| DeKalb, IL, August 1,
2001 -- LMC Inc. has been awarded its second grant
from the Department of Energy to work in participation
with Stanford University. The first phase, which was completed
in March, is part of a two-year project working with the
Stanford Linear Accelerator Center (SLAC) in Stanford,
CA. SLAC will work with LMC on the development of specific
manufactured components for the Next Linear Collider.
LMC continues to research new methods for manufacturing
utilizing adiabatics and will now design and manufacture
the complete press system to automatically produce components
specifically for their project.
In June, 2000, LMC received approval for the Phase
II Grant in the amount of US$ 750,000 to be applied
to the manufacture of the LMC Forming Press System (SIP400B)
needed to produce Copper Accelerator Cells for the Next
Generation Electron Positron Linear Collider (NLC).
The Stanford Linear Accelerator Center (SLAC), in collaboration
with other laboratories in the United States, Germany,
Japan and Switzerland, are currently working on conceptual
design and costing for the NLC at their Stanford University
facility in Pala Alto, California. Using the Adiabatic
Forming Press, the technology will allow for the manufacture
of the near-net shape accelerator cells eliminating
all the machining, milling and turning operations previously
utilized. The part will require only the final diamond
machining to achieve desired results.
In March 2000, LMC had successfully completed Phase
I Grant of this project. Prototype parts based upon
an actual scaled cell were produced on existing forming
presses at LMC facilities. Parts met all near net shape
specifications and tolerances. Metallography and chemistry
analysis were performed with the results showing that
crystal structure was the same in the material before
and after forming, and that no oxidation or any other
contaminants were evident in the material during and
after the forming process regardless of the environment.
Al Burgin, Engineering Manager, spearheaded this effort
with the close cooperation and support of the SLAC and
Stanford University physicists.
Lennart Lindell, CEO of LMC, stated "I am pleased
to have the opportunity to work with the professional
staff at Stanford and being involved with the Stanford
Linear Accelerator Center. Our new advances in adiabatics
will save considerable costs in the project. Engineers
are finally capable of designing unique parts that can
be manufactured to net or near net shape quality at
Dennis Hastert, Speaker of the House, US House of Representatives,
has personally expressed his appreciation to Lennart
Lindell, Chairman and Gordon Goranson, President in
recognition of the grant and for this technological
advancement. SEE PHOTO
In the year 2000/2001, LMC will now engineer and manufacture
the Adiabatic Forming Press (SIP400B) designed to complete
on a production basis the full size Accelerator Cells.
It has been estimated that up to 2 years of manufacturing
time will be saved utilizing the LMC SIP400B press system
over conventional methods. The cost saving to the project
is estimated in the tens of millions of dollars.
LMC has successfully advanced the adiabatic process
from the cut off of precision blanks to stamping, near
net shape forming and powder compaction. Development
agreements cover research with several multinational
corporations to bring their production of components
into the adiabatic age. Forming adiabatically allows
for engineers to design thinner gage components using
higher tensile materials. In the automotive industry
it means that cars can be manufactured with less weight,
greater strength, and therefore less energy consumption.
Powder compaction allows for the same benefit. LMC has
been successful in the compaction of metals up to 99.8%
without sintering, an accomplishment not achieved elsewhere
in the world. Patents are pending on all of the new
developments within LMC.
LMC, the foremost authority on Adiabatic Technology
for metalworking manufacturing, is recognized worldwide
for its precision cut-off of blanks from bar stock,
coil and tubing. Work continues by LMC in the engineering
and design of press systems to enhance the future development
of adiabatic technology. These new applications for
manufacturing have been developed with patents pending
on both the new processes and tooling. This efficient
adiabatic technology in the metalworking industry will
increase part productivity, quality, and be very cost
LMC designs, engineers and manufactures a complete
line of Adiabatic Press Systems which meets all the
conditions for Adiabatic Softening in most metals to
include low and high carbon steels, stainless, brass,
copper, titanium, aluminum and more. Regardless of the
metal, the process works the same.
The LMC Adiabatic Press Systems dramatically increase
quality consistency, increase productivity and cycle
times, allow for the reduction of floor space and allow
for reduced maintenance. The Presses are designed to
maximize energy levels, production rates and flexibility.
This technology will eliminate the drawbacks of the
conventional methods in the production of metal blanks.
LMC also provides roll straighteners, coil handling,
chamfering units and pointers.
LMC has recently introduced their new SIP25D Adiabatic
Press and their new Oscillating Rotary Arbor Straightener
that provides 1/4" (6.4mm) diameter cut offs at cycle
rates exceeding 800 ppm. Cut-off or fracture times are
less than a millisecond. This new press system that
can cut precision blanks from rounds, shapes or tubing
stock supplied from coil or bar. A turnkey press system
can include their Rotary Arbor Straightener, Power Infeed
and Payoff Uncoiler. The new Straightener provides straighteness
of .005" TIR per foot and the entire system will provide
length variations of less than +/- .001" which will
be maintained regardless of overall length of the part.
Specific mass volumes are maintained. Manufacturers
have been able to eliminate post-production inspection.
CPK results can be expected to significantly improve.
The process also allows for the elimination of secondary
machining such as end grinding and deburring.
LMC standard presses cut diameters from .060" to 1.00"
(1.5mm to 26mm) and stock up to 4" (100mm) has been
cut on specially designed presses. There is theoretically
no limit to the size of metal bar or tubing that can
be cut. Cycle times of 3600 parts per minute can be
achieved on LMC's SIP15 Adiabatic Press designed to
cut diameter stock up to 1/8" (3.2mm).
The APM Process Center, a division of LMC, with their
facility in the Midwest provides a Cut Off Service where
LMC will use their production facilities and provide
manufacturers with blanks of any shape from standard
bar stock, coil, extrusions, tubing, etc. to their specifications.
The Company has been providing the LMC Adiabatic Technology
to manufacturers throughout the world since 1980 from
its manufacturing facilities in DeKalb, IL and Cortland,
IL, both approximately 80 miles west of Chicago.