Shop Solutions
It was last November when TEM decided to go after titanium aerospace jobs. Their fi rst job involved removing 80 lb (36 kg) of stock from a 200-lb (90.7-kg) fuel tank mounting bracket made of forged TI6Al4V. Besides skinning off about 1" (25.4 mm) of
ERI AMERICA-05-14ME.pdf 1 4/13/2014 4:39:56 PM
Fine Boring is Now Exciting! Introducing the EcoLine Fine Boring System by Swiss Tools (Ø1.57 - 3.94” on an ER25 Taper)
DESCRIPTION ECO HEAD SET BRIDGE ONLY
BORING RANGE
ø1.57 - 2.75" (39.9 - 70.1mm) ø2.76 - 3.94" (69.9 - 100.1mm)
FEATURES
• ER25 connection does not require special masters or extensions by utilizing standard ER25 Collet Chucks . • Vernier Scales for rough adjustment. • Fine Adjust Dial (ø0.01mm/0.0004” DIV).
• Chuck cone grip and face contact, allow for impressive rotational accuracy, maximum rigidity, and substantial retention force.
M Y Y Y ERI AMERICA TOOLHOLDING SOLUTIONS
STANDARD PRICE
$1,800 $285
INTRO. PRICE
$1,440 $228
stock, specs require hogging out several pockets measuring 4" deep by 8" wide by 11" long (100.6 × 203 x 279 mm). TEM was already thinking high-feed practices at the time, but wanted to be sure they were using the latest and best. So at the bid stage, TEM considered the possibilities with Ingersoll’s David Gradie because of the company’s deep knowledge base in high-feed machining. In high-feed milling, stock is removed in shallower, faster passes, which enables higher metal removal rates (MRR) with lower cutting forces. This helps run ma- terial fast on 40-taper machines without stalling the spindle.
EcoLine head & CV40-ER25-160
EcoLine head with optional bridge & CV40-ER25-65
EcoLine head & optional bridge
www.eri-america •
info@eri-america.com 877-374-8005
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ManufacturingEngineeringMedia.com | May 2014
Gradie estimated that the new In- gersoll Hi-Quad-F cutter with new insert grade IN4030 could rough the parts in less than 15 hours, with a set of inserts lasting through an entire piece. Most important, the removal rate was about double what conventional milling cutters could deliver on a 40-taper machine. TEM had ballparked the job using conventional tooling, and came up with about 25 hours per part. Maximum pos- sible parameters for a 40-taper machine were 125 sfm (38 m/min), 6.6 ipm (167 mm/min), 0.100" (2.5 mm) DOC. “Had we run a conventional tool any faster on our equipment, either the inserts would rupture or the spindle would overload,” TEM said. So the high-feed approach defi nitely seemed the way to go. TEM got the job, with initial runs on the new tool coming out better than pre- dicted. Parameters were 125 sfm (38 m/min), 0.040" (1 mm) DOC, 30 ipm (0.76 m/min), yielding a cycle time of about 12 hours, with a single set of in- serts lasting all the way through. These are roughly the numbers on which TEM started machining.
Next, TEM started to push the enve- lope, ramping up the parameters, and found that with the new IN4030 coating,
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