Archive for October, 2008

Q & A: Polished acrylic machining

Posted in Uncategorized on October 17, 2008 by future man

you send us your problems which get answered by fellow machinists and fabricators

Problem

Let’s say I wanted to do some Taig CNC milling on an acrylic or
polycarbonate block. The result needs to have some decent optical
clarity but I expect the tooling will result in a fairly scratched,
milky surface.

Is there any simple answer for this? I know there are plastic polishes
that can kinda buff that out but I’d expect major problems getting a
Dremel buffer wheel into small low spots. Is there any magic cutting
head or something that results in a smooth surface, or some special tool
or chemical for removing them?

Solution

depends on the shape- if its a flat area you can get good results simply by
lacquering the parts, this hides the m/c’ng defects. This technique
can produce good optical clarity on prototypes with little need for excessive
polishing.

you can also use a small torch to feather the edges of clear acrylic,
you have to use with care. A Propane torch is an excellent choice, but as
I said, use with small strokes, and feather the heat to the
material, takes a little practice.

you can try the acrylic cement that is solvent base to try to
restore the surface shining in the machining area you can improve it
disolving in it some of the acrilic chips.

The next option is to get somo chlorinated solvent (chloroform is the
one that I used) and disolve some acrilic plastic on it up to get the
consisitncy of a light oil (is about 10% in weight of acrilic).

with this solution aply it to the surface and allow to dry, take the
normal precautions to the use of solvents (use it away from flames
and sparks and with a good air circulation)

If you need to polish some surface you can use your dental paste
(preference the white one) with a rag or you can use the polish
compound that is use for cars with good resuls if you need to use in
a small hole you can saturate a cotton cord with the polish paste and
past the cord back and for several times and that make the trick.
Jose L Sanchez

economy slowdown and the manufacturing sector

Posted in Uncategorized with tags , on October 17, 2008 by future man

So everyone is trying to explain the current economy today, a lot of people are worried, particularly small businesses, how much of this is psychological and how much is actually a physical barrier we are up against? A lot of talking heads and pundits have tried to explain this chrisis, often dumbing it down or skewing the facts, even creating simplistic childlike cartoons that insult the viewer’s/reader’s intelligence. CNC Machining Blog’s guest blogger Michael Hayes, gives his take on the so called “crisis”. My advice? DON’T PANIC.

So we all have seen or heard about this economic “crisis” that we are currently experiencing. The general person probably has no knowledge of what this crisis actually is, but a slightly more informed person (say, one who watches CNBC) would tell you that it is a capital problem, meaning that banks don’t have, or won’t part with, physical cash money… This is an issue.

People probably don’t realize how importance credit actually is; in fact, it took the biggest economic crash of the past 80+ years for people to come to terms with it, and slowly realize the err of our collective ways.

For the past decade or more, American’s have been on a credit binge. The average American has Six (6!) credit cards, Adjustable Rate Mortgages (ARM) have been screwing over homeowners left and right, and the mentality of Buy Now, Pay Later, has wrapped millions of American’s in a smothering blanket of debt that cannot be removed. This has lead to record numbers (unfathomable number, to be honest) of home foreclosures.

In that time period, the irresponsible borrowers were joined by similarly irresponsible, arguably predatory, Lenders. So much expectation was placed in the field of Mortgage Backed Securities (basically a Stock you can buy, that is publicly traded, that only value is the equity of a mortgage). Home values went up, more people bought more houses, people took second mortgages out on existing homes, more people purchased shares of the securities, more people took loans with balloon payments, and adjustable rates, Fannie Mae and Freddie Mac lent money to basically anyone, and then it all came crashing down.

People couldn’t pay, so banks foreclosed. The foreclosures lead to decreasing home values. Sooner or later, banks had assets that were worth less then the securities associated with it… Multiply this by a few millions times, and you have a conglomerate effect of created trillions of dollars of defaults.

You had Bear Sterns collapse under the weight of this, followed by AIG, Freddy and Fannie, Lehman Brothers. Keep in mind some of these firms had lasted through the Great Depression and both World Wars. It is a mind boggling cluster bomb of economic collapse that can really only be associated with greed, irresponsibility, and lack of oversight.

So what industries aren’t affected by this trend? Well, considering how massive this crisis is purported to be, there are vast industries that will not be hindered, and in fact may grow despite it.

Take for example dry goods, or hardware production. The world continues to show a demand for wheat grain no matter what Bear Sterns is doing, or what bill Congress passes. No matter what happens, American’s still need to fill up their gas tank (at least to the half way line) and the government is hell bent on removing us from the clutches of foreign oil, so that means more pipelines, more raw materials, more transport. This creates demand for metal fabrication, raw materials and mining operations, heavy duty hardware and fastener fabrication, and much more. You need the people that make the things that no one thinks they need: i.e. Gaskets, Pressure Gauges, Compressors, Metal Railings, etc. There will be a small “lack of growth”, do to less home building and the like, but a consistent growth is sometimes better then erratic growth/loss.

With Britain’s struggling economy, a situation that some have ventured to call a recession prior to the credit crisis, has significantly impacted its level of manufacturing. India, however, seems to remain unaffected and may in fact present an opportunity for growth.

“There has been a surge in foreign direct investment in the manufacturing sector and there have not been any signs of a slowdown, said Ajay Shankar, secretary of the federal department of industrial policy & promotion. ‘International confidence in Indian manufacturing is much higher than we seem to realize,’ he said.
Recently enough, Iraq’s stock exchange has soared over 30%, due to the falling dollar and a drop in violence throughout Iraq. Meanwhile areas like Turkey and South America seem to feel the crunch in the manufacturing center. Being a needs based, industry, there will never be a “crash” such as in the mysterious, erroneous and downright shady industries of finance. But there will be a decrease in a amount of business to some extent. Though this too will pass.

Simply put, the world will continue to turn, with or without available credit or liquidity issues, with Barack Obama or John McCain. So the hope is there, constant and consistent.

Posted in Uncategorized on October 16, 2008 by future man

cnc machining

Posted in Uncategorized on October 16, 2008 by future man

If you want to travel cross-country, you buy a Land Rover: The choice of royalty and the British armed forces for generations. If you want to travel cross-country at very high speed, you buy a Land Rover-based Bowler Wildcat: Not as practical as the standard Land Rover – there’s not enough room for a brace of pheasants, let alone a pair of gun dogs – but it’ll get you across any terrain quicker than almost anything else on four wheels. The only thing is, the Bowler Wildcat costs £50,000 ($100,000) which, unless you’re planning to enter the Paris-Dakar, is a lot of money for a weekend toy.

For about one-third the cost of a Bowler, a small but
expanding engineering business called Rage Motorsport in
Dunstable, UK, will sell you an off-road buggy powered by a
six-speed 180-hp Honda Fireblade motorcycle engine, with a
top speed of over 100 mph. It may not be ready to tackle
desert endurance races like the Bowler, but it can still make
you feel like someone has put the universe on fast-forward.
Rage Motorsport builds multi-terrain, extreme
performance vehicles that make even average drivers – with
bigger than average adrenal glands – feel like driving gods.
They’re exhilarating, hilariously fast and beautifully
engineered. The Land Rover-based Bowler does 0-60 in 4.8
seconds: Quick on the tarmac, let alone ploughing through
sand dunes. The top-of-the-range Rage weighs just 375 kg
and does 0-60 in just 3 seconds, and it’s equally at home on
the racetrack as it is off road. It’s no wonder the orders are
stacking up. To meet demand, the company’s manufacturing
operations are undergoing a major overhaul.
“Up until recently, we’d been subcontracting all of the
major machined parts,” says Sales Director Joe Adams, “but
we got to the point where we had to take stock of the situation
and decide what our business objectives were. If we were
going to grow the product range and the company, we realised
we’d have to take responsibility for all the quality-critical
operations. We couldn’t depend on suppliers any longer.”
Twins Steve and Adam Gentil, who’d been making highperformance
buggies for their own entertainment for around
15 years, started Rage just 4 years ago.
“Someone saw that they were making a world-class
product and suggested that they put them into production,”
says Adams. “Neither of them had any professional
engineering training, but they taught themselves how to
design a balanced, finely tuned chassis and marry it to a highpowered
motorcycle engine. It sounds easy, but building
something safe, fast and very driveable is no mean feat. Some
big automotive companies spend tens of millions to achieve
the same thing.”
Before investing in a Haas TL-25 CNC lathe with subspindle,
and a Haas VF-2 CNC vertical machining centre,
Rage took a careful look at what else was available.
“We looked at machine tool models that were cheaper,
and some that were more expensive than the Haas machines,
but we quickly concluded that we couldn’t do any better than
the cost/specification of the U.S.-built machines,” explains
the company’s co-founder and director, Steve Gentil. “Also,
others had recommended Haas to us – and told us that aftersales
service was second-to-none.”
Installed in June 2006, the two machines have been set to
work producing a wide range of parts for the company’s
increasingly popular and growing range of buggies. Parts
machined include front and rear hubs, uprights, discs, ball
joints and exhaust flanges, to name but a few.
“The exhaust flanges are quite tricky to machine,” says
Gentil. “They’re round on one side and oval on the other. But
complex components are simple to produce using the Haas
machines, even for relative novices.
“These are our first CNC machines; but to be honest, we
needn’t have worried about getting to grips with them. We
taught ourselves to program very quickly, and we were
making parts a day or so after they were installed.
“Operating the machines is like driving a Rage off-road
racing buggy,” laughs Gentil. “They go wherever you point
them, they’re responsive and they won’t let you down.”
Rage machines parts from aluminium, as well as mild,
stainless and chromium steels. Some, such as bearing sets, are
machined to particularly tight tolerances, which, according to
Steve, the Haas machines are more than capable of achieving.
“We work the machines really hard,” he says. “They’re
currently running 24 hours a day to keep up with demand,
but we’ve had few, if any, problems. They’ve given us the
quality and reliability we needed, so I’m pretty sure we’re
going to be investing in more in the very near future.”
Around 10 Rage buggies are built at a time, so batch sizes
vary from 100-off up to 1600-off for items such as small
wishbone tubes.
“Installing our own in-house CNC machining facility
has brought financial benefit, too,” concludes Steve. “Not
only have we gained greater control of our production
schedules, enabling us to be more productive, but we’ve also
cut our piece-part costs in half!”
Rage buggies have already become must-have weekend
toys for hundreds of enthusiasts, who typically claim that it’s
the most fun you can have on four wheels. They’re also fast
becoming the industry standard corporate-entertainment
vehicle, not just for their high fun quotient, but also because
of their inherent reliability.
“More and more hospitality companies are choosing
Rage buggies because they’re a safe investment,” says
Adams. “They’re rugged, with very high standards of buildquality
and engineering. The frames are laser-cut, powdercoated
tubular space frames; they have cross-drilled stainless
discs all round, with two-pot Brembo calipers; and we only
use the best fittings, such as Cobra FIA-approved race seats.”
There’s a road going version – the Road Rage! – currently
in testing, and there’s even talk of a race series or two.
“The eventual aim is to have official approval from the
racing authorities, so we can set up a UK, and eventually a
world-based, series,” says Adams, “perhaps with a purposebuilt
Rally-Cross version.”
For the time being, though, as word spreads, Rage
Motorsport is enjoying a ride almost as exciting as the one it
sells. If you want the fun of a Bowler Wildcat, but prefer not
to spend your child’s college fund on a two-seater 4×4, Joe
Adams will be happy to take your call.

These pages use Twisted Python with multiple threads NOT javascript

Posted in Uncategorized with tags on October 12, 2008 by future man

using process explorer,

Posted in Uncategorized on October 12, 2008 by future man

ever wonder whawt SVCHOST was and why it was running hogging all your memory, ever wonder even more why when you end one of the largest running SVCHOST process’s (usually around 10-25K) it often seems to not effect your machine at all?  well you can find out more at this neat article that answers the age old question.  basically if you have XP download Process Explorer, to see whats going on behind the task manager. and if you have vista there is an added “services tab” in the task manager that can run as a sort of trimmed down version of process explorer to, look more closely at the process’s you have running taking up memory on your machine.

maybe the best thing about vista

what is svc host

link to the full

What is svchost.exe And Why Is It Running?