Top 10 Most Read Features
Magnus Hi-Tech Industries, Inc. provides high quality
solutions to the machining and fabrication needs of the
defense, aerospace, medical and other demanding fields.
The newest member of this lineup is a Mazak 5-axis CNC
milling machine. “It is able to machine five sides of a cube
in a single set-up, drastically reducing changeover times
and machine downtime,” reports Mike Blake, Methods Engineer
/ Program Manager for Magnus Hi-Tech. It also has the
ability to perform its own in-machine measurements and data
collection with a CMM-type touch-probe, essentially
self-adjusting its programming and tooling to ensure close
tolerances are maintained by monitoring tool wear and
part-to-part variations.
A commitment to continuous improvement led the company to
seek a way to reduce engineering and CNC programming times
and decrease time to market.
CAMWorks
generated tool path for a battlefield chassis.
CAMWorks is an intelligent, intuitive, solids-based CAM
solution from Geometric Technologies, Inc., a subsidiary. It
provides an array of tools to simplify and automate even
complex programming tasks, speeding design and programming
changes. Its intelligent connection between the solid model
and tool path generation provides associativity between CAD
and CAM functions. This allows CAMWorks to identify and
recalculate toolpaths based on the changes to the part
model.
For example, when the depth of a pocket is changed,
CAMWorks can update the toolpath automatically. It also
supports CNC programming of multiple parts for production
machining and offers an accurate representation of the
virtual machining environment. The design and layout of
machine components, parts, work pieces, clamps and fixtures
provide a realistic representation of the machining
environment. This not only helps the manufacturing engineer
as he develops the program, but also the machine operator on
the shop floor, who has access to setup documents that show
where the parts and fixtures are positioned on the machine.
A key aspect of CAMWorks is its seamless integration with
SolidWorks®, the CAD program used by many metalworking
shops, including Magnus Hi-Tech. “We offer our customers a
fabrication house that can produce their products from
prototype to production,” says Blake. That journey from
prototype to production is rarely a straight line. Changes
frequently occur as problems and opportunities surface, and
those changes can be time-consuming. “We used to have to
reprogram the whole part with our previous CAM software,”
recalls Blake, “or else use the CAD package associated with
that software, which would not bring our SolidWorks model up
to the new revision.” CAMWorks eliminates such problems.
“There have been parts, for instance, where a customer
has needed to move some hole positions, or a pocket was
moved to a different location. We used to have to reprogram
the model. With CAMWorks, which can work inside SolidWorks,
we just change the model to the new revision, automatically
regenerate the tool path, then repost it to our Mazak mills
and we’re ready to run.
“CAMWorks’ ability to automatically accommodate changes
to the part model, eliminating a lot of time consuming CAM
system rework due to design updates, makes true associative
machining possible. Time savings are considerable.” This
type of scenario is not uncommon, says Blake, and with some
customers, it’s routine.
Within this suite, Automatic Feature Recognition (AFR)
has the potential to cut hours off the time it takes to move
from design to finished part through its ability to
automatically identify and define prismatic machinable
features.
AFR Technology does this by analyzing the solid model
geometry and identifying mill features such as holes, slots,
pockets, and bosses; turning features such as outside and
inside profiles, faces, grooves and cutoffs; and wire EDM
features such as die openings. AFR recognizes these features
regardless of the CAD system in which they were created.
Further speeding the design to machining process is
Geometric Technologies’ TechDB™ (Technology Database). Using
knowledge-based machining technology, the database
associates tooling, machining strategies and parameters to
the features. When operations are generated, CAMWorks
applies these settings automatically. Significantly, the
rules in the TechTB are fully customizable, enabling
companies to incorporate their best practices.
“I routinely use Automatic Feature Recognition in
creating fixtures for our machining operations,” notes
Blake. “Together with the Technology Database it enables
CAMWorks to automatically select the right drills and taps.
We used to spend most of the day programming fixtures -- not
anymore.”
Simultaneous
cutting of a battlefield override chassis on a
5-axis Mazak Machining Centers
Blake cites a major project that Magnus Hi-Tech recently
completed, machining critical components for a military
chassis. Consisting of a series of complex prismatic parts,
the job had to be done accurately and on time. Using
CAMWorks, Magnus Hi-Tech was able to create complex
machining programs for its Mazak five-axis mill in optimum
times, quickly make any required revisions, and generate
designs and toolpaths for the needed fixtures. The result
was a win for both the military and the company.
Summing up, Blake notes that CAMWorks’ tight integration
with Magnus Hi-Tech’s SolidWorks environment facilitates
true associative machining, so that any revision to a part
design updates the SolidWorks solid model as well as the
CAMWorks file, permitting CAMWorks to automatically generate
the new toolpaths, the tool list and, if required, the
fixture modifications as well. This has resulted in saving
time on revisions ranging from 20 to 60 percent.
“CAMWorks is very easy to install and the more advanced
stuff like 5-axis machining is not too hard once you have an
understanding of how the toolpathing works. In addition, the
interface is clean and easy to understand.”
Want more information? Click below.
Geometric
Technologies, Inc.
Tool failure while roughing scaly castings remains one of
the chief headaches facing fabricators of large parts. But
the root cause isn’t the scale anymore, thanks to improved
insert substrates.
“Today the real villain is the uneven cast surfaces,”
says Tom Noble, tangential milling manager at Ingersoll
Cutting Tools. “One instant the insert is ‘cutting air;’ the
next it’s burrowed deep enough into a high spot to snap
off.”
He added that today’s best practice for roughing uneven
cast surfaces is tangential milling (TM), which presents the
insert’s strongest cross section to the brunt of the cutting
forces. “As a result, you can dramatically increase
throughput, yet count on inserts lasting consistently
longer.”
Cases in Point
Recent experience at several big fabrication shops proves
the point.
Tangential
S-Max face mill buzzes through the ends of Terex’s
big transmission boxes for large construction
equipment. The switch to tangential milling doubled
throughput, increased edge life by 5 to 1, improved
finish and got rid of oil based cutting fluid. The
gain freed enough machine time on a big G&L mill to
eliminate the need for a second machine.
Off-road equipment maker Terex doubled throughput of huge
tubular transmission boxes and increased edge life by 5:1
with the switch to TM (fig 1). They also eliminated cutting
fluids and their inevitable oil-mist cloud. “Debottlenecking
our existing machines – reliably – boosts our capacity
without big ticket investments,” says Jim Rice, operations
manager at Terex’s Ciudad Acuna, Mexico plant. “That’s
exactly what tangential milling has done for our operation.”
Annualized savings are estimated at $50,000 on that one part
alone (annual volume 144 pc).
Hol-Mac Corporation eliminated tool wrecks and spindle
blowouts while doubling throughput on a variety of steel
castings used in mining and earthmoving equipment (fig 2).
Despite the increase in feed rate to 36 IPM from 16,
catastrophic tool ruptures – a chronic problem before --
disappeared altogether. On the very first part that the
company retooled with an Ingersoll S-Max tangential cutter,
cycle time was reduced by 44 minutes per part, saving
$125,000 annually. As a result, Hol-Mac has standardized on
TM for roughing and finishing more than 20 of the mainstay
castings that they run continuously.
Winegar, Inc. got into TM simply to reduce tool-up costs
for rough milling of a high volume steel casting, and ended
up with a throughput gain as well. The part is a plate
shaped roughly like a pizza box, which goes into the cab
mountings on off-road equipment. With a conventional radial
cutter, edges lasted six pc. With a tangential V-Max mill,
edge life doubled to 12 pc -- even at 25% higher feed rates.
Moreover, since the tangential inserts were double sided,
insert life actually quadrupled.
Edge Life Predictably Longer
Typical
skin milling operation on big steel castings at
Hol-Mac. The company has standardized on tangential
milling with S-Max face mills for initial operations
on most big castings. Despite the scale, sand
inclusions and very irregular as-cast surfaces on
the workpieces, throughput for skin milling has
doubled as a result, with edge life rising by 4 to 1
and cutter wrecks a thing of the past.
In all three cases, the TM inserts failed solely due to
gradual, predictable wear, never from catastrophic rupture.
Risk of such serious losses as tool wrecks, ruined high
value-added parts, safety hazards, spindle damage or motor
burnout is gone. “At the very least, rupture of one edge
renders the entire insert useless, regardless of how many
good edges are left,” explains Mr. Noble.
In a tangential cutter, the flat insert orientation
provides much more support and stability behind the cutting
edge and a stronger seat pocket and cutter body (fig 3).
“Orientation of the insert in a heavy roughing cut
contributes at least as much to longer edge life as a wear
resistant substrate.”
Lessons from a Matchstick
“Picture a matchstick clamped to the edge of a table with
a little bit of the end protruding above the surface” says
Mr. Noble. “Now take a horizontal swipe at it. That
unsupported protruding part snaps right off because the
cross section facing the brunt of the forces is so small.
But if you lay the match down on the tabletop and clamp it,
you can hit it the same way and it won’t break. It survives
because the force of the blow is absorbed by the entire
length of the match.”
The V-Max pocket geometry also creates a positive
presentation angle, reducing cutting forces on the insert.
This results in a stronger cutting system which generates
lower cutting forces.
Here is a closer look at the TM operations at Terex,
Hol-Mac and Winegar.
Debottlenecking at Terex
The Terex parts are transmission boxes, essentially huge
tubes big enough to stand in -- 9 or 12 ft dia, 8 to 10 ft
long with walls 4 ½ to 8 in. thick. The bottleneck
operation, run on a 40 HP G&L horizontal mill, is to
rough-mill about .700" of Rc32 cast alloy steel off both
ends. Previously, using a 6.00 inch milling cutter with
conventionally mounted inserts, it limped along, taking 3 ½
hours per part, wrecking inserts midway through the cut, and
occasionally fogging the work area with oil mist. Now with
an 8.00 inch diameter S-Max tangential mill, Terex runs the
operation at double the feed rate as before -- 30 IPM vs. 15
at the same 0.100 inch DOC -- and without cutting fluid.
Cycle time is now 1 ¼ hours, with absolutely no risk of
insert failure. “Obviously the chip loads and cutting forces
are reduced as well with the tangential system, or we
couldn’t have gone with the larger cutter without stalling
the machine,” says Mr. Rice.
At one point during testing the new cutter, they doubled
the DOC and fed at 25 IPM. The spindle nearly stalled at
this rate, but the tangential cutter was unscathed. Based on
this success, Terex is switching over to tangential milling
for all heavy roughing jobs.
In
smaller sizes, TM cutters are much stronger because
they retain more metal after seat pockets are milled
out. Left: one-inch 4-flute TM cutter body. Right:
one-inch 4-flute conventional cutter body.
No More Blown Spindles at Hol-Mac
“During a recent skinning operation, one edge failure
triggered a cascade that caused enough vibration to blow out
the spindle bearings before the operator had a chance to
shut down.”
So said John Scarbrough, Hol-Mac manufacturing
engineering specialist. That’s what triggered the company’s
transition to Ingersoll's S-Max tangential milling cutters
for all skinning operations. Conversion to TM not only
eliminated catastrophic insert failures but also doubled
throughput. Accordingly Hol-Mac standardized on the TM
process for face milling more than 20 different large
castings that the company regularly runs. Standard settings
for roughing are 550 SFM, 36 IPM, .100" (4 mm) depth of cut
(DOC). For finishing, only the DOC is reduced, to .010".
More recently, Hol-Mac switched to TM for a deep-reach
plunge milling operation on a big clevis. The setup uses an
S-MAX tangential face mill on a 10 inch extension.
Previously, chatter fractured inserts even under very gentle
cutting conditions because of the instability inherent in
such a long reach. Now that operation runs five times
faster, with edges lasting 12 times longer and never failing
by rupture. In the first year since the transition, savings
in machining time and tooling inventory are projected to
exceed $1 million – at just one of the three Hol-Mac plants.
Deliveries are also quicker because the processes are more
consistent.
Doubling Feed Rate “Conservative” at
Winegar
With an 8-effective conventional face mill, Winegar was
getting only six pieces per edge when milling the mounting
plate in a two-minute cycle. Tool life and cost were their
main concerns. Moving up to a 12-tooth tangential milling
cutter with a 30 degree lead angle improved edge life to 12
pc and reduced cycle time by 30 seconds per part.
“We probably could run the inserts longer, but routinely
index every twelve parts as a precaution, given the vagaries
in the incoming castings and condition of the machine we
use,” says Winegar process engineer Jerry Engrav. The
company runs the parts two-up on any of several mills, in
varying conditions, depending on which is open at the time.
“I tell many people that putting a tangential cutter on a
spindle for roughing a casting is like bolting a
turbocharger onto a race car,” says Mr. Noble. “You don’t
replace the engine: you simply get better performance out of
the existing machine.”
Ingersoll pioneered the tangential milling concept back
in the ‘60s. Today the line has expanded to include smaller
diameters and improved insert geometries that allow more
nonlinear toolpaths. Today, S-Max and V-Max tangential
milling tools are available in assorted styles from one to
twelve-inch diameters. Special configurations are also
available on request.
“We’re especially excited at TM’s success and potential
in smaller parts and on low HP machines,” says Mr. Noble.
“Inherent strength of the cutters coupled with freer
machining geometries makes tangential machining the go-to
solution for a much wider variety of rough milling work.”
Want more information? Click below.
Ingersoll Cutting Tools
When your livelihood depends on an inventory of tools
worth millions of dollars, you’re going to play it smart.
You’re going to take care of that inventory. At least, you
will if you’re Grede Foundries Inc., a Milwaukee-based
company specializing in ferrous castings.
While its plant in Reedsburg, Wisconsin, USA, casts
suspension parts, differential cases, crankshafts, and like
parts, inspectors there check hundreds of tools regularly
with a coordinate measuring machine (CMM) retrofitted with
an LC50 laser scanner from Nikon Metrology in Brighton,
Michigan. Their goal is to prevent the inevitable wear on
the surface of the tool from progressing to the point that
it causes quality problems and damage that is expensive to
repair.
Material
versatility ensures that components and systems are
“manufacturable” and will function as designed.
In casting, a tool called a pattern creates impressions
in sand to create a mold into which molten steel is poured.
The constant pushing of the pattern against the sand
causes a grinding action that abrades the surface and wears
away important details. To retard this wear, Grede protects
the surfaces by applying hard, abrasion-resistant chromium
based coatings chosen carefully for each job. In time,
though, the sand eventually wears them away too.
“After a specified number of cycles or when the operator
can see wear, a pattern has to be inspected,” says Bernie
Bill, Grede’s Layout Supervisor in charge of the Quality
Laboratory. “We will rescan it and compare the measurements
to the baseline.”
The baseline is the scan of a pattern that has been
proven to produce good castings. “We don’t compare
measurements to the original CAD model of the part because
the pattern has to vary from it slightly to accommodate
shrinkage,” says Bill. “We have to tweak the pattern to get
the castings to meet customer specifications.” Once the
patterns are able to make good castings and the customer
approves them, Bill’s team scans the tool and stores the
cloud of points as an STL file. The inspector aligns the
pattern to a jig mounted on the CMM, retrieves the program
used to create the baseline STL model of the pattern, and
lets the CMM inspect the tool.
Then, Bill uses Nikon Metrology’s Focus Inspect software
to compare the cloud of measurement points to the baseline
and generate a color-coded map of the part. “You can have
results within 15 minutes to a half an hour,” he says.
Because each color represents a deviation from nominal,
production can see at a glance where wear is occurring and
how much wear has occurred.
“The results tell them what the plan for the pattern is
going to be,” says Bill. “They know that they might be able
to get by with running 5000 more cycles before sending the
tool out for stripping and recoating.” Or they might pull
the tool immediately to prevent further wear that would
require welding and grinding the tool to bring it back into
specification. If, however, they were to find that they were
too late and that repairs were necessary, then the scanner
would check the repairs afterward against the baseline to
ensure that they returned the pattern to the approved
specifications.
Monitoring wear is not the only use of the laser scanner
and baseline scans. Scanning also comes in handy for helping
engineering troubleshoot problems. For example, scanning can
help diagnose an alignment problem that might prevent the
two halves of the mold from fitting together just right to
create a good seal. Without enough clearance, the two
sandbanks on the outer edges of the two halves of the mold
will crush each other, which can cause some sand to fall
into the cavity. Iron forms around the sand, creating holes
in the casting. Too much clearance, on the other hand, will
let some molten metal leak from the parting line. The
resulting thin, but hard flashing must be cut and ground
away.
“So we scan both patterns, put the scans together, and
check for clearance and crush electronically,” says Bill.
“When we put it on the screen, we can see whether it’s a
pattern problem and, if it is, exactly what they’ve got to
fix.” Not only do the color maps eliminate the need to pour
over tables of measurement data, but they also can be
attached to work orders to show the problem clearly and
exactly to toolmakers in the pattern shop.
In the past, the toolmakers would have had to weld and
grind the patterns based upon their experience. Sometimes,
the toolmakers would be lucky the first time, but most of
the time, four to six iterations would be necessary to
correct the problem. With laser scanning, however,
diagnosing problems and repairing patterns is no longer a
trial-and-error process. Because scanning collects more data
in less time and presents it in a format that can be easily
read, it eliminates guesswork. “Most of the time now, the
pattern shop is making the right correction on the first
try,” says Bill.
Moreover, scrap rates are way down. A good example is a
set of tools for making a bracket for automobile brakes.
Laser scanning helped engineering to find not only some
clearance in the patterns but also some variation in the
machine that exacerbated the problem and caused a lot of
scrap. Based on the information gleaned from the color maps,
engineering was able to reduce a 5.2% scrap rate down to
1.0%, thereby saving the company $48,000 a year on that job.
After using the scanner for six months, Grede estimated
that using the laser scanner only one shift a day would save
the company about $81,000 during the first year by reducing
scrap alone – and that was after paying for the Nikon
Metrology laser scanner and software. Almost six months
later, he could see that he was going to have to revise his
estimate upwards. So plans are to play it even smarter –to
scale up and run the scanner another shift.
Want more information? Click below.
Nikon Metrology Inc
By Ron Hoffman, VP/General Manager, MAG Maintenance
Technologies
With today's limited internal resources, it's tough to
transform machine maintenance from reactionary to
preventive, and ultimately proactive, despite the obvious
upsides in higher overall equipment efficiency (OEE), better
process control and lower total cost. Outsourcing this
requirement to a third-party specialist, however, is a
cost-effective alternative, according to companies that have
crunched the numbers.
Lockheed Martin offers a case in point. The company has
contracted with MAG for global service and support of
machining equipment and systems at all its major plant
locations around the world. The comprehensive agreement
provides interactive diagnostic help, preventive
maintenance, field service, training, replacement and spare
parts, productivity improvements, machine rebuilding, and
even machine and system relocation and set-up.
Manufacturers of all sizes – from single plant to
multi-plant and multi-national – can benefit from outsourced
maintenance to achieve world-class productivity and
competitiveness. There are six primary areas where a
single-source maintenance partner can optimize the capital
investment and provide cost savings through lower total cost
of ownership and increased return on investment.
Application Support
Machine tool experts can analyze the tasks assigned to each
machine and provide recommendations on process improvements,
cycle-time reduction strategies, proper cutting tools and
workholding configurations to optimize machine usage and
performance, and reduce work in process, setup times and
costs per part.
Training
Knowledge is power, and knowledgeable operators are key to
maximizing the production power of your machines. Ensuring
your personnel are trained on the latest operation and
maintenance developments and techniques is critical to
getting the most out of your machine tools. Training can be
individualized and conducted on-line for further cost
savings.
Service Support
When a machine goes down it immediately transforms from
income generator to expense. Timely service support is the
key to getting the machine back online and making parts. At
times when on-site maintenance is cost- or time-prohibitive,
interactive tech support, via video, voice and data
communications over a standard phone line, can quickly
diagnose problems remotely for faster service and less
downtime.
Preventive Maintenance
Knowing what areas of the machine need preventive
maintenance, and what level is cost-effective, are part of
the support partner's holistic services. A supplier that has
wide experience with many makes and kinds of machine tools
will know the typical service life of various components and
potential weak spots or problem areas with certain designs.
This enables closer monitoring, trend tracking, and
appropriately scheduled maintenance to prevent costly
downtime. Also, coordinated "ganging" of service to multiple
machines can produce significant economies of scale.
Machine Monitoring
Trends in production monitoring are moving rapidly from
machine-level to process-level intelligence, and Real-time
Performance Management (RPM) from a service/support partner
can optimize equipment utilization for greater manufacturing
efficiency, productivity and ROI. Computer-enabled data
collection tools identify and resolve out-of-cycle events as
they are happening, and provide interactive, on-demand
reporting of production equipment availability, utilization
and performance.
Spindle Replacement
For plants operating high-volume machining systems, such as
automotive, the service/support partner can take complete
responsibility for spindle inventory and replacement, often
working with a third-party spindle re-conditioner for new or
rebuilt units, reducing turn-around time to hours, instead
of days. At the same time, small-volume, high-value part
manufacturers can’t afford to let the huge overhead of a
giant gantry machine (both physically and financially
speaking) sit dormant, making fast response to spindle or
gear box replacement needs, and other major repairs,
critical.
Bonus: Machine Certifications and More
Service/support partners can also assist with machine
certifications after a relocation or in-plant re-assignment.
This may include inspection of axis alignment, coolant/lube
systems, toolchangers, and automation, as well as laser
calibration, ballbar testing and axis alignment. The goal is
to ensure the machine meets or exceeds OEM specs, and can
make quality parts per the program/contract requirements and
ISO 9000 or other standards.
A support partner can also provide consultation on
control retrofits, mechanical rebuilds, and machine
reassignments – analyzing the benefit to productivity and
the impact on operations the changes may have. This allows
you to see the "big picture" and thoroughly understand the
condition of the equipment before investing in updating,
rebuilding or relocating it.
Working with a single-source maintenance provider is an
economical way to ensure you are getting the most from your
machines, operating at your highest possible efficiency and
poised to handle changes to, and adaptations for, future
operations.
Want more information? Click below.
MAG
Aerospace, Medical and Other High-Tech Parts Made
Faster at Less Cost with New Volumill Software,7000 RPM at
252 IPM vs 1200RPM at 16 IPM
Advanced Machining Systems, a full-service CNC machining
and design shop that specializes in precision-machined
components for several industries including firearms,
semiconductors, aerospace, and medical, recently embarked on
a top-to-bottom analysis of its operations to determine why
it was having trouble winning new business.
Formed in 2002, the company’s philosophy is to partner
with customers through the design, modeling and prototyping
phases of product development, culminating in optimized
production. AMS employs 2010 SolidWorks CAD software and
Mastercam X4 with solids capability to support its business
model. A new, 10,000-square-foot plant was dedicated in 2006
to house the entire operation including CNC machining
centers, turning and turn/mill centers, plus extensive
quality-control equipment and all business processes.
AMS has streamlined its work flow, moved from single
work-holding devices to gang setups to minimize set-up times
and has invested in dedicated preset tooling since early
2009. In addition, the company decided to focus machines and
areas of the shop for certain types of parts, families of
parts and sizes of parts to maximize handling efficiency.
The shop specializes in the machining of incubators for
medical research companies, aerospace hydraulic systems,
interior parts and life support systems for medical
transport helicopters, control surfaces for general aviation
aircraft, as well as parts for experimental aircraft and
firearms.
Big Benefit from New Toolpath Generation
The change that has had the greatest impact, according to
AMS Manufacturing Engineer Mark Christiansen, has been the
addition of VoluMill™, the high-speed-machining toolpath
engine from Celeritive Technologies. Since VoluMill runs as
a direct and fully integrated plug-in to Mastercam, AMS was
able to incorporate its use without missing a beat.
Christiansen says, “I use VoluMill wherever I can now:
profiles, slots, pockets, steps. I have been able to save at
least 50 percent on my cycle time, even up to 80 percent in
many cases, and we’ve slashed programming time, especially
on complex parts. As a result, AMS is now more profitable on
current work, much more competitive on new business quotes,
and more responsive to customers’ needs.”
VoluMill is a CAM-neutral, ultra-high-performance,
easy-to-use, plug-in toolpath engine to be used in place of
traditional roughing methods when ease of programming,
reducing cycle times, extending tool life, and reducing the
stress on machine tools is a priority. This single-algorithm
software program allows the programmer to determine and
utilize the optimum material removal rate for any
combination of part geometry, material, machine and cutting
tool quickly and easily. VoluMill generates a dynamic
toolpath that delivers the most consistent cutting
conditions possible and allows the use of the entire flute
length of the tool. The use of VoluMill can significantly
reduce cycle times and wear on cutting tools and machines.
Christiansen learned about VoluMill from a colleague who
told him how much it was reducing his company’s programming
and cycle times. “So I went to the VoluMill website, tried
it, and discovered it did everything they claimed, plus it
reduced my tool inventory by allowing me to use solid end
mills versus indexable face-milling cutters,” he reveals.
“Well before the end of the 15-day trial, my bosses were
saying ‘buy it!’ So I did.”
Firearms Industry
Precision machining is critical in the manufacture of
fire arms and their internal components. AMS produces
compensators for 9-mm pistols from 7075 aluminum. VoluMill
has allowed AMS to realize a huge reduction in cycle time on
the compensators by taking a full, 1.6” depth of cut with a
.5” five-flute end mill. Taking a full-flute-length-deep cut
was not possible before.
“We went from machining this part in 9 minutes doing one
at a time before VoluMill to 3 minutes doing three at a time
with VoluMill,” Christiansen says. “That’s a 200%
productivity improvement, which was achievable not only
because VoluMill allows us to use higher feeds and speeds,
but in this case, the use of the full length of flute
eliminated the need for multiple stepdowns.”
Christiansen reports that he’s also using VoluMill for
several other operations when machining the compensators.
“I’m not just using it to mill pockets,” he says.
“Programming with VoluMill is so easy, it’s saving me tons
of time on programming open and complex parts that are so
difficult and time consuming to program with Mastercam. On
one open part, for instance, VoluMill takes the side profile
and allows me to use dashed lines to designate where the
stock boundary is to define the area to machine. VoluMill
just programs the part after that. It’s so simple. And it
knows how to remove the material much more effectively than
any Mastercam toolpath. It always starts out of the
material, which is a lot better on the cutting tool, and
it’s much faster, too. With Dynamic Mill, I have to create
dummy geometry, and then do some additional manipulation
just to prepare it to generate a toolpath. Before we started
using VoluMill, it took me 30 minutes and a lot of
frustration to program the part with Mastercam, but it took
me only 15 minutes to program it with VoluMill, and then
VoluMill roughed the part out better, too.”
Another firearms component on the AMS production schedule
is a part made of A6 tool steel that is used for rifle
testing. “It used to take 75 minutes to program the part and
35 minutes to rough out the first of two operations. With
VoluMill, it took only 45 minutes to program the part and
then 9 minutes to rough it out,” Christiansen notes. The
smooth and fluid tool motion in the VoluMill toolpath allows
AMS to machine the part at 7,000 RPM and 252 IPM with a
6-flute end mill. “I was only able to run the machine at
1,200 RPM and feed it at 16 IPM with a 1/8” step down
before, so now I’m getting much higher machine utilization
efficiency,” Christiansen explains.
AMS used to wear out two end mills per month on this part
that it produces regularly. Now, in the month that AMS has
been using VoluMill on this part, the shop has yet to change
the end mill. “We have seen hardly any wear on this tool,”
Christiansen says. “And it was a used end mill to start
with, actually a regrind.”
AMS also produces a 7075 aluminum part used in testing by
the semiconductor industry. The part took nearly 11 minutes
to machine using a traditional toolpath. Now, using a
VoluMill toolpath, the actual run time for the part is “3
minutes flat,” according to Christiansen.
VoluMill Adds Responsiveness
In addition to making it faster, easier, and more cost
effective for AMS to produce parts, VoluMill also allows the
shop to be more responsive to its customers. For example, an
engineer from a local construction company recently walked
into the shop needing four different spacers that were to be
used in a concrete mold for a building project his company
was working on at that time. He told Christiansen he was in
a rush so he needed the parts immediately.
“He was a new client; we’ve never done business with his
company before,” Christiansen recalls. “He needed the job so
fast that we didn’t even go through our usual new product
design and order processes. We designed and programmed the
four parts from hand sketches and then machined them in less
than an hour. We never would have been able to be that
responsive before. The programming and machining process
would have taken us at least 5 hours before VoluMill,”
Christiansen claims.
One of the parts was a 44x2.125” piece machined from 1045
steel bar stock. The run time was 2 minutes using a ½”
diameter, 5-flute carbide end mill run at 315 IPM and 10,000
RPM. AMS programmed a 1” axial DOC with a .125” radial DOC.
Christiansen indicated that before VoluMill, he probably
would have used a three-flute indexable milling cutter at 58
IPM with a .118” depth of cut. He estimates that it would
have taken 18 minutes to machine, or about nine times
longer.
In addition to the savings of time in programming and
machining, Christiansen also reports that the use of
VoluMill toolpaths is substantially reducing the wear and
tear on his tools and machines, and its use is changing the
type and number of end mills AMS keeps in its inventory.
“The biggest thing for me is the reduced wear on the end
mills, and the ability to run our operation while stocking
fewer tools,” says Christiansen.
Before AMS started using VoluMill it kept a large supply
of different sizes of end mills in inventory. This was a
natural requirement of the practice of starting with large
tools to remove as much material as possible from an area,
followed by a series of sequentially smaller tools to remove
the material where the previous, larger tools could not fit.
With VoluMill, AMS has found that removing all of the
material with smaller cutting tools that fit everywhere is
significantly more efficient than with prior methods. So,
with the company’s adoption of VoluMill, AMS purchased just
a few, smaller 5-flute end mills. Since then, Christiansen
says he “has not had to order any new end mills. With
VoluMill, they just don’t wear out, even on A6 tool steel.
“I have been able to push the boundaries on our end mills
and even push the conservative speed and feed estimates
provided by VoluMill,” he adds. “Moving forward, as we add a
new machine – which we do about once a year – we will look
for higher spindle speed and feed rate capability. I never
thought we’d need more than 8,000 RPM to cut steel, but with
VoluMill toolpaths, we can easily use much more than that.”
VoluMill also has had a tremendous impact on AMS’s
ability to win new business. According to Christiansen, many
of its competitors have slashed their shop rates in an
effort to attract new jobs, or even keep existing jobs, but
AMS hasn’t needed to follow suit. “With the increased
productivity and reduced costs that VoluMill has brought to
us, not only have we not lowered our shop rates, but we are
able to win bids against shops whose rates are now half of
ours, and still attain higher margins than we had before.
With VoluMill, our success rate on bids has improved
dramatically.”
While AMS made many changes to its operation since early
2009, it’s clear that the addition of VoluMill has had the
most impact. By reducing part programming and machining time
with VoluMill toolpaths, especially on complex parts, AMS is
more profitable, more competitive on new business quotes,
and more responsive to customers. Those are results that
breed success.
Want more information? Click below.
Celeritive
Fuse Pins Must Be Designed to Hold a Jet Engine on a
Wing, But to Break Away in Emergency Situations, Allowing
the Engine to Separate from the Wing to Prevent Catastrophic
Structural Failure and Fires
Knowing when to "hold 'em" and when to "fold 'em" takes
on new meaning when referring to the fuse pins designed to
hold a jet engine on a wing, but to break away in emergency
situations That is the performance dilemma faced by the
highly-engineered, precisely-manufactured aerospace
components produced by Sonic Industries. To achieve this
delicate "hold-or-fold" balance, Sonic relies on a new
Sunnen SV-1000 honing system to produce the 5-to-7-micron ID
tolerance and proprietary finish critical to the part's
performance. The CNC-controlled SV-1000 also allowed Sonic
to meet increased customer demand when it replaced a manual
honing system, reducing cycle times from 40 minutes to 10
and increasing productivity from nine to 40 parts per day.
Sonic Industries, based in Torrance, California, is part
of the Sargent Aerospace & Defense group. The ubiquity of
Sonic's fuse pins in today's commercial and military
aircraft, and the importance of their proper performance,
make the design and manufacture of these small parts as
important to air travel safety as the integrity of a wing or
soundness of an engine.
Sonic
used to hone fuse pins manually; the CNC-controlled
SV-1000 helped reduce cycle times by 75 percent, and
increased productivity from nine to 40 parts per
day.
The fuse pin, also known as a shear pin, affixes the
engine onto the wing via the pylon – the structural
component connecting the jet engine to the wing spar. When
necessary, it allows the engine to break away under an
impact load in the event of a crash or other hard landing,
protecting the fuselage from engine fire caused by a dragged
engine. Fuse pins serve a similar function for landing gear
assemblies. Located in a structural assembly nicknamed the
"doghouse fitting," fuse pins attach the landing gear to the
wing and are designed to "fail" in the event of an extreme
hard landing, allowing the main landing gear to safely break
away from the airplane and prevent rupture of the fuel tanks
inside the wing box.
Sonic
Industries must meet ID tolerances of 5 to 7
microns, with a surface finish in the range of 8-16
RMS, for its fuse pins. The pins attach jet engines
onto the wing and break away in emergency situations
to prevent catastrophic structural damage and/or
fires.
Previous versions of fuse pins were designed with a notch
that would act as a "weak spot" and facilitate them breaking
on impact. However, a cylindrical pin with a notch is more
vulnerable to excessive corrosion and fatigue damage.
Therefore, fuse pins were re-engineered without the notch,
making ID tolerance and finish the critical factors in their
performance.
Fuse pins are made of steel and stainless steel alloys
including 318 and 15-5; they have various diameters and
lengths up to 23 inches. The pins start as a bar forged to
specific geometry and are gun-drilled, then bored to a rough
preliminary hole size. The parts are then heat-treated and
tested to establish the shear value, and the entire lot is
processed to final machining and finish grind on the OD. The
heads are finish machined with slots or hexes. The pins are
then bored to a specified size and honed to establish the
critical ID size, geometry and surface finish required for
proper performance.
Prior to acquiring the SV-1000, Sonic honed fuse pins
manually with Sunnen MBB 1805 and CV-616 machines. "We
needed to increase productivity and decided automating the
honing process was the best way to accomplish it," said Roy
Franks, Facility Manager of Sonic Industries. "Before
purchasing the SV-1000 we conducted time studies with
Sunnen, and indications were we could achieve the production
levels we were looking for. The machine has since exceeded
the time study estimates and the finish is superior to the
previous manual-honing method."
Sonic's
fuse pins have various diameters and lengths up to
23 inches. The Sunnen SV-1000 handles diameters up
to 3 inches and stroke lengths to 31 inches.
While the OD is machined to standard dimensional
tolerances and is repeatable, the ID must meet tolerances of
5-to-7 microns (0.0002 in. to 0.0003 in.). The ID surface
finish of the fuse pins is also critical, and while the
precise surface finish specs are proprietary information,
Franks says they fall in the range of 8 to 16 RMS.
Consistent size and finish of the ID are very important, as
size variations or surface irregularities could affect the
performance of the pin. The ID geometry of the fuse pins can
vary from a thru hole to a blind hole with an angle and a
radius, or just a bottom radius.
By upgrading to the SV-1000 series machine, Sonic is able
to use the Sunnen MMT superabrasive tools to achieve the
required micron-level accuracy. MMT tools are specifically
designed to work with the SV-1000 series machines, and each
tool is custom-engineered to the application based on width,
length, expansion angle, and number and placement of stones.
This customization produces accuracies of 0.0006 mm
(0.000027 in.) for diameter, roundness, straightness and
taper. MMT tools are precision-machined with a body and feed
wedge made from hardened tool steel, and typically last five
times longer than conventional designs, reducing per-part
cost by 30 percent. More importantly, the custom design of
the tools allows placement of abrasives to cope with
challenges like blind holes.
Another advantage for Sonic going to the SV-1000 is the
machine's longer stroke length. "Our old machines were
labor-intensive and had a maximum stroke length of 9
inches," said Franks. "It limited the parts we could
produce, but now we're able to make more sizes, and we're
doing it faster." The SV-1000 handles diameters up to 3 in.
and has a 31-in. stroke length.
Sonic
uses Sunnen MMT superabrasive tools, which last five
times longer than conventional designs and can
reduce per-part cost by 30 percent.
Automating the honing process also freed up Sonic machine
operators to attend to more than one machine. "With the
manual hones our process was hone a little, then check the
part, hone a little more, then check the part again," said
Franks. "With the CNC hone we 'dial in' the settings on the
machine and 99 percent of the time the part comes out to
spec. That means the operator can have one eye on the honing
machine and one on another piece of equipment." After
honing, parts are measured using a scanning air gage.
Sonic was able to achieve a more than 300 percent
increase in productivity, but Franks thinks that number can
climb even higher. "We didn't get the rotary table with this
machine, and we could bump up productivity even more by
loading three parts in the rotary table and continuing to
hone parts while others are being checked. We're looking at
possibly purchasing another SV-1000 and we'll be considering
the rotary table with that one."
Want more information? Click below.
Sunnen
Economical manufacturing has never been more critical as
businesses seek new ways to remain competitive. Herker
Industries, a leader in precision machined parts, mechanical
assemblies and contract welding, has poised itself to
increase business and extend the value of efficient
production to its customers, helping to build their
profitability. Recent acquisition of eight advanced
machining stations including the Nakamura-Tome Super NTM3
CNC turning center from Methods Machine Tools, Inc.
(Sudbury, MA) increases the company’s ability to provide
custom machined components. Herker acquired the equipment
for its proven performance of high quality production at
tremendous speed.
The additional equipment also includes two horizontal
machining centers that provide greater breadth of milling
applications. Overall, the new machining centers expand
horizontal and vertical machining capacity. The increased
capability provides original equipment manufacturers with
machined assemblies for end products ranging from medical
devices to agricultural equipment, at highly competitive
prices.
“As part of our commitment to continually improve
technology, we’ve expanded our offering with an investment
in the latest generation equipment and machining process,”
said Dennis Driscoll, vice president of sales. “By staying
on the cutting edge we’re able to provide high quality
products with quicker turnaround and pass the cost savings
on to our customers. We’re constantly striving to do things
better while maintaining our strong business position.”
In the past five years Herker has reinvested over five
million dollars to offer versatility through technologically
advanced equipment for the changing demands of its
customers. The company has used their own cash for
everything they have purchased. They told Tooling &
Production they currently have zero debt. The contract
manufacturing operation is customized to meet unique
customer needs. From process design and production layout,
to supply chain management that delivers quality products on
a just-in-time basis at competitive costs, a complete
solution to a wide range of manufacturing industries is
offered.
Herker’s solution set includes an experienced team
dedicated to optimizing the latest machining technology
through continuing education programs including internal
performance audits. The average length of employment is 14
years, with many third-generation and thirty-year service
employees. Their machinists have been fully trained to
efficiently operate the new advanced equipment and maximize
capabilities for each new job.
For nearly six decades, Herker has served leading
companies in the fluid power, power generation, power
transmission, construction and agricultural equipment,
heating/ventilation/air-conditioning industries, motor
vehicle parts, medical and industrial machining industries.
Located in a comprehensive 130,000-square foot manufacturing
facility, Herker sets itself apart as a versatile company
committed to exceeding customer expectations with a
dedicated team of machining experts.
Turning Center Details
The Nakamura-Tome Super NTM3 PC-G from Methods
Machine Tools, Inc. is a state-of-the-art CNC turning center
proven to increase productivity and decrease milling and
turning production costs. The three-turret multi-tasking
machine achieves faster production by improving through-put,
minimizing set-up time and eliminating operations. NTM3
advanced programming provides computerized simulated 3-D
modeling for quick turn-around. With consolidated machining,
simultaneous production is executed within one NTM3
turning center, increasing capabilities and reducing cycle
time.
First machining and repetitive machining are executed to
exacting accuracy and high rigidity by the NTM3,
even in hard turning applications. High precision, tight
tolerance milling and turning of tough materials are handled
rapidly and flawlessly through advanced equipment and
computer programming. Features include:
- Opposed two spindle, three turret construction
- Two upper turrets equipped with “Y”-axes
- All turrets equipped with Mill/Drill capabilities
- Maximum capacity of 72 fixed tools and 36 driven tools
for milling
- Bar stock capacity range of 2mm to 65mm
- 12-foot auto loading bar feeder
Economies gained from NTM3 lights-out
production allow the company to extend lower costs to
customers. The high value of increased quality production
for less means OEMs can be competitive. Herker has been
successful for nearly 60 years through its niche of
versatility and customer commitment. Company owners
recognize that success lies in finding viable solutions to
changing demands. With their comprehensive quoting process
through looking at all methods of manufacturing for the best
possible solution, they can quote parts at a highly
competitive cost.
Want more information?
Click below.
Herker
Industries
Methods Machine Tools, Inc.
Free February SME Webinar Summaries Offered.
Does machining or molding something so small that you
can’t see it with the naked eye seem like science fiction to
you? Then perhaps you are one of the manufacturing
practitioners who need a few myths busted.
While they may sound like futuristic concepts, in fact,
micromanufacturing and nanomanufacturing are becoming the
biggest thing since the moving assembly line.
A recent survey by the Society of Manufacturing Engineers
(SME) found that out of 400 manufacturing professionals who
expressed an interest in micromanufacturing, only half are
already using it in their products today. And more than 60
percent indicate nanotechnology is important to their
organization’s future growth.
There are many myths associated with these smallest
manufacturing processes and SME wants to bust them into
nano-sized particles so that manufacturing practitioners can
take advantage of these real-life sci-fi opportunities.
Myth #1: Nanomanufacturing and
micromanufacturing are technologies that may be something
great in the future, but they are not viable for today’s
business environment.
Fact: Both nanomanufacturing and
micromanufacturing are actively being used by many
manufacturers. Nanomanufacturing is a key enabler of the new
generation of lithium batteries for electric cars.
Micromanufacturing is being used by Boeing, RubberMaid,
Gillette and many other companies.
Myth #2: Micromanufacturing is only used
in the electronics industry.
Fact: Not any more. Micromanufacturing
reaches far beyond electronics. For example, it is essential
in the production of many medical devices and critical
aerospace systems.
Myth #3: Micro and nano are just reduced
sizes of the “life-sized” objects.
Fact: The rules of the game are changed
when dealing with these technologies. There are significant
process and material behavior changes beyond size that you
need to understand.
Myth #4: If I can machine “small” stuff,
I can “micro” machine.
Fact: Machining micro pieces requires
special tools and skills. In traditional machining, the
greater force is exerted by the tool onto the material. For
micromanufacturing, it flips, and the material exerts more
force on the tool.
Myth #5: If I can mold “small” stuff, I
can mold micro particles.
Fact: Molding micro pieces also
requires special tools and skills. Often with micro molding,
the piece or feature is smaller than the pellet size of the
material. This requires special attention to the flow,
pressure, fill time and increased impact of the material
reaction with the mold wall and, most critically, the design
of the mold itself.
Myth #6: Even if I wanted to use micro
or nanomanufacturing processes, tools, suppliers and
materials are practically non-existent.
Fact: While that once was true, it’s not
so much any more. There are growing numbers of processes,
tools, materials and suppliers available for manufacturers
ready to move into micro and nano manufacturing.
Want more information? Click below.
SME
The family of turbocharger shafts produced at Cummins
Turbo Technologies, Palmetto, SC, has up to 11 diameters and
various lengths—a complex part to inspect consistently and
at rates that keep up with production. But Clayton Butler,
metrology technician, has a solution that has been working
on the Cummins shop floor alongside the grinding machines
for several years. He calls it his HOG -- the Hommel Optical
Gage.
Machine operators use the Opticline from Hommel-Etamic
America, Rochester Hills, MI, to measure a shaft and turbine
impeller wheel assembly for the turbochargers it produces--
diameter, run-out, straightness, length. The staff also uses
the gage on the shop floor to measure an impeller mounted on
an arbor. Each part is measured between centers.
Cummins began investing in the optical measuring
technology nearly 10 years ago and now operates 9 machines
of various capacities. It has five of the model 314
Opticline, capable of parts 300 mm in length and 140 mm in
diameter.
“We measure diameters to 4 microns with a gage R&R of
5%,” reports Clay. “You can’t touch that anywhere. We just
need to have the part extremely clean as it is an extremely
fine measuring device, yet it operates beautifully alongside
the grinders.”
Machine
operator loading Cummins Opticline.
Hommel-Etamic’s Opticline non-contact CNC shaft gaging
system measures form, dimensional, and positional tolerances
of shaft-type parts in submicron detail with a
maintenance-free two-camera system, recording results
instantly. The optical measuring machines are ideal for
complex parts as bearings, turbine blades on the shop floor,
in the metrology lab, or within a production system.
The fully flexible shaft gaging systems accommodate shaft
type part sizes from 0.2 mm to 480 mm diameter, 1 mm to 2500
mm long with measuring accuracies to +/- 1 micron, and
provide a powerful alternative to conventional shaft
measuring techniques that is faster, more accurate and more
complete.
Contour, diameters, length, roundness, concentricity,
cones, angles, flatness, parallelism, eccentricity, stroke,
threads, and more, can be recorded during a single pass of
the optical measuring head. Measurements are easily
completed within a production cycle for 100% quality
control.
“The versatility of the machine is a big help as we are
always improving shaft and wheel designs, and the Opticline
keeps up with that easily,” Clay said. “With air gaging or
hard gaging, there is a lot of setup and time-consuming
changeover, but with the Opticline, I can change programs in
about 15 seconds and be ready for the new part number.
Flexible chucking helps also.”
To create a program, Clay scans the part with the
Opticline cameras, establishes a length of scan, and then
starts a measurement cycle. “Previously, we would use touch
probe gages and compare that to a master,” Clay pointed out.
“To accomplish the shaft measurements with air gages or ring
gages, you would have multiple gages, which require setup,
mastering, and maintenance. This adds up to greater cost
over 3-4 shaft designs with a couple of sizes of each.”
Plus the accuracy for the optical gage is superior to the
ring gage approach. With the Opticline, the machine compares
the profile of the part to a nominal profile of the part.
As for the quality of the parts, the grinding machine
operators like Opticline. It is simple to use. They put the
parts between centers, start the measuring cycle, and in
less than a minute have complete measurement results while
they continue to monitor the cylindrical grinding machines.
Because the cycle is so fast, operators are more likely to
check parts and report any changes in the shape of the part
due to breakdown of the grinding wheel.
On the shop floor, the profile grinder operator produces
three diameters, then measures the profile, then moves the
workpiece to another grinder that creates a groove in the
shaft. The operator then measures the profile form,
location, diameter, lead direction, run-out and more.
“How many parts of a run are checked depends on the
capability of the process” Clay said, “but the operators
typically check 100% -- because with the Opticline, they
can. And there is a lot of capability for measuring
different features that we have not yet begun to explore,”
Clay said.
Want more information? Click below.
Hommel-Etamic America
DEFA, COFA and the Flex-Hone tools eliminate costly
and time-consuming hand benching
In the aerospace, automotive, semiconductor and medical
sectors, it is vital that fastener through-holes are
chamfered and free of metal burrs caused by the hole cutting
process to ensure a flawless fit and durability when parts
are assembled. With this in mind, progressive manufacturers
are increasingly automating this process by incorporating a
unique combination of cutting, edge breaking and deburring
tools plus a unique flexible hone called the Flex-Hone to
provide a smooth finish without hand benchwork.
In
combination with the Heule cutting tools, the Flex-Hone is
used for final deburring of through-holes, which is often an
expensive and time-consuming hand (bench) operation.
“Any time you drill a hole into nickel, Inconel,
waspalloy (nickel-cobalt alloy), any type of titanium or
stainless you will also create a burr,” says Gary Brown,
Vice President and General Manager of Heule Tool of North
America (Cincinnati, OH), a subsidiary of cutting tool
global leader Heule Werkzeug AG.
A precise, smooth through-hole is often a crucial
requirement,” says Brown. “In many applications you are
going to have several components, either static or rotating
parts that are assembled together. It is critical that the
hole drilling and edge breaking processes be performed so
that these parts stay together, which is particularly
important with the rotating parts. So, we stress making good
through-holes by drilling, milling or reaming – whatever
process is called for.”
Heule's
cutting tools, along with the Flex-Hone, remove the drill
burrs and drill caps that are inevitably created when
drilling a hole in nickel, Inconel, waspalloy, titanium, and
stainless steel. A precise smooth through-hole is a crucial
requirement in the aviation industry.
Brown explains that among the main goals among the
leading manufacturers is the avoidance of costly and
time-consuming hand benching operations, where components
are taken offline from the CNC operations so that holes –
normally chamfered - can be deburred and finished by hand.
“To avoid delays and keep tool costs to a minimum, some
shops are automating this process, incorporating Heule’s
DEFA precision chamfering tool and COFA universal deburring
tools plus a unique ball-style hone called the Flex-Hone
from Brush Research Manufacturing (BRM) of Los Angeles that
provides the final step in providing a flawless finish,”
says Brown.
The DEFA tool, available in sizes from 0.157 inch to
1.750 inch, is a double-bladed chamfering tools that creates
pre-adjusted front and back chamfers in a single pass
without stopping or reversing the spindle. Using this tool,
exact chamfer diameters can be set without trial and error.
The
Flex-Hone from Brush Research is characterized by the small,
abrasive globules that are permanently mounted to flexible
filaments. A flexible, relatively low-cost tool, it is
utilized for ultra-fine surface refinishing, de-burring,
plateau finishing, and edge-blending.
The COFA tool blade, available in sizes from 0.157 inch
to 1.614 inch, cuts a smooth tapered edge break from
0.005-0.020 inch, based on the tool size. A cassette option
is available for larger holes. The patented design
incorporates a unique Tin- or TiAlN-coated carbide blade
that allows for faster feeds and speeds, and provides
exceptionally long tool life.
The Flex-Hone, available in standard sizes beginning at 4
mm (custom sizes and abrasives are available) is
characterized by the small, abrasive globules that are
permanently mounted to flexible filaments. A flexible,
relatively low-cost tool, it is utilized in the
manufacturing marketplace for ultra-fine surface finishing,
de-burring, plateau finishing and edge-blending.
“Our tool cuts through the metal and puts the beveled
edges on the front and back of the metal part,” explains
Brown. “It produces the beveled edges on the front and back
of the part as well as removes the drill burrs and drill
caps that are created by the drill or reamer or end mill.
Our tools also perform the edge-breaking step. But we also
recommend the Flex-Hone to go in after we have created these
beveled edges, and the flexible hone will round the
transition between the beveled edge and the hole.”
Want more information? Click below.
Brush
Research Mfg. Co., Inc.
Please rate this article:
Very interesting, with information I can use
Interesting, with information I may use
Interesting, but not applicable to my operation
Not interesting or inaccurate
Comments: