Tag : us manufacturing

precision machine shop

How to Choose the Right Tools for the Job: Examples of CNC Machine Tasks

Just because the world of manufacturing has changed doesn’t mean that people need to stray from the basics. It is just as important to choose the right tools for the job today as it was hundreds of years ago. In actuality, as technology has advanced, there are more tools at someone’s disposal than ever before. With more choices, it has become harder to select the right tools. Now, there are CNC manufacturing tools available in almost every precision machine shop, leaving people to select which types of tools are most applicable to this advanced technology. What are some of the examples of tools that a CNC machinist might require? How can the right tools be identified?

Starting with Computer-Animated Drawing (CAD) Model Design

The first step in the CNC machining process is the creation of a 2D or 3D model of what is going to be produced. Typically, this is done through computer-animated drawing, or CAD. This is computer programming that plays an essential role in the CNC process. CAD allows manufacturers to put together a picture with the necessary specifications (including dimensions and various geometries) that will allow the product to be completed.

The designs of CNC machined parts are typically restricted by the geometry of the machine process itself. CAD helps manufacturers identify potential problems and limitations of the end product before the process gets underway. In this fashion, CAD saves both time and money in any precision machine shop. By identifying and fixing problems before the first machine is moved, a tremendous amount of stress is saved.

Once the CAD drawing is complete, the file needs to be exported and converted into a format that is compatible with CNC machining. Common formats include STEP and IGES. It is important for manufacturers to take a look at the various software programs that are available for CAD. The more familiar people are with CAD, the more efficient the CNC machining process will be.

Building the CNC Machine: Examples of Possible Tasks

Now that the CAD drawing is complete, the next step is to build the CNC machine. Depending on the actions that must be done to build the final product, this machine can take many forms. Some of the tools that the manufacturer will need to find include machinery spindles, machine vises, drill bits, end mills, lathes and more. These tools then need to be attached correctly for the various steps to be performed. It is important for everyone to identify the various steps that must be completed and build their machine accordingly. Some of the types of CNC operations that might be performed using custom machined parts include:

CNC Drilling: Drilling is a machine process that relies on the use of drill bits with multiple points that will produce holes in the desires workpiece. Using CNC drilling, the machine will feed the rotating drill bit into the perpendicular plane of the workpiece. This produces holes that are aligned in a vertical manner with diameters that match the width of the drill bit. Using advanced CNC machinery, holes can also be drilled at an angular manner. Drill bits can also be used to perform tasks such as reaming, countersinking, and counterboring. If these tasks are required, advanced drill bits might be needed. Manufacturers in a precision machine shop should plan accordingly.

CNC Milling: Another possible CNC task is called milling. In milling, a rotating multipoint cutting tool is used to remove certain amounts of material from the workpiece. The CNC machine will typically feed the workpiece into the cutting tool in the same direction as the tool’s rotation. This produces a smooth surface while simultaneously removing material from the surface of the workpiece. Depending on the program, CNC milling can either be used to cut shallow, flat surfaces with flat-bottomed cavities (called face milling) or to produce deep cavities such as slots and threads (called peripheral milling). Depending on the type of milling that people need to perform, they might prefer one type of equipment over the other.

CNC Turning: CNC turning is another possible task that can be performed by advanced CNC machinery. In CNC turning, the machine (such as a lathe) will feed the cutting tool into the workpiece in a linear fashion. Then, using a single point, the machine will remove material from the circumference of the workpiece. This will be continued until the desired diameter is achieved. Therefore, CNC turning can be used to create cylindrical parts. Advanced CNC turning can also be used to apply advanced internal features to the workpiece. This includes threads, tapers, and slots. If advanced features are needed, the manufacturer may want to investigate advanced CNC turning tools that are capable of doing this.

As a summary, CNC drilling is used to produce cylindrical holes of varying sizes. CNC milling removes material from the workpiece and produces a wider variety of shapes. CNC turning is used to create round or cylindrical parts. All of these require different manufacturing tools that interact with CNC machines in a different way.

A Revolution in US Manufacturing with Prototype Machining from CNC Manufacturing

While these are a few of the most common tasks that can be carried out using CNC tools, there are numerous other examples as well. These include lapping, honing, grinding, broaching, and sawing. These are advanced tasks that can be combined with those above to create additional features in the final product. With the advent of advanced CNC programming, machines in any precision machine shop can be set up to perform multiple tasks at the same time using custom machined parts. This has changed what people expect of their original equipment manufacturer (OEM) because this technology can increase both productivity and accuracy. It is crucial for manufacturers to embrace CNC manufacturing and invest in the proper equipment to ensure these expectations are met.

Choosing the Right Tools: Help from the Experienced Professionals

As the world of Denver manufacturing continues to change, it will only become more important to choose the right tools. The expectations of the consumer are going to change and precision machine shop businesses need to rise to meet them. This means putting CNC manufacturing to work in the right way with the right equipment and the right team. Because of this, anyone who is working in a custom machine shop Denver needs to make sure that they have access to every tool. This is where it is crucial to have a high-quality CNC Machinist available. To learn more about CNC manufacturing and how it can change your Denver manufacturing company, contact Tag Team Manufacturing today. Someone is always available to provide assistance.

U.S. Manufacturing

U.S. Manufacturing Myths and Misconceptions

It’s impossible to pinpoint when we collectively became Debbie Downers regarding U.S. manufacturing. People appear to equate the rise of Chinese manufacturing with the decline of U.S. manufacturing, although there is no truth to it. In fact, there is no truth to many of the myths and misconceptions about Manufacturing. Here are 10 of the worst offenders:

Manufacturing in the U.S. is in a Sharp Decline

A 2016 MAPI Foundation report claims that if U.S. manufacturing were its own economy, that economy would be the seventh largest in the world. The size of the economy based on manufacturing alone is greater than the economic output of Brazil, Italy, India, and Canada. Just to underscore – that’s the manufacturing sector alone. Nearly one-third of the U.S. economy is manufacturing-based. Consider the points scored politically by both sides of the aisle when politicians decry the loss of Manufacturing in the US. While it may benefit them in the short run, it does the public at large a disservice by painting a far bleaker picture then actually exist.

Jobs in Manufacturing are Dangerous

To be fair, there have been times in American history when manufacturing jobs were downright unsafe. Innovative laws, regulations, and technology introduced through the years have resulted in far safer workplaces. While the risk of injury exists at any place of employment, Americans working in manufacturing have a relatively low risk of being injured. This is according to a report by the Bureau of Labor statistics. Less injuries are partly due greater awareness, and partly due to newer, safer production techniques. It is in the best interest of both a company and its employees to employ practices designed to protect employee wellbeing.

Robots are Going to Replace Humans

Is impossible to deny that manufacturers have invested in greater automation technology. That fact in no way means that robots will replace humans. More than 12,000,000 Americans work in the manufacturing industry, a number that is expected to increase rather than decrease in the upcoming years. Automation was never designed to take over for humans, but to give them a competitive edge in the world marketplace. U.S. workers produce more than workers anywhere on the globe, and automation simply makes them more efficient.

Manufacturing Does Not Create Enough New Jobs

This myth practically busts itself. In an industry that employs more than 12,000,000 people, there are always jobs available. Manufacturing continues to represent one of the country’s most vibrant job markets. Positions in manufacturing, from CEO to CNC machining, must be filled in order to enjoy continued growth.

It’s Too Expensive to Manufacture Products in the U.S.

Due to the way in which U.S. manufacturers have “leaned” their production processes and received new tax breaks, the cost of American products have actually become less expensive, rather than more expensive. In order to compete, American companies are learning to work smarter (beginning with processes like Lean Manufacturing and Six Sigma). Combined with tax breaks, they are able to pass the savings to consumers. As easy as it would be to be cynical and assume that manufacturers are keeping the extra profit for themselves, they realize that they must offer competitively priced products in order to compete with production coming out of other countries. As an added bonus, U.S. manufacturing companies spend more on research and development then manufacturers from any other country in the world. The result is a better product and now, a better price.

American Manufacturers use Outdated Processes

This myth has just enough truth at its core to make it believable. It is, however, not true. It did take U.S. manufacturing more time than it should have to embrace new technology and the digital revolution. As more manufacturers realized that they would have to adapt to survive and that automation and streamlining could improve efficiency and output, they came on board. Today, you would be hard-pressed to find a successful manufacturer that does not use the most up-to-date processes. In fact, you need look no further than your local CNC machine shop for state-of-the-art technology.

It’s Fine to Outsource as Long as Product Design Stays in America

People have found ways to justify outsourcing since it began. They’ve said that they’re doing it to cut costs and save jobs in the U.S. They’ve said that it’s good for the global economy. They have also claimed that it’s fine to outsource production as long as product design stays in the U.S. This is a myth. As the former CEO of Intel, Andy Grove knows a thing or two about manufacturing processes. Grove argues that the best innovation takes places when designers and production teams are in one place. They can troubleshoot, give each other feedback, and fine-tune their designs.

The Only Manufacturing Jobs Available are Low-Skilled and Tedious

Today’s manufacturing involves the use of computers that can operate machinery in a way that allows for extraordinary precision. The field requires skills like the ability to problem solve on the fly, operate complex machines, and make quick calculations. Any job can be tedious. The best employees in manufacturing do not just consider the task at hand, but also think about ways they can improve the process.

Women are Unhappy in Manufacturing

The collective mental image we have of the American factory worker tends to be male. After all, it was men who filled the factories after World War II, and men we saw on the nightly news when they went on strike in the decades that followed. That image may be one of the reasons that a Women in Manufacturing survey found that less than 10% of women ages 17 to 24 listed manufacturing among their top five career choices. Perhaps the outcome would have been different had they known how happy women working in the manufacturing sector are. 82% of women who work in manufacturing say they find the field interesting and challenging. 74% felt that manufacturing offers multiple career opportunities. No matter a person’s gender, opportunity awaits in fields like CNC manufacturing, electronics, and apparel manufacturers.

Manufacturing has no Future

Change is not only inevitable, it is uncomfortable. While U.S. manufacturing evolved and some of the big players moved to a bench position, the myth that manufacturing in the U.S. has no future grew. Rather than marveling at the new and innovative businesses that were expanding their manufacturing base and much of the public focused on the big players that now seem somewhat small. The truth is, change is not bad, it’s just scary. Manufacturing in the U.S. is alive and well. The number of people needed to fill open manufacturing positions continues to grow and the impact the manufacturing sector has on the economy swells.

As manufacturing fuels the economy, there will be a need for more skilled workers, like engineers and machine operators who can work on custom machined parts. That’s good news for everyone. Tag Team Manufacturing, located in Parker, Colorado is looking to add machine operators and set up machinists to their team. Contact them today at 303-841-5697.

blurring in motion as a concept of modern technologies in Metalworking machine with control panel CNC machine

The Keys to Successful High Speed Machining in your Machine Shop

Advancements in CNC manufacturing and industry developments in high speed machinery are just two of the factors that are driving a global CNC machines market that is expected to reach $100 Billion by the year 2025, according to a research study. This industry growth is underpinned by CNC technology that provides manufacturers with a reduction in machining errors, lower operating costs for machine shops, and lower labor costs when state-of-the-art factory automation is implemented in US manufacturing sectors across the board.

Taking Advantage of CNC Manufacturing

The key to successful high speed machining in your machine shop is directly tied to your adoption of high speed CNC machines and tooling or partnering with a machine shop Denver that delivers high speed, custom machine shop services to US manufacturers. These companies provide mills, lathes, grinders, ad routers controlled by computer CNC programming to operate at a significantly higher feed rate – and with a minimum of tool breakage.

Expect a cleaner cut with high-speed machines that operate at lower heat per piece due to the efficient manner in which metal chips are evacuated. The result is tooling that remains cooler with less vibration and a reduction in other machining forces when compared to conventional machine shop operations.

These inherent traits of CNC manufacturing will also provide 3 other major benefits to US manufacturing production – repeatability, precision, and range of materials:

  • Improved Repeatability: CNC programming and machines can reproduce a shop outcome that is unchanged for multiple pieces running at high speeds. Even more important than accuracy, repeatability means errors can be traced and compensated for, to reduce scrap and gain higher precision for intricate geometry machining.
  • Component Precision: When 3D Computer Aided Design (CAD) software is used in conjunction with CNC machines, expect components that are manufactured to exact and extremely precise specifications. Complex shapes and fine or thin parts which at one time required a Master machinist and hours of labor are now easily manufactured without error.
  • Greater Range of Materials: Aside from common manufacturing metals, CNC machining is used to produce components and products from a wide range of materials, including steel, aluminum, bronze, gold, and silver. Today, many domestic consumer products manufactured from polymers such as ABS and PTFE are machined using high speed production as well.

4 Keys to Successful High Speed Machining

Staying competitive in an increasingly fast-paced manufacturing arena means achieving better productivity from your  manufacturing automation strategies. And when it comes to high speed machine shops, the following four keys will do more to ensure success than most other factors:

Material Selection Process

Due to the high feed rates of high speed machine (HSM) processing, softer materials don’t fare as well. For the best results, tough or hardened materials provide the best results. When you consider that different materials are processed at vastly different speeds, mostly due to the preservation of the machine’s cutting tool life, the most common metals include hardened steels, stainless steel, tool steel, and titanium, and often mild steel.

CNC machines are high performing and depend upon critical attention to every detail between the cutting tool, the CNC program, and the material being cut, including:

  • spindle rpm
  • spindle power
  • high feed rates
  • tool path rates

Material properties will affect the material removal rate and how much wear and tear is being placed on the cutting tool. Companies can overcome these material selection challenges by partnering with a machine shop Denver that specializes in CNC manufacturing and custom machine shop processes. Here you will find the expertise required to overcome component material specification and cutting tool material challenges and how material will relate to depth of cut, coolant flow rate, and the type of coating for the cutting tool.

Acceptable Workpiece Geometries

While CNC machines are regularly used to process common geometries, when it comes to high speed operations, the tool geometry and tool access to all parts of the working piece are dependent on the geometry of each component. Workpiece geometry with internal or ‘hidden’ cuts will often place a limit on to the maximum depth of an undercut.

Likewise, the stiffness of the workpiece and the tool must be matched to reduce deformation and vibration during machining, otherwise the temperature increase due to cutting forces are too great for high speed applications. Consideration of workpiece geometry also includes maintaining a minimum wall thickness for a successful component that is machined using high speed CNC equipment.

The Right CNC Machinery

If your CNC machines are not rated for high speed operations, then expect broken tooling and lot’s of scrap pieces. There are a wide range of factors that are needed for high speed production to run smoothly – and these factors mut be considered when selecting a CNC machine for your machine shop. From complex mechanical parts to mold & die processes, the right CNC machinery depends on:

  • Part Complexity
  • Machining Operations
  • Operator Training
  • CNC Control System
  • Cost Per Part
  • Available Floor Space

When setting up floor space for high speed machining, operations may need to be rearranged to accommodate material flow from point-to-point for increased productivity. When selecting a machine, worker safety and chip disposal during non-stop machining operations are an integral part of operations planning.

If you are in the process of choosing a CNC machine shop Denver to drive your high speed manufacturing projects, request samples of their previous work and discuss any in-house limitations they may have which can affect how flexible they can be during production.

Partner with a US manufacturing service provider that can run a range of project sizes from big scale productions to small prototype machining with a variety of materials.

Access to Trained CNC Operators

There is no denying that there exists a shortage of skilled CNC operators in America to fulfill the needs of manufacturers for trained and experienced workers to fill new positions in high speed manufacturing. The Golden Age of skilled machinists existed during the Baby Boomer generation – and today that workforce is retiring at a record pace.

The majority of Millennials that have entered the manufacturing industry have looked to supervisory or management positions in lieu of the traditional machine shop occupations that were held by their parents.

For these reasons, companies are finding access to trained CNC operators that are experienced in the nuances of high-speed manufacturing by turning to third party or outsourced, machine shops to meet demanding production schedules.

Partner with a high speed manufacturing machine shop that specializes in custom production at a facility that features clean and organized shop floors that are technology driven. Tag Team Manufacturing is dedicated to production quality and s inspired by today’s innovations in high speed machining processes.

At Tag Team, we work closely with your engineers to develop first-run prototypes, and we can collaborate with your product developers to deliver quality components at a competitive price with the ability to output up to 50,000 units annually.

CNC Manufacturing

How Changing Manufacturing Perceptions Are Shaping the Industry

The manufacturing industry in general, including CNC manufacturing and precision manufacturing, is one that is consistently recognized as one of the most important industries that contributes to economic prosperity. However, the US manufacturing industry is facing a gap. Not only are there not enough skilled workers available, but also there isn’t an interest in pursuing long-term careers in CNC manufacturing. A lot of this has to do with the public perception of the industry.

What Is the Public View of Manufacturing?

Americans value the industry, with 83% believing that manufacturing is important to economic prosperity in the country. Seven out of 10 Americans believe that the country should invest more in the industry. Eight in 10 Americans view manufacturing as an important way to maintain the standard of living in the country. Sixty-four percent believe that the manufacturing industry in the country is high tech. Even with these positive stats, Americans still aren’t choosing careers in CNC manufacturing. One-third would not encourage their children to pursue a career in manufacturing because they believe it doesn’t pay enough, is not a strong career path, and they are worried about the stability and security of the job. While 67% believe these jobs are rewarding and interesting, only half believe that a career in this industry provides good pay when compared to other industries.

Even though Americans aren’t encouraging their children to pursue those jobs and don’t seem to want to have these jobs themselves, they are optimistic about the future of manufacturing jobs and do believe that these perceptions can change and improve. Americans believe that future jobs can have better career prospects because they will require higher levels of expertise, have safer and cleaner environments, and be more innovative and creative. In order to get more people interested in manufacturing jobs, Americans believe there should be more targeted programs, such as apprenticeships and internships, as well as CNC manufacturing degree and certification programs. When Americans become more familiar with the industry, they are twice as likely to encourage their children to pursue a manufacturing career.

Education Matters in the Industry

As Americans are becoming more educated about the industry, their perception is changing. In order to fix some of these perceptions, it’s necessary to increase the pool of qualified candidates to be able to get the right talent to staff the roles that today’s manufacturing companies need. Community colleges, as well as technical schools across the country, are working with government and non-profit agencies, as well as manufacturers, to develop curriculum that will help make sure that students have the in-demand skills that are needed for these roles. These institutions, as well as manufacturers themselves, are better understanding the role that they play in transforming the public perception. Oftentimes in the past, manufacturers would spend money to invest in technology and equipment, but didn’t invest in their existing workforce and in the human capital. Due to this, the industry has fallen behind and is lagging when it comes to adapting to new operations in more technologically advanced environments. Schools have worked with private manufacturers in order to develop programs that will help focus on specific skills employers want, which not only makes it easier for the manufacturers themselves, but also benefits the students who want to make sure they can get a job when they are done with school. An example of this is a worker training program with American Makes. This organization is a leading partner in research for 3D printing and additive manufacturing. The organization is a public-private partnership that works to accelerate and innovate additive manufacturing with the goal to help increase the manufacturing competitiveness in the United States. The curriculum that is offered is skills-based training, and the apprenticeships offer a range of jobs that are in demand with a focus on the 3D workforce.

Improving the US Manufacturing Competitiveness

In order to improve perceptions about the industry, more than three-fourths of Americans agree that there needs to be a more strategic approach to invest and develop the manufacturing base. Seven in ten Americans believe that a strong manufacturing base should be a priority for the nation and there should be tax incentives to encourage it. There needs to be lowered health care costs, reforms in the education system, and a comprehensive energy policy. These are just some of the actions that Americans believe could help bolster the competitiveness of the US manufacturing industry.

What’s Really Happening in the Industry?

The manufacturing industry provides one of the most stable and secure career paths, and the average tenure of workers in manufacturing jobs is the highest among private sector industries. Manufacturing jobs have some of the lowest turnover rates as well. Despite what some think, CNC manufacturing jobs are paying well. According to statistics from the Bureau of Labor and Bureau of Economic Analysis, the average worker earned $81,289, which included benefits and pay, compared to the average worker in other industries only earning $63,830. Health benefits can be a concern with job seekers, and manufacturers have some of the higher percentage of workers who are eligible for health benefits provided by an employer. Skilled workers are needed, especially over the next decade. About 3.5 million manufacturing jobs will be needed, which is due to a combination of the retirement of Baby Boomers and the strengthening economy. By making these statistics more well known and increasing public awareness, it can help dispel false perceptions to help get the news out that the industry is actually doing pretty well. Manufacturing is a big contributor to the US economy. The industry employs about 12 million people and the effect of it ripples throughout the entire nation. For every one dollar that is spent in manufacturing, another $1.81 is added to the economy. For every job that is added in the manufacturing industry, four other jobs are added in the broader economy.

How Trends in the Industry Affect Perceptions

Different technological advances that are entering the industry, such as IoT and robotics, are also changing perceptions that are helping to shape the industry. Despite the new technology and many people thinking that technology is going to replace jobs, there is still a huge demand for jobs that are more skilled and can work alongside the changing technology. While some jobs are lost due to robotics and new technology, these jobs are being replaced with higher skilled jobs, which pay more and offer more stability. The newer jobs for higher skilled workers are exactly the kind of jobs that are needed to counteract the negative perceptions that go along with the industry.

GD&T

GD&T 101: Understanding Fundamentals of GD&T in a Machine Shop

In precision manufacturing, electrical specs are ideal for specifying electrical components appearing on a drawing. Mechanical components require unique spec system that are replicable.

Also, mechanical spec system should be clear, precise and not excessively restrictive. Geometric Dimensioning and Tolerancing (GD&T) is the new phase of precise designs.

What is GD&T?

Geometric dimensioning and tolerancing (GD&T) is the primary international language that aims to offer clarity in most drawing interpretations and specifications. The ideal use of GD&T in CNC manufacturing helps in the elimination of vague drawings. Vague drawings give room for guesswork, controversy, and assumptions in manufacturing and inspection processes.

GD&T is a language of standards and symbols wholly designed and used by top CNC machinist, engineers, and manufacturers worldwide. They use this language to describe products and facilitate communication between entities working together to create products.

Through advanced knowledge on the best practices to create a well-structured GD&T, you can improve communication with your custom machine shop Denver. As a result, everyone in the workplace speaks the same language.

Why is GD&T Important?

GD&T may seem like a complex language. It requires correct interpretation and specification for efficient and effective communication. Improper implementation can cost your company a lot of money. Nonetheless, excellent training offers your employees sufficient comprehension of GD&T and its proper application on a particular job.

Constant measurement and effective communication across engineering processes and disciplines are vital for production of superior products. GD&T helps you achieve this goal. It’s primarily designed to address major challenges facing companies and organizations when describing product geometry.

GD&T symbol language allows for accurate communication of all geometry needs for any related components and assemblies. Designers, engineers, and manufacturers use the ‘language’ to understand detailed engineering drawings in commercial design, automotive, manufacturing, electronics, and aerospace industries.

Moreover, it assists in controlling and specifying forms, location, and orientation of the features. GD& T also characterizes machine shop components and manufactured parts.

GD&T symbols for every dimension on a manufactured part or component are defined in connection to a datum. Datum is a theoretically perfect plane, point, or line on a manufactured component perceived to be the reference point for all dimensional measurements and tolerance calculations.

All datum(s) on every manufactured or designed component is considered as the ‘zero point.’ Calculations get built from the reference point to every other dimension to guarantee consistency of particular parts. Therefore, manufacturing, design, and quality engineers get great manufacturing and measurement clarity. Furthermore, incorporation of a datum dramatically simplifies all specification and design processes.

ISO-certified GD&T languages have successfully replaced complex and long industrial descriptions with simple symbols. The symbols are clearly and unanimously understood by all precision manufacturing personnel required to read and interpret any engineering drawing.

Benefits of GD&T

GD&T offers many benefits to OEM manufacturers. The entire design philosophy implemented in GD&T is similar to that extensively featured in functional dimensioning. Every part gets defined based on how it functions in the end product.

The designer meticulously bases the required tolerance on part function instead of copying it from a previous drawing. This strategy enables the use of maximum tolerance in the production of parts.

When applied appropriately, functional dimensioning, often multiplies the total tolerance on most component dimensions twice or thrice. Dimensioning significantly lessens the overall manufacturing costs.

With the incorporation of accurate coordinate dimensioning, all tolerance zones are not associated or connected to any functional requirements. In case a designer assigns tight tolerances, problems can occur since they are not in any way resolute in the determination of a beneficial and functional tolerance.

So, why use GD& T?

Round tolerance zones

Round tolerance areas permit roughly 57% supplementary tolerance compared to square zones which result in additional functional parts. The manufacturing process gets enhanced in capabilities when more tolerance on the parts. This helps in significant reduction of manufacturing costs.

Bonus Tolerance

Under certain conditions, GD&T creates room for a bonus tolerance in addition to round tolerance. The bonus comes from the use of Maximum Material Condition (MMC) modifier. The MMC modifier increases tolerance in precision manufacturing.

Bonus tolerance is a practical example of a win-win situation for the involved OEM since manufacturing can get further tolerance when holes are bigger than their smallest functional size. On the other hand, clients get a guarantee parts will assemble without a hitch.

Tolerance zone in coordinate tolerancing is always constant with size irrespective of hole conditions. Several functional parts can be scrapped to create a more rigorous condition for CNC manufacturing. Bonus tolerance allows for additional tolerance in production which assists in lowering operational costs.

Reduces Assembly Problems

GD&T inspection process ensures that all parts assemble correctly. Assembly procedures don’t necessarily require a CNC machinist on the assembly line using a hammer and a two-by-four.

Moreover, GD&T inspection process ensures that OEMs can obtain multiple sources or use competitive souring for the same part. The reduction of assembly problems consequently increases your company’s profitability.

Clear Communications for Inspection

GD&T’s datum system enhances clear communications of a single set up feature for inspection. The assessment equipment mainly stimulates datums. The symbol that is universally used in the specification of any datum denotes the part surfaces that meticulously touch the gaging apparatus during inspection.

All datum features get chosen based on part function and assembly requirements. They are in most cases the features that comprehensively mount and precisely locate parts in its specific assembly. The datum(s) reference letters get specified within the statistical and geometric controls. They also symbolize the series in which specific part surfaces majorly contact the gaging equipment.

GD&T supports SPC use

GD&T datum system offers repeatable part dimensions essential for designing a reliable SPC chart. SPC data might comprise of assumptions with implementation of coordinate tolerancing which diminishes the accurateness of data obtained. Profile control use is an ideal example of how GD&T supports SPC.

Profile control helps in the establishment of a mathematically distinct tolerance zone. Moreover, it relates extensively the obtained measurement to datums. Precise tolerance zone description does not exist whenever coordinate tolerancing is used.

Profile control together with datum system enhances the accuracy of the obtained SPC data. Therefore, no unnecessary changes are made in the Original Equipment Manufacturer and Denver Manufacturing processes. It saves time and money for the company.

For original equipment manufacturers to realize the benefits of GD&T, correct utilization is key. When used incorrectly, it can result in costly errors. For example, if a manufacturer uses erroneous drawings to choose machines to use and production rates, it results it incorrect cost estimates. In the long run, manufacturers end up using wrong equipment and producing substandard products. Solution?

Customers want to work with companies who have successfully used this incredible technology. Call or visit Tag Team Manufacturing to speak with our experts.

Manufacturing Sector

Is US Manufacturing Making a Profit?

Many people view the manufacturing industry in the US as one that is untouched by technological changes. This skepticism has led to some questioning whether the manufacturing industry is making a profit in this era.

Addressing concerns on the decline of the manufacturing industry in the US

The manufacturing industry experienced a major hitch during the recession, with more than 5.8 million workers losing their jobs between the years 2000 and 2010. While the 2007-08 recession played a major role, many attributed this to the automation and the introduction of robotics in the manufacturing industry, some thought that this was a sign of the slow growth of the US economy and that the US was losing its grip to support its population.

According to the IMF, the decline does not necessarily indicate a shift in the industry’s size. Instead, sector inequality is what is bringing about this concern. In a recent IMF report, Bertrand Gruss stated that “the decline in manufacturing need not be a source of concern as long as the policy mix is right.”

Though the industry has gone through dark times in the recent past, data from the US Census Bureau shows that it is making profits, with the first quarter of 2018 having a $154 billion, up from the $117.6 billion that had been realized in the last quarter of 2017.

Manufacturing trends behind the industry’s current profits

Labor automation
The use of CNC manufacturing has played a major role in the success of this industry. While this is no magic wand, it has made manufacturing companies more competitive. Automation of processes and the use of digital machines has led to increased productivity as tasks that were done manually at higher costs, and less accuracy are now automated. This has led to a significant drop in manufacturing jobs, but its benefits far outweighs the challenges. Through an efficient production process manufacturers realize an increased output which ultimately leads to increased profits.

Machine outsourcing and leasing
Automation has not come without its fair share of challenges. These human-capacity-saving machinery in most cases have extremely high upfront costs. However, any company can now walk into an Original Equipment Manufacturer and lease any machine. This, coupled with the many financing options has given the industry a major boost. Finance companies are offering to settle not only the machine’s cost but other soft costs such as its installation and freight.

Rising demand
The US remains to be a lucrative market for manufactured items. This has continued to lure both local and international manufacturers to open companies in the US. The streamlining of global logistics has opened up this industry to the world. Technological innovations have made the moving of products and services faster, cheaper, and easier. As such, manufacturers have increased their visibility to potential clients not only in the US but all over the globe. This has seen the demand soar especially in emerging economies. With the increased demand, manufacturers have doubled their output capacity, which explains their profit story over the last few years.

Further, the rise in global demand has led to US manufacturers seeking international allies. In most instances, the US manufacturer works on the design and the products’ functionality while the international partner manages distribution in the country they are in. This has also enabled the manufacturers to widen their global reach and maximize their revenues.

The rise in industry technologies
Manufacturers can now efficiently source for raw materials or deliver their finished products anywhere in the world. They can now have multiple facilities all over the globe, as opposed to the past where facilities were set up depending on the raw materials’ proximity. Through cloud connectivity, such facilities can sync data which is accessed by each facility in real-time.

Evolution in the precision manufacturing sector has made manufacturers maximize their production output, increase the machine’s running times, and reduce downtimes. Through design and simulation tools, manufacturers can validate the products’ design before the final production. This results in the production of perfect products and reduced design time.

Increased diversification to service provision
The integration of automated systems in the production process has necessitated that there be a constant support for optimal efficiency. Case in point is IBM, which actually sells more services than goods. Many Denver manufacturing shops also offer services that are meant to help companies maintain and upgrade their machines. This has led to diversification and eventual realization of profits.

The future of the manufacturing industry in the US

Concerns on whether the US will be able to recoup its position as a leader in the manufacturing industry continue to be a significant bone of contention. The US population is also waiting to see whether the current administration will deliver its promise, that is, ensure that the low and middle-class workers get their manufacturing jobs back. Besides, everyone wonders what impact increased manufacturing automation have on the workforce in the long run.

All indicators show that the manufacturing industry is experiencing a resurgence, and focus is shifting to policies that will accelerate this growth.  Policies such fewer government regulations and investment in infrastructure geared towards enhancing manufacturing are expected.

While manufacturing jobs are returning to the US, it will be necessary for any machine shop Denver, to employ the same skills that were applicable a few years ago. As a result, we will see more efforts from government agencies and corporates to bridge the skills gap. The curriculum also has to be adjusted and relevant programs introduced to ensure more skilled labor is available.

Also, no CNC machinist is going out of business as technological innovations lead to production efficiency and the production of high-quality products. Undeniably, we can only expect more automated processes. This will further be influenced by the evolution of the Internet of Things. We can expect advancement in M2M applications, 3-D printing, and AI equipment. It is hard to find a custom machine shop that is not making use of such technological innovations for products with multiple customization options and fewer flaws.

The manufacturing industry plays a major role in the US economy. Increase in efficiency due to automation will ultimately lead to increased production, time-saving, reduced downtimes due to the use of smart machines will all lead to higher profit amounts and a healthier economy. While these changes are welcome, they will lead to changes in the workforce and better products.

Education concept: Helpful Tips with optical glass

Tips for Choosing a CNC Machining Partner

While the US machine manufacturing industry continues to grow rapidly, choosing the best strategic partner for your CNC machining can be quite challenging. However, this process should not be that difficult if you have the correct pieces of advice beforehand. Below are some machine shop tips that you might want to put into consideration when sizing up for the best service provider.

#1: The Technology in Use

The power of technology cannot be underestimated in the engineering and manufacturing sector. Therefore, it is an excellent idea to know the type of technology in use in your preferred machine shop. While there are many companies out there relying on standard technology, this could be a constraint when it comes to both design and machining. That is why it is paramount to work with a manufacturer who is fully automated and equipped with all the necessary precision tools and equipment. At Tag Team, we have heavily invested in Computer Numerical Control (CNC) manufacturing that allows us to deliver precise component machining to our customers. Additionally, this revolutionary approach to manufacturing helps us to achieve zero-defects because once your design is fed into the computer; our CNC machines can repeat the production process multiple times. This also helps to lower lead-time.

#2: The Expertise of the Staff

Sometimes you may go with a price that you think is good only to end up with a component that does not conform to your print or assembly. In other cases, your project may be delayed, and the excuse the manufacturer tells you is “your component design is too complex.” Therefore, you need to be vigilant when dealing with machine shops and only work with a company that has a reputation for interpreting designs and prints accurately and delivering projects on time. At Tag Team Manufacturing, we have created a work environment where our machinists make a long-term career. We know very well that expensive equipment and software are worthless if they are not coupled with qualified and experienced staff to deliver quality services and meet the exact customer specifications. In fact, the vast majority of our machinists are US manufacturing schools graduates and can handle all complexities relating to components design and implementation.

#3: Range of Materials and Services

Choosing a manufacturer who offers diverse metal machining services can save you a lot of time and paperwork. Consider a case scenario where you want a design component that has to incorporate several metals or materials. Definitely, it would be much more convenient to outsource to one manufacturer than several of them for a single project. That is why we at Tag Team Manufacturing have CNC machining for a variety of materials including plastic, stainless steel, aluminum, copper, brass, carbon steel, and most alloys. Besides, we have an extensive network of support vendors who provide brazing, plating, heat treatment, painting, and welding among other services.

#4: Relationship Sustainability

For those considering to enter into an Original Equipment Manufacturer (OEM) contract with a CNC machining firm, you might need to evaluate the sustainability of the relationship. First, put into perspective whether the manufacturer has the requisite CNC automation to meet your demand and needs. Second, the machine shop you want to enter into a contract with should protect your business interests and keep the requirements of the end-users in mind. That being said, Tag Team has an excellent reputation for producing components for EOM’s in almost all industries. Our production capacity is about 50, 000 components annually, which means we can meet your demand without compromising on quality. In addition, we protect the interest of our clients, as we do not publicize our relationships with EOM’s who buy components from us.

Precision Machine Shop

Things to Look for When Hiring a Precision Machine Shop

People should look for several items when they are choosing a precision machine shop to make certain that they make the right choice.

Communication Skills
The person in the shop that you are telling about your job or project should have great communication skills. They should be skilled at their job and know what the others in the shop can accomplish. If this person is experienced, they will also have questions for you to help you to describe your job in as much detail as possible. Great communication is the first skill to look for, because if you and the shop manager are not on the same page, your project may not come out as you saw it.

Innovative Technology
A good precision machine shop is only as good as the available technology they use and it is based on the technician’s knowledge to use it. Research what types of equipment are needed to manufacture a prototype of your project. Then ask what types of equipment the machine shop uses such as CNC Machining, Manual Machining and Wire EDM. Also, ask if the process uses more than one type of machining for the run. The machine shop should also be able to have certified technicians to run the software available for the process so they can implement any changes in the design that you may ask for. Shops with the latest technology are forward thinking and will learn and implement new processes to keep up with the rising technology needed.

References and Samples of Work
A great machine shop will have a project book with photos of some of their past work along with the customer’s names and phone number and won’t be afraid to share these things with you. If they don’t give you references or explain past processes, they may be hiding something about their performance from you. The project book should have their most difficult jobs that they completed in it to show how capable the machine shop is in their business.

Flexibility
Machine shops that are proficient in their work will have some sort of process to allow flexibility in the project while it is underway. They should report to you at certain steps of the process to make certain they are on track and be able to change things if it isn’t to your specifications. This helps to get the first prototype correct and sets in place the specifics for a full production run of your products. If they don’t have a schedule set up, you may want to look elsewhere for a precision machine shop that is more compliant.

Quality Control
All machine shops should have a quality control inspector, whether in-house or out of house to ensure that your project meets all of the specifications that it should. They should be willing to talk about their quality certifications such as ISO 9001 and AS9100 standards and share with you what types of equipment they use to ensure the standards are met.

Looking for these items will help you to find a quality precision machine shop that you can use for prototypes, parts and projects of any size to successfully fulfill your wishes and demands.

high-speed machining

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.

Machine Shop

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.