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Decision-making in metal forming

May 21, 2015

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We live in the Information Age. But for many in manufacturing faced with costly decisions in design and manufacturing, it can seem like the Way Too Much Information Age. Large volumes of data and information are available from myriad sources. But publishing accessibility is widespread and easy,...

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Cheese, metal fabrication, and the future skilled worker

May 21, 2015

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Over the past two decades, Millerbernd Systems has evolved into a complex entity--part fabricator, part automation systems provider. It also launched a local education initiative to ensure talent remains in the pipeline.

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Stamper performs subassembly superbly

May 21, 2015

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DieMasters Inc. grew from a small diemaker shop to a 100-employee stamping contractor. The company added value to its bottom by making assemblies, which now comprise 70% of its revenue. The assemblies are a metaphoric representation of the company itself, which makes products diverse in every way possible—size, type, market, materials, complexity. While Diemasters’ success is the result of a concerted effort, President and CEO Virgil DeLay pulls the company together and keeps the band on cue with a well-defined production system.

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Talking about the next generation of fabricators

May 15, 2015

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While many people turned their back on manufacturing careers, Kyle Layman couldn't wait to get started. Now he's the impetus for growth at Layman Fabrication, North Vernon, Ind., while dad gets to focus on the fabrication activity that he's always loved.

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EBE Reduced Raw Material and Tightened the Production Belt for Fat-zapping Device

May 14, 2015

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Production difficulties due to the complex design of a heat exchanger for ZELTIQ® Aesthetic Inc.’s CoolSculpting® equipment designed to selectively reduce fat caused the company to fall behind on shipments. A redesign by Electron Beam Engineering Inc., Anaheim, Calif., reduced the amount of 5052 aluminum needed by about 15 percent, simplified production for a 20 percent time savings, and upped quality to over 99 percent. The 15-in.-long electron beam welds are pressure-tight, narrow, and do not require postweld finishing.

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Measuring weld heat to evaluate weld integrity

May 14, 2015

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Eddy current and ultrasonic testing are suitable for tube and pipe mills and have been used for weld seam flaw detection for decades, but a new process, thermography, is an alternative. By measuring the heat signature of the weld seam as it cools, it provides information about weld integrity at and below the surface.

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Choosing a welding process for tubular profiles

May 14, 2015

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Roll formers that want to branch out to welded profiles need to know about the main welding processes – GTAW, laser, and induction. This article compares and contrasts each process so roll formers can determine which is best for particular applications.

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Welcome to the world of “positioneering”

May 13, 2015

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A welding positioner can eliminate potential waste associated with inefficient material handling and help to improve weld quality. The key is finding the right positioner for the job.

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Lessons learned in a welding career

May 13, 2015

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The importance of saving money and of being safe on the job are among the lessons welding instructor Marty Rice learned throughout his welding career. Among those who taught him these lessons was Charlie.

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Vision-guided robots consolidate their place in the press shop

May 13, 2015

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Advancements in robotic technology are extending their functionality and improving their performance. Often a robot is expected to do more than move from programmed position A to position B; it must operate “smarter” and act upon other inputs, such as vision systems or force feedback. The applications for integration of vision systems and robots are almost endless but the most common application is vision guidance for the robot

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Getting the most for your tube bending buck

May 12, 2015

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Understanding the basic tube bending methods, including their capabilities and limitations, can help you uncover the best and most economical way to achieve a quality bend.

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Large-bed servo press line enhances auto supplier’s efficiency

May 12, 2015

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Automotive supplier of seating components Paul Craemer GmbH of Herzebrock-Clarholz, Germany, replaced two presses lines requiring press-to-press automation with one 35-foot tall, 48- by 25-ft. servo transfer press.

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Arc Welding 101: Plugging holes and pinholes

May 12, 2015

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Q: I am machining a bearing housing made out of 1045 and I have to plug and weld some cross holes. I am also using gas tungsten arc welding (GTAW) to eliminate a weld that is too large. My problem is that I am getting pinholes in my weld. Is it because I am welding 1018 to 1045? We didn’t machine...

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Replica cars? There’s a kit for that

May 12, 2015

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A component (kit) car manufacturer in Wareham, Mass., made two big process changes that helped streamline its manufacturing operations.

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Shop technology and 3-D CAD: Design for manufacturing

May 12, 2015

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Columnist Gerald Davis provides an overview of using CAD to develop a better design, which leads it to being more manufacturable.

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