Shape-Master’s other Laser Line machine features a stacker unit that doubles in capacity depending on the height of its pallets. When processing lower-profile/shorter tools, as many as eight pallets fit in the stacker, and each holds up to 300 pieces. Such flex- ible automation was a major factor in Shape-Master’s decision to acquire the Laser Line machines. “We’ve always used EWAG grind- ing machines,” said Dan Chambers, applications manager at Shape-Master Tool. “We first used EWAG manual machines, then added EWAMATIC Line CNC grinders in the 1990s, and those machines are still in use to this day.” Chambers said it took some time for Shape-Master to become com- fortable with the operation and ca- pabilities of its Laser Line machines. Formal training included a week at EWAG’s headquarters in Switzerland and a week of in-house training at the shop. But he said that training is always an ongoing process. “United Grinding is adamant about training and technical support of all the equipment they provide,” said Chambers. “Their customer support is extremely comprehensive and acces- sible. They are always there to handle any problem or answer our questions. I doubt we could have accomplished all we have without their support.” He added that the shop easily pro- grams the Laser Line machines with EWAG’s user-friendly software and that the software is based on the com- pany’s CNC grinding package. But, with multiple axes and laser heads, the Laser Lines act more like machining centers than CNC grinders. At Shape-Master, the Laser Line laser scan heads typically feed at feed rates of several thousand mm/min and with incremental stepovers as small as 0.2 μm as they traverse over


a tool. Laser machining cycle times range from roughly a minute to an hour depending on geometric complexity and tool size. Most of that time is spent on and very near the cutting edges.


December 2016 | AdvancedManufacturing.org 31


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