Boeing is Awarded a $35 Billion Contract

After a decade of delays, Pentagon awarded one of the biggest defense contracts ever to build airborne refueling tankers (flying gas stations) - to Boeing Company. These new airplanes will replace their peers from 1950s. Boeing will base the tanker on its 767 aircraft. The contract will mean 50,000 jobs.

Boeing Defeats EADS for $35 Billion Air Force Tanker Program - Businessweek

Machine Tool Sales (finally) Back to Normal

Statistics from 2010 looks promising. Manufacturing industry is finally back on track and companies have started to make investment.
Machine Tool Sales Return to “Normal” – Up 75% in December

Volume Based Feed Rate Optimization: Can We Rely On It?

Feed rate optimization of NC programs has started to become a hot topic for the past 5 years. Most CAM companies have developed some type of an optimization tool to adjust feed rate along the tool path. The idea behind feed rate manipulation is to dynamically change feed rate along tool paths where geometry varies. This way, a long G01 command with one feed value can be split into a number of shorter G01 commands with different feed rate. The fundamental assumption that such systems are based on, called Volume Based Optimization, is that 

Process outputs such as spindle power/torque, cutting forces, tool deflection, etc... are directly proportional to the material removal rate (or the volume of material removed)... 

Since CAM based systems only have the geometric information obtained from tool path simulation and workpiece geometry update, this assumption seemed valid at the time. However, researchers specialized in metal cutting prove this assumption wrong! It is very likely that two different cutting configurations with identical material removal rate may result 50%-100% difference in peak cutting forces, spindle power/torque, etc...

MACHpro: How to Reduce Cycle Times

It takes only three simple steps to set up MACHpro to analyze and optimize tool paths.

MACHpro: Basics of Part Program Optimization

Combining your expertise in machining with MACHpro's unique Virtual Machining technology, parts can be optimized prior to actual machining and productivity can be increased. MACHpro takes three inputs namely CAD model of the stock; original part program (tool path); and cutting tool geometries, and analyzes quality of the actual machining process. MACHpro automatically corrects feed rates of NC blocks when machining problems such as chatter vibrations and spindle overloading are detected. Corrected feed rates are inserted into the original part program and a new optimized part program is generated automatically.

MACHpro Virtual Machining is released!

The most comprehensive machining process analysis and optimization software, MACHpro Virtual Machining, is released. 

MACHpro is an integrated, science-based engineering software that notably improves competitiveness of manufacturing companies by significantly reducing overall cost per component through high performance machining.

Modeling and Simulation among U.S. Manufacturers: The Case for Digital Manufacturing

In partnership with Intersect360 Research, the National Center for Manufacturing Sciences (NCMS) conducted a broad-based survey of U.S. manufacturers regarding the current state of digital manufacturing technologies and the drivers and barriers to expanding adoption. This study reveals the desire and potential benefits of digital manufacturing for a broad range of companies, particularly the assistance needed by small and medium-size manufacturers (SMMs) and the partnerships they would seek.

An SME Finds the "Sweet Spot" and Achieves an Overnight Success

A progressive BC manufacturing company, Redline Pro Manufacturing, has always invested into new technologies, and they have benefited greatly over the years. They transformed 450 sq. ft. garage shop with a single low end machine tool into a successful, fully automated, state-of-the-art job shop that is running around the clock and making parts for the high tech sector.

Impressive Cycle Time Optimization in Stamping Die Machining

Stamping dies are one of the most time consuming, hard to machine components of the automotive industry. A typical machining strategy for contour surface is to use ball type cutters removing material at varying depths of cut. Long overhangs from the spindle nose puts excessive loading on the tool, and spindle. In addition, constantly varying part geometry and depths of cut make it extremely difficult to maintain a proper chip load on the cutting edges. As a result, process planners typically choose conservative cutting conditions because an error in part program is not affordable when it comes to machining small quantities. 

A striking example of chatter vibration suppression

We wanted to give an example of how to increase productivity by chatter suppression. Below, you will see two videos of machining an aluminum workpiece with two different cutting conditions. The first cutting condition is selected by a process planner based on recommendations of a tool vendor:

How to construct productivity charts

Productivity of a milling operation is directly proportional to the axial depth of cut, radial width of cut, spindle speed and chip load. Traditionally, the industry uses machinability data handbooks as a reference to select cutting conditions leading to a safe but conservative operating point. The most optimum cutting condition; however, can only be obtained by determining the limiting cutting conditions based on workpiece material properties, machine rigidity, cutting tool properties, rigidity of tool/work holding system and spindle capacity. One extremely powerful method to tune cutting conditions for optimum production is dynamic analysis.