When the word "multitasking" is applied to machine tools, the term generally refers to a machine that is capable of both turning and milling. That definition is fine as far as it goes. However, turning and milling are two fairly similar operations. They both use a cutting edge to make a chip, and they both occur at roughly the same stage in a production process. If the argument for multitasking has to do with reducing both the delay and the potential for error that come from transporting parts between different machines, then that argument gains strength if the multitasking machine can combine operations that are even further removed from one another in the production process.
For example, what about combining milling and grinding?
Grinding, of course, is typically thought of as a finishing operation. Milling is more about removing a stock envelope. In many plants, these two operations are performed in different locations. In an even larger number of plants, they are performed by different employees who have different skills. Combining the two operations would not seem to be an obvious choice.
This latter feature relies on proven technology. Specifically, it relies on a toolchange arm like that of a machining center, along with toolholders (or wheelholders in this case) that use the HSK interface of a machining center's toolholders. Taken together, this machine's tool changing, spindle power and rigidity produce the equivalent of a highly capable machining center. Precise heavy milling can be performed on this machine, and milling and drilling tools can be stored in the tool magazine alongside the grinding wheels.
Minimal Milling
Chris Stine is a vice president of United Grinding Technologies. He says performing chip-making operations such as milling and drilling on a grinding machine is best suited to certain types of parts. It also requires a particular mindset about production.
For a part to benefit from milling or drilling on a grinder, the cycle should consist of mostly grinding. The MFP-TC machine cited above remains a grinder first and foremost, offering precision beyond what might be associated with even a higher-end machining center, he says. As a result, the machine can't compete economically against a machining center if traditional metalcutting makes up most of the work.
However, many ground parts do feature a small but critical amount of this metalcutting. Even on a grinding machine equipped with multiple wheels and capable of high metal removal rates, there are plenty of features that simply cannot be ground. Holes, pockets and slots that don't run completely through the workpiece are examples. When the part has one or more features such as these, performing these cuts on the grinder can save considerable cost by eliminating the need to set up on multiple machines. This is particularly true for parts such as airfoils, in which the location of machined features may be defined with respect to ground surfaces that have complex geometries.
Another argument for consolidating operations relates to the part's size. Large parts magnify the savings in floor space that might result from combining grinding and machining center operations into one machine. Labor savings might also be more significant. The bigger the part, the better it is to set it up in just one place.
For particularly large parts, Mr. Stine says that the range of potential operations expands to include turning. A rotary table that can turn at 70 rpm can deliver 1,500 sfm of cutting speed to a turning tool that cuts at a diameter of 7 feet. This is exactly the solution that GE Gas Turbines (Greenville, South Carolina) adopted for machining large turbine wheels. Parts that used to be machined on a grinder, a vertical lathe and a boring mill now receive all of this machining on one Magerle machine tool. The change saves about 6 hours of setup time and 2 days of queue time, according to engineers at the plant. Overall, there has been a 30 percent cycle time reduction.
Process Perspective
These savings overcome the fact that the multitasking grinder is unlikely to be cost-efficient when it comes to milling or turning as isolated operations. Accepting this seeming inefficiency within the machining cycle, for the sake of a more efficient process overall, is part of the recipe for implementing these machines effectively.
Saturday, February 24, 2007
Hydraulic machine makes straight and angle cuts
The Blockshear is an easy, dust-free, and convenient onsite method for making straight and angle cuts. It produces split-face cuts on brick pavers and precast concrete blocks from 2.5-8-in. thick. The cordless, foot-operated hydraulic tool has a table that lowers and rises under pressure, much like air-assisted units. It cuts pavers, cast stone, and masonry retaining walls.
Release delivers new high speed tool paths—Mastercam/CNC, Inc., booth 427
Mastercam X's latest maintenance release, MR1, includes various new capabilities, such as added high speed machining tool paths, holder definition, the release of Mastercam X and more.
Seven high speed surface machining (HST) tool paths--two roughing and five finishing paths--have been incorporated into the release, including an interface for toolpath creation. These added types are tailored to high speed machining while offering smooth cutting motion and smooth entry/exits, says Mastercam/CNC Software. The high speed tool paths include core roughing, area clearance, waterline, scallop, horizontal area, raster and an enhanced pencil tool path.
Using the release, operators can define a holder (or select one from a library) and gouge-check the holder during toolpath generation. The holder definition can be used to detect possible toolpath gouges.
This release is now available to all maintenance customers. SP2, a service pack release, is also available to those who do not participate in the maintenance program.
Seven high speed surface machining (HST) tool paths--two roughing and five finishing paths--have been incorporated into the release, including an interface for toolpath creation. These added types are tailored to high speed machining while offering smooth cutting motion and smooth entry/exits, says Mastercam/CNC Software. The high speed tool paths include core roughing, area clearance, waterline, scallop, horizontal area, raster and an enhanced pencil tool path.
Using the release, operators can define a holder (or select one from a library) and gouge-check the holder during toolpath generation. The holder definition can be used to detect possible toolpath gouges.
This release is now available to all maintenance customers. SP2, a service pack release, is also available to those who do not participate in the maintenance program.
Shop Floor Inspection Machine measures compressor blades
Non-contact, automated Lightscan measures compressor blade airfoils for comparison with CAD data (with 160,000-point 3D point cloud) to obtain immediate go/no go sentencing. In addition to measuring sensor and associated application software, blade gauging inspection solution uses white light technology and has typ inspection cycle of 20 sec. With accuracy exceeding 0.0005 in., machine can be programmed to inspect new parts in as little as 4 hr.
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The new Lightscan non-contact blade gauging inspection from GE Inspection Technologies is a complete, automated, shopfloor solution for quickly and accurately measuring compressor blade airfoils for comparison with CAD data to obtain immediate go/no go sentencing. The new system offers significant cost-saving and time-saving advantages over conventional hard gage inspection and is the first system of its type to feature both measuring sensor and associated application software, providing a total turn-key inspection solution.
Using state-of-the-art white light technology, the operator-friendly, Lightscan has a typical inspection cycle of just 20 seconds, compared with the 60 to 90 seconds required by competitive equipment. It is accurate to greater than 0.0005", which is comparable with more cumbersome CMM equipment, and it can be programmed to inspect new parts in just four hours. Compare that to the 16-18 weeks required to manufacture of new hard gauges. As a result, Lightscan provides significant benefits in terms of production output and reduced tooling costs over hard gage inspection and provides significant improvements in manufacturing flexibility over mechanical and laser CMM systems and other white light systems.
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The new Lightscan non-contact blade gauging inspection from GE Inspection Technologies is a complete, automated, shopfloor solution for quickly and accurately measuring compressor blade airfoils for comparison with CAD data to obtain immediate go/no go sentencing. The new system offers significant cost-saving and time-saving advantages over conventional hard gage inspection and is the first system of its type to feature both measuring sensor and associated application software, providing a total turn-key inspection solution.
Using state-of-the-art white light technology, the operator-friendly, Lightscan has a typical inspection cycle of just 20 seconds, compared with the 60 to 90 seconds required by competitive equipment. It is accurate to greater than 0.0005", which is comparable with more cumbersome CMM equipment, and it can be programmed to inspect new parts in just four hours. Compare that to the 16-18 weeks required to manufacture of new hard gauges. As a result, Lightscan provides significant benefits in terms of production output and reduced tooling costs over hard gage inspection and provides significant improvements in manufacturing flexibility over mechanical and laser CMM systems and other white light systems.
The Hidden Benefits Of Machine Tools - Association For Manufacturing Technology report - Brief Article
The Association For Manufacturing Technology--AMT (McLean, Virginia) has released a new study detailing the substantial, unmeasured economic benefits of machine tools and advanced manufacturing techniques. The study concludes that traditional measurements of productivity do not include all the products and industries that have been positively affected by machine tool technology. AMT estimates that these unmeasured contributions have averaged nearly $200 billion per year during the past 5 years.
The organization recommends government policies that will extend the environment of rapid innovation and high R&D investments that has led to the nation's recent resurgence in productivity. Among other policy positions, AMT recommends keeping interest rates stable, encouraging additional investment through corporate tax reductions, accelerating capital expense write-offs and permanently extending the R&D tax credit.
The organization recommends government policies that will extend the environment of rapid innovation and high R&D investments that has led to the nation's recent resurgence in productivity. Among other policy positions, AMT recommends keeping interest rates stable, encouraging additional investment through corporate tax reductions, accelerating capital expense write-offs and permanently extending the R&D tax credit.
Tuesday, February 20, 2007
Toolholding for improved surface finishes—Rego-Fix Tool Corp., booth 3145
Rego-Fix Tool Corp. offers the Zero-Z, which is appropriate for multiple turning centers and small VMCs. The toolholder features a short projection, allowing for increased Z-axis stroke while accommodating greater workpiece size. The design involves a flush collet nut, whereby tool overhang is virtually eliminated.
Cartridge system provides the stability of an integral shank tool
The MTC Serrated Locking System (SLS) cartridge system from ManchesterTool Company consists of a toolholder and a cartridge, which simplifies the standard multicomponent design into one piece. Both the toolholder and the cartridge have serrations or interlocking ridges on the inner sides. These serrations create a tight fit between the cartridge and the toolholder, says the company. Once the toolholder and cartridge are locked together, the system provides stability that is said to be comparable to that of an integral shank tool.
The cartridge accommodates any of the MTC double-ended, double V design inserts. Each insert locks into position with one screw. These components perform cutoff, plunge-and-turn, plunge-and-contour and face grooving operations.
The cartridge accommodates any of the MTC double-ended, double V design inserts. Each insert locks into position with one screw. These components perform cutoff, plunge-and-turn, plunge-and-contour and face grooving operations.
Tool removes extraneous material—Brush Research Mfg., booth 5044
Brush Research Mfg. Co. has made several new additions to its line of miniature Flex-Hone products. Among the tooling offered is the FlexHone, which is applicable for bore sizes as small as 0.156" (4 mm). Comprised of abrasive globules that are laminated onto flexible nylon filaments, the tool is self-centering and aligns to the bore. It also compensates for wear. In addition to removing peaks from the surface, the tool removes cut, torn and folded metal that may linger after previous machining operations
Redesigned collet line—Somma Tool, booth 3153
Somma Tool Company has reintroduced the C series Flexi-Grip collets that were previously supplied by Sandvik and Balas. The company offers C3, C4, C6, C8 drill collets, along with STC4 tap collets. The C6 and C8 series have both been redesigned: however, the collets are interchangeable with the old design.
The company also offers chucks that are compatible with the collets.
The company also offers chucks that are compatible with the collets.
Cutting tool works with titanium alloy
Sandvik Coromant Co. offers Xcel as a solution for machining of titanium alloy and heat-resistant super alloy materials. According to the company, the tool provides design advantages not previously available with one tool when semi-rough turning into shoulders. In addition, the cutting tool is also said to offer the accessibility and programming of an 80-degree insert, along with reduced wear when compared to a square insert used at 45-degree entering angle.
Two insert sizes in three grades are available to suit depths of cut from 0.5 mm to 3 mm in intermediate stage machining. Machining into corners to produce complex shapes and the capability of machining in two directions are among the product's noteworthy capabilities
Two insert sizes in three grades are available to suit depths of cut from 0.5 mm to 3 mm in intermediate stage machining. Machining into corners to produce complex shapes and the capability of machining in two directions are among the product's noteworthy capabilities
New high speed tool paths—Mastercam, booth 5527
Mastercam X's latest maintenance release, MR 1, includes various new capabilities, such as added high speed machining tool paths, holder definition and more.
Seven high speed surface machining (HST) tool paths--two roughing and five finishing paths have been incorporated into the release, along with an interface for toolpath creation. These added tool paths are tailored to high speed machining while offering smooth cutting motion and smooth entry/exits, says CNC Software. The high speed tool paths include core roughing, area clearance, waterline, scallop, horizontal area, raster and enhanced pencil.
Seven high speed surface machining (HST) tool paths--two roughing and five finishing paths have been incorporated into the release, along with an interface for toolpath creation. These added tool paths are tailored to high speed machining while offering smooth cutting motion and smooth entry/exits, says CNC Software. The high speed tool paths include core roughing, area clearance, waterline, scallop, horizontal area, raster and enhanced pencil.
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