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October 4, 2012 A Penton Media Publication Tune in to EngineeringTV.com MESHING FOR CFD, page 38 BETTER DIE CASTING, TIGHTER TOLERANCES, page 44 ADHESIVES THAT CURE WITH VISIBLE LIGHT, page 52 Getting MOTION SYSTEMS up and running fast page 48 [ MOTOR TRUTH #13 ] Are you into belts and chains? If not, then you need SEW’s patented TorqLOC ® . Its keyless hollow shaft and taper bushings eliminate inefficient belts, chains, and sprockets thus reducing maintenance and energy costs while enhancing system safety. Its spacious air gap provides easy mounting. Its tightening bolts provide easy dismounting. No more tight tolerances! No more keys! Need retrofit? No problem. TorqLOC even mounts onto an existing shaft that has a keyway. Visit sewmotortruth.com/truth13 for other ways to save energy. sewmotortruth.com/truth13 864-439-7537 Mounting Dismounting RS# 101 OMEGA 0(*&)1010&-.1&)1$%.-,'0/10/&*0 0/01!++1 0/*0)-1 $,''&--0"1-,1%/1$%.-,'0/. !+++++1 /,"%*-. 1Τεμ περατυρε, πρεσσυρε, στραιν ανδ φορχε, φλοω ανδ λεϖελ, δατα αχθυισιτιον ανδ αυτομ ατιον προδυχτσ (.1/"0/&) 1Χαλλ ορ ϖισιτ υσ ατ ομ εγα.χομ (.-10#&0/ 1Σαμ ε−δαψ σηιππινγ ,/#"1$#( 1$%.-,'0/10/&*0 1Φρεε τεχηνιχαλ συππορτ ανδ λιτερατυρε © COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED ,'0(*,'11! OMEGA $0#0/(-0.1 +10(/.1,1*0##0)*01 &)1 /,*0 10(.%/0'0)-1()"1$,)-/,# © Petesaloutos / Dreamstime.com !+++++10(.%/0'0)-1 /,"%*-. RS# 102 FEATURES FASTENING/JOINING Authored by: Robert Michaels Vice President of Technical Sales Master Bond Hackensack, N.J. Edited by Stephen J. Mraz stephen.mraz@penton.com Resources: Master Bond, www.masterbond. com Curing adhesives with “normal” light A new adhesive from Master Bond cures under visible light (wavelength of 405 nm), not UV light. It can cure in 15 to 30 sec and adheres well to glass, polycarbonates, acrylics, and metals. Comparing light-curing adhesives ADHESIVE VISCOSITY AT 75° F CPS COLOR SHELF LIFE AT 75°F IN ORIGINAL UNOPENED CONTAINERS SERVICE TEMPERATURE LED401 100,000 to 150,000 Clear 6 months 60 to 250°F (51 to 121°C) LED401LV 60,000 to 80,000 Clear 6 months 60 to 250°F (51 to 121°C) LED403Med 1000,000 to 150,000` Clear 6 months 60 to 250°F (51 to 121°C) A new group of light-curing adhesives do not need UV light. A new group of adhesives have been developed that cure under visible light (405-nm wavelength). Traditional light-cure adhesives, by contrast, need ultraviolet (UV) light with wavelengths between 250 and 365 nm. The difference of a few dozen nanometers of wavelength may not seem like a big deal, but it opens up a range of bonding, encap- sulation, and sealing applications that were previously unsuitable for light-curing adhesives. On the factory floor, for example, shifting to visible light eliminates the need for expensive UV lighting. In- stead, inexpensive light-emitting di- ode (LED) lamps can handle the job. And eliminating UV lights means OCTOBER 4, 2012MACHINE DESIGN.com52 OEM SERVICES Getting the knurl right Adding a knurl to a machined metal part isn’t all that diffi cult. Any machine shop with the right tools can do it. Knurling gets a lot more diffi cult, however, when you try to cast it as a s urface feature. One concern is that the raised portions of the knurl pattern will interfere with the release and ejection of parts from the tool. The pattern may require slight modifi ca- tions near the par ting line. Typically, pattern changes are barely noticeable on the fi n- ished par t. Gate vestiges and par ting lines can also interrupt the knurled pattern, creat- ing a small fl at section near par ting lines. “Casting in a knurling pattern is harder than it looks,” says D ynacast’ s Helmut Wolf. The payoff , however, can be signifi cant if casting the pattern el iminates a machining operation. Accord- ing to Wolf, there are a few design steps that simplify the task of making knurling a net -shape feature. Consider ejection implications. On the Dixon job, Wolf recommended subtle chang es to the geometry of the knurl’s raised sections — rounder edges, fi l- lets, and draft — to ease ejection from the tool. He also slightly chang ed the pattern near the parting line. These geometry changes cannot be seen or felt by someone using coupling. “They were made only for reasons of manufacturability,” Wolf says. Consider cosmetics. To eliminate disruptions gating can make on the kn urling pattern, Wolf was careful to locate gates on the pads formed by raised portions of the knurling pattern. The pat- tern geometry around the parting line was al so slightly altered fo r cosmetic reasons. Die casting the knurled sleeves on quick-connect couplings eliminated several machining operations and substantially reduced production costs. Converting from machining (left) to die casting called for subtle changes to the knurled pattern that are imperceptible to most users. Comparing knurls pany’s supply-chain manager. “We had to make sure the potential manufacturability benefits of die casting would not come at the expense of durability and qual- ity,” Karriker says. With help from engineers at Dyna- cast, headquartered in Charlotte, Dixon managed to lower the cost of making its sleeve component while maintaining quality. Here’s some advice they offer oth- ers looking to do the same. Pick the right part. Not all machined parts are good candidates for die casting. Low-production volumes, for example, make it tough to justify the expense of hard tooling. Requirements for exotic metal alloys can also rule out die casting. Looking beyond these obvious deal breakers, many parts are excellent candidates for die casting, particularly when net-shape or near-net- shape casting replaces machining. At Dixon, eliminating several machining operations tipped the scales in favor of die casting. According to Karriker, the sleeve’s original two-piece design required three machining steps — roughing out the part, adding Engineers often have an important decision to make when they design and source a metal part: Should it be machined or die cast? In the past, a cursory review of production volumes, tolerances, features, and alloy requirements would clearly favor one manufacturing method over the other. Today, the choice is anything but clear. Advance- ments in die-casting technology now make it possible to cast tight-tolerance features that once would have required multiple machining operations. By eliminat- ing machining steps, near-net-shape casting offers a manufacturability advantage that can reduce the costs of many metal components. The experience of Dixon Quick Coupling, a manu- facturer of hose fittings and accessories, offers one such example. The Charlotte, N. C.-based company recently converted a knurled sleeve for a quick-connect cou- pling from machining to die casting. Converting a proven machined part to a die cast- ing can be a big step, says Cindy Karriker, the com- Net-shape castings that eliminate machining operations can cut costs. Authored by: Kenneth J. Korane Managing Editor ken.korane@penton.com Resources: Dixon Quick Coupling, www. dixonquickcoupling.com Dynacast, www.dynacast.com Die casting takes on machining on the cast part would have limited the advantages of net-shape die casting. To overcome this hurdle, Dynacast’s engineers worked with Dixon to replicate the knurling pattern on the tooling surface. According to Helmut Wolf, Dynacast’s special projects director, this tooling-based approach requires more upfront design effort. “It can be difficult to get the surface detail right when converting machined parts to die castings,” he says. But adding sur- face texture in the tool eliminated an entire machining surface detail, and cutting the part in half. The die-cast version maintains the two-piece design but the two halves require no machining prior to assembly, making die casting less expensive. “Multiple machining setups can drive a lot of cost,” Karriker says. Add surface detail in the tool. One challenge in Dixon’s switch from machining to casting involved the knurling on the connector surface. This ergonomic feature improves “grip-ability” and is easy enough to machine, notes Karriker. But machining the knurling OCTOBER 4, 2012MACHINE DESIGN.com44 OCTOBER 4, 2012MACHINE DESIGN.com 45 VOLUME 84 ISSUE 15 OCTOBER 4, 2012 Access our Reader Service Web site to quickly find and request information on the products and services found in the pages of M ACHINE D ESIGN . www.machinedesign.com/rsc 52 44 38 56 52 48 44 From CAD to CFD in 5 minutes How to mesh a realgeometry. Die casting takes on machining Net-shape castings that eliminatemachining operationscan cut costs. Software speeds valve- terminal commissioning Valve terminals control numerous devices and handlelots of data. New software makes programming and setup mucheasier. Curing adhesives with “normal” light A new group of light-curing adhesives do not need UV light. Scope this out An understanding of oscilloscope operations, abilities, and limits improves circuit-design analysis and even troubleshooting. OCTOBER 4, 2012MACHINE DESIGN.com2 Wire duct and flexible tubing Signal and sensor terminal blocks and power distribution blocks AutomationDirect has some of the best prices available for cables, wire duct and wire, terminal blocks, and even the enclosures to put it all in. Our latest addition of communication data cables are a direct equivalent of popular brands. So check out our prices to see how we can help you stretch your controls budget! Choose from over 1,600 Hubbell/Wiegmann enclosures across NEMA 1, 3S, 3R, 4, 4X, 6P, 12, 4/12, and 13 ratings www.automationdirect.com 1-800-633-0405 Go online or call to get complete information, request your free catalog, or place an order. From cable to enclosures . High quality, low-capacitance data cables are designed with impedances specific for RS-232/RS-422 and RS-485 communication applications in industrial environments. ((&%$$'#("' (&%!&'#(% ("$#&" ! "%($#( %#'#(!%'#!(%&(&%$$'#("' (# %$(% ' "'&'$'("$#&" (%$!&%"$(('& (($#((&%!&'#(% ('(!&'! (((((""&('$&!("% ''! Cat5e STP (Twisted Pairs with overall Shield) Ethernet Patch Cables 500’ reels starting at: $279.00 (L19772-500) 1000’ reels starting at: $455.00 (L19772-1000) 100’ coil st arting at: $66.00 (L19772-100) For complete details, visit: www.automationdirect.com/data-cables RS# 103 DEPARTMENTS For customized article reprints and permissions please contact: Penton Reprints, 1-888-858-8851, e-mail at reprints@pentonreprints.com or visit pentonreprints.com. Editorial content is indexed in the Applied Science Technology Index, the Engineering Index, SciSearch and Research Alert. Microfilm copies available from National Archive Publishing Company (NAPC), 300 N. Zeeb Rd., P.O. Box 998, Ann Arbor, MI 48106-0998, Ph: 734-302-6500 or 800-420-NAPC (6272), extension 6578. 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M ACHINE D ESIGN (ISSN 0024-9114) is published semimonthly except for a single issue in January, February, June, July, and December by Penton Media, Inc., 9800 Metcalf Ave., Overland Park, KS 66212. Paid subscriptions include issues 1-18. Issue No. 19 (OEM Handbook and Supplier Directory) is available at additional cost. Rates: U.S.: one year, $139; two years, $199;. Canada/Mexico: one year, $159; two years, $239; All other countries: one year, $199; two years, $299. Cost for back issues are U.S. $10.00 per copy plus tax, Canada $15.00 per issue plus tax, and Int’l $20.00 per issue. Product Locator, $50.00 plus tax. Prepaid subscription: Penton Media (M ACHINE D ESIGN ), P.O. Box 2100, Skokie IL 60076-7800. Periodicals Postage Paid at Shawnee Mission, Kans., and at additional mailing offices. Can GST #R126431964. Canadian Post Publications Mail Agreement No.40612608. Canada return address: Pitney Bowes, P.O. Box 25542, London, Ont., N6C 6B2. 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EDITORIAL Jobs and the reverse innovation mindset EDITORIAL STAFF LETTERS SCANNING FOR IDEAS Stand-alone lubricator keeps things humming Quick connector simplifies pneumatic and hydraulic testing REPORTER’S NOTEBOOK LOOKING BACK COMMENTARY Stressed at work?— Leslie Gordon VANTAGE POINT Forget college, go to trade school — Mitch Free SOFTWARE REVIEW A “personal factory” that lets you make almost anything PRODUCT SPOTLIGHT Cables & carriers PRODUCTS BUSINESS INDEX AD INDEX BUSINESS STAFF BACKTALK 10 12 16 20 30 36 8 37 66 68 70 76 77 78 79 OCTOBER 4, 2012MACHINE DESIGN.com4 www x Low Cost Vacuum Generators For Lifting, Clamping, Mounting, Vessel Evacuation and “Pick and Place”! WATCH THE VIDEO! www.exair.com/45/48045.htm Vacuum Cups, Fittings, Tubing, & More EXAIR can provide the accessories you need to build your vacuum system. 11510 Goldcoast Drive Cincinnati, Ohio 45249-1621 Phone: (513) 671-3322 Fax: (513) 671-3363 Website: www.exair.com Email: techelp@exair.com EXAIR Modular E-Vac® Vacuum Generator Modular E-Vac vacuum generators use a compact block design for convenient mounting which is ideal for use on your existing machinery. Fourteen models for porous and non-porous applications are available. orrrrrrrrrrrorrorrro Adjustable E-Vac® Vacuum Generator Adjustable E-Vac vacuum generators permit easy adjustment by simply loosening the locknut and turning the exhaust to increase or decrease the level of vacuum. Four models available. Ideal for porous and non-porous applications. a n oror E-Vac® Vacuum Generators E-Vac® Vacuum Generators are compressed air powered vacuum pumps that provide instantaneous response and are most commonly used for pick and place operations. These single stage vacuum pumps are a low cost venturi available in a variety of sizes and ows along with a selection of vacuum cups suitable for a wide range of applications. 7,*- "0-,.0 !)$ 7+/0 +0 +$,1/2 "11*1-0,& 7 /50,*,1+0 0-,(+0,%1/$ 7 +&(+$$.$#%,.'(&'$9"($+"50, *(+(*(6$",*-.$//$# (.1/ &$ ht In-Line E-Vac® Vacuum Generator In-Line E-Vac vacuum generators are cylindrical and compact. They can be threaded directly onto a compressed air line or held in place with a mounting clip. Fourteen models for porous and non-porous applications. e a RS# 104 .e air.com/45/480.htmcowww. xair.ii EDITOR’S WEB PICKS What’s new online machinedesign.com VIDEOS TELL ALL ABOUT NEW DOMORE PLC AutomationDirect’s newest controller, the Do-more H2 Series, is a “supercharger” for the industry proven DirectLogic 205 PLC hardware. Learn Do-more’s story with this video series: The Overview hits the highlights, and compares the Do-more H2 CPUs to the current DL205 models. The Quick-Start video demonstrates the steps to create a simple program with the new Do- more Designer software. The Math Instruction video details the use of the Math function block, which offers capabilities from simple formulas to statistical functions. Other topics address helpful hints for configuring and programming, serial port use, Data View and Trend View windows for troubleshooting, and use of the built-in PLC simulator. To view the Do-more PLC video series, visit http://learn. automationdirect.com and look under the PLCs tab. Or find them at: www.youtube. com/automationdirect. Become a subscriber and get alerts when new videos are uploaded. Motors and motion courses SMMA – The Motor & Motion Assn. has scheduled three courses on November 6, prior to the start of its Fall Technical Conference. They include Fundamentals of Electric Motor Design, Fundamentals of Brushless Motor Control, and Permanent Magnet Fundamentals. Get more details at www.smma.org. Compression-molding brochure The new Victrex Compression Molding Guide discusses how to form large and intricate parts out of advanced thermoplastics. It discusses processes that can deliver void-free moldings and explains materials options for making high-performance parts that lower overall costs in demanding oilfield, transportation, electronics, and medical applications. Learn more at www.victrex.com. Quarter-scale V8 engine The Stinger 609 is reportedly the world’s smallest production V8 engine. At IMTS 2012, an engineer from Conley Precision Engines discussed lubrication issues with small engines, and how a new honing process overcomes the problem of excessive oil flow. See it at www. engineeringtv.com/video/Stinger- 609-Quarter-Scale-V-8-E;Only- Engineering-TV-Videos. FREE WEBCAST: DESIGNING EFFECTIVE SAFEGUARDING FOR MACHINES Thursday, October 18, 2:00 p. m. ET Attend this Webinar to learn how to design effective machine safeguarding. Experts from Schmersal will discuss types of hazards, various options for separating guards and devices, different levels of circuit design, and how to engineer a complete safety system. The presentation will also review in detail: • Fixed and movable guards. • Reaching and guard-opening design. • Interlock switches, including limit, keyed, non-contact, locking, and key- exchange versions. Learn more and register at http://machinedesign.com/training. CNC info Fanuc FA America has launched a Web site (www.fanucfa.com) offering detailed info on the company’s CNCs, drives, lasers, and engineering support. An expanded Industries section tells users more about requirements for aerospace, ag and construction, automotive, energy, job-shop, medical, metal-fabrication, mold-and-die, and woodworking applications. Medical nonwovens Fabrico is hosting a discussion on medical nonwovens on its www.fabricoforum.com site. Design engineers can learn about nonwovens’ advantages over traditional woven textiles, pose question, and seek the advice of experts. The FabricoForum is an open dialog where design engineers and others interested in materials and product assembly can read opinions and weigh-in on various topics. OCTOBER 4, 2012MACHINE DESIGN.com6 Generic Motion Control Technology by THE INNOVATORS Perfection in Automation www.br-automation.com ` Maximum system productivity through exceptional performance and system synchronization ` Supports advanced manufacturing technologies by integrating CNC, robotics and motion control with integrated safety technology ` Easy implementation of machine options because of software compatibility across all drive technologies ` Supports all machine topologies through the use of centralized and decentralized drive technology ` 5HGXFHGKDUGZDUHFRVWVDQGVLPSOLÀHGVHUYLFH Booth 4337 RS# 106 EDITORIAL Jobs and the reverse innovation mindset When GE CEO Jeffery Immelt signed on to head up the President’s Council on Jobs and Competitiveness, he began encouraging U. S. manufacturers to export their goods as a way to promote U. S. job growth. Trouble is that for most manufacturers, exporting involves a lot more than just finding a dis- tributor and shipping products overseas. In truth, it might be easy for companies the size of GE to think about exporting, but obstacles in foreign markets can be close to insurmountable for the average manufacturer. To understand the problem, consider reverse innovation, today’s trendy idea for U. S. manufacturers. Its basic premise is that you do the innovating in emerging markets, then somehow morph the resulting technology into something that can be sold here. Manufacturers must take this tack, we’re told, because Indian and Chinese consumers aren’t interested in buying low-end or lightly modified goods that western manu- facturers make. If true, that pretty much kills the idea that we can generate jobs in the U. S. just by exporting to emerging markets. What kind of innovation do you need to sell stuff in places like India? An example is the ChotuKool refrigerator made in Mumbai. It lists for $69 and relies on a Peltier module for cooling, so there is no compressor or plumb- ing to boost the cost. This technique is only good for cooling to 36°F below the ambient temperature, but thanks to high-quality insulation, it is good enough for the low-income consumers it targets. The fridge can also run on batteries if need be because of the notoriously unreliable grid system in India. The lesson of the ChotuKool, says Vijay Govindarajan, a business profes- sor at Dartmouth College, is that western appliance makers could undoubt- edly come up with similar offerings, but never by customizing one of their existing refrigerators. ChotuKool developers went through several iterations working with rural Indians and Indian financial institutions involved with microfinance to come up with a product appealing to households earning about $5 a day. That sort of collaboration is only possible by having a team on the ground in India. And that’s why it probably seems out of reach to mid- level U. S. manufacturers that can’t fund multiyear expatriate assignments in the developing world for their key employees. The problem of resources becomes even clearer by considering the effort Deere & Co. had to put into developing an agricultural tractor for India. As Govindarajan reports, all Deere’s machines were too heavy and expensive for Indian farmers. The tractor maker came up with a model having a mere 35 hp, but it was far from being just a low-end knock-off of an existing ve- hicle. After two years of market research in India — which included disas- sembling six rival tractors — Deere eventually came up with a design that addressed complaints from Indian farmers about maintenance by incorpo- rating new clutch technology developed for more-expensive models. More to the point, Deere had to use a product-development process that employed about 120 people with many of them from Deere’s Indian opera- tions. And manufacturing takes place in Pune, India, not here. The magnitude of these reverse-innovation efforts might seem reasonable to manufacturers the size of Deere or GE. But it’s not clear how any of this will result in U. S. jobs, let alone products useful for U. S. markets. And so it is with all but a handful of reverse innovations, despite the cheerleading by Jeffery Immelt. — Leland Teschler, Editor RS# 107 OCTOBER 4, 2012 . to machine, notes Karriker. But machining the knurling OCTOBER 4, 201 2MACHINE DESIGN. com 44 OCTOBER 4, 201 2MACHINE DESIGN. com 45 VOLUME 84 ISSUE 15 OCTOBER. OCTOBER 4, 201 2MACHINE DESIGN. com52 OEM SERVICES Getting the knurl right Adding a knurl to a machined metal part isn’t all that diffi cult. Any machine