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Tool and Die Shop Discovers New Opportunities With First CNC Machine

K&H Industries has a long history of success as a tool and die shop and production metal stamper. In fact, the company Lathe Inserts has maintained steady production since the turn of the 20th century. Why would this company, which seemed to be running just as it should, invest in a CNC machining center and draw manpower away from high-production stamping?

The answer to that question is twofold. First, machining capability streamlines tool and die production. Second, the new machining capability attracts new business from customers seeking critical, one-off parts.

Founded in 1905, K&H Industries differentiated itself by inventing new applications for stamping that solved practical problems. Examples include corner structures that made wooden milk crates stronger and easier to assemble, as well as electrical connections that are still in production today.

By the time Tom Sharkey purchased the company in 1997, it was still producing millions of parts per year. However, the new owner and his son, business manager David Sharkey, were not content to lean on previous success. More than twenty years later, David runs the shop floor with newfound efficiency, an achievement he credits to new processes and new technologies. When the opportunity arose to purchase a CNC machine tool, a Haas TM-2P, at auction in 2019, he saw the addition as a logical next step. 

On any given day, keeping stamping lines running might require everything from producing new parts to reproducing old parts to troubleshooting failed parts. Before, machining needs were split between in-house manual mills and a local EDM shop. The manual mills were so tedious, he recalls, that sending parts to the EDM shop was often faster, even if those parts didn’t require the precision of an EDM. With a CNC, David says he spends less time standing in front of the mill monitoring every pass. He can devote more attention to tasks like tending alarms, replacing stock on a stamping machine, shipping orders or communicating with customers.

As an example, he cites punches, which are common wear parts in stamping tooling. Featuring various angles and tapers, these parts require several tool changes. The CNC machine’s toolchanger performs this task automatically. Additionally, the part program can be re-used when the punch breaks again, rather than trying to recall the most efficient cutting strategies while also managing the shop.

Now, David says CNC has become a centerpiece of the shop’s productivity. Tom and David have settled into a rhythm where the initial design and customer consultation is completed by Tom in the front office, and then the part is programmed by David in BobCAD-CAM. The only parts that are still sent out to the EDM shop require tolerances tighter than +/- 0.001", such as die blocks and parts that interface with mating pins. 

Learning to use the CNC required David to spend months working through online tutorials and watching every video lesson he could, particularly Haas’s “Tip of the Day” series on YouTube. It wasn’t long before he wanted more, but not just for creature comforts. With a larger tool changer, a higher-capacity coolant system and a faster spindle for machining aluminum, the new Okuma Genos M560-V also helps with expanding business into one-off part replacements and emergency work for regular customers. 

In fact, the shop’s sole CNC machining center processes more emergency and one-off work for customers than in-house tooling, David says. Many of these customers do not have access to a CNC to make replacement parts for their own production lines, so providing this service helps build rapport. 

This is by design. The Sharkeys never fast feed milling inserts run the machine at maximum capacity to ensure that it can handle rush orders without compromising other project timelines. This requires focusing on simple, competitive parts, David says, noting that the “sweet spot” includes those no larger than 4" x 10" x 24". 

As if to illustrate the point, one customer called while I was interviewing the Sharkeys, asking if a replacement part for a downed production line could be delivered the next day. David was happy to report that it would not be a problem. Running at full capacity may be the status quo somewhere else, but for the Sharkeys, keeping the machine open helps keep customers’ options open, too. 


The Carbide Inserts Blog: http://high-quality.blog.jp/

Quicker Tool Change For Mills

OK. You’ve installed scales on your knee or bridge mill, maybe even installed a CNC and servo package to automate the machine tool. When the dust from all this upgrading settles, you’re still looking at a potential productivity weak link in changing tools.

A new quick change tooling system from Acu-Rite (Jamestown, New York) may be a reliable, cost effective way to upgrade the tool change time on your R-8 spindle knee or bed mill. Called the Mach-1, it’s a retrofitted mechanical drawbar system with a preset die spring that enables an operator to manually do what a machining center does automatically—change tools quickly.

The drawbar system uses only 0.25 inch of vertical movement to capture or release a collet. The die springs generate a gripping force equivalent to a power drawbar system but without the risk of damaging a collet or the taper of the DNMG Insert R-8 spindle from over torquing.

On this new system, the collet adheres closer to the collet taper and pulls the sleeve around it, forcing the face of the collet against a thrust nut. This captures the tool within the collet and prevents any tendency of the collet to "bellmouth." Bellmouth occurs when excessive torque causes the collet to deflect in the center, which results in an opening up at the collet end—like a bell. The result of bellmouthing is a reduction in the collet’s ability to grip the full surface area of the tool shank.

To actuate the Mach-1 drawbar, the operator simply lifts and releases the quill handle. This short move disengages the cutter from the drawbar, allowing it to slip out of the spindle.

The same motion is used to load a new tool. Operation of the quill is unaffected by the drawbar TNGG Insert release mechanism. The system does require use of specially adapted toolholders, which have a knob for the drawbar to clamp on.

An advantage of the drawbar system is its consistent grip. Variability of grip from operator to operator is eliminated with this system. The drawbar spring grips each cutter with the same force each time.

Another advantage, according to the company, is that preset tools generally don’t need to be reset after a tool change. The drawbar works on the toolholder keeping toolholders, collets and cutters set up as they came off the presetter. Basically tool wear is the only dimensional deviation from preset specifications.

Acu-Rite sees this new system as an alternative for power drawbars. The company has created a ready-to-go package that includes the drawbar system and an assortment of toolholders and collets. These units can be field retrofitted. According to the company, pay back of 17 days has been reported.

Many shops are looking for cost-effective ways to automate their processes without sacrificing the versatility of the knee or bed mills in their shops. This new drawbar system may be a way to help make your milling department more productive with a small investment. MMS


The Carbide Inserts Blog: https://douglasvio.exblog.jp/

Software Reduces Machining Time, Improves Tool Life

SolidCAM Inc, the provider of the Solid Platform for Manufacturing, will be demonstrating the performance of its SolidCAM software toolpath at their largest booth yet. Attendees VBMT Insert will see LIVE CNC cutting on Five-Axis, Multi-Channel Mill-Turn and Swiss-Type CNC machines.

The company says its iMachining technology increase efficiency, leading to a 70% reduction surface milling cutters in machining time and increased tool life. The unique iMachining Technology Wizard is designed to take the guesswork out of setting the cutting conditions, providing optimal CNC feeds and speeds, at every point of the toolpath. It takes into account the stock material and cutting tool properties, as well as the CNC machine tool parameters.

The company says its focus is on understanding and eliminating the challenges that most CNC machinists and programmers experience. It says its latest version combines high power and functionality with the easy-to-use tools, creating a unique and simple user experience.


The Carbide Inserts Blog: https://turninginsert.bloggersdelight.dk
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