Monday, April 24, 2017

2017 American Eagle Excellence in Industry Award Winner

Engman-Taylor of East Peoria, IL, with headquarters in Menomonee Falls, WI, won the American Eagle Excellence in Industry award at the annual Industrial Supply Association convention in Denver, CO on April 24, 2017. Engman-Taylor’s supplier partner Walter USA of Waukesha, WI was also recognized.

The American Eagle Excellence in Industry sculpture is the industrial supply community’s most coveted and prestigious award. Winners are selected from numerous North American submissions, which are based upon contributions to industry.

Accepting the award on behalf of Engman-Taylor was Jim Mueller, Engman-Taylor’s Vice President of Operations. Jim was accompanied on stage by Brian Yount (Sr. Account Manager), Cathy Hall (Customer Service Supervisor), Bob Martins (Applications Specialist), and Mike Schmeling (Applications Specialist).

Engman-Taylor and Walter were recognized for a major cost savings at their mutual customer, Mennie Machine Company (MMC). Engman-Taylor has been MMC’s tooling integrator since 2006, and Walter has been a supplier to Engman-Taylor since 2001. MMC is a large contract machining company that services several industries from its 250,000 sq. ft. production facility in Mark, IL. Difficulties with production and profitability goals on a critical part cast from 1722 steel included long cycle time, excessive deburring requirements, inconsistent tool life and varying costs.

Via Engman-Taylor’s Cost Circles® and Walter’s Multiply programs, analysis began with a blank slate. Tools, fixtures, programs, cut and non-cut times, and related technical manufacturing areas were analyzed for cost and productivity. Tool prices, procurement and inventory costs, lead times, and reconditioning were factored in. The resultant annual savings, including increased machine capacity, reduced labor costs, and decreased scrap rate, was over $1,400,000. The savings was verified after program implementation, and has now been in place for over a year.

Jake Cimei, MMC Purchasing Manager stated, "The quality of this part has markedly improved, and our relationship with our customer is much, much better. This is definitely a win-win situation."

Engman-Taylor is an industrial distributor laser‐focused on the implementation of cost reduction services that are packaged with globally sourced products from best in class suppliers. For more information, please see www.engman‐ or call 1-800-236-1975.

Friday, April 14, 2017

Time is Money - Less Time is More Money

You make money when your machines are running.  You make maximum profit when they are running at peak efficiency.  Uptime and cycle time are important to you.  Need more capacity?

Even the simplest process can be improved by evaluating the components that make up "the system".  The tool, holder, machine, machining parameters, fixture, and coolant can all play a part in the efficiency of the process.  The tool path is another area for improvement.  We have become experts in helping you improve the overall process.

The cutting tool is only a small part of the system.  You don't want to spend a bunch of money experimenting but you know you need an improvement.  That's where we come in.  Our applications specialists will evaluate the current process and make recommendations.  The goal is to run as fast as each component will allow.

The faster you make parts - the faster you make money.  No complicated formulas here.

Are you running as "fast" as you can?  How do you know?  Need to reduce your cycle time?
Give us a shot.

Here is a real-world example:
In order to meet demand this customer needed to save at least 30 seconds per part.  We reviewed the operation, the g-code program, and the tooling.  We made a few recommendations, brought in a performance trial, and demonstrated that we can save 41 seconds per part.  41 seconds each - on thousands of parts - for a few hundred dollar investment.

Cycle time prior to ET review: 1m 46s
Cycle time after ET review: 1m 5s

Got a tough job? Need cycle time improvements?
Not local? No problem; we have solved many problems over the phone or via the web.  You can even email your g-code program and we'll review it for you.
Contact Engman-Taylor

Wednesday, February 22, 2017

Bandsaw Blades - More Than You Need to Know

If you are production sawing you probably know that getting the right blade takes some time.  Often times trial and error is the "method" of choice.  Selecting the right blade doesn't have to be painful though and we are always here to help.

Feel free to comment below or contact us with your particular application, we would be happy to help.  Below we have compiled some basic information on bandsaw blades.

Let's start with some basic terminology:

  • Blade Width: The dimension of the band saw blade from tooth tip to blade back.
    • When looking at the blade form the side you might think this is height, but height is not used when defining a band saw blade.
  • Thickness: The dimension from one side to the other (i.e. .045")
  • Blade Back: The body of the blade not including tooth portion.
  • Tooth Form: The shape of the tooth, which includes spacing, rake angle, and gullet capacity.
  • Industry terms include variable, variable positive, standard, skip, and hook.
  • Tooth Pitch: The distance (in inches) between tooth tips. (i.e. 4 TPI)
    • Variable Pitch blades will often be expressed as 4/6, 10/14, etc.
  • Tooth Set: The pattern in which teeth are offset from the blade. Industry terms include raker, vari-raker, alternate, and wavy.
  • Width of Cut: The distance the saw tooth travels continuously “across the work.” The point where a tooth enters the work to the point where that same tooth exits the work.

Material and Width of Cut are two factors that determine most of the bandsaw blade requirements.  Machine horsepower, age, lubrication, and other factors also play a part.

Blade Material

Several blade materials are available including: Carbon, Bi-Metal, and Carbide tooth.  Blades come in a one piece design such as a carbon blades or two piece design such as carbide tooth (alloy steel backing with carbide teeth).

Carbide Blades
These products will cut faster and last longer than any other bandsaw blade in a wide variety of sawing applications. The blades are designed and produced for high efficiency cutting of difficult and abrasive materials as well as high performance cutting of large and difficult to cut work pieces.

Bi-metal Blades
High-speed steel tooth tips, combined with flexible alloy-steel backing material results in the most cost effective bandsaw blades for most metal sawing applications.
Bi-metal bandsaw blades cover most market requirements, including multi-purpose blades and contour cutting, cutting tubes and profiles, foundry cutting and production cutting.

Types of Set

The set is the tilt, or angle, given to the teeth of the saw blade to provide clearance for the blade body and the tooth edges.  Below are different types of set:

Raker Set
In the raker set, one tooth is set to the left, one tooth is set to the right, and one tooth (raker) is unset. This set type is used on most evenly pitched blades such as regular and hook. It is also used for contour and friction cutting blades on vertical bandsaw machines.

Combo Set
In the combo set, used on combo toothed blades, a raker (unset) tooth is followed by teeth in a left, right, left, right sequence. This pattern is repeated with each series of teeth starting and ending with the largest tooth in the pattern.

Other Types of Set are available including: Vari-Raker, Alternate, Wavy, Vari-set, and more.  Different blade manufacturers will use different terminology.

Tooth Form

The shape of the tooth’s cutting edge affects how efficiently the blade can cut through a piece of material while considering such factors as blade life, noise level, smoothness of cut and chip carrying

Variable Positive: Variable tooth spacing and gullet capacity of this design reduces noise and vibration, while allowing faster cutting rates, long blade life and smooth cuts.
Variable: A design with benefits similar to the variable positive form for use at slower cutting rates.
Standard: A good general purpose blade design for a wide range of applications.
Skip: The wide gullet design makes this blade suited for non-metallic applications such as wood, cork, plastics and composition materials.
Hook: Similar in design to the Skip form, this high raker blade can be used for materials which produce a discontinuous chip (such as cast iron), as well as for non-metallic materials.

Tooth Selection Guide (teeth per inch)

Band saw tooth size (Teeth Per Inch) is determined by the size and type of material to be cut and the desired finish. To select T.P.I. using this chart, find the colored chart for the type of material you wish to cut. Move up to the correct material size next to the chart. Follow across to the chart for the appropriate T.P.I. for your blade.

The chart to the left is a good rule-of-thumb for selecting the correct TPI for the size and shape of your material.

Credit: Morse Cutting Tools

The number of teeth per inch (TPI) defines the pitch of the blade and can vary from less than 1 to 24.
Thin-walled work pieces like tubes, pipes and sheet require fine teeth, otherwise there is a risk of tooth damage or breakage.

Large cross sections should be cut with a coarse-pitched saw, i.e. fewer teeth per inch. The fewer teeth engaged in the workpiece the higher the cutting capacity. This is because the penetration capacity of each individual tooth is greater if the saw's feed pressure is distributed over a lower number of teeth. A coarse pitch (few TPI) therefore increases productivity and provides a desirable, large chip space.

Soft materials, such as aluminium and bronze require a large chip space. A coarse pitch prevents the chips from building up and packing together in the gullets, which can impair sawing and damage the blade.

Band Width

The band width is measured from the tip of the teeth to the back edge of the blade.

On horizontal machines, the band width is dependent upon the bandsaw machine being used. There is, however, some variation possible on vertical machines.

For contour sawing, the blade should be as wide as the machine permits, but still narrow enough so that it can cut the desired shape.

Feed Rate

It is important that each tooth of the bandsaw blade cuts a chip with the right thickness. This is determined by the selection of tooth pitch, band speed and feed rate. You can now set the correct feed rate by studying the chips which the bandsaw blade produces when cutting.

1. Thin or pulverised chips - increase feed rate or lower band speed
2. Loosely rolled chips - correct cutting data
3. Thick, heavy or blue chips - too high feed, lower feed rate or increase band speed

Bahco (A Snap-On Industrial Tools Company)
Lenox Tools
Morse (the M.K. Morse Company)

Monday, January 30, 2017

Seeking Balance? The Benefits of Balanced Tools

We could all use a little balance in our lives - especially when talking about rotating tool assemblies in modern machine tools.  While it might not seem apparent, out of balance tools can wreak havoc on your operations.  Part finish, size, insert life and cycle time are all affected by the balance of the tool assembly.  Less obvious is what out-of-balance tools do to the machine tool, especially the spindle.

Higher production is often achieved with higher spindle speeds.  Machine tool spindle speeds have continued to increase over the past two decades.  These higher spindle speeds accentuate any out-of-balance conditions.  Think about your washing machine; when the laundry is somewhat balanced the machine runs smoothly.  When the laundry is out of balance the machine sounds like it is going to come apart.  The more out-of-balance or the higher the speed; the more apparent the condition is.

Most tool assemblies, applications, and machine tools can benefit from balancing.

The tool pictured here is a typical external threading tool.  This tool rotates around the part and cuts threads.  It has three identical inserts spaced equally around the "business end" of the tool.  You would think that this tool is "balanced" right out of the box. This tool made good parts but the customer was looking for ways to reduce cycle times - increase production.

Upon our initial inspection we found the tool to be 141.3 grams out of balance.  Initially tested at a speed of 176 RPMs.  Imagine this tool running at 8,500 RPMs!  With a quick check on our Haimer Tool Dynamic balancer and some re-balancing (adding or removing material as needed) we were able to significantly improve the balance of this assembly.
The tool now measures 2 grams at 8,500 RPMs.  The difference can be felt and heard.  The tool runs noticeably smoother and in-turn can be run faster.  The end result is a better part, made faster, with less wear on the machine tool.

Isn't that what we all want?

The provided screen shots show the actual before and after tool condition.  These reports can be provided with each tool balance we perform.

To summarize; balancing your tool assemblies can improve surface finish, allow for increased speeds & feeds, improve cutting edge life (indexable insert life), and reduce wear and tear on the machine tool.

To learn more about Haimer balancers or our balancing services contact us.

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Friday, January 13, 2017

Free Tooling Consultations

"No such thing as free" you say?  Well, for more than 60 years we have been providing free tooling consultations.  No fees.  No add-ons.  No kidding.  Why would we do that?  It's simple; we want you to succeed and when you do we want you to come back to us again and again.

What is a tooling consultant?  First off, if you're one of those people that don't like "consultants" rest assured.  We are not trying to sell consultative services.  We are trying to sell tooling - but - we sell it at the same price as companies that don't provide the same level of tooling expertise.

Our tooling consultants are experienced, industry professionals.  Our diverse group of technical specialists all share the same goal: to assist you with your tooling needs.  Anyone in any department in any office can be called upon at any time - every member of Team ET is at your service.

No part number?  No problem.  Tell us what you are working on, or looking for, and we'll source the right tool for you.  Not getting the tooling life or cycle time you desire?  Reach out.  Advice is free.  Tooling up for a new part?  We provide complete tooling packages with balancing, presetting, heat shrinking, assembly, packaging and more.  Your new tools arrive ready to go in the spindle.  Tagged with machine, spindle number, length, and any other information you require.  Often for no additional charge.

No matter where you are located we can support you.  No job is too big or too small.  No project is too complicated or too simple.  Contact one of our tooling consultants for technical support, application recommendations, product sourcing, or a general question.  We are here to help.

Our consultative services are not limited to cutting tools. We have applications specialists in all product categories; abrasives, assembly tools, material handling, safety, and janitorial.

Call us or email us.

Thursday, October 27, 2016

Stop Presetting Tools in Your Machine

Your machine makes money when it is machining.  You do everything you can to maximize efficiency, increase productivity, and reduce downtime.  You have to.

Tool changers, pallet changers, quick-change fixtures, and dozens of improvements are made to reduce the time that a spindle sits idle.  So why do so many people still set tool lengths in the machine?  "Setting a tool only takes a minute or two."  Yes, but setting just 20 tools can mean a loss of 40 minutes of productivity.  That's 3-1/2 hours per week setting tools - working only one shift.  That equates to two days a month lost productivity.

Did you know you can also save time and money tooling up a new machine or job?  Next time you consider a new machine or a new job give us a call.  We can supply your tooling packages (no matter the size) fully assembled and preset.
Every tool arrives labeled and ready to put into action.

Contact us today to learn more.

Tool Presetters

Even the smallest machine shop can benefit from presetting tools.  Not sure which one you need?  Simply contact us, we are here to help.  We don't just sell them; we use them, we install them, and we service them.

Haimer Microset GmbH

Haimer Microset presetters are available with max. tool diameters up to 500mm and tool lengths up to 1000mm.

Tool presetting at a high level at an attractive price. The UNO works exceptionally accurately and offers perfect results for tool dimensions with a diameter of up to 400 mm and measuring lengths of up to 400 mm (optional: 700 mm). This is ensured by a thermo-stable construction, high quality measuring systems and a high-performance software.

The VIO series is designed for measuring all tools. It is compatible with the machine tools of all manufacturers and covers the most individual requirements with its numerous options. This version with a manual operating concept ensures high quality components and the high power software Microvision VIO as standard.

VIO linear – the premium solution for highest precision and speed.

Better than ±2 μm repeatability, up to 25 % faster measuring cycles and unique ergonomics are market leading features. This outstanding performance is made possible by the linear drives, which are used for the first time in tool presetting.

Parlec Presetters

Parlec offers several presetters from the entry level Origin for under $10,000 to full-blown CNC tool presetters.  Video measuring, powerful software, and quality construction add up to superior performance.

Parlec Origin Presetter

Let this entry level bench mounted Tool Measuring Machine be the beginning of your process. The Origin is designed to provide basic video tool measuring and inspection functionality at an economical price.
Imaging: 70x Video Measuring, 19" Monitor
Measuring Length: 483 mm (19”)
Measuring Diameter: 254 mm (10”)
• 360° Braking
• 360° Angle indicator
• Adapt to other connections with additional adapters

Parlec 1550TMM

The Series 1550 TMM® is the starter offering  into our production ready Tool Measuring Machines.

At the core of the machine is cast iron construction, high grade bearings and guideways that are paired with Parlec's unsurpassed ParleVision® imaging system. This unit is perfect for customization as there are many options available for this series tool measuring machine.

If the Origin is not quite enough and the 1850 seems like too much then the 1550TMM presetter might be right for you.  Not sure?  Let us help.  Give us a call 800-236-1975.

 At the core of the Series 1850 TMM® is ductile cast iron construction, high grade bearings and guideways that are paired with Parlec's unsurpassed ParleVision® imaging system. This unit includes many features such as a touch screen monitor, vacuum clamping, and surface inspection. Additionally that integrated base with retractable castors allows this unit to be placed virtually anywhere.

Watch our YouTube video of the Parlec 1850TMM with Speedscan technology.

The 1850TMM is the workhorse for the Parlec presetter family.  When precision, performance, and production really matter look to the 1850 series presetters.

Contact Engman-Taylor for all your production needs.  Presetters, tooling, tool packages, service, support & more.