Tag : mechanical engineering

Milling cutter work with splinters flying off, monochrome versio

High-Speed Machining: What Is It and How Does it Help?

According to the US mechanical engineering schools, high-speed machining can be defined in two different ways. However, the most commonly used definition is based on the relative surface speed between the workplace and the CNC manufacturing tool. This definition is primarily a thermo limit since most of the CNC mechanisms depend on temperature. According to surface speed definition, high-speed CNC machining is favored by metal cutting researchers and toolmakers from US manufacturing department.

Researchers and tool makers define high-speed machining by indicating the range of a transitional region which is yellow, conventional machining region which is green and high-speed region which is red and depend on surface speed. The surface speed is in meters per minute, and its equivalent to v=πdn where n is spindle speed and d is the diameter of the milling work piece.

The second definition which is widely used by mechanical engineering schools is the DN number that is centered on the rotation capability of the loaded spindle bearings. D is the diameter in mm of the larger bearing bore, and N is the spindle speed in rpm.

High-Speed Machining Principles

High-speed machining operates on several principles. Keep in mind that not every type of machining will benefit from HSM, but most applications could from HMS with implementation of CNC automation and assumptions. Below are high-speed machine principles.

CNC machine
Tool holders
Cutting tools
CAD system
CAM system

How Does High-Speed Machining Help?

Every machining shop desires high productivity and improved machining process. Machinists make complicated metal parts, shapes and need to run complicated programs to help them provide good services to their clients. Machinists use high-speed machining to make their work faster and easier. Here are some benefits of using high-speed machining.

Reduced Energy or Heat Loss

High-speed machining helps in increasing the rate and speed of material cutting which reduces excessive heat loss and transfer. When you reduce heat transfer, turnaround time and transmission are kept low which lowers energy consumption. Traditionally, time was provided for metals to cool down and form a hardened metal but in this case, the coolant is used in metal cooling which reduces heat loss and increases the speed of production since less time is spent on cooling.

Increased Productivity Rate

High-speed machining has driven manufacturers and machining shops to higher rates of productivity. Faster productivity rates mean the machines can produce more parts in a short period. However, the functionality of high-speed machining is often affected by the ability of the cutting materials themselves. Manufacturing in USA prefer the use of faster cutters since their productivity is high.

Even if all cutters are faster, the results produced by cutters of different materials are unique. For instance, diamond, ceramics, HSS, tungsten carbide and cermets cutters all provide different outputs. High-speed cutting tools can take a lot of time and may even lead to stress. The main problem that is associated with high-speed cutting tools is that they don’t manage heat effectively and require a coolant.

Krupp: Machine Shop IV. Date: 1911

History of Machine Shops

A machine shop is a specialized room, building, or big company where CNC machining and other types of machining are done. The activities that take place in such a shop involve experts/machinists using various machining tools and cutting tools to come up with different parts. People tend to think that a machine shop must be a massive building with complex equipment but this isn’t true.

A typical machine shop can either be a portion of a large factory or simply a small store such as a job shop. The various parts manufactured are usually sold to multiple lines in the US manufacturing industry, car industry, and even the aviation industry. The production of these critical parts typically involves cutting, shaping of the parts, drilling, and finishing.

History of Machine Shops

The history of machine shops can be traced back to the 19th century when the first mechanical engineering schools started to come up in the U.S. The first machine shop appeared around this time. It is also during this time that the industrial revolution was at its peak and there was a high demand for various parts. Before this era, critical parts and tools were mainly produced in local workshops in villages and cities. However, the production was limited to small-scale, and the parts were primarily sold to local CNC manufacturing artisans.

Production of parts in large factories took place on site where every part was produced individually. As time passed by, the plants started to come up with their workshops to deal with the production of the required parts. During those days, the textile was still the dominant raw material.

After the 19th Century

Further developments in mechanical engineering CNC machining took place in Germany, Scotland, and England after the 19th century which led to the development of cheaper and simple techniques for the massive production of steel. This development triggered the rise of second industrial revolution which played a significant role in the electrification of factories, mass production of parts, and also an uprise of more US manufacturing schools.

Machine shops gained popularity around this time as they were commonly referred to locations where complicated mechanical parts are cut to the required size and carefully put together to form complete mechanical units.

However, the rise of the machine shops came along with its fair share of both manufacturing and organizational problems. This triggered the emergence of various theories and publications trying to solve the problems.

One of the earliest publications in the field of mechanical engineering which gained a lot of popularity was a series of books titled; “Modern machines_ Shop economics” that was authored by Horace Lucian.

20th Century

The beginning of 20th century saw an increase in the number of publications relating to machine shops with various authors including Frederick Winslow Taylor and Howard Monroe More funds were directed towards research and invention which led to the invention of the electric motors in late 20th century.

The electric motors took over power supply of the common machine tools from the conventional mechanical belt. This era also ushered in CNC automation and numeric control in the field of manufacturing in the USA. The two aspects production design and primary production became integrated.

3d illustration of factory over USA flag background with steel bars and yellow arrow down

Popular Products Manufactured in the U.S.

Have you ever bought something because it read the label, “Made in the U.S.A.”? We’ve all been there. We all like American-made products and we value what’s constructed in our own country. Although the number is increasing, not a lot of products are made in the U.S. In fact, about 50% of the products we use are made in China. However, America is trying to even the playing field. With our increased knowledge of mechanical engineering and the US manufacturing schools available, more and more products involve manufacturing in the USA.

Furthermore, a new technology has advanced over the years — CNC machining and manufacturing. CNC manufacturing is a manufacturing process where a pre-programmed computer controls tools and machines. This is done through CNC automation, where computers and machines do all the work for us. This has created a mechanical engineering breakthrough leading to more excitement surrounding the United States manufacturing industry. But since China still makes over half of the products we use, what’s manufactured in the United States? See below for a list of the most popular products made on U.S. soil:

-Primary Metal
-Machinery
-Transportation Equipment
-Weber Grills
-Tesla Roadsters
-Harley Davidson Motorcycles
-Whirlpool Appliances
-KitchenAid Mixers
-GE Hot Water Heaters
-Stihl Gas-Powered Equipment

From machinery to kitchen mixers, the United States still makes some of the more important products that we use in our everyday lives. And with CNC manufacturing leading the way in mechanical engineering, machines are working smarter and more effectively. In addition, education for the mechanical industry is getting better year after year. Mechanical engineering schools are popping up everywhere and more people are realizing the importance of these skills.

Increased Productivity and Lower Costs Lead to US Manufacturing

With more and more products being manufactured in the United States, there has to be a reason why our production efforts have increased. One of them is our productivity. American workers have been proven to be more productive in the workplace. They are paid higher than employees are in other countries and the work environments are more enjoyable. With child-labor issues happening in China and other countries, more people choose U.S. made products for that reason alone. Another cause for increased U.S. manufacturing is shipping costs. Every day, it is getting more expensive to export materials from one country to the next. In order to save on costs and produce high-quality, dependable products, many manufacturing companies are choosing the United States are their hub.

The U.S. Prefers American-Made Products

The average American will choose an American-made product over one that’s produced in another country. Although China leads the pack for most of the products we use, that number is starting to decrease. One reason for the change is CNC manufacturing. As our technology gets more advanced, CNC automation and machining is growing in popularity. From production benefits to saving on costs, CNC manufacturing is here to stay.

If you’re looking for a professional, modern manufacturing company you can depend on, Tag Team Manufacturing is the company for you. We’ve been in business since 1987 and we specialize in machining CNC precision components for OEM’s in a wide range of different industries. We work with engineers to design effective materials that work properly and that last for many years to come. If you would like to learn more about Tag Team Manufacturing, don’t hesitate to give us a call today!

ISO or The International Organization for Standardization concept presented by businessman touching on virtual screen - image element furnished by NASA.

What is ISO and What are the Steps to Becoming ISO Certified?

ISO originated from the conglomeration of two different organizations namely United Nations Standard Coordinating Committee (UNSCC) and International Federation of the National Standardizing Associations (IFNSA) in 1946 when over 25 nations convened at the Institute of Civil Engineers in central London.

ISO (International Organization for Standardization) creates all the essential documents that provide specific guidelines, requirements, specifications, or characteristics that are used to ensure that materials, processes, products, and services are highly fit for their purpose. The body has published over 22025 International standards which can be purchased from the ISO store. The standards cover all sectors including manufacturing in USA, mechanical engineering schools, and even CNC automation.

The ISO standards bring real and more measurable benefits in various sectors since the standards underpin the technology most industries rely on and ensures quality is adhered to in every stage of CNC machining and CNC manufacturing. Some of the benefits of being ISO certified include improved efficiency and cost savings, widened market potential, higher level of client service which leads to higher customer satisfaction, and compliance with procurement tenders.

What Are the Steps to Becoming ISO Certified?

Obtaining an ISO certification for US manufacturing schools or any other industry player requires a significant investment of time, effort, and money. This is a process that will take some time to complete. Below are the essential steps to be followed while seeking ISO certification.

Select a Credible Certification Body

The journey towards being ISO certified starts with identifying a qualified certification body to help you in the process. Since most of the ISO standards for mechanical engineering are based on a three-year cycle, most of the certification parties will expect the company to sign up a minimum three-year agreement to be considered. Some of the certification bodies will insist on visiting your company several times a year to assess the progress, but a single visit is usually enough to establish the milestones achieved towards the certification.

Develop a Management System

Developing a Management System is an essential part of achieving ISO certification standards. There is the Quality Management System for ISO 9001 standard and the Environmental Management System for the ISO 14001 standard. The core components of the quality management system include analysis and improvement, provision of resources, processes of management activities, and product realization. Once you’ve developed your management system, you’ll be required to fully implement the system, verify if it’s effective, and register it.

Stage 1 Audit

Once you have the quality management system in place, a thorough audit of company activities is what follows. An auditor evaluates your existing systems and provides a well-analysed report identifying suitable actions that need to be undertaken to meet the specific standard. Stage 1 audit is mainly used as a roadmap to the next phase of auditing, so there is no need to worry if you feel like the company is underprepared.

Stage 2 Audit

Stage 2 audit involves fixing all the problems that were identified in stage 1 audit. Once you’ve implemented in the recommendations put forward in the report of stage one audit, an auditor will come in again to complete stage two audit. The purpose of stage two audit is to determine the effectiveness and efficiency of your management system and to establish whether it meets all the requirement of the ISO standards that you want. If the system is good and it meets all the requirements, then the company will be recommended for ISO certification.