SHOP SOLUTIONS They pushed the tool to 16 pieces and saw some
edge breakdown, so they reverted to 14 to keep the operation secure. The trials also pointed to tool ser- vicing savings since tips could be replaced without removing the tool from the spindle. Then Bryan Win- terlin ramped up to the parameters: 1000 rpm, 0.012” (0.30-mm) feed per tooth at the same depth. This reduced cycle time by 3 to 1 with no loss of edge life or as-machined part quality. Hudson standardized on those parameters and the 14-piece limit between tip changes. There hasn’t been a tool rupture or out-of-spec workpiece since, and the only failure mechanism is gradual flank wear. Winterlin said the key to the debottlenecking was the Chip-Surfer’s com- bination of heavier tool shank, free-machining geometry and coatings on the tip, as well as the quick, repeatable in-spindle tip change.
For further information about Ingersoll Cutting Tools, go to
www.ingersoll-imc.com, or phone 815-387-6600.
Tooling a Large Machine for Turbine Shaft Machining
S
caling up and tooling a multiproduct machining center (mpmc) to machine a giant turbine shaft for a US power engineering group was a challenge for Weingärtner Maschinen- bau (Kirchham, Austria). The timeframe and sheer size of the workpieces required Weingärtner to scale up one of its advanced technology mpmc 1200 machining centers to be able to ma- chine giant turbine shafts used in gas/steam turbine plants. The resulting mpmc 2000S-7000 machining center has a 2-m swing diameter over bed and carriage, maximum turning length of 7 m, and is able to completely machine workpieces weighing up to 80 t. This unit has a 72-kW main spindle, a 72-kW 3000-rpm turn milling head, and a 25-kW 6000-rpm high-speed milling head. Weingärtner’s first meeting with its American customer took place at EMO in September 2013. By that time, the company
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AdvancedManufacturing.org | March 2017 !
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