The PCD Edge system allows the profiling of polycrystalline diamond (PCD) cutting tools using a Fanuc iD series wire EDM machine. The system consists of programming/probing/cutting software; a microfinish power supply/generator for cutting PCD; a Hirschmann rotary axis; a machine-mounted Renishaw probe; and a tool clamping system. Designed for Cutting Tool Inserts PCD tooling OEMs, shops that maintain their own tooling and contract sharpening services, the system can be used to create original profiles or to sharpen worn PCD-tipped tools.?The system allows users to design tool edge contours on their own CAD systems, eliminating the need to learn a new system or change procedures. It provides special input masks to simplify parameter selection, program simulation, Lathe Inserts design modification and verification. With no advanced programming knowledge, the user can create as many as eight profile sections with specific parameters for each, the company says. The software and a rotary axis permit adjustment of the relief angles on each contour element as well as automatic measuring (with feedback) of 3D PCD tip positions such as rake and shear angles. With optional control software, the entire process can be automated for unattended operation, the company says.
The Carbide Inserts Website: https://www.estoolcarbide.com/coated-inserts/dcmt-insert/
Midwest Screw Products (Eastlake, Ohio) is a contract manufacturing operation for the aerospace, computer, medical, electronics, energy, telecommunications and fluid process industries. The company has a mix of multi-spindle chuckers and bar machines but found its capacity stretched by new orders. Production of one precision compression fitting posed a special challenge for Midwest’s horizontal two-axis CNC lathes. The hex-shaped stainless steel part required eight distinct secondary turning and milling operations. Notoriously stringy stainless steel chips and the expected high production volumes promised to make the job even more of a bottleneck.
"We figured we’d lose lots of time mainly during the loading cycle, cleaning the chuck, clearing chips and loading the next part," recalls plant manager and programmer Steve Zuzek. "We knew we wanted automatic loading and unloading but thought we’d just have to live with the chip-jamming problems."
A search for an automated solution soon centered on the EMAG VL3 inverted vertical spindle lathe from Hardinge (Elmira, New York). This machining concept suspends the headstock from an overhead carriage on linear roller guides above a 12-station turret carrying driven and static tools. The 21-hp overhead spindle of the VL3 turns at up to 7,500 rpm, 3 1/2 times faster than the spindles on horizontal bar machines. A 16-hp turret spindle enables live tooling under the workpiece to mill and drill stationary parts once they are turned.
The inverted spindle and coolant jets in the enclosed machining cube facilitate chip evacuation, hands-off, and prevent tools from re-cutting chips. A universal conveyor surrounding the work area accommodates parts of any shape up to 8.6 inches in diameter. With its glass scales, chip conveyor and mist collector, the integrated system costs 40 percent less than a horizontal lathe with separate bar feeder and chip conveyor, and it requires about half the shopfloor space.
Midwest Screw Products chose the EMAG VL3 because the machine provided flexibility to feed, turn and mill parts at higher production rates than other CNC machines, with minimal operator attention. "The big thing is you are no longer limited by the availability of an operator for either part handling or chip disposal," explains Mr. Zuzek. "With the VL3, as long as you have parts on the conveyor, it’s going to load itself. And with the vertical configuration. . .chips simply fall out Carbide Grooving Inserts of the way."
Midwest Screw Products typically assigns each operator one or two machines. The unattended operation of the new vertical lathe enabled an existing worker to serve a third machine.
In operation, compression-fitting blanks approximately 11/2-inch long by 9/16-inch diameter come to the vertical lathe from other multi-spindle machines. An operator loads 14 pieces at a time onto the built-in part feed conveyor. Workholding prisms that adjust to the programmed workpiece diameter grip the blanks, and the conveyor advances pieces to the overhead chuck. The machine faces, turns, drills, finish turns and finish bores, then roll cuts threads and roll-stamps each part.
Total cycle time per part is about 75 seconds. "Actual cutting time is about the same as for a conventional horizontal CNC lathe," Cutting Inserts says Mr. Zuzek, "but utilization, and therefore throughput, is up. We gain throughput because an operator doesn’t have to open the door, open the chuck, remove the part, clear chips, load the chuck, close the chuck, close the machine door and push a button." Time to load 14 parts on the conveyor is 42 seconds, versus approximately 5 minutes to feed the same number of parts manually. Chipmaking time from one part to the next is about 20 percent less than the same job done on a horizontal lathe. "We reclaimed 12 minutes of machining time per hour through higher utilization," says Mr. Zuzek.
The vertical lathe with its wraparound spindle maintains dimensional tolerances on the compression fitting within 0.0015 inch. The rigid machine with its stable base also provides a surprise benefit. "It’s still tough to estimate, but our tool life might be as much as 30 percent better," says Mr. Zuzek.
The cumulative effect of faster loading, faster part changes and less downtime for tool changes is more parts per day. Midwest Screw Products turns out 300 compression fittings per day on the vertical lathe versus about 230 per day on a conventional lathe.
Quick, easy setup is important for Midwest Screw Products to change from one job to another. "For an automated machine, it’s very user-friendly during setup," says Mr. Zuzek. "When you’re programming it, there’s not a lot of homework to do as far as the fixtures go. The machine handles a number of shapes very easily." The auto-loading system of the vertical lathe also has a cardanic sensing plate at the part pick-up station to ensure workpieces are properly seated in the chuck.
"The Hardinge-EMAG VL3 is probably the best designed and best built machine in our shop," says company president Rick Creveling. "Maintenance is easy due to the accessibility of hydraulic, electrical and mechanical components. Overall, this machine has improved our productivity and profitability."
The Carbide Inserts Website: https://www.estoolcarbide.com/product/tngg160402r-l-s-grinding-cermet-inserts-p-1212/
OK. You’ve installed scales on your knee or bridge mill, maybe even installed a CNC and servo package to automate the machine tool. When the dust from all this upgrading settles, you’re still looking at a potential productivity weak link in changing tools.
A new quick change tooling system from Acu-Rite (Jamestown, New York) may be a reliable, cost effective way to upgrade the tool change time on your R-8 spindle knee or bed mill. Called the Mach-1, it’s a retrofitted mechanical drawbar system with a preset die spring that enables an operator to manually do what a machining center does automatically—change tools quickly.
The drawbar system uses only 0.25 inch of vertical movement to capture or release a collet. The die springs generate a gripping force equivalent to a power drawbar system but without the risk of damaging a collet or the taper of the DNMG Insert R-8 spindle from over torquing.
On this new system, the collet adheres closer to the collet taper and pulls the sleeve around it, forcing the face of the collet against a thrust nut. This captures the tool within the collet and prevents any tendency of the collet to "bellmouth." Bellmouth occurs when excessive torque causes the collet to deflect in the center, which results in an opening up at the collet end—like a bell. The result of bellmouthing is a reduction in the collet’s ability to grip the full surface area of the tool shank.
To actuate the Mach-1 drawbar, the operator simply lifts and releases the quill handle. This short move disengages the cutter from the drawbar, allowing it to slip out of the spindle.
The same motion is used to load a new tool. Operation of the quill is unaffected by the drawbar TNGG Insert release mechanism. The system does require use of specially adapted toolholders, which have a knob for the drawbar to clamp on.
An advantage of the drawbar system is its consistent grip. Variability of grip from operator to operator is eliminated with this system. The drawbar spring grips each cutter with the same force each time.
Another advantage, according to the company, is that preset tools generally don’t need to be reset after a tool change. The drawbar works on the toolholder keeping toolholders, collets and cutters set up as they came off the presetter. Basically tool wear is the only dimensional deviation from preset specifications.
Acu-Rite sees this new system as an alternative for power drawbars. The company has created a ready-to-go package that includes the drawbar system and an assortment of toolholders and collets. These units can be field retrofitted. According to the company, pay back of 17 days has been reported.
Many shops are looking for cost-effective ways to automate their processes without sacrificing the versatility of the knee or bed mills in their shops. This new drawbar system may be a way to help make your milling department more productive with a small investment. MMS
The company offers a variety of products, including Z-Carb end mills; the S-Carb two-and three-flute end mills; and the V-Carb five-flute end mills. The Z-Carb family of end mills features an unequal helix geometry designed to maximize stock removal and improve productivity in milling operations. The S-Carb end mills are designed for machining aluminum and non-ferrous materials and are said to increase material removal rates and improve surface finish. The V-Carb five-flute end mills are designed for semi-finish and finish milling operations as well as heavy milling tasks, including roughing and Indexable Inserts slotting.?The company’s deburring rotary files will also be displayed. In addition to these products, the company will feature its multi-layer tool coatings. The Ti-Namite tool coatings are engineered for the company’s solid carbide rotary cutting tools.? According to the company, this multi-layering process results in maximized tool life Tungsten Steel Inserts and increased speed and feed rates. The line of tool coatings includes Ti-Namite titanium nitride (TiN); Ti-Namite-A aluminum titanium nitride (AlTiN); Ti-Namite-B titanium diboride (TiB2); and Ti-Namite-C titanium carbonitride (TiCN).
The Carbide Inserts Website: https://www.estoolcarbide.com/product/scmt09t304-scmt09t308-scmt120404-scmt120408-cast-iron-turning-inserts-p-1203/
To keep up with consumers' demands of greater quality, ISO 9001-certified Black & Decker U.S. Power Tool Operations (Fayetteville, North Carolina) knew it needed to seek the best technology. Goals included quieter, smoother operation for the small electric motors inside power tools and tight tolerances for surface finish and roundness of shafts and spindles for the small, high-speed electric motors.
At the heart of all the tools is the motor shaft or spindle. Typically steel, these parts are usually shaped on a screw machine and ground to finish specifications. Some are ground from barstock. Most have multiple diameters.
Black & Decker engineers knew that upgrading grinding capability could have a big impact on plant production quality and cost. Warranty and rework issues are important dollar concerns, and plantwide Cpk goal is six sigma.
The solution was to purchase two Koyo CNC precision centerless grinders with automatic parts feeders and parts handling. Previously, multiple diameters on armature shafts had been ground on a manual, between-center grinding machine with contact gaging and cam-type dressers. Production rates sometimes lagged demand, and part quality could be inconsistent. As production increased and tolerances tightened, it became clear that a multi-axis CNC infeed grinder with CNC wheel dressing capability would be needed to help the plant keep up with the production requirements of several million parts a year.
Black & Decker engineers decided that a Koyo Model 6015 CNC in-feed centerless grinder with 6-inch wide grinding and regulating wheels with multiple diameters would help them meet the challenge. "It permitted faster setups and greater throughput, and the CNC dressing eliminated cam templates, saving time and improving grinding accuracy and reliability," said Mike Hinnant, manufacturing engineer. "Wheels are pre-dressed. And with the combination of CNC and pre-dressed wheels, we can quickly dedicate the machine to any shaft or spindle our plant requires as they need them."
"On one of the shafts we produce, we cut the cycle time from 28 seconds to 13 seconds," Mr. Hinnant continued. "The machine removes 0.010 inch of stock on diameter and maintains a 2.0 Cpk while maintaining roundness and surface roughness to part print tolerances." On that shaft, the machine grinds four diameters.
The Koyo centerless grinder is equipped with nine axes for machining, including two axes for grinding wheel dressing, two axes for regulating wheel dressing, two axes of infeed, upper and lower slide, two axes for loading and one axis for automatic swivel for taper control. It also includes several sets of grippers for automatic loading of eight different part numbers.
Black & Decker 's second machine was a Koyo KC-200 CNC in-feed centerless grinder. The main need was to be able to grind longer parts than would fit on the 6015 and to provide increased capacity. For its part in the production improvement at the plant, the KC-200 cut cycle times approximately in half for a family of nine parts it grinds.
Part quality is checked automatically with a non-contact post-process laser gage. Size and taper data is automatically fed back to the CNC, which compensates by adjusting the table and swivel axes.
"Roundness on the motor shafts is a critical specification," said Mr. Hinnant. "If the shaft is not round, the motor will arc and fail. We are minimizing lobing by optimizing regulating wheel tungsten carbide inserts speed, number of dresses on the wheel, and blade height." With CNC, hydraulics have no part on the KC-200, and thermal effects on machine function are avoided.
In operation, several hundred parts are loaded at one time through a hopper, freeing the operator to perform other tasks. Parts cycle through the machine automatically, followed by a blow-off and the laser gaging before being deposited into a bin.
Environmentally, the machine is clean, said Steve Terry, group leader on the shaft machining line. A mist collection system keeps the air around the machine clean and free of irritating vapors. And the part blow-off at the laser gaging station is so effective that not only is gaging reliable, but the usual post-process part-cleaning operation has been eliminated, saving 55 gallons of solvent a year, yet permitting DNMG Insert a part storage life of up to 30 days, rust-free.
"All in all, the machines have been a very positive experience—with improved part quality, 50 percent greater productivity, and noticeable environmental improvement," Mr. Hinnant said.
The Carbide Inserts Website: https://www.cuttinginsert.com/product/blmp-insert/
