Do you get the point?
Keeping tools and cutters sharp is one of those inescapable overhead costs all manufacturers have to accept.
Like most other decisions in industry, deciding how and where to sharpen tools is a product-specific choice. It depends on overall cost, not just the rework fee.
Do-it-yourself sharpening is normally done by companies that can afford to have staff dedicated to this work or that need very specialized work.
But, overall, the trend seems to be greater use of outside sharpening specialists as manufacturers reduce labor costs. These services are frequently offered by tool manufacturers and by a large number of "regrind houses."
One company that has benefited from the trend to custom tooling is Acu-Grind Tool Works (Bradenton, FL). This operation specializes in both tool rework and the manufacture of specialized tools. Its president, Tony Antony, reports particular growth in the aerospace industry where tapered tools and tools for thin-wall cutting of aluminum are in demand.
In addition to reworking tools to custom specs the company also offers a design service to improve tool performance and life. "While this adds to up front cost, those who look at total cost per hole or cost per part will find we offer a cost advantage," according to Antony.
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According to Ed Sinkora, Walter Grinders (Fredericksburg, VA), their machines are optimized for tool grinding with a design that combines complete geometric freedom with high rigidity. "For example, with our machines, you are always grinding near the center of the work envelope. Overhang is minimal so vibration is minimized. These are patented features.
Walter's latest machine is called the Helitronic Vision, a 3D gantry design that has linear motors driving the linear axes and frameless torque motors for the rotating axes.
"We also beefed up the base, which is a 14,000-lb [6350-kg] mineral casting, to accommodate the extreme acceleration of the linear motors," he notes. (The machine weighs 20,000 lb [9071 kg].)
"Measuring the finished tool is an important issue," Sinkora says. "We use two systems. For in-process compensation, we use a probe system built into the machine that measures and adjusts diameter, flute depth, rake angle, helix angle, and back taper.
"But you can't certify a tool on the same machine on which it was made or reworked. It has to be an independent, off-line unit. We offer a machine that can measure down to ±0.7µm, proven with a NIST-certified gage.
As to market trends, Sinkora says, "The hottest new tools are those with variable helixes within the flute or helixes that vary from flute-to-flute on the same tool. Handling this work requires special programming."
Walter offers Tool Studio software to meet this need and other development challenges. It allows the user to create a grinding program while modeling the tool in 3D-the two functions are completely integrated. When you change the model, you change the program. There is no need to rewrite codes.
"Our software also contains a number of proprietary programs," Sinkora says. "We have a number of partnerships with major tool developers.
"The overall goal is achieving good surface-finish and accuracy at high speed. For example, we are able to grind and measure a K land.
Anca (Farmington Hills, MI) is a grinding machine builder specializing in tool sharpening. According to VP, Russell Riddleford, "Our company serves three markets: tool manufacturers, resharpening houses, and individual companies that have their own sharpening operations.
"Both the resharpening and individual companies are expanding, particularly those operations that can't afford a long turnaround time. You can't wait two weeks for a tool with a million-dollar machine sitting idle."
Riddleford says much of Anca's development work is aimed at improving software. "We have the dual goals of making it simpler, and handling the more complex geometries that tool designers continue to generate.
"We provide the customer 'lightsout' capability. You load the tools, set the programs, and that's it. The user need only program the tool's major parameters such as tool type [mill, drill], and key dimensions. On the other hand, these machines can be programmed for one-off capability.
"A unique feature of our machine is automated dressing. The user simply sets the frequency [every five tools, for example] and the dresser does the rest.
Measuring the reworked tool is an important aspect of the process. One example of the equipment used for this task is the Genius 3 from Zoller Inc. (Ann Arbor, MI). An automatic system that measures and inspects tools using incident and transmitted light, it magnifies the tool up to 200×. There is a measuring program for all critical parameters including radius contour, and tool contour and concentricity. It measures tools up to 600-mm long and 200 mm in diameter with repeatability of ±2µm and accuracy of 1µm.
Friday, April 06, 2007
CNC analysis aids machine design
Moore Tool (Bridgeport, Connecticut) currently designs, engineers and builds machines in conjunction with its sister company, Producto, in a 200,000-square-foot facility with approximately 200 employees. When the company set out to build a five-axis, high speed machining center for use in the production of critical components, it faced numerous challenges. The machine was intended to serve critical needs of the turbo machinery, mold and die, scroll compressor and medical markets. To help meet the needs of these applications, a control supplier analyzed the machine's control system in order to optimize the performance of this particular design.
The machine needed to possess capabilities such as high speed (30,000 rpm to 40,000 rpm) cutting capability when milling materials ranging from aluminum to hardened Steel and titanium; dynamic response; good stability and vibration dampening; automation adaptability; a user-friendly Windows working environment; onboard cooling; substantial onboard memory in a CNC without external devices for downloading complex programs; and, above all, high precision.
Moore Tool embodied a "from the ground up" approach to develop its Five-Sided Precision (FSP) line of machining centers. Speed and accuracy were considered when evaluating the needs of working with various materials, as were the differing requirements of production and part accuracy. The requirements of machining aluminum and titanium with high production rates can differ when compared to the intricate contours and features of mold components produced directly in hardened steel. Adding the requirements for efficient graphite machining also produces significant challenges.
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The company says the need for a combination of high precision and high material removal rates was evident. The complex contour surface profiling on leading and trailing edges of blades, and especially blisks and IBRs, made a high speed processor essential to maintain acceptable feed rates. The machine configuration, particularly as it relates to the position and configuration of the rotary tables and spindle, would also play an integral role in meeting the needs of Moore Tool's customers.
The machine's CNC is an 840D from Siemens (Elk Grove Village, Illinois). To maximize machine performance, Siemens performed a detailed dynamic analysis of the machine, control and servodrive system. This service is called "Mechatronics." Data gathered during the Mechatronics process are used to optimize the complete machine concept.
In complex blade contour and finishing operations, the CNC provides an aerospace-specific software feature, CompCAD, by which the control's compressor function smoothes point-to-point programming. The real benefit of the control is realized when processing the part using Non-Rational Uniform B-Splines (NURBS), with which the machine can reach an advanced level of smooth contouring and chatter elimination. This is achieved by using splines in an axis-specific tolerance window. According to the manufacturer, contour violations are thus avoided; the efficiency of acceleration/deceleration curves is increased; and slowdowns/speed-ups at block transitions are virtually eliminated.
According to Moore Tool's engineers, in programming, the open architecture of the CNC, along with its high speed, user-defined macros and block search capabilities, have made it an "ideal choice" for the FSP300X. They go on to say that the ability of the CNC to handle large programs, which are typical for intricate mold and die applications, without "drip feed" is also noteworthy.
Optional features that are available with the machine include high-frequency spindle options as high as 80,000 rpm; a range of robotic part loaders, all of which are designed and built by Moore Tool, with the control parameters incorporated into the host CNC; a graphite machining package; a laser tool-setter with measurement and compensation standards; and various customized configurations. The machine can be enhanced with Siemens' Simodrive 611D drive packages.
The machine needed to possess capabilities such as high speed (30,000 rpm to 40,000 rpm) cutting capability when milling materials ranging from aluminum to hardened Steel and titanium; dynamic response; good stability and vibration dampening; automation adaptability; a user-friendly Windows working environment; onboard cooling; substantial onboard memory in a CNC without external devices for downloading complex programs; and, above all, high precision.
Moore Tool embodied a "from the ground up" approach to develop its Five-Sided Precision (FSP) line of machining centers. Speed and accuracy were considered when evaluating the needs of working with various materials, as were the differing requirements of production and part accuracy. The requirements of machining aluminum and titanium with high production rates can differ when compared to the intricate contours and features of mold components produced directly in hardened steel. Adding the requirements for efficient graphite machining also produces significant challenges.
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The company says the need for a combination of high precision and high material removal rates was evident. The complex contour surface profiling on leading and trailing edges of blades, and especially blisks and IBRs, made a high speed processor essential to maintain acceptable feed rates. The machine configuration, particularly as it relates to the position and configuration of the rotary tables and spindle, would also play an integral role in meeting the needs of Moore Tool's customers.
The machine's CNC is an 840D from Siemens (Elk Grove Village, Illinois). To maximize machine performance, Siemens performed a detailed dynamic analysis of the machine, control and servodrive system. This service is called "Mechatronics." Data gathered during the Mechatronics process are used to optimize the complete machine concept.
In complex blade contour and finishing operations, the CNC provides an aerospace-specific software feature, CompCAD, by which the control's compressor function smoothes point-to-point programming. The real benefit of the control is realized when processing the part using Non-Rational Uniform B-Splines (NURBS), with which the machine can reach an advanced level of smooth contouring and chatter elimination. This is achieved by using splines in an axis-specific tolerance window. According to the manufacturer, contour violations are thus avoided; the efficiency of acceleration/deceleration curves is increased; and slowdowns/speed-ups at block transitions are virtually eliminated.
According to Moore Tool's engineers, in programming, the open architecture of the CNC, along with its high speed, user-defined macros and block search capabilities, have made it an "ideal choice" for the FSP300X. They go on to say that the ability of the CNC to handle large programs, which are typical for intricate mold and die applications, without "drip feed" is also noteworthy.
Optional features that are available with the machine include high-frequency spindle options as high as 80,000 rpm; a range of robotic part loaders, all of which are designed and built by Moore Tool, with the control parameters incorporated into the host CNC; a graphite machining package; a laser tool-setter with measurement and compensation standards; and various customized configurations. The machine can be enhanced with Siemens' Simodrive 611D drive packages.
Dual-spindle gang tool lathe
New from Miyano, the BX-26S gang tool lathe with two spindles offers complete part machining of complex bar work (1" diameter and under) in a single setup. Two gang slides and a 3D linear turret are said to further contribute to the lathe's precision and faster cycle times.
The lathe's linear turret and traverse-type identical left and right spindles, both with 5 hp, ensure stable cutting from end to end and make the lathe especially good for long shaft work, the company says. High speed turning at up to 8,000 rpm maximum is possible by built-in spindle motors and high-rigidity linear guides. The built-in motors with the same collet capacity also allow faster cycle times because of overlapping operations. The elimination of a guide bushing speeds up operation time with less maintenance.
The lathe also offers revolving tool (eight tools max at 4,000 rpm max); L-spindle brake; cut-off confirmation (by spindle torque); parts catcher and parts conveyor; high pressure coolant (160 psi); right spindle inner conveyor; high pressure coolant (160 psi); fight spindle inner coolant and all axis rapid traverse (944 ipm); and an optional hinge-type chip conveyor (right side discharge).
The lathe's linear turret and traverse-type identical left and right spindles, both with 5 hp, ensure stable cutting from end to end and make the lathe especially good for long shaft work, the company says. High speed turning at up to 8,000 rpm maximum is possible by built-in spindle motors and high-rigidity linear guides. The built-in motors with the same collet capacity also allow faster cycle times because of overlapping operations. The elimination of a guide bushing speeds up operation time with less maintenance.
The lathe also offers revolving tool (eight tools max at 4,000 rpm max); L-spindle brake; cut-off confirmation (by spindle torque); parts catcher and parts conveyor; high pressure coolant (160 psi); right spindle inner conveyor; high pressure coolant (160 psi); fight spindle inner coolant and all axis rapid traverse (944 ipm); and an optional hinge-type chip conveyor (right side discharge).
Tool Calibrator helps align/verify CNC punch press turret
Designed to verify and restore angular alignment of turret press punching stations, Pilot(TM) Tool Calibration System consists of matched set of upper and lower interlocking components loaded into machine's turret upper and lower chambers. It operates in Verification and Alignment modes and features tri-color indicator lights to warn when system is not aligned, aligned angularly and concentrically within 0.012 in., or aligned angularly and concentrically within 0.0003 in.
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Call 1-800-328-4492 For FREE Brochure
Anoka, Minnesota: Mate Precision Tooling leads the punching industry with another "first" - the Mate Pilot(TM) Tool Calibration System. Designed to verify and restore the angular alignment of punching stations of a turret press, this system is highly accurate and easy to use.
The Pilot Tool Calibration System provides punch press users with an effective and reliable means for maintaining top punch press performance while safeguarding tooling and eliminating scrapped parts because of turret alignment problems.
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System Ensures Precision Concentric And Angular Tool Component Alignment
Consisting of a matched set of upper and lower interlocking components, which are loaded into the machine's turret upper and lower chambers, the system operates in two modes:
Verification mode - Confirms the precise concentric and angular alignment of the punch press turret to maintain high quality piece part production and maximum tool life.
Alignment mode - Restores the concentric and angular alignment of each station with the same precision as the initial machine installation.
System Is Easy And Fast To Use
Simply install the two halves of the calibration instrument into the press turret station to be aligned. Then rotate the turret to position the station to be aligned under the machine's ram. Tighten the integral adjustment handle which draws the two halves of the calibration instrument together.
As this engagement occurs, the interlocking design of the interface causes the loosened die holder assembly to draw precisely together into concentric and angular alignment relative to the upper bore of the turret.
During this process, tri-color indicator lights on the top of the instrument signal alignment. When the indicator shows: Red - system is not yet aligned; Yellow - system is aligned angularly and concentrically within 0.012 inch / 0.030 mm; Green - system is aligned angularly and concentrically within 0.0003 inch / 0.008 mm (recommended when punching materials 0.078 inch / 2.00 mm thickness or less).
High Precision Components Ensure Accuracy, Long Life
Like Mate's high precision, long-life tooling, the Mate Pilot Tool Calibration System is quality manufactured to provide years of alignment service thereby ensuring top punch press and tool performance. Each calibration instrument is machined from a single piece of the highest quality tool steel. Upper and lower halves of the instrument are separated near the end of the production process and just prior to the installation of hardware. This ensures that the two components are a precisely matched set with high accuracy, thereby eliminating any possibility of cumulative tolerances adversely affecting instrument accuracy.
Mate Pilot Tool Calibration Sets Available For Amada And Finn Power Presses
Mate Pilot Tool Calibration sets are available for Amada thick turret and Finn Power presses in: A Station 1/2 inch (12.70 mm), B Station 1-1/4 inch (31.80 mm), C Station 2 inch (50.80 mm), D Station 3-1/2 inch (88.90) and E Station 4-1/2 inch (12.70 mm). Accessory kits consisting of alignment and adjusting bars are required that work with any station size.
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Call 1-800-328-4492 For FREE Brochure
Anoka, Minnesota: Mate Precision Tooling leads the punching industry with another "first" - the Mate Pilot(TM) Tool Calibration System. Designed to verify and restore the angular alignment of punching stations of a turret press, this system is highly accurate and easy to use.
The Pilot Tool Calibration System provides punch press users with an effective and reliable means for maintaining top punch press performance while safeguarding tooling and eliminating scrapped parts because of turret alignment problems.
Advertisement
System Ensures Precision Concentric And Angular Tool Component Alignment
Consisting of a matched set of upper and lower interlocking components, which are loaded into the machine's turret upper and lower chambers, the system operates in two modes:
Verification mode - Confirms the precise concentric and angular alignment of the punch press turret to maintain high quality piece part production and maximum tool life.
Alignment mode - Restores the concentric and angular alignment of each station with the same precision as the initial machine installation.
System Is Easy And Fast To Use
Simply install the two halves of the calibration instrument into the press turret station to be aligned. Then rotate the turret to position the station to be aligned under the machine's ram. Tighten the integral adjustment handle which draws the two halves of the calibration instrument together.
As this engagement occurs, the interlocking design of the interface causes the loosened die holder assembly to draw precisely together into concentric and angular alignment relative to the upper bore of the turret.
During this process, tri-color indicator lights on the top of the instrument signal alignment. When the indicator shows: Red - system is not yet aligned; Yellow - system is aligned angularly and concentrically within 0.012 inch / 0.030 mm; Green - system is aligned angularly and concentrically within 0.0003 inch / 0.008 mm (recommended when punching materials 0.078 inch / 2.00 mm thickness or less).
High Precision Components Ensure Accuracy, Long Life
Like Mate's high precision, long-life tooling, the Mate Pilot Tool Calibration System is quality manufactured to provide years of alignment service thereby ensuring top punch press and tool performance. Each calibration instrument is machined from a single piece of the highest quality tool steel. Upper and lower halves of the instrument are separated near the end of the production process and just prior to the installation of hardware. This ensures that the two components are a precisely matched set with high accuracy, thereby eliminating any possibility of cumulative tolerances adversely affecting instrument accuracy.
Mate Pilot Tool Calibration Sets Available For Amada And Finn Power Presses
Mate Pilot Tool Calibration sets are available for Amada thick turret and Finn Power presses in: A Station 1/2 inch (12.70 mm), B Station 1-1/4 inch (31.80 mm), C Station 2 inch (50.80 mm), D Station 3-1/2 inch (88.90) and E Station 4-1/2 inch (12.70 mm). Accessory kits consisting of alignment and adjusting bars are required that work with any station size.
Laser Projector does not require mold and tool targets
Eliminating need for cooperative retro-reflective targets on molds and tools used in manufacturing and assembly, TLP uses laser projector to scan features of object. Data acquired from those features is used to align laser projector with tools. Suited for use in composites, marine, and aerospace industries, targetless system also eliminates need for metrology systems and operator time spent acquiring and evaluating targets.
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Eliminates Costly Mold and Tool Targets Currently Required in Manufacturing
Manchester NH - July 20, 2005 - Laser Projection Technologies, Inc., the leading innovator and manufacturer of laser projection systems for manufacturing and assembly, launches its targetless laser projector system. Laser Projection Technologies' (LPT) newest product, called TLP, eliminates the need for cooperative retro-reflective targets on molds and tools used in manufacturing. The TLP system uses a laser projector to scan features of an object and use the data acquired from those features to align the laser projector with the manufacturing tools. This saves manufacturers valuable manufacturing time by eliminating the cumbersome task of placing targets and installing expensive targeting systems on their tools and molds. These tooling targeting systems have been required by all laser projectors until now. LPT's targetless laser projectors offer significant cost reductions and gains in manufacturing flexibility to OEMs in complex manufacturing and assembly, including the advanced composites, marine and aerospace industries.
Currently, most manufacturers make use of traditional hard tooling solutions in their manufacturing processes. Rigid material templates made from aluminum, Mylar, or even plywood serve as a guide for the manufacturing assemblers of products such as aircraft fuselages and boat hulls, as well as positioning ribs, brackets and substructures within a fuselage or hull. These templates have to be manually moved into position from their storage locations and are often heavy or unwieldy due to their size and weight. Templates are very costly to make, store and maintain. Most importantly, they are subject to human error in positioning and suffer distortion from alterations to the template material itself.
Traditional laser positioning systems replace the manual templates by projecting the outline of parts under manufacture onto the manufacturing surface or tools, eliminating the hard tooling previously required. In typical laser positioning applications, technicians must place reflective targets on the tooling for the laser positioning system to "see" and coordinate its projected images.
Targetless laser projection eliminates the expense of the targets, the expensive metrology systems (such as a laser tracker, a coordinate measuring machine or other similar types of measurement systems), and the system operator time to acquire and evaluate the targets.
Pricing & Availability
LPT offers its targetless laser projection system at a list price of $250,000 and is shipping units now. For information on custom installation and multiple unit pricing contact LPT's sales office, (603) 421-0209, or visit the company's website www.lptcorp.com for the representative closest to your location.
About Laser Projection Technologies, Inc.
Founded in 2000 and privately held, LPT has the largest installed base of laser positioning systems in the world. The world's leading manufacturers recognize LPT's laser positioning systems as the most accurate, easy-to-use, and robust laser projection systems available in the world. LPT's customers are constantly seeking leaner production methods to speed up manufacturing and lower costs.
********************
Eliminates Costly Mold and Tool Targets Currently Required in Manufacturing
Manchester NH - July 20, 2005 - Laser Projection Technologies, Inc., the leading innovator and manufacturer of laser projection systems for manufacturing and assembly, launches its targetless laser projector system. Laser Projection Technologies' (LPT) newest product, called TLP, eliminates the need for cooperative retro-reflective targets on molds and tools used in manufacturing. The TLP system uses a laser projector to scan features of an object and use the data acquired from those features to align the laser projector with the manufacturing tools. This saves manufacturers valuable manufacturing time by eliminating the cumbersome task of placing targets and installing expensive targeting systems on their tools and molds. These tooling targeting systems have been required by all laser projectors until now. LPT's targetless laser projectors offer significant cost reductions and gains in manufacturing flexibility to OEMs in complex manufacturing and assembly, including the advanced composites, marine and aerospace industries.
Currently, most manufacturers make use of traditional hard tooling solutions in their manufacturing processes. Rigid material templates made from aluminum, Mylar, or even plywood serve as a guide for the manufacturing assemblers of products such as aircraft fuselages and boat hulls, as well as positioning ribs, brackets and substructures within a fuselage or hull. These templates have to be manually moved into position from their storage locations and are often heavy or unwieldy due to their size and weight. Templates are very costly to make, store and maintain. Most importantly, they are subject to human error in positioning and suffer distortion from alterations to the template material itself.
Traditional laser positioning systems replace the manual templates by projecting the outline of parts under manufacture onto the manufacturing surface or tools, eliminating the hard tooling previously required. In typical laser positioning applications, technicians must place reflective targets on the tooling for the laser positioning system to "see" and coordinate its projected images.
Targetless laser projection eliminates the expense of the targets, the expensive metrology systems (such as a laser tracker, a coordinate measuring machine or other similar types of measurement systems), and the system operator time to acquire and evaluate the targets.
Pricing & Availability
LPT offers its targetless laser projection system at a list price of $250,000 and is shipping units now. For information on custom installation and multiple unit pricing contact LPT's sales office, (603) 421-0209, or visit the company's website www.lptcorp.com for the representative closest to your location.
About Laser Projection Technologies, Inc.
Founded in 2000 and privately held, LPT has the largest installed base of laser positioning systems in the world. The world's leading manufacturers recognize LPT's laser positioning systems as the most accurate, easy-to-use, and robust laser projection systems available in the world. LPT's customers are constantly seeking leaner production methods to speed up manufacturing and lower costs.
Wednesday, April 04, 2007
Machining outside the shop: machine tools will continue to find their way into unexpected locations thanks not only to their shrinking sizes and price
Machine tools are becoming smaller and less expensive. CAD/CAM software and 3D scanning technologies are becoming easier to use. As these trends continue, so too will the trend of machining work being performed outside of the traditional machine shop by non-machinists.
Machine tools will be used in hospitals and dental laboratories. They will be used in jewelry makers' shops. They will be used in upper levels of downtown office buildings without disrupting daily business activities.
One of the reasons that machining technology is becoming attractive outside the realm of the metalworking industry is that it offers a way to reduce or eliminate handwork. These often-time-consuming processes are common to components made for medical, dental and jewelry-making applications to name just a few. Another reason for their growing popularity is the chance to eliminate any disconnects or delays resulting from the separation of designer and machine shop. This is accomplished by allowing the part designer to quickly create a prototype on a machine tool located in the CAD department. For some manufacturers, the capability to machine one's own prototypes offers added assurance that proprietary concepts will be kept under wraps. The main obstacles to installing machine tools in a space such as an office have been the equipment's size and weight. Most machine tools are too heavy for a typical freight elevator to handle and too bulky to fit through a standard 36-inch-wide doorway. Haas Automation (Oxnard, California) is addressing these needs with its Office CNC mills and lathes. Sized to fit comfortably in an office, these machines can be moved with a palletjack or equipment dolly. Alternately, casters can be installed on the machines for easy maneuverability. These machines operate on 240-volt single-phase power, which any facility should be able to accommodate without much trouble.
According to Dave Hayes, Haas product manager, the Office machines are likely to find themselves in a variety of places where very small parts machining capability is needed. One non-traditional industry where these machines are likely to nest is the jewelry business. A jewelry designer can machine the bulk of a new product's general shape into a wax mold, leaving only fine details to be finished by hand. Another possibility would be to bypass the casting process and machine the actual piece of jewelry from stock. Rings, for example, might be turned on a lathe and then taken to a mill to machine the final details. The goal here is to reduce or eliminate the amount of hand carving in the creation of new jewelry.
A manufacturer or shop that is currently using machine tools to create its parts may also use such very small machines to take prototype machining off of the shop floor and into the CAD department. The result could mean quicker new product development and speedier time to market.
Scanning, Then Milling
The union of machine tools and 3D scanning capability is a marriage of technologies that is driving machining operations to atypical locations, often for rapid prototyping and one-off work. Hospitals and dental laboratories are two of these locations. The ability to directly machine a body part or dental profile, or to create a mold for such parts from a patient's scanned 3D feature, greatly speeds the generation of these unique parts.
For some, the term "rapid prototyping" is synonymous with additive-material processes, such as stereolithography. Subtractive processes, on the other hand, can be just as effective in generating a prototype post-haste and may even be able to produce it in the part's specified material. Such is the case with what Roland DGA Corporation (Irvine, California) calls the subtractive rapid prototyping (SRP) process, which combines a benchtop 3D scanning system with a benchtop milling machine. Among other applications, this system is being used in medical labs by anaplastologists who create prostheses for facial reconstruction. The capability to quickly mill the basic form of a patient's prosthesis allows anaplastologists to focus their clinical energy on the final details that make the prostheses look as realistic as possible. In the case of ear reconstruction, for example, a plaster cast of a patient's good ear can be scanned, mirrored and then milled for reconstructing the damaged ear.
Machine tools will be used in hospitals and dental laboratories. They will be used in jewelry makers' shops. They will be used in upper levels of downtown office buildings without disrupting daily business activities.
One of the reasons that machining technology is becoming attractive outside the realm of the metalworking industry is that it offers a way to reduce or eliminate handwork. These often-time-consuming processes are common to components made for medical, dental and jewelry-making applications to name just a few. Another reason for their growing popularity is the chance to eliminate any disconnects or delays resulting from the separation of designer and machine shop. This is accomplished by allowing the part designer to quickly create a prototype on a machine tool located in the CAD department. For some manufacturers, the capability to machine one's own prototypes offers added assurance that proprietary concepts will be kept under wraps. The main obstacles to installing machine tools in a space such as an office have been the equipment's size and weight. Most machine tools are too heavy for a typical freight elevator to handle and too bulky to fit through a standard 36-inch-wide doorway. Haas Automation (Oxnard, California) is addressing these needs with its Office CNC mills and lathes. Sized to fit comfortably in an office, these machines can be moved with a palletjack or equipment dolly. Alternately, casters can be installed on the machines for easy maneuverability. These machines operate on 240-volt single-phase power, which any facility should be able to accommodate without much trouble.
According to Dave Hayes, Haas product manager, the Office machines are likely to find themselves in a variety of places where very small parts machining capability is needed. One non-traditional industry where these machines are likely to nest is the jewelry business. A jewelry designer can machine the bulk of a new product's general shape into a wax mold, leaving only fine details to be finished by hand. Another possibility would be to bypass the casting process and machine the actual piece of jewelry from stock. Rings, for example, might be turned on a lathe and then taken to a mill to machine the final details. The goal here is to reduce or eliminate the amount of hand carving in the creation of new jewelry.
A manufacturer or shop that is currently using machine tools to create its parts may also use such very small machines to take prototype machining off of the shop floor and into the CAD department. The result could mean quicker new product development and speedier time to market.
Scanning, Then Milling
The union of machine tools and 3D scanning capability is a marriage of technologies that is driving machining operations to atypical locations, often for rapid prototyping and one-off work. Hospitals and dental laboratories are two of these locations. The ability to directly machine a body part or dental profile, or to create a mold for such parts from a patient's scanned 3D feature, greatly speeds the generation of these unique parts.
For some, the term "rapid prototyping" is synonymous with additive-material processes, such as stereolithography. Subtractive processes, on the other hand, can be just as effective in generating a prototype post-haste and may even be able to produce it in the part's specified material. Such is the case with what Roland DGA Corporation (Irvine, California) calls the subtractive rapid prototyping (SRP) process, which combines a benchtop 3D scanning system with a benchtop milling machine. Among other applications, this system is being used in medical labs by anaplastologists who create prostheses for facial reconstruction. The capability to quickly mill the basic form of a patient's prosthesis allows anaplastologists to focus their clinical energy on the final details that make the prostheses look as realistic as possible. In the case of ear reconstruction, for example, a plaster cast of a patient's good ear can be scanned, mirrored and then milled for reconstructing the damaged ear.
The incentive effect: an expanded variety of targeted cutting tool solutions is coming, and the reasons go beyond just the needs of production. Change
You get what you pay for. That time-worn statement is true in more ways than we may realize. You can't expect high value from an item purchased cheaply--that's what the statement usually means. But it also applies to the money we intend to spend. Whenever a group or an industry decides to pay for a particular thing, the decision creates an incentive that brings more of that very thing into existence. Whatever we are determined to pay for, that is what we're likely to get.
All of this may sound rather vague. But in a concrete way, the changing financial incentives in metalworking today represent a force that will drive the development of more capable, more targeted cutting tools during the next several years.
Bernard North makes this case. He is the vice president of research, development and engineering for cutting tool supplier Kennametal (Latrobe, Pennsylvania). While one might expect a VP of research to view the future in terms of the technologies being researched right now, that's not the way he sees things. All of the cutting tool technology we will need for much of the next decade probably has already been invented or identified, he says. The foreseeable future of cutting tools--that is, the tooling we will use in the next 5 or 10 years--will be determined not by what is newly discovered, but instead by what is brought out of the laboratory for commercial development. Economic incentives will shape and drive that progress.
The easiest example of an economic incentive affecting cutting tool development is the changing nature of the machining work that shops are asked to perform. Today, a larger share of metalcutting involves near-net-shape workpieces. Workpiece materials such as aluminum and magnesium are gaining favor as alternatives to iron and steel. Stainless steel, high temperature alloys and composites are also seeing more widespread use. Trends such as these obviously affect cutting tool development. But set aside the changes in the machining work, and Mr. North sees other forces in play. The three changes described on the following page are also powerful where cutting tool development is concerned, even though these changes relate to nothing more than how money is viewed and awarded.
1. Different terms for tooling suppliers
Metalworking businesses that are large consumers of cutting tools are starting to use their clout to make tool suppliers accountable for productivity. The agreement often goes like this: The customer awards a particular vendor all of its tooling business, but in return that vendor agrees to improve the customer's efficiency by X percent every year.
Such an agreement can dramatically change the calculus of cutting tool implementation. In the past, there was a clear and obvious risk for the tool supplier in bringing a new tool to market. In cases where the existing offerings were adequate and customers knew how to use them well, a new product might not win acceptance. But now, the greater risk lies in not applying new technologies and new ideas. Unless it can come up with continually better products for key applications, the tooling supplier might risk falling short of its improvement goal.
2. Different compensation models for manufacturing professionals
Mr. North says he finds it more common for managers and engineers overseeing production operations to have an element of their compensation tied to the operations' performance. That is, they stand to get paid more if the processes produce better. Decision-makers who have this personal incentive tend to be more aggressive about embracing and implementing change. This attitude not only makes it more likely for new products to win acceptance, but it also makes it more likely that the advantages of new products will be fully exploited through the use of aggressive cutting conditions.
3. Different ways of looking at cost
A particular shop's choice between higher performance and lower performance tooling would seem to be driven by the technical merits of the two tools. In fact, that's often not the case. The choice may instead be determined by how the shop looks at costs. If the tooling budget is distinct and separate from other monies, then the lower purchase price of lower performance tooling may be compelling. However, if savings in other parts of the process are included in the analysis--that is, savings in machine time, labor, utilities, real estate, work-in-process inventory and so on--then the higher performance tooling may be more attractive, simply because of this change in perspective.
Many manufacturers are changing their decision-making process to take this broader view of tooling into account. Consumable tooling accounts for 3 to 4 percent of the total cost of machining operations, but because of its influence on cutting parameters, cycle times and the extent of operator involvement in the process, the choice of tooling helps to determine many other cost components that go into each piece. The broader view recognizes that tooling with a higher purchase price may deliver a lower cost per workpiece in the end
All of this may sound rather vague. But in a concrete way, the changing financial incentives in metalworking today represent a force that will drive the development of more capable, more targeted cutting tools during the next several years.
Bernard North makes this case. He is the vice president of research, development and engineering for cutting tool supplier Kennametal (Latrobe, Pennsylvania). While one might expect a VP of research to view the future in terms of the technologies being researched right now, that's not the way he sees things. All of the cutting tool technology we will need for much of the next decade probably has already been invented or identified, he says. The foreseeable future of cutting tools--that is, the tooling we will use in the next 5 or 10 years--will be determined not by what is newly discovered, but instead by what is brought out of the laboratory for commercial development. Economic incentives will shape and drive that progress.
The easiest example of an economic incentive affecting cutting tool development is the changing nature of the machining work that shops are asked to perform. Today, a larger share of metalcutting involves near-net-shape workpieces. Workpiece materials such as aluminum and magnesium are gaining favor as alternatives to iron and steel. Stainless steel, high temperature alloys and composites are also seeing more widespread use. Trends such as these obviously affect cutting tool development. But set aside the changes in the machining work, and Mr. North sees other forces in play. The three changes described on the following page are also powerful where cutting tool development is concerned, even though these changes relate to nothing more than how money is viewed and awarded.
1. Different terms for tooling suppliers
Metalworking businesses that are large consumers of cutting tools are starting to use their clout to make tool suppliers accountable for productivity. The agreement often goes like this: The customer awards a particular vendor all of its tooling business, but in return that vendor agrees to improve the customer's efficiency by X percent every year.
Such an agreement can dramatically change the calculus of cutting tool implementation. In the past, there was a clear and obvious risk for the tool supplier in bringing a new tool to market. In cases where the existing offerings were adequate and customers knew how to use them well, a new product might not win acceptance. But now, the greater risk lies in not applying new technologies and new ideas. Unless it can come up with continually better products for key applications, the tooling supplier might risk falling short of its improvement goal.
2. Different compensation models for manufacturing professionals
Mr. North says he finds it more common for managers and engineers overseeing production operations to have an element of their compensation tied to the operations' performance. That is, they stand to get paid more if the processes produce better. Decision-makers who have this personal incentive tend to be more aggressive about embracing and implementing change. This attitude not only makes it more likely for new products to win acceptance, but it also makes it more likely that the advantages of new products will be fully exploited through the use of aggressive cutting conditions.
3. Different ways of looking at cost
A particular shop's choice between higher performance and lower performance tooling would seem to be driven by the technical merits of the two tools. In fact, that's often not the case. The choice may instead be determined by how the shop looks at costs. If the tooling budget is distinct and separate from other monies, then the lower purchase price of lower performance tooling may be compelling. However, if savings in other parts of the process are included in the analysis--that is, savings in machine time, labor, utilities, real estate, work-in-process inventory and so on--then the higher performance tooling may be more attractive, simply because of this change in perspective.
Many manufacturers are changing their decision-making process to take this broader view of tooling into account. Consumable tooling accounts for 3 to 4 percent of the total cost of machining operations, but because of its influence on cutting parameters, cycle times and the extent of operator involvement in the process, the choice of tooling helps to determine many other cost components that go into each piece. The broader view recognizes that tooling with a higher purchase price may deliver a lower cost per workpiece in the end
Machine molds/dies—no manual polishing required
o accomplish high-precision machining of complex molds and dies, close tolerances and favorable surface finishes are essential. The result, in many cases, is lengthy throughput time. According to Mazak Corp., such precision machining can now be accomplished without necessitating manual polishing, with its new Super Mold Maker 2500 [micro].
Standard features such as a 40-hp, 25,000-rpm spindle with 30-tool magazine; 0.8-second tool-change time; and a machining area of 40.1" x 22.0" x 18.1" enhance machining performance. Three-phase spindle balancing can also reduce spindle vibration from 0.0012" to 0.000059", while the base has modified reinforcement ribs and a wider mounting span for linear-guide blocks to improve rigidity. Also included is a Fanuc 18iCNC, which allows users to chose from as many as ten selectable cutting parameters for each workpiece. High-resolution scale feedback of 0.000002" is standard for all axes.
Standard features such as a 40-hp, 25,000-rpm spindle with 30-tool magazine; 0.8-second tool-change time; and a machining area of 40.1" x 22.0" x 18.1" enhance machining performance. Three-phase spindle balancing can also reduce spindle vibration from 0.0012" to 0.000059", while the base has modified reinforcement ribs and a wider mounting span for linear-guide blocks to improve rigidity. Also included is a Fanuc 18iCNC, which allows users to chose from as many as ten selectable cutting parameters for each workpiece. High-resolution scale feedback of 0.000002" is standard for all axes.
EDM Machine offers fine hole option
EDGE2 Ram EDM Machine is capable of burning holes as small as 0.0012 in. using tungsten rods that are 0.008 in. in diameter. With sapphire die guides as small as 0.0008 in., length-to-diameter ratios of 10:1 and 15:1 are achievable. Machine can be converted from fine hole function to standard Ram EDM functions in less than 5 min without changing dielectric fluid. It is available with 8, 16, or 24 station ATC, capable of changing electrodes as small as 0.004 in. dia.
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Advanced Technology and Superior Quality Ideal For Micromachining
AUBURN HILLS, MI-June, 2005- The EDGE2 Ram EDM machine with fine hole option has the capability to do fine diameter holes that are more accurate and precise than any water-based, hole-popping machine available. The vast majority of hole poppers in the market are water based machines that are dedicated to doing hole popping, and which have dimensional limitations on holes of around 0.010-inches in diameter.
The EDGE2 Fine Hole machine is capable of burning holes as small as 0.0012-inches (0.03048 mm) using tungsten rods that are 0.0008-inches (0.02032 mm) in diameter. With the use of sapphire die guides as small as 0.0008-inches (0.02032 mm) and a high-speed spindle, the length-to-diameter ratios of 10-to-l and 15-to-l are achievable. Fine Hole and Standard Burning
Most of the other manufacturers of oil based hole poppers that are capable of creating small holes below 0.010-inches (0.25400 mm) are bench top models. These are primarily dedicated to fine hole work, and have very limited capabilities to do other EDM work.
The EDGE2 Fine Hole machine can be converted from a fine hole function to standard Ram EDM functions in less than 5 minutes without changing dielectric fluid. And, this machine is capable of 60 amp burning with full orbiting capabilities the same as all other Makino Ram EDMs.
Also, with other bench top hole popping models, automation capability is either limited or nonexistent. The EDGE2 Fine Hole machine can be ordered with an eight-, 16- or 24-station automatic tool changer (ATC), capable of changing electrodes with diameters as small as 0.004-inches (0.10160mm).
The machine can also be ordered with an automatic guide changer (AGC) with a capacity for six different die guide sizes. This allows for users to program the burning of up to six different hole diameters with 24 different tools for maximum unattended machine time gains.
The machine's intelligent monitoring system measures the length of the electrode after each hole burn. It then determines when to put it away and take out the next available electrode of sufficient length and diameter to complete the process in a quick and high-quality fashion.
Achieving Results
With Makino's high-pressure pump system capable of pressures up to 1450 PSI, the EDGE2 Fine Hole machine provides reliable flushing through copper pipe electrodes as small as 0.004-inches (0.10160 mm). With this capability, length-to-diameter ratios greater than 25-to-l are achievable.
Due to the EDGE2 Fine Hole machine's orbiting capabilities, it is possible to size and shape specific hole diameters. This allows users to generate tapered holes or flared holes that can be square at the opening and round at the exit.
In a recent test, a series of six holes were burned 0.100-inches (2.5400 mm) deep with a 0.004-inch (0.10160 mm) diameter copper electrode. This resulted in holes with an entrance burn of 0.0048-inches (0.12192 mm) and an exit burn of 0.0045-inches (0.11430mm).
In another test, a part was generated using 0.005-inch (0.12700 mm) copper pipe going 0.200-inches (5.08000 mm) deep into a blind hole. This is accomplished using a length to diameter ratio of 40-to-l on 30 holes with maximum repeatability and reliability.
EDGE2 Fine Hole Features
The EDGE2 with fine hole option features 12 x 10 x 10 inch (304 x 254 x 254 mm) travels and weighs a sturdy 6,000 pounds (2,722 kg). The machine bed is a heavily ribbed, single piece casting. Anti-friction linear guides and bearings complete the high-performance design, combining excellent rigidity with low-mass dynamics. This heavy-duty construction, combined with the fixed table, brings high levels of rigidity to every application.
Makino's award-winning drop tank design with zero fill time and dielectric chiller completes these features. The drop tank improves many aspects of the EDM process, as the retractable tank walls provide wide-open table access for safe, simple slide-on loading and faster, more accurate setups. And the adjustable tank depth allows optimal matching of dielectric fluid level to workpiece size for overall dielectric savings.
********************
Advanced Technology and Superior Quality Ideal For Micromachining
AUBURN HILLS, MI-June, 2005- The EDGE2 Ram EDM machine with fine hole option has the capability to do fine diameter holes that are more accurate and precise than any water-based, hole-popping machine available. The vast majority of hole poppers in the market are water based machines that are dedicated to doing hole popping, and which have dimensional limitations on holes of around 0.010-inches in diameter.
The EDGE2 Fine Hole machine is capable of burning holes as small as 0.0012-inches (0.03048 mm) using tungsten rods that are 0.0008-inches (0.02032 mm) in diameter. With the use of sapphire die guides as small as 0.0008-inches (0.02032 mm) and a high-speed spindle, the length-to-diameter ratios of 10-to-l and 15-to-l are achievable. Fine Hole and Standard Burning
Most of the other manufacturers of oil based hole poppers that are capable of creating small holes below 0.010-inches (0.25400 mm) are bench top models. These are primarily dedicated to fine hole work, and have very limited capabilities to do other EDM work.
The EDGE2 Fine Hole machine can be converted from a fine hole function to standard Ram EDM functions in less than 5 minutes without changing dielectric fluid. And, this machine is capable of 60 amp burning with full orbiting capabilities the same as all other Makino Ram EDMs.
Also, with other bench top hole popping models, automation capability is either limited or nonexistent. The EDGE2 Fine Hole machine can be ordered with an eight-, 16- or 24-station automatic tool changer (ATC), capable of changing electrodes with diameters as small as 0.004-inches (0.10160mm).
The machine can also be ordered with an automatic guide changer (AGC) with a capacity for six different die guide sizes. This allows for users to program the burning of up to six different hole diameters with 24 different tools for maximum unattended machine time gains.
The machine's intelligent monitoring system measures the length of the electrode after each hole burn. It then determines when to put it away and take out the next available electrode of sufficient length and diameter to complete the process in a quick and high-quality fashion.
Achieving Results
With Makino's high-pressure pump system capable of pressures up to 1450 PSI, the EDGE2 Fine Hole machine provides reliable flushing through copper pipe electrodes as small as 0.004-inches (0.10160 mm). With this capability, length-to-diameter ratios greater than 25-to-l are achievable.
Due to the EDGE2 Fine Hole machine's orbiting capabilities, it is possible to size and shape specific hole diameters. This allows users to generate tapered holes or flared holes that can be square at the opening and round at the exit.
In a recent test, a series of six holes were burned 0.100-inches (2.5400 mm) deep with a 0.004-inch (0.10160 mm) diameter copper electrode. This resulted in holes with an entrance burn of 0.0048-inches (0.12192 mm) and an exit burn of 0.0045-inches (0.11430mm).
In another test, a part was generated using 0.005-inch (0.12700 mm) copper pipe going 0.200-inches (5.08000 mm) deep into a blind hole. This is accomplished using a length to diameter ratio of 40-to-l on 30 holes with maximum repeatability and reliability.
EDGE2 Fine Hole Features
The EDGE2 with fine hole option features 12 x 10 x 10 inch (304 x 254 x 254 mm) travels and weighs a sturdy 6,000 pounds (2,722 kg). The machine bed is a heavily ribbed, single piece casting. Anti-friction linear guides and bearings complete the high-performance design, combining excellent rigidity with low-mass dynamics. This heavy-duty construction, combined with the fixed table, brings high levels of rigidity to every application.
Makino's award-winning drop tank design with zero fill time and dielectric chiller completes these features. The drop tank improves many aspects of the EDM process, as the retractable tank walls provide wide-open table access for safe, simple slide-on loading and faster, more accurate setups. And the adjustable tank depth allows optimal matching of dielectric fluid level to workpiece size for overall dielectric savings.
Engraving Tool provides precise depth control
Suited for applications requiring precise depth of engraving on various materials, Depth Controlling Nosepiece System enables CNC machine operator to control exposure of engraving toolbit to engraved part in increments down to 0.001 in. It is used in conjunction with 2L Spring Loaded Engraving Tool, which provides flexibility of engraving on materials with inconsistencies and odd shapes. Software creates incremental serial numbers, text, logos, and drawings.
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2L inc. Depth Controlling Nosepiece System now available
Hudson, Massachusetts - 2L inc. announced today the release of the newest product in its' Engraving Tool Line. The Depth Controlling Nosepiece System is a significant advancement to engraving technologies currently available for companies who desire precise depth of engraving on a wide variety of materials.
The Depth Controlling Nosepiece System enables the CNC machine operator to control the exposure of the engraving toolbit to the engraved part in increments as small as 0.001". Designed to meet the specific needs of customers performing engraving that requires accurate depth control, the Depth Controlling Nosepiece System is used in conjunction with the patented 2L Spring Loaded Engraving Tool and allows for absolute depth control for engraving using CNC machines.
"We are pleased to be able to continue enhancing our products and offering simple and effective solutions to our engraving customers," A company spokesman said. "Our patented Spring Loaded Tool provides customers the unique flexibility of engraving on a large variety of inconsistent materials. The Depth Controlling Nosepiece System now expands on our goal of helping customers solve their most challenging high-production engraving problems by allowing for precise user-defined engraving depths on those same materials."
The 2L Engraving Tool Line now features products which simplify engraving on a diverse range of materials of most densities including aluminum, plastic, brass, copper, steel, and glass.
* The Spring Loaded Engraving Tool allows the engraving toolbit to float over inconsistencies and odd-shapes in engraving materials, prolonging the life of the toolbit and enabling more consistent engraving.
* The 2L Engraving Software creates incremental serial numbers, engraves text, logos and drawings by creating standard g-code that is compatible with any CNC control that recognizes G0 and G1 commands.
* The Reducing Shaft attachment allows the Spring Loaded Tool to be held in any common one-half-inch collet or endmill holder.
* The Depth Controlling Nosepiece allows precise engraving depth control by limiting the toolbit extension from the Spring Loaded Engraving Tool.
********************
2L inc. Depth Controlling Nosepiece System now available
Hudson, Massachusetts - 2L inc. announced today the release of the newest product in its' Engraving Tool Line. The Depth Controlling Nosepiece System is a significant advancement to engraving technologies currently available for companies who desire precise depth of engraving on a wide variety of materials.
The Depth Controlling Nosepiece System enables the CNC machine operator to control the exposure of the engraving toolbit to the engraved part in increments as small as 0.001". Designed to meet the specific needs of customers performing engraving that requires accurate depth control, the Depth Controlling Nosepiece System is used in conjunction with the patented 2L Spring Loaded Engraving Tool and allows for absolute depth control for engraving using CNC machines.
"We are pleased to be able to continue enhancing our products and offering simple and effective solutions to our engraving customers," A company spokesman said. "Our patented Spring Loaded Tool provides customers the unique flexibility of engraving on a large variety of inconsistent materials. The Depth Controlling Nosepiece System now expands on our goal of helping customers solve their most challenging high-production engraving problems by allowing for precise user-defined engraving depths on those same materials."
The 2L Engraving Tool Line now features products which simplify engraving on a diverse range of materials of most densities including aluminum, plastic, brass, copper, steel, and glass.
* The Spring Loaded Engraving Tool allows the engraving toolbit to float over inconsistencies and odd-shapes in engraving materials, prolonging the life of the toolbit and enabling more consistent engraving.
* The 2L Engraving Software creates incremental serial numbers, engraves text, logos and drawings by creating standard g-code that is compatible with any CNC control that recognizes G0 and G1 commands.
* The Reducing Shaft attachment allows the Spring Loaded Tool to be held in any common one-half-inch collet or endmill holder.
* The Depth Controlling Nosepiece allows precise engraving depth control by limiting the toolbit extension from the Spring Loaded Engraving Tool.
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