Laser welding and brazing is being applied more frequently in high-volume car and truck manufacturing. Advantages include high production rates, easy automation, cost effectiveness, high quality welds, and low heat input. Although steel sheet is the most laser-welded/brazed material, laser welding is gaining acceptance in many applications, as lasers can weld a large range of materials thicknesses and types, including aluminum.
Increasing requirements for product quality and production rates demand laser welding production systems that are self-monitoring and adaptable to real world conditions.
Laser vision cameras are being used successfully in many high speed sheet processes, such as for tailor welded blanks and laser brazing of car roofs to find, track, and adapt to joint location and shape changes. Laser vision cameras, placed right behind the laser welding head, can perform real-time weld quality assessment. To complement seam tracking and weld inspection, a laser process control system (LPCS) – using coaxial monitoring of the thermal radiation from the weld pool area and back reflection of the laser beam from the work-piece – can be used to look inside the process to detect internal defects such as pinholes. Pages 58 and 59 discuss how to incorporate a LCPS into production.
About the authors: Jeffrey Noruk is president of Servo Robot Corp. and can be reached at 262.613.2921 or firstname.lastname@example.org. Jean-Claude Fontaine is executive vice president at Servo Robot Corp. and can be reached at email@example.com.
Alternative manufacturing: How EDM and ECM can effectively reduce costs
Plan to attend the IMTS 2016 Conferences to learn about EDM and ECM effectively reducing costs for many of today's critical components, especialy those made from metals with high machinability ratings.
Chicago, Illinois – The quality required in demanding machining applications can be enhanced, with better surface finishes, using forms of electro discharge machining (EDM) and electro chemical machining (ECM) that have been developed and are in production today.
The productivity and suitability of both EDM and ECM are not dependent upon the machinability factor of the material; if it is conductive then both processes are effective, independent of the difficulty in machining by conventional means.
When correctly applied the results are obtained faster, with no post-processing required, than using previous generations of machines.
EDM applications such as single electrode shaped-hole cooling hole machining in turbine blades and vanes and ECM applications such as final form machining of medical devices, implants and special valves are discussed.
PECM, which utilizes pulsed power supplies and an oscillating head, is also discussed. This type of electro chemical machining has the ability to generate extremely intricate cavities with incredible definition and surface finishes; it can produce better surface finishes than low-wear EDM with no tool wear and no recast layer or heat-affected zone with production rates orders of magnitude faster.
About the speaker John Stackhouse has been involved with EDM, ECM and other non-traditional processes for more than 30 years. He was previously with Dynetics Corp. and Winbro Group Technologies and now is executive vice president of Global Specialty Machines.He is based in Boston, Massachusetts, but travels the world for Global Specialty Machines, utilizing his trained judgment and skill to promote EDM, fast hole drilling and electro chemical machining in key industries such as those of aerospace and industrial gas turbines
Maumee, Ohio – Dana Holding Corp. is building a new axle plant for Jeep models on the site of the old Willys-Overland Motors plant in Toledo, Ohio, where the original Jeep military vehicle was developed and built. The site is a few miles from FCA US LLC’s Jeep complex.
The Toledo-Lucas County Port Authority redeveloped the property in conjunction with NAI Harmon Group. The new facility, adjacent to Interstate 75, is optimally located to support automakers throughout the geographic region.
Dana plans to expand a recently constructed 100,000ft2 facility on the property to nearly 300,000ft2. Throughout the next few years, the company plans to invest approximately $70 million and employ more than 300 associates by 2020.
"Dana has remained committed to metropolitan Toledo, its home for nearly 90 years. In 2015, we strengthened our commitment to the area by consolidating numerous satellite offices in the region into our expanded World Headquarters and Technology Center in Maumee," says James Kamsickas, Dana president and CEO. "The investment in this new manufacturing facility is another substantial example of Dana's commitment to the city and our community. It is an honor for Dana to return manufacturing to the same historic site where Toledo's automotive industry began more than 100 years ago."
In addition to its longstanding partnership with the Jeep brand, the expanded Toledo facility will support axle assembly for another global automaker.
Beginning in late 2017, Dana plans to assemble enhanced versions of its industry-recognized Dana 30 and Dana 44 axles, which will deliver increased power density and performance in a smaller package. Future axle programs and assembly lines are also possible.
To support this investment, Dana received financial and other assistance from the State of Ohio and JobsOhio, the Regional Growth Partnership, Lucas County, the City of Toledo, the Port Authority, and First Energy. Dana's decision to locate the new facility in Toledo is subject to the formal approvals of financial incentives by state and local entities, which are expected later this month.
Bob Pyle, president, Dana Light Vehicle Driveline Technologies, says, "Our Toledo facility will integrate Dana's best global manufacturing practices and advanced operating systems. The plant's products, which will feature Dana's latest axle technologies – along with its close proximity to our customers and our World Headquarters and Maumee Technology Center – will benefit our customers, employees, and shareholders."
Chattanooga, Tennessee – Volkswagen Chattanooga has reached an early production milestone with the completion of the first assembled metal test body for the upcoming midsize SUV.
The production of the first assembled metal test body is an early step towards the full production of the Chattanooga-made midsize SUV, scheduled to begin production late this year and hit the market in 2017.
The first test body build is for the purposes of checking the calibration of body shop equipment and processes. The body is then passed on for further testing and development.
In the midst of its diesel scandal last year, VW reaffirmed its commitment to the Tennessee SUV and has continued engineering and manufacturing work to launch the vehicle.
Source: Volkswagen Chattanooga
Toyoda Machinery USA to host Walter Deep Hole Competence Builder
Lunch & Learn event is May 19, 2016 at Toyoda’s Upper Midwest Tech Center in New Brighton, Minnesota.
Nothing drives up production time like unstable machining on difficult materials. Experts know if you’re drilling deep holes using HSS drills or gun drills, the task becomes time consuming and challenging for deep hole applications. The Walter Deep Hole Competence Builder Lunch & Learn features two key parts in successful deep hole drilling. Beginning with a solid structure, Toyoda’s FH500J reaches spindle speeds up to 15,000rpm and 30/25hp direct drive power eliminates vibration – achieving longer tool and machine life. Superior component quality guided at the circumference and serious carbide strength from Walter Tools races the cutting forces and overcomes extreme mechanical stresses.
Register and attend the Walter Deep Hole Competence Builder to win one of three Visa gift cards – must be present at drawing to win. Spaces are limited, RSVP by Monday, May 16, 2016.