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March 2015 | AdvancedManufacturing.org 45
Andretti Corners Indy Racing with Innovative Tooling
Andretti Autosport, based in Indianapolis and led by
racing legend Michael Andretti, boasts four IndyCar
Series championships, two Indy Lights titles, one Pro Mazda
championship, one USF2000 championship and has won the
Read more, P46
HMC’s Precision Puts Clamps on Leaky Pipelines
P LIDCO-The Pipe Line Development Co. (Westlake, OH),
founded in 1949 by Joseph B. and Berneice K. Smith,
manufactures high-pressure pipeline repair and mainte-
nance fittings for onshore and offshore applications.
Read more, P48
Tooling Partnership Wins Races with Performance
Roush Yates Engines (RYE; Mooresville, NC) is a 10-year-
old company that was founded by Jack Roush, Robert
Yates, and Doug Yates to be the sole factory-supported
engine building facility for the Ford FR9.
Read more, P51
sSHOP SOLUTIONSProblem Solving on the ShoP Floor
Ryan Hunter-Reay took the checkered flag as the winner of the
98th Indianapolis 500 race. Four of five Andretti racers finished
in the top six of the race.
Roush Yates Engine D3 engine cover machined using Mitsubishi
Materials cutting tools.
Dan Shaw (left), CNC programmer, and Pete Haburt, sales manager,
inspect half of a 6" 3705wp PLIDCO Split+Sleeve that is being manufac-
tured on a Kitamura HMC for Tremco Pipeline Equipment Co. in Australia.
46 AdvancedManufacturing.org | March 2015
Indianapolis 500 three times—including its victory in 2014.
Staying on top and winning with this kind of consistency,
year in, year out, is a credit to the racers themselves, but
also to the engineers and machinists who are working
behind the scenes to produce the fastest, safest and best
automobiles possible. Getting the best performance out of
an Indy car requires vigilance in seeking the best applications
and best tools for the job, and it all has to be done with strict
adherence to the IndyCar Series rules and standards. This
is where the solid partnership that Andretti shares with BIG
Kaiser Precision Tooling (Hoffman Estates, IL) really shines.
The sandbox that Andretti and other IndyCar engineers
get to play in, in terms of innovation, is only so big. Event rules
carefully restrict many modifications, but they still allow techni-
cians substantial flexibility in critical areas, such as suspen-
sions. Kevin Harvey, lead machinist for Andretti, said that the
team has always had a shock and suspension program, but
it has ballooned in recent years. The Andretti shop recently
added DMG MORI DMU 3+2 five-axis machines that allow
for more machining flexibility than in the past. Machining for
suspension components and a few steering rack components
involves complex geometries that require getting deep into
solid forms to precisely machine at a deep reach.
Suspensions are a bit of a Wild West in the otherwise
strictly-governed IndyCar realm. They’re one of the few
elements Harvey and his team can change and manipulate
between races. These intricately machined suspension
components are extremely important because they allow
Andretti cars, and by extension, their drivers, to “get off the
corners” better than they ever have. The way in which the
tires are planted, which this component regulates, creates
the necessary traction, and allows drivers to go into the
corners and get out of them more quickly.
To get the best possible performance with the best
possible runout standards, even while reaching deep into
component features, Harvey turns to BIG Kaiser and its BIG
Daishowa Mega Micro collet chucks. A slim nut and taper
design prevents interference in applications with microdrills
and end mills. Mega Micro chuck’s notch-free nut design
prevents vibration and noise, while offering great balance
and concentricity. This smooth nut design not only eliminates
whistling noise and coolant splattering, but also increases the
strength of the nut itself.
“One of the areas in which the Mega Micro has really
come in handy is in parts where we’re doing three-dimen-
sional contouring on the inside of bores on the shocks, which
is very complicated machining. What BIG Kaiser tools have
allowed us to do is reach down inside this one particular
component, probably less than a 2" [51-mm] diameter bore,
and do complicated three-dimensional machining inside the
cylinder walls so we can rotate the part up,” Harvey said.
Harvey described this piece as machined from 10 different
angles, and despite being able to fit a couple of them within
the palm of your hand, they involve close to 100 steps in
programming. All told, it took about 25–30 tools to machine
this little part. Now, with BIG Kaiser tooling on a five-axis
machine, Harvey can complete the component in just two
setups. “We start where we have extra material on the back
side of the part and do the machining on all these different
angles by just holding onto the end of the block. Then, we
SHOP SOLUTIONSContinued from P45
Mega Micro collet chucks from BIG Kaiser Precision Tooling
allow Andretti Autosport machinists to reach deep inside the
bores of shocks to do 3D contour machining.
48 AdvancedManufacturing.org | March 2015
use a fixture that holds it on the second side, where we take
probably four more machining passes.”
Previously, Harvey and his team had to make their own tool
extensions to reach down inside these bores. The Mega Micro
series features a slim body, but with a tapered design for added
rigidity, and the new Mega 8S now offers the series a bigger
clamping diameter capacity to hold a larger shank tool. This
allows Harvey to rigidly hold the cutting tool, and still be able to
get down inside the bores without any extra, specialized tooling.
“We hadn’t found anything this long with this small of a di-
ameter. At least nothing that performs so well,” Harvey said.
“We’ve also been using the Mega Synchro Tapping Holders
from BIG Kaiser for a lot of our tapping operations, and we
use them from a 6-32 up to 3/8" [9.5-mm] diameters. We
don’t have much bigger fasteners than that in IndyCar. The
way the attachment is engineered, we have almost zero tap
breakage with these due to special damping mechanism in
the Synchro Holder,” said Harvey.
Andretti Autosport technicians are realizing a longer tool life
because the Synchro helps mitigate the initial shock of when
the tap hits the material, a critical moment. The toolholder’s
proprietary rubber-like bushing—the Synchro Adjuster—
dampens the tool when it starts cutting, stops, and then it
reverses. This is another critical point, so it replaces operations
that have, in the past, been straight, rigid tapping. “We’ve
seen an increase in tool life for sure,” Harvey said.
Cornering is critical in IndyCar. Tracks don’t consist of
the gradual, sweeping left turns of many other racing sports.
Instead, a track is punctuated by hairpin turns and switch-
backs—in both directions—between
220-mph (354-km/h) straights. To that
end, Andretti Autosport created an entire
suspension and damper department, and
it has really grown recently. If cornering
is the key to winning, the dampers take
either the blame or the praise for cornering
failure or success.
“Tooling in general from BIG Kaiser is far
and away above all the other tooling I’ve
used in the past,” Harvey said. “I now have
cutters that last so much longer. Because
of the runout control, everything is so
precise and the rigidity is great. My finishes
come off the machine like mirrors, and
that’s all due to the quality of the holders,
surpassing anything I’ve used.”
For more information from BIG Kaiser Precision Tooling
Inc., go to www.bigkaiser.com, or phone 847-228-7660.
Continued from P45
HMC’s Precision Puts Clamps on Leaky Pipelines
PLIDCO-The Pipe Line Development Co. (Westlake, OH),
founded in 1949 by Joseph B. and Berneice K. Smith,
manufactures high-pressure pipeline repair and maintenance
fittings for onshore and offshore applications for the global
gas, oil, water, chemical, steam, and slurry industries. Its
high-pressure clamps and fittings are used to quickly and
safely repair pipelines to avoid or minimize costly and danger-
ous shutdowns, saving risk, time, and money for customers
on land or subsea around the world. Kimberly Smith is the
third-generation president and general manager of the family-
owned company. “PLIDCO prides itself on the quality fittings
that leave our dock and make their way across the globe to
make hazardous piping safer,” said Smith.
“We are the first responders, the emergency room for the
global pipeline industry when they develop leakage in pipe-
lines on land, in refineries, or subsea that are carrying hydro-
carbons, natural gas, chemical products and oil,” said Pete
Haburt, PLIDCO sales manager. “Our products are code-engi-
neered and precision-manufactured from designs drawn from
the ASME section 8 codes, the API 6X codes, and B31 codes
for different industries,” said Haburt.
SHOP SOLUTIONS
Kimberly Smith, president and general manager, and operator Nick Panza with the
Kitamura HX630iTGA 630-mm HMC machining a 2" (51-mm) PLIDCO Split+Sleeve
fitting for the pipeline and repair industry.
March 2015 | AdvancedManufacturing.org 49
PLIDCO’s precision-machined components are designed
to withstand pressures up to 10,000 psi (69 MPa) and
temperatures that range from −250° to 1100° F in API pipe
sizes from 1 ½ through 48" (37–1219 mm). The PLIDCO
facility has ISO 9001:2008 and ISO
14001: 2004 certifications and oc-
cupies 56,000 ft2 (5202 m2) of office
and factory space. Manufacturing
processes include all of the standard
fabrication and machine tools plus
special equipment required to com-
pletely manufacture standard and
special fittings.
PLIDCO’s product categories
include leak enclosure fittings for
high-pressure lines, connector fittings
for pipeline repair, hot tapping and line
plugging fittings, and custom-designed
fittings. “The purpose of our ten or so
product lines is to provide an engi-
neered solution for the various types
of problems that can be encountered,”
said Haburt. “They require precision
machining and a substantial amount
of welding. We form plate and weld on
the side bars to form our basic shell
and make our sleeves out of varieties of
low-carbon steel.
To increase production and versatil-
ity of its machining of Split+Sleeves
from the smallest up to 30" (762-
mm) long PLIDCO acquired a twin-
pallet Kitamura HX630iTGA 630-mm
horizontal machining center, through
Tipton Machinery (Cleveland, OH). The
Kitamura HX630iTGA, which has been
in service a little over a year, features a
high-torque, four-step geared spindle
that can deliver torque up to 680 ft-lb
(921 N•m). The HX630iTGA features
box-way construction and twin
ballscrews for heavy-duty accurate
cutting of harder materials.
“Formerly, a lot of our products
were machined on older-style manual
machines that typically required that
we machine clamps and fittings on multiple machines,” said
Dan Shaw, CNC programmer. “With the Kitamura horizon-
tal, we can machine all operations completely on a single
machine, which improves throughput and accuracy. And
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50 AdvancedManufacturing.org | March 2015
having two pallets, we can set up one piece while another
one is still running so that we have continuous production.
In addition, the two-pallet system and rotary table enables
us to set up fixturing by part family and switch between
sizes within families quickly compared with the manual
machines,” said Shaw.
A definite benefit of having the advanced machining capa-
bility of the Kitamura is the new tooling available to PLIDCO
that can be used on the CNC machine. “The old-style blade
tooling that we used on the manual machines for holemak-
ing for studs required a lot of torque and was expensive. The
new CNC tooling for the Kitamura CNC is carbide or coated
inserts that are less costly, very repeatable without resetting
and requires a lot less torque and horsepower,” said Shaw.
For its largest workpieces, parts up to 118" (2997-mm) long,
60" (1524-mm) wide and weighing in at 15,000 lb (6804 kg),
PLIDCO uses a large vertical machining center. Programming
is done with Mastercam, which has postprocessors that can
be customized to each machine.
“With the Kitamura, it takes about 20% of the time to make
the same size hole that it took with the manual machines.
With its newer controller and tool probing capability to find the
workpiece, the Kitamura HMC has reduced machining time
significantly and increased production to 60%.” According to
Kimberly Smith, the Split+Sleeve is the fitting sold most often
to PLIDCO customers around the globe. “Saving time in the
manufacturing process shortens customer delivery times and
allows for emergency stock quantities to rise. That makes
everyone happy from the factory through the distributor and to
the end user,” said Smith.
PLIDCO founder, Joe Smith, had a saying, “One quick
look at any of our products reveals their quality. As I said
before, we do not care to be the biggest, we want to be the
best.” To that end, the recent purchase of the Kitamura and
the quality fittings it is producing is keeping the third genera-
tion of PLIDCO right on track.
For more information from Kitamura Machinery of USA Inc.,
go to www.kitamura-machinery.com, or phone 847-520-7755.
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SHOP SOLUTIONS
March 2015 | AdvancedManufacturing.org 51
Continued from P45
Tooling Partnership Wins Races with Performance
Roush Yates Engines (RYE; Moores-
ville, NC) is a 10-year-old company
that was founded by Jack Roush,
Robert Yates, and Doug Yates to be
the sole factory-supported engine
building facility for the Ford FR9. All of
the Ford FR9 engines that are used in
the NASCAR Sprint Cup, Nationwide
Series, and Camping World Truck Se-
ries are built by Roush Yates Engines.
Every Ford team on the track, includ-
ing Penske Racing, Roush Fenway
Racing, Wood Brothers, Front Row,
and Richard Petty Motorsports use
engines built by RYE.
“In addition to the Ford FR9 engine,
Roush Yates Engines produces engines
and components for the IMSA [Inter-
national Motor Sports Association] V6
Ford EcoBoost engine, which uses
70% factory parts, and the RY45
Platform, which is ideal for grass roots,”
said Michael Alvarez, director e-com-
merce and marketing. “We produce a
total of more than 800 engines a year
from all of our facilities.
As the Official Tooling Partner of
Roush Yates Engines, Mitsubishi
Materials USA Corp. (Fountain Valley,
CA) supplies tooling that is used in
more than 50 machines that are used
to manufacture engine components
throughout the Roush Yates Group’s
facilities in Mooresville, NC. In its
preferred position, Mitsubishi Materials
USA shares the commitment to R&D
that is advancing tooling technology
for producing components needed for Roush Yates Group’s
world-class racing performance.
“As far as machining requirements for our engine parts is
concerned, form, fit, and finish tolerances are just as tight as
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52 AdvancedManufacturing.org | March 2015
those for aerospace applications,” said Rodney
Tucker, manufacturing engineer, who has had ex-
perience in the aerospace manufacturing industry.
“Our tolerances are very tight. For example, true
positional tolerances that we have to meet on
compound angle holes through a plane on a cyl-
inder head are extremely tight. Just about every
part we manufacture goes through a CMM, and
just about every part has a first-article inspection
on it,” said Tucker.
Machining capabilities of the tooling that
Mitsubishi Materials has to meet include simul-
taneous five-axis machining, mill-turn machin-
ing, cellular machining on two Makino horizontal
machining centers with robot load/unload, several
four-axis Makino HMCs, and simultaneous ma-
chining on a nine-axis DMG Mori NT, as well as
other machining processes. “The Makino cell has
laser tool breakage detection and the reliability
SHOP SOLUTIONS
A selection of parts machined using Mitsubishi Materials tooling by
Roush Yates Engines for the Ford FR9 engine and the RY 45 platform.
March 2015 | AdvancedManufacturing.org 53
of the Mitsubishi Materials tools allows us to run lights-out
without worrying about tool breakage,” said Tucker. “The one
thing that is really nice with the reliability and repeatability
of Mitsubishi Materials’ tools—especially in the Makino cell
where we monitor tool life very careful-
ly—is that when we rate a tool for 2500
cycles, we know that we can count on
it delivering that level of performance.”
“We’re typically machining met-
als hardened to Rc 40 including 4140,
4340, titanium, and 6160 and 7075
aluminum, as well as proprietary met-
als. One of our big challenges involves
machining main caps that hold the
crank to the block, which is made of
some pretty tough materials and hold-
ing diametrical and locational toler-
ances that are really tight,” said Tucker.
The Mitsubishi Materials’ drills with
coolant-through really shine in drilling
deep holes in the main cap. The major-
ity of our machines have 1000 psi [6.89
MPa],” said Tucker.
“We’ve been using Mitsubishi Mate-
rials’ tools including face mills, end
mills, and drills long enough so that
we are able to judge their performance
by monitoring tool life and quality of
machined parts over a long period
of usage,” said Tucker. Typical tools
include Mitsubishi Materials’ ½" (12.7-
mm) end mills for roughing rocker
arms, 13.5-mm drills for cylinder head
machining, and boring bars to bore
IDs on shims.
“Like Mitsubishi Materials USA,
Roush Yates is a market leading com-
pany in their industry,” said Motoharu
Yamamoto, president and CEO. “As the
preferred cutting tool supplier for Roush
Yates Engines, we look forward to pro-
viding the best cutting tool materials,
products, and services to enhance their
reputation for power, performance, and
reliability. The partnership between our
two companies will lead to the develop-
ment of new tooling technologies, products, and processes
used in their manufacturing environment.”
For more information from Mitsubishi Materials USA
Corp., go to www.mmus.com, or phone 800-523-0800.
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