Hudson machines the splines to a 0.155” (3.9-mm) depth in a “cut and fl ip” cycle on a V-Tech bridge mill equipped with an indexer and water-based coolant. Depth of cut is 0.150” (3.8 mm), usually reached in two passes per groove. They check dimension with a ring gage after each end is fi nished. If oversize, which happened more than occasionally with the old cutter, they run another pass over that entire end. The recommended Chip-Surfer indexable mill features a husky tool steel shank with replaceable custom form-ground tips to match the profi le of the spline groove. The larger shank added the rigidity needed for form milling. All tips can be swapped out in seconds, right in the spindle, and with a 0.0005” (0.013-mm) repeatability that eliminates the need for touching off with every replacement. The shank is standard; only the tips
are custom. “This way, there is none of the supply-chain baggage associ- ated with pure specials,” Winterlin said. “New tips are available within six weeks, and Blackhawk can maintain a stock locally.” He added that Ingersoll regularly makes custom Chip-Surfer tips for dozens of applications. “We simply took their recommen- dation,” said Scott Shaver. “In a small job shop like ours, we don’t have the time or resources to test everything that’s out there to optimize every job. It’s good when tooling reps visit us often enough to see what’s actually running and suggest improvements on the spot.” Randy drops in about once a week and Bryan visits as needed. When the trial tool arrived, Paape
and Winterlin oversaw the conversion, startup, optimization, and operator training. Since longer tool life was the priority, they started with the previous parameters: 640 rpm, 0.004” (0.10- mm) feed per tooth, 0.180” (4.5-mm)
DOC. Under those conditions, the fi rst tip lasted through 14 complete pieces. The job ran noticeably more quietly as well, and the fi nished parts all came off in-spec with only two passes.
ONE ADAPTER. INFINITE OPTIONS.
SMARTER WORKHOLDING
Switch out chucks in minutes with our new Chuck Switching System. The precision adapter quickly and accurately connects any CCS chuck to the machine spindle and drawtube.
At SMW Autoblok, we have dozens of ways for you to hold workpieces better, stronger and smarter. Call or visit our website to learn more.
www.SMWautoblok.com 847.215.0591
March 2017 |
AdvancedManufacturing.org 37
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