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SHOP SOLUTIONS


DeZurik is a recognized leader in valves for municipal water, hydropower, and processing applications. The company pro- duces about 160 of each size per year, made to order, which occupies about 20% of machining time on the new machine.


Improve machine utilization.


Even in the dark. Rotary Loading System RLS – Your Entry into High-Efficiency Production


 Economical – A basis for the cost-effective machining is optimizing the feeding of parts in and out the machining center


 Flexibility – With its modular design, the Liebherr RLS Rotary Loading System offers a high degree of flexibility


 User-friendly – The proven Soflex PCS cell controller is user-friendly and offers integrated order planning


 Quality and Reliability – Quality is the top priority for Liebherr. When producing our products, every stage is monitored ensuring world-class products with the highest reliability and service life


Not surprisingly, management listened to Hennen and moved ahead quickly, bringing in their “go-to” tool vendor Ingersoll Cutting Tools (Rockford, IL) to pursue his idea. As a result, DeZurik reduced facing cycle time for the flanges from 18 minutes to 3 minutes. This saves about $114 per part on the two valves now running on the Mazak. Based on that success, the com- pany is standardizing on the process as quickly as possible, anticipating savings exceeding $100,000 a year. “A five-axis machine is a big-ticket item with a high hourly burden, so it’s vital to get the most out of it,” said Chandler Commer- ford, manufacturing engineer. The solution, according to Commer-


ford: “Live-turn” the flange in a macro helical mill-turn cycle and replace the single-point stationary stick tool with a multiedge rotating Ingersoll face mill. “We now get 11 cutting edges working at once, not just one,” said Commer- ford, who handled all the programming to make it happen. “Live turning also gets two spindles working simultaneously,” said Inger- soll field engineer Bryan Winterlin, who helped develop the solution. “Two-spindle machining will almost always remove more metal faster than a single-spindle process.” The method also reduces cutting forces. On a rotating face mill, each cutting edge takes off a tiny chip sequentially to achieve the cumulative result. This distributes the cutting forces evenly over all the edges, protecting both the tool and the machine.


Liebherr Automation Systems Co. 1465 Woodland Drive Saline, Michigan 48176-1259 Phone.: +1 734 429 72 25 E-mail: info.lgt@liebherr.com www.liebherr.com


The Group 2014-502_004_LVT_007_RLS_USA_GB_außerhalbMP-2.indd 1 56 AdvancedManufacturing.org | April 2015


The key to making the new process work was using a high-feed face mill that steps out of its comfort zone. The tool that made the difference at DeZurik is a 5" (127-mm) Ingersoll Hi QuadF face mill, nominally a high-feed mill involving high feed rates and shallow cuts. It boasts an extra thick insert and


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