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Another Look at Aerospace Machining

The tooling area of an EMAG PO 900 BF for the machining of blisks using Precise Electro-Chemical Machining (PECM) technology.
Competitors in this demanding hotbed of manufacturing are being pushed to find new ways of producing more complex parts. Here are some systems that can help them meet their needs.

High Feed Milling Cutter Reduces Cycle Times

MSX High Speed Milling Cutter achieves high feed rates of up to .055 IPT for significantly reduced cycle times.
The MSX mill from Sumitomo is ideal for ramping and helical applications using general steel, alloy steel, stainless steel and cast iron.

Replacing Tactile Probing with Laser Scanners

A close-up of one of the XC65Dx-LS laser scanners being used on a continuous wrist CW43 interface. Incorporating three lasers in a cross pattern, the XC65Dx-LS captures full 3D details of features and surfaces in a single scan.
This technical assessment explains how the new inspection methods for diagnostic measurement of sheet metal components and body-in-white assemblies at this Turkish automotive manufacturer involves cross scanners being used on coordinate measuring machines.

Shoot from the Hip

Custom shoulder implant parts on the NTX 2000 turn-mill center, which has opened up new possibilities for parts that previously required at least two operations. Rasp handles that were previously contracted outside will become some of the first components loaded on the new machine.
This orthopedics manufacturer achieves one hit machining in an automated lights-out environment using advanced turn-mill machines that take their custom implants for coated hip replacement to a whole new efficiency.

More Productivity, Less Power

Punching on the E6x punch press. The type of work which Dale Sheetmetal does lends itself to punching. It has made bespoke panels with 130,000 holes, while white laminated steel and coated aluminium are not suitable for laser cutting as it can damage the surface or make the coating difficult to remove. The shop does mix processes where appropriate, with both punching and laser cutting being performed on one part where this is faster.
For this family-run sheet metal fabricator, moving to Ex-Series servo-electric punch presses solved its power consumption problems and improved productivity at a stroke. 

Reinventing the Unbreakable Grip

SinterGrip jaws use scientifically designed, serrated, carbide inserts to penetrate the workpiece edge to a minimal, controlled depth and exert a push-down force on the part. Thin parts can be machined without deformation by clamping them at 6,600 lb force to achieve penetration, then lowering the force to 2,200 lb with no loss of gripping power.
Examine the design of these machine tool vise jaws to understand how they enable aggressive 5-axis machining of high-value medical and aerospace parts in a single setup by clamping on as little as 2 mm of surface.

Gear Hobbers and Control Migration

The machine utilizes full four-axis electronic gearbox capability of NUMgear to help speed production of complex gear parts. In conjunction with built-in high-speed synchronization facilities this allows the axial and radial feeds, and the hob head shift axis, to be geared to the work piece spindle.
This is the story of how Bourn & Koch upgraded its older gear hobbers to advanced CNC systems to machine large bull and cluster gears, worms, shafts, splines and pinions for the defense and aerospace, oil/gas drilling, mining, heavy equipment and power generation industries.

Taking Off Safely

Jan Horn of Lufthansa Technik (left), Ulrich Rienks of CAMTECH/Edgecam (center), and Julian Lüdecke of ZOLLER. 
By linking CAM software into an advanced tool presetting system, this airline manufacturing unit efficiently manages a large tooling database and machining simulation on highly complex aircraft parts to quickly respond to market changes.

Preheating Roll-Welded Pipe in Fabrication

Preheating pipe prior to welding and rolling pipe while welding are both common and important practices in fabrication shops. Rolling induction heating technology offers the benefits of rolled pipe welding while also addressing some of the concerns associated with other popular heating methods. 
As an increasing number of jobs require electric preheat, the ability to use induction heating while welding rolled pipe can benefit productivity, quality and safety and provide fabrication shops a viable alternative. 

New Tooling For Quick Changeovers

The CARVEsmart™ quick change vise jaw system from Bellatex Industries is ideal for production and tool room applications. It replaces the often cumbersome, conventional method of attaching vise jaws to a vise using face mounted cap screws.
These technical reviews examine some of the latest innovations in quick change tooling and  workholding that can help improve the profitability of your shop.
Events Calendar
September 15 - 17, 2014
San Diego Convention Center -- San Deigo, CA
September 15 - 17, 2014
Guangzhou International Mould & Die Exhibition, China Import and Export Fair Complex -- Guangzhou, China
September 16 - 18, 2014
Houston, TX
September 17, 2014, 10:30am - 11:30am
Webinar Hosted by Burr Oak Tool, Sturgis, MI
September 17 - 18, 2014
John S. Knight Center -- Akron, OH