Fiberglass molding

Fiberglass molding is a process in which fiberglass reinforced resin plastics are formed into useful shapes.

Mold Making

The fiberglass mold process begins with an object known as the plug or buck. This is an exact representation of the object to be made, and can be made from a variety of different materials. Certain types of foam are commonly used.

After the plug has been formed, it is sprayed with a mold release agent. The release agent will allow the mold to be separated from the plug once it is finished. The mold release agent is a special wax, and/or PVA (Polyvinyl alcohol). Polyvinyl Alcohol, however, is said to have negative effects on the final mold's surface finish.

Once the plug has its release agent applied, gelcoat is applied with a roller, brush or specially-designed spray gun. The gelcoat is pigmented resin, and gives the mold surface a harder, more durable finish.

Once the release agent and gelcoat are applied, layers of fiberglass and resin are laid-up onto the surface. The fiberglass used will typically be identical to that which will be used in the final product.

In the laying-up process, a layer of fiberglass mat is applied, and resin is applied over it. A special roller is then used to remove air bubbles. If left in the curing resin, air bubbles would significantly reduce the strength of the finished mold. The fiberglass spray lay-up process is also used to produce molds, and can provide good filling of corners and cavities where a glass mat or weave may prove to be too stiff.

Once the final layers of fiberglass are applied to the mold, the resin is allowed to set up and cure. Wedges are then driven between the plug and the mold in order to separate the two.

Advanced techniques such as Resin Transfer Molding are also used.

Making a Component

The component-making process involves building up a component on the fiberglass mold. The mold is a negative image of the component to be made, so the fiberglass will be applied inside the mold, rather than around it.

As in the mold-making process, release agent is first applied to the mold. Colored gelcoat is then applied. Layers of fiberglass are then applied, using the same procedure as before. Once completed and cured, the component is separated from the mold using wedges, compressed air or both.

Tool Management

Tool management is needed in the metalworking so that the information regarding the tools on hand, can be uniformly organized and integrated in the manufacturing environment and process flow. The information is stored in a database and is registered and applied using the tool management software. The tool data management consists of specific data fields, graphics and parameters which are essential in production, as opposed to a solution for the management of the general production equipment.

Unlike hand tools, a tool in the CNC-production is composed of several parts. Putting the parts together accurately into an assembly is a requirement in order to achieve error-free production.

Processing a part with the CNC machine (machining operation) requires several tool assemblies, which are documented in a list. Each component, each assembly and each list has an identification under which the specifications are found. The tool management is divided into the documentation of the tools (master data) and the logistics (transaction data). The documentation includes, at the very least, all information needed for a trouble-free and a comprehensible production process. Moreover, spare parts, experiences in production and the corresponding data can be managed. Several functions are available to manage, process, print and combine with other applications.

The logistics deal with demand planning, supplies and the location of the tools. This includes, on one hand, the location in the warehouse and the purchasing of individual parts with the corresponding consumption report. On the other hand, it also allows the planning and coordination of the movements of the assemblies within the shop floor.

Master Data of Tools

The master data describes the tools with regards to the geometric characteristics, the composition and the usage. The information is divided into th actual description of the tool (specifications), the work instructions for use through people and the description for the use through machines (Instruction set). The master data describes the tool in its qualitative aspects, but does not provide quantities and locations.

Components

Outline sample for chamfer tools.

The components are individual parts, which can be combined into an assembly. Components are purchased as a unit and stored in tool release. There is a distinction between cutting components (ex.:collets) and non-cutting components (ex.:collets ). Cutting components are worn out during use and therefore must be purchased and replaced periodically. Non-cutting components are practical unlimited in use. They are often acquired together with a new tool machine. Clamping equipments are handled like non-cutting components.

• The header data is uniformly structured and contains information such as name, supplier's product code, and a unique item number. Each component is assigned to a specific tool type, which defines the number and description of the required data fields. Each component is also linked to a tool category that belongs to a user specific tree structure, which serves to find the tools according to their technical criteria without indicating the number.

• The descriptive data (geometrical value) vary depending on the type of tool. The data fields are specified in the class list of characteristics. The meaning of the geometrical data fields is illustrated in diagrams and pictures. The DIN 4000 recommends diagrams and pictures for their explanation. Varying graphics for different functions are stored either in the database, or on the components through data links.

DXF according ISG/BMG Standard.

*Generally, there are four types of graphic illustrations:

1. 2D drawings, for example, in DXF format according to the ISG/BMG standard for geometrical information,
2. PDF data of the tool manufacturer as a data sheet with exploded view,
3. 3D data (ex.: STEP or STL) for the use in CAM systems,
4. Photos (ex.: JPG) as graphical information

• Cutting data (speed and feed) is stored for the cutting components for optimal chipping efficiency. The different data for varying materials and processing methods, number of revolutions, progressive feed, cooling and production method.

Tool Assemblies

The tool assembly is built out of several components. The component at the rear end must fit to be connect the machine tool , and the cutting component is found on the other end (ex.: drill or insert). Varying components are used intermediately (ex.: extension, collets) in order to reach the desired geometry of the assembly. The documentation of the assembly describes how the components need to be assembled, in order to ensure that the applied geometry in the CAM system matches that of the real tools in the CNC machine.

• The header data contains information such as identification, a specific number and the allotted tool class.

• The geometric fields are computed directly through the data of the applied components. Adjustable tools (ex.: fine drill tools with adjustable diameter) are stored in addition to the data of the assembly.

• The assembly instructions contain the bill of material as well as the data for the parts assembly that is important for the specific assembly (ex.: adjusting tolerance + 0.03/-0.01 mm).

• The nominal values for the presetting serve as a default in the measuring process with a tool presetting machine. The exact position at the tool and the measuring method can be specified, in addition to the nominal values of the geometry, so that, for example, the left or right corner has to be measured for a grooving tool.

• The cutting data is typically used for the cutting components as a recommendation for the assembly. This can be adjusted to the specific situation for the assembly. The specifications are continually improved with the help of the practical experience in the factory and are automatically made available for the NC programming in the CAM system.

Tool lists / manufacturing operation

The tool list includes all tool assemblies that are needed for a machining operation. It will be printed as picking list and is used for commissioning and providing advises for the assembly setup. Often there are instructions and information contained therein that are not directly related to the tools (e.g. clamping, clamping fixtures, the name of the NC program, etc.) to ensure that all documents for an operation can be viewed together.

• The header data include information such as name, unique identification and the allocation to the right machines. As identification is used e.g. the combination of "part number + operation". Instead of the part number, the drawing number can be used.

• The list of assemblies contains all the assemblies needed for the operation, along with the designated pocket in the machine (T number, Turret). That list also includes those requirements for the assembly, valid for this specific operation only (such as minimum cutting length). The assemblies are listed in the order in which they are used in the NC program.

• The print edition (picking list) is used for the picking of components and assembly of the complete tools in the tool output. It includes the necessary components and their storage location and the important geometric details and tolerances of the complete tool.

Auxiliary Tables

Match conditions for tool components.

In addition to the actual tool data, auxiliary data tables simplify the data acquisition, using values selected from a table instead of having to collect them. Compared to a manual input, this ensures a more comfortable and consistent data collection.

• On both sides of a component match conditions indicated the geometric condition another component must meet to be connected. If a component has on the right side matching conditions such as a next component on the left side, the two can be assembled. The use of match conditions makes searching matching components easier and more secure. When entering the component into the database, for both sides the right match conditions are selected from a table.

• A list of the work materials is required for the assignment of the cutting conditions. Different qualities and additional terms for the materials are also contained in the list, and extended by the individual designations as used by the respective enterprise.

• The tool classification is used to organize the tools in technical terms. All tools assigned to the same tool class are suitable for the same task, but they have different sizes. The tool classes are organized in a tree, which is adapted and expanded by the user.

• The tool types with the corresponding images describe the required geometric values and where they are measured. Each tool type is assigned to a class list of characteristics that define the data fields of the components.

• The locations are used in order to specify the location of the assemblies and components in logistics. They are a reflection of the manufacturing environment and include all stands where tools and equipment could stay. They are divided into storage locations, intermediate locations, preparation- and production units (machines). Several locations are grouped into departments. The locations themselves can be divided into individual places. The level of detail and depth of the structure are defined only as far as the logistcal aspects are actually necessary.

• The cost centers are used in logistics to evaluate the use of tools in different departments (e.g. turning). With the removal of a component from the storage, an indication is specified at the cost center it relates to. The cost center of the tool management must be adjusted with those in the PPS system.

Transaction Data (logistics) of Tools

Tool Components on stock.

Logistic is concerned with the inventory, the storage areas and the purchasing of tools. Within the logistics, there is a differentiation between the components and the assemblies. The components themselves have a differentiation between internal material flow and purchasing goods from external suppliers (stock control).

Stock control of Components

The logistics of the components includes primarily the inventory management, the planning of requirements and the monitoring of the minimum stock level. When reaching the minimum level, the tool management triggers a procurement process, which is handled by the Purchasing Department, with the ERP system. The logistic of the tool management uses a workplace-tuned user interface and has interfaces to storage systems and other facilities within the shop floor. Requirement for coordinated inventory of components is a central organization of the tools in which all components of a production unit are stored at one location, and each withdrawal is recorded reliably.

In-house logistics of Components

In-house logistics is mainly interested in what place a wanted component currently is, and at what cost center it was consumed. This method only consumes wear parts (cutting), the other components (holders, clamping devices) are only be moved between toolroom, storage places, and machine tool. The booking of the components at the individual cost centers and locations occurs simultaneously with withdraw / restore in the toolroom. The preparation of tools and resources is triggered by a production order. It refers to a tool list in the master data, in which all required components are listed. Prior to the usage in the machine tool, the components are assembled, according to the specifications and work instructions in the tool list. When scheduling the production orders, for each component will be checked if the available inventory is sufficient to assemble the tools required.

In-house logistics of Assemblies

tool Assemblies loaded.

The assemblies are built from components, and after usage usually disassembled into components and restored again. From an assembly, multiple copies can be assembled simultaneously, if the components are available in sufficient numbers. The logistic of assemblies refers to the condition and location of these copies.

Each copy of an assembly can typically be in three various states:

• not yet assembled (the components are available as individual parts)
• Assembled in the intermediate storage (e.g. on a shelf)
• assembled on the CNC machine

When scheduling a production order, the relevant, for the work required assemblies are known, based on the tool list. Also, known is which assemblies, required for the machining process, are already located on the machine tool. The necessary, but not yet available assemblies are calculated and printed in a net loading list. They either have to be assembled or removed from the intermediate storage. With a coordinated logistic of the assemblies it is possible to reduce the time required for providing and replacement of assemblies at the machine.

Integration of Tool Data

The tool management serves to guarantee an efficient and faultless order processing in the manufacture. Existing knowledge is made generally available and the guidelines stated in the master data are noticed. The integration of tool data enables other applications to use the tool data which is maintained with the tool management. Thereby, the applications either fall back on the tool management's database, or the data will be replaced by the interfaces. Especially in CNC manufacturing where several persons are involved in the production process the integration avoids faults, delays and multiple data recordings. As follows you will find a short description of some of the respective connections between the most important applications and the tool management.

PDM (documentation)

In the PDM system every product's work plan is saved which comprises the CAD Models, the description of the working steps and the list of the needed equipment. The detailed description of the equipment themselves takes place in the tool management because the PDM system does not offer functions and data fields do describe them in detail. It typically offers links to external data. If a product is to be produced, a production order will be generated with the ERP system which comprises the link to the work plan stored in the PDM system. The needed resources such as NC programs, tools, and instructions will be requested in the production from the tool management. Integration means to guarantee the availability of the actual information in the tool management system mentioned in the PDM system. The basic objective for integration is a systematic numbering of the documents and resources.

ERP (purchase)

The RP system plans raw material, consumable items and other resources. It is closely connected with the PDM system and assumes the tasks of the materials management and logistics. Related to the tools, this concerns the consumable components (cutting items). If the inventory of the components is conducted with the tool management system, purchase orders will be transmitted as purchase requisitions to the ERP system which assumes the actual order. This requires that the products are registered in both systems with the same number. Additionally all internal stock movements of the tool components for the costing can be handed over to the ERP system with the integration.

CAM

With the CAM system the G-Code commands (NC program) for the CNC machine are generated. Geometry, description and cutting conditions of the assemblies are selected and received directly from the tool management database. This ensures that all tools used are documented and consistent with the reality in the workshop. From the CAM system, all tools used in an NC program are automatically saved as tool list in the tool management. This ensures the correct use and equipment of the tools during the preparation of the working process.

Storage systems

Besides the conventional tool cabinets, storage systems which provide the operator with the shelf containing the desired product are often used. The relationship between the item number and the storage place is saved in the tool management. When booking a tool removal in the logistics area of the tool management the storage system is operated automatically. Alternatively, the assignment of storage locations can be configured in the storage system. The removal is then performed on the storage system and the inventory change is transmitted to the tool management.

Presetting

At the processing to the tools' positioning the CNC machine needs their exact measurements. Therefore, the length and diameter of the complete tools must be entered when inserting them in the machine. These setting values of the tools can be measured with an external pre-setter. Convenient pre-setters assume the nominal values, tolerances and designation from the tool management and pass the measured actual values directly to the control of the CNC machine. The integration of the tool management with the pre-setters takes place in the exchange format of the respective equipment manufacturers and also includes the graphics and information about the method of measurement.

Tool catalogues

To reduce the cost of the initial data acquisition of the components in the tool management solution, tool manufacturers provide the data and graphics in appropriately conditioned form. For the technical data of the tools, the DIN 4000 and the ISO 13399 exchange format are currently used. Wherever required, the 2D graphics are provided in accordance with the ISG / BMG DXF standard. For 3D graphics a standard is not defined yet. Normally, STL and STEP format are offered and axis position is chosen according to the application on the machine.

Motivation for Tool Management

Utilization of New Technologies

Rising demands in design und quality, combined with time and cost pressures, force companies to permanently invest in more efficient equipment and procedures. Modern CNC-Machines (i.e. Mill-Turn-Machines) are highly productive, however they are very demanding in terms of preparation and application. A prerequisite for the successful use of new technologies is therefore the simultaneous adaptation of the organization together with the opportunity to include the storage und retrieval of necessary operational information. The additionally required knowledge can subsequently be included in the operational procedures and made available for each necessary task. This avoids the situation that instructions allocated regarding equipment and tooling are flawed or incomplete resulting in the interruption of the production.

Supplying the Right Information

Newly Purchased equipment is supplied with specific information for its usage (i.e. cutting data with tools). This Information is however found in the supplier specific (i.e. maximum allowed diameter of a fine boring tool). Before the new acquisition can be utilized, the data must be integrated in the company orientated specific task format. (i.e. The exact setup values for a required fine boring tool). Furthermore, this information must be made available to all participating work areas. (i.e. the exact adjusted diameter must be made known to the NC programming and tool store departments). Processed company information is then made available as general or as specific part data instructions (i.e. appropriate cutting values for a particular tools usage with a specified material) and must be managed and integrated within a workflow to prevent valuable production capacity is lost or tool life is reduced due to unsuitable cutting data.

Make Information Available.

Tool and production data is managed within a company database and in a specific format. For this purpose a software application is utilized so that information can be accessed across all departments and be accessed and used by different people without repeatedly registering duplicate data. So that the data can be utilized by various other software applications (i.e. CAM-Systems, tool pre-setters, shop floor logistics), suitable interfaces are integrated to secure a smooth, seamless workflow. Central data management reduces errors and stoppages in production.

Planning and Preparation

To plan a machine schedule and preparing tools for a night shift, purchasing consumable articles or a decision for a new requisition requires the necessary sufficient information. The structured administration of all data pertaining to tools makes it possible to access pertinent information and relevant data within a short term.

Necessity of a solution

The importance of exchanging information between operational areas varies according to each type of company. Generally it can be said, that missing or unclear information means that sources of errors are made transparent through loss of capacity, delays and inefficient work flow. Manual interfaces and information passed on by word of mouth are without doubt potential error sources and obstacles for new employees. The more people that are involved in the production process; the necessity and importance of binding instructions and clear cut procedures become clearer. Activities that are to be frequently carried out must of organized just as efficiently as a seldom duty. Especially important are binding specifications that are involved in complex working situations to reduce the chance of machine damages as well as the risks involved with defective deliveries.

Tool management

Tool management is needed in the metalworking so that the information regarding the tools on hand, can be uniformly organized and integrated in the manufacturing environment and process flow. The information is stored in a database and is registered and applied using the tool management software. The tool data management consists of specific data fields, graphics and parameters which are essential in production, as opposed to a solution for the management of the general production equipment.

Unlike hand tools, a tool in the CNC-production is composed of several parts. Putting the parts together accurately into an assembly is a requirement in order to achieve error-free production.

Processing a part with the CNC machine (machining operation) requires several tool assemblies, which are documented in a list. Each component, each assembly and each list has an identification under which the specifications are found. The tool management is divided into the documentation of the tools (master data) and the logistics (transaction data). The documentation includes, at the very least, all information needed for a trouble-free and a comprehensible production process. Moreover, spare parts, experiences in production and the corresponding data can be managed. Several functions are available to manage, process, print and combine with other applications.

The logistics deal with demand planning, supplies and the location of the tools. This includes, on one hand, the location in the warehouse and the purchasing of individual parts with the corresponding consumption report. On the other hand, it also allows the planning and coordination of the movements of the assemblies within the shop floor.

Master Data of Tools

The master data describes the tools with regards to the geometric characteristics, the composition and the usage. The information is divided into the actual description of the tool (specifications), the work instructions for use through people and the description for the use through machines (Instruction set). The master data describes the tool in its qualitative aspects, but does not provide quantities and locations.

Components

Outline sample for chamfer tools.

The components are individual parts, which can be combined into an assembly. Components are purchased as a unit and stored in tool release. There is a distinction between cutting components (ex.:collets) and non-cutting components (ex.:collets ). Cutting components are worn out during use and therefore must be purchased and replaced periodically. Non-cutting components are practical unlimited in use. They are often acquired together with a new tool machine. Clamping equipments are handled like non-cutting components.

• The header data is uniformly structured and contains information such as name, supplier's product code, and a unique item number. Each component is assigned to a specific tool type, which defines the number and description of the required data fields. Each component is also linked to a tool category that belongs to a user specific tree structure, which serves to find the tools according to their technical criteria without indicating the number.

• The descriptive data (geometrical value) vary depending on the type of tool. The data fields are specified in the class list of characteristics. The meaning of the geometrical data fields is illustrated in diagrams and pictures. The DIN 4000 recommends diagrams and pictures for their explanation. Varying graphics for different functions are stored either in the database, or on the components through data links.

DXF according ISG/BMG Standard.

*Generally, there are four types of graphic illustrations:

1. 2D drawings, for example, in DXF format according to the ISG/BMG standard for geometrical information,
2. PDF data of the tool manufacturer as a data sheet with exploded view,
3. 3D data (ex.: STEP or STL) for the use in CAM systems,
4. Photos (ex.: JPG) as graphical information

• Cutting data (speed and feed) is stored for the cutting components for optimal chipping efficiency. The different data for varying materials and processing methods, number of revolutions, progressive feed, cooling and production method.

Tool Assemblies

The tool assembly is built out of several components. The component at the rear end must fit to be connect the machine tool , and the cutting component is found on the other end (ex.: drill or insert). Varying components are used intermediately (ex.: extension, collets) in order to reach the desired geometry of the assembly. The documentation of the assembly describes how the components need to be assembled, in order to ensure that the applied geometry in the CAM system matches that of the real tools in the CNC machine.

• The header data contains information such as identification, a specific number and the allotted tool class.

• The geometric fields are computed directly through the data of the applied components. Adjustable tools (ex.: fine drill tools with adjustable diameter) are stored in addition to the data of the assembly.

• The assembly instructions contain the bill of material as well as the data for the parts assembly that is important for the specific assembly (ex.: adjusting tolerance + 0.03/-0.01 mm).

• The nominal values for the presetting serve as a default in the measuring process with a tool presetting machine. The exact position at the tool and the measuring method can be specified, in addition to the nominal values of the geometry, so that, for example, the left or right corner has to be measured for a grooving tool.

• The cutting data is typically used for the cutting components as a recommendation for the assembly. This can be adjusted to the specific situation for the assembly. The specifications are continually improved with the help of the practical experience in the factory and are automatically made available for the NC programming in the CAM system.

Tool lists / manufacturing operation

The tool list includes all tool assemblies that are needed for a machining operation. It will be printed as picking list and is used for commissioning and providing advises for the assembly setup. Often there are instructions and information contained therein that are not directly related to the tools (e.g. clamping, clamping fixtures, the name of the NC program, etc.) to ensure that all documents for an operation can be viewed together.

• The header data include information such as name, unique identification and the allocation to the right machines. As identification is used e.g. the combination of "part number + operation". Instead of the part number, the drawing number can be used.

• The list of assemblies contains all the assemblies needed for the operation, along with the designated pocket in the machine (T number, Turret). That list also includes those requirements for the assembly, valid for this specific operation only (such as minimum cutting length). The assemblies are listed in the order in which they are used in the NC program.

• The print edition (picking list) is used for the picking of components and assembly of the complete tools in the tool output. It includes the necessary components and their storage location and the important geometric details and tolerances of the complete tool.

Auxiliary Tables

Match conditions for tool components.

In addition to the actual tool data, auxiliary data tables simplify the data acquisition, using values selected from a table instead of having to collect them. Compared to a manual input, this ensures a more comfortable and consistent data collection.

• On both sides of a component match conditions indicated the geometric condition another component must meet to be connected. If a component has on the right side matching conditions such as a next component on the left side, the two can be assembled. The use of match conditions makes searching matching components easier and more secure. When entering the component into the database, for both sides the right match conditions are selected from a table.

• A list of the work materials is required for the assignment of the cutting conditions. Different qualities and additional terms for the materials are also contained in the list, and extended by the individual designations as used by the respective enterprise.

• The tool classification is used to organize the tools in technical terms. All tools assigned to the same tool class are suitable for the same task, but they have different sizes. The tool classes are organized in a tree, which is adapted and expanded by the user.

• The tool types with the corresponding images describe the required geometric values and where they are measured. Each tool type is assigned to a class list of characteristics that define the data fields of the components.

• The locations are used in order to specify the location of the assemblies and components in logistics. They are a reflection of the manufacturing environment and include all stands where tools and equipment could stay. They are divided into storage locations, intermediate locations, preparation- and production units (machines). Several locations are grouped into departments. The locations themselves can be divided into individual places. The level of detail and depth of the structure are defined only as far as the logistcal aspects are actually necessary.

• The cost centers are used in logistics to evaluate the use of tools in different departments (e.g. turning). With the removal of a component from the storage, an indication is specified at the cost center it relates to. The cost centersof the tool management must be adjusted with those in the PPS system.

Transaction Data (logistics) of Tools

Tool Components on stock.

Logistic is concerned with the inventory, the storage areas and the purchasing of tools. Within the logistics, there is a differentiation between the components and the assemblies. The components themselves have a differentiation between internal material flow and purchasing goods from external suppliers (stock control).

Stock control of Components

The logistics of the components includes primarily the inventory management, the planning of requirements and the monitoring of the minimum stock level. When reaching the minimum level, the tool management triggers a procurement process, which is handled by the Purchasing Department, with the ERP system. The logistic of the tool management uses a workplace-tuned user interface and has interfaces to storage systems and other facilities within the shop floor. Requirement for coordinated inventory of components is a central organization of the tools in which all components of a production unit are stored at one location, and each withdrawal is recorded reliably.
In-house logistics of Components

In-house logistics is mainly interested in what place a wanted component currently is, and at what cost center it was consumed. This method only consumes wear parts (cutting), the other components (holders, clamping devices) are only be moved between toolroom, storage places, and machine tool. The booking of the components at the individual cost centers and locations occurs simultaneously with withdraw / restore in the toolroom. The preparation of tools and resources is triggered by a production order. It refers to a tool list in the master data, in which all required components are listed. Prior to the usage in the machine tool, the components are assembled, according to the specifications and work instructions in the tool list. When scheduling the production orders, for each component will be checked if the available inventory is sufficient to assemble the tools required.

In-house logistics of Assemblies

tool Assemblies loaded.

The assemblies are built from components, and after usage usually disassembled into components and restored again. From an assembly, multiple copies can be assembled simultaneously, if the components are available in sufficient numbers. The logistic of assemblies refers to the condition and location of these copies.

Each copy of an assembly can typically be in three various states:

• not yet assembled (the components are available as individual parts)
• Assembled in the intermediate storage (e.g. on a shelf)
• assembled on the CNC machine

When scheduling a production order, the relevant, for the work required assemblies are known, based on the tool list. Also, known is which assemblies, required for the machining process, are already located on the machine tool. The necessary, but not yet available assemblies are calculated and printed in a net loading list. They either have to be assembled or removed from the intermediate storage. With a coordinated logistic of the assemblies it is possible to reduce the time required for providing and replacement of assemblies at the machine.

Integration of Tool Data

The tool management serves to guarantee an efficient and faultless order processing in the manufacture. Existing knowledge is made generally available and the guidelines stated in the master data are noticed. The integration of tool data enables other applications to use the tool data which is maintained with the tool management. Thereby, the applications either fall back on the tool management's database, or the data will be replaced by the interfaces. Especially in CNC manufacturing where several persons are involved in the production process the integration avoids faults, delays and multiple data recordings. As follows you will find a short description of some of the respective connections between the most important applications and the tool management.

PDM (documentation)

In the PDM system every product's work plan is saved which comprises the CAD Models, the description of the working steps and the list of the needed equipment. The detailed description of the equipment themselves takes place in the tool management because the PDM system does not offer functions and data fields do describe them in detail. It typically offers links to external data. If a product is to be produced, a production order will be generated with the ERP system which comprises the link to the work plan stored in the PDM system. The needed resources such as NC programs, tools, and instructions will be requested in the production from the tool management. Integration means to guarantee the availability of the actual information in the tool management system mentioned in the PDM system. The basic objective for integration is a systematic numbering of the documents and resources.
ERP (purchase)

The ERP system plans raw material, consumable items and other resources. It is closely connected with the PDM system and assumes the tasks of the materials management and logistics. Related to the tools, this concerns the consumable components (cutting items). If the inventory of the components is conducted with the tool management system, purchase orders will be transmitted as purchase requisitions to the ERP system which assumes the actual order. This requires that the products are registered in both systems with the same number. Additionally all internal stock movements of the tool components for the costing can be handed over to the ERP system with the integration.
CAM

With the CAM system the G-Code commands (NC program) for the CNC machine are generated. Geometry, description and cutting conditions of the assemblies are selected and received directly from the tool management database. This ensures that all tools used are documented and consistent with the reality in the workshop. From the CAM system, all tools used in an NC program are automatically saved as tool list in the tool management. This ensures the correct use and equipment of the tools during the preparation of the working process.
Storage systems

Besides the conventional tool cabinets, storage systems which provide the operator with the shelf containing the desired product are often used. The relationship between the item number and the storage place is saved in the tool management. When booking a tool removal in the logistics area of the tool management the storage system is operated automatically. Alternatively, the assignment of storage locations can be configured in the storage system. The removal is then performed on the storage system and the inventory change is transmitted to the tool management.
Presetting

At the processing to the tools' positioning the CNC machine needs their exact measurements. Therefore, the length and diameter of the complete tools must be entered when inserting them in the machine. These setting values of the tools can be measured with an external pre-setter. Convenient pre-setters assume the nominal values, tolerances and designation from the tool management and pass the measured actual values directly to the control of the CNC machine. The integration of the tool management with the pre-setters takes place in the exchange format of the respective equipment manufacturers and also includes the graphics and information about the method of measurement.
Tool catalogues

To reduce the cost of the initial data acquisition of the components in the tool management solution, tool manufacturers provide the data and graphics in appropriately conditioned form. For the technical data of the tools, the DIN 4000 and the ISO 13399 exchange format are currently used. Wherever required, the 2D graphics are provided in accordance with the ISG / BMG DXF standard. For 3D graphics a standard is not defined yet. Normally, STL and STEP format are offered and axis position is chosen according to the application on the machine.

Storage systems

Besides the conventional tool cabinets, storage systems which provide the operator with the shelf containing the desired product are often used. The relationship between the item number and the storage place is saved in the tool management. When booking a tool removal in the logistics area of the tool management the storage system is operated automatically. Alternatively, the assignment of storage locations can be configured in the storage system. The removal is then performed on the storage system and the inventory change is transmitted to the tool management.

Presetting

At the processing to the tools' positioning the CNC machine needs their exact measurements. Therefore, the length and diameter of the complete tools must be entered when inserting them in the machine. These setting values of the tools can be measured with an external pre-setter. Convenient pre-setters assume the nominal values, tolerances and designation from the tool management and pass the measured actual values directly to the control of the CNC machine. The integration of the tool management with the pre-setters takes place in the exchange format of the respective equipment manufacturers and also includes the graphics and information about the method of measurement.

Tool catalogues

To reduce the cost of the initial data acquisition of the components in the tool management solution, tool manufacturers provide the data and graphics in appropriately conditioned form. For the technical data of the tools, the DIN 4000 and the ISO 13399 exchange format are currently used. Wherever required, the 2D graphics are provided in accordance with the ISG / BMG DXF standard. For 3D graphics a standard is not defined yet. Normally, STL and STEP format are offered and axis position is chosen according to the application on the machine.

Motivation for Tool Management

Utilization of New Technologies

Rising demands in design und quality, combined with time and cost pressures, force companies to permanently invest in more efficient equipment and procedures. Modern CNC-Machines (i.e. Mill-Turn-Machines) are highly productive, however they are very demanding in terms of preparation and application. A prerequisite for the successful use of new technologies is therefore the simultaneous adaptation of the organization together with the opportunity to include the storage und retrieval of necessary operational information. The additionally required knowledge can subsequently be included in the operational procedures and made available for each necessary task. This avoids the situation that instructions allocated regarding equipment and tooling are flawed or incomplete resulting in the interruption of the production.

Supplying the Right Information

Newly Purchased equipment is supplied with specific information for its usage (i.e. cutting data with tools). This Information is however found in the supplier specific (i.e. maximum allowed diameter of a fine boring tool). Before the new acquisition can be utilized, the data must be integrated in the company orientated specific task format. (i.e. The exact setup values for a required fine boring tool). Furthermore, this information must be made available to all participating work areas. (i.e. the exact adjusted diameter must be made known to the NC programming and tool store departments). Processed company information is then made available as general or as specific part data instructions (i.e. appropriate cutting values for a particular tools usage with a specified material) and must be managed and integrated within a workflow to prevent valuable production capacity is lost or tool life is reduced due to unsuitable cutting data.

Make Information Available.

Tool and production data is managed within a company database and in a specific format. For this purpose a software application is utilized so that information can be accessed across all departments and be accessed and used by different people without repeatedly registering duplicate data. So that the data can be utilized by various other software applications (i.e. CAM-Systems, tool pre-setters, shop floor logistics), suitable interfaces are integrated to secure a smooth, seamless workflow. Central data management reduces errors and stoppages in production.

Planning and Preparation

To plan a machine schedule and preparing tools for a night shift, purchasing consumable articles or a decision for a new requisition requires the necessary sufficient information. The structured administration of all data pertaining to tools makes it possible to access pertinent information and relevant data within a short term.

Necessity of a solution

The importance of exchanging information between operational areas varies according to each type of company. Generally it can be said, that missing or unclear information means that sources of errors are made transparent through loss of capacity, delays and inefficient work flow. Manual interfaces and information passed on by word of mouth are without doubt potential error sources and obstacles for new employees. The more people that are involved in the production process; the necessity and importance of binding instructions and clear cut procedures become clearer. Activities that are to be frequently carried out must of organized just as efficiently as a seldom duty. Especially important are binding specifications that are involved in complex working situations to reduce the chance of machine damages as well as the risks involved with defective deliveries.

Injection Molding: Drafting and Wall Thickness

Draft and wall thickness are two of the most critical and overlooked fundamentals when manufacturing and designing for injection molding.

Draft

Draft is a design feature that involves tapering the side walls of a part to allow it to be released from the mold when the mold opens. Drafting walls in the direction of the mold helps to prevent sticking and dragging as the part ejects.The recommended draft angle for parts is 0.5 to 1 full degree of draft on all surfaces. If your part includes textured walls, you will need to increase the amount of draft to ensure clean ejection. We suggest that 1.5 – 2 degrees of draft be used per 0.001″ of texture depth. This rule is for sidewalls of the tool that will shrink away from the cavity. Areas in the part that will shrink toward the core of the tool will require more draft. The amount of draft needed for these walls will vary based on part design.

Wall Thickness

Wall thickness is another critical component of design that can affect the success of your injection molded part. If the walls of your part are too thin, you may have cracking or warping of your part. The type of plastic resin that you choose will help determine the wall thickness needed. Each resin has a unique blend of properties that include varying amounts of plasticizers, stabilizers, fillers, and other additives. These properties determine each resin’s flow and strength values. Refer to the chart to the to see the recommended wall thicknesses of some common resins.

Top 10 tips for transfer tooling

1. Who owns the tooling? Who owns the hot runner control? "In this age of acquisitions, a lot of times the tooling goes from molder to molder and may not even be owned by the OEM, so you lose traceability on the tooling," Mulville says. In one mold move, when Mulville laid down the stipulations for the move, he included the HR control. However, the molder informed him that it owned the control, and Mulville's client had to make an offer for it. "You have to clear that up front," he says. "It's an unpleasant surprise to find this out at the last minute."

2. What condition is the tool in? (i.e. the age, number of cycles already run) Is the tool "capable"? This would seem like a no-brainer. "Yes, molders keep these records, but sometimes they don't like to part with that information," Mulville explains. "Sometimes you're invited to move molds because the molder can no longer be competitive and profitable on them. Invariably they're cooperative, but now and then I hear about hostile situations where there are collections implications. You need to evaluate the mold in advance with the existing molder, preferably while it's running.

"Short of that, retained parts are invaluable," he continues. "You can ascertain what condition the mold is in. Do the parts have known defects that have deviations or waivers to mold what is essentially a defective part, but is acceptable by the customer? If you know these deviations are good with the current molder, then there's no burden on the new molder to make a part that is otherwise impossible to make. If the mold has problems, is it reparable? The OEM doesn't usually know the condition of the tool. It's not so much about what people tell you—it's what they don't tell you that's important."

3. What type and size of press is currently being used? As the new molder, you need to do your homework to make sure you've got the available capacity. "Often they think they can run the mold in a similar press, or have several presses they believe will fit that mold, but then find out that they don't really have the right size press or can only run the mold in one press, which can cause a log-jam in the production schedule," explains Mulville.

4. What is the tiebar spacing and the knockout layout? Again, this is to ensure that you've got the right type of equipment that can handle the mold. Don't wait until the mold comes in the back door to find out whether or not it will fit your presses.

5. What environment does the mold/press run in? Providing the required environment for the type of parts, while not necessarily an ISO requirement, might be critical to the customer requirements. One molder might run an entire production floor as a "clean environment," while the new molder might have to install a cleanroom because his plant overall isn't a clean environment and would not be able to meet the minimum customer requirements.

6. What are all the recorded tool and part numbers? "We had a major audit for transferring molds as the result of an acquisition of business by a big corporation, and their list of acquired tools didn't match what I had in my database," says Mulville. "Often, the minute the tooling comes in the door, the new molder will assign its own in-house tooling and part numbers for control, which makes sense because you can't have everyone's numbers on your books. But make sure you reconcile the former tooling and part numbers with the new ones so there's no confusion about the molds."

7. Is there any peripheral equipment required? Are there any fixtures or special measuring devices needed? Do the parts require secondary operations such as hot stamping, ultrasonic welding, or assembly? If you don't have the equipment to do this, then you might need to bring in the equipment or find a vendor to supply these so you can fulfill parts orders.

8. Are there molding specifications with the mold? Often that information has gone missing or the former molder won't give it up. What grade of material is required? Who is the supplier? Are additives required? Colorants? And what are the let-down ratios?

9. What documentation exists to support change-out configurations? Where there's a family tool or a production tool that molds different configurations of the same part with separate cores and cavities, you need to have all the components, know how it's done, and what is required for these various configurations.

10. Is there full documentation on the mold? In many cases, Mulville notes, the molds have been moved so often that the drawings are gone or the documentation has been lost. That can create problems for the new molder.

Basic Leather Carving

The embellishment of leather goods via cutting, stamping, and tooling date back into antiquity, and though these techniques have been simplified by modern tools and automation, the medieval leatherworker's craft has changed little in the intervening centuries. The techniques and patterns used to decorate modern saddles are repeated on specimens in European museums and, if I am any example, can be learned by artistic Neanderthals with a bit of hard work.

Basic Carving Technique

The amount of time devoted to detail and perfect carved edges depends entirely on the application. A leather coronet, bible cover, or tooled pouch would be small enough, and sufficiently scrutinized to be worthy of full detailing as described below. Larger projects, intended to be viewed from a distance (such as a shield, belt, or sign) might omit several of the edging and finishing steps. The resulting project will have less terrain, rougher edges, a non-uniform background, and take one-tenth the time to finish. Furthermore, none of these deficiencies would be visible further than a foot away. Ultimately, the level of detailing depends on the purpose, scale, and price of the piece.

An early example of the cut, bevel, and backgrounding work is the satchel of the book of Armagh. It was carved sometime in the 8th century to carry a much larger book, but later found use with the smaller book now at Trinity College Dublin. The satchel lives in the special collections room of the new library, and you can see it if you ask nicely (and pretend to be a graduate student in art). To give you an idea of the scale of the pattern, the interlacing stripes are about 6mm in width.

Obtain a piece of naturally tanned leather. Vegetable and oak-bark tanning will work nicely, while modern chrome tanning will not (it waterproofs and softens the hide too much to retain tooled designs). If possible, try to work in the center of a piece somewhat larger than your pattern. Meanwhile, copy your pattern onto waterproof tracing paper (wax paper works).

Both sides of the leather are wetted, either with a sponge, quick dunk, or running under poured water. Attempt to wet the surface without allowing water to pool and saturate the piece. Overly wet leather gets mushy, and dry leather can crack under the increased force needed to form it (some folks prefer dry leather for stamping).

Secure the traced pattern onto the leather (tape only to the back of the leather!), make sure the inked side of the paper is facing up (!) and transfer the pattern by pressing on the paper with a rounded stylus (ball-point pen). Smooth any mis-tracings with a modeling (or ordinary) spoon. Remove the tracing paper, and let the surface dry a bit.

Carve the lines you have just transferred, about 1/2 the hide thickness deep with a swivel (an Exacto results in non-uniform lines, but can be substituted) knife. Carving is the critical step to creating striking, non-stamped designs. When done well, it creates enough contrast to skip one or more of the following steps in a lower-detail project, or ease the remaining steps of a higher-detail project.

Bevel along the carved lines, by placing the deep part of the beveler into the groove, and the shallow part toward the side to be depressed. With each mallet stroke, overlap the previous stamping by 2/3 of the tool's length, trying to tool to at least half the thickness of the hide. This step is the most dull and time-consuming (a 40" knotwork belt required 25 hours of beveling, 5 of design & tracing, 3 of carving, and 4 of finishing!), but results in smooth, finished edges which collect dye and produce an automatic graded-shading effect. Also, beveling down the edge pattern creates deeper patterns and simplifies the next step. However, its use, except for small sections, may not be justified or reasonable for larger projects.

Most modern designs use a raised foreground and a flattened background to maximize topographic contrast (the opposite, inverted tooling, is also common). A flat tool, either textured (which collects dye and automatically darkens the background) can accomplish this, overlapping profusely (as with beveling) to avoid individual too-marks. The degree of overlap, again, depends on how much time the artisan wishes to devote to "perfection," as does the effort expending in pounding down exactly "inside the lines" (and beveled edges provide a large margin for error) Alternative backgrounding techniques involve stamping a repeated pattern, filigreeing (cutting away the background leather completely), or poking a nail the leather to create a speckled pattern.

Another technique, used as extensively in period as today, is stamping. Once the stamp is created, the above sequence is limited to wetting the leather, transferring some alignment marks, and pounding away. This demands a pattern be used numerous times, as modern custom stamps can quite expensive, and period stamps were often painstakingly carved from wood (and incidentally didn't last very long). The hybrid technique of using common stamps (crescents, ropes, circles) in creative ways to augment a hand-carved design can save immense amounts of time, while still producing one-of-a-kind projects.

Paints and dyes:

Let one pigment dry (overnight if possible) before applying a different one.

Paint with water-based acrylics. Leather paints are more flexible than normal ones.

Water and spirit-based dyes should be diluted for a full range of effects.

Oil based dyes are rich, deep, permanent, and rather cheap if you buy by the quart.

Lacquers (like Neat-Lac) work well as resists for Antiquers (I like Tandy's browns)

Leather sealers make the piece waterproof and shiny, but also less flexible.

Basic Leatherworking Tools:

T-square, yardstick, compass:

Measure & shape your leather accurately.

Exacto knife and/or leather shears:

N.b. leather will destroy "cloth only" shears

Edge Beveler (#2):

Round the fresh edges for a more finished and durable piece.

Beeswax & Bone folder/wheel:

Finish the edges nicely.

Barge Cement:

Let set for 20 minutes before bonding two ROUGH surfaces. Ventilate very well!!

Leather Tips:

Vegetable-Tanned or Oak-Tanned only! Tooling chrome-tanned leather is a hopeless cause

Choose light-colored leather in the thickness desired (one "ounce" is a 1/64" of thickness)

Some leather is of a lower grade due to a few, bad defects, or small size.

Depending on your project, this could be a good value for you...

Scraps (anywhere but Tandy or Leather Factory) are cheap and ideal for practice and small projects.

Try to select your leather in person, especially when buying shoulders and sides.

Cut the Chatter - Tooling Tips to Eliminate Vibration in Cavity Milling

Eliminating chatter or noisy vibration in moldmaking and other cavity milling operations pays off in greater productivity. It increases metal removal rates, enhances surface finishes with fewer finishing steps and reduces scrap.

Figure 1: Cutting tool specifiers can reduce overall cutting force and resulting vibration by using positive rake inserts shown on this cutter. The shearing action of positive rake cutters reduces cutting forces by more than 20 percent versus zero- or negative-rake milling tools.

Chart I: Insert shape influences vibration by altering the entry angle of the cutting edge to work. Rounds are most prone to vibrations, 45-degree lead angles are the least. In addition to insert shape, users seeking to minimize vibration should consider inserts protected by thinner PVD coatings.

Figure 2: Rigid couplings in modular tooling will reduce vibration. In one modular tooling system, the couplings feature 100 percent contact area between the components for rigidity and even distribution of torque.

Eliminating vibration also reduces wear on cutting tools and machining centers to minimize machine downtime. Poor fixturing, workholding and machine maintenance all contribute to vibration and its associated problems. The best way to quiet chatter is often a combination of remedies. However, machine operators and manufacturing engineers generally look first at their cutting tools. A knowledgeable supplier of both segmented and solid carbide cutting tools can integrate total solutions to stop the chatter.

Figure 3: This hydromechanical chuck grips the tool firmly in place without slippage, resulting in excellent tool balance. It offers two to three times the clamping force of traditional types and permits 20-second tool changes.

Vibration in cavity milling creates uneven wear on cutting tools and shortens tool life. While indexable insert milling cutters and solid carbide endmills differ in construction, they are both vulnerable to chatter and share some common vibration remedies. Indexable insert milling cutters are generally available in diameters down to one-half inch. They use replaceable inserts with a choice of geometries and coatings. Smaller openings call for solid carbide endmills with two, three or four cutting edges. There are steps that users can take to end vibration with both milling cutters and endmills.

Milling Cutter Chatter

Use cutters with fewer inserts. Although it may seem counterintuitive, the first step to reducing chatter in milling operations is to switch to a cutter with fewer teeth. In general, the coarser the cutter pitch, the lesser the chance of harmonic vibration. Sometimes, replacing a 16-tooth cutter with a 12-tooth tool ends chatter altogether. A differential-pitch cutter may be required in more difficult cases to eliminate troublesome harmonics.

The larger the cutter, the better the performance will be. Conditions permitting, larger cutters provide more choices about how to approach the workpiece. Varying the relative position often helps damp vibration. Manufacturing engineers should try to keep the cutter diameter 20 to 50 percent larger than the width of the cut. The cutter should be sized so that no more than two-thirds of the inserts are engaged in the cut at any time. These guidelines help produce an ideal entry angle, thereby reducing cutting forces and vibration.

Optimize insert geometry. The shape of the cutting inserts often determines their vibration tendency. Round inserts are most vibration prone, while those with 45-degree lead angles are the least prone to chatter. The smaller the entry angle of the cutting edge to the work, the lower the tendency to vibrate. Chart 1 ranks the various insert shapes for vibration tendency.

Cutting tool specifiers can reduce overall cutting force and resulting vibration by using positive rake insert geometry. The shearing action of positive rake cutters reduces cutting pressure by more than 20 percent versus zero- or negative-rake milling tools (see Figure 1). The sharper edge and angle of entry of this type of insert also helps to reduce the power needed to penetrate the surface of the workpiece.

Choose insert coatings carefully. Coatings on inserts perform many functions, but their primary jobs are protecting against heat, maintaining lubricity and preventing build-up on the insert. To reduce edge rounding and chatter, you should look to replace inserts protected by thick CVD coatings with those wearing thinner PVD coatings. Though CVD treatments are formulated for wear resistance, PVD coatings provide a sharper insert edge and a more positive rake angle to help minimize vibration.

Stiffer Tools, Less Vibration

The same anti-vibration principles true for indexable milling cutters also apply to solid endmills. To reduce vibration, users should select endmills with fewer teeth and a high helix. A steeper helix corresponds to a more positive rake. A shallow helix is equivalent to a negative rake. To minimize vibration, endmill users should examine using helix angles from 30 to 60 degrees relative to the centerline of the tool.

Minimize length; maximize diameter. In addition to positive rake and high helix angles, both milling cutters and endmills should be as stiff as possible. Machine operators and manufacturing engineers should do everything possible to minimize the bending or deflection of cutting tools. A rule of thumb states that reducing the length of the tool by 20 percent reduces the amount of bending in the tool by 50 percent. Likewise, increasing the diameter of a cutting tool by 20 percent cuts deflection in half. In practical terms, this usually means that you should try to use the largest diameter tool you can to do the job.

In addition to large diameter tools, try to use the shortest tool possible for each application. Many operators tend to choose a tool that meets the most demanding case on a workpiece requiring multiple operations. For a workpiece with several hole depths, the same long tool selected to make the deepest hole is also used to make shallower penetrations. Using a longer-than-necessary tool in shallow holes contributes instability to the entire operation and invites chatter. Programming the machine to use the right tool for each step minimizes vibration and maximizes productivity for the entire job.

Feeds, Speeds and Angles

Maintain feed pressure per tooth. To minimize vibration, don't try to go easy on tools by reducing feed pressure. Too light a feed allows the tool to slip and is just as prone to generate vibration as too heavy a feed pressure. Use the loading recommended by the tool supplier to minimize chatter and maximize tool life.

Increase feed rate. Machine operators commonly respond to a vibration problem by reducing the cutting speed and leaving the table feed alone. Speeding up the machine or the feed may seem like a recipe for disaster. However, an increase in feed at the same rpm may turn out to be the ideal solution. Anyone who has experienced harmonic vibrations in a car on the highway knows either speeding up or slowing down can end the noise. Similar experimentation can counter the complex harmonics of milling chatter.

Vary entry points. Moving the centerline of the cutter slightly to either side of the entry point on the workpiece can often reduce the tendency to chatter or vibrate. The offset creates a finer entry angle and prevents forces from oscillating from one side of the cutter to the other. For a two- to three-inch facemill, the offset may be 3/16". For a one-inch endmill, the offset may be 0.0050". Again, experimentation can determine the low-vibration setting.

Toolholding Options

Balance and true cutting tools. Cavity milling operators seeking to minimize vibration should make sure that their tool is properly balanced and that it is mounted true to the spindle center. Strategies for connecting the tool to the machining center vary widely. Especially on milling jobs with long overhang, machine operators should avoid toolholders that rely only on setscrews or keyways to transmission of torque. Modern toolholding solutions, like a modular toolholding system, can help ensure balance and true mounting (see Figure 2).

One system reduces tool runout to less than eighty millionths of an inch. The holder design maintains 100 percent contact in the clamping area where torque is transmitted to the tool. For shanked tools, a hydromechanical chuck improves tool balance and stability, and thereby reduces uncontrolled vibration (see Figure 3).

Integrated Solution

Chatter is the product of every element in the cavity milling process, including the tools, the machine and the workpiece. The total system remedy is to eliminate all vibration sources that can lead to harmonic responses. Run the job on the "tightest" machine available. The more that the machine's ways and spindle are tight and robust, the less vibration will occur. Keep the structure rigid from spindle to cutting edge. Clamp the part to minimize movement, vibration and deflection. Add support close to the areas to be machined.

Vibration is most likely in workpieces with a long overhang. As a rule of thumb, whenever a cutter's shank aspect ratio - its length-to-diameter ratio - exceeds three to one, the risk of vibration rises rapidly. With ratios over five to one, vibration-damping adapters/extenders and modular toolholders can help. Unlike solid adapters that transmit vibrations readily, today's vibration-damping adapters have an internal chamber containing a heavy body suspended on rubber bushings. Machine operators should position the milling cutter as close to the tuned adapter as possible.

Tooling is just one element in the campaign against vibration. If none of these remedies work in your particular case, ask your tooling supplier for recommendations on your machine, your workpiece and your procedures. A knowledgeable supplier can provide insight into vibration problems and cut the chatter.