In preparation for the summer grilling season, my wife bought me a Bluetooth-connected digital thermometer, possibly in hopes of getting properly cooked steaks. It’s a simple device – connect it to my phone or tablet, insert it into a hunk of raw meat, program in the target internal temperature, wait for the alarms.
With expensive New York strip steaks, continuous monitoring resulted in perfectly medium-rare meat with a nice outside sear. However, the thermometer really shines when dealing with tough, cheap cuts that take hours to break down – low and slow as the Texas
Any great outdoor chef will tell you that opening the lid on a grill or smoker too often ruins the meat. The thermometer gives me the confidence to keep the lid closed because I know nothing is overcooking. Instead of peeking every hour for a visual inspection and temperature check with an analog thermometer, I get a continuous flow of data. The app gives suggested temperatures for doneness levels, tells me when the meat’s about
So obviously, cooking makes me think about IMTS – The International Manufacturing Technology Show. Every Industrial Internet of Things (IIoT) or Industry 4.0 press release I read gets me thinking about backyard cooking. The principles are the same – replace occasional checks with real-time data.
Before I had the wireless thermometer, I had to plan outdoor cooking based on published cook times – every pound of meat means this many minutes on the grill at that temperature. While helpful, those guides can’t take all the variables that go into a good brisket into account – ambient temperature, humidity, heat fluctuations from a bad burner, and dozens of others.
Industrial best practices are much the same. Though useful for shopfloor process planning, what works for a company in Switzerland may not work in Ohio. Even following identical task lists, shops can produce different results based on variables that best practices don’t measure.
A constant flow of objective, hard data allows companies to use estimates as planning tools but run operations on a more thorough vision of reality. Instead of replacing inserts after a set number of uses – a figure set by historical usage data – use a monitoring system to measure cutting performance and a camera to inspect edge sharpness. Instead of disassembling spindles to check for wear, add a Bluetooth vibration monitor and measure changes to spot potential problems.
The IIoT, Industry 4.0, my backyard Internet of Meat – the goal of these technologies is to eliminate uncertainty and replace guesswork with intelligence. If my recent top sirloin roast is any measure of the technology’s potential, quality and productivity will improve measurably in the coming years.
1) Near-net-shaped (NNS) forgings and additive layer manufacturing (ALM) are getting more popular in automotive, lowering metal-removal needs. How is Iscar keeping up?
Traditional machining can involve numerous processes to get to the finished product stage. With NNS and ALM only semi-finishing and/or finishing may be needed in turning these components. Historically, larger inserts were needed for heavy or rough turning. Those may no longer be needed.
Iscar has developed our new FLASHTURN turning line just for this reason. The tools are smaller inserts that handle up to 80% of the depths of cut as their larger cousins. More economical, they often cost 25% less than traditional inserts.
2) How is Iscar increasing tool life for automotive manufacturers?
One major issue in turning is coolant delivery. You need to be very precise as to where the coolant is being placed in the cutting zone. Iscar’s JETCUT tooling line delivers high pressure coolant and reduces the need for cumbersome lines and hoses that can get in the way of the turning process. Pinpoint accuracy of JETCUT systems improve tool life and chip control, even at low pressures.
3) What other improvements has Iscar made to help with chip control in turning?
Chip control is very important in automotive because so many processes are unattended. Long, stringy chips interfere with the ever-growing use of robotics, so Iscar has developed many new chip formers for carbide inserts and cermet grades.
We have a couple of new chip formers that are assigned to the ISO P, or steel material group, designated M3P and F3P for the medium and finishing depths of cut. We also have these available for the ISO M, or stainless-steel material group, which are designated M3M and F3M. These new chip formers can replace two to three of the previous chip formers, reducing costly inventory.
4) Does Iscar offer turning products for hardened materials?
Iscar has a very wide range of cubic boron nitride (CBN) turning inserts. CBN offers less-complex machine setups, shorter cycle times, ease of programing versus dressing grinding wheels, and disposal of chips rather than grinding swarf.
Numerous grades and geometries offer continuous and interrupted hard part turning (HPT). Multi-cornered CBN products can make HPT even more economical. Chip formers with our CBN inserts include HM for medium depths of cut and HF for finishing.
5) What other Iscar innovations could be advantageous in automotive manufacturing?
Iscar’s new LOGIQ4TURN could be a game changer. The standard, widely used CCMT insert geometry offers stability in turning where part size is small and depths of cut are not large. Although the LOGIQ4TURN insert CXMG 4 size can take a 0.200" per side depth of cut, it is double sided and has four cutting edges versus two for the CCMT.
Tool holders have the high-pressure coolant, JETCUT, option. The LOGIQ4TURN also uses dovetail pocketing geometry, making it a superior performer with economic advantages due to longer tool life, higher feed rates, and shorter cycle times.
John “Jack” Ross Schirra
John "Jack" Ross Schirra, a longtime sales associate for GIE Media’s Aerospace Manufacturing and Design, Today’s Medical Developments, and Today’s Motor Vehicles, died earlier this year, following a prolonged illness. He was 81.
After graduating from high school in Baldwin, Pennsylvania, in 1955, Schirra applied his drafting and engineering skills to the Bettis Atomic Power Laboratory, producer of the first nuclear-powered submarine. In 1962, then 25-year-old Schirra began selling advertising for the Pittsburgh Yellow Pages, starting a 55-year career in publishing. Working mostly for
Following his retirement from Penn-Well, he started his own publication in 2003. He later joined GIE Media as a regional director, working for longtime friend and then-group publisher Joe DiFranco, representing GIE industrial magazines throughout the West. GIE Manufacturing Group Publisher Mike DiFranco, Joe’s son, said of Schirra, “He will be greatly missed as he was not only a valuable member of our team but also a longtime friend of my dad’s and someone I looked up to for years."
Jack is survived by his wife of 60 years, Ellie Schirra, two children, and six grandchildren.
Fiat Chrysler Automobiles (FCA) CEO Sergio Marchionne died in late July, days after the company replaced him as its chief due to complications following surgery.
“I believe that the best way to honor his memory is to build on the legacy he left us, continuing to develop the human values of responsibility and openness of which he was the most ardent champion,” FCA Chairman John Elkann said.Marchionne had planned to retire next year, but the sudden departure of the executive who shepherded massive restructuring of Fiat, merging it with Chrysler in 2009, will be a loss. Mike Manley, a longtime FCA executive who has seen Chrysler through two ownership changes (from Daimler Chrysler to Cerberus Capital Management-owned Chrysler LLC to Fiat Chrysler) has taken over as interim CEO. Manley led FCA’s Jeep and Ram truck businesses and has been credited with the successful product revivals of both brands.
Marchionne had an almost immediate impact on Fiat after joining in 2004. The Italian automaker was struggling in Europe against better-financed competitors. An attempted merger with General Motors failed when the Detroit-based automaker decided it didn’t want most of Fiat’s assets. Marchionne won a $2 billion settlement from GM for breaking the deal and plowed those funds into new product development – eventually creating a revived Fiat 500 subcompact car.
In 2009, during the Great Recession, GM and Chrysler filed for U.S. government-back bankruptcies. GM remained independent, but members of President Barack Obama’s administration did not think Chrysler had the financial or technical resources to restructure itself, so merging with Fiat became a condition of the federal bailout.
Marchionne didn’t offer any cash, only vehicle designs, technical support, and promises to invest in U.S. production. In 2014, Marchionne took FCA public, and the following year, he held a $10 billion initial public stock offering for Ferrari, separating it from FCA.
Ford Motor Co. Executive Chairman Bill Ford says, “Sergio Marchionne was one of the most respected leaders in the industry whose creativity and bold determination helped to restore Chrysler… His extraordinary leadership, candor, and passion for the industry will be missed.”
United Auto Workers President Gary Jones says, “During the industry’s dark days of the recession, Chrysler, Dodge, Jeep, and Ram were at a perilous point… When history looks back at his legacy, despite bumps and bruises along the way, in the end, the sun wasn’t
The 2SP-2500H lathe combines two spindles on one machine for increased throughput of mass-produced parts. At IMTS 2018 it will demonstrate cutting an automotive bearing.
A standard, high-speed overhead gantry loader enables long, unattended production runs. A modified turret orientation allows easier access to tools, reducing workpiece transport and changeover times to slash cycle times up to 17%.
Okuma America Corp.
IMTS 2018 Booth #338500
Large through-hole sealed chuck
The sealed BP series chuck with large through-hole combines the flexibility of a standard open center power chuck with the long life and precision of sealed chucks, making it suitable for bar and bar stock clamping as well as shaft clamping.
Available in three sizes, the BP is sealed from outside contaminants to maintain constant grip force for repeatability and consistency. Non-sealed chucks can lose more than 50% of the grip force if not maintained properly.
IMTS 2018 Booth #431700
Rotary axis calibration software
CARTO 3.0 software for the XR20-W rotary axis calibrator allows users to quickly capture and analyze machine performance data from rotary axes. The XM-60 multi-axis calibrator can be used with the XR20-W rotary axis calibrator, providing a single software solution for multiple laser-calibration products.
Combining the capabilities of the XR20-W, XM-60, and CARTO 3.0 reduces calibration time for a 5-axis machine tool from several days to within half a day.
It analyzes multiple error types during different time frames, building a comprehensive overview of a machine’s performance. CARTO 3.0 automatically stores complete datasets for each machine tool within a single database. By independently comparing the errors associated with each axis, users can plan preventative maintenance schedules.
IMTS 2018 Booth #135509