SHOP SOLUTIONS
systems are rotary tools, and the shop plans to continue to widen its product offerings beyond that.
In addition, Shape-Master was able to bring parts back in house that it previously had to outsource. This capability is especially important because it aligns with Shape-Master’s overall philosophy and goal of keeping as much work in house as possible. Shape-Master’s EWAG Laser Line machines use state-of- the-art, ultra-short pulse laser technology to enable single- clamping, high-quality production of cutting tools with very complex geometries. With their patented EWAG Laser Touch Machining Pro- cess technology, the machines handle all the latest com- mercially available cutting tool materials, including carbide, CBN, PCD, CVD, and MCD. The machines do not generate heat-affected zones, and resulting tools have exceptional surface fi nish quality and longer tool life. Laser Touch Machining is a tangential laser beam machining process that generates cutting tool edges
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and geometries by shaping tool surfaces using the outer surface of the laser beam in ultra-short, 10-picosecond pulses. These ultra-short laser pulses directly vaporize ma- terial without any signifi cant heat generation. A repetitive hatching pattern of the laser scanning unit coupled with simultaneous movement of the machine’s eight CNC axes generates the tool geometries. With just under 30 employees, Shape-Master pumps out thousands of tools per month with its laser processing ma- chines and CNC grinders. The majority of tools the company produces are CBN, although a signifi cant percentage of dia- mond tools also come through the shop. The shop also uses automation to keep production running beyond its standard 1.5 shift-per-day production schedule.
Shape-Master’s EWAG Laser Line machine is automated with a six-axis FANUC robot, a two-in-one HSK 63-tool rack, and pal- lets for lights-out production of rotating tools.
Each of Shape-Master’s Laser Line machines is equipped with automation. One has an integrated six-axis FANUC robot, a two-in-one HSK 63-tool rack, and pal- lets, confi gured to provide continuous, fully automated and lights-out production of a variety of rotating-type tools. This machine also automates the shop’s high-volume production of inserted diamond tools.
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AdvancedManufacturing.org | December 2016
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