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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.

Porsche Classic begins supplying classic parts from a 3D printer

For collectors of rare classic cars, the unavailability of spare parts can quickly lead to problems. In the worst-case scenario, the car may even be forced out of action -- just sitting in a garage and maybe looking pretty.

Porsche Classic, the division of Porsche dedicated to classic vehicles, is developing a solution to this problem: producing extremely rare parts that are only needed in small quantities using 3D printers.

All parts that are produced using the 3D-printing process meet the requirements in terms of absolute fidelity to the original specifications, both from a technical and a visual perspective.

The Porsche Classic stable currently includes some 52,000 parts. If a certain spare part is no longer in stock or if stock is dwindling, the part is reproduced using the original tools. For larger quantities, production may require the use of new tools. But ensuring a supply of spare parts that are only required in very limited numbers sometimes poses a major challenge, even for the experts. Producing small batches using new tools would be largely inefficient and incredibly expensive. Nonetheless, before embarking on a project to produce a particular component, Porsche Classic always evaluates various manufacturing processes and the price that is willing to be paid.

As the quality of "additive" manufacturing processes continues to improve with generally decreasing costs, this new form of manufacturing presents an economic alternative for the production of small quantities. Say, for example, the release lever for the clutch on the 1983 Porsche 959 is no longer available. This component, made from grey cast iron, is subject to very high quality requirements. But it is in very low demand, because only 292 of these 450-hp super sportscars, notable for their aerodynamically optimized bodies featuring a rear wing integrated in the bodyshell, were ever produced.

Porsche 959 [Courtesy: Porsche Classic/Christophorus]

 

 

The only manufacturing process worth considering would be selective laser melting. To manufacture the release lever, a layer of powdery tool steel less than 0.1 mm thick is applied to a processing plate in a computerized process. In an inert atmosphere, a high-energy light beam then melts the powder in the desired locations to create a steel layer. Thus, the complete three-dimensional component is produced, layer by layer.

Both the pressure test with a load of almost 3 tons and the subsequent tomographic examination for internal faults were passed by the printed release lever with flying colors. The practical tests -- with the lever installed in a test vehicle coupled with extensive driving tests -- confirmed the impeccable quality and function of the component.

Due to the consistently positive results received to date, Porsche is currently manufacturing eight other parts using 3D printing. The parts in question are steel and alloy parts produced using the selective laser melting process. Plastic components are manufactured using an SLS printer. SLS stands for selective laser sintering, a process where the material is heated to just below melting point and the remaining energy is applied through a laser to fuse the plastic powder at a selected point.

All parts are subject to the quality requirements of the original production period as a minimum, though they usually meet higher standards. Accuracy in terms of size and fit is ensured by performing tests with the part installed. Depending on the area of application, plastic parts made of various materials -- as in the original -- must be resistant to oils, fuels, acids, and light.

Porsche Classic is currently testing whether 3D printing is suitable for the production of 20 other components. Key benefits are that the three-dimensional design data or a 3D scan of the component is a sufficient basis to commence production, and that the components can be produced on demand if needed, thereby eliminating tool and storage costs.

Porsche classic car owners also get the parts quite quickly, so they can get their slick rides out of the garage and on the road faster.

Source: Porsche Classic

Published February 2018

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