Archive for the ‘Mill’ Category

Machining refers to the industrial process of cutting and fabricating metals and other materials into predetermined shapes and sizes. Machining process is controlled with the help of computer numeric control (CNC) software that guides the cutting equipment along the lines and arcs of a computer aided design (CAD) drawing.

A machining process may involve the use of different techniques depending on the number of parts being manufactured and the type of material. Machining techniques may include manual machining, which is used for cutting metal sheets in simple shapes such as circular, square, and rectangular. This process is however being replaced by automatic machining systems and processes that can cut any type of shape out of metal sheets needed for different purposes.

Chemical etching machining technique is mainly used for producing typical precision parts. The machining system offers a great flexibility for producing precision parts with unusual configuration as well as metals with tight tolerance within .0005′. Besides this, chemical etching machining is capable of producing small holes and bars that are not possible with other machining techniques. Another common process is Wire Electrical-Discharge Machining (EDM) in which the metal is separated from a conductive work piece by means of electrical erosion. During this process, the wire never touches the conductive work piece and leaves a path on the work piece, which is slightly larger than the wire.

Another technique known as the metal stamping machining phenomenon, which is also referred to as progressive die stamping or long run metal stamping, is extensively used in production of precision parts with thickness from .002′ to .135′. The technique is mainly used for processing typical low price parts that are formed into three dimensions.

Apart from these, some modern techniques are also in use such as abrasive water jet and laser machining that are more accurate and environment friendly as compared to conventional machining techniques.

Originally posted 2007-09-30 09:18:07. Republished by Blog Post Promoter

Mill/turn complete machining CAM module allows operators to switch between turning and milling strategies at any time whilst they are programming

At the UK’s MACH 2008 machine tool exhibition, Open Mind Technologies UK will present its latest innovations for efficient CAM programming. Highlights will include the mill/turn hyperMILL millTURN module for complete machining on milling and turning machines, the new CAD integration of hyperMILL in SolidWorks and the latest version of hyperMill V10 – all to be shown in the UK for the first time.

The capabilities of Open Mind products will be highlighted with numerous live demonstrations of workpieces programmed using hyperMILL.

These will take place on the Open Mind stand as well as on the stands of the various machine tool partners.

Open Mind’s technology partners include the following.

* Agie Charmilles UK.

* CG-Tech.

* CMS Group.

* DMG UK.

* Hurco Europe.

* Mori-Seiki UK.

* Seco Tools UK.

* YMT.

Some of which will be using hyperMill cam software at MACH to provide live machining demonstrations.

Live demonstrations taking place at MACH, said Open Mind to manufacturingtalk.com, will show that hyperMILL is not only a flexible and user-friendly cam system but also a system that delivers first-class machining results.

Further details on live demonstrations can be found on the Open Mind stand at the show.

* Mill/turn in one program – as well as providing multiple demonstrations at MACH with its technology partners, visitors to Open Mind’s stand will be able to witness the hyperMILL millTURN Version 10 CAM software for milling and mill-turning with just one program.

The ability to accurately manufacture complex parts in a single set-up, reduce set-up times and increase efficiency has brought considerable demand for the mill/turn module that has been integrated into hyperMILL.

Users can switch between turning and milling strategies at any time whilst they are programming.

It also allows users to generate NC programs very easily.

The tool database, automatic stock tracking, stock management and collision control are available for all turning and milling strategies.

A mill/turn postprocessor ensures that a complete NC file is produced.

In addition to the new mill/turn module, hyperMill V10 promises to increase performance considerably thanks to its multi-core processor support.

Alongside this will be version V10 presented for the first time at MACH.

This is destined to be a major highlight for all SolidWorks users as this version includes the new CAD integration of hyperMILL in SolidWorks.

This integration allows users to work with hyperMILL in their familiar SolidWorks environment.

This version will also support Windows Vista.

* Open Mind at MACH 2008, NEC, Birmingham, UK, April 21-25, Hall 5, Stand 5556.

Originally posted 2008-01-09 23:55:35. Republished by Blog Post Promoter

Originally posted 2008-02-12 16:45:37. Republished by Blog Post Promoter

Industrial Information – High Speed Milling Machines

High speed machining is a proven stipulation characterized by low cutting forces and high metal removal. High Speed Milling is a technique used in the CNC Milling Industry that combines high spindle speeds with increased feed rates. This results in a high chip-forming rate and lower milling forces, producing an improved surface quality and closer tolerances. In high speed milling, the electronics can make all the difference. The right CNC coupled with other elements of the control system can let a slower machine mill a given form faster than a machine with a higher top feed rate.

1. High Speed Uses

High-speed CNC milling is used, for example, to machine the titanium rotors of the first high-pressure compressor stages of the EJ200 engine. High speed CNC milling allows cost-effective milling of the airfoil geometry from the solid. By subsequent finishing operations the planned surface finish is achieved. The CNC milling which caters to high speed must be structured with an axis movement system that is suitable for machining.

2. Axis Movement

The high-speed CNC milling machines required for the process must be fitted with an axis movement system suitable for machining blisks, which should be at least 5 axes simultaneously, depending on the milling task involved and an efficiently high-speed control system.

3. 3D Surfaces

High Speed CNC milling machines working on 3D surfaces in any materials produce a finer surface finish and higher accuracy in less time that the traditional milling machine. Acceleration is the most critical factor that affects the high speed machining. Since one or more axis are always increasing or decreasing velocity in a 3-D cut, ultimate feed rate is directly related to acceleration

4. What Can A High Speed Control Possibly Do?

A CNC milling machine which possesses a higher structural stiffness has a greater potential acceleration rate. Box shaped high speed CNC milling machine, like Bridge and Gantry is the mostly widely used types of High speed CNC milling tools. The overhead type Gantry exudes the highest stiffness, acceleration and accuracy among other high speed CNC milling tools. Due to its scalability, this machine type is available in sizes to match the work piece, from small to large.

In usual terms, it simply gives you the ability to finish one task faster and move along to the next sooner, making work output higher. In drilling and tapping, this can result in faster hole-to-hole times, quicker spindle reversals for tapping, and substantial cycle-time reductions. The most dramatic benefits, though, come in 3D designs machining. Few, drilling and tapping jobs require a million lines of machine codes. In molds, dies, patterns, and prototypes, complex surfaces comprising a million or more line segments are not at all uncommon. Saving just a fraction of a second per move can result in substantial cycle-time improvements.

5. Downsides – When Is Fast Too Fast?

But despite all these benefits, in high milling, the tool path segments can be so short that a machining center moving at a high feed rate can?t accelerate or decelerate fast enough to make direction changes accurately. Corners may be rounded off and the work piece surface may be gouged. Look-ahead is one answer. Look-ahead capability can let the CNC read ahead a certain number of blocks in the program, to anticipate sudden direction changes and slow the feed rate accordingly.

6. Additional Benefits:

- Improved accuracy
- Better fit
- Superior finish
- Better life
- Produce more work in less time
- Improving the accuracy and finish
- Reducing polishing and fitting time
- Tools simply last longer because their chip load is more consistent

About the Author:

For more great milling machine related articles and resources check out http://www.millinginfo.com

Originally posted 2007-11-13 10:18:07. Republished by Blog Post Promoter

Mill/turn centre has a lower turret equipped with a 60mm Y-axis traverse that increases capability for new processing applications and cutting tools

With a lower turret equipped with a 60 mm Y-axis, Yamazaki Mazak UK said that the versatility of its Integrex e-420H-ST II mill/turn centre is considerably expanded. It delivers increased capability for new processing applications and cutting tools. The ability to mount turning tools, tailstock, steady rest attachment or special fixtures on the lower turret opens up numerous machining possibilities for delivering maximum productivity from a single machine tool.

The Integrex e-420H-ST II has upper turret axis travels of 845mm and 420mm (X and Y) complemented by a lower turret with axis travels of 232mm and 60mm (X and Y) and upper and lower Z-axis movements of 2088mm and 1893mm respectively.

Yamazaki Mazak told manufacturingtalk.com that the machine can meet almost any kind of production requirements.

These large and multiple axis movements are combined with powerful main and second spindles (4000 rev/min, 30kW), both equipped with C-axis, which is capable of the smallest of incremental movements.

For rotary tool applications the upper B-axis spindle is a 12,000 rev/min, rated at 22kW, while the lower rotary tool spindle is a 6000 rev/min, 5.5kW unit.

* Reducing manufacturing costs – this combination of machining capacity and power makes the Integrex e-420H-ST II a complete fusion of machining centre and turning centre to provide a machining platform capable of reducing manufacturing costs through improved productivity.

The Mazak e-machines fully embrace the Information Technology age and bring the idea of the ‘intelligent machine tool’ to reality.

The Mazatrol Matrix control has been developed with a number of intelligent functions that assist the operation of the machine and allow communication between the machine tool, control and the manufacturing/production system in operation within a factory.

These functions also provide both management and operator with a wide range of relevant production information and feedback.

For example, the e-tower, which is integral with the e-machine, provides the operator with, for example, set-up support and access to operating and maintenance manuals and work schedules.

Management, in turn, can download programs, scheduling data and component drawings, while receiving real-time information relating to machine and job status.

** Yamazaki Mazak UK at MACH 2008, NEC, Birmingham, UK, April 21-25, Hall 5, Stand 5360. Request a free brochure from Yamazaki Mazak UK….

Originally posted 2008-02-12 16:31:20. Republished by Blog Post Promoter

Precision machining is a process that is used to produce a large number of both large as well as small objects that we make use of in our daily lives. Each intricate and detailed piece that makes up an object needs the touch of a machinist’s skills. Similarly, a machine or tool that is worn down will require the action of machine tool calibration quite frequently. There are also other facilities provided by precision machining apart from calibration. These would be detailed welding or grooving carried out by a precision machinist. Ranging from aircraft aluminum alloy production right till devices for surgically drilling of bones precision machining caters to almost every industry and technology. Put simply, if an object is made of parts, it would have needed precision machining.

While the majority of precision machining companies usually work with one form of CAD/CAM programs or another, they still do often work with sketches that are hand drawn. Although the hand sketches are usually made use of only in the initial phases of a design. Precision machining can be used on a variety of materials that include graphite, bronze, steel, plastics and glass to name just a few. Based on the project size and the materials that are to be used, different kinds of precision machining tools are put to use. Precision machining is indispensable to numerous industries and various kinds of technologies. Without precision machining we would be unable to manufacture a number of detailed and intricate parts of various objects. The detail and accuracy it brings into the manufacturing procedure is what renders precision machining as so indispensable. There is a long list of machining companies that specialize in precision machining and you can use the Internet to locate them and avail their services. Precision machining is an integral part of mechanical and manufacturing industries.

Originally posted 2007-09-28 01:46:30. Republished by Blog Post Promoter

As every one knows, chips are formed during the machining of workpieces. The side of the chip in contact with the cutting tool is normally shiny, flat and smooth while the other side, which is the free workpiece surface, is jagged due to shear.

It is important to study the formation of chips during the machining process as the former affects the surface finish, cutting forces, temperature, tool life and dimensional tolerance. Understanding the chip formation during the machining process for the specific materials will allow us to determine the machining speeds, feed rates and depth of cuts for efficient machining and increased tool life in the specific actual machining operation. During the machining process, three basic types of chips are formed. They are discontinuous chips, continuous chips, and continuous chips with built-up edge.

Discontinuous chip formation normally occurs during machining of brittle work material. This type of chips also occus in machining operation with small rake angles on cutting tools, coarse machining feeds, low cutting speeds. Discontinuous chip formation results in poor workpiece surface finish.

During continuous chip formation, a continuous "ribbon" of metal flows up the chip-tool zone. This is considered to be the ideal condition for efficient cutting action.

Continuous chip with built-up edge formation is basically the same process as continuous chip formation, except that as the metal flows up the chip-tool zone, small particles of the metal begin to adhere or weld themselves to the edge of the cutting tool. As the particles continue to weld to the tool, it affects the cutting action of the tool.

This type of chip formation is common in machining of softer non-ferrous metals and low carbon steels. Common problems are the built-up edges breaking off and being embedded in the workpiece during machining, decrease in tool-life and final poor surface finish of the workpiece.

Studies on the built-up edges have shown that the chip material is welded, deformed and then deposited onto the rake face of the tool layer by layer. It is thus possible to observe the presence of built-up edges by studying the back face of the chip during the machining process. This is normally used in micro or ultra precision machining operation.

To reduce built-up edges, improve the lubrication conditions, use sharp tools and better surface finish tool and also apply ultrasonic vibration during the machining process.

About the Author

Author Ken Yap is a director of Suwa Precision Engineering Pte Ltd in Singapore and represents precision metal stamping, swiss screw machining, miniature precision balls and printed circuit boards manufacturers from Suwa, Japan.

Originally posted 2007-10-04 15:33:07. Republished by Blog Post Promoter

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Originally posted 2007-09-23 09:45:04. Republished by Blog Post Promoter

A very compact universal CNC 3-axis milling machine for general machining is being offered at an unrivalled price-performance ratio, selling for under EUR 50,000

Emco Group, based in Austria, said it is widening the ‘design-to-cost philosophy’ into ‘designed to costs and market’, with its ongoing additions to its successful E25/45/65 milling machine series. The new Emcomill E 600 – a modular and compact design – is being offered at an ‘unrivalled price-performance ratio’.

The Emcomill E 600 is the result of a successful joint operation between Emco and its Italian subsidiary, Famup.

The CNC universal miller is offered for general machining as well as tool and prototype construction.

The Emco Group, in a report to manufacturingtalk.com, said it has created a new machine generation for the standard 3-axis machined parts production.

The Ecomill E 600 is available for EUR 49,990.- euros.

Managing director of the Emco group, Gerhard Glanz, said: ‘Presently, only cheap products from Taiwan and similar countries can be found on the market at these prices’.

Rapid traverse speed is 24m/min and number of tools (standard) is 20.

In Emco’s ‘design-to-cost’ approach, all components that contribute to performance, precision and long duration of a machine are optimised, focussing at the same time on main functions for the user.

* Mechanical engineering without compromises – the Emcomill E 600 is designed as a very compact universal 3-axis machine for general machining.

The machine base, the support and all three slides are of massive cast design and form the basis for the robust machine structure.

The excellent damping properties of the cast material result in high surface qualities with ample cutting values, said Emco.

The roller guides with their parts that provide high support and stiffness values make the slides traverse precisely and without jerking.

The tool turret is designed as a very quick two-arm turret as a standard.

Tool changing times of 1.6s facilitate more than quick change to other tools and thus ensure production that saves time and costs.

* Modular structure – the highly proven modular concept allows machine customisation.

The main modules are as follows.

Spindle variants are available as, following.

* Basic version – 10,000 rev/min with direct drive (Siemens CNC) or 8,000 rev/min with direct drive (Fanuc CNC).

* 12,000 rev/min with direct drive as a variant for internal coolant supply.

* 15,000 rpm as motor spindle version.

* Tool magazine.

In the basic version the tool magazine (drum magazine) contains 20 tools.

Upon request the drum magazine can be expanded to 30 tools.

* Control options – the customer may choose between a Siemens 810D and the Fanuc 0i.

* chip removal – the standard design consists of a chip tray with simple lateral chip removal.

For automatic chip removal a chip conveyor can be integrated as a module into the machine structure.

* coolant supply – the coolant supply is carried out via lateral nozzles at the spindle nose.

As an option, an internal high-pressure coolant supply through the spindle and tool may be chosen.

* Round table/4th axis – for 4-axis applications a robust round table with a diameter of 200mm, resolution up to 0.001 deg and NC interpolation is available.

* Options – Emco offers to the customer a standard selection of accessories for the new Emcomill E 600, as follows.

Measuring sensor for tool or workpiece measurement.

Hand wheel.

Band filter.

Cleaning nozzle.

Alarm lamp.

Blow-out device.

Chip flushing.

Automatic door system.

• HK Technologies: contact details and other news

Originally posted 2007-11-11 17:07:51. Republished by Blog Post Promoter

Having acquired a large capacity VMC, and oil and gas industry components supplier can now cost-effectively machine 2.5m long workpieces in one set-up

Nexus Precision Engineering has acquired a large capacity Hartford Sumo vertical machining centre (VMC) from Ward CNC to cost-effectively machine 2.5m long workpieces in a single set-up. The 3m bed capacity VMC features an integrated fourth axis and right-angle machining head, as well as 60-tool auto toolchanger.

Project manager at Nexus’ Broxburn (Edinburgh) site, Paul Rafferty, said: ‘The whole concept of Nexus’ operation has been to identify niche requirements then source machines to satisfy them.

And the deal with Ward CNC of Sheffield was no different – we saw an opportunity and we invested appropriately in a machine that was fit for purpose’.

Nexus employs 40 to manufacture a wide range of components – including undertaking a certain amount of assembly – to satisfy a ‘blue chip’ customer base in the UK and Singapore.

Nexus supplies a variety of workpieces for oil and gas work, and in particular, downhole tooling to companies such as Baker Hughes ProductionQuest, FMC and Schlumberger with The Hartford Sumo was purchased primarily to satisfy the need for the one-hit machining of downhole gauge carriers for Baker Hughes ProductionQuest.

Required in batches of two-/12-off, currently on average 15/month are being supplied.

Made from 4140 or 420 stainless steel, these are received by Nexus as offset bored and honed ‘blanks’ in a variety of sizes from 100mm to 150mm diameter and from 1800 mm to 2.5m long.

Once the journals are turned (within the dedicated cell built around the Hartford machining centre and a lathe ) each carrier enters the Hartford Sumo for a series of milling and drilling routines.

Routines include component-length slot production, to tolerances of +/-0.05mm using bull nose cutters.

Nexus then completes premium (licensed) threading before pressure testing.

‘The key to the success of the Hartford Sumo, apart from its extra long bed capacity, is the integrated fourth axis and right-angle head,’ said Rafferty.

‘These features enable all prime machining operations to be performed in a single loading – there’s no second operations and therefore no inter-operation handling to extend lead times and overall costs.

The machine is the ideal solution’.

He continued: ‘When the opportunity came along to machine these parts, we obviously looked at other machines but quickly decided on the Ward CNC solution because of the capability it offered and the fact that it was a tremendous value-for-money package.

It was also supplied with Fanuc-based CNC, which offered a degree of uniformity across the shopfloor’.

* Open-fronted design VMC – of open-fronted design, the construction of the Sumo 3100 AG VMC is based around a cast iron frame with hardened and ground box slideways.

It has a table of 3100 by 1050mm able to accommodate 4,000kg workpieces, and X, Y and Z travels are 3050mm by 1016mm by 1070mm.

As standard, the 18.5/25kW spindle produces speeds of 50 to 6,000 (optionally 8,000) rev/min (pulley-style – 40 to 4,000/6,000 rev/min geared).

The BT 50 taper machine is supplied with a 20- (optional 32- or 40-) tool automatic toolchanger.

* Reduced programming times – running the Sumo ‘around the clock’ on a two-shift basis, product manager Mark McLellan said the Hartrol-Fanuc AI100/0iMC programming package is especially useful.

The Hartrol advanced functionality programming routines consist of a series of easy-to-use cycles designed to simplify and speed up programming times and therefore reduce downtime along with other useful setting and maintenance functions for ease of operator use.

These routines include, for example, the following.

* workpiece datum setting using edge setter.

* Manual tool setting using calibrated setting block.

* Tool magazine tracking (for arm-type ATC).

* Tool logging.

* Spindle load monitor.

* Full M Code listings.

* Comprehensive set of special canned cycles.

The Hartford Sumo is also allowing ISO 9001:2000 accredited Nexus to gain additional cycle time reductions by the use of new tooling, said Ward to manufacturingtalk.com.

The VMC also has the ability to run existing tooling at faster speeds.

McLellan said: ‘For example, we can now utilise carbide inserted FMR (fast metal removal) face mills of 50-63mm diameter at 3,000 rev/min spindle speeds compared to 1,000 revs/min, and at feed rates of 3000mm/min compared to 500mm/min.

This is making a massive contribution to shorter cycle times.’ Rafferty concluded: ‘Like all our investments, the new machine was justified on the basis of volume of orders, and the buoyancy of the market in terms of future projected loading.

We partner our customers in the true sense of the word – beginning with dedicated key project/account managers to offer a personal service with a single point of contact.

On this basis we are able to make calculated decisions regarding all machine installations, which have totalled around GBP 2 million during the past three years’.

With annual turnover forecast to reach GBP 6 million during the next four years, it is clear that since the company was established in 1997 Nexus continues to build a successful business in the oil and gas industry.

Ward CNc said that there’s also no doubt that investment in the appropriate machining technology is central to that success.

Originally posted 2008-01-20 00:21:16. Republished by Blog Post Promoter