A Special Report
especially true when it comes to the aerospace, automotive and energy sectors.
In fact, manufacturers are more positive about the US than other parts of the world. PwC reported that 60% of large global manufacturers surveyed for its third-quarter Manu- facturing Barometer were optimistic about the US economy, versus 40% for the global economy. “The US remains the growth driver in the industrial manufacturing sector, with continued signs of healthy demand, pricing strength, new product investment and hiring,” Bono said. “Overall top line growth expectations remain moderate and management teams are continuing to take a careful approach to capital allocation and cost management while preserving liquidity.” Here’s how specific areas of the manufacturing industry are faring now:
Machines & Automation
The days of one man-one machine are, for the most part, dead.
The advanced manufacturing machines of today are aimed at doing many tasks at one time, in one setup, and better yet, around the clock and without anybody watching. For now, subtractive manufacturing, versus new additive (3D) methods, remains the primary means of making these things.
Material removal (chip making) and form-
With that in mind, many of the subtractive manufactur- ing machines and ancillary equipment are becoming more advanced than ever.
Advanced manufacturing technologies include the latest high-precision, multifunction machine tools, related ancil- lary equipment, CAD/CAM and controls software available to improve productivity, processes and products, and increase competitiveness. Advanced machine tools include multitask- ing mill/turns, five-axis machining centers, and the latest high- power lasers and waterjets, as well as automation and related componentry-like sensors.
Manufacturing tools and machines have grown in complexity and sophistication, requiring much more skill from workers who use them.
ing continue to be the principal means of shaping materials, including metals, ceramics, plastics for prismatic parts and turned components, like shafts and other rotating parts. While innovative 3D printing, also known as Additive Manufacturing (AM), is regarded by some as the most likely next game-chang- ing or disruptive manufacturing technology, it is not yet ready for mass production. 3D printing replaces the traditional metal removal or metal forming processes with an additive process of building workpieces up through layering plastics and metals and hardening the parts with application of a heat source. AM, which has cut its teeth in one-off prototyping applications, limited production, and fixture building, is moving into lower volume applications, especially of smaller complex workpieces with internal cavities. The limitation of work envelope size and scalability for 3D printed metal parts is being addressed by one machine tool builder that has introduced 3D printing on standard machining center platforms.
The distinction between machines that perform only one dedicated process like milling (for prismatic parts) and turning for shaft or rotating parts is rapidly disappearing. The reason: combining multifunction operations on multitasking machines eliminates the need to refixture components as they move from one machine/process (milling) to another (turning) and drilling, as well as grinding and other processes. Single setup minimiz- es, if not totally eliminates, quality-robbing tolerance stackup and deviation from final part print dimensions. The trend toward flexible machining center and turning cen- ter cells that can run untended 24/7 is also continuing. OEMs and tier manufacturer suppliers to the automotive industry, for example, are using machining centers that can be configured into cells tended by robots and serviced by rail-guided pal- letization systems. Cells can be reconfigured and repurposed as product model designs and requirements change based on MTConnect-enabled production and scheduling data collection.
March 2014 |
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