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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.

How to float your coffee creamer: Study explains how droplets can 'levitate' on liquid surfaces

By Jennifer Chu, MIT

A drop or two of cold cream in hot coffee can go a long way toward improving one's morning. But what if the two liquids didn't mix?

MIT scientists have now explained why, under certain conditions, a droplet of liquid should not coalesce with the liquid surface below. If the droplet is very cold, and the bath sufficiently hot, then the droplet should "levitate" on the bath's surface, as a result of the flows induced by the temperature difference.

The team's results, published in the Journal of Fluid Mechanics, offer a detailed, mathematical understanding of drop coalescence, which can be observed in everday phenomena, from milk poured in coffee to raindrops skittering across puddles, and sprays created in surf zones.

The results may help researchers understand how biological or chemical substances are spread by rain or other sprays in nature. They could also serve as a guide for droplet-based designs, such as in microfluidic chips, in which droplets carrying various reagents can be designed to mix only in certain locations in a chip, at certain temperatures. With this new understanding, researchers could also engineer droplets to act as mechanical ball bearings in zero-gravity environments.

VIDEO: This video shows that a temperature difference between a droplet and a bath can help levitate droplets without any direct contact.

"Based on our new theory, engineers can determine what is the initial critical temperature difference they need to maintain two drops separately, and what is the maximum weight that a bearing constructed from these levitating drops would be able to sustain," says Michela Geri, a graduate student in MIT's Department of Mechanical Engineering and the study's lead author. "If you have a fundamental understanding, you can start designing things the way you want them to work."

Geri's co-authors are Bavand Keshavarz, a lecturer in mechanical engineering, John Bush, professor of applied mathematics in MIT's Department of Mathematics, and Gareth McKinley, the School of Engineering Professor of Teaching Innovation.

An uplifting experiment
The team's results grew out of a question that Bush posed in his graduate course 18.357 (Interfacial Phenomena): Why should a temperature difference play a role in a droplet's coalescence, or mixing?

Geri, who was taking the course at the time, took on the challenge, first by carrying out a series of experiments in McKinley's lab.

She built a small box, about the size of an espresso cup, with acrylic walls and a metal floor, which she placed on a hot/cold plate. She filled the cube with a bath of silicone oil, and just above the surface of the bath she set a syringe through which she pumped droplets of silicone oil of the same viscosity. In each series of experiments, she set the temperature of the hot/cold plate, and measured the temperatures of the oil pumped through the syringe and at the surface of the bath.

Geri used a high-speed camera to record each droplet, at 2,000 frames per second, from the time it was released from the syringe to the time at which it mixed thoroughly with the bath. She performed this experiment using silicone oils with a range of viscosities, from water-like to 500 times thicker.

She found that droplets appeared to levitate on a bath's surface as the temperature gradient between the two fluids increased. She was able to levitate a droplet, delaying its coalescence, by as long as 10 seconds, by maintaining a temperature difference of up to 30 deg C, or 86 deg F, comparable to the difference between a drop of cold milk on a bath of hot black coffee.

Geri plotted the data and observed that the droplet's residence time on the bath's surface seemed to depend on the initial temperature difference between the two fluids, raised to the power of two-thirds. She also noticed that there exists a critical temperature difference at which a droplet of a given viscosity will not mix but instead levitate on a liquid surface.

"We saw this relationship clearly in the lab and then tried to develop a theory in hopes of rationalizing that dependence," Geri says.

A cushion's character
The team first looked to characterize the layer of air separating the droplet from the bath. The researchers hypothesized that a temperature difference between the two fluids may influence this air cushion, which may in turn act to keep a droplet afloat.

To investigate this idea mathematically, the researchers performed a calculation, referred to in fluid mechanics as a lubrication analysis, in which they appropriately simplified the complex equations describing fluid motion, to describe the flow of air between the droplet and the bath.

Through these equations, they found that temperature differences between the fluid drop and the fluid bath create convection, or circulating currents in the intervening layer of air. The greater the temperature difference, the stronger the air currents, and the greater the pressure that pushes against the droplet's weight, preventing it from sinking and making contact with the bath.

"We found the force coming from the droplet's weight and the force coming from the recirculation of the air layer will balance at a point, and to get that balance, you need a minimum, or critical temperature difference, in order for the droplet to levitate," Geri says.

Inside a single drop
Next, the team looked for a mathematical explanation for why they observed the 2:3 relationship between the amount of time a droplet levitates on a liquid surface and the initial temperature difference between the two fluids.

"For that, we had to think about how the temperature of the drop changes over time and approaches the temperature of the bath," Geri says.

"With a temperature difference, you generate a flow inside the drop, drawing up heat from the bath, which circulates around until the droplet temperature is the same as the bath and you don't levitate anymore," Bush adds. "We were able to describe that process mathematically."

To do so, the researchers adapted another set of equations, which describe the mixing of two fluids. They used the equations to model a warm parcel of liquid within the droplet that has been warmed by the bath below. They were able to characterize how that parcel of liquid mixed with the colder portions of the droplet, warming the entire droplet over time.

Through this modeling, they could observe how the temperature difference between fluids decreased over time, to the point at which a droplet stopped levitating and ultimately mixed with the rest of the bath.

"If you study that process mathematically, you can show the way in which temperature is changing in the droplet over time is exactly with this power law of 2/3 that we observed in our experiments," Geri says.

Bush says that their results can be used to characterize the spread of certain chemical and biological agents that are transferred through raindrops and sprays.

"There are a lot of biological and chemical mixing events that involve droplet interactions, including in the surf zone, with waves breaking and small drops flying everywhere, and in hot tubs, with bubbles bursting and releasing droplets that skitter along the surface," Bush says. "The rate at which these agents mix will depend on how long drops stay afloat before coalescing. Now we know that depends on temperature, and we can say exactly how."

This research was supported, in part, by the National Science Foundation and MIT Energy Initiative through the Energy Fellowship Program.

Published November 2017

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