New Machine Announcement - 5 axis milling

This week we welcomed a new member to the Lean Machine family, a brand new CR Onsrud 5 axis Gantry mill.  This incredible machine will allow us to process aluminum extrusions from all sides in minimal setups.

 Put in place and unwrapped the mill is considerably taller than our other machines and the machine fits perfectly in it's new home.  This machine features a Fanuc control for X, Y, Z, C, A axis.  The gantry is extremely heavy and rigid and features a water cooled spindle. 

Put in place and unwrapped the mill is considerably taller than our other machines and the machine fits perfectly in it's new home.  This machine features a Fanuc control for X, Y, Z, C, A axis.  The gantry is extremely heavy and rigid and features a water cooled spindle. 

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Shallow cuts that are almost impossible on a saw (and inaccurate on a miter saw) are easily performed.  Notice the Kurt Vises mounted to a linear rail for flexability in setup.

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Some cleanup being done on the bottom side of the tube.  The Albrecht tool holder has a super long reach with tight runout for optimum balancing and tool life.

Part count reduction

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Limiting the number of parts required to produce a design saves time, space, confusion, and alleviates jigging concerns.    The upright components of this steel weldment would normally be fabricated from 4 miter cut tubes (8 parts per assembly) which would require a lot of careful alignment and handling of many parts.

Rather than fabricating parts in that way, we machine holes and reliefs for bends which brings the 8 parts down to 2.  Putting a steel tube across a CNC mill also ensures quality of cut squareness, length, and hole position.  Our new bent tube also reduces welding and grinding by 6” (a 25% reduction).

Then, fold it up!

 Eat your wheaties.

Eat your wheaties.


When a jig is required for final welding, the laser and brake can make quick work of that.   This jig features easily interchangeable pieces and bolt together construction.

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Heavy Router Machining

Our Onsrud CNC Router machines are great at cutting thin sheet, but their heavy build also makes them ideal for machining thicker pieces of aluminum. An advantage of using the router table is that it does not have the machining travel limits inherent in a more typical Vertical Milling Center, such as our HAAS VF4 machine.

This means we are able to machine large parts in one operation, eliminating errors caused by part sensing and greatly reducing setup times.  Below is video showing one of our Onsrud routers cutting a new welding jig for our shop out of a ¾” thick sheet of 6061-T6 Aluminum. After deburring, the part is ready to have components installed and be put into use as a robotic welding jig!

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Mill and Turn all in one

Our awesome new Okuma lathe isn't just a lathe! This machine can turn round parts but can also mill perpendicular and parallel to the part.  Here is a video of us making weld flanges for piping assemblies.  The entire part is done in one process instead of turning the part in a lathe and then sending to a mill to put the bolt pattern in. 

 The CAD drawing for the part shows the blind, tapped holes. 

The CAD drawing for the part shows the blind, tapped holes. 

 

 

Automated feed, turning, threading

Automated feed, turning, threading

This post is a continuation of our previous post: http://www.leanmachinecnc.com/news/2016/12/27/lathe-machining-cost-reduction

Whenever possible, we program our parts on several different machines so they can all be run simultaneously to shorten overall cycle times and give us redundancy of resources.

With our Okuma dual spindle lathe and Autodesk HSM we are able to automate parts that have several operations.  The programming and setup time are intense but the result is a part that can run in a fraction of the time with very little human interaction.  In this example, we took a part that required several hours of total human attention to a 45 minute unmanned operation.

Here is the Inventor drawing of the part.  It's a small brass adapter with different threads on either end.

Moving from CAD to CAM seamlessly is the key to our engineering process.  If we change a size in the 3D model the tool path will automatically update.  Below is a screenshot of the HSM programming for this part.

Like our previous gang-tool setup this turning strategy uses Iscar's latest technology Pentacut.

 The Iscar pentacut uses a 5 sided insert.  The insert is a strong design put into a rigid holder and has a chip forming profile which makes for accurate parts and a great finish.

The Iscar pentacut uses a 5 sided insert.  The insert is a strong design put into a rigid holder and has a chip forming profile which makes for accurate parts and a great finish.

The video below is a run through of the cycle.  What the video doesn't show is that the main spindle will bar feed the secondary spindle so we can run a longer bar without interruption.

Below is the finished part ready to ship!

New turning center!

We have a commitment to staying at the leading edge of manufacturing technology.  Our newest addition is at the forefront of CNC turning.  The Okuma Genos 300-MW is a full CNC lathe with tool changing, live tooling for milling, and a second spindle to finish the backside of a part all in one operation.

 Here is a view inside the machine.  On the left is the main 10" spindle, center is the tool turret, and the right is a 7" sub-spindle.

Here is a view inside the machine.  On the left is the main 10" spindle, center is the tool turret, and the right is a 7" sub-spindle.

 The 2nd day into training and we are already getting good parts off!  These parts previously would have required a flip in a conventional machine to finish the backside edge.  Now the operator can open the door to a finished part.

The 2nd day into training and we are already getting good parts off!  These parts previously would have required a flip in a conventional machine to finish the backside edge.  Now the operator can open the door to a finished part.

Machining Raw Material Transfer

Relating to our previous post about Lathe cost reduction, here is a view into the world of how we transfer our raw material into finished product. 

 

  The first step when a work order is posted to the shop floor is to log into our Inventory system and find the correct raw material to use.  This computer screen is one terminal that runs a mobile app that we've created.  The App can be viewed on any device and is 100% cloud based. 

The first step when a work order is posted to the shop floor is to log into our Inventory system and find the correct raw material to use.  This computer screen is one terminal that runs a mobile app that we've created.  The App can be viewed on any device and is 100% cloud based. 

  The Inventory tag matches up to the record found in the App. 

The Inventory tag matches up to the record found in the App. 

  The material is loaded into one of our saws.  Here is the back-end of our Hydmech S23-A band saw.   The "-A" in the saw model number denotes it's fully automatic feeding capability. 

The material is loaded into one of our saws.  Here is the back-end of our Hydmech S23-A band saw.   The "-A" in the saw model number denotes it's fully automatic feeding capability. 

A very underrated piece of our equipment is our S-23A band saw. This machine can automatically cut to length round bar, flat bar, tube, and pipe by entering in the length and quantity required. This video is cutting 4" sch40 aluminum pipe to length.
  Presto, finished parts come out the other end!  Not really.  Once the raw material processing is complete, many different part routings can take place such as these parts that have been through the saw and lathe. 

Presto, finished parts come out the other end!  Not really.  Once the raw material processing is complete, many different part routings can take place such as these parts that have been through the saw and lathe.