Slivers On Rolled Steel Products

May 17, 2012

Slivers are elongated pieces of metal attached to the base metal at one end only. They normally have been hot worked into the surface and are common to low strength grades which are easily torn, especially grades with high sulfur, lead and copper.”- AISI Technical Committee on Rod and Bar Mills, Detection, Classification, and Elimination of Rod and Bar Surface Defects

Slivers are loose or torn segments of steel that have been rolled into the surface of the bar.

Slivers may be caused by bar shearing against a guide or collar, incorrect entry into a closed pass, or a tear due to other mechanical causes. Slivers may also be the result of a billet defect that carries through the hot rolling process.

This is my lab notebook sketch for slivers ‘back in the day…’

Slivers often originate from short rolled out point defects or defects which were not removed by conditioning.

Billet conditioning that results in fins or deep ridges have also been found to cause slivers and should be avoided. Feathering of of deep conditioning edges can help to alleviate their occurrence.

Slivers often appeared on mills operating at higher rolling speeds.

When the frequency and severity of sliver occurrence varies between heats,  grades, or orders, that is a clue that the slivers probably did not originate in the mill.

This is how Slivers present under the microscope. Note decarburization (white appearance.)

Slivers are often mistaken for shearing, scabs, and laps.  We will post about these other defects in the future.


Laps On Rolled Steel Products

May 15, 2012

“Laps are longitudinal crevices at least 30 degrees off radial, created by folding over, but not welding material during hot working (rolling). A longitudinal discontinuity in the bar may exist prior to folding over but the defect generally is developed at the mill.”- AISI Technical Committee on Rod and Bar Mills, Detection, Classification, and Elimination of Rod and Bar Surface Defects

Here is my lab notebook entry for a lap back in 1985…

In plain language, a lap is a ‘rolled over condition in a bar where a sharp over fill or fin has been formed and subsequently rolled back into the bar’s surface.’

Photo of a lap from AISI Surface Defects Manual.

An etch of the full section shows what is going on in the mill. Laps were often related to poor section quality on incoming billets, although overfill scratches, conditioning gouges from “chipping” have also been shown to cause laps.

Cross section of steel bar exhibiting laps (white angular linear indications). When two laps are present 180 degrees apart, the depth to which they are folded over can indicate where in the rolling the initial over fill ocurred. White indicates decarburization, which confirms my interpretation that this lapping occurred early in the rolling.

Laps are often confused with slivers, and mill shearing which we shall describe and post soon.

The term ‘lap seam’  is sometimes used, but it is careless usage; it implies the lap is caused by a seam – it is not; a seam is a longitudinally oriented imperfection, and so is used in this mongrel term as a shorthand way of saying ‘longitudinal.’

Modern speakers sometimes try to use the word ‘lamination’ to describe laps but as we will see, not all lamination type imperfections are laps…


Reduced Summer Shutdown Precision Machining Production To Remain High

May 10, 2012

Ford announced it is reducing its summer shutdown in several North America plants, including six assembly plants, from the traditional two weeks to one.

It is going to be a busy summer for all of our shops making components for automotive applications.

Plenty of parts, plenty of machine adjustments, maybe time at the beach or fishing not so plentiful.

The  summer production boost is consistent with Ford’s plan to increase annual production capacity by 400,000- though the additional week is likely to only increase  vehicle production by 40,000.

Why is this important to your shop?

  • If you were planning on taking a shutdown to do major maintenance, you may not be able to schedule the time.
  • While Ford has made the announcement, you may not see the demand jump on your latest forecast.
  • Now might be a good time to review your barstock inventory, order book, and adjust accordingly.

They can’t make cars without parts… the parts you make!

Cleantechnica photo of technican at Helios inc.


Approved Stainless Steels for Your Rube Goldberg Kitchen Project

May 3, 2012

The choice of materials for food applications is critical if we are not to poison someone.

As Masters of Metals- ahem, machinists- many of us feel that there is no need to buy the expensive store bought items that we can easily cobble together from a few common on hand materials.

Personally the use of the galvanized garbage can doesn’t bother me nearly as much as the possibility of galvanized wire cages being used for grates for fire or grills for food contact.

I’ll pass along the University of Maryland’s  word of caution to avoid zinc  for food contact and high temperature (fire) applications.

While the temperatures involved in smoking foods are far lower than those encountered in welding and metal flame cuttting, the minimal risk of zinc is unneccessary.

The use of galvanized (zinc containing) steel grates – from old refrigerators or chicken cages or galvanized fencing should be avoided for applications actually touching food.

.
So if you are determined to make your own Rube Goldberg  food preparation equipment what  metal should you use?

Stainless steel baby! Use Stainless!

National Sanitation Foundation (NSF) recommends stainless steel:

NSF 51 Sect 7.1 Stainless steel

7.1.1 Stainless steel used in food equipment shall be of a type in the AISI 200 series, AISI 300 series, or AISI 400 series.

7.1.2 When used in a food zone, stainless steel shall have a minimum chromium content of 16%.

Stainless steel with a chromium content of less than 16% may be used for cutlery, blades, and similar applications requiring a sharp edge, provided the alloy has been hardened or tempered by an appropriate post-weld heat treatment process.

We don’t know why NSF thinks that the heat treat needed is a post weld heat treatment, (who is welding blades?) The blades may be quench and tempered to develop microstructure and toughness… but we’ll still trust their opinion about the safety aspects.

Now who has a great recipe for a dry rub…

NSF 51 pdf

Garbage can smoker


Robot Safety, R15.06, OSHA And Your Precision Machining Shop

April 19, 2012

Robots continue to find their way into our precision machining shops as we move away from departments of similar machines as a business model.

Savvy shops today are creating cells that use the robot to efficiently transfer work from one type of machine to another.

Robots can also deburr, pick and pack or present to inspection equipment.

As robots become more common in our operations, we need to assure that we are up to date on safety practices and procedures for our employees who are now sharing the same  shop floor work environment with our robots.

Chapter 4 of the OSHA Technical Manual is a “must understand” reference for shops with Robots. You can get it at the link below for free:

Industrial Robots and Robot System Safety

This is a comprehensive resource covering an introduction to robotics, types of robotic systems etc.

I believe that you will get your greatest takeaway in the sections covering hazards and control and safeguarding personnel.

Also you need to be aware of the ANSI RIA 15.06 Standard.

The current US robot standard is the 1999 version of R15.06 which was reaffirmed in 2009.

You can buy it from ANSI here. (cost $45.00)

This standard is currently being updated, with a major focus on risk assessment.

ANSI/RIA R15.06 will combine the ISO 10218-1 standard  ( cost: 146 Swiss francs) which applies just to the robot, with ISO 10218-2 (cost 184 Swiss francs) which covers the integration of the robot into your systems. While these have been finalized by ISO, the final adoption into ANSI RIA 15.06 has not yet taken place. The updated  ANSI/RIA R15.06 standard will include both of these as well as some additional USA requirements. The Canadian standard Z434 committee is also at work on the national adoption of these ISO standards. We have our fingers crossed that the U.S. and  Canadian robot standards will be harmonized.

While we’re waiting for the updated ANSI/RIA R15.06 to be published, you probably ought to make sure that your team is up to speed on the OSHA material mentioned above.

And for $45 the current (2009) version of ANSI R15.06 is worth your time and monies to obtain.

Just remember that when the update is released, it will be best practice and authoritative.

Want more info? Siemens is sponsoring a webinar on April 25, 2012 at 2:00 P.M. Eastern time.

Here’s a link: Siemens Industry Robotics Changes Webinar

PMPA is not a sponsor of this webinar.

But we are committed to giving our members tools they can use to keep their shops safe, competitive, and sustainable.


Infrared Thermography- Preventive Diagnostic For Your Shop

April 13, 2012

We first used a digital infrared non-contact thermometer back in 1993 to get some diagnostic insight into the failures we were having in my cold finished mill. Unscheduled equipment and electrical breakdowns were keeping us from profitability.

With this technology we could see mechanical failures developing before they shut us down.

When we built the mill in Georgia, the engineers never gave a minute of thought to the  operating temperature differences the equipment would have to endure compared to our experiences up North. We just  ‘knew‘ our problems were thermal, the failures ‘clustered’ in the summer months. How to prove it?

The first bearing we found running hot with our IR thermometer allowed us to plan for a repair rather than lose valuable production time.

That first preventive/proactive repair paid for our investment in what the boys in the shop thought was a “heat gun.”

But when we turned this technology to the electronics controls- that is when we hit the real pay dirt.

At a $3000 per circuit board and 5 days via air freight from Europe, our IR thermometer helped us justify to the stingy “Just say NO’” bean counters that air conditioned electrical enclosures would pay for themselves by reducing both downtime and  unbudgeted expenses to replace failed  sensitive electronic components.

And they did. The IR thermometer properly deployed helped us finally achieve our business plan.

Its much easier to achieve your business plan when your equipment is actually operating.

Today, IR thermometers are very affordable. But if I was managing a shop today, I don’t think that I’d be satisfied with just a “heat gun.”

Would you rather have just temperature numbers to base your decision on,  or a compelling image of the problem? (Images courtesy of FLIR)

This photo is worth a thousand words to the maintenance team, eh?

Electrical issues become pretty obvious using infrared imaging- don’t you agree?

Why wouldn't you want to know what this technology has to show you?

One of my favorite quotes came from one of the Dune series books by Frank Herbert- “Who knows what senses we lack that we might better see the world around us?” the hero asks.

Today I can answer that question.

“With Infrared Thermographic imaging-  we can see electrical and equipment failures before they happen.”

I can’t imagine trying to keep a shop running without it.

Video of IR imaging in your shop

Video- not just for the shop

Fluke IR

Photos


Shop Safety Guided Tour PMPA NTC 23 April 2012

April 11, 2012

At PMPA’s National Technical Conference, attendees will be presented with a wealth of programs to help them ‘further their degree in precision machining.’

I am pretty excited about  the Honing the Tool Whisperer  in you session; Gary Griffith’s  (Griffith Training) GDT session on orientation tolerances; Automation and Robotics presented by Don Engles of Productivity Inc.

I’ll be presenting a session monday afternoon titled Shop Safety- A Photo Tour. No sermon, not a lot of 1910. here comes trouble. Just a tour of shops demonstrating best safety practices, and maybe some opportunities to improve.

When I say best practices, this is an illustration of what I'm talking about. How does your housekeeping compare to this?

I don’t expect folks to fly to Chicago to see my Shop Safety Photo tour.

But I know that the one’s who do will leave with a vision of what best practices can be, and a handful of links to authoritative OSHA references.

Plus the latest news on the issues that we are engaging with OSHA  in our industry.

Program details

Technical track, Quality Track, Management Track, Leadership Gold Certification session, Critical Process Thinking in the Quality Profession.

Yes, we’ve got a great program lined up for you.

Register


The Difference Between Accuracy And Precision Measurement In Your Machine Shop

March 27, 2012

Your QA manager can put you to sleep explaining the difference between these two terms- but you really need to know the difference.

Accuracy describes 'close to true value;' Precision describes 'repeatability.'

Accuracy in measurement describes how closely the measurement from your system matches the actual or true measurement of the thing being measured. It is the difference between the observed average of measurements and the true average.

Think of accuracy as the “trustworthiness” of a measurement system.

Precision in measurement describes how well a measurement system will  return the same measure; that is its Repeatability.

As the targets above show, it is important to be both Accurate and Precise if you are to get useable information from your measurement system.

But the repeatability has two components- that of the measurement system (gage) itself and that of the operator(s). Differences resulting from different operators using the same measurement device- this is called Reproducibility.

In our shops, we cannot tell if our measurement system has repeatability or reproducibility issues without doing a Long Form Gage R&R study.

Gage repeatability and reproducibility studies (GR&R) use statistical techniques  to identify and discern the sources of variation in our measurement system: is it the gage, or is it the operator?

Gage error determined by the GR&R is expressed as a percentage of the tolerance that you are trying to hold.

Typically, 10% or less Gage Error is considered acceptable. Over 30% is unacceptable; between 10 and 30% gage error may be acceptable depending on the application.

Regardless- any level of gage error is an opportunity for continuous improvement.

Target Graphic


OSHA Haz Comm-Your Work Is Just Beginning

March 21, 2012

The new HAZCOMM 2012 ‘Right to Understand’ will impact 5 million businesses at an OSHA estimated cost of only $201 million dollars.

Thats just $40 per workplace to cover:

  • Cost of classifying Chemical hazards to meet the new GHS criteria;
  • Cost to revise Safety Data sheets and labels to meet the new format and content requirements;
  • Cost to train 43 million employeeson the new format and content of material symbols and data sheets;
  • Cost to management of those 5 million workplaces to become familiar with the new GHS requirements, assess, revise, develop and implement new compliance materials needed to adopt GHS;
  • Cost for printing new packaging and labels in color;

OSHA thinks that we can do it for $201 million a year- that’s just $40 per workplace!

OSHA says this is all it will cost your shop to adopt this new standard, become familiar with its requirements, reclassify all your chemicals, train your people, change all labels and data sheets. WHAT were they thinking?

Using Department of Labor enforced Federal Minimum Wages, $7.25 an hour, that means that they think that it will only take 5,5 hours to get a shop into compliance.

(Please, correct my math if I’m wrong!)

5-1/2 hours!

The PDF of the final rule is 858 pages!

Just to read that in 5.5 hours would mean reading 156 pages per hour.

At a nickel a page, just printing the final rule puts us over at $42.90.

Who the heck does these estimates? What were they thinking?

We really understand that regulations can provide a benefit to workers, companies and communities.

Especially where hazardous chemicals are involved.

But when the regulators underestimate the potential costs of adoption and compliance by such a large factor, it makes us wonder what other assumptions are they working under that are just as wrong?

P.S.  Do you think that OSHA or OIRA actually have  employee’s that can read 156 pages of federal technical regulation in an hour? At $7.25 an hour?


CNC Machining Is The Foundation Of Manufacturing- Peter Zelinski

March 20, 2012

Zelinski: “Any product you pick up and touch, it’s not too many steps away from a machining process.”

Most of the parts in your car engine come from a CNC machine. Medical devices, your kitchen cabinets — CNC machine. Your computer case, your iPhone earbuds — well, no. But the mold that created them — CNC machine.

The growth of these machines represents the biggest change in manufacturing over the last 20 years. The people who run them are factory workers.

But they also have to be computer programmers. And they are in high demand.

Marketplace on  American Public Media /National Public Radio Closed with a story on the importance of CNC machining last night.

You can access the podcast and read the full transcript at NPR CNC STORY 

Bottom line : Skilled operators of CNC machine tools are in high demand.

High enough demand to make the national financial news on NPR.

Tip of the hat to Peter Zelinski at Modern Machine Shop magazine, for effectively describing and communicating the opportunity of CNC machine technology for our workforce.

Modern Machine Shop is the Flagship publication of Gardner Publications, who co-produce Production Machining Magazine with PMPA.

CNC Podcast

Photo credit Dustin Dwyer at MarketPlace


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