How does it work?

The current state of augmented reality (AR) allows users to see the real world enhanced by computer generated information. On the work floor it can be helpful to guide and assist employees through AR. Examples such as measurements, tool information, walkthroughs and other information can be depicted digitally. This information can be shown on mobile devices, tablets and AR supported eyewear.

Benefits of Augmented Reality for operational excellence

Computer Aided Design (CAD) and Computer Aided Manufacture (CAM) software has been developed since the late 1950s and is an essential component of modern manufacturing. The term CAD covers a range of applications from 2D drafting packages to full 3D design packages with simulation and analysis tools. CAM software covers any system that generates programs for use in manufacturing, typically using a 3D model or 2D pattern as input.

Tool wear describes the gradual failure of cutting tools due to regular operation. It is a term often associated with tools used for example on turning, milling, drilling and other types of machining operations where chips are made. We could also say “We started with a new cutting edge and at the beginning of the operation everything was working well. After a certain amount of time things started to change. Tolerances were out, surface finish was bad, vibrations occurred, more power was used and the many more things that can happen when the cutting edge has reached its end”.

Tap testing, also known as modal testing, is an experimental method that is used to excite the machine-tool system in order to extract its harmonic information such as natural frequencies, modal masses, modal damping ratios and mode shapes.  This is normally done in static conditions, using the impact hammer as the excitation mechanism, and an accelerometer as the sensor.  In theory, the tool tip should be given a perfect impulse which excites a range of frequencies with a constant amplitude in an infinitely short duration.  This allows us to obtain a clean frequency response function (FRF)

Model Based Definition is a new strategy of product lifecycle management in which the CAD models (Computer aided design) change from simple models with only the geometric data to extensive information sources containing all product manufacturing information (Alemanni, Destefanis, & Vezzetti, 2010).

Small and medium machining shops are often arranged as job-shops. In a job-shop the production is usually done in small batches, and the machines are arranged in functional units, or cells (milling cell, drilling cell, etc). Each part or product to manufacture needs to follow a sequence of operations (a route) to be performed in different machines.

Residual stresses are generated in a part during manufacturing which typically involves sequential thermo-mechanical processing including forming and heat-treatment steps. These stresses can then be influential during subsequent machining operations where the removal of material results in the redistribution of bulk stresses within the part leading to potentially significant distortions and problems with dimensional tolerances. Contour method is a residual stress measurement technique that can provide information about the magnitude and distribution of these stresses.

The first spinning-tool technology was developed jointly by Mori Seiki and Kennametal around 2008.
Designed to distribute heat and wear more effectively than a single-point lathe tool, the new turning spinning-tool technology can increase productivity by up to 500% and tool life by up to 2,000%. This cutting technology employs a specialized insert similar in design to a round, or full-radius insert mounted at the bottom of a cylindrical tool shank held in a rotary spindle.

Hard turning with PCBN cutting material is defined as the process of single point cutting of part pieces that have hardness values over 45HRC. CBN is mainly used to turn parts in the region of 58-68HRC.

What is PCBN?

Polycrystalline Cubic Boron Nitride (PCBN) is a man-made product and found nowhere in any form in nature. Its unique properties of high hardness (only diamond is harder), its ability to keep its hardness at elevated temperatures makes PCBN an ideal cutting material for machining hard and abrasive ferrous materials.

What is a wiper insert.

The first wiper geometries were first  introduced by Sandvik Coromant in 1997.The wiper technology for turning is based on a carefully developed series of radii that make up the cutting edge. On a conventional insert, the nose of the edge is just one radius. The wiper edge, however, is made up of a large, main radius complemented by several smaller radii.

How does it work?

By use of a head mounted display and a set of controllers, the user is placed in a virtual environment where they can practice, learn and improve their skills. The user will enter a scenario in which they have to perform a set of tasks to reach a goal. The scenario depends on the type of training.

Benefits of virtual training for operational excellence

Graphite has specific properties that make machining a challenge. It’s strong, but also brittle, and is susceptible to chipping if not handled properly. Cutting Graphite (or carbon) is different from cutting Metals. Metal exerts plastic deformation when a tool edge cuts it producing a curl or chips. When graphite is machined small powder-like particles separate from the work piece as a result of brittle fracture caused by the stress produced by the cutting tool edge. Graphite machining can be challenging. Especially if you are not prepared to work with its unique and messy properties.