Microbots in Manufacturing - Electronics Manufacturing

Wong-Foy’s robotic workers have already proved capable of building towers 30 centimeters long from carbon rods, and other platforms able to support a kilogram of weight. The robots can work with glass, metal, wood, and electronic components.

http://www.technologyreview.com/news/526601/microrobots-working-together-build-with-metal-glass-and-electronics/

Machine Tools for High Performance Machining - Norberto Lopez de Lacalle, Aitzol Lamikiz Mentxaka - Book Information

Machine tools are the main production factor for many industrial applications in many important sectors. Recent developments in new motion devices and numerical control have lead to considerable technological improvements in machine tools. The use of five-axis machining centers has also spread, resulting in reductions in set-up and lead times. As a consequence, feed rates, cutting speed and chip section increased, whilst accuracy and precision have improved as well. Additionally, new cutting tools have been developed, combining tough substrates, optimal geometries and wear resistant coatings. “Machine Tools for High Performance Machining” describes in depth several aspects of machine structures, machine elements and control, and application. The basics, models and functions of each aspect are explained by experts from both academia and industry. Postgraduates, researchers and end users will all find this book an essential reference.

Springer 2008

http://books.google.co.in/books?id=ORIsgY57mP8C

Adoption of High Speed Machining by TRW Automotive Canada

TRW Automotive Canada replaced EDM process with High Speed Machining in Die machining.

This change has certainly paid off for the company. It has seen dramatic increases in productivity.  The new process has halved the toolroom’s overall process time for die production. Moreover, it has trimmed the number of steps needed to manufacture tooling from nine to only six and significantly boosted labor efficiency.Compared to the old method, the company was  to produce more dies today with considerably fewer people.

2003 article

http://news.thomasnet.com/IMT/2003/10/08/auto_parts_make/

High Speed Machining

Now machining of aluminium can be done at cutting speeds of 3000 mt/min.

About High Speed Machining
http://www.cnccookbook.com/CCCNCMillFeedsSpeedsHighSpeedMachining.htm
Sandvik says spindle speed above 18,000 rpm is HSM


2010
Direct volumetric HSM of solid models
http://www.cnc-arena.com/de/virtualgibbs/blog/new-high-speed-machining-hsm-for-direct-volumetric-machining-of-solid-models--90.html

Comparing EDM with HSM 2001
http://www.interempresas.net/Plastics/Articles/15015-EDM-with-high-speed-machining.html

History of HSM - 1999
http://www.unimep.br/phpg/editora/revistaspdf/rct13art01.pdf

Applications

Aerospace components
http://www.spm-precisionmachining.com/high-speed-machining-complex-shapes-general-aviation.html




Economics

2013
The Real-World Economics Of High-Performance Drilling
http://www.mmsonline.com/articles/the-real-world-economics-of-high-performance-drilling

Economics of HSM - 2010 talk
http://www.blogtalkradio.com/highspeedmachining/2010/07/12/the-economics-of-high-speed-machining



High Speed Machines

Siemens Solutions
http://www.industry.usa.siemens.com/drives/us/en/cnc-for-machine-tool-solutions/cnc-applications/hs-machining-applications/pages/cnc-high-speed-machining.aspx

One measure of HSM is w/rpm less than 3.5W/rpm is HSM
Matrix 1000-1300 machine has 40 kW and 28,000 rpm   40,000/28,000  = HSM.
http://www.breton.it/machinetool/en/product/All/5-axis_high-speed_machining_centre_MATRIX_1000-1300

Squeeze Casting Process

It is a combination of casting and forging

Squeeze Casting Process: Part One
http://www.keytometals.com/page.aspx?ID=CheckArticle&site=ktn&NM=172


SQueeze Casting - Furture - A Report 2011
http://issinstitute.org.au/wp-content/media/2011/05/ISS-FEL-REPORT-A-IYER-low-res.pdf


Aluminium in Automotive - Casting Processes Manual
http://www.alueurope.eu/wp-content/uploads/2012/01/AAM-Manufacturing-1-Casting-methods.pdf

Forged Crankshaft - Materials and Process

Crankshaft Machining Process - Balu Crankshafts
_______________

_______________

Kobe Steel develops new forging method for built-up crankshafts used in ship engines - 2013
http://www.kobelco.co.jp/english/releases/2013/1188623_13522.html


A steel ingot is heated in an oven to about 2,200 degrees F amd is then placed in a forging die and squeezed into the approximate shape of the desired crank profile. This “squeezing” is performed either by a hammering or pressing process.

http://www.precisionenginetech.com/tech-explained/2009/06/02/forged-crankshaft-tech-part-1/
http://www.precisionenginetech.com/tech-explained/2009/06/02/forged-crankshaft-tech-part-2/

http://www.thyssenkrupp-forginggroup.com/language-gb/produkte/geschmiedete_kurbelwellen.htm

Corus steel for crankshafts
http://www.tatasteeleurope.com/file_source/StaticFiles/Business%20Units/Engineering%20steels/Automotive%20Components.pdf

Handbook of Manufacturing Engineering - Crowson and Walker - 1996 - Book Information

Publisher CRC Press

Google Book Link with Preview Facility
http://books.google.co.in/books?id=d9cCLVrWEVYC


2006 Edition

http://www.crcpress.com/product/isbn/9780824723415


Contents

Table of Contents
Volume I: Product Design and Factory Development
Product Development; Jack M. Walker and Richard D. Crowson, with Geoffrey Boothroyd
Product Design; Jack M. Walker and Richard D. Crowson
The Deductive Machine Troubleshooting Process; Richard D. Crowson
Factory Requirements; Vijay S. Sheth and Richard D. Crowson
Factory Design; William L. Walker
Human Elements in the Factory; Jack M. Walker with Timothy L. Murphy, Jeffery W. Vincoli, and Paul R. Riedel
Computer and Controllers; Allen E. Plogstedt with Marc Plogstedt
Index
Volume II: Factory Operations: Planning and Instructional Methods
Practical Cost Estimating for Manufacturing; John P. Tanner
Product Tooling and Equipment; Richard D. Crowson, with Clyde S. Mutter
Computer-Aided Process Planning; Alexander Houtzeel
Work Measurement; Kjell Zandin
Control of Production and Materials; Stephen C. Cimorelli, with Greg Chandler
Control of Quality; Robert L. Lints
Index
Volume III: Parts Fabrication: Principles and Process
Principles of Structural Mechanics; Jack M. Walker
Materials Characteristics of Metals; Jack M. Walker
Conventional Fabrication Processes; Jack M. Walker
Nontraditional Machining Methods; Lawrence J. Rhoades, with V.M. Torbillo
Nonmetals: Plastics; Bruce Wendle
Composite Manufacturing; John F. Maguire with Don Weed and Thomas J. Rose
Finishing; Frank Altmayer with Jack M. Walker and Robert E. Persson
Index
Volume IV: Assembly Processes: Finishing, Packaging, and Automation
Manual Assembly; John P. Tanner and Jack M. Walker
Assembly Automation; Jack M. Walker and Vijay Sheth
Electronics Assembly; Michael Pecht, Denise Burkus Harris, and Shrikar Bhagath
Index