smooth simultaneous multi-axis movement to access the front, back, left and right of the traverse axis to achieve minimum cycle times. The ANW-4100, for example, is a 3000-rpm twin-spindle machine with 30 hp (22.38 kW) and a 12-position turret. Fuji supplies the built-in robotic automation, in-process auto gaging, and custom workholding, and consequently is able to guarantee takt time, cycle time, and Cpk
for its turnkey solutions. Cutting Tools Take a Big VTL Bite Out of Large Parts
When you specialize in large-part machining for the oil field, everything about the operation is big—especially the stakes when adding new equipment. Breaux Machine Works LLP (Tomball, TX) machines parts weighing up to 50,000 lb (22,679 kg) for the petroleum, industrial, and service markets, running 24/5 in a contract machine shop with 80 employees. “We pride ourselves getting large-scale components right the first time,” said president Tommy Breaux. Not surprisingly, most of Breaux Machine’s work is one-off. Last year, management decided to commit more than $3 million to increase workpiece weight capacity to 95,000 lb (43,091 kg) on both VTL and milling processes. The new equipment choices included a Kuraki KBT15 CNC mill and an O-M vertical turret lathe, which has 160” (4 m) swing, with 11' (3.25 m) under the rail. Modernizing tooling on both machines with advanced turning and milling tools from Ingersoll Cutting Tools (Rockford, IL), Breaux effectively got two VTLs for the price of one, improved milling removal rates by 20%, and drastically reduced MRO costs. Advanced Ingersoll T-Force 40 turning tools literally doubled VTL through- put. The Ingersoll Gold Quad F face mill improved rough milling rates by 20%. “At these rates, we’ll break even on the investments two years sooner than on our four-year projected ROI,” said Vice President Gary Breaux.
“It isn’t unusual that shops running low volumes for valves and seats will change over twice or three times a day.”
When the machines arrived, Breaux started the trials with Ingersoll’s suggestion, mainly to double the already-hefty depth of cut leaving everything else the same. After tweaking for optimal tool life, a slightly lower speed and slightly higher feed at the same 0.750" (19-mm) DOC were settled on. At those rates, the cutting edge lasted through 28" (711 mm) of feed; almost ten times the time in cut as before. “Based on these trials, the Ingersoll T-Force 40 tool would give us the effect of a second VTL,” says Tommy Breaux. “This, at a time when there’s a real shortage of large-scale turning capacity to serve the oil and gas business. We gained both strategically and financially.” Ingersoll’s T-Force 40 is an insert with a longer cutting edge and free cutting insert geometry, seated rigidly in place with double-lever clamping. The combina- tion enables exceptionally deep cuts without fracturing the insert or overloading the machine. Although Breaux limits DOCs to ¾" (19 mm) to protect the machine, the T-Force 40 tool geometry itself enables 1 ¼" (31.7-mm) DOCs. In the double-lever
April 2016 |
AdvancedManufacturing.org 55
Beyond Evolution EASY kits are currently
50%* OFF
when you order using the promotion code:
B01KGL1C116-P3
* Savings compared to sum of kit component list prices. Offer cannot be combined with other discounts/offers. Offer ends June 30, 2016. Only available through participating distributors.
CALL
kennametal.com/BeyondEvolution
1-844-314-1977
Active Coolant Control
delivers more tool life or higher metal removal rates.
PRODUCTIVITY MADE
Chip Breaking Effect
Fan Effect
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