At the turning and milling center of this pump factory, an extremely rigid tool clamping system was used, creating a good platform for improving production efficiency.
When people saw the NT4250 DCG machine installed in the workshop of the Mori Seiki distributor J&H Machine Tool Company, the Imo water pump manufacturer also began to realize that they needed to consider purchasing a well-equipped turning and milling machining center. , and make careful choices in the tool clamping system. They realized that only by using a machine that integrates rolling and milling can they combine multiple sets of commissioning and commissioning to complete the tasks of turning and milling through a set-up commissioning process, thus enabling the company to achieve streamlined operations in screw processing production.
The factory's processing plant was set up in the Monroe area of ​​North Carolina, and Jonathan Hunter, a production engineer at the Imo water pump manufacturing plant, explained: “Initially, we used a completely different approach for rough milling these screws. At the beginning, we needed Using multiple machines to machine these screws, now only one machine is needed to complete the complete machining of the screw. Between turning, keyway milling and thread milling, I think we can dispense with five different commissioning cards. program."
Finally, at a unique spindle interface, the shop chose a milling chuck, specifically the Capto C6 chuck, to machine the workpiece so that the machine achieves high cutting efficiency and enables machining. Cycle time is reduced by 15% to 20%.
The Imo Pump Plant designs and produces screw pumps of various shapes and sizes, of which the power rotor screw in the pump is a special part processed by the plant. The pump produced by the company is simple in design and can be operated under high-speed and high-pressure working conditions. The noise is very low and the application range is extremely wide. It is suitable for application in various fields. The use of such pumps can be seen in barges and various transport vessels in the engine compartments of commercial seagoing vessels and warships, to which just a few examples are given.
The power rotor screw is usually made of 4140 steel and is driven by a motor, which then drives the other two follower screws of the low-pulse pump. Thanks to this active screw, this 3 screw pump is guaranteed to be stable and run smoothly. For this reason, the shop must ensure that it can run on a stable basis and then precisely process it, which is very important. In order to achieve this goal, the Imo water pump manufacturing plant needs to reconstruct the original process section, namely to modify the rough-cutting machining operation. This operation involves rough milling of the thread. The tool used for machining is a 3/4 in (1in = 25.4mm) carbide carbide face milling cutter with 4 cutting grooves.
Mr. Jack Burley, Vice President of Big Kaiser, commented: “For the part itself, this keyway is a key part, which plays a decisive role in the success or failure of the entire process.â€
Fig. 1 In the previous method, due to the insufficient clamping force of the tool, flutter noise and vibration may occur during processing. With the new milling chuck, the clamping rigidity of the tool increases, which allows the company to shorten the machining cycle and improve the cutting accuracy.
Flutter noise
So far, the company has not yet solved how to clamp carbide carbide face end mills with sufficient rigidity to achieve the required high depth of cut (DOC) and high-speed rough milling of the threads. The Imo pump manufacturer realized that the tool's clamping force was not suitable and could result in a rough surface finish after machining and frequent tool fracture and workpiece sticking. To this end, the manufacturer conducted a series of tests.
J&H Machine Tool carried out various tests at its Charlotte plant in North Carolina. During the experiment, they had tried various methods, but it turned out that all of this seemed unrealistic and unsatisfactory in terms of processing cycle and concentricity. For example, the use of face milling cutter holders and ER spring chucks have certain limitations. In short, for this field, both types of tool clamping lack the necessary rigidity characteristics, which means that the processing speed of the parts will be slow.
Mr. Hunter explained: “The ER spring chuck actually pulls the tool out of the tool holder during roughing, which results in the incomplete size of the cutting process. The standard face milling tool holder can generate additional tooling When it was clamped in such a way, I noticed that the tool would generate extra wear. Excessive vibration would cause excessive stress, causing the face milling cutter to retreat. With this type of chuck, we only It can reach half the depth of cut. In addition, due to the low running speed we use, the chuck can easily stick to the workpiece."
The correct connection method
After several weeks of trial operation, it was still unable to meet the pre-determined operating parameters. The trial working group began to solicit public opinions and consulted Richard Bevers, regional manager of Big Kaiser. The machining shop chose a Capto C6 chuck compatible with the spindle interface according to a certain standard. As explained by Mr. Burley, the Capto C6 interface chuck has a certain rigid base, and the rigidity can be further enhanced if an appropriate tool clamping system is used.
Mr. Burley explained: "This spindle interface consists of a three-lobe conical male connector, so when it is put into the interface, it does not really need to use the drive key connection. Because it is on the taper, it can be Make it accurately positioned on the spindle."
As a licensed manufacturer of Coromant Capto tool systems, Big Kaiser offers a wide range of tool clamping systems that can be matched with a spindle with a Capto interface. After reviewing this application area, Mr. Bevers believes that the use of Mega Double Power milling chucks can solve the flutter noise problems associated with the other two fixtures. Then through inventory availability, the tool can be immediately installed into the operating system. As the vibration problem was solved, the Imo pump manufacturer improved the DOC level, as well as the feed rate and working speed.
Fig. 2 In this configuration, the density of the coolant can be used to facilitate the rinsing of the cutting groove, even when the tool is used without the coolant input hole inside.
High concentricity
According to the manufacturer, the rigidity of the fixture itself and the way it grips the tool can eliminate machine vibration. At the equivalent of 4 times the diameter, the locking nut is arranged in such a way that the accuracy of the chuck is 0.0002 in. This means that all cutting grooves in contact with the workpiece can be balanced.
Rigid clamping starts from the outer diameter of the tool holder and this device is completely symmetrical. To secure the tool in place, the operator only has to use a special wrench to tighten the nut clockwise. This wrench is duplicated by Mega's wrench and matches the diameter of the nut. One-way clutch is used. It grips the smooth outer diameter tightly but does not leave a wrench mark on the clamping nut. When the nut is fully tightened, a double contact surface can be formed between the tool clamping device and the nut.
Burley said: "The milling chuck has a high clamping force and its clamping force is 7 to 10 times more than that of a conventional chuck. It provides excellent performance compared to the end mill fixture. Radial runout error accuracy, high quality and shock absorption ability.When the tool cuts into the workpiece, relying on these capabilities can greatly improve the cutting speed, due to the tool's clamping structure has a huge rigidity, coupled with the tool's anti-vibration performance, Make cutting more smooth and smooth.
Mr. Burley estimates that after the Imo pump manufacturer adopted this tool solution, the DOC efficiency and feed rate can be increased by more than three times compared to the original ER chuck and the standard face milling cutter fixture.
Imo has made significant progress in improving cutting efficiency, thanks to Big Kaiser's double-click technology (DS). All Big Kaiser's tool clamping devices have a standard feature. The peripheral cooling system transfers coolant through the fixture directly to the edge of the face milling cutter. To this, Mr. Burley explained: “There are many small holes in the tool clamping device that allow the coolant to flow through the holes. This not only helps flush the chips, but it also cools the blades.â€
Since May 2007, this turning and milling machine has settled down at the Monroe production plant of Imo Water Pump Manufacturing. Thanks to the machining capability of the machine itself and the new milling chuck, the company's screw production has achieved streamlined operations. In addition to increasing the tool life, the company also saved an average of 35% of the tool's average commissioning time and significantly increased production efficiency.
Mr. Hunter said: "We noticed that the service life of this specific tool has been greatly improved, but we only added a chuck." According to everyone's statement, although the initial cost of the tool clamping system itself is higher than other Options are expensive, but they are worth configuring. Finally, Mr. Bevers concluded: “The cutting tool system is crucial, and it has a very significant effect on improving the production efficiency. But in the long run, this is more important than saving a few dollars on the tool clamping system. â€
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