Machining Centers & Cells
Currently, the Palletech cell runs, for the most part, non- stop during Hansen’s two 10 to 12-hour daily shifts, six days a week. “The key to the system’s untended operations is the
The modular, pre-engineered Palletech System allowed Hansen to add a second machine, a Mazak Horizontal Center Nexus (HCN) 8800-II machining center with hard metal spindle package.
SWING CLAMPS?
WHY CARR LANE ROEMHELD
Designed for 1,000,000 cycles 2,000,000+ cycles tested at full load
• Rod diameter 30% larger to eliminate part deflection
• Viton wiper is standard (metal wiper optional)
• Exclusive safety clutch design available to prevent damage to part, fixture, or operator
• Reinforced swivel mechanism with 2 or 3 helix paths depending on size for longer life
• Up to 7500 psi maximum pressure for more compact clamp design
• Position monitoring available, either inductive or pneumatic via movable sensing bolt
• Over 1000 different standard sizes and styles available with clamping forces from 130 lb. to 8265 lb. stroke up to 2”
• Special stroke and clamping forces available upon request.
View CNC Machining at:
www.clrh.com
Ellisville, MO 63021 (636) 386-8022
reliability, precision and performance of the Mazak machine tools,” said Lay. “The repeatability of the machines is phe- nomenal. Once we know our programming and tooling are good, we don’t worry about the Mazaks. They give us good parts every time,” said Lay. “Plus they feature large tool stor- age capacities—120 tools on both the e-1060V/8 II and on our HCN 8800-II, for extended run times.” Hansen has so much experience in machining titanium that it touts itself as a “titanium expert” that has perfected its machining of the material in particular during lights-out operations. According to Lay, processing titanium efficiently requires a combination of machining techniques and ad- vanced machine tools like the Mazaks. The two techniques used most often by Hansen are high-speed machining and what Lay referred to as “sneaking up on a part.” The part is rough machined, checked and straightened, then machined some more, checked and again straightened. Roughing is done on the HCN 8800-II and finishing is done in single setups on the Integrex e-1060V/8 II using five-axis cutting and the machine’s 5000-rpm, 50-hp (37-kW) high-torque milling spindle. Surface finishes achieved range from Ra
125 to 63 and tolerances can be as tight as ±0.0004" (0.010 mm).
Cells Are Only as Good as the Machines in Them “What’s happening today is that the aerospace OEMs want to build airplanes like cars, and to do that production has to be consistent and predictable,” said Scott Walker, president, Mitsui Seiki (USA) Inc. (Franklin Lakes, NJ). “The days of taking an aerospace engine part from the machine to buffing and measuring to final assembly are coming to an end. In the future, you’re going to have 15 machines lined up and a robot will feed parts in and out. The process will be basically hands- off for machining, inspection, buffing, and the part will go into the box ready for assembly,” said Walker.
“The same is true for hardened nickel-based IBRs [inte- grally bladed rotors]. Typically, IBRs are EDM’d, ground, or CBN ground, going back and forth. They want to automate all of that and know that they will get a certain number of IBRs a day. Based on that they will need to build X number of engines a day and put them together like car engines,” said Walker. For example, Mitsui Seiki has just converted a production line to a fully automated FMS cell which pro- vides complete machining and inspection for 63 new part numbers, magnesium or aluminum castings for gearboxes for the new 737x.
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ManufacturingEngineeringMedia.com | August 2013
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