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SHOP SOLUTIONS Continued from P47 “The biggest positive about the Jet Edge waterjet is the


reliability,” he said. “This appeals to us because the tool is there when we will need it, and it has the capacity to handle specialized projects in the timeframe we need. The reason we would recommend Jet Edge, aside from reliability and dependability, is because of their customer service. The Jet Edge team understands the business and provides prompt customer service. Jet Edge has a great, reliable team, just like the machine. When we have questions or need to call, there are always people ready to assist no matter the ques- tion. The great customer service is one of the reasons we are so satisfied with the machine.” Jacobs attributes the company’s success to its large team of experienced employees who understand their custom- ers’ sense of urgency. “Rapid has grown and will continue to grow because we recognize that our team of employees is key to the success of the business,” Jacobs said. “Part of having a great team is their commitment to always exceeding customer needs. The attitude to grow, and improve cus- tomer experience has allowed us to offer more services for a frictionless customer experience.” According to Jacobs, Rapid’s consistent quick-turn


service requires a large and highly skilled workforce. “This size gives us the capacity for large projects. We are better positioned to meet peak demand periods, and employee vacation and sick days don’t have an impact on lead times or deliveries. Rapid operates at a minimum 24/5 and, in some divisions, 24/7. Parts are always moving through our shops, permitting us to ship expedites within 24 hours if necessary.” “On the experience side, our employee bench is incred- ibly deep with dozens of master CNC machinists and sheet- metal mechanics, do-it-all guys, with the critical knowledge gained through years of experience. We ship well over 100 unique parts every day, and the majority are parts we have never made before and will never make again.” In 2015, Rapid manufactured more than 33,000 unique parts. Rapid recently developed a free add-in for Solidworks, eRAPID, that allows users to quote sheetmetal parts within Solid- works instantly. Its add-in also provides design feedback regarding proper sheetmetal design for manufacturing. This addresses a very common problem for many mechanical and design engineers with tight deadlines to get quotes and parts instantly. For more information about Rapid, go to www.rapidma- nufacturing.com or call 603-595-1400; for more information about Jet Edge, visit www.jetedge.com or call 800-538-3343.


Continued from P38


Smart Milling Saves Time, Improves Part Quality


L


icon MT (Laupheim, Germany) was able to save time, trim costs, and improve part quality roughing a key part on one of its machining centers using a roughing tool from Walter AG (Tubingen, Germany; Waukesha, WI). In addition, dramatic savings in finishing time were also realized at Licon’s main plant in Laupheim where it employs 200 people. Walter’s know-how and innovative tooling are credited by Harald Dammann, head of Licon MT’s production/work preparation, with producing impressive results. “We were simply not satisfied with the previous machining times.” Two successive work processes on one component seemed too lengthy and too expensive to this experienced technician. The component in question is part of the Liflex II 444 five-axis, twin-spindle horizontal machining center. The work processes involve the rough and precision machining of an internal opening on a Z-slide that is 55.12" (1400-mm) long and whose width and height are both 11.81" (300 mm). The workpiece, which weighs almost 440 lb (200 kg), is made of ductile cast iron and has a tensile strength of 600 N/mm2


. Circular interpolation milling is used to expand


the opening from a diameter of 7.87–9.49" (200–241 mm). Licon MT uses special milling cutters for the rough machin- ing, and for the subsequent finishing. The roughing tool has an extremely large projection length of 21.77" (553 mm). “On tools of this length, ensuring suf- ficient toughness and stability is an important aspect in order to achieve the required machining quality,” said Dammann. “However, to make this tool easier to handle, the tool shank, which weighs more than 22 lb (10 kg), is made from alumi- num rather than steel. This is not good for achieving a high level of stability. For this reason, milling cutters and indexable inserts are required that contribute to stable machining with a high level of operational smoothness.” The roughing takes place on a large four-axis horizontal machining center with a horizontal/vertical milling head. Until recently, this process took a full 56 minutes and the subse- quent finishing of various surfaces took another 48 minutes. To reduce these times, the head of production/CAM pro- gramming, Marcus Breymayer, contacted Martin Huber from Walter at the start of September 2015. Huber, an experi- enced application engineer, has had a close working relation-


September 2016 | AdvancedManufacturing.org 97


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