Product category:
Vertical machining centres (VMC)
News Release from: Haas Automation | Subject: VM-2 vertical machining centre at PIF, Portugal
Edited by the Manufacturingtalk Editorial
Team on 14 May 2008
Vertical machining centre finish suits
press tools
Portuguese press tool manufacturer reports that components produced by a vertical machining centre can be used from the machine tool, without having to apply extra finishing processes.
Aveiro, Portugal-based PJ Ferramentas Lda (PJF) specialises in progressive press tools and dies The tools are complex but PJF said that they need little or no human intervention between material feed and completed component
This article was originally published on Manufacturingtalk on 17 Jul 2008 at 8.00am (UK)
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A couple of years ago, PJF began a project to refurbish its ageing machining capacity.
The company bought and installed a Haas TL-1 CNC/manual toolroom lathe.
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This was followed soon after by a TM-1 toolroom mill, a VF-7B vertical machining centre and, most recently, a VM-2 vertical machining centre.
Linear tolerances on PJF's machined components are typically 0.05mm with 0.02mm usually required for positioning.
Surface finish is also critical.
"On some parts, such as stamping punches and dies, the finishing is very important," said PJF company director, Pedro Santos.
"Just like on moulds for plastics injection processes we need a very smooth finish to avoid friction in the sheet metal forming process.
Today polishing has no part in our production process: the component has to come off the Haas machines in a finished condition." Santos, said: "The Haas machines represent a very competitive price-to-specification ratio".
The company uses its Haas machines to manufacture tool steel components.
The fixtures typically hold multiple parts, which are frequently left to run unattended overnight or at weekends.
The advantage gained in cycle times, however, is difficult to estimate, said Santos.
He explained: "It's very different from part to part; we don't machine two parts alike.
Every part has a different definition so we don't measure cycle times.
Instead we compare the estimated production time with the actual time achieved, and also the time taken on different machines".
* No CAD/CAM department - PJF shop floor operators program all of the Haas machines.
There is no CAD/CAM department at the company.
The reason is that the company decided several years ago to optimise its resources and train operators in the latest programming skills.
Currently PJF has five operators trained to work with Haas machine, with a further two to be fully trained and ready by the summer of 2008.
Regular customers typically order six to eight tools to fulfil a particular project.
PJF develops up to 12 progression tools a year for each client.
The company manufactures progression tools up to 3m in length and also undertakes ongoing reconditioning and tool modification programmes.
PJF is actively pursuing opportunities to manufacture transfer press tooling.
"Our company deals in quality," said Santos.
"At PJF quality is never an accident; it always results from intelligent work.
We are certified to ISO 9001:2000 and we were the first company in Portugal to obtain the accreditation with regard to the design and manufacture of stamping and cutting tools".
Quality is just one of the differentiating factors that PJF is hoping will help retain and win business in what is sure to be a period of change.
"We've enjoyed good success in recent years and results have been positive," said Santos.
"We are now very well known in the European automotive market and our goal is to become an industry 'reference point' for the design and manufacture of tools to form sheet metal parts".
* About competition - PJF's advantage is founded on its deep understanding of die development.
Santos made a recent trip to China to assess the competition and believed that Far East rivals have yet to gain the same level of know-how, mainly owing to process complexity.
Following the receipt of a customer component drawing, PJF develops a 'strip layout' using CAD software.
This is submitted for client approval before further discussions lead to the development of detailed 3D CAD drawings.
These are again submitted for approval before the designs are finalised and raw materials can be ordered.
Machining, hardening and assembly follow before the tool is tested using PJF's in-house press.
The first parts to come off the tool allow the company to focus on improving tolerances so that dimensional reports can be submitted that meet customer requirements.
Once the report is accepted, PJF has to prove the same characteristics on the customer's press.
Only when this final phase has been successfully negotiated does PJF get paid.
When the customer's plant is in Europe, it's difficult for overseas companies to provide such a high level of service and commitment.
"China has the ability to manufacture simple tools, but not tools for complex processes such as deep drawing," said Santos.
"In time this will change, of course, but until then hopefully we can take steps to ensure we remain competitive".
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