U.S. Manufacturing Is Rebounding and Calling for Machine Tool Productivity Enhancements

There’s no denying that the manufacturing sector in the United States is seeing a resurgence. While we’ve long trailed behind other countries in terms of innovation and technological improvements to machine tools, the growing demand for domestic production is finally pushing the industry to catch up. Not to mention the $2.1 trillion of federal funding that has been put toward domestic manufacturing initiatives through legislation including the Infrastructure Investment and Jobs Act (IIJA), Inflation Reduction Act (IRA), and CHIPS and Science Act.

This “manufacturing renaissance,” as it’s been called, is driven in part by the need to build up the supply chains of critical and emerging industries domestically. For example, the lead time for semiconductors was 3-4 months before the pandemic, but between 2021 and 2022, it increased to a year or more. As key industries like artificial intelligence (AI), energy, semiconductors, metal-making and paper and pulp are all projected to grow in the coming years, bolstering domestic manufacturing and supply chains is crucial and calls for much needed upgrades to existing infrastructure and machinery.

The Need for Innovative Machinery

With increased demand comes urgency, and manufacturers will need to maintain pace with the needs of the market. To do so, machinery needs to be able to operate at higher speeds with improved precision and accuracy, as well as higher energy efficiency and productivity. With over half of U.S. manufacturing infrastructure being more than 30 years old, there’s an even greater need for machine tool productivity enhancements.

As technological advancements like AI and the Internet of Things are helping computer numerical control (CNC) machines become more adaptive and efficient, innovations in the machinery parts themselves are needed to ensure the equipment can work at the higher speed and quality standards demanded by the manufacturing renaissance. Specifically, the design and performance characteristics of the components that move machines—bearings—must innovate to meet these needs.

For centuries, bearings have enabled the growth of industries and enhanced the overall quality of human life in a wide range of applications. Over the years, bearings have evolved to meet the changing needs of challenging industries. One innovation is the development of super-precision bearings, which paved the way for better precision, increased speed, reliability and improved productivity of machines.

With today’s growing demand, manufacturers expect more than just high precision. Machines will also need to function much more efficiently. That requires higher operating speeds. Component manufacturers are beginning to push the boundaries of machinery, introducing innovative, high-speed parts that improve quality and efficiency and build upon the accuracy of super-precision parts.

Pushing the Boundaries of Machine Tools with Ultra-Fast Bearings

Ultra-fast, super-precision angular contact ball bearings are the next phase of innovative parts, designed to handle extremely high rotational speeds while maintaining precision and accuracy. This is achieved through advancements such as steel heat treatment, increased raceway surface hardness, optimized internal bearing geometry, specially designed cages and ceramic rolling elements.

These innovative bearings have about 20% higher rotational speed capabilities than non-ultra-fast, super-precision bearings and can be optimized for the application, production, maintenance and lubrication to help manufacturers reach their desired productivity.

Together with high-speed grinding spindles—which can operate at extremely high rotational speeds of over 20,000 revolutions per minute—ultra-fast, super-precision bearings improve the surface finish and accuracy of cuts, resulting in a higher-quality finished part. At the same time, these parts help reduce frictional torque in the machine, improving energy efficiency as well as the thermal stability of the machine tools. Because of this, lubrication needs for the machine might be reduced and, in some cases, the need for dedicated cooling systems can be eliminated.

When separate cooling systems are no longer needed, machines can switch from oil or oil-air lubrication to grease lubrication, a simpler method that reduces maintenance costs for operators. Grease-lubricated bearings can help boost sustainability and reduce operating costs by eliminating energy consumption for coolant circulation. They also reduce noise levels, creating a quieter and safer work environment.

With all of these benefits, ultra-fast, super-precision bearings are emerging as a top solution for manufacturers looking to increase productivity while meeting today’s industry standards for sustainability and quality.

Making the Shift to High-speed Machine Tools

As the manufacturing sector grows, machinery needs to improve and innovate to deliver high-quality output at faster rates. Ultra-fast, super precision ball bearings and high-speed grinding spindles are often compatible with existing machinery, making upgrading seamless. Investing in these upgrades today will pay off in the long run, and not just in terms of boosted production. The reduced friction and heat generation in ultra-fast bearing applications results in improved bearing and machine performance, making them even longer lasting.

Stepping into the future of machinery and productivity is within reach for manufacturers. For those looking to make the shift to high-speed machine tool applications, working closely with an innovative bearing supplier will be crucial to ensure that this new technology can be integrated with current systems, installed properly and set up to achieve productivity goals.

The right supplier will help manufacturers navigate this technical competency journey and continue to support them through routine condition monitoring to ensure all parts are working properly and performance is optimized as the machinery ages. As manufacturing takes center stage once again, machinery needs to as well. Machine tool productivity enhancements will be crucial for manufacturers to meet demand with high-quality products.