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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.

Couplings solve misalignments more precisely with targeted center designs

ALS Couplings from Miki Pulley feature a simplistic, three-piece construction and are available in three different types for more precisely handling parallel, angular, or axial misalignment applications. The key feature of this coupling design is its center element. Each of the three models has a center member that has a unique and durable material and shape. Also called a "spider," the center is designed to address and resolve the type of misalignment targeted. Ideal for unidirectional continuous movement or rapid bidirectional motion.
Learn more.

What is 3D-MID? Molded parts with integrated electronics from HARTING

3D-MID (three-dimensional mechatronic integrated devices) technology combines electronic and mechanical functionalities into a single, 3D component. It replaces the traditional printed circuit board and opens up many new opportunities. It takes injection-molded parts and uses laser-direct structuring to etch areas of conductor structures, which are filled with a copper plating process to create very precise electronic circuits. HARTING, the technology's developer, says it's "Like a PCB, but 3D." Tons of possibilities.
View the video.

Army Research Lab test drives flapping-wing Robo-Raven drone

By David Vergun

John W. Gerdes III, mechanical engineer at the Vehicle Technology Directorate, prepares to fly Robo-Raven at Aberdeen Proving Ground's Spesutie Island Robotics Research Facility on Chesapeake Bay, MD, Nov. 3, 2015. [Photo Credit: Todd Lopez]

 

 

 

 

In the future, it's possible that some unmanned aerial vehicles, or UAVs, might sport wings that flap like a bird or a butterfly.

The Army Research Lab (ARL) at Aberdeen Proving Ground, MD, is testing that concept at the Spesutie Island Robotics Research Facility on Chesapeake Bay.

John W. Gerdes III, mechanical engineer at the Vehicle Technology Directorate, has been testing such a UAV, known as Robo-Raven. He designed the vehicle in collaboration with the University of Maryland.

During an open house Nov. 3, Gerdes took Robo-Raven for three test flights. He held it aloft in his hand, sort of like a falconer might do. With the other hand, he switched on the transmitter -- the sort found in hobby shops for drones and toy vehicles.

The wings started flapping immediately as soon as he threw it aloft. Up and away it went, flapping around in a light breeze more like a butterfly than a bird. A gust blew it backward, but Robo-Raven made course corrections on its own so that Gerdes continued to maintain nearly full control of its flight.

After a minute or two, a curious raptor, possibly a hawk, circled Robo-Raven from above. At this point, Gerdes decided to land his mechanical bird. He raised his arm, and Robo-Raven obediently landed on his outstretched hand.

Raptors, if given the chance, will destroy Robo-Raven, he said. Once in the past, he said he flew his bird up to about 300 feet and a falcon dive bombed it, destroying its gossamer wings.

Once the falcon disappeared, Gerdes launched a second flight. This time, a flock of seagulls circled it. Gerdes noted that non-birds of prey will come over to investigate, but will not attack Robo-Raven -- at least not yet.

Unfortunately, Gerdes' landing didn't go as smoothly as the first and it crashed into the grass nearby. Fortunately, his half-pound bird sustained no damage. Observers wore hard hats and goggles, just to be safe.

Had his Robo-Raven been destroyed in a crash or by a raptor, Gerdes had two backups, each of which looked similar, but were slightly different in shape and size for testing.

The third flight went well and landed back in Gerdes' hand.

Why design a flappy bird?
"Ultimately, what we're trying to go after is a vehicle which, at least in part, duplicates some of the great things animals can do," he said. "The benefit of the flapping air vehicle is obvious when you look at nature."

Flying creatures are so good at what they do because of how well in harmony all their subsystems work, he said. "Everything is perfectly matched to itself, so they are able to perform at the highest possible level, given their size and weight. We're curious to discover the tricks they're using."

The challenge is to engineer a system that can duplicate such behaviors, he added.

Gerdes provided another illustration.

A quad-copter is great for flying at slow speeds, hovering, maneuvering, and avoiding obstacles, he said. On the other hand, an airplane is great at flying high, far, and fast.

"When you take either of those platforms out of their intended mission space, they do very poorly," he said. "Animals, on the other hand, can do all these things quite well." The reason why is they can reconfigure their wings and orient themselves to take advantage of the airflow. "All these different details we're trying to learn about here."

Animals that fly are able to do so because of an enormous number of muscles and nerves that control their flexible wing and body, he said. The slightest alteration of a wing can send a bird soaring hundreds of feet into the air on an updraft.

"It's extraordinarily difficult to unravel all of the pieces of that problem," where there are flexible wings, sensors, and controls distributed everywhere, he said. "It's just too difficult to engineer at this point. But we can approach that solution, at least."

On the other hand, Robo-Raven has some advantages over real birds.

For instance, Robo-Raven doesn't need to eat or reproduce. "Animals make sacrifices that are different that don't make sense from a robotics standpoint, so it gives me hope that one day we can do better than an animal," he said.

Raven's design
Robo-Raven's design is a terrible approach from an efficiency standpoint, Gerdes said.

For one thing, it has two motors that independently control each wing. There are commercial flappy-bird designs that work more efficiently using just one motor to control both wings. For example, "you wouldn't drive a car with a different motor on each wheel. You'd be carrying unnecessary extra weight," he said.

Video: One version of the University of Maryland Robo-Raven features updated solar panels in the wings to help generate power. The basic version tested at Aberdeen Proving Ground has wings that were made, in part, using a 3D printer.

But from a scientific standpoint, this approach lets one learn a lot more about the platform and explore interesting spaces of the design, which wouldn't be possible with a traditional flapping-wing single-motor design, he said. With a single motor, one can only speed the wings up and slow them down, which doesn't do much to inform learning of the system.

So, the goal is not to build the best flapping wing possible. "It's our goal to build the most amount of knowledge about flapping-wing air vehicles as possible," Gerdes said.

Robo-Raven's wings were designed with the help of ARL's 3D printer. Gerdes programmed a commercial off-the-shelf Arduino micro-controller that controls the flapping motion.

A hobby shop transmitter and receiver is used to send and receive commands to Robo-Raven. It can fly for 10 to 15 minutes before the motors overheat.

Looking ahead
Inside Gerdes' lab is a breadboard with wires connected to sensors. In about a month, he said he hopes to have a more robust Robo-Raven that can carry this full suite of sensors, which will measure altitude, air speed, wing position, flapping speed, power draw, battery charge, acceleration, roll, and so on.

These sensors will provide a huge body of data, he said, to begin to get at the "diabolically hard problem to solve" of flight similar to birds.

Down the road, he said ARL might come up with an innovative flexible material that would boost the chance of bird-like flight. He said the various labs across the Army collaborate very well on projects like this, and others are aware of what he's doing.

Ultimately in the future, Gerdes said he wants Soldiers to have a single platform that's safer, quieter, stealthier, more versatile, that can do a wide range of missions.

"It's an exciting project, full of possibilities, but unfortunately right now, it's not the finished product we're after," he said. That will be years from now. At that point, the U.S. Army Aviation and Missile Research, Development and Engineering Center might work on it.

Published November 2015

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