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Heimatec designed this special 90º angle head for cutting the keyway in a high-precision cutting tool head used in the oil & gas industry.


Nitralloy. For many years, the production had involved the use of a shaper to produce the keyway in the bore of the die head. Typically, the bore ranged from 6 to 13" (152–330 mm) in di- ameter and more than 12' (3.65 m) in length. Tese keyways have extremely tight tolerances, with location at +/- 0.0005" (0.0127 mm), width at +/- 0.001" (0.0254 mm) and depth to +/- 0.0025" (0.0635 mm). One style of cut is a three-step keyway that does not run all


the way through the bore, stopping at a window that is milled from the outside diameter. Tis situation prevented the PMC machining department from using a ram EDM to produce the keyway. Te only options previously used were to rough the keyway on an old shaping machine, then send it out for ram EDM. Tis process required 50 hours on the shaper, plus ap- proximately a week for the ram EDM. Another option was to do the job entirely on the shaping machine. Roughing the keyway had to be much more precise and usually required about 61 hours. Plus, an additional 145 hours were required to finish the part, normally. Tese times included 10–12 hours for setup.


Meeting All the Requirements Te team at PMC, led by Milling Foreman Rick Kokish,


decided to explore other methods to produce this part on its Monarch 175B VMC. Tey conducted an exhaustive search on the Internet, turning up more than 133,000 hits for 90° angle heads. Aſter better than 30 hours of winnowing out the unsuitable products, they narrowed the search to just two vendors. Both manufacturers visited the facility and brought out their standard angle head designs. One of the companies, Heimatec, quickly realized this job would require a custom 90° head design to satisfy all the requirements. One competitor brought a standard 40 taper tool, while Heimatec presented a larger, heavier 50 taper unit.


A week later, Preben Hansen, Heimatec’s president, sup-


plied a drawing for the proposed custom product. PMC engineering reviewed both the standard and custom designs and awarded the project to Heimatec. Te angle head supplied was designed to perform a wide


variety of cutting tasks on the various end products produced by PMC. On the keyway in a bore 6" in diameter and 12" (305 mm) in length, using the Heimatec 90° head, PMC spent six hours in setup, three for roughing and three for finishing, plus 12–16 hours of actual cutting time. Tis represented a total savings of 184 hours on a single part. Tough the head appeared too slender to remain rigid during the entire cut- ting cycle, according to PMC sources, the performance was deemed very successful.


A High Level of Engagement Heimatec’s head design for this custom radial drilling and


milling head features an adjustable tool stop, three support pins for stabilizing the tool, CAT 50 taper style, 360° index- able pivot on the angle head and inclined tooth gear design for maximum rigidity. During the project, Heimatec’s Hansen supervised the


installation. Aſter the stop block attachment and grinding of the supports pins for the head were accomplished in just one day, the head was mounted and several experimental cuts were performed. Hansen spent time with PMC’s Kokish and CNC programmer Barry Spence discussing various options for programming the head on the Monarch VMC. Te very next morning, the setup was performed and an actual keyway was roughed.


Edited by Yearbook Editor James D. Sawyer from material provided by PMC-Colinet.


Energy Manufacturing 2014 61


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