position (CVD). Te lower temperature reduces microcracks, leaving a smoother surface with fewer stress raisers. “We’ve worked with high-feed mills in the past, and the
performance of this new Ingersoll Hi-Quad-F mill has been surprisingly impressive,” said TEM. “Te geometry fulfills the full potential of high-feed machining practice. Moreover the coating enables us to crank up the surface speed beyond what we believed possible.” In fact, TEM is in the process of converting all their 34
mills over to the new Hi-Quad-F for roughing. We’re doing this also to take advantage of the Ingersoll ‘free cutter’ promo- tion running throughout 2014,” said TEM. Based on actual results on the titanium job, TEM expects
to save at least $500,000 a year in machining costs when all 34 machines are retooled this way. “More important, it will boost our overall production capacity. We can take on more work without having to buy larger taper equipment, especially more titanium work which puts us in a much more competitive bidding environment. Now, shops with 40-taper machines can compete for titanium work.” ✈
A Legacy of Quality
TEM toolsetter indexes inserts for new Ingersoll Hi-Quad high-feed mill.
TEM got the job, with initial runs on the new tool coming
out better than predicted. 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 inserts last- ing all the way through. Tese are roughly the numbers on which TEM started machining. Next, TEM started to push the envelope, ramping up the
parameters, and found that with the new IN4030 coating, it would withstand a lot higher sfm without wearing the inserts. Tey were able to run 243 sfm (74 m/min), and by maintain- ing the same chipload, feed rate went to 59 ipm (1.5 m/min). Tat was almost double the starting point, and it cut cycle time to five hours. Insert edges still lasted through the entire part. Tese are now TEM’s standard parameters for roughing all titanium jobs. “High-feed machining works because the cutter’s positive
presentation geometry creates a shearing and chip thinning action, which enables very high feeds without excessive cutting forces,” said Gradie. “Te cutting forces are resolved axially rather than radially, reducing pressure on the bearings in 40-ta- per spindles.” Extra durability of the new IN4030 grade oxide insert
coatings results largely from the different way it is deposited. First, the substrate surface is etched to create a larger gripping area. Next, the alumina coating is deposited by physical vapor deposition (PVD), which runs cooler than chemical vapor de-
TEM Inc. provides government machining services to the defense and aerospace industry for the production of defense parts, and has been entrusted to machine quality components for highly sensitive applications for companies such as Pratt & Whitney and General Dynamics. Before Don Churchill and Charlie Wojchowski, the founders of TEM, retired, they established the company as a leader in the tooling engineering and machining industry—which contributes to its current success, according to the company. Founded in 1976, TEM began as a small shop special- izing in the design of dies and tooling. But it was not long after starting the company that Churchill and Wojchowski realized that in-house manufacturing would provide them with more quality control over their products compared to outsourcing their designs. Over the next 14 years, TEM continued to prosper in size, capabilities and customer base, and later relocated to a new 18,000 ft2 m2
(1674
) industrial plant in Buxton, ME, in order to meet the demands of their growing business. Wojchowski retired, and Churchill managed TEM until 1998, before it was acquired by David King, an employ- ee who had been with the company since its inception, and who is still the company president today. The company has expanded its operation into a (2418 m2
26,000 ft2 ) facility equipped with state-of-
the-art CNC machining, and over 40 full and part-time employees. The technical staff includes both engineers and machinists who are highly skilled in their trade and offer a wide breadth of expertise to assist with the design and production of their products.
Aerospace & Defense Manufacturing 2014 63
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