Product category:
Milling cutters
News Release from: Walter GB | Subject: Walter tooling products
Edited by the Manufacturingtalk Editorial
Team on 11 July 2002
Modern tooling systems help cut cycles
by 70%
The combination of modern tooling and FMS machining technology has enabled a UK machine tool builder to reduce cycle times by up to a staggering 70 per cent.
The combination of Walter tooling and Mazak machining technology has enabled Yamazaki Machinery U K to reduce cycle times by up to a staggering 70 per cent on its new four-machine flexible manufacturing system (FMS) for small prismatic parts In addition, by optimising the contents of the horizontal machining centres' 120-pocket toolchangers, the world-leading machine tool manufacturer has also gained the ultimate in production flexibility by being able to process any component at random on any one of the line's Mazak FH 8800 high-speed horizontal machining centres
This article was originally published on Manufacturingtalk on 20 Jun 2001 at 8.00am (UK)
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Installed as part of a GBP 10 million re-investment and modernisation programme at the Worcester site that was originally opened in 1987, the new four-machine FMS has replaced a seven-machine line that, says machining manager, Gary Whitehouse, had been operating around the clock for 15 years.
"As well as taking advantage of today's more efficient machining and tooling technologies, the line needed revamping to suit the wider and more complex range of components now being produced for our current machines as well as new models forecast for the near future," he comments.
The grade 250/300 cast iron workpieces processed on the new line remain within a machining envelope of 800mm by 800mm by 1000mm high and, as before, require a variety of milling, drilling and boring operations.
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Likewise, a 162-pallet stacker storage/transporter facility continues to feed the line.
But the wider range of more complex parts being processed placed new demands on the levels of flexibility required and on the machining methodologies utilised by Yamazaki Machinery UK to maintain its impressive annual output of 1,000-1,200 machines (up to 90 per cent of which are exported mainly to Continental Europe and the Middle East).
"The original FMS was commissioned to produce parts for only four models of machine," continues Gary Whitehouse.
"Today, as a result of our continuous improvement programme, we manufacture 16 different models and, without exception, all are of higher specification than their predecessors.
They require more complex component parts in terms of accommodating more powerful axis drives, higher spindle speeds, larger tool magazines, double arm changers and, for example, the C and Y axes and second spindles on our Super Quick Turn turning centres.
"Importantly, the strategy was to use modern machining technology to produce more parts with fewer machines, and with the Mazak FH 8800s we knew this was no pipe dream." Quoted as the fastest machining centre in its class, the ISO 50 spindle taper Mazak FH 8800 utilises a 37kW spindle motor to achieve a maximum spindle speed of 10,000 revs/min and rapid traverse and feed rates each of 40m/min.
Importantly, Walter's tooling proposals had to capitalise on the available spindle power and, in the event, the tooling actually produced significant increases in cutting data compared with the old FMS.
"With such a machining performance we knew we couldn't fail, especially in combination with Walter's carbide tooling technology.
Over the years we have built up a good rapport with Walter GB of Redditch, and due to time constraints - the new line had to be installed and commissioned within 12 weeks - we placed total responsibility for the tooling package on Walter.
"We showed Walter the 60 different, two-operation components that would be processed and supplied the appropriate drawings.
We indicated the required cycle times and, of course, we liaised closely as the project proceeded - but the onus was on Walter to deliver what we wanted and on time!" Walter's response was to project engineer an array of tooling, including special side and face milling cutters as well as face and T-slot milling heads, twin-lip boring systems, drills and special-purpose tooling.
All the tooling is either indexable or solid carbide and embraces the innovative Tiger.tec (registered) inserts that combine a mixture of aluminium oxide and titanium nitride coatings on a tungsten carbide substrate.
In one example, the use of the Tiger.tec Star Drill has enabled cutting data to be increased by 75 per cent on the Mazaks.
As well as meeting Gary Whitehouse's desire for 'best price', Walter also had to ensure that the tooling-machine combination would satisfy Yamazaki Machinery U.K.'s desire for 60 per cent reductions in cycle times.
In the event, Walter helped achieve reductions of 70 per cent in some cases.
A number of factors have combined to generate such impressive savings.
For example: * A new approach angle for surface milling operations produced a 20 per cent increase in feed per tooth; * Finish milling is up to 150 per cent faster through the use of wiper inserts; * Drilling cutting data has been increased by 80 per cent with straight flute solid carbide drills; and * Walter's twin boring system increased cutting data by up to 35 per cent in some applications.
In addition, Gary Whitehouse had also specified side-lock holders, for more positive clamping, as well as greater tool optimisation.
"A lot of drilling operations, for example, require drills 150mm long," he says, "but we still need the machines to carry a 250mm long drill for certain tasks.
"Walter, therefore, had to optimise the 120-pocket tool stocks across each of the four machines, to cope for all eventualities, while at the same time avoid production bottlenecks.
We needed the ability to process any workpiece on any machine.
"I wanted true flexibility throughout the line, and I wanted to minimise dead time - and we achieved that." Novex porcupine cutters, in particular, played a key role in tool optimisation and in reducing tool change times, by being used for profiling and slotting as well as circular interpolation of rough bores.
Also, on the long extension tools, the Novex NCT modular jointing system allowed increased cutting data.
While the success of the new FMS has led to Walter's increased involvement throughout the site-through the provision of consignment stocks of face and end milling inserts, as well as ripping cutters for the turning section - Gary Whitehouse continues to strive for further efficiencies in tool usage.
"We're currently trialling a tool replacement procedure based on 'vending machine' principles," he concludes.
"The idea is that rather than having to go to the tool pre-set area and request inserts, the operator accesses the vending machine's PC (by swipe card) to gain access to relevant drawers that dispense inserts singularly.
"The process will not only give operators instant access to exactly what they require - and thus minimise the time spent locating the correct inserts - but it will also allow us to monitor in real-time what is being used and where.
The plan is to eventually link the machine to our enterprise network and, as insert stocks are used, for the system to automatically email Walter to request top-ups.".
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