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Machining

Aggregate sawing

Aggregate sawing

An aggregate tool is a combination of a gear box and a right angle adapter.  Aggregate tools allow us to drill or cut from the side of a part instead of just from the top on a typical 3 axis machine.

Here is an an example of an aggregate tool.  The top of the tool attaches to the spindle and turns at a speed of 10,000 rpm.  Different drills or cutting tools can be attached to the collets at either end.

Here is an an example of an aggregate tool.  The top of the tool attaches to the spindle and turns at a speed of 10,000 rpm.  Different drills or cutting tools can be attached to the collets at either end.

This is a saw blade attached to the aggregate head mounted to the spindle of the machine.  The machine is about to cut a part for a customer made from aluminum extrusion.  The extrusion is mounted in a custom fixture on our C-axis router.

This is a saw blade attached to the aggregate head mounted to the spindle of the machine.  The machine is about to cut a part for a customer made from aluminum extrusion.  The extrusion is mounted in a custom fixture on our C-axis router.

Here is the finished angle cut on the end of the extrusion.  Conventional tools would have to be very long to make a cut like this from the top plane and would not have the great finish and accuracy that the aggregate saw tool has. 

Here is the finished angle cut on the end of the extrusion.  Conventional tools would have to be very long to make a cut like this from the top plane and would not have the great finish and accuracy that the aggregate saw tool has. 

New Machine!

New Machine!

Lean Machine has added a brand new machine, and in turn, a brand new process.  We are now able to machine long aluminum extrusions in a fraction of the time and with increased accuracy.  Our other milling machines are able to travel 30" to 60" distances which is great for small machined parts but not ideal for 144" long extrusions.  There are milling machines available with longer travel, but they are meant for very large parts and have trouble milling long, but short in height, parts.  We have purchased a new machine and are in the process of setting it up to meet our needs. 

This is a huge step for Lean Machine as we currently process many long parts, and this will be another way for us to create parts for customers with increased accuracy and reduced cycle times.

Here is an end view of a typical aluminum extrusion.  Both drilling and cutting operations need to be performed on the top and sides of the part which takes several set-ups on traditional milling machines but only one set-up on our new machine.

Here is an end view of a typical aluminum extrusion.  Both drilling and cutting operations need to be performed on the top and sides of the part which takes several set-ups on traditional milling machines but only one set-up on our new machine.

The new CR Onsrud Gantry Router with a 4th (C) axis right after it was unloaded by crane at our facility.

The new CR Onsrud Gantry Router with a 4th (C) axis right after it was unloaded by crane at our facility.

After bolting down a thick sheet of aluminum we put a 3" face mill in the machine and planed the sheet flat.  Being able to do this operation right on the machine means the machine will be perfectly square to itself.

After bolting down a thick sheet of aluminum we put a 3" face mill in the machine and planed the sheet flat.  Being able to do this operation right on the machine means the machine will be perfectly square to itself.

This is the machine after the planing process.  It looks pretty cool with all the machining marks in the table!

This is the machine after the planing process.  It looks pretty cool with all the machining marks in the table!