CNC Machining, CAD/CAM Prototyping

Close Tolerance Grinding

2008-10-15T12:45:00.000-07:00

One of the things that separate competent machine shops from a precision shop is the ability to grind shapes to close tolerances. In prototype work, this means having the ability to grind parts with in ±10 microns with some companies grinding to a precision level of +1.00 micron. To give some perspective, a human hair is 75 microns thick. That’s how exact things have to be to meet the engineer’s original designs of today.

In order to get precision, it is paramount that all inputs in the process are strictly controlled. For example, slight differences in atmospheric temperature can effect feature size because of expansion/contraction factors (steel expands 2½ microns/25 mm/10°F). So, it’s important to have close tolerance parts measured between 68°F-72°F to ensure accuracy and repeatability of measurement.

As the demands for precise fits and finishes increase, grinding processes will be improved to meet the need. There are four basic grinding processes in prototype manufacturing; Surface Grinding, JIG Grinding, ID grinding, and OD Grinding. Surface Grinding is a processes referred to mostly when grinding flat surfaces. Jig Grinding is mostly used for grinding small diameter holes, such as dowel holes, in fixtures tool and dies. ID and OD Grinding pertain to grinding internal and external cylindrical shapes. These parts include bushings, shafts, rollers bearings, tubing, etc.

Grinding is an important component of prototype development and needs to be handled by an experienced shop that takes accuracy very seriously.

Mike Webster, Webster Engineering is a prototype and low-volume machine shop specializing in complex and precision metal work since 1962. Located in Roseville, Michigan, Webster Engineering is privately owned and certified to the ISO 9001:2000 International Standard. Webster Engineering has a reputation for providing solutions that exceed expectations for speed, accuracy, delivery, quality and cost – achieving real customer satisfaction. Contact Webster Engineering at 586-777-0116 or CNC Machining or Close Tolerance Grinding

Webster Engineering Implements A New Paperless Process Documentation System

2008-09-29T10:04:00.000-07:00

July, 2008

Webster Engineering has implemented a new paperless process documentation system throughout the organization to further enhance customer service and promote best practices.

According to John Webster, Manufacturing Manager, the new system is composed of ten computer stations placed in strategic locations throughout the organization linked together via a network. As orders are processed, employees document their value added activities at one of the work stations. Once the order is completed, documents are maintained electronically and available to all employees. If an employee wishes to look at a prior job, the only requirement is to know the job number.

These new paperless process documents include:

APQP/Open Issues,
Control Plans,
Shop Routings including Process Operations and Descriptions and Employees Responsible,
Tool & Fixture Drawings,
CNC Programs,
Set-up Instructions,
Operation (Work) Instructions,
In-process & Final Inspection Results
Customer Correspondence Including Drawings and Sketches.

Mr. Webster emphasizes the importance of having a central place for all product realization information to gather. "It replaces those little scraps of paper that employees use when brainstorming then toss when the job is complete" he says; referring to the sketches employees would make when designing a manufacturing process. "We are now able to gather and maintain all the information in making a part so five years later we don’t need to re-invent the wheel".

The new system was designed and implemented by the employees of Webster Engineering. "It was going to be too expensive to bring in a consultant, we just don’t make that kind of money anymore" explains Mike Webster, Company President. He further explains "the system works for us and for our customers, and that’s all that counts".

Mike Webster, Webster Engineering is a prototype and low-volume machine shop specializing in complex and precision metal work since 1962. Located in Roseville, Michigan, Webster Engineering is privately owned and certified to the ISO 9001:2000 International Standard. Webster Engineering has a reputation for providing solutions that exceed expectations for speed, accuracy, delivery, quality and cost – achieving real customer satisfaction. Contact Webster Engineering at 586-777-0116

Webster Engineering Announces the Purchase of a Hass Trunion Table

2008-09-29T10:01:00.000-07:00

Webster Engineering has purchased a Haas model 1065XB 5-Axis Trunion Table from Haas Automation, Oxnard, California. The table will be bolted to a Haas VF-SSYT Vertical Machining Center purchased in late 2005. The purchase was made to help with efficiencies in productions.

According to Mike Webster, President of Webster Engineering, the 5 axis attachment was purchased to machine automatic transmission torque converter components. Mr. Webster further explains that the geometry of the torque converter; the converter blades, the torus rings, the stator, the impeller and turbine components lend themselves to 5-Axis machining. The savings in time and money will be significant compared to using older conventional methods for prototyping.

Webster Engineering has specialized in transmission prototypes for the automobile and off highway industries since 1962. In addition to torque converters, the company makes valve bodies, pumps, transmission cases, gears, carriers and a variety of stampings. They are also actively seeking to expand their business in the construction equipment industry.

Webster Engineering is a prototype and low-volume machine shop specializing in complex and precision metal work since 1962. Located in Roseville, Michigan, Webster Engineering is privately owned and certified to the ISO 9001:2000 International Standard. Webster Engineering has a reputation for providing solutions that exceed expectations for speed, accuracy, delivery, quality and cost – achieving real customer satisfaction. Contact Webster Engineering at 586-777-0116

Webster Engineering Purchases A Hitachi Seiki HMC 630 Dual Pallet Horizontal Machining Center

2008-09-29T09:56:00.000-07:00

August 2007

Webster Engineering, a prototype engineering firm, has agreed to purchase a Hitachi Seiki HMC 630 Dual Pallet Horizontal Machining Center from Pinnacle Machine Tool Co., Sterling Heights, Michigan. This One Degree Indexing Horizontal Machining Center has a work envelope of 35” in the X-Axis, 31½” in the Y-Axis and 28” in the Z-Axis, with a Pallet size of 24¾”X24¾”.

Mike Webster, company President, states the new machine will expand the company’s capabilities for machining larger parts at higher volume levels. Webster further explained the machine will open up new markets for machining automotive and off road Transmission Cases, Differentials, Engine Blocks, Cylinder Heads and other larger Powertrain Commodities. The expected delivery of the machine is September, 2007.

Webster Engineering has been in the business of manufacturing experimental automotive and off highway powertrain components since 1962. The company specializes in offering professional prototyping services to Product Engineers throughout the United States and Canada. Webster engineering is diversifying its business and is currently seeking quotes from outside industries such as construction equipment, agricultural and heavy industrial engines.

CNC Machining – Thinking of Taking it in House?

2008-09-29T09:40:00.000-07:00

First of all what exactly is CNC machining? It stands for computerized numerical control. But what CNC machining really means is perfection. It’s all about producing top quality parts on prototypes and low volume production runs at low costs and being as close to the original design as possible. Being an expert at the intricacy of the technology and capabilities is critical to achieving this goal. And we’re talking about 1 ten thousands of an inch here. The mind set for businesses that do their own CNC machining or are considering taking their current CNC machining in house, has to be perfection.

With low volume prototype production of 1 to 1,000 parts, CAM (computer aided manufacturing) programs must be used to truly optimize the CNC machining process.

Applying best practices throughout, from design to manufacture, should drive the machined parts to your exact designs. Keeping material scrappage as low as possible, will also help in keeping your costs down. In addition, working with skilled and experienced staff can play a major role in CNC machining that’s done properly. In that there is still an “art” side of CNC machining that needs experienced eyes to see and make immediate corrections and adaptations.
Quality control is a very important aspect of CNC machining. Every machining operation and part needs to have a process for inspection to ensure compliance to your specifications and designs. Completed products need to be evaluated and documented as proof positive that they meet your standards.

The critical thing here for businesses that are considering taking their CNC machining in house is that they should take their time to adequately plan and prepare. They should have a process and system for their prototypes. One or two mistakes will often eliminate any savings, and often raise the costs substantially than if they where to just to outsource the project in the first place.

Mike Webster, Webster Engineering is a prototype and low-volume machine shop specializing in complex and precision metal work since 1962. Located in Roseville, Michigan, Webster Engineering is privately owned and certified to the ISO 9001:2000 International Standard. Webster Engineering has a reputation for providing solutions that exceed expectations for speed, accuracy, delivery, quality and cost – achieving real customer satisfaction. Contact Webster Engineering at 586-777-0116

CNC Machining - An Overview

2008-09-29T09:32:00.000-07:00

CNC stands for computer numerical control. It refers to a computer "controller" that reads instructions code which dictates how a machine operates. And is typically associated with the removal of material such as metal for the creation of a complex part. The design and cutting is controlled by software programs like, CAM and others.

The earlier version of CNC was a system referred to as NC or Numerically Controlled machines, which were basically physically wired and their operating parameters where difficult at best to change, if at all.

Punched tape was used and continued to be used as a medium for transferring codes into the controller for many decades after 1950’s. It is now replaced with computer networks and software program that aid greatly to efficiencies and the ability to adapt mid project.

CNC machining have changed the tool and die industry and manufacturing in general since their introduction. The programs have lead to eliminating most of the human involvement. For example, curves are now as easy to cut as straight lines, complex 3-D structures are much easier to produce, and the number of steps to produce a part has been dramatically reduced.

Beside the efficiencies of manufacturing created by CNC, a further benefit has been a major improvement in quality control. With less human involvement more consistency in production, quality has been the result. Bottom line, CNC eliminates many mistakes and errors that human involvement can lead too.

In a company that focuses on CNC machining, they often set up a series of CNC machines sometime referred to as a Cell. The interesting thing here is that a series of CNC machines can be set up together allowing the part to go from one machine to the next, all without human involvement. For example, some companies have automated the process to the point that they will leave their machines running over night and over weekends with no operator involvement. Laser devices check for quality control and alert the controllers if any defects are found.