10:45 am – 11:20 am
Optimization of Manufacturing Processes Using MTConnect
Colin Tilzey, Ceng, Kennametal, Inc.
Shop floor systems and devices deliver value in two forms.The first is from the design intent; its contribution toward producing a part.The second and less common form of value is delivered when these systems and devices communicate with each other, generating data that is of greater value than the sum of the individual pieces. Big data analytics can unlock this second type of value and expose optimization opportunities.
In this session, attendees learn how Kennametal implemented MTConnect throughout its global steel manufacturing facilities to improve production efficiency, decrease cycle times and standardize manufacturing processes. Real world data will compare the process plan with what actually happens on the shop floor and illustrate how to automate the collection and digitization of tribal knowledge. Attendees gain insight into the value of big data, predictive analytics, and digital communities of knowledge in closing the machining talent gap.
- Case Study: Implementing MTConnect to increase productivity
- Making shop floor systems and devices deliver value
- How to automate the collection and digitization of tribal knowledge
- Insight into digital communities that close the machining talent gap
Bio: Colin is an accomplished business leader in developing high performance global teams across varied disciplines resulting in the transformation of business strategies and results.
He has over twenty years of multidisciplinary experience with proven unique combination of expertise in innovation management, entrepreneurship, customer insights, marketing, program & technology management and strategic planning.
Colin has international experience living and working on two continents with increasingly complex levels of global multi-functional responsibilities, delivering proven top lien growth models in B2B and Industrial products.
1:30 pm – 2:05 pm
Additive Manufacturing Using Metals – Technology Choices and Applications
Jeffrey Crandall, CCAT Connecticut Center for Advanced Technology
The Additive Manufacturing industry is growing rapidly as more people become aware of the strengths of the various additive technologies and how to apply them. Additive manufacturing (or 3D printing) using metals is an exciting subset of the total spectrum of additive technologies that exist today. The concept of making fully solid, functional metal parts in a wide range of materials makes this an incredible tool that allows you to produce finished or near net shaped parts. Building new parts is certainly the most widely used function of additive manufacturing, but it is only one of the many capabilities of the technology.
So, what can you do with metal additive manufacturing? In very general terms, additive manufacturing allows you to:
- build new parts;
- do effective rapid prototyping;
- make repairs or add material to something that already exists; and
- conduct materials research and development.
- Basic understanding of the main metal additive manufacturing technologies
- Decision matrix for determining the best technology and equipment choices
- Examples of case studies using metal additive technology
Bio: Jeff is currently the Metals Additive Manufacturing Applications Engineer for Connecticut Center for Advanced Technology (CCAT) in East Hartford, CT. He is directly responsible for projects involving metals additive manufacturing, is the project coordinator for other laser materials processing projects and is currently working on several federal government additive programs and additive technology development and feasibility projects for private manufacturing companies. The projects reflect the diversity of metals additive manufacturing including rapid prototyping and new part builds, critical component repair and modification, and materials research and development.
2:15 pm – 2:50 pm
Using High Pressure Coolant to Reduce Downtime and Increase Throughput
Kermit Wright & Jill Taylor, MP Systems Pressure Coolant Systems & Accessories
- Define high pressure coolant.
- Define vapor barrier.
- Explain problems associated with not using high pressure coolant
- Heat, Friction, Tool Life
- Explain benefits of using HPC
- Cooling, Lubrication, Productivity
- Describe through visuals and video examples of better productivity with HPC
- Describe problems associated with machine tool plumbing and how we size our system.
- Application – when to use a chiller
- Q&A can be geared towards application or the design of MP Systems
- How to improve tool life
- How to make more parts faster with less downtime
- Review of machine plumbing
- Debunking the myths associated with HPC (High Pressure Coolant)
Bio: Kermit Wright oversees national sales for MP Systems, a manufacturer of high pressure coolant systems. Kermit began his career in manufacturing in 1984 as a tooling engineer for a New England- based carbide company. He moved into sales and product management in the 1990’s. Kermit has extensive technical and application knowledge about high pressure coolant systems. He is a frequent speaker at industry events; a member of the NTMA, and is an active solutions provider with Okuma Partners in THINC.
Bio: Jill Taylor leads the marketing for MP Systems, and works with MP Engineering to launch new products to benefit machine tool customers. She supports the North America machine tool distributors and their customers in high pressure coolant education and sales. Jill develops and delivers training seminars to educate customers and distributors on real-world application of high pressure coolant.
3:00 pm – 3:35 pm
Using Simulation Software to Achieve True “Lights-Out” Machining
Jeff Ulrich CMFgE, CGTech
When most people talk about “Lights-Out” machining, they are often referring to automation. By adding a multi-pallet system to the machining environment, manufacturers can run proven programs on an unattended machine long after the human operators have gone for the day. Benefits of running lights-out are obvious: manufacturers can increase efficiency, productivity, and competitiveness with minimal impact on labor costs. Additionally, machine tools use a lot of electricity. Some power companies offer lower rates for off-peak power usage, offering another financial benefit of automation.
But what about NC programs that have not been run on the machine before? Only after the part has been proven can the machine actually run lights-out, which typically involves an operator tending to the CNC machine during the prove-out process. Even if a problem is not discovered, machine time has been wasted. There is a better way. By proving-out all NC programs off-line, the operator does not even need to be aware of which NC programs have been run previously on the machine. Running a first-time part lights-out requires 100% confidence in the software that verifies the NC program offline, and some manufactures are skeptical in believing this is truly possible.
- Automation to increase efficiency without adding to labor costs
- Efficiency gains that automation offers
- Taking the prove-out process off-line using simulation and software to improve manufactures confidence
3:45 pm – 4:20 pm
Additive Technology: Metal Injection Molding
Todd Jensen & Jim Bever, Smith Metal Products
The advantages of utilizing Powdered Metal and/or Ceramic Injection Molding (MIM & CIM) to produce precision components, over machining, casting, and other powdered metal technologies. It is capable of providing tolerances of +/-.5% of dimensions as tight as +/-.011” on features of .200” or less. This is an excellent fit for companies in need of 10,000 or more components annually of medium to high complexity or that require high strength or chemical resistance. It also provides the opportunity to combine multiple parts into a single piece to reduce assembly count and labor. There are also opportunities to “core out” the components to reduce the part weights and cost. Basic “Design for Manufacturability” guidelines to consider when designing a part for MIM.
- How the powdered injection molding (PIM, MIM, & CIM) technology works
- The benefits that these may offer
- Which types of applications are best suited for metal/ceramic injection molding
- Basics for how to design components for metal/ceramic injection molding
Bio: Todd Jensen – 20 years in powered metal industry, 15 years in Engineering, Program Management, Product and Process Development, Manufacturing, and Plant Management in Metal Injection Molding sector.
Bio: Jim Bever – 34 years experience in Molding Industries, specific experiences in Molding, Inspection/Quality, Product Engineering, Program Management, Sales, and Marketing of Plastic, Rubber, Silicone, Machined, and Metal Injection Molded Metal Components and Assemblies.
4:30 pm – 5:00 pm
Brew & View Presentation
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Unique, Repeatable Clamping System for Large Parts
Darrell Johnson, Product Manager Milling Consumables, Single Source Technologies
A presentation of a unique work holding system that is engineered for each application to increase productivity, accuracy, and repeatability. The key advantage of this system is reducing set up time from hours to minutes while increasing rigidity, part accessibility and security.