July 21, 2020 | Volume 16 Issue 27 |
Manufacturing Center
Product Spotlight
Modern Applications News
Metalworking Ideas For
Today's Job Shops
Tooling and Production
Strategies for large
metalworking plants
3D-printing materials just keep getting better -- and now there are more choices than ever. Watch as Walter Voit, SVP Polymer Materials, Desktop Metal, describes the 3D printing of DuraChain Elastic ToughRubber photopolymers, which produce tough and resilient end-use parts while eliminating the need for a two-part resin. DuraChain photopolymers also demonstrate a long pot life of roughly one year, depending on environmental conditions, making them more suitable for volume production and reducing waste from spoiled, unused material. These materials are offered exclusively on the ETEC Xtreme 8K top-down DLP systems. ETEC is a wholly-owned subsidiary of Desktop Metal.
Learn about this exciting material.
Learn about the ETEC Xtreme 8K DLP systems -- and what makes them so much better.
THK has developed its best-performing, high-speed rotary bearing ever: the High-Speed, Double-Row Angular Contact Ring BWH. This rotary bearing has balls aligned inside a cage between the inner and outer rings and is part of the THK Rotary Series, along with the cross-roller ring. The main features of this product are its ability to receive loads in all directions as well as its high rigidity and rotational accuracy, which are equal to that of cross-roller rings. By adopting a new structure to change the rolling elements from rollers to balls, this product achieves the greatest high-speed performance ever offered by THK.
Learn more.
Ruland Manufacturing has expanded its jaw coupling line to meet the demands of high-torque applications, now offering bore sizes up to 1-3/4 in. or 45 mm and torque capacities of 2,655 in.-lb (300 Nm). Target uses are in precision systems with high deceleration and acceleration curves, such as semiconductor, solar, conveyor, and warehouse automation applications. Features include zero-backlash, industry-leading misalignment capabilities, and a balanced design that reduces vibration at speeds up to 8,000 rpm.
Learn more.
Can you get a design and functional edge with a wedge? In this animated video, Nord-Lock explains the principle behind their original wedge-locking technology, which secures bolted joints even when exposed to severe vibration and dynamic loads. The company says it is impossible for this washer type to loosen unintentionally, due to the wedge created underneath the bolt head and nut.
View the video.
Copper foam from Goodfellow combines the outstanding thermal conductivity of copper with the structural benefits of a metal foam. These features are of particular interest to design engineers working in the fields of medical products and devices, defense systems and manned flight, power generation, and the manufacture of semiconductor devices. This product has a true skeletal structure with no voids, inclusions, or entrapments. A perennial favorite of Designfax readers.
Learn more.
Rotor Clip has just launched its new, patented InterShim™ Wave Spring design, which has been engineered for high-acceleration electric motor applications. It features alternating turns between inactive (flat) and active (waved) turns to ensure reliable performance under torsional loads and precise rotational movement. The highly customizable wave spring's advanced design addresses physical challenges such as extreme forces and vibrations, making it a versatile solution for high-speed and high-stress applications across various industries.
Learn more.
Xometry's just-launched downloadable Laser Tube Cutting and Tube Bending Design Guide covers design tips and tricks for cutting parts, including minimums, tolerances, and sizes. The guide also covers important rules for mandrel tube bending, like tolerancing, distance between bends, and bends to avoid. Interested in even more in-depth information? Watch the corresponding on-demand webinar, which introduces how Xometry is bringing AI and machine learning to provide instant pricing and lead time on tube bending and cutting to its Instant Quoting Engine.
Get the guide. No registration required.
Watch the extended Best Practices webinar.
A new additive manufacturing material from Stratasys and BASF is aimed at driving greater part quality, versatility, and cost efficiency. SAF™ PP is recognized for its exceptional chemical resistance and airtight capabilities, making it the ultimate choice for complex applications across various industries. It can also be welded to other polypropylene components.
Read the full article.
The new CFL Series cam follower from IKO International boasts a unique, space-saving outer ring design and polymer layer that exceeds the capabilities of conventional resin-type cam followers. Many conventional cam followers press-fit a layer of resin onto the unit's standard outer ring to maintain radial load capacity and provide quiet, clean, and durable operation. However, this thicker assembly makes it difficult to fit into constrained spaces. The CFL Series significantly improves on this design with a polymer layer that is molded directly onto the IKO exclusive thin-walled steel outer ring. This construction solves the dilemma of being able to install a cam follower with special polymers, offering self-lubricating and shock-absorbing properties into existing applications.
Learn more.
SPIROL's new video showcases their updated Model PR and Model CR Semi-Automatic Installation Machines for Pins, Alignment Dowels, and Bushings. The video demonstrates how to operate the machine, details standard features, and optional quality and error-proofing enhancements. More than 80% of the components in this installation equipment are standard, pretested, production-proven, off-the-shelf parts. This translates into faster delivery, greater reliability, and lowest cost for equipment of comparable quality.
View the video.
Greg Paulsen and Steve Zimmerman from Xometry present a comprehensive understanding of CNC design principles, what features are considered common, and what can drive costs. The experts also go through guidance to make great technical drawings to communicate design intent to manufacturers. Lots of good info here. Flip through now and take it all in later when you have the time.
View the video. No registration required.
igus has a new and improved 24-piece iglide® sample box that engineers can request and receive gratis. All iglide components are self-lubricating, resistant to dirt and dust, and offer low rates of wear. The sample box contains bearings, gears, piston rings, and more, and includes many of the most widely used iglide materials. Nothing like having the materials in hand to really check them out.
Learn more.
Zero-Max's ServoClass-HSN Couplings address noise and vibration issues that can be experienced in high-gain, high-speed stepper/servo motor applications such as linear actuators, high-response gantry systems, pick-and-place systems, and semiconductor manufacturing equipment. Featuring a Highly Saturated Nitrile Rubber (HSN/HNBR) flex element, these couplings are specifically designed for maximum damping and performance. They incorporate the field-proven ServoClass clamping hub system and have a zero-backlash design.
Learn more.
UK-based company Fyous is launching the world's first infinitely reusable molding technology that can shapeshift in under 20 minutes, producing zero tooling waste and making usable parts 14 times faster than 3D printing. Sort of like a kid's pin art toy, Fyous' PolyMorphic molding can be set, used, and then reset to help create parts from carbon fiber, polyurethane, PET sheet (thermoformed), foods like chocolate, and more.
Read the full article.
Stock Drive Products/ Sterling Instrument (SDP/SI) has expanded their selection of flexible couplings to include the single disk-type couplings (short-type) series S50XHSM and the double disk-type couplings (standard length-type) series S50XHWM. The disk-type flexible couplings are an economical option that provides greater torque capability and improved performance in a reduced size, with torque ratings of 0.6 up to 12 Nm -- an improvement over similar products.
Learn more.
The superyacht Sea Eagle II. [Photo: © Royal Huisman]
Dutch shipbuilder Royal Huisman applied the same concurrent engineering process developed by the European Space Agency (ESA) for space missions to the design of superyacht Sea Eagle II, due to become the world's largest aluminum sailing yacht when delivered to its owner this spring.
This uniquely contemporary 81-m-long (266-ft) three-masted schooner was recently transported by barge from the company's shipyard in the Dutch city of Vollenhove to Royal Huisman Amsterdam, where its carbon composite rig will be installed, leaving her ready for sea trials and on-board crew training.
Sea Eagle II's modern style extends to its design, which took place using concurrent engineering, taking inspiration from the long-established Concurrent Design Facility (CDF) at ESA's technical center ESTEC in Noordwijk, the Netherlands, where it is employed for performing preliminary design and assessment of potential future space missions and systems.
"Satellites and superyachts are both complex machines, and concurrent engineering is advantageous in designing any complex system," says Massimo Bandecchi, founder of ESA's CDF. "The basic idea is simple: Bring together all necessary experts and design tools into a single room to work together as a team on a shared software model that updates immediately as changes are made, to assess design feasibility and tradeoffs in a much more effective and reliable way.
"While our main focus is fulfilling the needs of ESA engineering, there has also been strong interest in our work from industry. Concurrent engineering's improved performance in terms of time, cost, and efficiency speaks for itself. The result is that more than 50 centers have been built following ESA's original CDF model and are now in operation across Europe -- the majority in the space sector, plus around 10 non-space centers."
Stefan Coronel, Royal Huisman's design and engineering manager, received training from Bandecchi and his team before setting up his own concurrent engineering room. "Yacht building is not rocket science," he says, "but it does involve a complex, multi-disciplinary system, with lots of tradeoffs to be decided."
"The traditional 'over the hedge' design method -- where one knowledge field does its work, then throws it across to the next team in sequence -- demands the subsequent checking of feedback then possible design adjustments, so is quite a time-consuming process. In the modern yard-building world, there isn't so much time to spare.
"That said, compared to the dramatic shortening of satellite conceptual design time achieved by ESA, the main benefit we see from concurrent engineering is not gaining time but that the quality of the final design ends up much better, and more complete -- giving us confidence to proceed to the build phase."
Royal Huisman is now applying concurrent engineering to all of their new builds, and many of their refitting and service projects.
"Our room is not as fancy as ESA's CDF, but has the same basic approach of a place where everyone can contribute," says Coronel, "with means of accessing all normal engineering tools and calculation methods, plus a splinter room for small separate discussions."
In the same way that satellite design is broken down into subsystems, yacht design involves some main disciplines taking part in all the sessions: structural strength and stiffness; deck and sail handling; systems such as propulsion, power, heating, and air conditioning; electronics; and finally interior design -- creating a desirable, luxurious interior. Additional external experts, such as noise and vibration specialists, attend as required.
"The kind of tradeoffs that concurrent engineering makes easier to resolve include such deceptively simple tasks as placing a side hatch or staircase," says Coronel. "In the case of a hatch, it would need to be watertight and endure loads from sea waves, while also integrated with the living space and looking good when trimmed with wood. Any staircase needs to be open and attractive, while also having pipes and electrical cables run through it, and meeting all relevant fire and safety regulations."
The company's adoption of concurrent engineering also meant Sea Eagle II's aluminum panels have had holes and support structures added to them in advance, saving time in construction and the integration of features such as winches or hatches.
European companies and institutions have variously adopted concurrent engineering for educating students, designing automobiles, planning oil platforms, and optimizing the production plant of dairy product company FrieslandCampina.
Source: This article was reposted with permission from the European Space Agency (ESA). Read about more ESA developments at www.esa.int.
Published March 2020