Troll Kingdom

This is a sample guest message. Register a free account today to become a member! Once signed in, you'll be able to participate on this site by adding your own topics and posts, as well as connect with other members through your own private inbox!

Introduction To Machine Tools

Goat

wolverines ate my mother
Introduction to Machine Tools
This document will introduce some of the basics of machine tool use for prototype fabrication. There are graphics and sections of video that can be accessed throughout the document. After brief explanations of some machining operations there will be hypertext links to short (about 30 second) video clips. All links in italics access video. The links at the head of the documents allow one to jump forward to desired subject matter.

Shop Safety
Metal Cutting Physics
Measurement
Part Layout
Band Saw
Belt Sander
Drill Press (and tapping holes)
Lathe
Milling Machine
Grinding and Buffing
Working with Sheet Metal
 
Machine Shop Safety
Safety Glasses
EVERYONE MUST WEAR SAFETY GLASSES IN THE SHOP.
Even when you're not working on a machine, you must wear safety glasses. A chip from a machine someone else is working on could fly into your eye.

Clothes and Hair
Check your clothes and hair before you walk into the shop. In particular:
IF YOU HAVE LONG HAIR OR A LONG BEARD, TIE IT UP.
If your hair is caght in spinning machinery, it will be pulled out if you're lucky. If you're unlucky, you will be pulled into the machine.
NO LOOSE CLOTHING.
Ties, scarves, loose sleves, etc. are prohibited
NO GLOVES
REMOVE JEWELERY
WEAR APPROPRIATE SHOES
No open toed sandals. Waer shoes that give a sure footing. If you are working with heavy objects, steel tes are reccommended.

Safe Conduct in the Shop
Be aware of what's going on around you. For example, be careful not to bump into someone while they're cutting with the bandsaw (they could lose a finger!).
Concentrate on what you're doing. If you get tired, leave.
Don't hurry. If you catch yourself rushing, slow down.
Don't rush speeds and feeds. You'll end up damaging your part, the tools, and maybe the machine itself.
Listen to the machine. If something doesn't sound rigth, turn the machine off.
Don't let someone else talk you into doing something dangerous.
Don't attempt to measure a part that's moving.

Machining
IF YOU DON'T KNOW HOW TO DO SOMETHING, ASK!
BEFORE YOU START THE MACHINE:

Study the machine. Know which parts move, which are stationary, and which are sharp.
Double check that your workpiece is securely held.
Remove chuck keys and wrenches.
DO NOT LEAVE MACHINES RUNNING UNATTENDED!

CLEAN UP MACHINES AFTER YOU USE THEM!
A dirty machine is unsafe and uncomfortable to work on.
Do not use compressed air to blow machines clean. This endangers people's eyes and can force dirt into machine bearings.


Return to outline
On to metal cutting physics
 
Metal cutting Physics
Idealized Chip Formation
Built Up Edge
Calculating Speeds and Feeds


Idealized Chip Formation
The figure below depicts an idealized, two dimensional view of the metal cutting process. The assumptions in this model are that the tool is perfectly sharp, that the cut depth t and the cutting speed V are constant, and that the cut depth is small compared to the cut width. In this idealized model, the material layer at the top is formed into a chip by a shearing process in the primary shear zone at AB. The chip slides up the rake face undergoing some secondary plastic flow due to the forces of friction. This idealized model correctly predicts that cutting force increases with cut depth, material hardness, and friction coefficient. Cutting forces are inversely propoortional to rake angle. Power required increases with the feed rate.

Idealized Chip Formation

metal_cut


Built Up Edge
One important effect that is not considered in the model above is built up edge. Under most cutting conditions, some of the cut material will attach to the cutting point. This tends to cause the cut to be deeper than the tip of the cutting tool and degrades surface finish. Also, periodically the built up edge will break off and remove some of the cutting tool. Thus, tool life is reduced. In general, built up edge can be reduced by:

Increasing cutting speed
Decreasing feed rate
Increasing ambient workpiece temperature
Increasing rake angle
Reducing friction (by applying cutting fluid)
bue.gif

Built Up Edge



Calculating Speeds and Feeds
Cutting speed refers to the speed at which the tool point of the cutter moves with respect to the work measured in feet per minute. Feed is the rate at which the work moves into the cutter measured in feed per tooth revolution. Feeds and speeds affect the time to finish a cut, tool life, finish of the machined surface, and power required of the machine.

The cutting speed is mostly determined by the material to be cut and the material of the tool. To find the right speed for any task, refer to the Machinery's Handbook or other reference. To calculate the proper spindle speed, divide the desired cutting speed by the circumference of the tool (or of the part if it is rotating) expressed in feet. The feed rate depends on the width and depth of cut, finish desired and many other variables. To calculate the desired feed setting from the feed rate, multiply feed per tooth per revolution by number of teeth and rpm of the spindle.


Return to outline
On to measurement
 
Measurement
Introduction
Calipers
Micrometer


Introduction
Measurement is the comparison of an unknown dimension to a known standard. Good measuring instruments were a key to high volume production. Without them, parts could not be built accurately enough to be interchangeable. Each assembly had to be hand fitted together. Today, measuring tools are essential for most machining operations from initial part layout to final inspection.


Calipers
The figure below depicts a caliper. It can measure lengths from 0 to 7.5 inches to a precision of one thousandth of an inch. One can measure the outside of a part with the jaws, the inside of a hole or slot with the nibs, or the depth of a hole or shoulder with the extension bar.

This particular one is has a vernier scale. It takes a little practice to read it properly. Calipers often have a dial or digital readouts instead.
http://www-me.mit.edu/Lectures/MachineTools/measure/caliper.gif[/IMG]

A Vernier Caliper

To read a vernier caliper:

Read the large number division first.
Read the small number division.
Read the number of smaller subdivisions. Each represents 0.025 inches to be added to the measurement.
Read which line on the vernier lines up with a line on the main beam. For each line a thousanth must be added to the measurement.
An example follows:
read_vern.gif

Reading a Vernier Scale - An Example

Micrometer
A micrometer generally provides greater precision than a caliper, but can measure a smaller range of lengths. A micrometer is depicted in the drawing below.
micro.gif


Parts of a Micrometer

To use a micrometer, place the part in the opening. Next, turn the thimble until the spindle contacts the work. To apply a consistent pressure to the part, use the ratchet stop. Use the clamp ring to hold the thimble in place while you read the micrometer. To read the micrometer:

Read the exposed number on the barrel.
Read the number of divisions past the number. Each division represents 0.025 inches.
Read the division on the spindle. These usually read to less than thousandths of an inch.
read_micro.gif

An example of reading the micrometer follows:
Reading a Micrometer - An Example
Return to outline
On to part layout
 
Part Layout
Introduction
Scribing Lines
Using a Center Punch
Using a Compass



Introduction
Always have your drawings completed before coming to the machine shop. The shop can be distracting and you're bound to make mistakes if you try to drafting or design work there.

One good way to lay a part out on a piece of stock is simply to plot out a 1:1 scale drawing of the part and glue it to the part surface. If you do it this way, you can be sure no errors will be made in transferring the part from the computer to the suface of the part.

If a scale drawing is not available, the part can be layed out by hand. First, apply a thin coat of blue die. If you apply too much, it will have a tendency to flake off when you try to scribe a line through it. You can use a square and a scribe to make a line perpendicular to an edge on your part. The scribed line will be about 0.002 inches wide, so you can make a reasonably accurate part by milling up to such a line by eye.
(click here for video)1.6MB



Scribing Lines
You can make a line that is parallel to an existing edge on your part by offsetting a specified distance with a ruler or, more accurately, with parallel plates. Parallel plates come in widths spaced 1/16 inch apart and can be stacked up to achieve desired dimensions. Note how an extra parallel is held vertical to provide alignment with the edge of the part.
(click here for video)1.6MB

Another way to scribe lines offset from an existing feature is with a caliper. First, set the desired offset and lock it in. Then, run the caliper along the edge of the part scribing a line with the point of the caliper as you go. This is quick and easy, but somewhat less accurate than using parallel plates.
(click here for video)1.5MB


Using a Center Punch
Locations of holes referenced to corners can be found by crossing two scribe lines. Hole positions should be marked with a center punch. If accuracy is important, use a magnifying glass to set the punch on the mark. Then, give the punch a couple of light taps with a hammer.
(click here for video)0.7MB

The centerpunch creates a dimple that tends to guide the drill bit to the proper location. Withou the dimple, the drill bit can "walk" away from the desired location.


Using a Compass
Circles and fillets can be layed out using a compass. Just set one end at the center of the arc, then scribe the arc.
(click here for video)1.4MB


Return to outline
On to band saw
 
Band Saw
Labeled Photograph
Description
Selecting and Installing a Blade
Operating a Band Saw
Lubricating the Blade
Cutting Round Stock

bandsaw.gif




A Bandsaw in the 2.70 Shop


Description

The bandsaw is useful for cutting stock to size and roughing out shapes. It contains a serrated blade that forms one continuous loop. The blade is stretched over two pulleys, the upper one idle, the lower one driven by a variable speed electric motor.


Selecting and Installing a Blade
There are many different types of blades that can be installed in a band saw. They vary in tooth size, tooth shape, blade material, etc. If you're unsure of what type of blade to use for a particular task, the job selector dial may provide guidance, or refer to a handbook or manufacturer's documentation. The material to be cut should be at least three tooth widths in thickness. Therefore, it is often best to cut thin sheets with a shear rather than with a bandsaw (see Working with Sheet Metal). When the proper blade is found, it can be cut to length and welded into a continous band using an electrical resistance welder built into the band saw. Upper and lower doors open to expose the pulleys. A tensioner allows the upper pulley to be raised and lowered. Lowereing the upper pulley makes it easier to install a new blade. The blade must lay properly in the upper and lower blade guides. Once the blade is in place, the tension should be set and locked.


Operating a Band Saw
Before starting the bandsaw, you should adjust the blade guide/guard to the appropriate height. The less blade that's exposed, the safer you will be. Always set the blade guide just high enough to clear the part you're cutting.
(click here for video)635kB

The appropriate cutting speed varies widely for different jobs. For instance, mild steel should be cut at much lower speeds than Aluminum alloys. The Job Selector Dial may help you choose the right motor speed for your task. To adjust the blade speed the motor must be on. Motor speed can be varied with the variable speed control while motor rpm is monitored on the speed indicator dial.

When cutting with a bandsaw, proper technique is important. Do not lean excessively into the work and keep your hands braced against the table.

One of the best features of the bandsaw is its ability to cut curved shapes. Watch for proper position of the hands in this clip.
(click here for video)697kB


Lubricating the Blade
If you're making a long or deep cut, lubricate the blade with stick wax. Just push the tube briefly into the running blade. Do not attempt to apply wax with your fingers.
(click here for video)573kB


Cutting Round Stock
The band saw has a tendency to spin round stock and the rough edges of the stock could cut your hands. To avoid this, secure the stock in a drill press vise before cutting.
(click here for video)1.6MB


Return to outline
On to belt sander
 
Belt Sander
Labeled Photograph
Description
Operating a Belt Sander
Using a Small Belt Sander

beltsand.gif


A Belt Sander in the 2.70 Shop


Description
A belt sander is useful for removing burrs and rough edges from parts. It is composed of a belt coated with abrasive riding about two pulleys. The lower pulley is driven by a motor. The upper pulley follows and allows tension in the belt to be adjusted.

Beltsanders are effective on wood, most metals (aluminum, steel, brass, etc), and some plastics. The small particles generated by the belt sander can be toxic. It's good to use a sander with a vent attached to it and to wear a mask when using the belt sander. Don't use the belt sander on printed circuit boards or fiberglass; they create toxic particles.


Operating a Belt Sander
When smoothing edges and rounding corners, the part should be supported on the table of the machine. The part should be moved back and forth to achieve a better finish and to avoid hot spots on the belt.
(click here for video)1.76MB

To round off the edges of a part, one must hold the part on an angle with respect to the belt. Be sure that the belt is pointing down into the belt as demonstrated in the video. If the part is pointing up, the belt could catch on the part and throw it down into your hand. Note the size of the gap between the belt and table is wider than the workpiece. This is a ddangerous situation. The gap should be adjusted.
(click here for video)2.25MB


Using a Small Belt Sander
Some jobs cannot be done on the large belt sander shown above. For instance it is impossible to smooth out the faces of an inside corner. For this task, a smaller machine with a thin belt is appropriate.
(click here for video)636kB

As the small belt sander was previously configured, it is difficult to smooth out convex features without creating facets on the part. This problem can be alleviated by reconfiguring the machine. The table and platen can be removed to allow the belt to conform to the shape of your part.
(click here for video)2.03MB


Return to outline
On to the drill press
 
Drill Press
Labeled Photograph
Description
Using a Center Finder
Drilling a Hole
Deburring a Hole
Reaming a Hole
Thread Standards
Tapping a Hole

drill.gif


A Drill Press in the 2.70 Shop


Description
A drill press is preferable to a hand drill when the location and orientation of the hole must be controlled accurately. A drill press is composed of a base that supports a column, the column in turn supports a table. Work can be supported on the table with a vise or hold down clamps, or the table can be swiveled out of the way to allow tall work to be supported directly on the base. Height of the table can be adjusted with a table lift crank than locked in place with a table lock. The column also supports a head containing a motro. The motor turns the spindle at a speed controlled by a variable speed control dial. The spindle holds a drill chuck to hold the cutting tools (drill bits, center drills, deburring tools, etc.).

The quill is moved up and down with a lever on the side as shown here.
(click here for video)328kB


Using a Center Finder
A center finder is useful for setting the spindle of a drill press or mill accurately over a known point. A center finder is made of two searate pieces spring loaded together.
(video missing for now)

The center finder is used by installing it in the chuck, placing the pointed end into a centerpunch mark, and pressing down lightly on the quill. At first, the two parts will probably not be concentric. (video missing for now)

The bed of the drill or mill can then be adjusted to until the two halves are concentric. Check for concentriccity by running your fingers up and down the center finder. You should detect no steps. You should be able to locate the desired position to within .001 inches using this technique. Now the hole is ready to be drilled.


Drilling a Hole
First, a center drill should be used. A center drill has a thick shaft and very short flutes. It is therefore very stiff and won't walk as the hole is getting started. It doesn't cut as easily as a drill bit, so you should use cutting fliud.
(video missing for now)

Now the hole can be drilled. If the hole is large, its a good idea to drill a smaller pilot hole before drilling the final one. Your hole will be more accurately positioned, rounder, and the bits will last longer. If the hole is deeper than it is wide. use coolant and back off occaisionally to clear the chips. As you step up in drill size, you will need to reduce the spindle speed. If drilling a through hole, ensure that the bit will not drill the table after moving through your work. To set a desired depth of hole, there is a depth stop on the quill.
(video missing for now)


Deburring a Hole
Usually, the top edge of the hole will be fairly clean, but the bottom edge will have substantial burrs. To remove them, insert a deburring tool into the hole and run the tool about the edge of the hole with moderate pressure.
(video missing for now)


Reaming a Hole
A drilled hole will be accurate to about two thousandths of an inch in diameter. If greataer precision is required for slip fits or interference fits, a reamer must be used. The straight flutes of a reamer cannat drill a hole. You must drill a hole slightly udersize to start. Be sure to drive the reamer down with a constant, slow speed.
(click here for video)1.27MB


Thread Standards
The threads cut by taps and dies conform to a standard for the shape of the threads. Often it is the Americain National Standard in National Coarse (NC) or National Fine (NF). NC has fewer threads per inch than NF. NC is most common while NF is favored in prcision assemblies. Also in common use is the Unified Thread System with UNC (coarse) and UNF (fine). The onlt difference between National and Unified threads is the shape of the root and crest. The threads in the two different standards will mate. Fasteners are designated by their diameter, number of threads per inch, and shape. For example, 1/4-20NC means 1/4 inch diameter, 20 threads per inch, and National Standard. Threads smaller than 1/4 inch are designated by number from 0 (smallest) to 12 (largest). To convert number to diameter multiply by 0.013 and add 0.060.

threads.gif

Thread Standards


Tapping a Hole
If you want to cut threads in a hole, use a tap. The picture below shows what a tap looks like. It has cutting edges to cut the threads and straight flutes to allow chips to be expelled. Note that the end is tapered slightly to help the tap get started. Taps and dies are hard and brittle so you should be careful working with them (try not to drop them or force them into a hole when stuck). Be sure that the hole you drilled is the correct size for the tap you're using or it may break inside your part. Refer to a chart or machinist's handbook. The die in the picture is for cutting external threads on a shaft.

taps.


Two Taps and a Die

In the clip below, the hole is tapped by hand. Note that the tap did not go in quite straight. It is better to use the drill press to help maintain alignment as you tap the hole. First, use the centerfinder to place the spindle directly above the hole. Then install a tapered guide into the chuck. Put the tap in place and apply moderate pressure with the quill as you turn the tap. It's good peactice to back the tap up a bit for every quarter turn of thread you cut.
(video missing for now)


Return to outline
On to lathe
 
Lathe
Labeled Photograph
Description
Choosing a Cutting Tool
Installing a Cutting Tool
Positioning the Tool
Feed, Speed, and Depth of Cut
Turning
Facing
Parting
Drilling
Boring
Single Point Thread Turning
Advanced Work Holding

lathe.gif


A Lathe in Building 35


Description
The purpose of a lathe is to rotate a part against a tool whose position it controls. It is useful for fabricating parts and/or features that have a circular cross section. The spindle is the part of the lathe that rotates. Various workholding attachments such as three jaw chucks, collets, and centers can be held in the spindle. The spindle is driven by an electric motor through a system of belt drives and/or gear trains. Spindle speed is contolled by varying the geometry of the drive train.
The tailstock can be used to support the end of the workpiece with a center, or to hold tools for drilling, reaming, threading, or cutting tapers. It can be adjusted in position along the ways to accomodate different length workpices. The ram can be fed along the axis of rotation with the tailstock handwheel.
The carriage controls and supports the cutting tool. It consists of:


A saddle that mates with and slides along the ways.
An apron that controls the feed mechanisms.
A cross slide that controls transverse motion of the tool (toward or away from the operator).
A tool compound that adjusts to permit angular tool movement.
A toolpost T-slot that holds the toolpost.


Choosing a Cutting Tool

cutterms.gif


Cutting Tool Terminology

The figure above shows a typical cutting tool and the terminology used to describe it. The actual geometry varies with the type of work to be done. The standard cutting tool shapes are shown below.


Facing tools are ground to provide clearance with a center.
Roughing tools have a small side relief angle to leave more material to support the cutting edge during deep cuts.
Finishing tools have a more rounded nose to provide a finer finish. Round nose tools are for lighter turning. They have no back or side rake to permit cutting in either didection.
Left hand cutting tools are designed to cut best when traveling from left to right.
Aluminum is cut best by specially shaped cutting tools (not shown)that are used with the cutting edge slightly above center to reduce chatter.

cuttools.gif


Standard Cutting Tools

Installing a Cutting Tool
Lathe cutting tools are held by tool holders. To install a tool, first clean the holder, then tighten the bolts.
(click here for video) 2.11MB

The tool post is secured to the compound with a T-bolt. The tool holder is secured to the tool post using a quick release lever.
(click here for video) 1.99MB



Positioning the Tool
In order to move the cutting tool, the lathe saddle and cross slide can be moved by hand.
(click here for video) 860kB

There are also power feeds for these axes. Procedures vary from machine to machine.

A third axis of motion is provided by the compound. The angle of the compound can be adjusted to allow tapers to be cut at any desired angle. First, loosen the bolts securing the compound to the saddle. Then rotate the compound to the desired angle referencing the dial indicator at the base of the compound. Retighten the bolts. Now the tool can be hand fed along the desired angle. No power feed is available for the compound. If a fine finish is required, use both hands to achieve a smoother feed rate.
(click here for video) 2.05MB

The cross slide and compound have a micrometer dial to allow accurate positioning, but the saddle doesn't. To position the saddle accurately, you may use a dial indicator mounted to the saddle. The dial indicator presses against a stop (often a micrometer as shown in the clip below).
(click here for video) 1.29MB



Feed, Speed, and Depth of Cut
Cutting speed is defined as the speed at which the work moves with respect to the tool (usually measured in feet per minute). Feed rate is defined as the distance the tool travels during one revolution of the part. Cutting speed and feed determines the surface finish, power requirements, and material removal rate. The primary factor in choosing feed and speed is the material to be cut. However, one should also consider material of the tool, rigidity of the workpiece, size and condition of the lathe, and depth of cut. For most Aluminum alloys, on a roughing cut (.010 to .020 inches depth of cut) run at 600 fpm. On a finishing cut (.002 to .010 depth of cut) run at 1000 fpm. To calculate the proper spindle speed, divide the desired cutting speed by the circumference of the work. Experiment with feed rates to achieve the desired finish. In considering depth of cut, it's important to remember that for each thousandth depth of cut, the work diameter is reduced by two thousandths.


Turning
The lathe can be used to reduce the diameter of a part to a desired dimension. First, clamp the part securely in a lathe chuck (636kB). The part should not extend more that three times its diameter. Then install a roughing or finishing tool (whichever is appropriate). If you're feeding the saddle toward the headstock (as in the clip below) use a right-hand turning tool. Move the tool off the part by backing the carriage up with the carriage handwheel, then use the cross feed to set the desired depth of cut. In the clip below, a finish cut is made using the power feed for a smoother finish. Remember that for each thousandth depth of cut, the work diameter is reduced by two thousandths.
(click here for video) 821kB


Facing
A lathe can be used to create a smooth, flat, face very accurately perpendicular to the axis of a cylindrical part. First, clamp the part securely in a lathe chuck (636kB). Then, install a facing tool. Bring the tool approximately into position, but slightly off of the part. Always turn the spindle by hand (248kB)before turning it on. This ensures that no parts interfere with the rotation of the spindle. Move the tool outside the part and adjust the saddle to take the desired depth of cut. Then, feed the tool across the face with the cross slide. The following clip shows a roughing cut being made; about 50 thousandths are being removed in one pass. (click here for video) 2.35MB If a finer finish is required, take just a few thousandths on the final cut and use the power feed. Be careful clearing the ribbon-like chips; They are very sharp. Do not clear the chips while the spindle is turning. After facing, there is a very sharp edge on the part. Break the edge (205kB) with a file.


Parting
A parting tool is deeper and narrower than a turning tool. It is designed for making narrow grooves and for cutting off parts. When a parting tool is installed, ensure that it hangs over the tool holder enough that the the holder will clear the workpiece (but no more than that). Ensure that the parting tool is perpendicular to the axis of rotation and that the tip is the same height as the center of the part. A good way to do this is to hold the tool against the face of the part. Set the height of the tool, lay it flat against the face of the part, then lock the tool in place. (click here for video) 2.45MB When the cut is deep, the side of the part can rub against sides of the groove, so it's especially important to apply cutting fluid. In this clip, a part is cut off from a piece of stock.
(click here for video) 246kB


Drilling
A lathe can also be used to drill holes accurately concentric with the centerline of a cylindrical part. First, install a drill chuck into the tail stock. Make certain that the tang on the back of the drill chuck seats properly in the tail stock. Withdraw the jaws of the chuck and tap the chuck in place with a soft hammer. (click here for video) 1.93MB

Move the saddle forward to make room for the tailstock. Move the tailstock into position, and lock the it in place (otherwise it will slide backward as you try to drill). Before starting the machine, turn the spindle by hand. You've just moved the saddle forward, so it could interfere with the rotation of the lathe chuck. Always use a centerdrill to start the hole (2.30MB). You should use cutting fluid with the centerdrill. It has shallow flutes (for added stiffness) and doesn't cut as easily as a drill bit. Always drill past the beginning of the taper to create a funnel to guide the bit in (click for computer generated animation of funnel effect, not yet available). In this clip, a hole is drilled with a drill bit.(click here for video) 1.07MB Take at most one or two drill diameters of material before backing off, clearing the chips, and applying cutting fluid. If the drill bit squeeks, aplly solvent more often. The drill chuck can be removed from the tail stock by drawing back the drill chuck as far as it will easily go, then about a quarter turn more. A pin will press the chuck out of the collet. (click here for video) 554kB

Boring
Boring is an operation in which a hole is enlarged with a single point cutting tool. A boring bar is used to support the cutting tool as it extends into the hole. Because of the extension of the boring bar, the tool is supported less rigidly and is more likely to chatter. This can be corrected by using slower spindle speeds or by grinding a smaller radius on the nose of the tool.

bore.gif


Boring On a Lathe

Single Point Thread Turning
External threads can be cut with a die and internal threads can be cut with a tap. But for some diameters, no die or tap is available. In these cases, threads can be cut on a lathe. A special cutting tool should be used, typically witha 60 degree nose angle. To form threads with a specified number of threads per inch, the spindle is mechanically coupled to the carriage lead screw. Procedures vary for different machines.


Advanced Work Holding
Some parts require special techniques to hold them properly for lathe work. For instance, if you wish to cut on the entire outside diameter of a part, then the part cannot be held in a chuck or collet. If the part has a hole through it, you can press it on to a lathe arbor (a slightly tapered shaft), and clamp onto the arbor rather than the part itself. The hole must have an adequate aspect ratio or the part will not be firmly supported.
(click here for video) 554kB

If the part has a very large hole through it, a lathe arbor may not be a practicable solution. You may instead use the outside of the jaws to hold the inside diameter of the part.
(click here for video) 983kB

If the part has a very complex geometry, it may be neccesary to install the part onto a face plate. The face plate is then attached to the spindle.
(click here for video) 452kB


Return to outline
On to the milling machine
 
Milling Machine
Labeled Photograph
Description
Tramming the Head
Squaring the Vise
Types of Milling Cutters
Removing and Installing End Mills
Climb vs. Conventional Millng
Calculating Speeds and Feeds
Setting Spindle Speed
Using an Edge Finder
Using the Micrometer Dials
Squaring Stock
Face Milling
Milling Slots
Advanced Work Holding


mill.gif



Description
Milling machines are very versatile. They are usually used to machine flat surfaces, but can also produce irregular surfaces. They can also be used to drill, bore, cut gears, and produce slots. The type of milling machine most commonly found in student shops is a vertical spindle machine with a swiveling head. Although there are several other types of milling machines, this document will focus only on the vertical milling machine.

A milling machine removes metal by rotating a multi-toothed cutter that is fed into the moving workpiece. The spindle can be fed up and down with a quill feed lever on the head.
(click here for video) 656kB.

The bed can also by fed in the x, y, and z axes manually. In this clip the z axis is adjusted first, then the y, than the x.
(click here for video) 1.33MB

Once an axis is located at a desired position and will no longer be fed, it should be locked into position with the gibb locks.
(click here for video) 247kB

Most milling machines are equipped with power feed for one or more axes. Power feed is smoother than manual feed and, therefore, can produce a better surface finish. Power feed also reduces operator fatigue on long cuts. On some machines, the power feed is controlled by a forward reverse lever and a speed control knob.
(click here for video) 739kB


Tramming the Head
The head of a vertical milling machine can be tilted from side to side and from front to back. This allows for versatility of the machine, but these adjustments can drift. Occaisionally, one should check and adjust the head so that the spindle will be normal to the plane of the table. Install a dial indicator into the spindle so that the dial is offset at least six inches from the axis of the spindle and the indicator probe is facing down. Lower the spindle until the dial indicator contacts the table then registers about one half of a revolution. Set the dial indicator is toward you and set the bezel to zero. Rotate the spindle by hand 180 degrees. If the dial indicator still reads zero, the spindle is aligned front to back. If not, adjust the head until the dial reads half of the original reading and iterate the entire process until the error falls within acceptable limits. Repeat the process with the dial displaced left and right to alight the head side to side.


Squaring the Vise
Work on a milling machine is most often held in a vise clamped onto the bed. To make features aligned with the edges of the stock, it's neccessary to align the vise with the feed axes of the mill. To do this, mount the vise on the bed and secure it with T-bolts, but only lightly so as to permit adjustment of the orientation of the vise. Mount a dial indicator in the spindle of the machine with the probe facing away from you. Lower the spindle and run the bed of the table back until the fixed jaw of the vise is in contact with the indicator and further until the indicator registers one half of a revolution. Set the bezel to zero. Use the cross feed to run the indicator ocross the face of the vise. If the vise is squared, the indictor will remain at zero. If the dial indicator does not read zero, tap lightly with a soft hammer to realign the vise reduce the indicator reading to half of its previous value. Iterate this procedure until the dial indicator reads zero through the full travel across the face of the vise. Tighten down the T-bolts be careful not to change the vise orientation. Recheck the alignment of the vise.


Types of Milling Cutters
In vertical mills, milling cutters with solid shafts are usually used. Milling cutters with keyed holes are predominantly for use in horizontal mills. End mills are designed for cutting slots, keyways and pockets. Two fluted end mills can be used to plunge into work like a drill. End mills with more than two flutes should not be plunged into the work. Ball end mills can produce a fillet. Formed milling cutters can be used to produce a variety of features including round edges.

mcutters.gif


An Assortment of Milling Cutters

Removing and Installing Milling Cutters

End mills can be held by the spindle in several ways; a few of the ways are shown in the figure below. On most machines, a draw bar is used to pull a spring collet into a taper in the spindle.

cut_hold.gif


Methods of Retaining an End Mill

collets.gif


Spring Collets

To remove a tool, move the quill to the highest position and lock it in place. Then, engage the brake while loosening the draw bar with a wrench. Ensure that the draw bar's threads are still engaged in the collet. Tap on the end of the draw bar to release the collet from the spindle. If the threads of the draw bar are not engaged, the milling cutter will fall, and could be damaged. Finally, unscrew the drawbar from the collet.
(click here for video) 2.29MB

To install a tool, place the desired milling cutter in a collet that fits the shank of the cutter. Insert the collet into the spindle. Ensure that the key way on the collet mates properly with the key in the spindle. While holding the tool with one hand, start the threads of the draw bar into the collet by hand. Use a wrench to tighten the drawbar down with one hand while holding the brake.

Climb vs. Conventional Milling
When milling, one should be aware of the difference between conventional,and climb milling. In conventional milling, the workpiece is fed into the rotation of the cutter. This type of cut requires lower forces and is preferred for roughing cuts. In climb milling, the work moves with the rotation of the cutter. This produces a better finish. It is not recommended if the workpiece cannot be held securely or cannot support high forces.

convmill.gif


Conventional Milling

climb.gif


Climb MIlling

Calculating Speeds and Feeds
Cutting speed refers to the speed at which the tool point of the cutter moves with respect to the work measured in feet per minute. Feed is the rate at which the work moves into the cutter measured in feed per tooth revolution. Feeds and speeds affect the time to finish a cut, tool life, finish of the machined surface and power required of the machine.

The cutting speed is mostly determined by the material to be cut and the material of the tool. To find the right speed for any task, refer to the Machinery's Handbook or other reference. To calculate the proper spindle speed, divide the desired cutting speed by the circumference of the tool expressed in feet. The feed rate depends on the width and depth of cut, finish desired and many other variables. To calculate the desired feed setting from the feed rate, multiply feed per tooth per revolution by number of teeth and rpm of the spindle.


Setting Spindle Speed
Spindle speed is varied by changing the geometry of the drive train. On many modern machines, it can be adjusted continously with a hand crank. The spindle must be turning to make the adjustment. A dial indicator reads the speed in rpm.
(click here for video) 738kB.

The spindle speed dial indicator shown above has two scales, one for low range, and one for high range. The machine is swithched between ranges with a lever. Sometimes, the spindle must be rotated slightly to allow the gears to mate properly.
(click here for video) 370kB.


Using an Edge Finder
Before doing precise work on a milling machine, one must locate the edges of a part accurately. An edgefinder is designed to help you do this. An edgefinder is composed of two concentric cylinders, spring loaded together. To use it, offset the two halves slightly so that there is a wobble as it spins. Then, move the part into the tool slowly. The edge finder will center up, then break out of concentricity suddenly. At that point, reset the dial indicator or digital readout for that axis of the machine to a value equal the radius of the edgefinder. Repeat the process at least once.
(click here for video) 2.46MB


Using the Micrometer Dials
Most milling machine manual feeds are equipped with dial indicators. If you know how far you want to feed the bed, you can set the dial indicator to that number (in thousandths of an inch). Just turn the locking ring counterclockwise to free the dial indicator, set the dial, and lock in the setting. Be cetain that the backlash in the mechanism driving the table is taken up prior to setting the dial indicator.
(click here for video) 1.19MB

Many modern machines have digital readouts. These are preferred since they measure the bed position directly so you need not be concerned with backlash. They also readout bed position in metric units if desired.

Squaring Stock
To create a square corner on a part, first orient an already finished edge vertically in the vise and clamp lightly onto the part. Set a machinist's square against the finished edge and the bottom of the vise. Lightly tap the part with a plastic hammer to align it with the square. Clamp the vise down securely. Now the top edge of the part is ready to be milled to horizontal.
(click here for video) 1.23MB


Face Milling
It is often necessary to create a flat face on a large part. This can be done best with a facing cutter. Select a cutter about one inch wider than the workpiece so that the facing can be accomplished in one pass.

facing.gif


Face Milling

Milling Slots
End mills are designed to cut square slots. They will produce a slot to within two onethousandths of an inch in one pass. If greater accuracy is required, use an end mill a little smaller than the desired slot. Measure the slot produced and open it to the desired dimension with a second pass. The following clip shows and end mill cutting a slot. Note that the depth of cut is approximately equal to the diameter of the cutter.
(click here for video) 1.31MB


Advanced Work Holding
To hold round stock more securely in a vise, use a v-block. The work can be held vertically or horizontally.
(click here for video) 1.11MB

Round stock often cannot be held securely in the vise without damaging the work. A collet block is designed to hold round stock. Square collet blocks allow the part to be indexed to put in features at 90 degree increments. To mill features at 60 degree increments, use a hexagonal block.
(click here for video) 3.19MB

A workpiece can be set up easily when the desired features are parallel with or perpendicular to the workpiece edges. When the features are at an angle to the edges, more ingeniuty is required. Here, an angle plate is used to set the position of a vise within a vise. Thus a slot can be milled into a workpiece at any desired angle.
(click here for video) 418kB

Some parts don't fit well into a vise. These parts can be secured directly to the bed of the machine with hold down clamps. It is good practice to create a gap between the bed and the work with parallels. The clamps should be tilted down slightly into the work.
(click here for video) 1.95MB

To create circular features on a mill, a rotary table can be installed onto the bed. The table allows the workpiece to be rotated. A dial indicator allows precise control of the angle of rotation.
(click here for video) 290kB


On to grinding and buffing
Return to outline
 
Grinding and Buffing

grind.gif


A Pedalstal Grinder
The primary purpose of a grinding wheel is to sharpen tools (eg. drill bits). The hard abrasive of the wheel is made for removing very hard materials like high speed steel. Never grind on the side of the wheel. Also, never grind a soft material such as Aluminum. The material will coat the wheel and prevent the abrasive from working properly.
(click here for video) 1.15MB


If Aluminum is pressed against the wheel for too long the wheel could heat exessively and explode. If the grinding wheel does become coated with metal, dress the wheel prior to use.
(click here for video) 2.85MB

A deburring wheel is made of a material similar to a pot scrubber -- a mesh of abrasive fibers held together with adhesive. It's good for intermediate polishing. Even very hard materials such as tool steel can be removed with a deburring wheel. A tool that has been smoothed out in this manner can be used to burnish a part in the lathe to achieve a very fine finish.
(click here for video) 1.09MB

Working with the deburring wheel, it is critical to maintain proper orientation of the part. If a corner catches on the wheel, it can be thrown down forcefully. The part will probably be marred and you could easily be hurt. This applies to buffing and grinding as well.
(click here for video) 964kB

A buffing wheel is made of cloth. By itself it is not abrasive. To make it work propoerly, abrasive must be applied. Abrasives come in a tube and are suspended in wax. The tube is pressed onto the wheel as it spins, melting the wax which helps the abrasive adhere to the cloth.
(click here for video) 1.58MB

To buff a part, hold it against the wheel with a firm pressure. Keep moving the part about and gradually lighten the pressure as the finish gets finer and finer.
(click here for video) 1.45MB


Return to outline
 
Working with Sheet Metal
Shear
Notcher
Press Brake



Shear
Straight edges can be cut onto sheet metal stock using a shear. Ensure that the shear is rated to cut the gauge of sheet metal you're working with, or you may damage the blade. The gauge rating of a shear is generally marked prominantly on the machine. Sheet stock should be placed on the table and slid below the plexiglass shield. When the stock is oriented properly, make a cut by stepping down on the treadle. When the material shears, the treadle may slam down forcefully. The treadle stops are designed to prevent the treadle from crushing your someone's foot. Still, it is good practice to make sure your other foot isn't benieth the treadle.

shear.gif


A Shear


Notcher
The machine shown below will create 90 degree notches in sheet metal. This makes it possible to create profiles that can then be bent into three dimensional shapes (like boxes). Lay the work on the table. The guides can be used to help orient the part as desired. Pulling on the actuating lever will cut a notch in the work.

notcher.gif


A Notcher


Press Brake
A press brake can be used to bend sheet metal. The work must be slid under the shoes. Raise the shoes with the elevation levers, slide the work in place, and lower the shoes back down. The radius of the bend can be set with adjustment bolts on both sides of the machine. Minimum bend radius is a function of the ductility and thickness of the material being worked. For aluminum sheet, the bend radius should be greater than the sheet thickness. Bend the work by applying force to the bending lever. It is necessary to bend the work slightly beyond the desired angle as the metal will "spring-back"; elastic deformation is recovered when the bending force is relaxed.

press.gif


A Press Brake
 
German machine tool industry consolidates Following a record production year in 2001, when sales rose by 10%, the German machine tool industry expects a fall of 10% back to year 2000 level. Already a year ago VDW reported that the German machine tool industry is in top shape and has achieved a higher production than ever before. At that time, it was hardly to be seen that our industry could once more surmount this result by two digits.

However, the production actually increased in 2001 by another 10%, to EUR10 billion.

This was the best result of all times until now.

With these dynamics, the German machine tool industry left all important international competitors far behind.

Having entered into the upswing later, it still is far above what the machine industry was able to achieve as a whole.

At the same time, Germany improved to become the biggest machine tool market of the world.

Although the advance over the previous titleholder USA is only extremely thin, it was possible for the first time to decline the presently pausing champion to second place.

Also in the competition for world market share, the Germans have caught up distinctly.

With a portion of 21%, we are following the chief competitor Japan, having 22%, closely on its heels.

German machine tool industry well positioned both nationally and internationally - at the end of the year, the industry employed 69,500 male and female persons.

This corresponds to a growth of approximately 2400 employees or 3.6% in the course of the year.

It still has medium-size structure, meaning that 70% of the enterprises employ less than 250 persons.

The now seven years of boom have been used by the machine tool industry to optimize its structures and to strengthen its international competitiveness.

With the build-up of production and/or distribution and service locations in key markets such as Western Europe, USA and Brazil, it has often followed its main customers from the automotive and supplier industry and thus is appearing in international presence.

Internally, efficiency was increased and production processes were made flexible, in order to be able to react to demand variations more efficiently.

Technologically, the performance of German machine tool manufacturers is excellent.

This refers to the changing product innovations of their customers for useful machine concepts, and also to application of latest methods and materials in the industry itself.

The best proof for their innovation leadership and creativity is that many production technologies of the big industry today can also be controlled by medium-size enterprises.

The past year profited to a high degree of the good order cushions from 2000.

We started with an order volume of almost 9 months.

This ensured capacity utilisation almost to the top until far into 2001.

Finally in December, almost 93% were still measured.

Bottlenecks came up additionally due to the lack of qualified personnel, but also due to the purchase of components and control systems.

The draught horse for the machine tool industry was exports absorbing more than half of the total production.

With an increase of estimated 9% to EUR 5.6 billion -- figures differentiated according to purchasing countries are at the moment available only from January to September -- it broke all earlier records.

The most important single market still are the United States.

For a long time, the German manufacturers were able to contrast positively from the US market decreasing as a whole, due to the fact that the US automotive industry honoured their technical competence.

Nevertheless, the USA are belonging with a minus of 9% from January to September to the declining markets among the 10 most important sales markets, besides Great Britain (-24%) and Austria (-11%).

However, the Nafta business in total remains on a growth rate.

Great importance as sales market is attributed to Western Europe that absorbs almost half of all machine tool exports.

Six Western European countries alone are included among the 10 most important markets.

Domestic sales grew slightly disproportionately by 11% to approx.

EUR 4.4 billion.

The main customer automotive industry realized a series of strategic projects.

The good capacity utilization in machine building also is giving strong impulses.

Imports rose by 11% to EUR 3.5 billion now.

This corresponds to an import quota of approx.

45%.

Based on the data situation, a ranking of the most significant import countries can at the present time only refer to the first half of the year.

Traditionally, Switzerland is the biggest foreign supplying country in the German market, with a share of about one quarter.

This place has successfully been expanded during the first half of 2001.

The Swiss have their domain in the spark eroding technology.

The following places have been held for many years in an unchanged sequence by Japan, Italy, France and the USA.

Japan has been able to expand its directly chargeable exports in 2000 only slightly.

However, Japanese companies often have production locations in Europe, the exports of which do not come up in the statistics of Japanese exports.

Germany for the first time the World's biggest machine tool market - parallel to the German machine tool industry, German machine tool consumption also developed magnificently.

With EUR 6.24 billion, the meanwhile highest domestic market volume has been reached.

Germany was even able to increase by 11%, while the consumption of the USA in second place diminished by approximately one fifth.

With EUR 6.17 billion, the USA are only slightly behind Germany.

However, the Americans are benefiting from an exchange bonus.

World-wide, the machine tool industry had to lose feathers in 2001.

As a total, the production volume decreased by more than 2% to approx.

EUR 39 billion.

This figure is understood with respect to the comparability of the national data without parts and accessories amounting to about 17% of the total production value.

In 2001, Germany has greatly maintained its position in the world standard and, with a production of EUR 8.7 billion, a growth of 10% and a world market share of 21%, is closely on the heels of chief competitor Japan.

The Japanese had to accept a decrease, but with a world market share of 22% they defended their top position.

With a production measured half as high as the top level, Italy ranged on rank 3 with a share of 12%.

The USA followed on rank 4 with a share of 9.5%.

Surprisingly good were the Chinese who already have reached 5th rank with EUR 2.4 billion.

The Chinese have succeeded in increasing the value of their own production by means of consequently demanded technology transfer.

This will also cause the own production to profit increasingly from this giant market.

In exports, Japan is with EUR 6.1 billion still far at the top, before Germany, Italy, the United States, and Taiwan.

Both the Europeans and the USA were able to expand their export business while the two Asian countries were losing feathers among the great exporting countries.

The machine tool imports of the Japanese give a traditionally modest impression with EUR 718 million and a decrease of 23%.

At the top of the importers are the USA and Germany.

On rank 3, just behind Germany, China already follows with machine tool imports of Euro 2.6 billion.

This is an increase of 27% and thus the greatest rise among the countries with a remarkable import volume of more than EUR 1 billion.

In 2002, calming down expected - seven years of boom coming to an end - in spite of high capacity utilisation, time pressure, long delivery periods, and increasing sales, it became visible at an early point that the steep flight was not going to continue.

Already during the first half of 2001, the orders received severely decreased and did not cover production any longer.

This particularly concerned our most important market, the USA, with its demand weakness exerting a reducing action on the Nafta countries and the South American key market of Brazil.

In Western Europe, the British proved to be weak in particular.

There, the finish of the procurement programmes of Rover came to negative effect.

The horrible terror attacks of September 11, 2001, additionally intensified the weakness of demand in almost all economic regions and therewith the uncertainty about the further development.

In the course of the declining foreign business, also the domestic investment readiness decreased noticeably within six months.

In total, the receipt of orders in 2001 dropped by 13%.

The order volume was EUR 9.4 billion by the end of the year, i.e EUR 4.8 billion from foreign countries and EUR 4.6 billion from within Germany.

However, various companies are differently affected by the decrease, with respect to whether a company is coupled to the strategic procurement process of the automotive industry or is serving a wider market.

Due to this, the individual economic situation of a company is gaining more and more importance.

For production we expect in 2002 a decrease of 10% to then again EUR 9 billion.

This would nevertheless allow to repeat the second best result of all times from 2000.

It will however be decisive whether the often stated expectation, that the total economy will accelerate again in the second half of 2002, may become reality.

Frankfurt, Germany, March 2002
 
Italian machine tool exports to USA increase
More than eighty Italian companies were present at IMTS machine tool exhibition, as the USA consumption of Italian machine tools in 2003 has grown by 30.8% compared with 2002.
Note: Readers of the Editor’s free email newsletter will have read this news the week it was announced. Send us a blank email now to join the circulation. It’s free!
More than eighty Italian companies were present at IMTS, the most important American production equipment show, in Chicago from September 8th to 15th. To honour the presence of Italian manufacturers, UCIMU-Sistemi per Produrre, the Italian machine tool, robotics and automation machinery manufacturers association, partnered with ICE (Italian Institute for Foreign Trade) to organize a meeting for the sector professionals at IMTS to promote Italian-made products. Now in its fourth edition, the Italian Machine Tool Dinner was held on Wednesday, September 8th in the splendid scenery of the Museum of Contemporary Art of Chicago, packed with 150 honoured guests, including sector professionals, US import agents, local officials, representatives of the institutions and journalists representing the main trade journals.

The Consul General of Italy in Chicago, Eugenio Sgr, also attended.

Alberto Tacchella gave the welcoming address in his first international event as president of UCIMU-Sistemi per Produrre.

He highlighted the value of Italian quality in the sector.

'An industry,' proclaimed Tacchella, 'made up of small- to medium-sized companies that can successfully compete on the international market and stand up to much larger foreign competition, thanks to flexibility, problem-solving and a tradition of service.' 'Key concepts,' continued Tacchella, 'that hold the secret to the gradual rise of the Italian machine tool industry in the US, which today represents the third largest market for our products.

Italian products have gained a reputation on this market, in terms of market shares acquired and the value of exports, which have grown exponentially, and Italian manufacturers are present with a sales and post-sales service organization.' According to the 2003 closing figures, exports of Italian machine tools to the American market have resumed growth, posting a 30.8% rise with respect to the value posted a year earlier.

In 2003, Italian manufacturers have exported to the American market machine tools for nearly EUR 164 million, a value of 9.4% of total Italian industry exports.

President Tacchella's speech was followed by glowing commentaries by American clients and experts in the sector on the technological excellence of Italian products.
 
2005 Machine Tool Exporters Guide to
China
2
Overview
China acceded to the WTO four years ago and is currently in the process of completing
a seven-year transition. Accession to the WTO symbolizes China’s ongoing integration
into the world economy. There is no doubt that China’s transition from central planning
to market-based regulatory principles offers significant improvements in market access
for many American exporters. However, from an American supplier’s perspective, the
transition process is incremental at best and not without bumps in the road.
Meanwhile, China's macro economy continues to be extremely healthy. According to
China’s National Bureau of Statistics, China’s economy increased by 9.5 percent in
2004. Retail sales rose 14 percent last year and are expected to continue to rise
rapidly in 2005 as a result of increased consumer credit. Foreign currency reserves
exceeded USD 600 billion by yearend, up 52 percent from yearend 2003. After rising
sharply earlier in the year, inflation declined to a 3.9 percent rate at year’s end. In
2004, the government fiscal deficit declined. Total trade resulted in a small surplus.
Fixed asset investment rose rapidly (25 percent) to reach USD 846 billion (slightly more
than 50 percent of GDP). China attracted USD 60.6 billion in foreign direct investment
– mostly in manufacturing or real estate – ranking second only to the United States.
Despite the high level of interest, China remains a developing market, albeit one with
vast potential. Spread over a population of 1.3 billion, China’s 1.65 trillion USD
economy does not represent a large amount of disposable income for each person. By
the end of 2004, the Chinese government reported that the annual rural per capita net
income was USD 355 and urban per capita disposable income was USD 1,140 at
current exchange rates.
Rapid economic growth has fueled strong growth in imports. According to the National
Bureau of Statistics, the total value of imports increased to USD 561.4 billion, up 36
percent. China is now the world’s third largest trading nation behind the United States
and Germany.
According to U.S. Customs statistics from January to November 2004, China-U.S. trade
reached a historical high of USD 210.7 billion during the first 11 months of 2004. The
U.S. imported USD 179.2 billion of goods to the United States, up 29 percent. China is
our second largest supplier, after Canada. The U.S. exported 31.5 billion to China
3
during the same period, up 25 percent from the year before. China has become our 5th
largest export market. As a result of these trends, the bilateral trade deficit with China
increased 29 percent to USD 147.7 billion in the first 11 months of the year.
Machine Tool Market in China
The dramatic growth and development in China’s manufacturing sectors over the past
decade has fuelled the country’s market for sophisticated machine tools. Currently the
world’s largest consumer and importer of machine tools, China is a growth market for
many U.S. manufacturers of technologically advanced machinery. Some of the leading
sectors driving machine tool consumption include automotive, aviation/aerospace,
shipbuilding, and information technology related manufacturing.
China is currently the world’s largest consumer and importer of machine tools. In 2004,
China’s consumption of imported machine tools reached more than $5.9 billion, with US
imports constituting $482.9 million or 8% of the total. Japan (33%), Taiwan (21%), and
Germany (15%) account for a substantial portion of China’s machine tool imports.
According to some estimates, nearly one-half of China’s machine tool market is
comprised of imports.
The growth in machinery exports to China over the past several years is driven by a
number of factors:
· Demand for superior quality and precision technology not available in China.
· Expansion of China’s manufacturing capacity and increased competition
among domestic manufacturers for quality output.
· Influx of foreign invested manufacturing facilities requiring world -class
machinery.
· WTO mandated tariff reductions.
Sampling of China’s Leading Machine Tool Imports
Grinders
Lathes
Spindles
Tool Carriages
Ball-screws
Tool System Manipulators
High Speed Protectors
Precision Tools
4
In order to deal with the increased market opportunities and competition resulting from
entry into the WTO, China has placed high emphasis on upgrading its conventional
industries with more advanced high-tech machinery and equipment. China is also
moving rapidly to restructure the state-owned, exclusively invested and private
enterprises. The two initiatives, along with the start-up of numerous major national
projects, are stimulating rapid growth in the demand for machine tool and tooling
products in China. This provides market opportunities for machine tool builders, as
China is expected to import advanced equipment and technology valued in the tens of
billions of US dollars. The budget for the reconstitution of the conventional industries
into modern, competitive companies will total in the tens of billions of US dollars.
Some of the major events, projects and other developments in China that will impact
machinery exports are as follows.
Beijing 2008 Olympics
The City of Beijing is planning to invest more than US$ 23 billion in preparation for the
Olympic Games in 2008. Much of this money will be spent on construction projects in
the following areas: Olympics facilities, transportation, telecommunications, and
environmental improvements. Some of the projects are continuations of city
improvements that have been planned for years. Others are entirely new projects that
will now come to fruition since Beijing has been officially selected to hold the Olympics.
Coupled with the Beijing municipal government promise that bidding on these projects
will be open on an equal basis to both foreign and domestic companies, the 2008
Games could be a very enticing business opportunity.
China's Machine Tool
Import Composition
Taiwan
21%
Japan
33%
United
States
8%
Other
Countries
23%
Germany
15%
5
World Expo 2010
Shanghai recently won its bid to host the World Expo in 2010. Shanghai plans to invest
hundreds of millions of dollars in new urban infrastructure to prepare for this
momentous event.
Automotive
China’s automotive industry has witnessed rapid growth since the country opened to
the outside world and adopted economic reforms. Currently, domestic motor vehicles
have more than a 95 percent market share.
In order to keep costs down, most foreign-invested manufacturers in China are
localizing their supply chain. For the automotive industry, this has led many first and
second tier suppliers to set up operations in China. Increasingly, foreign-invested
manufacturers in China have been sourcing from local Chinese suppliers. Indeed,
these manufacturers are sourcing not only for the domestic Chinese market but also for
export markets. Therefore the demand is not only for price competitive components but
also for world-class quality production.
Currently in the Shanghai area, foreign invested manufacturers such as auto and other
industrial OEMs are actively nurturing local suppliers to help get them up to
specification so they can bring costs down.
The demand by foreign and high-end Chinese automotive producers for locally
manufactured, high-quality components has led to increased acquisition of advanced
manufacturing technologies throughout the supply chain and across many sectors in
China. These foreign and Chinese manufacturers should be the target clients for US
exporters of machinery and industrial equipment. US firms have a reputation for high
quality in the Chinese market. Many Chinese buyers have a favorable opinion of
American suppliers but often comment that US companies do not have the same
aggressive local presence as their Japanese and European competitors.
There is generally demand among local components manufacturers who are interested
in improving manufacturing technologies in order to move up the value chain in the
following areas:
· Deep drawn parts, high-precision screw machined parts
· Motors, engine assemblies
· Mold makers
· Extruded body castings
Energy Sector
China's overall energy consumption ranks second in the world. China's growing
demand for energy has caused this traditionally off-limits sector to gradually open up to
increasingly larger scale foreign participation. Reluctance to change has made progress
in the oil and gas sector slow for foreign firms in China, but government encouragement
has produced progress. The best opportunities for foreign participation are in natural
gas infrastructure development and offshore oil exploration and production. Onshore oil
projects are far less attractive due to lack of access to satisfactory leverage and
6
geological data, and a greater tendency to source equipment, services and technology
domestically. Offshoot industries with high technology components are in high demand.
The development of China's petrochemical industry in the Tenth Five -year Plan period
(2001-05) will focus on increasing the production of refined oils. Demand for oil
products is expected to witness a sizable increase in the next five years, with total
consumption of gasoline, diesel and kerosene achieving an annual growth rate of 4.3 to
4.6 percent, reaching 136 million to 138 million tons by 2005. Structu ral reforms will be
carried out in major petroleum and petrochemical enterprises such as CNPC (China
National Petroleum Corp.), Sinopec and China National Offshore Oil Corporation to
sharpen the industry's competitive edge in the world market, while further opening-up
policies will be initiated to attract more foreign investment. China will try to bring the
overall oil refining capacity to 270 million tons, including over 75 million tons of sulfur
crude; build eight to nine oil refining bases, each with a refining capacity of 10 million
tons; adjust installations, optimize crude varieties, increase the output of diesel and
naphtha, expand gasoline export, raise the output of fuel oil, provide more quality raw
materials for ethylene production; and also produce more high grade road asphalt,
quality lubricants and paraffin. In 2003, China gradually opened its gasoline and diesel
market and increase the import of oil products, which have an import quota of 25.3
million tons (i.e. including 20 million tons quota for state trade and 5.3 million tons quota
for non-state trade).
China now is carrying out several huge oil and gas projects to meet its growing energy
needs. Major projects are being driven by a combination of political, environmental and
market factors. The ongoing Guangdong LNG Terminal and Supply Project, West to
East Gas Project, coal liquefaction, natural gas exploration, and the Bohai Bay
exploration projects will continue to provide export opportunities for foreign companies.
Good opportunities exist in both upstream and downstream engineering, project
supervision, licensing, equipment, technology, consulting, marketing and supply
sectors.
Downstream infrastructure development in China centers primarily on upgrading
existing refineries rather than building new ones, due to current overcapacity. In the late
1990s, the Chinese Government shut down 110 small refineries, which generally made
inferior quality petroleum products. Sixty two other small refineries owned by provincial
and local governments are also likely to be merged into CNPC and Sinopec (China
Petroleum & Chemical Corp.) in the near future. Another major issue in the Chinese
downstream sector is the lack of adequate refining capacity suitable for heavier crude
oil, which will likely becom e a necessity as Chinese imports rise in the mid-term.
Several existing refineries are being upgraded to handle heavier and the more sour
grades of crude oil.
Transportation Infrastructure Industry
The Chinese government is in the midst of a massive upgrade of their existing
transportation infrastructure. Until recently, China’s economy was able to continue to
grow despite deficiencies in infrastructure development. This is no longer the case, and
the Chinese government realizes that, in order to keep their economy moving forward,
they must have an efficient system in place to move goods and people across this
9.326 billion sq. km. land mass. According to World Bank statistics, goods lost due to
poor or obsolete transportation infrastructure amounted to one percent of China's GDP
as recently as the most current survey (mid 1990's). Logistics accounts for 20 percent
7
of a products price in China, compared to 10 percent in the US
Passenger rail traffic has priority over freight on the many single-track rail lines across
China, extending trips which should last a few days to two weeks or more, and limiting
investment interests in all but a few coastal regions. Rail tracks are now being doubled
to alleviate the freight train conflict issues, expressways are being built to cut down on
vehicular travel times, sealed roads are being extended to new locations, ports are
being improved for greater use of China’s waterways, and airports are being improved
across the country. All of these projects bring opportunities to US construction
equipment, engineering, and electronics and safety devices companies, especially for
projects funded by the World Bank, Asian Development Bank, OECF, and similar
multilateral lending agencies that use transparent bidding procedures.
Distribution Services
Foreign companies have been barred from engaging in freight forwarding unless they
form a joint venture with local partners. Many have stayed away. With China’s
accession into WTO these and other structural issues are moving to positions more in
line with international standards. These changes are to be fully compliant with
negotiated accession terms within five years of the accession date.
Highways
China’s has been rapidly developing its highway system in the past few years.
Investment in highways for 2001 was US$ 37.66 billion. China added 36,000km of
highways and 3,152km of expressways in 2001 alone. In adherance to the
government’s stance on western expansion, Sichuan province plans to have 1,500 km
of expressways built by 2002 and 4,600 by 2020.
Ports
China has sixteen major shipping ports with a capacity of over 5 million tons per year,
combined for total country shipping capacity in excess of 1.4 billion tons. The Port of
Shanghai is going through a significant upgrade. The Shanghai Model Port Alliance, is
behind many of the upgrade activities that will make Shanghai a more automated port
facility, minimizing loss of goods and time while helping Customs collect more accurate
tariffs. If the Shanghai project accomplishes its goals, there is interest in replicating the
process in other Chinese ports.
8
Suggested Market Entry Strategy
Do your due diligence and visit China often.
Continuous communication with contacts, agents, customers, suppliers and your
competition is key to assessing this market. China is not right for everyone, but you
need to be here to make that decision. A number of companies are here and losing
money, because they were lured by less than rational predictions and over-optimism.
Other companies that should be here are not, because they did not invest the time to
research the market.
Identify an agent or other partners.
This is a key step for making sales and setting up distribution and logistics channels.
The first steps should be low-risk. US companies need someone with Chinese
language capabilities, acting as either an agent or company employee, if they want to
sell to Chinese customers.
· Appointing an agent is a good step. But agents aren’t always as aggressive as
companies would like.
· Setting up a Rep Office in the market is a logical next step to support an existing
agent or to identify sales leads. Providing after sales service and maintenance
and engineering support is a challenge. A good agent should have these
capabilities.
· More and more firms are looking into setting up a wholly owned foreign
enterprise (WOFE) as a manufacturing, trading, service or consulting entity to
offer additional sales service and after sales support.
Recognize and Handle Challenges.
There are a number of challenges facing manufacturing exporters selling to China. The
US Commercial Service stands ready to assist US firms where possible to address
these problems. US manufacturing exporters in China commonly face the following
issues:
· Finding good information.
· Increased local and foreign competition, especially from Japan, Germany and
Taiwan.
· Protecting intellectual property continues to plague foreign companies.
· Shorter project cycle times for big projects .
· Getting paid.
· Other transaction costs like travel, negotiation, and shipping, letters of credit.
· Hiring and keeping good staff .
· Visas to the United States for buyers and technical experts.
· Export controls.
9
Make a commitment to the market
China is a complex and potentially lucrative market for US manufacturing exporters.
The following information is important to keep in mind when evaluating your company’s
commitment to successfully selling into the market.
· Devote time to developing relationships.
· Be willing to train your agents and customers in China
· Have some type of local presence to build credibility.
· Be open to understanding the cultural, social and economic situation of your
potential buyers.
Model marketing plan for Company ABC (machinery exporter)
Goals:
1. Identify strategic channels to market machinery to end-users in China
2. Identify a company in China to act as an agent for Company ABC in the local market
Phase 1: Market Research
· Develop an introductory letter and basic marketing materials in Chinese
· Identify firms in machinery market in China
· FCS to conduct pre-screening of potential candidates
· FCS to conduct additional market research to identify key sectors and regions
Agent qualifications
· Extensive experience in machinery industry
· Interested to partner/serve as agent for US machinery exporter, complementary
interests
· In-house engineering capability to install and provide after sales service to
machinery in China
· Established marketing/sales networks
· Strong communication skills, English language capability desired
Phase 2: Establishing agent relationship
· Establish contact with firms identified by FCS China
· Evaluate firms according to above criteria
· Develop working relationship with one or more firms, set up points of contact
· Intensive "get to know you" including communication by email, telephone,
· Visit agent in China and/or host them at Company ABC’s headquarters
· Sign an agency agreement with selected candidate (exclusive or non-exclusive)
10
Basic cooperation model:
The Chinese company represents Company ABC in China acting as their agent.
Company ABC will assign one person from their company to serve at the China
Account Manager. Likewise, the Chinese company would designate someone to work
with American contact to develop business opportunities. When an opportunity is in
sight, ABC and the Chinese firm would develop a proposal and bid on the job together,
maximizing and complementing the strengths of each company to be more competitive.
The terms of cooperation would be spelled out in an agency agreement or contract.
Phase 3: Find projects and making proposals
· Team up with Chinese company to network and begin marketing
· Develop hot list of clients with whom Company ABC has supplied to in the US
with emphasis on clients who have operations in China
· Identify strategic first project and go full-out
11
How the Foreign Commercial Service Can
Help Your Company
The U.S. Commercial Service in China assists U.S. companies with U.S. exports to
China, emphasizing help for U.S. small and medium sized companies. We have five
offices in China - Beijing, Shanghai, Shenyang, Chengdu, and Guangzhou - offering
customized solutions to help U.S. companies enter and expand in the China market.
THE US COMMERCIAL SERVICE (US&FCS)
The US&FCS, assists US firms in realizing their export potential by providing: 1)
exporting advice; 2) information on overseas markets; 3) assistance in identifying
international trading partners; 4) support for trade events; and 5) advocacy, among
other services. US&FCS trade specialists work in more than 100 Export Assistance
Centers across the United States and in more than 150 overseas posts, in
12
approximately 80 foreign countries, which combined represent more than 96 percent of
the world market for exports. Lists of trade specialists by US city or country can be
found at http://www.export.gov
.
CS Core Services
Export Promotion
International Buyer Program (IBP)
Supporting 28 major domestic trade exhibitions annually and bringing more than
125,000 visitors from around the world, the International Buyer Program undertakes for
each show a worldwide promotional campaign aimed at maximizing international
attendance through work with the overseas network of Commercial Service and
Embassy offices. Qualified buyers and prospective distributors, many brought as part of
delegations led by overseas commercial staff, are assisted in meeting with interested
exhibiting firms and provided services aimed at helping them find new suppliers and
trade partners. Each show features an International Business Center at which export
counseling, matchmaking, interpreter, and other business services are provided to
international visitors and exhibitors.
Video Conferencing Programs
Most of our overseas and domestic offices offer video conferencing services and use
that equipment to create programs that provide an effective tool to help US companies
assess an overseas market or overseas business contacts before venturing abroad to
close a deal. Companies can use these cost-effective video services to interview
international contacts, get a briefing from overseas industry specialists on prospects
and opportunities, or develop a customized solution to international business needs.
Business Facilitation
• Gold Key Matchmaking
• International Partner Search
• International Company Profile
Trade Promotion Events
· Catalog Exhibitions
· International Buyer Programs
· Trade Missions/US Pavilions
Market Research
•Market Research Library
•Customized Market Research
•China Commercial Brief
Customized Programs
•Advocacy
•Business Consulting
13
Trade Missions
U.S. Government-sponsored trade missions offer great promotion potential at a
relatively low cost. A government official escorts a group of U.S. companies to one or
more foreign markets where they are provided a schedule of meetings with potential
foreign agents, distributors and/or joint-venture partners. Meetings may also take place
with in-country government and regulatory officials, depending on the scope of the
trade mission. Check the latest calendar on export.gov for a list of upcoming missions.
Commercial News USA (CNUSA)
CNUSA, a catalog-magazine containing advertisements of US products serves to
promote US products and services to more than 400,000 potential buyers and partners
in 145 countries. This service was temporarily suspended fall of 2003, soon to
reemerge in early 2004. Please contact your local US Export Assistance Center for
more information.
Trade Information Center
The International Trade Administration’s Trade Information Center (TIC) is an excellent
first stop for new-to-export companies seeking export assistance from the federal
government. TIC Trade Specialists: 1) advise exporters on how to find and use
government programs; 2) guide businesses through the export process; 3) provide
country and regional business counseling, foreign import tariff/tax rates and customs
procedures, trade opportunities and best prospects for US companies, distribution
channels, standards, and common commercial difficulties; 4) provide information on
domestic and overseas trade events; and 5) provide sources of public and private
sector export financing. TIC trade specialists also assist exporters in accessing reports
and statistics from the computerized National Trade Data Bank and direct them to state
and local trade organizations that provide export assistance. To contact the TIC, call 1-
800-USA-TRADE; FAX (202) 482-4473; e -mail: [email protected]; or visit the Web site
http://export.gov/tic.
14
List of Key Chinese Trade Associations
Shanghai Non-Ferrous Metals Industry Association
Mr. Le Shen Tong
Tel: 86-21-6205-6287
Fax: 86-21-6205-6287
Email: [email protected]
Shanghai Automotive Trade Association
Mr. Hu Ling Zhang
Tel: 86-21-2201-1507
Fax: 86-21-2201-1777
Email: [email protected]
China Association of Automobile Manufacturers
Mr. Yan Chen
Tel: 86-21-5426-2002
Fax: 86-21-6485-2542
Email: [email protected]
Automotive Parts Circulating Trade Association
Ms. Mei Xia Zhang
Tel: 86-21-5919-3807
Fax: 86-21-6919-1685
Email: [email protected]
Shanghai Foreign Investment Enterprise Association
Mr. Zhao You Zhan
Tel: 86-21-6275-1309
Fax: 86-21-6275-1423
Add: Suite 615, No.55 Lushanguan Road, Shanghai 200336
Shanghai SME International Cooperation Association
Mr. Xu Wei - Secretary of General
Tel: 86-21-6336-6547
Fax: 86-21-6320-3807
Add: Suite 324, No.22 Zhong Shan Road (E.2), Shanghai 200002
Shangahi Die & Molds Industry Association
Mr. Gao Hou Shen
Tel: 86-21-3301-1579
Fax: 86-21-6325-7006
Email: [email protected]
Add: 3/F,No. 35 Tianmu road east, Shanghai 200071
The Plastic Trade Association of Shanghai
Mr. Yang Han Jun
Tel: 86-21-6298-5029
Fax: 86-21-6298-5029
Add: Suite 409, No. 84 An Yuan Road, Shanghai 200060
15
Shanghai Electronic Components Trade Association
Mr. Li Xue Zhao
Tel: 86-21-6252-3309 ext. 245
Fax: 86-216251-7323
Add: No. 68 Zhao Hua Road, Shanghai 200050
China Foundry Association
Mr. Zheng Ling - Foundry 2004 show Manager
Tel: 86-10-8851-1712,8851-4539
Fax: 86-10-8851-4540
Email: [email protected]
Add: No.5 Xi-san-huan Bei Lu, Beijing 100089, P.R.China.
Casting Association of Shanghai
Mr. Zhang Fang Tao - Secretary of General
Tel: 86-21-5662-3698
Fax: 86-21-5698-8408
Add: 960 Zhong Xin Road, Shanghai
Shanghai Steel Tube Trade Assoc iation
Mr. Jian Chu Shen
Tel: 86-21-6467-0065
Add: Rm. 3046 No. 679 Xujiahui Road Shanghai 200023
Shanghai Electronic Machinery Industry Association
Mr. Xu Chen Sheng
Tel: 86-21-6546-2374
Fax: 86-21-6545-8339
Add: No.178 Wu Huang Road, Shanghai 200086
China National Hardware Association
Mr. Zhang Dongli
Tel: 86-10-6426-9040
Fax: 86-10-6426-0466, 6426-0160
Email: [email protected]
Add: No.6 Dixing Ju An Wai, Dong Cheng District, Beijing 100011
China General Machine Components Industry Association
Mr. Du Guosen
Tel: 86-10-6859-4863
Fax: 86-10-6857-2092
Email: [email protected]
Add: Rm 1011, No.46 San Li He Road Xicheng District Beijing 100823
16
China Machinery Related Trade Events
The Fourth China International Equipment Manufacturing Expos ition
Dates: August 30- September 3, 2005
Venue: Shenyang Exhibition Center
U.S. Commercial Service Shenyang
Ms. LIU Yang
Tel: 86-24-2322-1198 Ext. 8142
Fax: 86-24-2322-2206
E-mail: [email protected]
Website: http://www.buyusa.gov/china/en/cieme05.html
Metal Working China 2006
Date: October 11-14 2006
Venue: Shanghai New Int'l Exposition Center - Pudong
Organizer: Hannover-Messe Int'l GmbH
Address: 24A, New Shanghai Int'l Tower
Tel: 86-21-68863286
Fax: 86-21-68863797
Email: [email protected]
Website: http://www.hfchina.com
Metallurgy China 2006
Date: April 18-21 2006
Venue: China International Exhibition Center, Beijing
Organizer: Metallurgical Council of CCPIT (MC -CCPIT)
Address: 46 Dongsi Xidajie, Beijing, China 100711
Tel: 86-10-65220753
Fax: 86-10-65233861
Email: [email protected]
Website: http://www.metallurgy-china.com
 
There are strong indications of a re-emergence of EU manufacturing – in technical, environmental and social terms. But such sustainable development requires consistent and effective research over the next decade.

Despite growing globalisation and challenges from low-wage economies, manufacturing has a bright future in the sustainable, knowledge-based European society envisaged in the Lisbon Council strategy. However, sustainable development in the EU manufacturing sector requires continuing innovation in the underpinning products and processes. And policymakers have a major role to play in ensuring coherent support.

Manufacturing has an important position as a provider of necessary goods, an employer and an exporter. There are more than 20 million companies in Western Europe (the EU, Iceland, Liechtenstein, Norway and Switzerland), providing employment for 122 million people – and a further six million companies in the enlargement countries. Of these, two million are manufacturers, employing 24% of the workforce. In the EU itself, manufacturing represents some 22% of the gross national product– about €4 000 billion – and accounts for 18% of jobs.

Notable characteristics of the sector as a whole are the large number of SMEs involved – responsible for two thirds of total employment – and their wide geographical spread, as well as the importance of manufacturing in the enlargement countries.

The overall EU trade balance in manufactured goods is positive, in strong contrast with the USA. Particular European strengths lie in machinery and equipment, non-metallic mineral products, chemicals, rubber and plastics, transport equipment and metal products. But the growth in productivity has been less in the EU than in the USA in recent years. Europe lags behind the USA and Japan in its total share of exported high technology products. But, while the USA is ahead of the EU in information technology, pharmaceuticals and biotechnologies, the EU is well ahead of the USA and Japan in materials technologies.




Global lead in machine tools
The machine tool industry, which supplies high technology manufacturing equipment to a whole gamut of European production companies – including the automotive, aerospace and supply chain sectors – is a particular success story.

Figures from the European Committee for the Co-operation of the Machine Tool Industries (CECIMO) indicate that Europe currently dominates the global machine tools market, with the 15 CECIMO countries (Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Italy, Netherlands, Portugal, Spain, Sweden, Switzerland, Turkey and the United Kingdom)providing some 52% of the worldwide value of machine tool production in 2002. Japan was second with just over 20%, China third with 9.6% and the USA fourth with 6.1%, followed closely by Taiwan at 5.6%.

Estimates covering the CECIMO member states indicate that machine tool production was worth €17 512 million in 2002, of which 42.8% was generated by Germany, 22.9% by Italy, 11.2% by Switzerland, 5.2% by Spain, 4.7% by France, 3.6% by the UK and 9.6% by the rest. Total employment in the machine tool sector was around 158 000, spread over some 1 474 companies. It thus makes a key contribution to the European economy and balance of payments, both as an industry in its own right and by its contribution to the manufacturing community as a whole.

Yet, manufacturing industry in general has an image problem. It is seen as quite traditional and a generator of both unemployment and negative environmental impacts, making it difficult to recruit the right people – particularly the young. Industrial research must change this image by supporting new production and consumption approaches based on better, cleaner and safer technologies.




Demand for new technologies
“Making industrial systems more competitive while ensuring sustainable development requires radically new strategies,†emphasised Research Commissioner Philippe Busquin when speaking to the international press at the EMO 2003 machine tool fair in Milan on 22 October. “We need to federate efforts, pool talent, and network resources in order to maximise research investments and develop common technological platforms for industrial innovation. New manufacturing technologies are a forward-looking field. They will play a pivotal role in ensuring renewed economic growth, and fostering a healthier environment and better quality of life.â€

Ever more flexible, sophisticated and accurate machines are essential to support European enterprises as they strive constantly to deliver updated products that keep them ahead of global competitors. There have been major changes in production industry over the past 20 years, leading to demands for:


Higher precision machining systems to handle progressive miniaturisation, as well as micro/nano structured surfaces for enhanced tool performance, greater reliability and better energy efficiency;
Processes and machine systems able to handle advanced materials that include glass and ceramics;
New tooling materials, such as diamond and cubic boron nitride (CBN), for greater machining accuracy;
Replacement or elimination of hazardous and environment-polluting cutting fluids; and
More flexible programming systems drawing on the latest advances in information and communications technology.


Above-average investment
This has led the machine-makers to progress rapidly from purely mechanical engineering towards ever-increasing use of electronics. It is also encouraging a trend to develop total manufacturing solutions in partnership with customers, rather than simply supplying equipment alone.

“Suppliers of manufacturing systems have to face a highly complicated environment,†pointed out CECIMO Vice-President Dante Speroni at EMO. “It is characterised by a dynamic of non-linear evolution. This comes from the fact that machine tool manufacturing systems are complex assemblies of different technologies. The customers play a fundamental role in this mechanism, often assuming the role of drivers of the innovation process: the evolution of market needs implies a continuous and fast mutation of company internal dynamics.â€

There is thus a constant pressure to pursue more groundbreaking research, as envisaged under the EU Sixth Framework Programme (FP6).

“Today, modern machine tools operate at speeds of up to 100 000 rev/min. And tools accelerate at up to 2g,†points out Commissioner Busquin. “In ten years, the dynamic performance of machines has been multiplied by ten. All this is thanks to investment in research by enterprises, often small and medium sized, and through close liaison with research centres and universities. This sector invests 10% of its turnover in R&D.

“I am simply delighted, as this meets the call I made at the Barcelona Council, that investment efforts in research should be increased from the current 1.9% of European revenue to 3% – this is the only way to face up to the challenge posed by our development of a knowledge-based society. This objective can only be met by an increased effort in the private sector, enabling traditional industry to evolve towards an industry with high added value.â€




Frontier of understanding
Commissioner Busquin emphasises the valuable contributions being made by universities and research institutes. “Technological innovations today demand multidisciplinary approaches, bringing together competences in areas as varied as engineering, mechanics, materials science, informatics, and the pure sciences, environment, security… Problems become more and more complex as the accuracy required and the speed of machining increases. Today, we are at the frontier of our understanding and, with machines able to reach machining accuracies in the order of hundreds of nanometres, we are entering the area we call nanotechnologies, where scientific excellence is fundamental.


“The demands are such that the fragmentation of research efforts is a brake on European industrial innovation. Certainly, basic discoveries are often made in small laboratories, but their fine-tuning and dissemination require so much effort that a single organisation – or even a single country – can no longer undertake such work alone.â€





Benefits of collaboration
The scale of programmes that can be generated with the European Research Area will stimulate the sharing of resources, and the integration and networking of competences – enabling Community research to deliver more effective results.

Working with the Commission’s Research DG, CECIMO plays a major role in helping to foster collaborative research initiatives at the European level. Member companies co-operated closely in the Expressions of Interest exercise in 2002, which helped put together the work programme for the FP6 industrial technologies priority (Priority 3) on nanotechnology and nanosciences, knowledge-based multifunctional materials, new production processes and devices. They also participated in proposals for new funding instruments – both Integrated Projects and Networks of Excellence – in response to the initial calls for FP6 in December 2002.




Projects show the way
Three projects from the FP5 GROWTH programme illustrate the results that can be achieved through collaborative effort:


ECOSYSTEMS (Advanced machining systems for environmentally friendly manufacturing) is developing new, more flexible machine concepts, components, systems equipment and tools aimed at reducing the environmental impact of machining transfer lines for medium and large batch production of mechanical components – particularly where these involve difficult-to-cut materials.


MACH21 (Multipurpose and cross-sectoral modernisation of manufacturing processes through parallel kinematics) has prepared the way for meeting future needs of factories through the implementation of manufacturing processes using machines employing the emergent technology of parallel kinematics. These have the potential to offer faster, more flexible, more accurate and less costly alternatives to conventional systems.


MANTYS – the CECIMO-coordinated European Thematic Network for Manufacturing Technologies – is promoting innovation in manufacturing technologies, particularly machinery. It provides a platform for researchers and industry to exchange views and results relating to technology, society, the economy, sustainability and quality-of-life in all aspects of manufacture. It involves: more than 20 European laboratories and research institutes; a task force of experts from universities, companies and machine tool builders' associations; and an Industrial Advisory Committee representing the automotive, aerospace, mechanical and machine building sectors. Potential synergies between projects are made apparent and co-operation encouraged, enhancing the creation of the European Research Area in manufacturing technologies.
Several other European projects are of interest in this context:
TEMCA2 responds to the need to develop critical technologies for large machine tools, with particular respect to the development of new electromagnetic compatibility (EMC) test methods. EMC is equally important for other large machine industries, such as refrigerating/air handling, printing machines, textile machines, injection-moulding equipment, assembly lines and woodworking machines.


STEP-NC is updating numerical control (NC) programming, to replace international standards originally based on punched card input. The initiative for designing a new NC programming interface started in Europe under ESPRIT in the mid 1990s, and is continuing on a global scale as an Intelligent Manufacturing System2 (IMS) project involving also the USA and South Korea.


OSACA (under ESPRIT III) is specifying a manufacturer-independent system architecture for open control systems. These will reduce the time to market for new products as well as increasing the flexibility of customised control systems and reducing the cost of development, maintenance, training and writing of documentation.
In a further relevant GROWTH initiative, VISIONONLINE, the European society for precision engineering and nanotechnology (euspen) is raising awareness and creating opportunities for industries, universities and research institutes to meet, network and derive mutual advantage from the promotion of ultra-precision technologies.


Directives shape the future
As well as creating a climate in which Europe can continue as the world’s leading machine tool supplier, a second objective of research co-operation is to assist industry by reducing trade barriers within the Single Market itself, through the establishment of common approaches to safety and supply criteria.

A central element in this process is the Machinery Directive and its revision, as proposed by the Enterprise DG, which provides the regulatory basis for harmonisation of the essential health and safety requirements for machinery at EU level. It not only promotes the free movement of machinery, but also guarantees a high level of protection to EU workers and citizens.

Other relevant current and impending legislation and standards development includes:


Electro-Magnetic Compatibility Directive (Enterprise DG);
Pressure Equipment Directive (Enterprise DG);
Draft Framework Directive on Eco-design for End-use Equipment/Energy using Product (Enterprise DG);
Low Voltage Directive (Enterprise DG);
Physical Agents Directive (Employment and Social Affairs DG);
Waste Electrical and Electronic Equipment Directive (Environment DG);
Safety of Machine Tools (CEN TC 143); and
Machine Tools (ISO TC 39).


Towards a Manufacturing Technology Action Plan
The European Commission and its industrial and research counterparts agree on the need for a long-term strategic research agenda to manage the transition of Europe’s manufacturing industry and ensure that the EU remains a world leader in this area over the next decade. Comparable agendas have already been identified in areas such as aerospace, surface transport, the chemical industry and hydrogen/fuel cells.

At the EMO meeting, the Commission announced its intention to launch proposals for a Manufacturing Technology Action Plan (MATAP). The recommendations will be based on information gained from two foresight studies – FutMan and INFORMAN – plus reactions to soundings on a similar proposal for environmental technology (ETAP), and responses to the first calls for proposals under Priority 3 of FP6. A conference entitled ‘European Manufacturing of the Future: role of Research and Education for European World Leadership’ in Milan on 1 and 2 December 2003 will provide a forum for the initial presentations.
 
Top