Machining components for surgical tools is complex work, but Metal Craft prefers a simpler approach to automation. “We just want it to load the machines, so our people can go and do something else,” says Jeff Thrun, general manager.

The Profeeder robot cell from Easy Robotics significantly reduced the engineering effort that would be required to develop a part-staging system in-house. As detailed below, the shop has also added its own methods of part staging. Photos by Peter Zelinski.

Limiting the use of robots to machine tending contrasts starkly with the recommendations of many outside integrators, Thrun says. “They’ll say, ‘Just tell us what you want done, and we’ll turnkey it in our facility and deliver it to you.’ I’ll say, ‘Great, you can put it there on Monday, and I’ll call you back on Wednesday, because that job will be done.’”

In other words, loading and unloading parts is low-hanging fruit for Metal Craft’s collaborative robots. More ambitious work – say, deburring or inspection – might be possible to automate in some cases, but part quantities are often too low and process variability too high for it to be practical. A more limited approach results in a process that still requires attention, but not at the cost of an idle machine tool spindle. “A person has to go over and do the quality inspections, do the SPC [statistical process control] charting, change the tools when they meet their tool life expectancy, and that kind of thing – that doesn’t change,” Thrun explains. “But now, they can run two or three machines instead of one.”

Holding tolerances measured in tenths on parts like this surgical tool assembly component requires the shop’s smallest cutting tools and most precise five-axis machine tool.

This focus has made automation easier to implement, but the team also has made extensive efforts to ensure seamless changeovers from job to job. One result of this work is a modified part-staging system that flexes as-needed to accommodate different-sized workpieces. Another, more recent example of how repeatable setups help make the most of automation involves not a robot, but a pallet changer. In this case, job changeovers are a matter of simply “picking one pallet up off the (conveyor) chain and putting another one on,” Thrun says.

Experience with both robots and pallets has enabled the shop to evaluate the relative merits of both systems for its applications. Those merits aside, the broader lesson of Metal Craft’s journey is that a varied mix of complex work need not deter any manufacturer from automating, whether with robots, pallets or both. As Thrun puts it, “these are just two different ways of delivering parts to the machine.” Success depends on how they are used – and, increasingly for this Minneapolis medical manufacturer, the equipment to which the automation is attached.

Jeff Thrun, general manager at Metal Craft, explains one of the company’s first robot automation applications: for high-volume electrical discharge machining (EDM). Now, less expensive, easier-to-program collaborative models that require no caging are beginning to populate other areas of the machine shop floor.

Unattended Only, Please

A tour of the 83,000-square-foot shop floor quickly reveals one of this 150-employee company’s most striking characteristics: For most of its history, machining has depended as much on the machinists as the machine tools. Thrun cites expertise with setups and workholding as critical to weaning the maximum capability from milling and turning machines.

In addition to precision machining of individual components, Metal Craft offers Design for Manufacturing (DFM) as well as assembly of complete surgical tools from its Minnesota facility. A nearby sister company, Riverside Machine and Engineering, focuses more on aerospace work.

The difference today is that a phrase like “milling and turning” is more likely to describe the same machine. Bar-fed turn-mills have become more common, as have five-axis machining centers, because consolidating setups improves both the Carbide Milling Inserts quality and the speed of machining.

Both goals are critical because customer requirements are changing, Thrun says. That goes not for just the work itself, but also demands surrounding it, such as increased inspection requirements. Meanwhile, machinists remain as hard to find as ever. “In order to grow, we need our people to accomplish more without working any harder. We plan to do that through unattended machining.”

So far, the most significant investment toward meeting that goal is a pallet-fed five-axis machining center with capability that sets it apart from the rest of the shop. Capable of machining to accuracy of less than 2 microns and achieving nanometer-level surface finishes, the GRA200 from Jingdiao North America is also an unusual make and model for a U.S. machine shop generally. However,Tungsten Carbide Inserts the builder is working to change that, and more broadly, to emphasize the role of high precision in ensuring reliable lights-out machining. In fact, Metal Craft’s opportunity to purchase the machine came with one condition: It would be displayed at IMTS 2020 first.

Based in China with a U.S. office near Chicago, Jingdiao specializes in high-precision machining. Metal Craft reports that ensuring quality parts is easier and faster with, among other capabilities, single-setup, five-axis processing; robust software simulation; and a 24,000-rpm, through-coolant spindle driving the shop’s smallest tools (some applications reportedly involving roughing with a 0.020-inch end mill).  

When that event was cancelled, Metal Craft took delivery early. The machinists tasked with running the new machine made the most of the extra time, even opting to master the builder’s own CAM system rather than choose a more common option. Nonetheless, the machine “hit every bullet item flawlessly” in a six-month trial.   

In addition to the machine itself, Metal Craft had to make the most of the pallet system that came with it. This provided an opportunity to test another form of automation against the shop’s first collaborative robot, where the team had already made significant strides in tending a less-precise machine.

Making Setups Repeatable

Thrun credits multiple team members for the success of that first robot, a UR-10 from Universal Robots. He also credits the integrator who sold it, PCC Robotics, for appreciating the challenges associated with an environment where a “high-volume” order amounts to only 100 parts at most. However, he says the effort really began with the hiring of a young automation engineer who started with Metal Craft as a college intern. In early attempts to maximize unattended machining time, he set the same goal for the robot that the machinists would set later with the pallet system: ensuring time spent setting up did not exceed the time spent cutting parts.

The system of overlapping trays visible here is an in-house modification. Sliding the top piece at an angle enables adjusting the size of the opening between 1/2 and 2 inches to accommodate varying sizes of stock while maintaining a repeatable part-to-part position increments for the robot. With programs and sets of 3D-printed jaws at the ready when a part order repeats, robot changeovers from one unique part number to the next generally take less than half an hour.

The solution was the same as well: ensuring repeatable setups and, by extension, seamless changeovers from batch to batch. The part-staging system implemented by the automation engineer, pictured above, will likely be replicated as the shop adds more collaborative robots.

A machinist demonstrates what it took to swap a setup prior to the addition of more workholding. Now, pallets are pre-staged.

As for the pallets, the basic idea is also to standardize on workholding and pre-stage setups as much as possible beforehand. To that end, the shop has invested heavily in pallets, 5C collets and two types of vise (a model from Lang Technovation that machinists appreciate for tool clearance, as well as a model from Jergens that they appreciate for a secure grip).

With workholding pre-configured and already mounted on the pallet and standard sizes for blanks, changing over to a new part is a simple matter of choosing the right-size collet or vise, and in the latter case, a new set of custom jaws. Generally, the only items to affix or remove from the pallets are the workpieces themselves.

“All things equal” comparisons of the two delivery mechanisms are easy for Metal Craft because they are seen as just that: delivery mechanisms.

Stretching Skills Further 

Although the pallet system has more than paid for itself, Thrun says Metal Craft’s future is likely with additional collaborative robots, even as it plans to expand its capacity for fine-tolerance machining.

With one workpiece per station, he explains, the pallet-fed machine can cycle through 24 workpieces before someone has to attend to it. However, only half are likely to be finished parts, because even a five-axis machine requires a second setup for sixth-side operations. Barring an investment in a larger pallet changer (and more pallets to set up beforehand), a robot could conceivably cycle through more parts without intervention, simply because more parts can be staged in front of it. Running only one unique part number at any given time also makes robots a better choice for avoiding line clearance issues – that is, avoiding mixing between jobs, which can be a hazard for quality control.

Regardless, focusing too much on the merits of either system risks missing the point. “All things equal” comparisons of the two delivery mechanisms are easy for Metal Craft because they are seen as just that: delivery mechanisms. Which part runs where depends not on the robot or pallet system, but on the machine itself. Suffice it to say, Metal Craft plans to install another five-axis Jingdiao, although this machine might be fed by a collaborative robot rather than a pallet system.

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On one hand, Alexandria Industries’ first attempt at machine-tending robotics was Rosie. On the other, it was not so rosy.

“Rosie” is the name the aluminum extruder, machining and fabricating company picked for its first machine-tending robot. Installed in one of its Alexandria, Minnesota facilities in 2001, the cell this robot was to anchor was designed for a family of parts for the telecommunications industry. The cell included two CNC machine tools; two conveyors that would feed Rosie fresh workpieces to load into the machines; a camera to enable her to locate workpieces on the conveyors to pick, eliminating the need and cost for hard fixturing; and an area where she would deliver completed parts to awaiting pallets.

However, a downturn in the telecommunications industry caused the company to lose the work for which the machining cell was created before production ensued. As a result, there was a significant need to redeploy the cell, one that was no small investment.

Eventually, the company came up with a strategy it hoped would help the cell investment return: It identified an existing repeating job—extruded aluminum housings for oxygen delivery systems—that also featured a family of like parts. The idea was to dedicate that job to one of the cell’s conveyors and machines, and then work in other jobs to keep the remaining conveyor and machine (and Rosie) busy.

Capacity and CNC Robotics Manager Todd Carlson admits that this strategy did not work so well. When one machine was down for a new-job setup, maintenance or other reasons, the robot and second machine also had to be shut down because shopfloor employees needed to enter the cell to safely perform their tasks. With this configuration, the cell never delivered the production efficiencies the company hoped for.

“We thought we’d never try our hand at robotic automation for CNC machining again,” Mr. Carlson says.

After struggling with it for a couple of years, Alexandria Industries decided to simplify the cell. It removed one of the machines and dedicated the cell to the family of oxygen-delivery-system housings. In making this change, spindle uptime and production output for the cell’s sole machine increased by more than 30 percent. Mr. Carlson says it was at that point that the company realized simplifying and standardizing its approach to automation could help it realize more of unattended machining’s potential benefits.

Alexandria Industries has since applied that thinking to the design of various robot-tended machining cells. In fact, the company now has more than 20 robots in this facility, some of which are collaborative models (aka “cobots”) that feature force-sensing technology so that employees can safely work alongside them to measure, deburr or package components. (For example, if a cobot unexpectedly contacted a person or object, it would recognize that and stop moving before injury or damage occurred.)

All its robot-tended machining cells are designed to accommodate numerous jobs, as many as 50 in some cases. When designing these cells, concessions had to be made in terms of production speed and flexibility. Still, traditional job shops thinking about adding machine-tending robots are well-served to consider Alexandria Industries’ strategy of setting up cells to succeed in a high-mix/low-volume part-machining environment.

Keep it Simple, Standardize

Alexandria Industries was founded as Alexandria Extrusion Company in 1966. Its 188,000-square-foot facility located in the city that shares its name features a range of manufacturing capabilities. There, it extrudes and machines 30 million pounds of 6000-series aluminum alloys per year, much of which undergoes additional machining, fabrication and other value-adding operations. (The company has another location in Alexandria as well as facilities in Wheaton, Minnesota; Indianapolis, Indiana; and Carrolton, Texas.)

The raw material used at this facility is delivered in 20-foot-long bars—either 3.5 or 7 inches in diameter—that the company refers to as “logs”. This facility has two 7-inch extrusion presses and one 3.5-inch press. (The Indianapolis facility has a 10-inch press.) Prior to extrusion, the logs are sawn into 18 to 28-inch billets. Each section is then brushed to remove any oxide coating from its surface and delivered to an induction heater that heats it to as much as 850° F in a mere 75 seconds. The extrusion press pushes the soft, heated aluminum through a die to create the desired profile. This Alexandria facility extrudes approximately 3,500 components and has approximately 5,500 dies (some of which are copies). After cooling, the extrusions are sawn to length, and many require some machining work.

After dialing in its first robot-tended machining cell, the company decided to give automation another go by standardizing the process. In 2005, it installed two cells with infeed and outfeed parts conveyors, FANUC LR Mate robots and Haas VF2 vertical machining centers (VMCs) with fourth-axis rotary indexers. These were integrated by the company’s machine tool distributor, Productivity Inc. Like Rosie, the robots in these cells also used cameras to locate parts to be picked from the infeed conveyor.

Alexandria Industries’ goal with these cells was to run a mix of parts with maximum lengths of 8 inches. “We looked for repeating jobs in which parts were similar in size and shape, and required somewhat straightforward machining work,” Mr. Carlson explains. “We wanted to establish a family of like parts for each cell instead of trying to accommodate any and all jobs. We didn’t want to run complex parts unattended in the cells. Those jobs we’d rather run on standalone machines with an operator standing by to perform part inspection, monitor tool wear and, in general, keep an eye on the process.”

Within six months of installation, the two cells were running 24/7 at full capacity, machining as many as 30 different jobs. The company added two more identical cells, and those were soon running at full capacity, too. Today, it has six VF2 cells, and one operator can tend three cells at a time. Standardizing on equipment and process makes it easy for operators to comfortably tend any of those cells, Mr. Carlson notes.

Alexandria Industries also standardized its workholding strategy for the robot-tended machining cells. Initially thinking it would use the fourth-axis indexers only for parts that required machining on multiple sides, the company removed the indexers from the machines when they were not needed and replaced them with hydraulically actuated vises. However, the company discovered that it made more sense keeping indexers mounted in the machines and making fixtures for the indexers for parts that required machining on only one side. By maintaining that same indexer location, the company would not have to tweak robot programs because the indexer was not re-installed at precisely the same position as before. It justified the added cost for indexer fixturing because this strategy sped and simplified change-overs. Mr. Carlson says it could take two hours to reinstall an indexer and modify the robot program.

That said, the reason the company limited the cells to parts no longer than 8 inches is because of how the parts were loaded into the machines. In order to enable operators to access a machine’s CNC and door, a side window was installed through which the robot would load and unload parts. As a result, the robot could not extend a part longer than 8 inches through the window and maneuver it to the fixture.

Despite these limitations, the company wanted to automate the machining of longer parts. It initially created a cell with infeed and outfeed conveyors around a bigger Haas VF6 VMC with five-axis trunnion table that could accommodate parts as long as 24 inches. Eventually, it replaced that with a Haas UMC 750 five-axis machine. It now has three UMC 750s in identical cells with safety fencing that enables operators to access the machines’ CNCs.

Looking to automate the machining of parts as long as 50 inches, Alexandria Industries created six similar cells around Haas VF6 VMCs with fourth-axis rotary indexers. At first, an operator could tend only one cell at a time largely because of the size of the parts and the manual deburring and washing operations they required.

With the VF2 cells, operators could grab a number of parts and place them in a vibratory tumbler to deburr them, and then wash them prior to packaging. That is why one operator could tend multiple machines. Given the longer parts that run through the VF6 cells, operators could manually deburr and wash only one part at a time, meaning they could only keep up with one cell at a time. As a result, robotic deburring and part-washing capabilities were added to each VF6 cell, enabling one operator to tend two cells.

Alexandria Industries has since turned to collaborative robot technology to enable VF2 VMCs to machine parts ranging in length from 8 to 24 inches. Because of the collaborative nature of these robots and appropriate risk assessment and mitigation, the cobots can be positioned in front of the machines to load parts through the machines’ doors (instead of a smaller side window) while operators perform other duties in the same vicinity.

Robots and People Getting Along

The company purchased its first cobot, a UR5 model from Universal Robots, four years ago. These robots use sensors to detect when they unexpectedly contact something (or someone) as they move through their programmed path. Alexandria Industries now has four VF2 cobot cells that one person can tend while performing duties such as in-process inspection and packaging.

Mr. Carlson says this robot technology is a good example of the trade-offs a machine shop might have to consider when deciding which configuration of robotic cell makes the most sense for their business. For instance, the UR5 models have a maximum payload capacity (including end effector) of 11 pounds. Lathe Inserts Conventional industrial robots have higher payload capacities, but this is not an issue because the cobots at Alexandria Industries are handling relatively light, aluminum workpieces. The cobots also move at a slower speed than industrial robots for safety purposes because they are not operating alone in a secure work area that people cannot access during operation.

However, a low price point makes cobots attractive. Company manufacturing engineers integrated the cobots themselves, eliminating the cost of an outside integrator. Operators have found that programming the cobots from the touchscreen control pendant is intuitive and relatively easy.

Cobots can also be redeployed to tend other machines or perform other duties. In fact, the base designed for the cobots includes forklift pockets that would WCMT Insert enable them to be easily moved throughout the shop. That said, each time the company added a cobot cell, that cell would quickly reach maximum capacity, so it did not make sense to redeploy the cobots. However, its most recently purchased cobot is currently not assigned to any machining cell. The base for that cobot also includes forklift pockets as well as wheels to enable it to be moved through the shop. The company is currently working to identify non-machine-tending applications for it, such as deburring, riveting, assembly and simple tapping.

Automation’s Affect

Mr. Carlson says production employees were initially leery of the robots, thinking they might eventually take away jobs. However, automating the repetitive, monotonous task of loading and unloading machines has enabled the employees to grow their technical skills and focus more on problem solving. He believes that it also has helped the company retain some of its best talent. In fact, robotic automation makes the company more enticing to potential new hires who see they won’t be performing basic manual labor all day long.

“The robots have really helped grow the company’s sales,” Mr. Carlson says. “We’ve actually had to add employees since we started adding robots due to that growth.”

And while Rosie has officially retired, her robotic successors look forward to long lives working next to the company’s 625 employees.

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Touch trigger probes that require probe deflection could contact the part, in this case the top of a small bore, before completing deflection.

Granted, this isn’t the type of part a machine shop is likely to measure. But WNMG Insert this does demonstrate how micro motion technology allows this touch probe to measure very delicate part features.

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Multisensor measurement systems combine the strengths of two or more sensor technologies on a single inspection platform so that all critical features of a complex part can be measured. These systems often include non-contact sensors—video and/or laser—for surface and edge measurements, and touch-trigger probes to reach part features that the non-contact devices can't access, such as cross holes.

In some cases, the size of a typical touch-trigger probe may prohibit the measurement of very small slots, holes, grooves or bore draft angles, for example. The touch-trigger measurement technique may also prevent such measurements. Because the probe must deflect in order to register a Cemented Carbide Inserts position, it is possible that the probe's shank could contact the part before completing this deflection (this is known as shanking error).

SmartScope multisensor measurement systems from Optical Gaging Products (Rochester, New York) offer touch probing technology that requires no stylus deflection. The technique uses a miniature probe that is in constant micro motion. As the probe's small stylus ball approaches the object to be measured, its micro motion is damped by the part being measured. When the system detects this change in micro motion, it registers the measurement. The probe does not deflect at all, which allows its diameter to be so small and also enables measurement of very flexible of materials in X, Y and Z axes.

To guard against damage when not in use, the probe retracts into a protective housing and deploys only when very fine touch probing routines are required. The probe and housing can be stored in a probe change rack as any other probe could.

The Carbide Inserts Website: https://www.estoolcarbide.com/

Market demand trends
With the technological progress of petroleum, mining, automobile, machinery and other related industries, the upgrading of Chinese tungsten carbide market will be accelerated, and the general low-end product market will gradually shrink. Demand for solid carbide tools, ultra-fine grain size carbide and large special-shaped products continues to increase. Although the concentration for tungsten carbide industry is relatively low and the competition is relatively scattered, the specialized products of different manufacturers are quite different, and their bargaining power for downstream will depend on the product and demand. Chinese high-end manufacturing industry has entered a golden growth period, providing a good opportunity for it’s carbide industry. The stable development of the downstream market will help the future demand tungsten carbide inserts of the industry.
Market competition trends
From the current status, the future competition of tungsten carbide industry will still have a relatively fierce competition pattern in the future with the development of the industry and the expansion of downstream demand. Although the price of some products of relevant enterprises in Chinese carbide market is currently higher than that of foreign enterprises, the price-performance ratio of some products is slightly lower than that of some foreign enterprises, especially in terms of product service life. Chinese tungsten carbide still need continuous and in-depth research and development. The market competition trend should focus on improving the life of product tools, and under the same conditions, product quality and service life should be TNGG Insert given the top priority in development.

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A drill bit is a tool used to drill through holes or blind holes in solid materials, usually in the range of 0.25 to 80 mm. Common drill bits mainly include twist drills, flat drills, center drills, and deep hole drills. Although reamer and boring drills cannot drill holes in solid materials, they are customarily classified as drill bits.

Contents hide 11.Twist drill 22.Flat drill 33.Deep hole drill 44.Broaching drill 55.Countersink drill 66.Center drill 7How to select suitable drills made of tungsten carbide? That’s the few types of carbide drills shown as follow, 81.Carbide indexable insert bit 92.solid carbide drills 103.welding carbide drill 114.Replaceable carbide drill bit with a crown1.Twist drill

Twist drills are the most widely used hole machining tools. Usually, the diameter ranges from 0.25 to 80 mm. It consists mainly of the working part of the drill bit and the handle. The working part has two spiral grooves that resemble twists. In order to reduce the friction between the guiding portion and the wall of the hole during drilling, the twist drill is gradually reduced in diameter from handle toward the shank and has an inverted cone shape. The helix angle of the twist drill mainly affects the size of the rake angle on the cutting edge, the strength of the blade and the chip removal performance, which is generally 25° to 32°. The spiral groove can be machined by milling, grinding, hot rolling or hot extrusion, and the front end of the drill bit is sharpened to form a cutting portion. The standard twist drill has a cutting edge angle of 118, a transverse blade bevel angle of 40° to 60°, and a relief angle of 8° to 20°. For structural reasons, the rake angle is large at the outer edge and gradually decreases toward the middle, and the rake edge is a negative rake angle (up to -55°), which is squeezed during drilling.

In order to improve the cutting performance of the twist drill, the cutting portion can be ground into various shapes (such as a group drill) according to the nature of the material to be processed. The handle of the twist drill has two types: a straight shank and a taper shank. The former is clamped in the drill chuck while the latter is drilled into the taper hole of the machine spindle or the tailstock. Generally, twist drills are made of high-speed steel. Twist drills with carbide inserts or crowns are suitable for machining cast iron, hardened steel, and non-metallic materials. Solid carbide small twist drills are utilized to process instrument parts and printed circuit boards.

2.Flat drill

The flat drill has a simple structure and low cost of craft. Its cutting area has a spade shape, so that the cutting fluid can be easily introduced into the machined hole. It is undeniable that the flat drill has poor cutting and chip discharging performance. Flat drills are available in both integral and assembled versions. The monolith is mainly used for drilling microholes with a diameter of 0.03 to 0.5 mm. The assembled flat drill blade is interchangeable and can be internally cooled, which is mainly used for drilling large holes with a diameter of 25 to 500 mm.

3.Deep hole drill

Deep hole drilling generally refers to a tool that machines holes with a hole depth to hole ratio greater than 6. Commonly used are gun drills, BTA deep hole drills, jet drills, DF deep hole drills, etc.

4.Broaching drill

Reaming drills have 3 to 4 teeth and are more rigid than twist drills to broach existing holes and improve the accuracy of machining and finish.

5.Countersink drill

The countersink drill has many teeth, and the hole end is processed into a desired shape by a forming method for processing the countersunk holes of various countersunk screws or flattening the outer end faces of the holes.

6.Center drill

The center drill is used for drilling the center hole of the shaft workpiece. It is essentially a composite of a twist drill and a boring drill with a small helix angle, so it is also called a composite center drill.

How to select suitable drills made of tungsten carbide? That’s the few types of carbide drills shown as follow,1.Carbide indexable insert bit

Drills with carbide indexable inserts have a wide range of machining depths from 2D to 5D (D is the diameter of bore) for lathes and other rotary machines.

2.solid carbide drills

This drill is suitable for use in advanced machining centers. Made of fine-grained hard alloy material, it is also treated with TiAlN coating for extended service life. The specially designed geometric edge shape enables the drill bit to have self-centering function and good chip control when drilling most workpiece materials and chip removal performance.

3.welding carbide drill

This drill is made by firmly welding a carbide crown on a steel drill body. The self-centering geometry blade type has a small cutting force and can achieve TCGT Insert good chip control for most workpiece materials. The finished hole has a good surface finish, high dimensional accuracy and positioning accuracy, and no further finishing that is required. The drill is internally cooled and can be used in machining centers, CNC lathes or other high-rigidity, high-speed cutting machines.

4.Replaceable carbide drill bit with a crown

This type of drill is a new generation of drilling tools developed in recent years. It is a combination of a steel drill body and a replaceable solid carbide crown. Compared with a welded carbide drill’s, the machining accuracy of this type is comparable. Besides, since the crown can be replaced, the machining cost is reduced along. This drill bit achieves precise hole size increments and does automatically self-centering, which result in the high hole VNMG Insert machining accuracy.

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