the grind - Energy Issue

t l

energyINDUSTRY FEATURE

A GLIMPSE INTOWILLIAMS’ LIFE page 26

A BRIGHT AND STRONG TOMORROW page 47

also in this issue . . .

LOW-COST NATURAL GAS AIDS U.S. MANUFACTURING

A FIRM FOUNDATION SUPPORTS CONTINUED GROWTH page 3

ALL ABOUT GRINDING QUILLS, page 6

AMERICA´S UNCONVENTIONAL REVOLUTION: Energy, Security and Innovation, page 10

MEGA-WATT TURBINES GENERATE LARGE-SHAFT GRINDING CHALLENGES, page 23

2 CAREER TRACK

3 MY THOUGHTS

4 GRINDING IN MOTION

26 A GLIMPSE INTO

33 DIGITAL DIGEST

40 OPTIMIZE

44 IN THE ZONE

47 LAST THOUGHT

t l

GQ/Energy Issue 2014 1

D E P A R T M E N T S

page 40

page 3

8

page 23

F E A T U R E S

6 All About Grinding Quills Everything you need to know to specify the right quill for your precision grinding application.

10 America´s Unconventional Revolution: Energy, Security and Innovation

An unconventional revolution has unfolded pretty fast. It is striking to think back to the turmoil of 2008, when it was widely assumed that a permanent era of energy shortage was at hand.

14 Some Certainty, Many Questions in 2014 Washington Oil and Gas Outlook

Leaders in the oil and gas sector provide insights into the future of the U.S. energy industry.

20 Think Big Big part manufacturing opportunities abound in

energy and resource sectors.

23 Mega-Watt Turbines Generate Large-Shaft Grinding Challenges The higher megawatt-generating output, the bigger the wind turbine, and the larger the gearbox parts that will need to be ground.

28 Supply, Meet Demand Oil and gas are healthy, but moving product to market remains a challenge.

34 Positive Energy Low-cost natural gas aids U.S. manufacturing.

38 Manufacturing Robot Can Touch and See Like a Human

Ford Motor Company reduces process variations with advanced robotic automation.

42 Effective Cooling of Nickel-based Superalloys

During Grinding Improvements in coolant application lead to reduced

thermal damage and increased productivity.

2 GQ/Energy Issue 2014 GQ/Energy Issue 2014 3

Most high school students participate in extracurricular activities such as football, basketball, or even drama. These activities, however, typically don’t lead to promising career opportunities. But there is one extracurricular activity that helps lead students down a lucrative career path in science, technology or engineering: the FIRST Robotics competition for grades nine through 12.

Since 1989, FIRST (For Inspiration and Recognition of Science and Technology) has designed accessible and innovative programs that motivate young people. The FIRST Robotics program, in particular, allows students to work alongside professional engineers and use sophisticated software and hardware to build and compete with a robot of their own design. Every year, FIRST Robotics hosts the FIRST Robotics Championship, an international event that involves teams of high school students that, over a six-week period, use core principles of engineering and mathematics to build a robot. Instead of just talking about the process of building a robot in class, students involved with FIRST Robotics receive hands-on training. Thereby, they get to explore their natural curiosities in the world of engineering, physics and math in a team environment. Several companies in the manufacturing industry, including UNITED GRINDING, sponsor FIRST Robotics teams around the world, sharing their part production expertise and sometimes the equipment needed to take a robot from idea to reality.

Furthermore, these sponsorships expose students to manufacturers they would probably never hear about inside a classroom. It also shows the investment companies are making to help close the skills gap that is currently present in manufacturing. High school students interested in FIRST Robotics should talk with their principals or technical arts teachers about joining a team or starting one at their school. More information about FIRST Robotics is available at www.usfirst.org.

For more information and pictureswww.grinding.com

CAREER TRACK

FIRST® Robotics Competition

UNITED GRINDING North America510 Earl Blvd. Miamisburg, OH 45342, USA Tel +1-937-859-1975 Fax +1-937-859-1115 [email protected]

Fredericksburg Branch Office 5160 Lad Land Drive Fredericksburg, VA 22407, USA Tel +1-540-898-3700 Fax +1-540-898-6819 [email protected]

United Grinding Mexico S.A. de C.V. Blvd. Bernardo Quintana No. 7001 Of. 1003 Querétaro, Qro. 76079, Mexico Tel +52-1-555-509-7739 [email protected]

CYLINDRICAL Hans Ueltschi Vice President, Sales 510 Earl Blvd. Miamisburg, OH 45342, USA Tel +1-937-859-1975 Fax +1-937-859-1115 [email protected]

TOOL Markus Stolmar Vice President, Sales 5160 Lad Land Drive Fredericksburg, VA 22407, USA Tel +1-540-898-3700 Fax +1-540-898-6819 [email protected]

SURFACE & PROFILE Larry Marchand Vice President, Sales 510 Earl Blvd. Miamisburg, OH 45342, USA Tel +1-937-859-1975 Fax +1-937-859-1115 [email protected]

CUSTOMER CARE Joseph Szenay Vice President, Customer Care 510 Earl Blvd. Miamisburg, OH 45342, USA Tel +1-937-847-1234 Fax +1-937-859-6915 [email protected]

the GRIND Publisher Ted Neckel Director of Corporate Marketing [email protected] Tel +1-937-847-1229

Layout & Design dgs Marketing Engineers

© 2014. All Rights Reserved.

UNITED GRINDING Group InternationalKörber Schleifring Machinery (Shanghai) Co., Ltd. 1128, Tai Shun Road Anting Town Jiading District Shanghai 201814, China Tel +86-21-3958-7333 Fax +86-21-3958-7338 [email protected]

Körber Schleifring Machinery (Shanghai) Co., Ltd. Beijing Branch Office Room 202, Building 18 Tower B, Universal Business Park No.10 Jiuxianqiao Road Chaoyang District Beijing 100015, China Tel +86-10-8526-1040 Fax +86-10-6500-6579 [email protected]

Körber Schleifring Machinery (Shanghai) Co., Ltd. Chongqing Branch Office 15-11 Building 4, No.18 Jinshan Road, Longxi Street, Yubei District, Chongqing 401147, China Tel +86-23-6370-3600 Fax +86-23-6374-1055 [email protected]

Körber Schleifring Machinery (Shanghai) Co., Ltd. Guangzhou Branch Office Room 2003, 20/F Center Plaza Tower B 161 Linhexi Road Tianhe District Guangzhou 510620, China Tel +86-20-3862-1241 Fax +86-20-3862-1270 [email protected]

United Grinding GmbH India Branch Office No. 487 - D1 & D2A 4th Phase, KIADB Main Road Peenya Industrial Area Bangalore 560058, India Tel +91-80-415-54-601 Fax +91-80-415-54-603 [email protected]

United Grinding GmbH Moscow Office 1-j Kasatschij Pereulok 5/2, Strojenije 1 119017 Moskau, Russia Tel +7-495-956-93-58 Fax +7-495-956-93-59 [email protected]

A Firm Foundation Supports Continued Growth

M Y T H O U G H T S

Terry Derrico

President and CEO,

United Grinding North America, Inc.

There is an expression ’baptism by fire’ that describes the initiation into a new

role, but my first whirlwind month here at UNITED GRINDING, was more like a

continuous blast of water to the face from a fire hose. I did a lot of traveling, met all

the team, learned about the individual members’ roles and responsibilities, and was

then totally immersed in the company’s expansive product and service offerings.

I gained an incredible amount of knowledge about the company in my first

month, but nothing stood out more than the talent, passion and dedication of the

UNITED GRINDING team. They truly drive this highly dynamic company and, most

importantly, form the cornerstones of its amazingly strong foundation. As the new

team leader, I am dedicated to supporting and building upon the foundation they’ve

worked hard to establish.

Together, we will advance into UNITED GRINDING’s next stage of growth and

development, both horizontally and vertically, and in the total grinding solutions

market. We will further our development of innovative technological solutions

as well as enhance and hone our responsive value-added services to keep our

customers productive, profitable, and most importantly, competitive.

The fact that we provide more than precision grinding machines is what differentiates

UNITED GRINDING. Our complete part processing solutions, including advanced

automation, is what fulfills our customers’ specific production needs, but it is our

team’s dedication and commitment that makes the significant difference. With that

said, we will continue to cultivate new potential customers, work with customers in

true partnerships and take full ownership/responsibility of projects — driving them

from conception to satisfied implementation.

In its current state of success, UNITED GRINDING is moving at a good clip, which

drives us to continually improve and set new strategic plans to ensure sustainability

and growth. I want our solid foundation to stand the test of time and propagate,

and I believe our strong teamwork and customer partnership culture will drive

continued success.

We will further our development of innovative technological solutions as

well as enhance and hone our responsive value-added services to keep

our customers productive, profitable, and most importantly, competitive.

CyClotron ProduCts, InC.

Visit our website: www.cyclotronproducts.com

Cyclotron Products, Inc. offers a complete line of filtration systems designed to remove solid particles from water soluble and synthetic industrial fluids using the most economical and efficient methods.

Leaders in Filtration Systems

CYCL

ONIC FILTRATION

ENVIRONMENTALLY RESPONSIBLE

Economical Efficient•Extendscoolantlife.•Upto30%longer grinding wheel life.•Nopurchaseof replaceable filter media.•Lowmaintenancecosts.•Smallfootprint.

•Morepartsperdressingcycle.•Lessmachinedowntime.•Eliminatesamountof liquid waste.•Consistentcoolantaeration eliminates bacteria problems.•Closertoleranceson critical parts.

Enviromentally ResponsibleCyclonic filtration benefits the environment as

no disposable media is used in the process. This saves petroleum, preserves countless trees, and eliminates the associated environmental

impact created by the disposal of spent filter media.

Contact us to discuss all of your filtration needs. (262)898-0710•Fax(262)898-0748•1509RapidsDrive•Racine,WI53404


UNITED GRINDING recently named National Machine Tool Financial Corporation (NMTFC) the preferred financing provider for its grinding machines. Through this new partnership, UNITED GRINDING customers in North America now have quick, easy access to a variety of competitively priced financial services.

Established in 1986, NMTFC is an independent financing company with its roots firmly planted in the machine tool industry. In fact, the company has a certified machine tool sales engineer (CMTSE) on staff who can assist

UNITED GRINDING customers in ways that are more effective than they would be through the traditional banking experience.

NMTFC, understanding that machine tool purchases are not one-size-fits-all, follows a customized and flexible funding model, with a variety of lease and loan options for UNITED GRINDING equipment that costs anywhere from $10,000 to $10,000,000. There are also “application only” programs that do not require a company’s financials or tax returns for equipment up to $350,000.

Furthermore, there are several other benefits that come with financing through NMTFC as opposed to a bank, including: factory-sponsored finance programs, factory rebates and credit decisions within 24 hours. Plus, NMTFC can often times finance the tougher credit deals that banks are unwilling to consider.

Having provided close to $1 billion in financing to more than 10,000 customers and a credit team with more than 50 years of combined experience in the finance industry, NMTFC has what it takes to provide UNITED GRINDING customers with a highly productive financing experience.

Learn moreTo learn more about NMTFC and its financial services, please visit netlease.com.

UNITED GRINDING Names Captive Finance Arm

Renewable wind energy will soon reach new heights across the United States as well as strengthen the country’s wind turbine component manufacturing segment.

With wind conditions often being low or turbulent near ground level — which limits the amount of electricity generated from wind turbines — the U.S. Department of Energy has pledged $2 million in funding to better harness wind energy through taller towers that can take advantage of the stronger, more consistent winds available at higher altitudes.

Such funding supports the department’s broader Clean Energy Manufacturing Initiative that aims to increase the efficiency of the U.S. manufacturing sector and ensure clean energy technologies continue to be made in America.

Under this funding, the Department of Energy will support projects that involve design concepts for fabricating and installing wind turbines with a minimum hub height of 393 feet (most of today’s utility-scale turbines average near 300 feet high).

Enabling the cost-effective deployment of wind turbines with hub heights up to 459 feet will unlock an additional 1,800 gigawatts in wind power resource potential across 237,000 square miles of the United States — an area roughly the size of Texas.

Read morewww.energy.gov

Wind Energy: REACHING NEW HEIGHTS

The U.S. Department of Energy

has pledged $2 million in funding

to better harness wind energy

through taller towers that can

take advantage of the stronger,

more consistent winds available

at higher altitudes.


F E A T U R E

Material Density Hardness Modulus (lb/in3) (HRc) of Elasticity (x 106 psi)

Tungsten Carbide 0.500 86-90 77

Heavy Metal 0.610 24-26 40

Hardened Tool Steel 0.283 56-62 30

Grinding Quills

Instead, they produce a single design with a standard interface to which customers can design quills to suit their individual requirements. A well-designed quill has a long lifespan, allowing the user to mount grinding wheels to it over and over again.

Quill Material Choices and Trade-OffsQuills are generally constructed from one of three materials, each with its own pros and cons:

Tungsten Carbide Quills are the ideal choice for precision internal grinding applications because they are very stiff. Of the materials available, tungsten carbide is the most expensive, but is long lasting and ideally suited to precision grinding applications because of its rigidity, which results in the least amount of deflection under load. For the tightest possible part tolerances, carbide can’t be beat. Due to its brittle nature, however, care must be taken when handling carbide quills to prevent breakage.

Heavy Metal Quills are ideally suited for applications where vibration absorption is desired. Heavy metal has a cost and stiffness in-between that of tungsten carbide and steel, and its damping characteristics make it particularly desirable for certain applications. Heavy metal is relatively soft, so it may not be the ideal choice for applications where the quill is subject to frequent abrasion, for example when mechanically removing glued-on wheels. Also, as the name suggests, the material is quite “heavy,” so care must be taken to ensure it is properly balanced.

Hardened Steel Quills are the least expensive and fastest-delivery choice but do not measure up to the other alternatives in terms of tensile strength and stiffness. However, they are an acceptable choice, particularly if a short, stubby quill geometry can provide sufficient stiffness to suit the requirements of the application.

New Advanced Quill Materials on the Horizon New materials utilizing Metal Matrix Composites are beginning to gain a foothold in the industry. Examples include quills constructed from a combination of carbon-fiber/steel and also from solid ceramics. Although generally more expensive, these materials offer high stiffness at a fraction of the weight of traditional materials.

By Bruce Northrup,

Vice President and General Manager

Meister Abrasives USA

Everything you need to know to specify the right quill for your precision grinding application

nyone who does CNC grinding knows what a grinding quill is, but few actually understand the important contribution the quill makes to optimized abrasive

machining processes. In the rush to fine tune their grinding operations, abrasive machinists turn their attention to such things as feeds and speeds, abrasive wheel shapes and materials, dressing options and appropriate coolant choices.

Quills seem to be too mundane to merit much consideration. That is generally a mistake, because, like other grinding process variables, quills have an important role to play. Selecting the right quill for the job can make a tremendous difference in whether or not you realize your grinding process objectives.

The Quill’s PurposeThe purpose of the quill is to get the wheel into the part to reach the surfaces you need to grind. It is a highly customized and tightly toleranced tool that serves as an extension of the spindle itself.

It would not be economical for spindle manufacturers to produce thousands of different spindle designs to reach into every possible interior geometry.

ALL ABOUT

Quill Features and Nomenclature

Internal Thread and Location Shoulder

External Location

External Thread

Shaft

Gluing Diameter

Taper

Wrench Flat

Bottom LineThe wheel of choice and the quill should be designed to work in harmony with each other.

Users who specify precision super-abrasive wheels for their grinding application and couple them with a less than adequate quill undermine the total performance of their abrasive system. This is why Meister routinely presents the most appropriate wheel specifications, wheel geometries, and quill configurations as part of a single super-abrasive system. Each of these elements works in concert to give the user the best possible result for the application.

The Swiss precision of Meister Grinding Quills provides the rigidity and accuracy required for close tolerance grinding along with durability to ensure long-lasting performance.

Learn morewww.meister-abrasives.com


Quill Configurations: Mounting to SpindleQuills are generally mounted to the grinding spindle via one of two methods. The chosen method depends on the spindle manufacturer’s design.

Threaded Spindle Method: This is the most common quill/spindle interface. It comprises of three key features: the precision thread, a tight-tolerance locating diameter to ensure the quill screws in on center, and a ground face on the back of the quill shoulder to ensure a square and solid support once the desired mounting torque is achieved.

Taper-Lock Method: Less common than the threaded interface, the taper-lock design has the advantage of simplicity with one locating surface that provides both concentric positioning and support.

Quill Configurations: Wheel MountingThere are several methods by which wheels may be mounted to the working end of the grinding quill. These choices are governed by customer preference along with the requirements of the application.

Glue-on by Customer: Users may select a style of quill that allows the wheel to be glued to it. This approach provides excellent stiffness at the lowest costs because less precision machining is required to manufacture the quill. However, re-gluing replacement wheels to this type of quill requires removing the worn wheel and residual glue from the quill, gluing on a new wheel and allowing for the glue to set. Manufacturers who use this approach generally invest in additional quills so that they have pre-mounted wheels available as needed.

Glue-on by Meister: Customers may also elect to send used glued-on wheels and quills back to Meister where wheels are carefully removed, and the quills are cleaned of residual glue and inspected to make sure they are still in good condition. Then, new wheels are mounted on the quills as part of a low-cost continuous process. Meister trues all of its wheels before they leave the factory. In this case, they are trued while mounted on the quill, so that grinding surfaces are in proper alignment to begin grinding immediately after changeover. Many users find that this approach saves time, provides better control over wheel and quill inventories, avoids the re-use of damaged quills, and results in more efficient changeovers.

Screw-In Mounting: Screw-in wheel mountings allow for fast wheel changes on the fly without having to remove the quill from the spindle. The precision threaded mount makes alignment of the wheel very easy. This style is frequently used in high production applications that require frequent wheel changes. The quills are more complex due to the internal threads required, however, fewer of them are needed in inventory because they can stay on the machine.

Collet Mounting: For shops that perform many short-run grinding operations using abrasive wheels of different sizes, it is possible to mount a variety of straight-shank mounted wheels to a single quill using a precision-machined collet system. This gives manufacturers the flexibility to change wheel sizes frequently without always having to swap out the quill. Carbide wheel shanks provide excellent rigidity and a given size quill can accommodate a wide range of wheel sizes.

Thru-Coolant Quills: There is one other quill configuration abrasive machinists should be aware of — quills that allow for the passage of high-pressure coolant from the spindle directly to the grinding zone. This approach provides exceptional flushing of debris from grinding operations within deep holes and pockets. Not all machines have the ability to accommodate thru-coolant but when they do, this allows a precision grinding operation to make the best use of it. In some cases, thru-coolant spindles are used in conjunction with specially designed wheels with holes allowing for passage of coolant through the quill and the wheel directly onto the grinding area.

Rules of ThumbHere are some rules of thumb to make sure the quill you are using or designing is adequate for your application:

Quill Length: Use the shortest possible quill that allows the wheel to reach the part and to be dressed for the full usable life of the wheel. For bore-grinding operations with oscillation, it is generally a good idea to design the quill long enough to be able to push at least ½ of the wheel through the bottom of the bore you are grinding. Also, when moving to the deepest position, you need to consider how much room is required at the nose of the spindle for peripherals such as coolant nozzles and gauge fingers.

Quill Diameter: To ensure good rigidity, optimal quills have the largest possible shaft diameter that will fit safely inside the feature being ground, while still allowing dressable life on the wheel and adequate flow of coolant in and out of the grind zone.

Stiffness: When designing your quill, you should keep in mind that the effective stiffness is proportional to: (E)*(D4) / (L3), where:

• E = Modulus of Elasticity of the chosen quill material• D = Diameter• L = Length

For example, when comparing possible design alternatives, an increase in diameter of 10 percent will increase stiffness by 46 percent. Reducing the length by 10 percent will increase stiffness by 37 percent. Changing from steel to carbide will increase stiffness by 257 percent.

Threaded Spindle Method

Taper-Lock Method

Glue-on by Customer

Screw-In Mounting

Collet Mounting

Meister Grinding Quills

Grin

ding

Qui

ll Con

figur

atio

ns

Bighorn Basin

Wind River BasinGreater GreenRiver Basin

Uinta Basin

San JuanBasin

PiceanceBasin

DenverBasin

AnadarkoBasin

PermianBasin Ft. Worth

Basin

W. Gulf Coast Basin

Texas-Louisiana-Mississippi Salt Basin

Appalachian Basin

Williston Basin

North-CentralMontana Area

Penn-PermCarbonate

Wilcox Lobo

Travis Peak

Berea-Murrysville

Mesaverde Cleveland

Sussex-ShannonCodell-Niobrara

Red ForkPictured Cliffs

Morrow

Olmos

Bossier

Bradford-Venango-ElkMuddy J

DakotaGranite Wash

Stuart City-Edwards

Cotton Valley

Medina/Clinton-Tuscarora

Niobrara Chalk

Gilmer Lime

Bowdoin-Greenhorn

Cretaceous

Cretaceous Lower Tertiary

Abo

Thirty-One

Ozona Canyon

Vicksburg

Davis

Austin Chalk

MesaverdeLance-Lewis

WasatchMesaverde

MesaverdeMancos-Dakota

Judith River-Eagle

NW Shelf

Eastern Shelf


he United States is in the midst of an unconventional revolution in oil and gas that, it becomes increasingly apparent, goes beyond energy itself. Today, the industry supports 1.7 million jobs — a considerable accomplishment given the relative newness of some of its technology. That number could rise to 3 million by 2020. In 2012, this revolution added

$62 billion to federal and state government revenues, a number that could rise to about $113 billion by 2020. It is helping to stimulate a manufacturing renaissance in the U.S., improving the competitive position of the U.S. in the global economy, and beginning to affect global geopolitics. This revolution has also engendered two debates — about the environmental impact of shale gas development and about the role of U.S. energy exports.

The unconventional revolution has unfolded pretty fast. It is striking to think back to the turmoil of 2008, when it was widely assumed that a permanent era of energy shortage was at hand.

In the BeginningThis development is a story of entrepreneurship and innovation. Although hydraulic fracturing dates back to the late 1940s, it took from the early 1980s to the end of the 1990s, in the face of much skepticism and disappointment, to establish that natural gas could be economically extracted from shale rock using that technology. By 2003, it was successfully yoked with another technology, horizontal drilling, to provide proof of concept.

Still, the dominant conviction for the next few years was that the U.S. was going to become increasingly short of natural gas and would become a large importer of liquefied natural gas. Only in 2008 was it observed that U.S. natural gas production was going up, instead of down. Many more companies entered into shale gas development, and the pace of effort intensified. Since then, output has grown rapidly, indeed well beyond the capacity of the current market to absorb it. It was not until the autumn of 2009

that the shale revolution became apparent to the policy community. And it was only around 2010 that producers began to shift from focusing on gas production to producing oil and liquids-rich natural gas using the same techniques.

The Economic Impact While various states had begun to home in on the economic development aspects of shale gas and tight oil, it was only in about 2011 that its significance for the national economy started to come into focus. So far, this unconventional revolution is supporting 1.7 million jobs — direct and indirect. It is notable that, owing to the long supply chains, the job impacts are being felt across the United States, including in states with no shale gas or tight oil activity. For instance, the state of New York, which presently bans shale gas development, nevertheless has benefitted with 44,000 jobs. Illinois, debating how to go forward, already registers 39,000 jobs.

By Daniel Yergin, Guest Columnist

Manufacturing Engineering

Energy, Security and Innovation.

MAJOR TIGHT GAS PLAYS, LOWER 48 STATES

An unconventional revolution

has unfolded pretty fast. It

is striking to think back to

the turmoil of 2008, when

it was widely assumed that

a permanent era of energy

shortage was at hand.

F E A T U R E

Tight gas formations include deposits in shale as well as in other types of formations.

Tight Gas Plays Basins

Stacked Plays Shallowest / Youngest

Deepest / Oldest

Inter-Basin Areas


The Environmental ImpactHow to assess the environmental aspects? The most notable impact is in terms of CO2 emissions. U.S. carbon dioxide emissions from energy consumption are down 13 percent since 2007. The economic downturn is part of the story. But the most significant part is the result of natural gas supplanting coal in electric generation at a rapid rate.

Hydraulic fracturing has only been recently applied at this scale and with this degree of intensity in regions that are more densely populated and that are not accustomed to oil and gas development. Understandably, the environmental impacts need to be carefully assessed and monitored, and the public needs to be confident about these impacts.

In March 2011, President Obama spoke about how “recent innovations have given us the opportunity to tap” large reserves of natural gas — “perhaps a century’s worth of reserves.” But he added that the public needs to be assured that it is being produced safely. As a consequence, a subcommittee to the Secretary of Energy’s Advisory Board was established to examine the environmental questions. Its work identified three major environmental issues — water, local air pollution, and community impact. Each, the subcommittee concluded, needs to be managed with great attention and that can be achieved through best practices in operations and regulation, continuing technological innovation, and community engagement. We see continuing effort going into these endeavors — with, for instance, recycling of water and new approaches to wastewater treatment.

One observation that came out of that study is what seems to be a mismatch between perceptions of regulation and actual regulation. Drilling is a highly-regulated activity, but it is mostly regulated at the state level. We identified the need to continue to support, with what amounts to very small funding, the activities of STRONGER — State Review of Oil and Natural Gas Environmental Regulations — a collaborative benchmarking and standard-setting organization that evaluates and promotes continuing improvement of regulatory activities among the states.

The total revenues flowing to governments from unconventional gas and oil amounted to $62 billion last year. Companies are now committing or planning investments that in total appear to go into the hundreds of billions of dollars. A large number of chemical companies, for instance, have announced plans to build or expand facilities in North America — with capital expenditures totaling close to $100 billion. Will all be built? Time will tell. But what is striking is that, half a decade ago, these companies would have scoffed if they had been told that they would be investing back into the U.S. The investments are coming both from U.S.-based companies, which are “on-shoring” in response to lower energy costs, and from foreign companies. Many other kinds of manufacturing firms are also investing and expanding based upon this growing business.

Gas and Oil Imports, ExportsU.S. imports and exports of energy have been a major issue for almost 70 years. Until the end of the last decade, it seemed that the main question about oil imports was how fast they would increase as a share of total consumption; and, for gas, how large the exports would become. This unconventional revolution has turned around the direction of imports. U.S. net imports of oil have declined from a peak of 60 percent in 2005 to about 40 percent today. That is the consequence of surging tight oil production, and reduced demand, owing to both greater efficiency and the weak economy. Moreover, the flow of imports has changed. Canada now supplies about 27 percent of total U.S. imports.

Net imports of crude will continue to decline. But the U.S. will continue to remain a net importer for some time. Our import levels are still higher than they were at the time of the first oil crisis, in the 1970s. However, we will see the Western Hemisphere, and North America in particular, moving towards greater self sufficiency. At the same time, the very large, technically-advanced refining complex on the Gulf Coast — along with the shifting domestic product demand — will put the U.S. in the position to continue to expand exports of refined products.

While markets and economics will eventually determine the realistic scale of U.S. exports, one also has to take into account wider considerations in assessing policy regarding future exports. For decades, the U.S. has made the free flow of energy supplies one of the cornerstones of foreign policy. It is a principle we have urged on many other nations. How can the U.S., on one hand, say to a close ally like Japan, suffering energy shortages from Fukushima, ‘please reduce your oil imports from Iran,’ and on the other, turn around and say that new natural gas exports to Japan are prohibited?

The Geopolitical ImpactOne immediate impact has already been cited. Tighter sanctions on Iran have succeeded in taking half of Iran’s oil exports out of the market, even as global demand for oil continues to expand. The increase in Saudi output was part of the formula. But also of great importance has been the growth in U.S. supply — at a rate higher than generally anticipated.

Certainly expanded domestic supply will add to resilience to shocks and add to the security cushion. Moreover, prudent expansion of U.S. energy exports will add an additional dimension to U.S. influence in the world. However, there will remain only one global oil market, and a major disruption anywhere would affect the entire market. The question as to how the unconventional revolution will affect U.S. involvement in the Middle East is moving to the fore. Current net U.S. imports from the Persian Gulf are equivalent to 8 percent of total consumption, as it is. Even if that number goes down, the nature of U.S. interests in the region go well beyond direct oil imports to the importance of the region for the global economy and global security.

Altogether, the unconventional oil and gas revolution has already had major impact in multiple dimensions. Its significance will continue to grow as this revolution continues to unfold.

Daniel Yergin is Vice Chairman of IHS and Founder of IHS Cambridge Energy Research Associates. He is author of The Quest: Energy, Security, and the Remaking of the Modern World and received the Pulitzer Prize for his book The Prize. He serves on the U.S. Secretary of Energy Advisory Board. This article is excerpted from Yergin’s testimony before the Subcommittee on Energy and Power of the House Energy and Commerce Committee on February 5, 2013.

U.S. Natural Gas Imports by Country(Percent), 2011

Source: U.S. Energy Information Administration, Natural Gas Monthly. Table 4 (April 2012).

Qatar26%

Yemen17%

Trinidad & Tobago37%

Egypt10%

Peru5%

Norway4%

Nigeria1%

This outcrop in Highland County, VA, is part of the Marcellus Shale,

which has helped propel the U.S. unconventional gas and oil revolution.

Phot

o co

urte

sy U

.S. G

eolo

gica

l Sur

vey/

phot

o by

Jam

es C

olem

an.

Despite having large natural gas reserves, the U.S. still imports a fair share.

Altogether, the unconventional oil and gas revolution has already

had major impact in multiple dimensions.

Its significance will continue to grow as this revolution continues to unfold.


F E A T U R E

Some Certainty, Many Questions in 2014 Washington Oil and Gas Outlook

Leaders in the oil and gas sector provide insights

into the future of the U.S. energy industry.

By Nick Snow, Washington Editor

Oil & Gas Journal

Domestic crude and condensate production

7.5 million b/d

15.4% more than 2012´s

6.6 million b/d.

Crude oil imports

dropped 9.6% to an average 7.7 million b/d

in 2013

from 8.5 million b/din 2012

U.S. oil product exports rose to an

average 3.5 million b/d in 2013

a 9.3% jump from 2012.


“Let’s get out of living in the past with antiquated policies that keep markets from operating properly,” Drevna said. “Let’s not live in the shadows of the past that have absolutely no bearing on what’s happening today. It’s going to require some changes in the way some of our elected officials think.”

The indisputable U.S. oil and gas production renaissance which has occurred from tight shale formations raises the question of whether the federal government will encourage or inhibit it, Independent Petroleum Association of America (IPAA) President Barry Russell said. “It particularly involves possibly federalizing what states have been doing effectively,” he said on Jan. 22. “It’s important to make sure state programs are up to the challenge. There also are some orchestrated acts by some environmental groups to deal with.”

“It has become clear that unconventional oil and gas production is for real,” API Upstream Director Erik Milito said on Jan. 14. “The technologies are successful. But there will continue to be issues for the industry to make sure roadblocks don’t get in the way of our progress while we address concerns of those who are worried it might harm the environment.”

IPAA’s prioritiesSafeguarding federal tax provisions its members consider essential, combating aggressive campaigns against hydraulic fracturing, and reducing opponents’ abuses of the federal

Endangered Species Act are IPAA’s three main priorities for 2014, Russell told OGJ. “If Congress is deadlocked on certain issues, our focus has to shift to the agencies where we make comments and hold informal meetings to explain our position, particularly if executive orders are increasingly used,” he said.

“We don’t expect Congress to make major reforms, so we’ve had to shift our focus to agencies which are trying to federalize regulations,” said Lee O. Fuller, IPAA’s vice president of government relations. “You have to be much more specific because nearly everything establishes a record.” IPAA has brought more of its technical people in to discuss proposed drilling regulations at the U.S. Bureau of Land Management and the U.S. Environmental Protection Agency’s new source performance standard proposal for producers, he told OGJ.

“Some regulatory proposals appear innocuous individually,” added Susan W. Ginsberg, IPAA’s vice president of regulatory affairs. “But they can turn into Death by a Thousand Cuts for a small producer. An independent producer can look large from a production standpoint, but not have many employees.” Cooperating associations have been valuable in bringing such matters up on the state and local levels, she added.

IPAA officials have been impressed by their meetings with Sally Jewell, who succeeded Ken Salazar as U.S. Interior Secretary in 2013. “She knows the industry from having worked in it,” said Daniel T. Naatz, IPAA’s vice president of federal resources and political affairs. “She recognizes there are challenges. There are questions about federal land access she’s ready to discuss. She and the White House need to address revenue and resources.”

Helping shape the next five-year U.S. Outer Continental Shelf program is among API’s top priorities, Gerard said. “We’re working with [the U.S. Department of the Interior] to do seismic in the Atlantic,” he said. “Governors of coastal states from Virginia south support this.”

”Gas has brought an extraordinary manufacturing renaissance to this country, which will help correct

our huge foreign trade deficit...

that´s unprecedented ... more infrastructure will

be needed but that the Federal Energy Regulatory

Commission should be able to respond.“

...NGSA´s latest forecast calls for U.S. gas consumption

to grow 3 times as quickly from 2012 to 2020 as

it did from 1987 to 2012...

The industry’s domestic performance clearly improved last year. API’s year-end statistics on Jan. 23 showed domestic crude and condensate production averaged 7.5 million b/d, 15.4 percent more than 2012’s 6.6 million b/d. Meanwhile, crude oil imports, excluding purchases for the U.S. Strategic Petroleum Reserve, dropped 9.6 percent year-to-year to an average 7.7 million b/d in 2013 from 8.5 million b/d in 2012.

Downstream, total domestic products supplied grew 2.2 percent year-to-year in 2013 to an average 18.9 million b/d, according to API’s statistics. U.S. demand may have fallen, but oil product exports jumped 9.3 percent from 2012 to an average 3.5 million b/d in 2013, they indicated. That made them the single largest U.S. export component, Gerard noted on Jan. 7.

‘A new day’“Some prohibitions and policies are vestiges of the past,” he said. “The president talks about doubling exports. Energy can contribute, particularly oil and gas. API reaffirms its support for free trade. It’s a new day, a new time for us to change policies from the 1970s when supplies were scarce.”

The U.S. has the most efficient refineries to process crude from new domestic source, American Fuel & Petrochemicals Manufacturers (AFPM) President Charles T. Drevna observed. “We could do a lot for energy and national security,” he told OGJ on Jan. 7. “But we shouldn’t squander this incredible opportunity.

oil and gas leaders began 2014 with a handful of certainty and a bucketful of questions about what might happen in Washington during the coming year. Prospects for legislative reform

looked dim amid likely continued congressional gridlock, but the possibility of administrative actions creating new regulations without full consideration of their consequences began to emerge.

President Barack Obama and other political leaders acknowledged during 2013 that the domestic oil and gas outlook had changed to increased abundance from growing scarcity. “It’s positive he recognizes it,” Interstate Natural Gas Association of America (INGAA) President Donald F. Santa told Oil & Gas Journal (OGJ) in late December. “Although decisions may be made elsewhere, he can use his position as a bully pulpit to convince decision-makers that something needs to be done.”

But campaigns leading up to mid-term elections this coming November are likely to drive legislative policymaking into the background at a time when reforms are badly needed. “Congress is a lagging indicator. It responds to the voters,” American Petroleum Institute (API) President Jack N. Gerard said during a press conference at the association’s annual State of American Energy event on Jan. 7. “That’s why we have an extensive network of grass-roots activists.”

Some Certainty, Many Questions

in 2014 Washington Oil and

Gas Outlook

By Nick Snow, Washington Editor

Oil & Gas Journal


while, we’ll be able to look more closely at these issues,” he said. “There could be a lot of tough battles ahead. History shows that as an administration approaches its final days, it can start to issue regulatory orders that aren’t always fully thought out.”

When it comes to reforming the Renewable Fuels Standard (RFS), Drevna said he thought there is less than a 50 percent chance of Congress passing a bill this year. “But I expect the discussion to continue,” he told OGJ. “We knew we’d be in this for the long haul, and we’re prepared to continue.” He said he was encouraged by EPA’s finally acknowledging a blend wall exists in the RFS’s ethanol blend quotas, which sent a signal to Congress. “We’re no longer a voice in the wilderness,” AFPM’s president said. “A lot of other people realize there are problems with the RFS.”

Growing product exports have shown that reports of the U.S. refining industry’s demise were premature, he maintained. “Everyone knows that’s what has kept us alive as domestic demand has flattened,” Drevna said. “But we can’t keep going indefinitely without a free market in our own country.”

Milito said operators should come together and develop best practices for working in communities where there hasn’t been much oil and gas activity. “It has to be collaborative and cooperative with local officials. It involves learning from each other,” he said. “From a boom-and-bust perspective, you need to consider how other industries will thrive. Processing plants will be needed. So will steel, chemical, and other manufacturing facilities in proximity to production. Texas and Oklahoma have shown it can continue for years.”

In his address, Gerard said API’s “America’s Energy, America’s Choice” campaign will send a message to lawmakers at all levels of government that it’s time to end the intrusion of extreme political ideology or personal agendas, and that the only limits on U.S. energy potential will be those that are self-imposed by short-sighted politicians.

“In my view, it would be unforgivable if this country were to abandon or ignore its responsibility to future generations by missing this opportunity based on flawed science, outdated assumptions, and political orthodoxy,” he declared.

Learn moreContact Nick Snow at [email protected]

This article first appeared in Oil & Gas Journal’s 2014 Industry Forecast and Review Webcast and Articles, and is used with the permission of Oil & Gas Journal.

Specialist for CNC rotary tables

General importer for North America

Rotec Tools Ltd.5 Schuman Road, Millwood, NY 10546

Phone: (914) 941-7311Fax: (914) 941-0226

Email: [email protected]

Wanted: local representatives

New generation 500:• Modular design: 4 basic modules – over 170 variations• Up to 111 min-1 – clamp and release quickly – short cycle time• High degree of accuracy: concentricity, geometry and positioning • Compact and rigid construction – high spindle clamping torque• Fully impervious to IP67 as standard – IP68 optional (waterproof in bath)• Large workpiece clamp range• Competitive prices

Rotec Tools Ltd.

ww

w.le

hman

n-ro

tary

-tabl

es.c

om

IMTS 2014See us in

Booth #N-7223

Long-term thinking“We’re trying to think long-term by looking at the Atlantic, the Arctic, and the eastern Gulf of Mexico because it takes 15 years to get development going,” Milito explained. “We need to make sure we’re not making decisions in 2017 that make it impossible to have a lease sale before 2023 and for production to begin 10 years.” He said one powerful argument is that from 2007 to 2012, the number of domestic oil and gas extraction jobs grew by 40 percent, compared to 1 percent for the U.S. economy in general.

Another is the significant reduction in U.S. carbon dioxide emissions, which are at their lowest levels in nearly 20 years, largely thanks to the abundant domestic gas supply that came from horizontal drilling and fracking, Gerard said in his State of American Energy address. “Further, since 2000, the oil and gas sector has spent more on low and zero-carbon technologies than the federal government and nearly as much as all other industries combined,” he said.

“Gas has become so successful so quickly that it has made proponents of a low-carbon economy feel the transition they want is beginning to look less likely,” Santa said. “The abundance has become the conventional wisdom, along with the consequences. Gas can’t fly under the radar screen anymore. At the same time, it has a great story.”

“It’s part of so many debates now,” added Martin E. Edwards, INGAA’s vice president for legislative affairs. “Given the supply situation and its impact on prices, it’s in the center of discussions about energy security, manufacturing, or controlling greenhouse gas emissions whether people like it or not.”

“Gas has brought an extraordinary manufacturing renaissance to this country, which will help correct our huge foreign trade deficit,” Natural Gas Supply Association (NGSA) President Skip Horvath said on Jan. 6. NGSA’s latest forecast calls for U.S. gas consumption to grow three times as quickly from 2012 to 2020 as it did from 1987 to 2012, he told OGJ. “That’s unprecedented,” Horvath said, adding that much more infrastructure will be needed but that the Federal Energy Regulatory Commission should be able to respond.

More rail transportAFPM’s Drevna said development of technologies to produce tight oil came more quickly than pipelines to transport it, putting a greater burden on rail. “At the Philadelphia Energy refinery, they have the daily capacity to off-load three unit trains with 120 cars each,” he said. “It’s quite a spectacle.”

Gerard said the industry is expected to spend more than $80 billion on infrastructure during 2014. “When I talk to local heavy equipment dealers, they say the biggest demand is coming from energy,” he said. Rail’s growing crude transportation role demonstrates the market will adjust if administrative inaction, such as continuing to delay a decision on the proposed Keystone XL crude oil pipeline’s cross-border permit, distorts the market, API’s president said.

“Our focus is on safety,” he said. “We need to get to the root causes of rail accidents, such as another train’s being derailed. Three years ago, government began to call for better tank car design, and the industry immediately adopted it. But root causes such as derailed cars shouldn’t be ignored.”

Several association officials who spoke to OGJ said they have seen the Obama administration’s outlook toward the oil and gas industry improve since the beginning of the first term, when the emphasis seemed to be on developing alternatives. “It’s an ever-growing, ever-evolving education effort,” said Naatz. “We just try to lay out the facts, build relationships, and be fully transparent because they’re getting pressure from the other side.”

“There’s no regulatory issue the opposition won’t try to elevate into a fight,” Fuller said. The “sue-and-settle” technique — which involves suing a federal agency, then encouraging it to quickly reach a court-approved settlement so it won’t have to pay legal fees — has been around for years, but occurs more frequently now, he told OGJ.“Frankly, we’re very concerned,” said Fuller. “We don’t want sue-and-settle to become the norm.”

‘Tough battles ahead’Naatz said he hopes Congress will exercise its oversight responsibilities and try to get agencies to explain why they’re doing something, and what they hope to accomplish. “Now that we have some regular order in the budget for a

”From 2007 to 2012, the number of domestic oil and gas

extraction jobs grew by 40 percent, compared to

1 percent for the U.S. economy in general.”

he energy and resource sectors are crucial to Canada’s economic well-being. No longer the “hewers of wood and drawers of water,” professionals in this area drive innovation throughout the supply chain, with specific expertise in manufacturing, transporting, and maintaining

large and sophisticated technologies in remote locations.

The industry is also expanding into new areas, such as wind, which is now economically viable.

20 GQ/Energy Issue 2014

“The wind sector has been driven by economic development and opportunities,” says Robert Hornung, president of the Canadian Wind Energy Association. “It is now competitive from a cost perspective.”

The industry is being driven by local content requirements in Ontario and Quebec, which have resulted in the creation of a wind energy supply chain. Now, shops and fabricators active in other areas have begun to diversify into wind. It makes sense: much of the manufacturing expertise needed to serve their client base in other industries can transfer over.

“If you go to a trade show floor you hear a common refrain,” says Hornung. “People will tell you that while wind is not the biggest part of their business, it’s the fastest growing. That’s one reason people are making investments in the sector.”

Hornung says that wind is a capital intensive industry, with most of the costs driven into the manufacturing process. This is good news for fabricators and manufacturers. Mississauga, Ontario-headquartered Samuel, Son & Co., Ltd., for example, has taken its expertise as a metal processor and metal manufacturer to target the wind opportunity.

“We receive all the wind energy market information to see where the farms are going up and who is producing them,” says Bill Hutton, corporate VP, marketing and national accounts for Samuel. “If someone wants metal products for the wind energy market, that’s not a problem — we have the inventory and the processing capabilities.”

In the wind sector, Samuel will supply all different kinds of metal products, metal processing and metal manufacturing.

The towers themselves are big, and require significant industrial capacity to build and transport. But there is opportunity in more detailed manufacturing, too.

“A turbine itself has about 8,000 parts,” says Hornung. “As a result, there have been significant opportunities for manufacturers to move into this sector during a time when other areas have faced challenges.”

Go big or go homeOne of the reasons why Canada makes sense as a place for manufacturers to embrace wind — aside from favorable policy and plenty of open space — is our industrial expertise in oil and gas, mining, and pulp and paper. These sectors have unique requirements, but also something in common: they require the ability to manufacture large, durable parts, to get them to remote areas, and to maintain them.

“Some of our items might weigh 40,000 tons or more,” says Jason Young, VP of sales at Standard Machine in Saskatoon, Saskatchewan, which is active in the mining sector. “We supply gearboxes, large shafts, and gears.”

In mining, typical mill shapes and forms rely heavily on steel and carbon alloy, with castings and forgings having a high content of gray and malleable iron. This is heavy stuff. Standard Machine not only manufactures the parts, it also has to address trucking and shipping issues to clients as far away as South America. This ability to manufacture large pieces of equipment and to move them — something new players in the wind sector also must figure out — means that local capabilities can add value to far away locations.


Big part manufacturing opportunities

abound in energy and resource sectors.

By Tim Wilson, Contributing Editor

Shop Metalworking Technology

One of the reasons why Canada makes

sense as a place for manufacturers to

embrace wind — aside from favorable

policy and plenty of open space — is

our industrial expertise in oil and gas,

mining, and pulp and paper.

These sectors have unique requirements,

but also something in common: they

require the ability to manufacture large,

durable parts, to get them to remote

areas, and to maintain them.

F E A T U R E


“We design things to break down and ship,” says Dustin Smith, engineering manager at TS Manufacturing, Lindsay, Ontario, which is active in the pulp and paper as well as the mining and aggregate industry. “We are working on a tubular section now that is 250 feet long and 12 feet wide. For something like that, a customer might want an escort for a wide load on a flatbed, or they might want smaller parts to be assembled on site.”

The challenge is that with long distances, more assembly capabilities are required by clients that are harder to service.

TS Manufacturing, which uses a lot of hot-rolled steel, has shipped to Paraguay, with everything sent in containers and, as much as possible, pre-assembled in Lindsay. These skills are learned here in Canada.

“We shipped a job to Nunavut,” says Smith. “That had to go in on a barge before the freeze up. These are logistical problems, and always doable, but shipping can be a major setback on big projects.”

The good news is that Canadian companies have had years of experience — TS Manufacturing has been in business over 40 years — in dealing with these sorts of challenges.

“For us, a typical flatbed truck load is about 40,000 pounds,” says Matthew Webb, manager at Kubota Materials Corp. in Orillia, Ontario. “Our biggest customer area is in petrochemicals, for which we supply steel alloy foundry castings. We ship across North America and into South America, Australia, and Europe.”

Webb says that the largest part Kubota ships is “a couple of tons,” but that the company may also ship multiple smaller units for assembly on site.

Either way, Kubota is a big operation with a long reach.

“We make 300 tons a month of castings,” says Webb.

“Right now we have a three to four month backlog, and in the past that has extended to a year.”

That’s a hefty amount of business serving a global industry — something that Canadian manufacturers, perhaps more than any in the world, will be able to capitalize on for years to come.

Learn morewww.shopmetaltech.com Generate Large-Shaft

Grinding Challenges

he higher the megawatt-generating output, the bigger the wind turbine, and the larger the parts needed to build them. Today’s 2- and 3-megawatt wind turbines

are huge — some with rotor diameters of 300 feet and nacelle structures as big as single-car garages and weighing up to 500 tons.

By Ralf Schürl,

Area Sales Manager for SCHAUDT and MIKROSA Brands

UNITED GRINDING Group

Mega

-Watt

Turbi

nes

Grinding machines with two OD spindles allow turbine makers to load a conventional wheel for the hardened steel sections of wind turbine shafts and a second diamond or CBN wheel for the thermal spray coated areas.

length of a shaft to detect any taper from one end to the other. Plus, it is possible to control/check a second and even a third different diameter on the same part.

Shops can measure long gearbox shafts with a gauge mounted on the machine’s table. However, when moving to a second location/journal for measuring, the gauge moves with the table and away from where the grinding wheel is actually working. With this setup, shops can grind only one journal location and with in-process gauging capability, while other journal locations have to be ground indirectly. Using the DIATRONIC system, on the other hand, makes it possible to grind multiple journals all with in-process measurement.

As the power generating capacities of wind turbines increase, so will their overall sizes and internal components. And to grind these large turbine parts, shops serving the wind energy sector will require bigger machines that provide versatility through multiple-process/multiple-wheel capabilities and allow for completing parts in single setups while also improving precision and output.

Learn morewww.grinding.com


Of all the components that make up a wind turbine nacelle, the majority that typically require grinding operations are within the gearbox. Turbine gearboxes connect the turbine rotor shaft to the turbine’s generator and transfer the slow rotational speed of the blades into the faster rotational speed needed for the generator to achieve a high enough power-generating ratio.

Turbine gearbox shafts are probably the largest of gearbox components and ones that present quite a challenge when it comes to grinding. In addition to their size — between 10 and 30 inches in diameter, up to five-feet long and weighing from 600 to 1,200 pounds — today’s gearbox shafts also incorporate thermal spray coatings that further complicate grinding operations.

Part volumes in wind turbine manufacturing are low, so shops supplying that sector need grinding machines that are flexible, multi-operational (OD and ID work) and can be quickly changed over from one job to the next. And because workpieces, such as shafts, are big and heavy, these shops need machines with large swings that allow for grinding part ODs and IDs. But for gearbox shafts in particular, grinding machines equipped with two types of OD grinding wheels are most advantageous.

For example, the SCHAUDT FlexGrind M universal ID/OD grinder from UNITED GRINDING features a high-precision B-axis turret that swivels at an angle of -45° to +225° and is equipped with two OD grinding spindles and one ID spindle.

While most gearbox shafts require little, if any, ID grinding, they do, in fact, involve a lot of OD grinding and using two different types of wheels. The reason for this is the steadily increasing application of thermal spray coatings, in particular the high-velocity oxygen fuel (HVOF) type.

HVOF coatings significantly enhance part surface qualities such as wear resistance and strength. They also make manufacturing operations more cost effective.

A 1,200-pound steel shaft, for example, can be quite expensive in terms of raw material alone. So to control costs, many of today’s turbine builders opt for a more classical engineering approach and apply HVOF coatings only to the high-stress areas/journals of a gearbox shaft to boost strength and wear resistance. Without the selectivity coatings provide, the whole shaft would have to be made from a costly higher grade of material when only certain portions of it need the added strength and wear resistance.

Turbine builders continue to trend toward turbine parts that provide lifetimes of wear resistance. Because, no one wants to remove, repair and replace huge heavy gearbox parts in a turbine nacelle hundreds of feet in the air on a regular basis.

The HVOF class of thermal spray processes involves a mixture of gaseous or liquid fuel and oxygen fed into a combustion chamber, ignited and continuously combusted. The resulting HVOF coatings can be applied up to 0.5 inches thick consisting of wear and corrosion-resistant ceramic or metallic layers of stainless steel, nickel-based alloys and other materials.

Turbine manufacturers grind the high stress areas of gearbox shafts undersize, apply the coating and grind the section to size. However, the extremely hard thermal spray materials require grinding with diamond or CBN wheels. Just the coated portions get ground with these wheels, while the other areas are done with conventional grinding wheels.

Grinding machines, such as the SCHAUDT FlexGrind M, that feature two OD spindles allow turbine makers to load a conventional wheel for the normal hardened steel shaft sections and a second diamond or CBN wheel for the HVOF coated areas. This capability is the key to process flexibility — grinding parts complete in one machine setup — and ensures the highest levels of machine utilization as well as the shortest possible ROI.

Completing large heavy parts in single machine setups also requires in-process real-time part gauging capability. Turbine shops can adjust for grinding wheel wear and thus control part size more accurately and on-the-fly with such functionality.

During in-process real-time part gauging operations, machines activate measuring units that move to the workpiece, check diameters and retract out of the way. Ideally, these measuring units should ride on the same base as the machine’s grinding wheel and gauge parts at a location directly opposite of the grinding wheel work zone, as is the case with the units in the DIATRONIC measuring system on SCHAUDT machines.

Gauging on the same base as the grinding wheel and directly opposite of where it is working not only makes real-time gauging possible, it allows shops to measure along the whole

Others may try to “razzle dazzle” you, but when you need high-quality, reliable spindle repair,

there’s no illusion, rely on Fischer Precise USA.

Fischer Precise USA has over 70 years of experience in spindle manufacturing, maintenance and repair.

Our legacy has been built on the highest levels of customer service and support.

There’s nothing up our sleeves … Fischer Precise USA provides the ultimate in service and repair. Our skilled technicians

are familiar with all major brands.

We have the capabilities, capacity and expertise to restore your spindle to peak...

dare we say it… magical performance.

Visit www.fischerprecise.com to learn more about our repair services, technical support and capabilities.

Not Smoke & Mirrors

High Performance Spindle SolutionsFISCHER PRECISE U.S.A., RACINE, WI 53405 U.S.A.262.632.6173 800.333.6173 FAX: 262.632.6730Email:[email protected] www.fischerprecise.com

While most gearbox shafts require little,

if any, ID grinding, they do, in fact, involve

a lot of OD grinding and using two different

types of wheels.The DIATRONIC system on SCHAUDT grinding machines makes it possible to grind multiple turbine shaft journals all with in-process measurement.


n my work at UNITED GRINDING, I have many roles. My official title is executive administrative services manager, and I support the president and CEO of the company. In addition, I function as the facility manager for our headquarters located in Miamisburg, managing

building upgrade projects as well as vendors contracted for building maintenance. I also lead the employee satisfaction team, a group of volunteers that represents each department and strives to improve satisfaction levels of our employees. Furthermore, I lead the organizational support team, a team formed of the administrative support personnel and one in which we collaborate on projects, policies, procedures, events and other administrative news.

Because I am very passionate about what I do and like to help others, I’ll do anything to assist in getting the job done. I am hands on and often considered the go-to person for many projects and tasks. If someone comes to me with a question, more than likely I’ll know the answer. If I don’t, I will help find it for that person.

There are strong parallels between my work life and home life. I always say that I leave this job and go home to my second job of tending to my family’s very active schedule. My husband Tony is an engineer and senior project manager for a local construction company. We have two boys: Alex, a high school freshman who is 15, and Tyler, who is 13. Both of the boys are active in sports, and when it comes to managing their schedules, I take responsibility for getting all the soccer games, track meets, and other activities on our calendars so that we know where we have to be and when, much like I do for the president of United Grinding North America, Inc.

The Work and Home Life

of Cindy Williams

A G L I M P S E I N T O

As a family, we are always on the go and outdoorsy people. We enjoy riding ATVs, canoeing and kayaking as well as fishing and spending time on our ski boat. To relax from my busy work and home schedules, I have a garden, and believe it or not, weeding the garden actually relaxes me. My husband will help, and we chit chat about work, family life and any upcoming outings we have planned.

Much like the open communication between my husband and myself, I truly feel that the employees at UNITED GRINDING know that they can also come and talk to me no matter what the problem or situation. Because I lead the employee satisfaction team, employees can voice their concerns through me or anonymously with any of the team volunteers. The team meets at least quarterly to discuss employee concerns and the emotions within the company. We know that we cannot solve certain situations, but we are the voice of the employees so to speak. We listen then take issues to our executive management team to keep them aware of current situations so that they can work on solutions as necessary. We perform employee surveys and try to improve areas where employee satisfaction levels are low. The satisfaction team also plans and conducts fun activities such as cookouts and other special events for the employees.

I greatly enjoy working with the people here at UNITED GRINDING. They are a good group of people, and I make it a point to try to get know each and every one of them. I’ve been here eight and half years, and I can happily say that this is the best company for which I’ve ever worked. And by the way, my second job of 19 years — married and raising a family — isn’t too bad either.


F E A T U R E

MBAB

BC

YT

SK

NT NU

ON

QC

PE

NB

NS

Existing Pipeline Conversion

New Pipeline Construction Terminals

Receipt Points

Hardisty

Moosomin

Montréal

Saint JohnLévis

The existing gas pipeline system consists of several individual pipes running in parallel with each other. This project will entail the conversion of just one of those individual pipes.

Cacouna

By Jim Anderton, Editor

Canadian Metalworking

Oil and gas are healthy, but moving product to market remains a challenge

n Canada’s oil and gas industry and for the economy as a whole, 2014 may become the most important year in decades. Persistently high oil prices combined with strengthening natural gas pricing is driving considerable investment in exploration and development, with one significant bottleneck: transportation. With inadequate pipeline capacity crude oil is increasingly

hauled by rail, which after the Lac Megantic disaster is certain to be burdened by increasingly strict safety regulations and local resistance to train routing near population centers. Pipelines are the obvious solution, but a difficult combination of environmental concerns and U.S. politics are conspiring to make new projects difficult to launch.

Pricing Drives the PlayLike any other industry, in oil and gas it’s all about price and in 2013 pricing was highly supportive of capacity expansion. On the oil side, pricing remained near or above $100 per barrel supported by a recovering global economy and political uncertainty. Gas, after flat to falling pricing since 2004, saw its first year-over-year improvement in 2013, aided by an unusually cold winter and depletion of existing low-cost gas stocks. According to the Conference Board of Canada, in the last quarter of 2013, the natural gas benchmark in Alberta averaged $3.4 per million BTU, a 40 percent increase from the CA$2.4/mmBtu price in 2012. Prices are expected to retrench this summer, although the Board doesn’t expect a return to the peak gas pricing of the early 2000s. The ability of fracking to unlock large U.S. shale gas formations has increased U.S. gas production and reduced U.S. imports significantly. Oil, however, has a more complex pricing environment.

Bottlenecks in pipeline capacity have had an interesting effect on pricing. According to the U.S. Energy Information Agency (EIA), the base stock for Gulf Coast refineries (the target market for Keystone XL transported Canadian bitumen) is West Texas Intermediate (WTI) which is predicted to trade at a discount of about $10 per barrel

The existing gas pipeline system consists of several individual pipes running in parallel with each other. This project will entail the conversion of just one of those individual pipes.

Pipeline maintenance and repair are significant job creators for decades after construction is complete.

Imag

e co

urte

sy tr

ansm

ount

ain.

com

in 2014 compared to benchmark North Sea Brent, reflecting the additional transportation costs in getting North American oil to the refineries. This discount is a significant driver of new rail capacity and a real impetus to approval of Keystone XL. Shipped by either method, Canadian and U.S.-based “tight oil” may have a “knock on” effect of moving currently imported foreign oil to East Coast ports as well as introducing the possibility of Gulf Coast upgraded oil and refinery products moving to Canadian Eastern markets by sea. It’s just one factor in an increasingly complex pricing environment for oil. Current unrest in the Ukraine, Syria and ongoing sanctions against Iran are all upward drivers on price, while increasing adoption of fracking technology is opening large reserves of previously inaccessible oil both in Canada and the U.S., depressing prices. The EIA predicts a benchmark Brent crude oil price average of $105 per barrel in 2014 and $101 per barrel in 2015 respectively. Oil is globally denominated in U.S. dollars, making the current Canadian dollar weakness a distinct advantage for Canadian producers. Natural gas, however, cannot be cost-effectively transported by rail, making pipelines essential regardless of regional political and environmental issues.

Pipelines in PlayMoving product from Alberta and Saskatchewan to the major markets is a three-way conundrum. There are disadvantages to direct transport of the petroleum to the large central Canadian markets, while Asia, particularly China, is an expanding and lucrative export market, especially as large-scale liquid natural gas transport by tanker has become economically

viable. The southern demand, especially from the Gulf Coast refinery complex continues to grow, adding additional political pressure to a highly charged U.S. debate over Keystone XL. A TransCanada Corporation project, Keystone XL is the final phase of the Keystone pipeline system, which is designed to transport bitumen from Hardisty, Alberta to Midwest and Gulf Coast refineries. After President Obama’s 2012 rejection of the XL application due to protests about potential environmental damage in Nebraska, TransCanada changed the proposed route, which was approved by Nebraska governor Dave Heineman in January 2013. More widespread environmental protests based on the atmospheric CO2 contribution from Alberta oil sands sources is a major factor in the current U.S. administration’s approval decision. With a chance to wrest control of the House of Representatives from the GOP in this year’s mid-term elections, the Obama administration is playing for time in delaying an approval, avoiding a sensitive issue with the Democratic Party base.

The Energy East Project also proposed by TransCanada is designed to carry 1.1 million barrels of crude oil per day from Alberta and Saskatchewan over a 2,858 mile pipeline to

refineries in Eastern Canada. Like Keystone, the starting point is Hardisty, Alberta and the project will involve new construction in Alberta, Saskatchewan, Manitoba, Eastern Ontario, Québec and New Brunswick as well as conversion of existing natural gas pipeline for oil transport. The project proposal includes marine facilities to move product to other markets by tanker.

In the opposite direction, Kinder Morgan Canada’s Trans Mountain Expansion Project proposes to move petroleum to Pacific coast port facilities for export to Asia. The company filed a facilities application on December 16 with the National Energy Board. The project is in fact an expansion of the existing Trans Mountain pipeline which if approved would twin the line, increasing system nominal capacity from 300,000 barrels per day to 890,000 barrels per day. The project would cost approximately CA$5.4 billion to add 609 miles of new pipeline and reactivate existing lines as well as add 12 new pumping stations. Existing storage terminals in Burnaby, Sumas and Edmonton would receive 20 new tanks and the Westridge Marine Terminal in Burnaby would be expanded with three new berths to accommodate increased tanker traffic. The existing line carries multiple petroleum products simultaneously, but the


Source: U.S. Energy Information Organization

Dollars per barrel

Oil Price Forcast: Brent vs WTIC

ourt

esy

Kind

er M

orga

n C

anad

a

Trans Mountain Expansion Project

Shell’s Northwest Seaeagle LNG tanker is a typical modern liquefied natural gas ship, carrying 81 cubic miles of LNG. To move LNG to China, politically controversial British Columbia coast facilities will be needed.

Imag

e co

urte

sy S

hell


proposed would carry heavier oils with light crude capability. Kinder Morgan has stated that the proposal would include CSA and API specification pipe using specialty steel grades such as X–90 through X–120 along with stringent control of welding processes and NDT.

All three pipeline projects face resistance from multiple quarters. Keystone XL is primarily a U.S. political problem as most of the Canadian engineering is already in place, but Trans Mountain and Energy East face opposition from Canadian aboriginal groups, environmentalists and local ratepayers concerned about possible spills and the impact of construction, and more ominously for the long term, by global warming activists.

At press time, the Intergovernmental Panel on Climate Change (IPCC) released a new report entitled Climate Change 2014: Mitigation of Climate Change which states that global emissions of greenhouse gases have risen to unprecedented levels despite current efforts to reduce emissions. According to the report, emissions levels rose quickly between 2000 and 2010, more than any of the three previous decades. According to the report, 1,200 scenarios for scientific literature have been analyzed, generated by 31 modeling teams from around the world and the results suggest that to limit the increase in global temperature to 35.6°F, greenhouse gas emissions must be lowered globally by

40 to 70 percent relative to 2010 levels by 2050, and to essentially zero by the end of the century. While natural gas is a widely endorsed intermediate fossil fuel useful for the transition from coal, Alberta oil sands petroleum is widely regarded as CO2 emissions-heavy due to the energy intensive extraction process.

While it is not widely known that the majority of petroleum trapped in oil sands formations is relatively inaccessible and will be extracted through steam or solvent injection processes and recovered through wells, surface mining makes Alberta oil a target for the environmental movement globally. If the IPCC report resonates politically in Europe for example, it’s possible that a tax or tariff on oil sands derived Alberta petroleum could be levied. Possible solutions include local carbon capture and storage or a switch to alternate forms of process heat for the extraction process.

Between politics, the environment, aboriginal rights issues and the fragile global economic recovery, for oil and gas in Canada, 2014 is a very interesting year.

Learn more www.canadianmetalworking.com

Modern pipeline construction uses API specified pipeline grade steels and qualified welding processes.

Imag

e co

urte

sy tr

ansm

ount

ain.

com D I G I T A L D I G E S T

enerating strong, interesting social media content for your business should be a core focus of your daily marketing efforts. Unfortunately, basic, text-based

posts are no longer enough. You need the power of video to transform your content into highly engaging, sharable posts that will boost your brand’s presence and authority across several online platforms.

Videos, as compared to other forms of content, generate more likes, comments and shares on social media. According to Hubspot, an inbound marketing and sales software company, people share videos 12 times more than text and link-based posts combined. And by 2016, Cisco’s Visual Networking Index expects video delivery to reach 86 percent of consumer Internet traffic.

If you want to energize your social media efforts through video, all you really need is a little creativity and a smartphone. Here are some tips to help get you started.

Create an informational video on YouTube that showcases a

new product or complex machining process. Be sure to include industry

keywords in your title, description and tags to help viewers find

your video online. With the right keywords, which can take the form of

branded names or generic industry terms, you will rank higher in search

engine results. If you need help selecting your keywords, there

are several tools available online.

Post an “insider’s look” video on Facebook to provide your

fans a behind-the-scenes glimpse of your company. Such content gives

fans a sense of inclusion and increases their loyalty to your company.

Just remember the best videos teach something. So, if you want to

film your part production efforts, you need to explain the process,

including the people, materials and equipment involved, and

how it benefits customers.

Host a Q & A session through Google+ Hangouts, a

platform that allows up to 10 people to participate in a private video

call. With Hangouts On Air, you can broadcast live discussions to the

world through Google+ and YouTube. Once finished, the broadcast

automatically posts to your YouTube channel, which you can then

share. To best utilize Hangouts On Air, you need quality equipment,

an adequate network connection, a knowledgeable host,

a program outline and a promotion plan.

Launch a video contest on behalf of your business to engage

customers and get them to create content around your company with

little effort on your part. For example, you could encourage customers

to submit short videos of them using your product or benefitting from

your service. Then let your fans and followers choose the winner through

social media. To promote the contest, you will need to create a video

explaining the contest and post it to your social networking sites.

CONNECT WITH UNITED GRINDING - Social - @UnitedGrinding


Lower gas prices result largely from the adoption of hydraulic fracturing, a new well-drilling technology that provides cost-effective access to vast stores of gas trapped in deep formations of shale rock. Fracturing or “fracking” involves drilling into the shale and then injecting high-pressure fluid and materials that crack the rock formations and release the gas. Recent advances in drilling technology permit drilling a mile or more deep then employing a directional tool that permits lateral drilling for two or more miles. The long bores through the gas-laden shale enable collection of large volumes of gas.

Although gas has been produced via fracking for more than 100 years, newer drilling technologies have made the technique more profitable, resulting in a fracking boom

that began around 2010. According to the U.S. Energy Information Administration (EIA), natural gas prices rose as high as $18.48/MMBtu in February 2003, but with increased fracking activity the price of gas has been at or below $5/MMBtu since the beginning of 2010. And, with lower gas prices comes lower manufacturing costs.

In its World Energy Outlook in November 2013, the International Energy Agency said lower gas and electricity prices in 2012 in the United States relative to Europe equated to an estimated savings of close to $130 billion for the U.S. manufacturing industry. A recent Boston Consulting Group study estimates that cheap natural gas reduces U.S. manufacturing costs by 1 to 2 percent overall.

F E A T U R E


Low-cost natural gas aids U.S. manufacturing

n recent decades, U.S. manufacturers relied on offshore production to benefit from lower material, labor and energy costs. Today, however, some of those operations are returning to domestic plants as manufacturing overseas is no longer as cost effective, with higher shipping costs,

land prices, employee wages and product rejection rates. Furthermore, domestic production has become more competitive through innovative management strategies, highly productive manufacturing technology and lower energy prices, specifically those of natural gas.

Natural Gas PricesU.S. Energy Information Administration

2003$18.47/MMBtu

2010$5/MMBtu

Today’s lower gas prices result largely from the adoption of hydraulic fracturing.

burning natural gas still produces carbon dioxide, although less than burning coal.

There are indications that the low-cost advantage of natural gas may be decreasing somewhat, as spot prices rose to about $6/MMBtu during the first quarter of 2014 following a colder-than-normal winter that depleted gas storage inventories. Discussions about exporting gas have led to speculation that such efforts will reduce the domestic supply and result in higher prices in the United States. And other countries are beginning to explore new gas-extraction technologies; according to the EIA, China’s shale gas reserves are the largest in the world.

It is obvious inexpensive energy is an important element in reducing manufacturing costs and maintaining competitiveness in domestic production — but it is not the only factor. There are other aspects contributing to the growth of U.S. manufacturing, including lean initiatives and highly productive multi-tasking and automated equipment. And, as experts foresee off-shored work continuing to come back to the United States well into the next decade, it is extremely important for manufacturers to constantly evaluate all aspects of their production processes and remain as efficient as possible.


Several manufacturing sectors benefit from lower gas expenses. For example, industries that use petrochemicals in their end products, such as makers of plastics, coatings, packaging, soaps and solvents, benefit from cheaper feedstocks. The Pittsburgh Tribune Review reports that Royal Dutch Shell has proposed spending $2 billion in Beaver County, Pa. to build a petrochemical “cracker” plant that would extract ethane from local shale gas and use it to manufacture plastics and other products. The site of the proposed plant is in the heart of the huge Marcellus Shale formation, believed to be the third-largest gas field in the world.

Lower energy costs should also provide U.S. chemical manufacturers with a competitive advantage in world markets. Additionally, because natural gas is widely used in the agriculture, pharmaceutical, transportation and construction industries, opportunities for U.S. participants in global markets will most likely increase.

Furthermore, gas-related job growth has become a hot political topic. Pennsylvania state officials estimate that the Shell cracker plant project could result in up to 8,000 new permanent jobs. In his most recent State of the Union address, President Obama said, “One of the biggest factors in bringing more jobs back is our commitment to American energy. Businesses plan to invest almost $100 billion in new factories that use natural gas.”

Research firm IHS Global Insight, which recently prepared a report entitled “Impact of the Manufacturing Renaissance from Energy Intensive Sectors” for the U.S. Conference of Mayors, predicts that as many as 3.8 million new jobs will be created in the United States, either directly or indirectly related to the natural gas industry, by 2025. The report examined recent growth in the nation’s manufacturing industry, with a focus on the metropolitan districts of interest to the mayors.

IHS found that energy savings from 2011 and 2012, which resulted from unconventional gas and oil production as well as demand for new pipelines and mining equipment, boosted activity in the nation’s steel, iron, fabricated metals and machinery manufacturing industries. Sales and employment in those businesses in U.S. metro areas increased 17 percent and 9.7 percent, respectively in that span of years. From 2010 to 2012, energy intensive manufacturing sectors added over 196,000 jobs and increased sales by $124 billion in the nation’s metro areas. The study notes that metropolitan areas accounted for more than 78 percent of the total employment and 82 percent of the sales in energy intensive manufacturing industries. On a national basis, IHS projects energy intensive manufacturing employment to expand by more than 1 percent annually through 2020.

The Chairman of the U.S. Conference of Mayors Advanced Manufacturing Task Force, Lansing, Mich., Mayor Virg Bernero,

said, “We believe the energy revolution is helping the United States regain its footing in the manufacturing sector.”

Inexpensive natural gas is a key element of some newly developed manufacturing processes. For example, an alternative form of steelmaking called direct reduced iron uses gas to produce 97 percent pure iron from iron ore without the use of a blast furnace. The new method eliminates many of the process steps and capital investments traditionally required in steelmaking.

It should be noted that there is not total agreement regarding the actual extent of the effects of lower gas prices on manufacturing activity. In a research note last year, Goldman Sachs Chief Economist Jan Hatzius wrote that his analysis indicates that industries such as plastics, basic metals and chemicals have not seen an increase of output despite lower energy prices. He pointed out that energy expenses make up only a small part of overall costs for many companies.

Availability of inexpensive energy does not by itself result in growth of manufacturing activity. Analysts point out that energy-rich areas of the Middle East or South America, for example, generally do not have strong manufacturing industries. In regard to the fracking process itself, there are concerns about environmental effects ranging from water pollution to noise to earthquakes, as well as recognition that

On a national basis IHS projects

energy intensive manufacturing

employment to expand by

more than 1 percent annually

through 2020.

From 2010 to 2012, energy

intensive manufacturing sectors

added over 196,000 jobs and

increased sales by $124 billion

in the nation´s metro areas.

One of the biggest factors in bringing more jobs back

is our commitment to American energy,

Businesses plan to invest almost $100 billion in new factories that use natural gas.


Robotics has worked with Ford Motor Company to develop robots with real-time tactile feedback for delicate assembly and machining. The robots use ABB’s Integrated Force Control to

manage process variations with the sensitivity of the human hand. The touch capabilities of Integrated Force Control were designed to adjust the path and speed of the robot based on sensor input. The robot can also mimic motions of a human arm to find the correct position to assemble a part.

ABB has also introduced Integrated Vision, a smart-camera system designed to make vision-guided robotics easy to deploy. Integrated Vision was created to help manufacturers to track products, troubleshoot challenging lines and processes, and expand the use of robotic automation.

ABB’s Integration Force Control is a consolidation of software features that have been available in ABB machining and assembly tools. ABB force control technology was designed to help robots handle process variations with real-time external inputs, much like a human uses when handling a delicate item with precise dimensions.

Robots deployed with Integrated Force Control react to their surroundings and deviate from their programmed path or speed based on feedback from the force sensor. This enhances conventional robotic movements that are typically controlled by predefined paths and speeds. The force control technology makes it possible to automate complex tasks which previously required skilled personnel and advanced fixed automation.

F E A T U R E

Ford Motor Company

reduces process variations

with advanced robotic

automation.

By Rob Spiegel, Senior Editor

Design News

Integrated Force Control was 10 years in the making. ABB initially developed the tactile feedback capability to solve Ford’s need to take the assembly of fork converters from manual assembly to automated assembly. “It’s a difficult thing to assemble with all the gear meshes. Ford came to us and asked if it was possible to have a robot feel its way through the gear meshes,” Nick Hunt, manager of technology and support at ABB Robotics North America told Design News. “From there it was a joint effort. Ford was giving us direction on how they would like to see it, and we figured out how to give the robot tactile feedback.”

A force-controlled robot can be programmed to mimic the movements of a human arm, applying search patterns to find the correct position to assemble a given part. This feature significantly reduces the risk of assembly failures which can result in production problems or damaged parts. While Integrated Force Control was initially developed to solve a problem at Ford, ABB quickly realized it would be more useful if deployed in a real-time setting. “The initial force control began with Ford powertrains. It involved developing a high robot RAPID code. The routines that were written were written at the high level. We didn’t yet have those in the real-time operation system,” said Hunt. “As we saw the usefulness of this and began to have some success with it, we decided to offer it to our users in the command center.”

Once ABB created the real-time functionality, the team added existing ABB force tools to reduce the user’s need to add original programming. “We wrapped it in feedback tools and made it easy for a user to actually use the feature without having to write a lot of code,” said Hunt. Integrated Force Control will likely migrate to a wide range of applications. “This technology will help any time you need to feel your way through something without breaking your tooling,” said Hunt. “We use it on bunting, grinding, force milling, testing. We also get a lot of requests for testing the technology to see how often you can apply force something — like closing a door or placing an object on something. This technology helps you measure those forces.”

Learn more www.designnews.com

ABB´s newest manufacturing robot can sense

its environment and apply pressure according

to its function and surroundings.

Manufacturing Robot Can Touch and See Like a Human

Provide links back to your website: When pulling content from your company website or landing pages be sure to include links back to each source. Posts that link to other pages gain more credibility in the eyes of a search engine as well as provide the reader an easy gateway to more information on your company and products.

Engage, engage and engage: Shares, likes and comments are extremely important in an effective social media strategy. The more engaged you are with your social media followers, the more likely they are to engage with your content. And, when others share, like and/or comment on your post, this increases the authority of the content and boosts your company’s search engine ranking.

When UNITED GRINDING implemented these best practices, the company saw an increase in its Google search results ranking and traffic to its website. Social media can bring a competitive advantage to any company that dedicates the time and resources to properly utilize it. Just look at what it’s done for UNITED GRINDING.

Source ¹ Data from Chitika Insights June 2013: http://bit.ly/1eJ9ipR

oday, social media is a crucial part of any online

marketing strategy, but very few people realize the

true value it brings to the world of search engine

optimization (SEO). Any company that wants to increase

its online search rankings or website traffic should consider

social media as a part of its SEO strategy. The content

your company posts on its social media platforms can

have a profound influence on its Google search results.


To see the direct impact social media has on Google search results, UNITED GRINDING serves as a good example. Simply type in UNITED GRINDING on Google and press enter. You will immediately notice two things:

1. Updates from UNITED GRINDING’s Google+ page are shown at the top right of the search results. Google values current and relevant content and gives additional search results benefits to those that use its services.

2. On the first two pages of search results, several of the top results tie into social media accounts (Facebook, LinkedIn, Twitter and YouTube).

With 91.5 percent of all search users clicking on the first page of results¹, this is extremely valuable for a keyword with hundreds of search queries a month.

The UNITED GRINDING example shows how social media can have a direct impact on your search engine results. It also demonstrates how important it is for companies to use social media effectively to achieve SEO success. Such accomplishment, however, does not occur overnight; it takes dedication and hard work to reap the benefits. So how should you get started? Here are some best practices to keep in mind:

Post updates on a regular basis: Developing a posting schedule that keeps your social media accounts current allows search engines to provide the most up-to-date information in its results. Daily updates provide plenty of opportunities for search engine results.

Create quality content: Strong content is just as important as the frequency of posting. Pulling rich content from your website or landing pages allows you to use readily available content that is devoted to representing your brand effectively. The addition of multimedia components, such as YouTube videos or photos, also enhances the quality of each post.


Best practices in social media

can bring competitive

advantage to any company.

By Leslie Galbreath,

Executive Vice President and CMO,

dgs Marketing Engineers

O P T I M I Z E

ickel-based alloys retain much of their strength at elevated temperatures, prompting their use in a wide range of aerospace, energy and other critical applications. That beneficial property, however, also results in relatively low productivity and rapid tool wear in grinding operations,

even when machining at low speeds. In addition, the low thermal conductivity of these alloys makes it more difficult to transfer heat away from the grinding zone.

The high surface temperatures that occur during grinding can result in a variety of damage to expensive superalloy work material, including microstructural transformations, oxidation, white-layer, thermal softening, microcrack development, unfavorable residual stress profiles, and accelerated grit wear.

A strategy to reduce thermal damage and increase productivity when grinding these materials involves improving coolant application so that the wheel porosity carries the fluid through the chip forming zone. If the coolant only quenches the hot surface after the wheel has moved by, the surface integrity of

Improvements in coolant application lead

to reduced thermal damage and increased

productivity.

By Dr. John A. Webster, Consultant and Manufacturer

Cool-Grind Technologies


F E A T U R E

the finished component can suffer. On the other hand, carrying the coolant through the process allows extreme pressure additives in the fluid to lubricate the chip forming zone, reducing the generation of wear flats on the abrasive grains and minimizing clogging of the wheel structure with chips.

The delivery speed of the coolant jet is crucial in achieving effective cooling. In many cases, the air boundary layer that surrounds the periphery of the rotating grinding wheel can have sufficient energy to deflect a low-pressure stream of coolant applied to its surface by the nozzle, preventing wetting of the grinding wheel. Published information discussing the influence of jet speed on grinding performance shows that a jet speed of at least 70 percent of the wheel speed should be used, while 100 percent is preferred. For example, if the grinding wheel peripheral speed is 6,000 surface feet per minute (30 m/s) then the coolant jet speed should be between 4,200 and 6,000 sfpm (21 to 30 m/s). With water-based coolants, a nozzle pressure between 32 and 67 psi (2.2 to 4.6 bar) is needed to create the necessary jet speed. Straight oil coolants require a slightly lower pressure due to their lower specific gravity.

Cool-Grind Technologies pioneered the use of coherent-jet nozzles for grinding processes 25 years ago. Laser-like round and flat jets that target the exact position on the grinding wheel are very effective in wetting the process, with much lower flowrate and pumping energy than traditional dispersed jets. The nozzle aperture of the nozzle is determined by matching the applied flowrate to the maximum grinding spindle power using the mathematical model of 1.5 to 2 gallons per minute per grinding horsepower, or 8 to 10 liters per minute per kilowatt. The more grinding power, the more flowrate is needed to cool the process.

Application of coherent-jet nozzle technology can overcome problems encountered in the grinding of nickel-based superalloys. For example, a gas turbine blade manufacturer suffered surface integrity issues on a part after grinding. More and more coolant nozzles were added to the twin CBN wheel machine in attempts to resolve the situation. Once the total number of nozzles equaled 10 and the filter system could not keep up with the resultant flowrate, the manufacturer considered using coherent-jet nozzles.

Ten open pipe nozzles with internal diameters of 0.44" (11 mm) were replaced by five coherent-jet nozzle tubes with 0.19" (4.4 mm) jet diameters. Although the flowrate with the coherent-jet nozzles was only 33 percent of that with the open pipe nozzles, the grinding wheels lasted twice as long and no surface integrity issues remained.

Nozzle tubes are very effective for large batch sizes and complex wheel profiles, but are difficult to adjust for smaller batch sizes and different grinding wheel widths. The 4" (100 mm) nozzle system shown was developed for a BLOHM profile grinder and directly replaces the original wedge nozzle on the servo adjuster. Each of the four 1" (25 mm) wide nozzles can be swiveled, aimed and clamped with tamper-resistant recessed screws. When using narrower wheels, up to three of the four nozzles can be switched off by pushing in the plungers. A laser aiming system, like the one shown, fits to the end of the nozzle and enables dry setup with guaranteed first part quality.

The ultimate nozzle for small batch complex wheel profiles is the patented Saint-Gobain card-key nozzle system. Adjusting the aim of the jets for a different wheel profile is achieved within a few seconds by changing a single jet card. The jet card slides into the end of a flow-conditioned plenum chamber that stabilizes the flow before the jets are formed. Each jet card is machined using a coherent-jet profile form cutter to produce multiple round jets that conform to the profile of the wheel.

Coolant application on precision grinding machines is a highly neglected area. The price of an engineered nozzle is often much less than 1 percent of the price of the grinding machine and can have an ROI in just a few months due to reduced scrap, better part quality, and longer wheel life. The benefits of engineered nozzles are especially evident in the grinding of tough nickel-based superalloys.

Dr. John A. Webster is a grinding consultant and manufacturer of coolant application hardware, based in Connecticut.

Learn more www.cool-grind.com

The Patented Saint-Gobain Card-Key Nozzle System

BLOHM Profile Grinder 4" Nozzle System

Laser Aiming System

of Nickel-based Superalloys During Grinding

BEFORE AFTER

Ten open pipe nozzles with internal

diameters of 0.44" (11 mm) were replaced

by five coherent-jet nozzle tubes with

0.19" (4.4 mm) jet diameters. Although

the flowrate with the coherent-jet nozzles

was only 33 percent of that with the open

pipe nozzles, the grinding wheels lasted

twice as long and no surface integrity

issues remained.


The BLOHM PROFIMAT MT 608 production-grinding machine provides high metal-removal rates and application versatility. A spindle drive power of up to 60 kW and a maximum cutting speed of 558 ft/s ensure top performance in continuous-dress creep-feed, in-process dress and CBN grinding. A large selection of process-optimized accessories, which includes auxiliary spindles, indexing tables, tilting chucks, probes and special part clamping and handling systems, permits each machine to be tailored to specific production requirements. Target grinding applications include energy-industry parts such as turbine blades, shrouds and fluid-handling components, as well as a wide variety of components in automotive, tool and die, and aerospace manufacturing.

PROFIMAT MT 608 Delivers Power, Flexibility and Production

F E AT U R E S A N D B E N E F I T S O F T H E B L O H M P R O F I M AT M T 6 0 8 :

• High-grade gray cast iron modular platform, optimized via finite element analysis, minimizes thermal variations and vibration

• Pre-loaded anti-friction linear guideways and precision recirculating ballscrews provide consistent performance

• Grinding spindle drive power up to 60 kW and maximum cutting speed of 558 ft/s

• BLOHM software ensures exact axes interpolation

• Siemens Sinumerik 840D CNC control with grinding-specific graphic interface enhances ease of use

• Table and overhead dressing devices permit in-process and continuous dressing

• X longitudinal travel 35", Y wheel head vertical travel 22" (optional 31.5"), Z cross column travel 20.5"

• Grinding wheel size (d x w x bore) up to 20" x 8" x 5"

• 11.5' width x 9' depth

• One of six available PROFIMAT MT machine sizes with grinding ranges from 16" x 31.5" to 24" x 79"

In t

he Z

ON

EI N T H E Z O N E

High metal removal rates Application versatility

Grinding spindle drive power up to 60 kW Maximum cutting speed of 558 ft/s

The MÄGERLE MFP 100 grinding center facilitates multi-face machining of large and complex workpieces in a single clamping. Featuring spindle power up to 50 kW, the MFP 100 has a generous working zone configured to handle big workpieces. For multi-task machining, the grinder has a 30-station tool changer that can be expanded to 60 stations and loaded with tools such as drills and milling cutters in addition to grinding wheels. A two-axis CNC control is standard with a three-axis system optional, enabling efficient processing of complicated contours. With high working speeds and fast tool changes, the MFP 100 is well suited for energy-industry applications including the processing of gas turbine and wind power components.

MFP 100 Processes Large Parts Complete

F E AT U R E S A N D B E N E F I T S O F T H E M Ä G E R L E M F P 1 0 0 :

• X longitudinal stroke 39", Y vertical stroke 35", Z transverse stroke 29.5"

• Wear-free hydrostatic wrap-around guideways for heavy loads and dampen vibration

• HSK tool mounting permits quick tool changes with absolute repeatability

• Water-cooled direct-drive spindle motors enable continuous operation

• Automatic nozzle changer with NC control optimizes coolant delivery

• Overhead and table dressing devices support continuous and in-process dressing

• Dual gripper changes wheel and dressing rolls simultaneously, minimizing idle time

• Tool changing capability for maximum 12" diameter grinding wheels and maximum 6" diameter diamond dressing rolls

• NC table loads from the front or overhead, manually or via robot

• 15' width x 13' depth

Multi-face machining Spindle power up to 50 kW

Two-axis CNC control 30- to 60-station tool changer


ately I have been pondering about North America manufacturing’s yesterday, today and tomorrow. It seems to me like it was only yesterday when North America manufacturing was in the depths of despair. Back then, producing durable goods in North America,

particularly in the United States, seemed to be rapidly succumbing to a newly evolving business philosophy referred to as “offshoring.” I distinctly remember reading not so long ago about facilities being shuttered from coast to coast with many jobs lost to lower labor cost countries. Of course, the so called Great Recession did not help matters when it disastrously engulfed the North America economy only slightly less than six years ago.

Yes, from my perspective it was only yesterday when doom and gloom dominated the national news whenever United States manufacturing was the topic of conversation. And yet during that same time period, many North America durable goods producers, from large to small, were saying to the media naysayers “don’t be so fast to pronounce North America manufacturing DOA.” UNITED GRINDING North America, possessing the same positive attitude and outlook for the future, implemented plans to successfully endure the severe downturn and simultaneously made significant investments to prepare for an economic rebound. One that would eventually come sooner and much faster than anyone originally anticipated.

Reflecting on today, I find it truly amazing how fast North America manufacturing has changed and adapted especially during the last five years. I think what influenced this the most was management business philosophy changes, geopolitically and financially driven business decisions, and a stark realization that low-labor-cost-focused offshoring is fraught with dynamic disadvantages and consequences more than offsetting expected savings. North America enterprises that never gave up in the face of economic upheaval and took actions to modernize their production capabilities during a time of extreme uncertainty are finding that today is a great time to be producing durable goods for national consumption and to export.

L A S T T H O U G H T

By Rodger Pinney,

Vice Chairman, Board of Directors,

United Grinding North America, Inc.

MÄGERLE MGC ST horizontal-spindle surface and profile grinding machines provide productive metal removal rates and maximum efficiency in creep-feed grinding as well as profile and flat grinding operations for energy-industry components. With 180˚ swiveling tables, the machines permit loading and unloading of workpieces while grinding operations continue undisturbed, thus minimizing downtime associated with workpiece changes. Adding an automatic loading and unloading system to the machines speeds output in both small- and large-batch situations. The MGC ST is one example of the MÄGERLE MGC series of surface and profile grinding machines that also includes MGC FT (stationary table), MGC RH (rotary table), MGC RV (rotary table and vertical spindle) and MGC-optional (extended configurations for individual solutions) machines.

MGC ST Provides Productive Grinding and Workhandling Efficiency

F E AT U R E S A N D B E N E F I T S O F

M Ä G E R L E M G C S T M A C H I N E S :

• Available in five sizes with X-axis longitudinal strokes from 51" to 130"

• Y-axis vertical strokes from 18" to 35"

• Z-axis transverse strokes from 14" to 29.5"

• Depending on machine size, grinding wheel spindle drive power 25 kW to 115 kW

• Grinding wheel peripheral speed 115 ft/s, up to 207 ft/s with options

• Depending on machine size, grinding wheel diameter from 16" to 24", width from 6" to 12"

• Swiveling table with two clamping surfaces (l x w, depending on machine size) from 30" x 13" to 45" x 24"

I N T H E Z O N E


I am particularly pleased to see industry increasingly embrace “nearshoring” and “reshoring” manufacturing to North America. Why is this happening? In my opinion, logistics are simpler, United States and Mexico unit costs of labor are increasingly affordable, intellectual property is safer, product quality is better, delivery times are more reliable, and scrap and rework operating expenses are less. Plus, it’s important to note that the nearshoring and reshoring of durable goods production to North America is coming not only from Asia but also from many other parts of the world. Further, I am aware that foreign investment in United States manufacturing has been at unprecedented levels the past several years and is expected to remain elevated for the foreseeable future. Wonderful news for North America manufacturing indeed!

UNITED GRINDING North America advanced its manufacturing solutions, keenly focused on enhancing customer satisfaction, and successfully maintained its highly competent staff during the Great Recession. Today the company is realizing unprecedented business growth because of these and other reasons. However, customer feedback is currently telling the UNITED GRINDING North America Team in no uncertain terms about the many new demands they are experiencing with their customers with no end in sight. Translation: what UNITED GRINDING North America is providing for its customers today has to evolve and expand even further to help its present and future customers consistently realize a bright and strong tomorrow.

And what do I think about tomorrow as far as North America manufacturing is concerned? Do I think this is just another business cycle bubble about to burst or does it have enough legs to get us to at least the beginning of the next decade? Of course, no one really knows for sure but I am definitely leaning toward a strong belief that the future of producing durable goods in North America looks quite good for the next three to five years. I strongly feel that investments associated with the aerospace, automotive, energy and medical industries in particular will grow substantially during this timeframe. Leading this charge is the evolution and utilization of new materials, needing to get products to the market faster, increased fuel efficiency, technological advances, higher product reliability and quality requirements, and the never-ending drive to reduce manufacturing costs through automation and plant modernization. Conversely, a major issue for North America manufacturers will be the development and ongoing training of a highly productive and efficient workforce that must possess many new skills and capabilities. Without doubt, meeting the ever-changing demands of tomorrow is not going to be easy for North American durable goods producers, but from what I saw them successfully overcome only yesterday, their near to middle term business challenges don’t look all that daunting to me.

My last thought…I know for sure that today the UNITED GRINDING North America Team is fully ready to successfully meet whatever challenges and opportunities they encounter tomorrow.

L A S T T H O U G H T continued

I strongly feel that investments associated with the aerospace, automotive, energy and medical industries in particular will grow substantially during this timeframe.

Leading this charge is the evolution and utilization of new materials, needing to get products to the market faster, increased fuel efficiency, technological advances, higher

product reliability and quality requirements, and the never-ending drive to reduce manufacturing costs through

automation and plant modernization.

CHAD CRISOSTOMO Technical Product Manager FARO TechnologiesYEARS ATTENDING IMTS6GOAL FOR IMTS 2014I’m looking to seek out new, innovative products and processes in manufacturing that challenge the status quo. While attending, I hope to network with other like-minded individuals. It’s not often that you get the opportunity to be in the same place with so many industry colleagues.

Documents

the grind - Energy Issue