Technical Article - 3M Art of Styling Steel

PURCHASE 18 April 2011

Art Art of Styling Styling Steel Steel

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Conventional

abrasive

construction

TMTrizact

Abrasive construction and

wear out pattern

of STYLING STEEL”. The solutions include a wide range of innovative products like

TM TM TMTrizact , Scotch-Brite & Cubitron .

TMA combination of 3M Trizact & 3M TMScotch-Brite products can generate

industry finishes meeting unique satin, hail line & matt finishes. The products come in the disc, belts & brush form that can be used in a simple and comfortable way by operators and requires lesser polishing skills.

TM3M Trizact abrasives, unlike a conventional abrasive, is an engineered abrasive product, designed to achieve uniform finish giving the edge to stainless steel fabricators. Due to the unique construction of the abrasives, produced by

TMMicro-replication Technology the Trizact abrasives cuts in a similar pattern, provides uniform finish, throughout the life of the product, as can be seen in the picture alongside. By generating uniform scratch pattern, it helps achieve the uniform finishes in subsequent stages.

Stainless steel, a matchless metal in both properties and usage, has

slowly and steadily made an influence in our daily life, be at our home, at our office, at shopping malls, travelling in a metro or even the new bus shelters sprouting up in major metros. In any given day we come across many products that are now using stainless steel, starting from bathroom fittings to office chairs, building interiors to street furniture’s and artifacts. The unique properties of stainless steel have been known and major factors which have influenced its extensive usage are its non rusting properties, no painting & beautiful finishes that can be achieved on it. These unique properties help it get desired prescriptions from many engineers and architects in their designs. Some interesting trends indicate extensive usage of stainless steel in architectural, building, construction and equipments industry replacing conventional choices of wood, mild steel & even plastic in certain cases due to inherent advantage of Stainless Steel.

is the in-factor as it reflects the trend shift from conventional to new choices of finishes that increases the aesthetic appeal to the end customer. Fabricators of Stainless Steel are looking for solutions and systems that can help them to achieve these customer requirements. These finishes look very attractive but achieving UNIFORM and UNIQUE FINISHES is an extremely challenging job for the fabricators of stainless steel.

A typical stainless steel fabrication steps includes cutting, bending, welding, weld grinding & blending, including the corner weld finishing, followed by series of finishing sequence. At every stage of fabrication, stainless steel poses some challenges i.e, preserving & restoring the finish of stainless. Abrasive products are used to not only to generate and repair the, but also provide solutions for the grinding and blending of the weld as well, which not only helps improve the finish, but also help achieving consistent and better output as well.

3M through their abrasive ranges of products have been upgrading metal fabricators to the latest products & techniques through an interactive approach which is know as “Art

“New and trendy Finishes and Style’s”

TMScotch-Brite

Construction TMForms of Scotch-Brite


Machine ToolsINDUSTRY FOCUS

Post the generation of uniform TMscratch pattern by the Trizact ,

TMScotch-Brite product range provide the final finishing to the surface so as to generate the desired finishes. Due to their open construction of Scotch-

TMBrite , finish generation is consistent & prevents any heat build up on the substrate. Simple

TMconstruction of the Scotch-Brite , allows this universal product to be available in many forms, as depicted in the pictures

3M provides a unique and a quick way to finish the corner

TMwelds using the 3M Roloc abrasive products, available in

TMScotch-Brite and coated abrasives. The proper sequence of usage, not only helps blend the weld effectively, it also ensures that the corners and other portions of the base material have similar finish. This helps reduce the rework time and improves the overall productivity.

Over the period of time, abrasive industry has developed many products that help achieve better finishes and improve productivity, apart from other benefits to the fabricators.

Promising the brand value of 3M in developing innovative products that are effective and relevant for the customers, for the first time, 3M has developed revolutionary product that contain a SHAPED ABRASIVES.

The new mineral used in the 3M TMCubitron II abrasive products is made up of

precisely shaped triangles of mineral oriented to direct the cutting points toward the work surface. These self sharpening triangles are designed to fracture as they wear, continuously forming new, super-sharp

points and edges that slice cleanly through the metal like a knife, instead of gouging or plowing. This prevents heat from building up in the work piece – reducing heat-related stress, cracks and discoloration. And, because the abrasive itself stays cooler and sharper, it gives a much better life as compared to conventional ceramic grain products.

TMThe 3M Cubitron II products are shaping the future of abrasive solution for all metal fabrication solutions weather it is grinding or finishing. The products made from this mineral, when used with a proper backing and



Conventional Ceramic Grain

TMPrecise Shaped Grain - Cubitron II

an appropriate tool just excites the user by helping complete his job much faster and increases the comfort level of usage leading to a much lesser fatigue.

3M, with its engineered, practical and ergonomically designed solutions, and pioneering way the Stainless Steel is finished, not only helps provide solutions to achieve new and trendy finishes, but also is making conscious efforts to ensure that latest technology reaches the market and educate the fabricators to make their lives simpler.

To know more about the Art of styling steel and the exciting products for metal fabrication, please log into our website to find out more details www.3m.com/in/abrasives.

Mr. Vijay Krishnan



The machines installed in a plant must have a overall thought about reliability

and energy efficient design. The reduction of mechanical linkages like belts, gear boxes will result into power saving of anything from 20% to 54%. Further the use of motors with efficiency higher by 5 to 10% and power factor improvement will lead to a multiplied effect. Consider the following diagram:

Through the research and many experiments in Europe the discovery of permanent magnet brushless motors in high torque and low RPM has given way to both the above arguments. The brushless motor, like any other motor, is built up on the delivered torque and not on the yielded power.

As a consequence, in any application a low speed of the motor will correspond to a low specific power and a low yield. Nevertheless we must point out that the brushless motor contemplates no minimum speed (it purely depends on the sensor; some applications are available with axle speed of 1 revolution per

year).Consequently, the decision to act on the transmission to allow a high rotating speed of the motor is acceptable only when it is important to minimize the size of the motor (i.e. with electric traction) or to Maximize the yield; on the contrary.

Thus using Torque motors and the Brushless servo motors introduced by Compage Automation systems Pvt. Ltd. You can get rid of many mechanical linkages and

calculate your per hour saving as follows:Saving in Rs pr hour = KW saved per hour x 4.5KW saved = hp x L x 0.746 x 100 - 100Where: hp = Motor nameplate ratingL = Load factor or percentage of full operatingLoadEstd = Standard motor efficiency under actual Load conditions multiplied with the efficiency of belt drive/gear boxEHE = New-efficiency of motor and without gearing arrangement underActual load conditions

PURCHASE 78

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Gearless Drivesand Efficient Motors

Introduction of

for the Machines

Energy

By Mr Anil Aggarwal, MD

Does the failed production volume come

as a surprise to you? Many times you

feel that had your main stream CEO known

about the factory problem in time, the break

down could have been corrected by the

right people in time.

PURCHASE 79April 2011

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ProductionRemote

Monitoring

Production Status Monitoring

How much was produced in last shift? Which product is under production?

Alarm

Can get SMS for type of alarm- (a) Electrical power not present

(b) Motor running at low speed. i.e. roll change time higher than normal.

© Electrical or Mechanical breakdown.

Report Generation

Break down history, shut down time in each shift. Production data of the day/week.

Connectivity

Online monitoring helps in: Supply chain Management & Timely customer deliveries.

Akshay Aggarwal, Director, Compage

Automation Systems Pvt. Ltd. Faridabad

introduces the company’s value added

solution at very low cost.

With the advent of information

technology - the world has changed the way

we bank, record data and register our

complaints on customer care 24X7. SCADA

has been long in our process industry to run

and monitor the production output, speed

achieved etc in whichever format we want.

Food packing industry which is the almost

largest and the most essential industry is still

in the nascent stage of adoption of

automation and online monitoring systems in

our country. For now at many places the

machine speed and average running hours

are the only parameters to calculate the

machine production of the day. But the trend

is changing fast to upgrade and attain the

perfection and accuracy.

To break free from individual’s

dependence on production monitoring,

Compage introduces an SMS service for the

machine owners who would like to receive

the information of the day’s production in

exact number of packages/bags. GSM/GPRS

service is independent to any

communication or internet services being

utilized in the factory infrastructure. The data

is taken to a centralized server where it is

compiled and translates into useful

information for the beneficiary of the

production. This type of topology is the best

method to receive factual data in safe hands.

We can monitor any parameter such as –

day’s production, machine average running,

machine speed, wastage (empty pouches,

boxes), component failure, breakdown time

etc.

Moreover, with the help of GPRS

technology the machine can be connected to

with remotely. Any failure in the machine can

be solved by remote assistance. This makes

the troubleshooting process faster and thus

cheaper. In today’s world of all the complex

technologies it is not possible for the expert

to maintain the machine in the plant.

Whereas a team of people can support multi

locations sitting from one help desk. For now

we see this technology penetrated in the IT

industry for troubleshooting the IBMs and

the DELLs. Fortunately now the need for this

value added service is being felt in the

manufacturing industry also. Compage has

introduced the PLC/CNC controllers of the

machinery with the capability of uplink.

Hence the customers have option to fulfill

their planned production.

[email protected]

PURCHASE 80

Industrial AutomationIndustry Watch

April 2011

Pro-Active Maintenance is a system or a life style of keeping the system healthy

and is actually a Life Extension System which supplants the philosophy of ‘Failurereactive’ with the ‘Failure Pro-Active’ by avoiding the conditions that lead to machinefaults and degradation. The Pro-Active Maintenance technique consists of actionsthat abolish the root cause of the failures, not just symptoms. Pro-Active maintenance is now receiving the recognition as the only means of reducing and saving on the burgeoning maintenance cost, for extending the performance life of systems, conservation of oil and conservation of energy without much expenditure on the system or equipments.

It’s a known fact that over 75% of the breakdowns and the maintenance expenses in any industry is because of hydraulic and lubrication oil system failures which isattributed to excessive contamination level In the system fluid which has a clear cutindication towards the necessity of Pro-Active Maintenance. In fact without properlyunderstanding and adopting the Pro-Active Maintenance Techniques, we can not becompetitive and grow faster.

In absence of Pro-Active Maintenance Technology the normal approach is FailureReactive rather than Pro-Active, and the contamination is not controlled andremoved from the system oil, it becomes contaminated and the looses its properties;resulting the replacement of oil. The disposal of discarded oil damages theenvironment. Also the contaminations enter into the gap/clearance between themoving parts and the parts start scoring, damaging and restricting the movement,resulting malfunctioning, Loss of production, Loss of Energy and frequentbreakdowns.

Many industries carry planned activities of Preventive Maintenance associated withPredictive maintenance. Under Preventive Maintenance the repair/replacement ofparts and components is done when often nothing is broken. This is a scheduledactivity, expecting that the life of part, component or system is over and can give

away any moment. This approach allows the failure of parts and system as a routineand normal, permitting the crisis of failure and maintenance. While under PredictiveMaintenance diagnosing, assessment, investigations and testing are carried out tofind the condition and life span of the parts and components. Lot of money and timeis spent for prediction of the condition and life of the components. Alternatively thePro-Active Maintenance protects the system against the Degradation and Failures;and hence Preventive and Predictive Maintenances are practically not required.

It is easy to understand the Pro-Active Maintenance by putting parallel with our body and health, for the reason that human body is very similar to a Hydraulic/Lubrication oil system. We all know that by simply Morning walk and taking healthy fibrous foods, fruits & vegetables in place Fried, Junk foods and Animal Fats which lead to generation of bad Cholesterol (being Contaminations in the blood); to keep us healthy, extend our life and improve our efficiency & performance. Similarly keeping the system fluid clean and free from contaminations (Dirt, Moisture/water and heat etc. being the main Contaminations in the System Fluid) by adopting the SystematicApproach to Pro-Active Maintenance; to keep our Plant, Machinery and Systemshealthy, extend the life of Hydraulic and Lubrication Systems & Componentsmanifold times and improves the efficiency, performance & Productivity of our Plant,Machinery and Systems and also to conserve the Energy and costly oils.

In view of the above facts, one must choose the Pro-Active approach in place of the Failure Reactive approach. Er. Ashok Kumar Gupta the founder and Chairman of the Crane-Bel Group has taken a challenge of promoting the Pro-Active Technology inIndian Industries through Seminars, Workshops, Presentations and PracticalTraining to achieve the following important and significant results:lConservation of Oil: Resulting up to

90% saving on oil Procurement and

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Pro-ActiveMaintenance


Environmental Protection.lConservation of Energy: Resulting

saving on the Power Bills and also saving the Environment.lMinimising the Breakdowns: No

Breakdown Maintenance and No loss of production.lImprovement in the Efficiency of

Plant, Machinery and Systems.lProtection and Retention of Additives

so that no deterioration of hydraulic and Lubrication oils is there, resulting No degradation of oil.lIncrease in the Operational Life and

Performance of systems and components.lNo undue wear and tear of parts and

components and saving on Maintenance cost.lManifold times increase in the life of

systems including hydraulic pumps etc. Resulting the huge saving in the money spent for procurement of costly hydraulic pumps and systems.lIncreased efficiency of machinery and

systems result in Higher Productivity, Higher Profits, Competitiveness and Growth of business.lMaintaining Clean & Healthy

Environment, Ecological Balance,Protection of Lakes, Rivers & Underground water and subsequently thePlanet Earth.

When it comes to implementation of Pro-Active Maintenance, the Japanese may bethe global leaders. They have clearly taken a ‘Do-it, Don’t-just-talk-about-it’approach. Evidence of this comes from reports by two of the world's largest steelmills, Nippon Steel and Kawasaki Steel, both in Japan:lAfter Nippon Steel implemented the

Pro-Active Maintenance program plantwide, involving contamination control both improved filtration and rigorous fluid cleanliness monitoring, pump replacement frequencies were reduced to one fifth and the cumulative frequency of all failures related to wear and contamination was reduced to one tenth.lLike wise the implementation of Pro-

Active Maintenance Technology in the lubricating systems involving both journal and roller bearings and maintaining the system fluid clean through proper contamination control program, Nippon Steel reported after the three-year period study, that they have successfully achieved a 50 percent reduction in the bearing purchase plant-wide.l International Paper Company reported

Implementation of Pro-Active Maintenance System

nearly a 90 percent reduction in bearing failures in just six months after the implementation of Pro-active Maintenance System and improved filtration and contamination control in their paper mill.l? Likewise, Kawasaki Steel, not to be

outdone, implemented a similar Pro-active Maintenance program and achieved an almost unbelievable 97% reduction in hydraulic component failures.l? The British Hydromechanics Research

Association (BHRA) conduct their own controlled studies for three years and carefully monitored 117 Hydraulic Machines including Injection Moulding, Machine Tools, Material Handling, Mobile, Construction, Marine, Metal Working and Test Stands, to establish the benefits of Pro-Active Contamination Control Maintenance. The results of the study showed a dramatic relationship between fluid contamination levels and service life. Improved system cleanliness achieved extended the time between failures from 10 to 50 times depending on cleanliness.lA study by the Naval Air Development

Centre in Warminster. Pennsylvania performed on aircraft hydraulic pumps showed nearly a 4-fold wear-life extension with a 66 percent implementation of Pro-active Maintenance and improved filtration and a 13-fold wear-life extension with a 93 percent implementation of Pro-active Maintenance and improvement in filtration.l? The benefits associated with the Pro-

Active Maintenance Technology in theDiesel Engine lubrication oils are great. Historically, there have been manymisconceptions regarding the influence of contamination of engine service life.Hence, filters with very poor efficiencies have been, and are still specifiedfrequently for engine oils. However, from a number of important new field andlab studies, we have concluded that lubrication oil contamination is the primarycause of engine wears that begins what is referred to as the chain-reaction tofailure.

For any further questions please contact:Er. Ashok Kumar GuptaChairmanCrane-Bel GroupE-7, Kavi Nagar Industrial Area,Sector-17, Ghaziabad-201002, (NCR), INDIAE-mail: [email protected] , [email protected]


Oil, Lubricants & Gas Special Industry Review

Past and Present Technology Traditional

bevel gear cutting blade inspection

machines have three linear axes for setup.

One of the three axes is used for advancing

the blade towards a mechanically or opto-

electronically functioning measurement

probe. In many cases the blade is inclined

versus the major measurement plane by the

angle of the cutter head slots of the

particular blade type and perpendicular to

the sides of the blade shank. This results in

three linear freedoms of blade movements in

connection with one to five probes and one

inclination (commonly realized with a

tapered block).

Figure 1: Dr. Hermann J. Stadtfeld is Vice

President of Bevel Gear Technology of the

Gleason Works. His team of Research &

Development scientists in Rochester, New

York developed together with Gleason

Metrology Systems in Dayton, Ohio the most

modern CMM measurement for gear cutting

blades, including closed loop corrections.

Gleason is represented in India with Gleason

Works (India) Pvt Ltd. in Bangalore.

The Gleason No. 562, shown in Figure 2

is an example of a manually operated blade

inspection device as described above. The

blades are inclined at the same angle of the

slot inclination in the respective cutter head.

The blade geometry is described in the offset

plane of the cutter head. The offset plane in

face milling cutters is approximately the

normal plane to the cutting velocity (offset

plane ˜ cutting plane). In face hobbing

cutters, the offset plane is designed to be

close to the cutting plane for the majority of

the gear designs considered to be cut with

the particular cutter.

The No. 562 device measures up to 5

points, three on the cutting edge and two on

the clearance side of the blade. With such a

measurement it is possible to determine all

of the following blade features, which are

important to the final part geometry, as well

as the clearance side definition:lClearance AnglelBlade Top Width

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Dr. Hermann J. Stadtfeld, Vice President – Gleason Corporation

Bevel Gear Cutting Tool Inspection and

Closed Loop Corrections

No. 562 Blade inspection device

lPressure AnglelBlade DistancelTOPREM Position (rise) on Cutting

EdgeIt seems that the measurement results of

the No. 562 are highly operator dependent.

An interesting phenomenon that applies to

the No. 562 unit is that the absolute accuracy

of the results is well suited for a correction of

blades in order to establish cutting blades

within the accepted tolerance. However, the

repeatability from blade to blade seems

rather fair, which has its cause to the largest

part in the aforementioned operator

dependency.A complimentary fixture, shown in Figure

3 is used for the comparison from blade to

blade within one set. The so called

comparison checker in Figure 3 uses

mechanical dial indicators with an anvil, that

allows a sideways blade location on its two

datum surfaces. A reference blade is gently

pressed towards the anvil and then shifted

axially onto the blade top location stop. In

this position, the probe tips (linked to the dial

indicators) are adjusted e.g. to top and flank

points on the cutting edge as well as the

clearance side. The probe tips are pointed

and therefore have to be located slightly

behind the cutting edge. Now, the indicators

are set to “zero” with a probe deflection

equivalent to about 2 pointer revolutions on

each indicator. This assures the elimination

of stick-slip and provides an adequate

pressure between indicator stem and linkage

as well as probe tip and blade contacting

point. Even though, the blade comparison

fixture has an obvious dependency on the

way the operator feeds the blades into the

stop position and holds it there, it still is the

most used device for comparing the blades

in a set with the reference blade. Blade

comparison utilizing the device in Figure 3 is

straight forward and fast and delivers a

sufficient accuracy level in order to prepare

blades to be accurately build in a cutter

head.

It is a desirable goal to present a blade to

a measurement sensor on a stiff and

temperature stable structure. The

arrangement should have a minimum of

slides and rotary axes. The lowest possible

motion travel of the machine axes promises

the most accurate and repeatable measuring

results. Also the elimination of operator

influence would result in a high repeatability

and improve the absolute accuracy in terms

of GR&R evaluations. Finally, the speed of a

complete blade measurement is a

substantial factor for the success of a cutting

blade measurement apparatus. An

acceptable measurement time for an

average blade lays in the vicinity of 30

seconds to one minute.

A fast minimum measurement has to be

able to capture three points on the cutting

edge and two points on the clearance edge,

based on a coordinate system which has its

Goals for a Fast and Reliable Blade Measurement

Desired Measurement Features

Blade comparison checker

Blade measurement coordinate system


Gears & Motors Industry Spotlight

orientation from the cutting plane and the

two seating surfaces of the blade shank

(Figure 4). Such a minimum measurement

would correspond closely to the No. 562

apparatus and use the least possible amount

of measuring time. A complete

measurement of all blade features would

require a cutting edge scanning and a

technique to capture the location and shape

of the blade front face as well as the relief

surfaces of cutting and clearance side. In both cases, minimum or complete

measurement, it is most important to relate

all measured points to the correct blade

coordinate system X10-Y10-Z10 as shown in

Figure 5. This coordinate system is used to

define the “tooth forming contour” of the

blade which defines together with the basic

settings the particular bevel gear geometry.

The Y10-Z10-axes are aligned to reflect the

cutting plane, while the Y10-axis is collinear

with the cutter head axis. The plane X10-Z10

is tangent to the top of the blade. The

coordinate origin on the X10-axis lays on the

front wall of the blade shank, which is

towards the cutter head center. The X10-axis

is collinear with the cutting velocity direction,

which is not the direction of the front face

distance. The normal distance from the

extended front blade shank wall to the

theoretical blade point defined by the blade

front face distance determines the location of

the front face (in blade thickness direction);

this is the definition of the front face distance

as shown in Figure 5 [1].

The following list includes all global blade

features (also shown in Figure 6 and Figure 7):lSide Rake Angle (Figure 6)lTop Rake Angle (Figure 6)

Blade Features to be Verified


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Gears & MotorsIndustry Spotlight Gears & MotorsIndustry Spotlight

Blade coordinate system and front face distance

Global blade features [2]

lCutting Edge Hook Angle (Figure 6,

right)lBlade and Slot Inclination Angle

(Figure 6)lSide Relief Angle (Figure 6)lTop Relief Angle (Figure 6)lTop Slope Angle (Figure 7)lTop Width (Blade Point) (Figure 6)

Specific features of the “tooth forming

contour” are shown in Figure 7 and Figure 6:lPressure Angle lClearance AnglelBlade DistancelFront Face Distance (Figure 6)lEdge Radius Pressure Angle SidelEdge Radius Clearance SidelToprem DepthlToprem AnglelBlended Toprem Radius (not shown)lFlankrem DepthlFlankrem Angle

lFlankrem Radius (not shown)lBlade Curvature Radius

A more advanced and automated

Blade Coordinate Measurement with Gleason GBX

measurement was

developed on the

basis of a three-

dimensional coordinate

measurement machine using a

three-dimensional scanning probe.

Figure 8 shows the Gleason GBX, a

coordinate measurement machine,

dedicated to cutting blade measurementThe measurement of the GBX

machine takes place at or behind the

cutting edge, inside of the side relief

surface with the spherical tip of a

measurement probe. The blade front face

is measured along a triangular path,

which establishes the front face surface

as a plane using an approximation

method (Figure 9). The knowledge of the

approximate shape and orientation of the

relief surface angles allows the

calculation of the theoretically correct

path behind the cutting edge (adjusted

nominals). The accuracy of this

[email protected] features of tooth forming contour

Gleason GBX

Measurement principle of front faceand below the blade edge



procedure is significantly above the

measurement results of the No. 562 device.

Beyond that, it is possible to evaluate

additional blade features versus the No. 562,

such as blade curvature radii, Toprem rise,

edge radii and front face distance.Metrology devices, as shown in Figure 1

and 8 are not really suited for a production

measurement (comparison) of complete sets

of blades after the blade grinding and in

order to qualify sets of blades for being

assembled in cutter heads. The duration of a

blade measurement is in the vicinity of the

time it takes to grind a blade which is not

easily acceptable for a production

measurement.Figure 10: Universal GBX blade

holding fixture, RSR® blade left, Pentac®

blade rightThe strength of the Gleason GBX is the

fact, that it represents a CNC controlled,

highly accurate metrology device which is an

integral unit together with the blade

mathematical software (GEMS) and the

control software. The components of the

integral unit work together in a semi real

time mode which allows the different

measurement steps, like the cutting edge

measurement being influenced by the

previously conducted front face scanning.A prismatic V-block fixture with a spring

loaded arm for holding rectangular blades

(Figure 10, left) as well as Pentac® blades

(Figure 10, right) has been developed. The

probe will scan the seating surfaces of the

fixture during a setup/calibration mode. No

blade datum surface scanning is required

during the regular blade measurement cycle.

Studies with the newly developed GBX blade

holding fixture have shown that the achieved

accuracy is high and the repeatability is

excellent. Those attributes are combined

with a rather short measuring time because

of the elimination of individual datum surface

measurements.

In a measurement cycle, the front face is

scanned first along a triangular path (Figure

9). The knowledge of the front face location

and orientation is used by the blade

mathematical software to calculate the

nominal cutting edge function, considering

the actual front face. The knowledge of the

side relief surfaces is used in order to

calculate a scanning path between 0 to 15

?m behind the cutting edge (adjusted

GBX Measurement Cycle and Correction


[email protected]

Gears & MotorsIndustry Spotlight

Universal GBX blade holding fixture, RSR® blade left, Pentac® blade right

Nominal-actual bladecontour and No 562 points

nominals). Next, the cutting edge blade tip

and clearance side of the blade is scanned.In cases of complicated blade contours,

large blade distortions or the requirement of

highest accuracy, a software option allows

the use of the actually measured blade edge

coordinates as “distorted nominals” and

repeat the blade edge scanning. The results

will be more accurate since the probe

deflection is minimized in this mode. The

blade evaluation module receives a

measurement result in the absolute blade

coordinate system and compares this with

the adjusted nominal blade contour behind

the cutting edge. The difference between the

actual and the adjusted nominal contour is

used to compute blade corrections.Figure 11 shows the nominal bade

contour (black line) and the actually

measured blade contour (red line) in one

graphic, together with the No. 562

measurement pin locations. The No. 562 pins

are only for reference or comparison with

older developments. The experience gained

during many measurement studies indicates,

that a real comparison between the No. 562

and the GBX is not very useful because the

significantly higher accuracy of the GBX

leads in cases of small blade deviations to

different, but more correct results. In case of three-face ground blades, the

misslocation of the actual front face results

in a front face distance, side rake and top

rake angle (blade hook angle) correction

output. In case of two-face ground blades,

the cutting edge and clearance side

corrections are calculated such that the

correct tooth slot is cut, considering the

wrong front face location and orientation.

Figure 12 shows the correction output

screen of the GBX-GEMS software.

[1] Stadtfeld, H. J.

Handbook of Bevel and Hypoid Gears -

Calculation, Manufacturing, Optimization

Rochester Institute of Technology, Rochester,

New York, 1993

[2] Stadtfeld, H. J.

The New Freedoms - Three- & Four-Face

Ground Bevel Gear Cutting Blades, Gleason

Company Publication, June 2007

Literature

[email protected]

Blade correction output screen



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PREMIER CNC GEARSHAPING MACHINE,MODEL: PSC-250 WITH ELECTRONIC GUIDE:

Introduction:

In Gear shaping, the gear shaping cutter &

workpiece axes are rotating parallel in

mesh (conjugate generating motion)

according to the number of teeth in both

cutter & the workpiece, while gear shaping

cutter reciprocates on the spindle for the

metal removal action (cutting motion).When cutting helical gear, on gear

shaping machine, an additional spiral motion

is introduced to the gear shaping cutter by

the helical guide. During return stroke (relief

stroke), the gear shaping cutter is removed

away from the workpiece to prevent flank

contact (back-off direction motion)These motions are basic functions of the

gear shaping process. The CNC Gear

Shaping Machine is equipped with radial

motion of Work Table (X-Axis), cutter

generating motion (C-Axis), Work Table

generating motion (E-Axis), stroke

positioning motion of gear shaping cutter (L-

Axis).In case of manufacture of Spur Gears on

Gear Shaping Machines, Spur Hydrostatic or

Spur Mechanical Guides are used and for

manufacture of Helical Gears, Mechanical or

Hydrostatic Helical Guides with required

Leads are used.Changing the mechanical/Hydrostatic

Helical guide in gear shaper cutter spindle

unit takes an enormous amount of time &

has to be carried out without restriction,

particularly when changing between

workpieces with straight, left-hand & right-



hand teeth.To counteract the drawbacks of a

restricted helix angle & of inflexible tooth

trace modifications, the

Mechanical/Hydrostatic helical guide has

been replaced in the design by a Electronic

guide. This is possible due to the latest

development in high-performance torque

motors and by exploiting the maximum

dynamics of modern NC controls. This

electronic helical guide allows back lash free

generating drive of the gear shaping cutter

which can perform all the additional

rotational movements of the cutter. This

feature enormously increases the efficiency

of the Gear Shaping machines. In newly designed gear shaping machine,

the desired helix angle can be entered in the

software dialogue programme on a flexible

basis. This means even a small correction to

the helix angle, resulting from changing

corrections due to heat treatment distortions

are easy to change without the gear shaper

cutter or the helical guide. Any helical gear

with different helix angle & helix direction in

one setting is possible with this innovative

concept which reduces set up time.

The CNC Gear Shaping Machine with

electronic guide, which is adopted for

finishing gears up to 250 mm dia & having 5

module & helix angle upto 45o consists of

the following main components.Machine Bed:The Machine Bed supports the Sub Base

& Table Slide. The machine bed also

incorporates the coolant reservoir. The

machine bed is made of high grade ferrous

casting & is double wall construction rigid in

design to absorb all the cutting forces

without any distortion, during gear shaping

operation.Table Slide:The Table drive indexing is an integrated

part of the table. A separate AC servomotor

is provided for table rotation. The table

rotation & gear shaper cutter rotations are

synchronized for gear generation through

electronic gear box. The table slide is moved

in & out by AC servo motor & preloaded ball

screw for accurate depth & radial feed

control.

Machine Construction:

Upright:Upright is mounted on the sub base

which is mounted on machine bed. Upright

is made of high grade casting & well

proportionately ribbed to enhance the

machine rigidity.

Cutter Head:The cutter head rotation is provided by a

separate AC servo motor. The gear shaping

cutter spindle reciprocates during rotation

through the electronic guide mounted in the

cutter head. A separate motor is provided to

get infinitely variable cutter stroke per

minute.A separately designed back off cam

relives the cutter during every return stroke.

The stroke length required for a particular

face width can be adjusted by the eccentric

mechanism in the crank head. The Gear Shaping cutter head has

been completely redesigned with backlash

free direct drive for the cutter spindle in

order to deliver higher flexibility & operating

ranges than earlier Gear Shaping Machines.

This new technology provides the user

with huge potential for savings:lNo investment in Helical guides required.l? Elimination of lead times needed to

purchase mechanical guides.l? Zero set up timel? Flexible setting of any helix angle upto 45

degree.l? Simple helix angle corrections (e.g. lead

angle errors due to hardening)lReduced machining times through

accelerated return stroke.lUse of direct drive servo spindle motor

for cutter spindle allowing for a nearly

constant cutting speed, this improving tool

life Vs the non constant velocity of eccentric

drives.This newly designed concept of adopting

Electronic Guide on CNC Gear Shaping

Machine was developed by Premier and

after thorough testing of machine, the said

machine was displayed in 15th Indian

Machine Tool Exhibition (IMTEX) 2011. FIE

Foundation authorities visited our stall and

understood the unique feature of

development of Electronic Guide on Gear

Shaping Machine and Premier won FIE

Foundation Award for this new

development.

Benefits to User:


[email protected]

Gears & MotorsIndustry Spotlight

Approximately a million paid

visitors—and many a passerby—visit

the Hoover Dam eachyear to take photos or tour the area to learn

more about the dam’s operation andappreciate its incredible engineering. Its

primary purpose, however, is to provide

flood control on the lower Colorado River as

well as deliver water and power to residents

and businesses in the region.“The reservoir impounded by the

dam, Lake Mead, stores ColoradoRiver water for delivery to users insouthern Nevada, California,Arizona and northern Mexico,” saidBob Walsh, Regional ExternalAffairs Officer, Bureau ofReclamation, Lower Colorado

Region. “As this water is releasedfrom the Hoover Dam, hydroelectricpower is generated; this power isdistributed to southern Nevada,southern California and Arizona.”

The Bureau of Reclamationcompleted the Hoover Dam in 1935—with

power generation beginning the followingyear—and now operates and maintains it.

This includes coordinating water and poweroperations, as well as managing water

releases to protect two endangered fish

species in Lake Mohave, immediately

downstream of Hoover Dam.With the dam operating around-the-clock,

it is important to continuously monitor manypieces of equipment. This had proven

challenging to perform cost-effectively with

the previously installed

video projection system.That video system

utilized 12 projectors,

each with a 42-day

defined bulb life. Thesebulbs needed to be

replaced frequently, at a

cost of several hundred

dollars each—andif a bulb failed while in a

projector, the projector

was damaged. Plus, the

video systemdid not focus clearly

when translated onto the

screens in the dam’s

control room, making

PURCHASE 82

Tech

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April 2011

Hoover Dam OperatorsUsingMonitor Processes

Red Lion PAX MetersDynamic Mapboard with

them somewhat difficult to read.To address this issue, Reclamation

decided to replace the video monitoring

system. Following a request for bids, a

contract for a dynamic mapboard was

awarded to MonitorMapboard Systems based in Dayton,

Ohio. This mapboard provides a dynamicrepresentation of the system in use—from

power generation to water levels—in realtime, allowing operators in the control room

to view system status information at aglance. Combined with more than 75 PAX

meters by Red Lion, it delivers a reliablemonitoring solution in a cost-effective,

simple-to-use design.The mapboard displays all standard

operating indications—megawatts of power

beingproduced by each unit, as well as VARS and

voltage. It shows whether a unit’s breakeris open or closed, how much power is being

requested from the system and how muchpower is produced. This information is

displayed for the 17 commercial generators,

as well as for the two power plant station

service units and the station service

distributional breakers and switchgear.Gene Hosler, Production Operations

Manager for Monitor Mapboard Systems,said the mapboard has delivereddependable results with little maintenanceneeded.

“Managing the Hoover Dam is an

amazing job, with operations running 24

hours a day—and since video has a shorteroperational life, it was costing Reclamationthousands of dollars a year to maintain andreplace equipment,” Hosler said. “Amapboard gives you more than what youcan observe on a video screen. It providescrisp images, LED indicators, and real-timestatus readouts of all collected informationusing Red Lion’s easy-to-read PAX meterswith a half-inch digital display.”

The integrated PAX meters connect

simply to SCADA systems and use Rs232communications to deliver real-time

readouts of all collected system data. Thecombination of the dynamic mapboard and

PAX meters has offered operators at theHoover Dam “system at a glance”

information with less upkeep and

replacements, facilitating simple monitoring

and allowing them to easily perform

preventative maintenance on the mapboard

when required.“The mapboard’s enhanced readability

assists the operators in monitoring allequipment,” said Vince Blaeser, Vice

President of Sales and Marketing for MonitorMapboard Systems. “The reliability and low

maintenance cost, combined with thegraphics, dynamic indicators and readouts

supplied by Red Lion’s PAX meters, makesthis dynamic mapboard an awesome

operational tool.”To learn more about the Hoover Dam and

the Bureau of Reclamation, visitwww.usbr.gov/lc/hooverdam. For more

information on Monitor Mapboard Systems,

LLC, visit www.mapboard.com.Red Lion Controls, Inc. is a leading

manufacturer of industrial control solutionsworldwide. Products include digital/analog

control, monitoring and panel meters, PIDcontrol, human-machine interface panels,

and signal conditioning. For more

information,or to find the Red Lion distributor nearest

you, go to www.redlion.net or contact: RedLion Controls, Inc., 20 Willow Springs Circle,

York, PA 17406; (717) 767-6511.


Industrial AutomationIndustry Watch



Process visibility:

While most modern equipment on the

factory floor offers some degree of

performance and productivity monitoring,

tying equipment and devices together for

meaningful and immediate expressions of

productivity often remains a hurdle.

However, overcoming this challenge pays

big dividends. In a landmark presentation of

Overall Equipment Effectiveness (OEE),

Rohm and Haas Corporation found that

OEE is ten times more cost-effective than

adding capital capacity.1 With findings this

dramatic, deploying broad performance

monitoring measures are easy to justify.

OEE is a vital metric that combines three

key performance indicators (KPI) into a

single calculation, measured as a percentage

against an ideal combination of machine

uptime, plus the

quantity and of the

products being

produced. The

percentages of each

of these three KPI are

multiplied together to

provide the OEE rate

quality

(OEE = % Availability

X % Performance X %

Quality).

If the goal is

performance

improvement, OEE is

a concise indicator

that focuses on how

effectively a machine

or process is running at a given moment. An

established benchmark provides a baseline

for operators based upon what’s actually

being produced, tying actual plant floor

realities together with the losses that create

equipment- and process-related wastes.

While it’s unlikely that any plant can operate

at 100% OEE, many manufacturers set a

benchmark of somewhere around 85% OEE

as a goal.

The true goal of measuring OEE is to

improve the productivity of your equipment,

and since operators are the ones most

directly responsible in this effort, they

should have front-row access to OEE data.

OEE should be looked at as a plant floor

Two essential requirements for successful OEE

Tech

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Scaling real-time OEE from devices to the process levelDavid Harris, Red LionVice-President

improvement tool, and by definition should

be clearly and quickly conveyed to

operators. This relationship with the data not

only helps operators develop the best “feel”

for their machines, but also focuses their

attention on maintaining productivity levels.

In turn, shift or line supervisors receive

better, more timely operator feedback

regarding the equipment status—empirical

data on which to base actions and decisions.

For OEE to be a truly effective tool for

analyzing and improving operations, two

conditions must exist:

The first is visual accessibility. OEE

statistics must be viewable to the plant floor

so that operators in control of the process or

machine may respond immediately to the

displayed calculations. Large overhead plant

floor marquees are often used to display

OEE metrics on the whole, while smaller

display boards might service an individual

work cell or machine.

The second and most critical aspect for

successful OEE is that data must be

displayed in real time. If performance suffers

during a shift but operators are not informed

of this shortfall until an end-of-week

spreadsheet is generated, reconstructing the

cause of the reduction is almost impossible

if problematic conditions have already

passed or the data is incomplete. By

monitoring live performance, an operator

can immediately assess declining OEE rates

and remedy problems, whether they are

mechanical or materials related.

One of the best ways to acquire data for

OEE is to let the production equipment

measure itself, as most

machines today have the intelligence to

measure one or more of the three OEE

parameters. For instance, once

a machine is programmed for an optimized

production rate, most equipment can

monitor throughput against its

designed specifications. Many systems can

also track first pass yield against the total

units started, and as

PLCs are time-based, they can easily track

the amount of operational time.

Most plants use devices made by various

manufacturers, and manufacturers use many

The challenge of consolidating data and

integrating devices

different communication

protocols in order to support legacy

products, accommodate new technologies

or restrict customers to their own

proprietary networks. For example, a

packaging machine may only be

programmed to understand how

many parts are produced in comparison to

its engineered throughput rate, while a piece

of inspection equipment would only know

how many good and rejected parts were

produced. Data from both must be

communicated and consolidated in order to

calculate OEE.

Today, data management devices can

provide seamless communications and

protocol conversion to collect

data from an array of disparate equipment

and PLCs. When used as a host device to

drive plant floor marquees, a data

management device can be a very effective

and versatile solution for delivering real-time

OEE output to a desired visual interface.

In addition to data management

solutions, a number of human-machine

interface (HMI) panels also facilitate

communication of data for OEE while

providing a control interface for operators to

monitor and control

processes. Pairing protocol conversion with

data collection and math capabilities, as well

as providing a direct path from the HMI or

operator interface (OI) directly to the plant

floor display, ensures operators can monitor

OEE values in real time.

Because they are integrated into the

process, advanced data management and

HMI devices bypass the need for

a PC, long wire runs or offline processing.

They can also provide advantages including

the integrated math

function capability required to pre-analyze

hard point data, as well as the capabilities to

manage multi-vendor

equipment (including PLCs, drives, PCs and

PID controllers) and perform data logging.

Some solutions offer the ability to network-

and Web-enable plant floor machinery,

including legacy serial devices. These

capabilities vastly simplify the acquisition

and movement of data to facilitate scalable

OEE.


Industrial Automation Industry Watch

Technical Article - 3M Art of Styling Steel

Technology

Transcript of Technical Article - 3M Art of Styling Steel