SHOP SOLUTIONS
The Mazak Integrex i-400S allows Land & Sea to machine parts in single setups and minimizes fi xtures, tools, work handling and non-cut time for the shop as well.
because they must contend with custom part designs requiring the use of individual specifi c tools. “With the Variaxis i-700, there are 29 tools that stay loaded, plus a probe,” he said. “Thirty of the machine’s
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40 pockets are used, leaving 10 pockets for specialized tools when they are absolutely necessary. But a job that needs even fi ve spe- cialty tools is extremely rare. It is thrilling when we eliminate a tool on the list by redesigning a part, therefore eliminating the need to custom load a tool along with the required setup time associated with it.” At Land & Sea, standardization is the means to maximum tool fl exibility. For instance, the shop threads a variety of hole diameters with a single-point thread mill and can typically do many different holes—including tapered pipes—with one tool. And while a multipoint tool might thread a bit faster, it would claim an additional pocket in the tool magazine and would have to be loaded and touched off each time it was used. Tool standardization and machine rigidity and reliability have also helped the shop reduce tooling costs. “We hardly ever break tools now,” said Bergeron. “We use the right tool all the time and have centralized our machine programming so that none of it is performed on the shop fl oor. Even tool compensa- tion codes are sent to the machines from the programming offi ce. And in doing so, we have basically eliminated the risk of loading the wrong tools or applying them incorrectly.” Success with its fi rst Mazak prompted Land & Sea to
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AdvancedManufacturing.org | January 2017
purchase its Integrex i-400S that combines the capabilities of a turning center with those of a machining center. It features a second turning spindle that enables parts to be fully machined in one setup and minimizes fi xtures, tools, work handling and non-cut time. The machine can process prismatic parts from solid blocks or castings (chucked or bar-fed work), round parts or highly contoured sculptured parts. Land & Sea’s version of the machine features a 72-tool changer. Initially, Bergeron thought a second spindle might be un- necessary because he knew parts could be quickly fl ipped manually. However, it became clear that such interruptions in the part process can be sources of error. “We had plenty of parts end up in the scrap bin because
they were chucked or fi xtured wrong, but that doesn’t happen anymore,” said Bergeron. “When machining short runs, there is no room for error. If you haven’t made the part before, you don’t know if that manual move from one side to the other is going to give you a good part. With the second spindle, we get a good part every time, and that is critical when a job calls for making just three parts.”
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