ChipChat: Journey of a Part – Done in One
Over our ChipChat webinar series, we have covered several topics from technology and process improvements to automation and market trends. In our latest ChipChat webinar, we partnered with ESPRIT, Sandvik Coromant, and Royal Products to merge two topics together to bring you the second installment of “The Journey of Part: Done in One” We have taken the topics of technology, programming, tooling, and part handling covered in the first installment and applied it to the principal of “Done-in-One” machining. Read along and view the recorded webinar to discover how you can improve your productivity, efficiency, and profitability by achieving done-in-one machining from start to finish.
If you missed the webinar, continue reading and view the recording.
Done-in-One Multi-Axis Machines
In our previous “Done-in-One” ChipChat, we focused on the benefits of optimizing your machining process and consolidating multiple 2-axis lathes and 3-axis mills into single multi-axis machines. Taking that one step further we are now focusing on an operator’s span of control. In a traditional shop we would likely see a machine to operator ratio of 1:1. To increase productivity, we might see a 3:1 ratio with an operator working in a cell with multiple mills and lathes to complete a single part. By consolidating 3 machines into a single multi-axis machine, you can return to a 1:1 ratio but with increased productivity from reduced setups, interruptions, inspections, and load/unload times. Place an operator into a cell with 2 multi-axis machines and you reach the equivalent of a 6:1 ratio with less than half of the floorspace. By switching to multi-axis you can achieve Done-in-One with a single setup on a single machine to MAKE MORE time, parts, and money for your shop.
Grant Hughson, Solutions Specialist at DP Technology – ESPRIT, covers how to achieve Done-in-One through programming with confidence, efficiency, and flexibility. With ESPRIT’s CAM system, you can improve confidence in your programming before you begin running the machine. With ESPRIT’s machine-aware multitasking, full machine simulation & verification, proven posts, and support, you can utilize a digital twin of your machine while programming to eliminate errors, optimize your tool paths, and achieve confidence in your program. Improve efficiency through adaptive or highspeed machining, in CAM probing, tailored relevant training, and options for standardizing your programs with templates for faster programming of new parts. Additionally, ESPRIT’s CAM system offers flexibility features to make switching a part program from lathe to Mill-Turn and back without needing to reprogram.
Keith Brake, Turning Specialist at Sandvik Coromant, discusses how new cutter technology can enhance tool life, efficiency, and material removal to achieve Done-in-One. Sandvik offers their multi-directional turning tool, CoroTurn® Prime which gives machinists the ability to rough and finish with the same tool, and reduce the number of tools in the magazine. The Coromant Capto® tool holding system and range of modular tooling offers fast and versatile tool switches with pre-set tooling, easy navigation for unseen change-overs, and works for turning, milling, and drilling applications to reduce setup and tool change times. Additionally, Sandvik offers tooling with multiple geometries to achieve deburring cuts to achieve Done-in-One machining without having to add an additional operation.
Done-in-One Part Handling
Zak Lyon, Regional Business Manager at Royal Products, demonstrates how the way we hold our parts with chucks can increase our throughput and profitability. Traditionally, most machines come standard with a 3-jaw chuck which offers large diameter capacity, but also has longer set-up times, tool clearance issues, grip force limitations, and requires regular maintenance. By switching to a collet style chuck, you can achieve reduced set-up times, minimize centrifugal forces, increase ramp up and down rates, low maintenance, and has a small nose diameter with better tool clearance. Royal Products Quick Grip Collet Chuck delivers 10 second collet changes making part set-ups quick and easy, completely sealed and ultra-precise part clamping, and maximum rigidity for superior part finishes. By utilizing a collet chuck with a more rigid, full contact grip with easy 10 second changes, you can transition between operations faster, and reduce chatter to improve the finish of your part.
Done-in-One the First Time, Every Time
Every manufacturer’s goal should be to achieve world class excellence in delivering quality parts while maximizing profitability and productivity. World class excellence is achieved when manufacturers can reach 85% spindle utilization with their machines. By utilizing multi-axis machines, innovative CAM systems, new cutting tool technology, and more efficient workholding solutions, shop owners can reduce setup, loading, tool change, and inspection time to keep their machines running without interruption. Get the tools you need to MAKE MORE for your shop to achieve Done-in-One.