ShopSolutions
Machining a Superhard Variety of Energy Metals
S
eeley Machine (Queensbury, NY) is a small business, family-owned by Barb, Charlie, and Craig Seeley. Begun in the Seeley garage, today the shop occupies a split-level facility where large-part machining takes place on the lower level and smaller parts and machines are on the upper level. Material often moves from one level to the other—roughing on one level, finishing on the other, by some 20 employees. Manufacturing space occupies 20,000 ft2
(1858 m2 ).
“We are pretty much the definition of a job shop,” said Ed Leonard, shop supervisor. “We process a wide range of materials, including exotics, Inconel, Hastelloy, Waspaloy, 300–400 series stainless steel and some aluminum. Over the past 10 years, the energy segment, specifically power genera- tion, has been our bread-and-butter focus. For example, we produce several sizes of labyrinthine bearing seals, which
Owner Craig Seeley (left) and Shop Supervisor Ed Leonard. The new standard for roughing applications
Productivity Tool life
Process reliability Runout accuracy License partners
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Sandvik Coromant, Kennametal, Emuge Franken, Data Flute, Helical HAM, Walter, Widia, Seco, Sumitomo
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redirect coolant or lubrication around a shaft. Many of these seals are larger than we technically should be doing on our new Hyundai WIA F-M Series vertical machining center. Many of the seals coming off the F750B are up to 32" [812 mm] in diameter and 3–8" [76–203-mm] thick. These typically are machined from aluminum, exotics and different grades of stainless and involve significant stock removal, tight tolerances and fine sur- face finishes,” Leonard said. The typical seal starts as rough alu- minum stock, which is placed on a sub- plate setup with locating pins. They run “OP1” and machine the part to a certain stage, hitting all the features on the part in one setup. If they have a batch of 40, they will run all 40 parts through OP1. Next, they set up OP2 where they flip the part and come back through and hit the remaining features. In OP1, they locate off rough surfaces and locating pins, and once OP1 is done they have machine-known surfaces for locating during OP2. They continue then with the same subplate, locating against pins and known surfaces until they get through all the features on the seal. “The surface finishes on the bearing seals are very critical,” said Leonard. “On some we get to a 32 Ra
+ 30 %
+ 200 % 100 %
< 3 µm , but the majority of our surface finishes are
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