25 Years of Technology
A special look at the trends that have changed the industry in the last quarter-century
April 7, 2011
Top 10 technologies of the past 25 years.
The results of a recent and quite informal survey have revealed the increased use of computer numerical control (CNC) as the most significant advancement of our generation. It comes as no surprise since bending, laser cutting, milling, turning, grinding, and measuring tools have all benefited from the power of the computer.
Since Canadian Industrial Machinery was first circulated 25 years ago, machines have transformed from bulky, ugly, stand-alone pieces of equipment into tools that are faster, more productive, and more accurate than at any time in history.
Yamazaki Mazak Corp. recently turned heads with its new product line designed by world-famous car designer Ken Okuyama. With names like Ferrari, Maserati, and Porsche in his portfolio, Okuyama’s machines feature rounded contours, giving them an aesthetically appealing look while making them more ergonomic. According to Yamazaki Mazak, every facet of the Okuyama-designed machines related to operation and maintenance was strategically engineered to minimize user discomfort and maximize ease of use.
It’s not just the sheet metal on the outside of today’s machines that have changed, either.
Data-sharing and real-time process adjustments have closed the machining loop to create systems that can adjust themselves automatically based on changing variables, such as tool wear and temperature change.
True lights-out systems now can monitor themselves and make adjustments on-the-fly, virtually eliminating out-of-tolerance parts.
In the not-too-distant future, the increased use of linear drives will increase speed even more, improve machine durability, and refine the attainable surface finishes by eliminating backlash.
Machining and measuring in five axes, multitasking, and high-speed machining will all change how shops process material. The use of automation will continue to increase, and electrically powered machines will become even more popular.
This is simply the future of the industry.
With technologies jostling for position like thoroughbreds leaving the starting gate, it was a difficult race to handicap, and somebody’s favorite is sure to be left behind. But, a recent polling of industry experts showed the following as the top 10 technologies of the past 25 years:
The List
10. High-pressure coolant pumps
9. CNC press brake backgauging
8. Machine tool engineering/development using FEA
7. Five-axis machining
6. Linear drives
5. Closed-loop machining
4. Laser cutting
3. Multitasking
2. Tooling coatings
1. CNCs.
American author Louis L’Amour wrote that a ship does not sail with yesterday’s wind. And, while this father of the classic American Western novel was literally writing about a ship, he could have been talking about process improvement.
Today’s shops have a continuous need to improve every aspect of their production. This will not change in the shops of tomorrow. The only thing that will change is the technology.
Tomorrow’s Tooling
“Twenty-five years ago coating technology on inserts was very limited. The most popular coating was a single layer of CVD TiN,” explained Tungaloy Canada General Manager John Mitchell. “Today coatings have advanced, and there are numerous, different coatings applied to each insert that significantly enhance a cutting tool’s performance.”
Decades-old tooling has no top form geometry or even chip breakers. Three-dimensional pressing technology now has allowed for very creative insert forms to be created. This 3-D pressing technology has allowed for the design of inserts to direct heat into the chip, reducing cutting forces, improving speeds and feeds, and extending tool life.
“The new technology of pressing indexable inserts has given cutting tool manufacturers the opportunity to produce new, unique insert shapes that can significantly improve productivity and profitability for the customer,” said IMC Group CEO Jacob Harpaz.
IMC Group is the parent company of Iscar Tools, Tungaloy, and Ingersoll Cutting Tools.
Tooling also must be able to keep pace with advancements in machine tool technology. For example, multitasking machines that can both mill and turn are requiring the development of cutting tools that will accommodate this concept.
“The makers of machine tools are advancing in the direction of faster machining at very high RPMs,” said Harpaz. “Cutting tools must cope with the requirements of these high-speed machines, without dropping the level of productivity.”
The rising cost of the raw materials used to produce cutting tools is also forcing cutting tool manufacturers to produce inserts that have more cutting edges and are smaller and lighter.
New binding agents are being developed to eliminate the use of cobalt. According to Iscar Tools Drilling Product Manager David Vetrecin, this development will allow higher cutting speeds to be achieved.
Tool Management
“In our view, tool management will take a quantum leap this year as we see more and more companies wanting to save on tooling costs, and wanting to utilize existing tools to their maximum capability,” said Zoller Canada General Manager Chander Bhardwaj.
Tool inventory control and its integration with the various manufacturing software will be a key for implementing an effective tool management system.
“Automation in manufacturing and effective machining with tool collision detection, as well as tool life management and control, all will be a key part of total tool management,” said Bhardwaj.
Tomorrow’s Machines
Another area that will be explored in a variety of industries is the use of linear drives. The elimination of ball screws and servomotors will eradicate backlash. It’s not just traditional machine tools that will take advantage of this technology.
“Linear drives in CNC grinding will have a dramatic influence on speeds, durability, and surface finishes attainable, as it is a backlash-free design,” explained Machine Tool Systems President John Manley.
While linear-drive technology has been available on certain tool grinders for many years, it has now been introduced to universal grinders as well.
Another interesting development for the future was shown at last year’s International Manufacturing Technology Show (IMTS). At this exhibition MAG IAS displayed a new, futuristic-looking, through-spindle, through-tool cryogenic cooling system.
Using liquid nitrogen (-321 degrees F) may seem extreme, but the company is pleased with the results being shown.
“Cryogenic machining has never been done this efficiently before, with liquid nitrogen passed through the spindle and into the insert," explained MAG Vice President of Engineering Doug Watts. “Through-tool cooling provides the most efficient heat transfer model and consumes the least amount of liquid nitrogen. Our development work to date has focused on milling and boring, where consumption has been about 0.04 liters per minute per cutting edge. We believe drilling and tapping should be even less.”
According to Watts, early results indicate this technology could dramatically improve the life cycle cost model for machining in a hard-metal environment by reducing the required number of machines and associated plant infrastructure, or possibly increasing tool life beyond anything thought possible today.
“Costwise, cryogenic machining becomes even more competitive when you consider it’s a nonissue environmentally. There is no mist collection, filtration, wet chips, contaminated workpieces, or disposal cost,” said Watts.
Sheet metal manufacturers won’t be left behind either. Several key manufacturers recently introduced fiber lasers to the marketplace.
“Fiber lasers have proven themselves in numerous applications in all industries and because of their reliability, high beam quality, high efficiency, small footprint, and lower total cost of ownership, they will continue to gain acceptance and increase market share,” said IPG Photonics Canadian Sales Manager for Industrial High Power Lasers Chris Pilcher. “Fiber lasers have already become the tool of choice for many marking, welding, cutting, drilling, and cladding applications, and as more companies become aware of their capabilities, this will only increase.”
Fiber lasers are expected to find their way into more fab shops, especially as word spreads about the technology’s ability to slice through thin-gauge at incredible speeds and to cut reflective material effectively. Already, machine tool manufacturers such as Amada, Bystronic, and Salvagnini have launched fiber laser cutting machines in recent years.
The Future: Automation
Automation of any kind will change the culture of any shop. The ability to run in a totally lights-out manner will depend on the dependability of tomorrow’s automation.
“While every robot installation is different, it is no longer limited to applications in large lot sizes,” said Paramount Machinery President Eric St. James.
Green Technology
Long gone are the days when “green” was simply the only choice of color for your machine tools.
“Electrically powered machines and greener technology such as electric tube benders and press brakes are coming to the fabrication industry,” said Neiman Machinery Sales President Kurt Neiman.
Alternative energies, a reborn auto sector, and an aerospace industry that still awaits the emergence of the F-35 Lightning II will drive the future of metal manufacturing in the Canada of tomorrow.
Missed a technology? Where does the future of your shop lie? Contact Joe Thompson
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