Tool made using VISI helps COVID-19 plan

An injection moulding specialist helped a public school in Rutland to produce thousands of pieces of PPE for frontline workers during the early days of the COVID-19 crisis.

While Oakham School was closed during lockdown, staff used 3D printers and laser cutters from the Design and Technology Department to begin making face shields. The department approached local company, Rutland Plastics, to help it boost productivity, which took the team from manufacturing just a handful, to 8000 a day.
Rutland Plastics’ technical manager Carl Martin says they were originally asked to 3D print a number of headbands for the shields, but decided it would be more cost effective to manufacture a mould tool using its VISI software package, from which the plastic product could be injection moulded.
“We received the initial design for the 3D printed product, and modified it in VISI to make it suitable for injection moulding,” he says. “Once that was completed and approved, we designed the tool in VISI using a Meusburger bolster with aluminium bolster plates.”
The design then went into the tool room and was milled on the company’s Mazak VCN 530C CNC machining centre, with tool paths created through VISI’s CAM functionality. From taking in the initial 3D design, through turning it into a mouldable product, and finalising the mould tool, took less than a week.
When the two-impression mould was set up on Rutland’s 80-tonne Engel moulding machine, both parts of the headband were formed from a medically-accredited polypropylene every 24 seconds during the production run of 25,000. To complete the full screen face masks, Oakham School arranged for the headbands to be attached to plastic visors, which were then distributed to front line NHS staff.
For further information www.visicadcam.com

Manufacturing Holds Key to Recovery of Oil and Gas Markets, revealed at this week’s ADIPEC Energy Dialogue

Bounce back in China’s manufacturing sector points the way; other countries expected to follow as lockdown is lifted

Latest in series of on-line ADIPEC Energy Dialogues hears it could be late 2021 before oil and gas markets recover to 2019 volumes
OPEC+ supply constraints coming under pressure from US shale and indebted oil producers as prices strengthen; production cuts likely to be rolled over and extended

Abu Dhabi, UAE – XX June, 2020 – A revival in manufacturing across the world holds the key to the mid-term recovery of oil and gas markets, with consumer demand likely to lag as the energy industry begins to recover from the twin shock of the COVID-19 crisis and the resulting demand crash.

Participating in the latest online ADIPEC Energy Dialogue, Rachel Ziemba, an economic and political risk expert and Founder of Ziemba Insights, said the early signs from China, the first major economy to exit from the COVID-19 induced lockdown, are that manufacturing has bounced back more than consumption and that trend could be repeated in other countries.

“It is notable that the COVID crisis and the associated economic and energy crisis has really been the first to blow out the global consumer,” Ziemba said. “2008 was much more of a hit to the financial sector and manufacturing. This time it is the reverse. The big question is how quickly consumer demand will come back.”

Ziemba added it could be well into 2021 before oil and gas markets get to volumes approaching where the industry was at the end of 2019.

Looking at the trends likely to impact the recovery of oil markets in the mid-term, Ziemba said the OPEC Plus group of producers has had some success in tightening the market. But a question mark hangs over how long supply can be constrained.

“The challenge is that a few countries, those that are most economically strapped and not eligible for debt relief, are not complying in full and some have barely reduced production,” Ziemba said. “Despite pressure from the likes of Saudi Arabia and Russia, it is going to be very difficult for them to comply because these are countries that had big fiscal deficits when oil was $70 a barrel.

“The other challenge is that we are starting to see parts of the US shale industry starting to reverse shut ins. We are also seeing more rig activity after many weeks of decline. In a price range of mid-30s into a 40 range, there will be more entities that can make some money and the risk is that it puts even more pressure on OPEC Plus. So, I do think the most likely scenario is a rolling over and extension of the supply cuts.”

Access to credit, to support economic recovery, is an additional challenge for indebted oil producing countries, which are having to deal with multiple shocks at the same time, including sizable outbreaks of the COVID-19 coronavirus that may or may not be under control. Many of the oil producers that are in a tougher financial position than their rich peers are too wealthy to qualify for debt relief, Ziemba said, heightening social, political and economic risks which could further impact the oil and gas industry.

Elsewhere, as oil and gas companies seek for ways to recover, Ziemba said she expects to see some industry consolidation, particularly in the United States with more cash rich entities looking to go into smaller, more speculative areas that are lower cost. She also highlighted the possibility of further job cuts as companies become leaner and decide between boosting commercial reserves, or partnering with governments. Meanwhile, she added she expects to see more National Oil Company enter into partnerships, for example Middle East producers and Asian buyers, which enable greater creativity in payment terms and contracts.

The ADIPEC Energy Dialogue is a series of weekly online thought leadership events created by dmg events, organisers of the annual Abu Dhabi International Exhibition and Conference. Featuring key stakeholders and decision-makers in the oil and gas industry, the dialogues focus on how the industry is evolving and transforming in response to the rapidly changing energy market.

ADIPEC 2020 is projected to attract more than 155,000 energy professionals from 67 countries; including senior decision-makers and energy industry thought leaders, over 2,200 exhibiting companies and 23 national exhibiting pavilions as oil and gas companies convene to share views and best practices to address the long-term impact of the triple challenge of lower oil prices, weaker demand and over supply.

Held under the patronage of His Highness Sheikh Khalifa Bin Zayed Al Nahyan, President of the UAE; hosted by the Abu Dhabi National Oil Company (ADNOC); and supported by the UAE Ministry of Energy & Industry, the Abu Dhabi Chamber, and the Abu Dhabi Tourism and Culture Authority, ADIPEC is scheduled to take place from November 9 to 11, at the Abu Dhabi National Exhibition Centre (ADNEC).

To watch the Energy Dialogue series go to: https://www.youtube.com/channel/UCnFtPtFwMrRkuGUTk4Rh4tA

New software added to TNC controls

Heidenhain has incorporated new software into its TNC control systems that allows complex trochoidal milling routines to be programmed conversationally on the shop floor, without having to download the cycles from a CADCAM station

OCM (optimised contour milling) functionality is a new option available for the company’s TNC640, TNC 620 and TNC 320 CNC systems.
The OCM algorithm takes conventional ideas for trochoidal milling, traditionally used to achieve high material removal rates when slotting, and considerably expands the range of application. In addition to the roughing of any open or closed pocket or island, the software also offers cycles for finishing the floors and side walls.
A milling tool’s wrap angle can be limited to reduce heat generation and prolong cutter life. As cutting forces are lower, delicate and thin-wall parts can be machined with greater accuracy, and even spindles with low power and torque can be used successfully, says the company. Moreover, as the milling cutter occupies less of the area of a slot or pocket during machining, the accumulation and re-cutting of chips is minimised, which is particularly important for features that are deep in comparison with their width.
The control automatically calculates the best tool paths for maintaining constant cutting parameters. Subsequent machining operations run with continuously optimised cutting values, resulting in increased machining speed and a noticeable reduction in tool wear, reports Heidenhain. A sample part produced recently in Germany demonstrated the effectiveness of the new milling strategy: OCM lowered the machining time and raised tool life by a factor of three compared with conventional milling strategies.
For further information www.heidenhain.co.uk

COVID secure

Companies looking to return back to work safely can tap into a new service launched by In-Comm Training that will help them become COVID-19 secure.

Health and safety experts from the Aldridge-based training provider have created a new consultancy package that will walk firms through the different measures and policies they need to put in place to protect their staff and conform to Government guidelines. The support will also help businesses with more than 50 employees, who must have a COVID risk assessment available for staff and visitors before they can open.
For further information www.in-comm.co.uk

Major release from ModuleWorks

ModuleWorks has released its 2020.04 CADCAM software components – the first major release of 2020 – which is available now for download from the ModuleWorks website.

Each ModuleWorks release contains new and enhanced features across the product range. This latest release contains new quality-enhancing features for five-axis and three-axis machining, as well as improved visualisation for the MultiXPost post processor.
In five-axis machining it is not always possible to create a collision-free lead for the machining process. The new automatic tilting feature uses an intelligent algorithm to automatically tilt the tool to avoid collisions, thereby improving the safety and efficiency of the machining process, particularly when working with complex tool shapes such as barrel-mill cutters.
Setting the constraints on the lead tilt angle and side tilt angle enables users to adjust the machining process in different ways depending on the tool’s contact point and the machining surface. To provide even more application flexibility, the user-defined contact point and angle limits can now be measured relative to the surface normal, instead of the initial tool orientation. When working with barrel-mill cutters, this feature gives users better control over the cutting conditions upon tool engagement.
With regard to three-axis operations, floor machining for pocket/boss areas is now available to complete the basic product portfolio of roughing and finishing cycles based on a wire-frame geometry. This new cycle creates engrave cuts at a specified depth. The pattern can be used with open and intersecting drive curves and is suitable for engraving text and single-line font machining. To optimise tool loading, users can now create a specified number of engraving tool-path slices with variable depths.
The posting of three-axis tool paths on a machine usually requires constant adjustments to the position of the table or head, which may not always be desired when viewing the simulation. To provide an improved user experience, MultiXPost is now able to eliminate continuous movement and keep the table or head axis in a fixed position while ensuring the whole tool path is simulated within the machine limits.
For further information www.moduleworks.com