Gardner Business Media

Methods - Aug 2018

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"We were a bit skeptical that finding the right solution was going to be an easy process because it is a very unusual, difficult part to machine. You have to be very careful not to let the friction and heat melt the part because we're working with Lexan," explained Kozar. "We sent Methods solid models and a part diagram. They programmed the part, made refinements and within one month we were ready to move ahead on producing it. We were incredibly impressed with the engineering expertise and service we received." The new AS-200 was installed in March 2015 and features a single 4,500 RPM spindle and a 7.5 HP milling motor on a 6,000 RPM 12-station turret featuring 24-tool capacity in a heavy duty, compact machine. It is well equipped, with a high-speed C-Axis and 82 mm stroke Y-Axis for accurate, finished parts. Maximum turning diameter is 13.4 inches (340 mm) and maximum turning length is 11.8 inches (300mm). The turning tool is 1.0 inch (25 mm) and the inside boring shank is 1.25 inches (32 mm). The AS-200 is designed with a 10.4" high-resolution LCD panel which works in conjunction with the latest Fanuc 0i-TD controller to give a high degree of functionality, coupled with fast processing speeds. The AS-200's NT Nurse II software provides user- friendly operation, programming and production support. In addition, NT Work Navigator software facilitates easy part set-ups with no fixtures required. "The part is fairly complex and requires both inner and outer diameter acme threads, which produces many nuisance chips," said Kozar. Initially the AS-200 was producing foot-long chips that were slowing down the production process. To address the problem, Methods created a chip management system using a single point 60% carbide bar for pecking along with programming solutions to cut the chips down to a much more manageable size of four or five inches. "The frequent pecking action along with the friction and heat generated by the production process creates substantial wear on the tools. We are now currently running diamond coated drills in an effort to further extend tool life and reduce downtime related to changing worn out tools," commented Kozar. ROI in No Time The Nakamura AS-200 was just what the doctor ordered for this complex part. "We were very impressed with the turnkey solution Methods provided," stated Dillon. The AS-200 is running mostly lights out, approximately 20 hours a day, consistently providing high-tolerance, exceptional quality parts. Dillon continued, "Methods' expert engineering experience was critical in determining the ideal dedicated solution for our application. The service team was here at a drop of a hat to ensure the ongoing efficiency of making the part. They delivered on what they promised driving the ROI for PSP. Their technical team programmed the part efficiently from the start." While performance is a key component of success, today's manufacturers also need to be able to justify their investment in a new solution. "Payback was incredibly fast," said Dillon. "We attained break-even within six and a half months. The AS-200 is very efficient and a unique solution for this challenging application." "Most of the time, machine installations and qualifications encounter some hiccups. Methods made these problems look insignificant by providing service and engineering support even on the weekend," commented Dillon. "Armand Flemate, Sales Representative at Methods, orchestrated on a Saturday afternoon a high pressure coolant pump exchange and by Monday afternoon, we had a higher pressure coolant pump that resulted in an improved chip control system. This type of service and commitment is hard to find in this industry; however, it is the most over looked attribute of a new machine acquisition." 17

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