Adjusting to Unleaded-In Brass

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Unleaded brasses are not necessarily harder to run than leaded brass. They are just different. By recognizing and accommodating for their lack of Lead, and the resultant different thermal conductivity, differences in chip forming, and the need to up-tool for heavier feeds rather than higher speeds, your shop can also be successful at making parts from these newer, more challenging grades.

Same yellow color, Just no Lead in the Grain Boundaries — Same yellow color, just no Lead in the grain boundaries

It is widely established that Lead promotes machinability. To get the maximum production from automatic machines, additions of Lead have been commonly used in metals, particularly steels and brasses. In brass, dispersed in the grain boundaries, Lead acts as an internal lubricant- it reduces friction, and thus heat. By reducing the heat, Lead allows the metals to which it has been added to be machined at much higher speeds than the comparable non-leaded grades. These higher speeds [rpm or surface feet per minute (sfm)] result in shorter cycle times to produce each part. Short cycle times mean less expensive parts.

Leaded Brass offered these historical advantages

Excellent surface finish
Forgiving of machine mis-adjustments
No thermal issues
Fast cycle times
No chip control issues

When machining non leaded materials, we have to somehow maintain surface finish, get to commercially feasible cycle times, and deal with less than ideal chip characteristics.

What are some strategies for machining the new unleaded brasses?

Increase the feed. Since we lost the lead and the ability to run at higher speeds, increasing the feed can help us get to equivalent cubic inches of removal rates.

Improve the machine rigidity. Heavier feeds mean that your machine needs to be adjusted and solid. It also means more horsepower required- again mandating a rock-solid setup.

Improve the tool. 4 % lead is very forgiving of tool quality; The new nonleaded grades are the opposite, they present a number of challenges to your tools. Improved materials, geometry and coatings are key to machining unleaded brasses with minimum issues. also, they will require fewer replacements, helping to get more net production at the end of the shift.

Improve the chip management. some unleaded grades replace the lead with zinc, resulting in a grade with a type III chip- stringy and birds-nest prone. With these grades payespecioal attention to drills selected, and try inserts with chip control features to help you manage that chip.

Deal with the increased heat. The Lead helped to reduce friction and heat in the Leaded grades. with the lead removed, you will have increased heat generated. Carbide is more forgiving of heat, as are tool coatings. Talk to your supplier of Metal working fluids- Chances are that they will have a fluid that will help manage thiose extra BTU’s and maintain your tools’ edges.

Change your ideas about machining brass. unleaded brass machines more like steel than brass. as long as you think of it like leaded brass you will fight it. instead, think of it as just a yellow version of 1215 steel or stainless and your expectations will be much closer to reality.

Our cheat sheet for moving from leaded steel to unleaded steel provides a roadmap for adjusting to unleaded brass

Unleaded brasses are not necessarily harder to run than leaded brass. They are just different. By recognizing and accommodating for their lack of Lead, and the resultant different thermal conductivity, differences in chip forming, and the need to up tool for heavier feeds rather than higher speeds, your shop can also be successful at making parts from these newer, more challenging grades.

The market for our precision machined parts continues to be evolve. Evolve your thinking and processing to adjust to the realities of unleaded materials to remain a viable and preferred supplier.

For more details on grades and recommendations, read our article Adjusting to Unleaded

ISM PMI Declines in January, Still Bodes Well for Manufacturing

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The Institute for Supply Management (ISM) reported to day that the PMI for January
PMI was at 53.5%a decrease of 1.6% points from 55.1% in December. The employment index was at 54.1%, down 1.9 percentage points from 56.0% in December. The New Orders Index came in at 52.9 percent, a decrease of 4.9 percentage points from the seasonally adjusted reading of 57.8 percent in December.
These numbers are softer than we expected for January, but are still indicative of positive news for manufacturing- “Economic activity in the manufacturing sector expanded in January for the 20th consecutive month, and the overall economy grew for the 68th consecutive month, say the nation’s supply executives in the latest Manufacturing ISM^® Report On Business^®.”
Markets (industries) of interest to our shops that reported growth in January 2015 included: Fabricated Metal Products; Electrical Equipment, Appliances & Components; Transportation Equipment; Chemical Products; Machinery; Food, Computer & Electronic Products.
For PMPA’s 2014 Year end summary of our Business Trends Index click here.
Calendar year 2014 was strong and steady until the final quarter with its seasonal and expected fall off. Over 90% of respondents in December 2014 shared positive (same or improved) expectations for Net Sales, Lead Times, Employment, and Profitability for the first quarter of 2015. With strong expectations in Automotive, Aerospace, Housing, and Medical Device Industry, we believe that the first quarter of 2014 will be a busy one for precision machining. – See more at: https://www.pmpa.org/news/latest-news/2015/01/22/business-trends-2014-review-and-summary#sthash.BXDQAFun.dpuf
We just came back from 5 days on the West Coast visiting shops and sentiments were positive and optimistic except for the outlook for finding skilled workers.
Manufacturing continues to be a great place to be in the current economy.

Hat tip to Calculated Risk Blog for their Chart of ISM PMI

60 Years of Continuous Improvement- The Vanamatic Journey

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It has been my pleasure to work with the folks at the Vanamatic Company since the late 1980’s as a steel supplier technical representative, as a PMPA staffer, and as a friend.

A passion for improvement is what drives the folks Vanamatic.

I can say that over a big chunk of those 60 years, there were a few things that remained constant- fair dealings, honest communications, and an unrelenting focus on continuous improvement.
I was not at all surprised when I got a call from Jeff saying that they were going to have something to announce and could I help them with it.
Of course there is something new at Vanamatic.
They are always working on ideas for improvement.
I was surprised when they told me it was a brand new website for the company’s 60th anniversary.
60 years was quite a surprise.
It has not been an easy time for manufacturing these last 60 years.
Frankly the last 8 years were pretty tough.
The Rise of China at the beginning of the new century wiped out a lot of the companies that were not very serious about their business.
Congratulations to Vanamatic for 60 years of leadership through continuous improvement. Improvement of people, process, and culture.
Oh, and improvement to the their online presence through their new website.

NIMS Announces Record Number of Metalworking Credentials issued in 2014

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Credentials issued by NIMS in 2014 show that more students are preparing for success and high-demand careers.

In 2014, NIMS issued 18,947 industry-recognized credentials, representing a 36% increase from 2013.
36% increase!
“It is clear that the precision manufacturing sector is strong and growing, and more students and workers are preparing for success in the wide variety of jobs our industry offers,” said Jim Wall, Executive Director, NIMS. “NIMS would like to congratulate more than 8,000 individuals who earned at least one industry-recognized credential last year and have the ‘mark of excellence’ that will make them highly sought-after talent.”
PMPA is a founding member of NIMS, and is pleased to see this success at credentialing talent to enter our high tech industry. Credentialing real people for in demand careers, developing standards and credentials, this is how we develop an advanced manufacturing workforce to sustain manufacturing in North America. As NIMS continues to upgrade and adapt the standards to our evolving technology, we have confidence that our credentialed new hires will be up to speed and able to safely add value on the first day of the job. NIMS standards are the basis for the Right Skills Now Program.
The National Institute for Metalworking Skills (NIMS) was formed in 1995 by the metalworking trade associations to develop and maintain a globally competitive American workforce. NIMS sets skills standards for the industry, certifies individual skills against the standards, and accredits training programs that meet NIMS quality requirements.
For more information on NIMS, visit NIMSREADY
For the full release on 2014 credentials earned, visit RELEASE
For information on Careers in Advanced Manufacturing check out our career blog at YOURCAREERFACTS

December ISM PMI Report- Beware the Bears!

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There are a number of reasons that one could be bearish about the December ISM PMI report. But that doesn’t mean that we should be.

“The December PMI^® registered 55.5 percent, a decrease of 3.2 percentage points from November’s reading of 58.7 percent. The New Orders Index registered 57.3 percent, a decrease of 8.7 percentage points from the reading of 66 percent in November. The Production Index registered 58.8 percent, 5.6 percentage points below the November reading of 64.4 percent. The Employment Index registered 56.8 percent, an increase of 1.9 percentage points above the November reading of 54.9 percent. Inventories of raw materials registered 45.5 percent, a decrease of 6 percentage points from the November reading of 51.5 percent. The Prices Index registered 38.5 percent, down 6 percentage points from the November reading of 44.5 percent, indicating lower raw materials prices in December relative to November.”

test text — Actually, look how far above we are above the expansion / contraction line…

“The December PMI declined 3.2 percentage points from November,” roared the bear.
“The New Orders index dropped by 8.7 percentage points from November’s reading,” growled his sidekick.
“The Production Index fell 5.6 percentage points from November,” sang the Bear Chorus.
What are we to make of these Bearish indicators? Not much, really. Here’s why.

Its seasonal really. It is the end of the year. Companies are going to have to pay taxes on unsold inventory.
Yes it is below expectations. But does that tell us more about the PMI, or about the quality of the “expectations?”
11 of 18 manufacturing industries reported growth in December.

So please, before you order flowers and a sympathy card- consider this. The December reading above 50 indicates Manufacturing expansion for the 19th consecutive month, and by being above 43, an expansion of the US economy- for the 67th consecutive month.
P.S. Not to worry “The Employment Index registered 56.8 percent, an increase of 1.9 percentage points above the November reading of 54.9 percent. Inventories of raw materials registered 45.5 percent, a decrease of 6 percentage points from the November reading of 51.5 percent. The Prices Index registered 38.5 percent, down 6 percentage points from the November reading of 44.5 percent, indicating lower raw materials prices in December relative to November.” Stronger employment lower inventories, and lower material prices are all positives for Manufacturing.”
The decline in the December 2014 PMI index is normal expectancy and nothing to worry about as I see it. Just look at the graph and all the other positive indicators.

Bear photo courtesy The Duffel Blog
Graph courtesy The Calculated Risk Blog
Waving bear link

2014 in review

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The WordPress.com stats helper monkeys prepared a 2014 annual report for this blog.

Here’s an excerpt:

The Louvre Museum has 8.5 million visitors per year. This blog was viewed about 130,000 times in 2014. If it were an exhibit at the Louvre Museum, it would take about 6 days for that many people to see it.

Click here to see the complete report.

Ancient Orichalucum Metal Ingots Recovered from Shipwreck off Sicily

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2600 years later, we have samples to analyze... — 2600 years later, we have samples to analyze…

According to Discovery News this week, “Gleaming cast metal called orichalucum, which was said by Ancient Greeks to be found in Atlantis, has been recovered from a ship that sunk 2,600 years ago off the coast of Sicily…the 39 ingots found on the sandy sea floor represent a unique finding.”
“Today most scholars agree orichalucum is a brass-like alloy, which was made in antiquity by cementation. This process was achieved with the reaction of zinc ore, charcoal and copper metal in a crucible.
Analyzed with X-ray fluorescence by Dario Panetta, of TQ – Tecnologies for Quality, the 39 ingots turned to be an alloy made with 75-80 percent copper, 15-20 percent zinc and small percentages of nickel, lead and iron.”
Ancient Origins reports “The name orichalucum derives from the Greek word oreikhalkos, meaning literally “mountain copper” or “copper mountain”. According to Plato’s 5th century BC Critias dialogue, orichalucum was considered second only to gold in value, and was found and mined in many parts of the legendary Atlantis in ancient times.
Maybe the greenhouse gasses emitted by Atlantis’ cementation industries producing orichalucum caused the seas to rise, covering Atlantis…

OSHA Reporting Requirements for Employers Now in effect- Update

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Employers! These requirements are now in effect!
A new wallet card issued by OSHA will help your supervisors understand the changes to Injury and Illness Reporting Requirements that go into effect in January 2015.
Get the card here as a printable pdf

What are the new requirements?

“Under the final rule, employers must report the following events:
    1. Each fatality resulting from a work-related incident, within 8
hours of the death. This requirement applies to all fatalities
occurring within 30 days of a work-related incident. See Sec.
1904.39(a)(1) and (b)(6). This is the same as the current regulation
and the proposed rule.
    2. Each in-patient hospitalization resulting from a work-related
incident, within 24 hours of the hospitalization. This requirement
applies to all in-patient hospitalizations occurring within 24 hours of
a work-related incident. See Sec. 1904.39(a)(2) and (b)(6). Under the
proposed rule, employers would have been required to report all in-
patient hospitalizations within 8 hours, for hospitalizations occurring
within 30 days of a work-related incident. Under the current
regulation, employers are required to report, within 8 hours, in-
patient hospitalizations of three or more employees, for
hospitalizations occurring within 30 days of a work-related incident.
    3. Each amputation resulting from a work-related incident, within
24 hours of the amputation. This requirement applies to all amputations
occurring within 24 hours of a work-related incident. See Sec.
1904.39(a)(2) and (b)(6). Under the proposed rule, employers would have
been required to report all amputations within 24 hours, for
amputations occurring within 30 days of a work-related incident. Under
the current regulation, employers are not required to report
amputations.
    4. Each loss of an eye resulting from a work-related incident,
within 24 hours of the loss of an eye. This requirement applies to all
losses of an eye occurring within 24 hours of a work-related incident.
See Sec. 1904.39(a)(2) and (b)(6). The proposed rule would not have
required employers to report losses of an eye, and the current
regulation also does not require them to do so.”- Federal Register

These requirements go into effect January 1, 2015
Get the wallet card and review the upcoming changes with your team now.

Capturing the Holiday Spirit

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No telling on what the State troopers busted this jolly old elf for, but we bailed him out with donations to the local food bank... — No telling on what the State troopers busted this jolly old elf for, but we bailed him out with donations to the local food bank…

We are fortunate to have our trade, our businesses, our ability to produce highly engineered components that make a difference in peoples lives by making technology operate safely and as expected.
I call the satisfaction from my work the “existential joy of engineering,” though that phrase is not original to me.
The holidays are a great reminder of the blessings that we have, and the fact that we are more fortunate than others.
I hope that your celebration of the holidays remind you of what is right in your world, and of your opportunity to help others as you see fit.
And like the Medina Post of the Ohio State Patrol, I hope that you too get to “capture” a bit of the holiday spirit (or elf) to share with your family and friends.
Thanks to the Medina Post of the Ohio State Patrol for their part in the “Can the Cruiser” food drive.
And our best wishes and gratitude to you, the men and women of the precision machining industry, our world is safer and more reliable because you do what you do.