Machine Tools for High Performance Machining

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During the visit, we experimented with a variety of cuts similar to ones required on the glass molds, in scrap pieces of stainless steel with some stock tooling. The customer later ran additional tests on actual parts based on our work. First, he drastically increased the speeds and feeds. Then, he increased the toolpath tolerance and decreased the stepover to reduce hand work. This made for a longer part program. The cutting tool and toolholder were already high quality, so did not need replacing. The machining time for one part had been 50 min.

After the tests, machining time was reduced to 10 min and quality improved. Same machine, same tool, five times the production rate. Cheaper isn't always better. That may not always be the case. In fact, there comes a time when further improvements are not possible without purchasing a new machine tool. But before going that route, make sure to get the absolute most from existing machines and tooling. When looking at tooling, machine tools, and software, do not select the lowest bidder without weighing the benefits of higher-priced options. Quite often, a moreexpensive version will lower costs in the long run.

Performance is what makes profits, not a low base price. Invest in a flexible CAM system. Applications engineers are required to program a wide variety of complex parts, often with the assistance of a CAM system.

High-Performance Machining Capabilities: Doctor Recommended, Operator Approved

Based on my work with CAM software, in most cases, the best CAM system is not necessarily the one with the most features, but the one with a strong set of standard machining cycles that the user can easily augment. The ideal software enables programmers to create customized routines that extend beyond ordinary toolpaths. CAM that includes Visual Basic facilitates easy customization by supplying an industry standard macro language.

Further, users should be able to store their machining knowledge and preferences inside the CAM system in the form of a database that can be accessed for use on any part. In addition, a full library of editable postprocessors should be available so that users can adjust them to suit their specific machining needs. Realistic simulation that shows the machining in the same manner as the machine would move is also a part of a successful CAM system. This feature is particularly useful on multisided parts machined with rotary tables.

When running a difficult part, it helps to have a PC on the shop floor.

Kundrecensioner

Investing in machinery, tooling, and software means not just purchasing a product but investing in a company. Buyers and sellers really become partners, so it is vital to choose your partners carefully. Shops purchasing new equipment, tooling, and CAM applications should look for companies that not only listen to their ideas, but actually incorporate them into practical additions to the product. A good partner company will stick with you and ensure that the return on your investment is truly highperformance machining. Shortly after installation, the customer claimed the machine would not bore good quality holes in mold bases.

We visited the customer and observed 1. Worse, measured diameters varied considerably from hole to hole. Investigating the tooling, we determined that the boring tool was an ancient brazed-carbide boring bar, and the drills were high-speed steel twist drills.

By substituting state-of-the-art insert drills and boring tools suited for HPM, the resulting drilled and bored test holes were mirror finish round within 0. The same customer also asserted that the machine would not mill. Again, they were using older HSS end mills. By switching to aggressive, indexable insert milling cutters, the cuts removed more material faster than the HSS tooling and the machine handled these cuts with ease.

The owner was amazed to say the least. We got out catalogs and ordered upgraded tooling immediately. In this example, both the milling and boring issues started out as a perceived problem in the machine. As is often the case, the customer had mistakenly thought that the machine had a bad spindle or some other rigidity issue.

In reality, with some changes in strategies and tooling, the machine ran the parts faster, tooling costs were lower per part, and the process was easier on the machine.

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Web page addresses and e-mail addresses turn into links automatically. Lines and paragraphs break automatically. Leave this field blank. Ultradent now manufactures and packages more than materials, devices and instruments used worldwide by dentists, group practices, dental and veterinary labs, government agencies and universities. Engineers, programmers and machinists work together seamlessly in the development of new products, reducing the opportunity for errors and increasing the understanding of design intent. Even the smallest over-looked details can be hammered out on the shop floor, no questions asked.

The machine was purchased with several upgrades, including a 20,rpm spindle, 5th-axis rotary table and a laser tool-length measurement system.


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The S56 allowed us to remove these constraints and put all of our focus on innovation. We can take a mold hot out of the machine without any handwork, deliver it to the injection facility and have finished silicone parts in a day. An additional benefit to their investment in the S56 is the ability to test prototypes on the spot to find and fix any potential design errors. Fischer called me about a new screw-style locking mechanism for an advanced version of our Valo light wand.

That same day we designed and developed a prototype and had it shipped to him in Texas within 24 hours. The differences Ultradent observed between the S56 and other previous machines led to additional Makino investments in , including a second S56, an SP43 wire EDM and an a61 horizontal machining center with 4th-axis NC rotary table with pallet changer.

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Our experience has taught us that you get what you pay for, which is exactly why we selected Makino. One recent application performed on the SP43 was an endo file gauge used to check cleaning files used during root-canal operations. To facilitate greater accuracy in part setups, Ultradent also produces several custom fixtures using their a61 horizontal machining center.

Designed in the same CAD software used for their part and mold designs, this fixturing device eliminates the need to dial in datum points, as they are already programmed into the CAD software. This allows our operators to spend less time on setups and removes any doubt as to whether our parts are positioned correctly. Ultradent has designed fixtures for both their vertical machining centers as well as the tombstones used on their a Transfers between vertical and horizontal machining centers are simple, reliable and can be performed in a matter of minutes.

Emuge High Performance Machining in 32RC Steel

The shop is currently engineering a way to transfer fixtures between the milling machines and the SP43 as well. This has been a major factor in the ROI of our Makino machines, which run continuously two shifts a day and oftentimes unattended over nights and weekends.