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hp tooling 2020 #3

  • Text
  • Components
  • Processes
  • Coating
  • Materials
  • Measuring
  • Milling
  • Grinding
  • Machining
  • High precision
The journal of hp tooling is an english, global publication on all aspects of high precision tools, accessories and their applications.

components CNC upgrade

components CNC upgrade program provides US cutting tool manufacturer with major productivity advantage US cutting tool manufacturer McQuade Industries, Inc., has gained a highly cost-effective productivity advantage by implementing a CNC upgrade program for a line of 5-axis insert grinders. The upgraded machines are much easier to set up and operate, which has enabled the company to shave more than ten minutes per part off the production time of complex geometry cutting tools. Founded in 1978, McQuade Industries has built an enviable reputation in the metal cutting industry for the very high quality of its precision indexable cutting tools. The machines that are being upgraded are RS12 insert grinders, originally manufactured by Ewag AG in Switzerland. McQuade installed a number of these highly regarded precision grinders back in 1988, and over the years they have provided stalwart performance. Aside from the fact that the insert grinders still represent a valuable asset, McQuade had developed a large number of part programs over the years, which ideally would need to run on any replacement machines without requiring modification. The company therefore decided to preserve its investment by implementing a program to upgrade the machines’ CNC systems, and subsequently engaged the services of Advanced Machine Technologies, LLC., a specialist CNC retrofit company based in Owosso, Michigan. RS12 insert grinder after upgrade The original RS12 insert grinders were fitted with NUM 760 CNC systems, NUM Guttinger NGS 610 servo drives and NUM/SEM brushed servomotors. Having partnered with NUM on numerous automation upgrade projects over the past 22 years, Advanced Machine Technologies has considerable experience in replacing legacy systems such as these. In this instance, the company recommended upgrading to NUM’s latest-genera tion Flexium+ 68 CNC system, and replacing the drives and motors on all five axes with NUMdrive X digital servo drives and new NUM brushless servomotors. The all-new Flexium+ CNC system By transitioning to NUM’s Flexium+ CNC platform, McQuade would secure full grind cycle flexibility while continuing to use a familiar HMI (human-machine interface) and machine setup operations. This upgrade path also provides full backwards compatibility with part programs that the company had made over the last thirty years. Furthermore, the embedded PC in Flexium+ represents a flexible IIoT platform which is Industry 4.0 ready, offering McQuade powerful connectivity advantages for future productivity enhancements and enabling NUM or AMT to provide remote support services if required. McQuade sanctioned the work, requesting that Advanced Machine Technologies initially upgraded a single machine so that its performance could be evaluated before progressing further. As part of the upgrade, in addition to the CNC system, drives and motors, the insert grinder was fitted with a new NUM FS-12 touch-sensitive operator’s panel, an MP08 machine panel, and an HBA series portable hand-wheel. The variable frequency drive for the existing grinding spindle motor was also replaced, using a smaller footprint NUM DriveX servo drive to fulfill the role. This approach has the advantage that all command, feedback and status information is now exchanged over a fast digital bus, which simplifies wiring and improves diagnostic capabilities. The upgrade has proved a resounding success. The move to all-digital drives and motors has significantly increased the overall speed and performance of the machine, resulting in faster grind feed rates and improved surface finishing. The first upgraded RS12 insert grinder is now in full operation on McQuade’s production line, and the company has already commenced upgrading the next machine on the line. further information: www.num.com 44 no. 3, September 2020

components Sludge Barrier removes impurities Retrofittable separation system removes sludge and residual particles from the cooling lubricant Mayfran International, the specialist for material handling and coolant treatment in the metalworking industry, has developed a “Sludge Barrier”. The magnetic separation system for the cooling lubricant tank, which can also be retrofitted, removes iron particles. It is suitable for all machining processes involving magnetic materials such as steel, cast iron or nodular cast iron. It can also be used in washing systems for parts cleaning. Light and portable The Sludge Barrier is available in different sizes and designs: The Manual Sludge Barrier (SB) catches the chips and small iron particles with a built-in magnet. The stainless steel construction is particularly compact and easy to carry. It works in water and oil-water emulsions with temperatures up to 60 ° Celsius. The sludge is emptied manually at certain intervals by means of a demagnetising lever. This means that the unit does not need its own power supply. Retrofitting to practically any existing coolant tank is possible without any problems. Two sizes, which differ in terms of magnetic flux density and their maximum absorption capacity, are initially available. The SB4012 offers a maximum holding capacity of 1.6 kg of cast iron chips or approximately one kilogram of short steel chips at a flux density of 970 Gauss (0.097 Tesla). The SB4024 reaches 1200 Gauss (0.12 Tesla) flux density and can hold up to 3.6 kg of cast iron or 2.7 kg of steel chips. Automat also removes tramp oil and floating sludge The Auto Sludge Barrier (ASB), also made of stainless steel, catches the particles on a circulating magnetic strip. A long drying zone ensures that the sludge is as dry as possible before it is automatically discharged into a collection container. Its compact design combines high performance with a small footprint. An easily adjustable timer function minimizes coolant carry-over. In addition, the ASB also removes tramp oil and floating sludge from liquids in a machine tool. The automatic version of the Sludge Barrier can also be retrofitted to practically all existing coolant tanks. In the 50 Hz version for Europe, it generates a magnetic force of 900 Gauss (0.09 Tesla). This enables the ASB to extract up to 40 kg of cast chips per hour (approx. 60 liters chip volume) or 30 kg of short steel chips (approx. 50 liters chip volume) per hour from the cooling lubricant. In addition, the ASB can remove up to a third of a liter of tramp oil per hour. Protects the environment and pays for itself quickly The sludge barrier combines economy and ecology, as a typical example shows. In a metal- working company, the lubricant tanks of the machine tools had to be cleaned every two months on average. Effort: up to two days. During this time, machines and workers are not productive. The Auto Sludge Barrier could be installed almost without interrupting production and immediately removed kilograms of sludge from the tanks. Cleans cooling lubricants and lets them live longer: the new “Sludge Barrier” from Mayfran is easy to retrofit and removes iron particles such as steel, cast iron or nodular iron by magnetic means, it is available in a manual and an automatic version The tank cleaning intervals could then be extended from two to almost six months. The costs for the coolant were reduced by up to 30 %. But that’s not all, the cleaner KSS also increased the service life of the tools. In less than six months, the ASB had recouped their costs - and significantly reduced the burden on the environment thanks to the lower consumption of coolant and tools. further information: www.mayfran.com no. 3, September 2020 45

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