags to clearly identify specific lifting points during wear and safety inspections and manage them digitally and without system interruption.
Learn more.

Promising new research identifies innovative approach for controlling defects in 3D printing

By Brett Hansard, Argonne National Laboratory

Argonne scientists use temperature data to tune -- and fix -- defects in 3D-printed metallic parts.

With its ability to yield parts with complex shapes and minimal waste, additive manufacturing has the potential to revolutionize the production of metallic components. That potential, however, is currently limited by one critical challenge: controlling defects in the process that can compromise the performance of 3D-printed materials.

A new paper in the journal Additive Manufacturing points to a possible breakthrough solution: Use temperature data at the time of production to predict the formation of subsurface defects so they can be addressed right then and there. A team of researchers at the U.S. Department of Energy's (DOE) Argonne National Laboratory, together with a colleague now at Texas A&M University, discovered the possibility and developed a process for it.

"Ultimately, you would be able to print something and collect temperature data at the source and you could see if there were some abnormalities, and then fix them or start over," said Aaron Greco, group manager for Argonne's Interfacial Mechanics & Materials group in the Applied Materials Division (AMD) and a study author. "That's the big-picture goal."

For their research, the scientists used the extremely bright, high-powered X-rays at beamline 32-ID-B at Argonne's Advanced Photon Source (APS), a Department of Energy Office of Science User Facility. They designed an experimental rig that allowed them to capture temperature data from a standard infrared camera viewing the printing process from above while they simultaneously used an X-ray beam taking a side view to identify if porosity was forming below the surface.

Porosity refers to tiny, often microscopic "voids" that can occur during the laser printing process. These keyhole defects can make a component prone to cracking and other failures.

According to Noah Paulson, a computational materials scientist in the Applied Materials division and lead author on the paper, this work showed that there is, in fact, a correlation between surface temperature and porosity formation below.

"Having the top and side views at the same time is really powerful. With the side view, which is what is truly unique here with the APS setup, we could see that under certain processing conditions based on different time and temperature combinations porosity forms as the laser passes over," Paulson said.

For example, the paper observed that thermal histories where the peak temperature is low and followed by a steady decline are likely to be correlated with low porosity. In contrast, thermal histories that start high, dip, and then later increase are more likely to indicate large porosity.

The scientists used machine learning algorithms to make sense of the complex data and predict the formation of porosity from the thermal history. Paulson said that in comparison to the tools developed by tech giants that use millions of data points, this effort had to make do with a couple hundred. "This required that we develop a custom approach that made the best use of limited data," he said.

While 3D printers typically come equipped with infrared cameras, the cost and complexity make it impossible to equip a commercial machine with the kind of X-ray technology that exists at the APS, which is one of the most powerful X-ray light sources in the world. But by designing a methodology to observe systems that already exist in 3D printers, that wouldn't be necessary.

"By correlating the results from the APS with the less detailed results we can already get in actual printers using infrared technology, we can make claims about the quality of the printing without having to actually see below the surface," explained co-author Ben Gould, a materials scientist in the AMD.

The ability to identify and correct defects at the time of printing would have important ramifications for the entire additive manufacturing industry because it would eliminate the need for costly and time-consuming inspections of each mass-produced component. In traditional manufacturing, the consistency of the process makes it unnecessary to scan every metallic component coming off the production line.

"Right now, there's a risk associated with 3D-printing errors, so that means there's a cost. That cost is inhibiting the widespread adoption of this technology," Greco said. "To realize its full potential, we need to lower the risk to lower the cost."

This effort is made all the more urgent in recognizing one of the key advantages that additive manufacturing has over traditional manufacturing. "We saw with the recent pandemic response how valuable it would be to be able to quickly adapt production to new designs and needs. 3D technology is very adaptable to those kinds of changes," added Greco.

Looking ahead, Gould said the research team was hopeful that what he called a "very, very good first step" would allow it to keep improving and expanding the model. "For machine learning, to build accurate models you need thousands and thousands of data points. For this experiment, we had 200. As we put in more data, the model will get more and more exact. But what we did find is very promising."

This research effort was supported by Argonne's Laboratory Directed Research and Development program.

Published September 2020

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