Production Machining

DEC 2018

Production Machining - Your access to the precision machining industrial buyer.

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:: Micro-Mechanics has two LB4000 EXII two-axis turning centers in its production area and another in its engi- neering department. This machine is built on Okuma's Thermo-Friendly Concept for minimal thermal growth, and it features slanted box bed construction. Equipped with Okuma's high-power, high-torque Prex motor, this machine is designed for high-quality machining from heavy- to high- speed cutting with a through-hole diameter able to accom- modate large workpieces. The open-architecture OSP-P control is what allows easy integration with the app. machines, where improvements can be developed without impacting production jobs. Clear Direction According to Mr. Borch, a big part of the success on the Okuma machines comes from the tool presetting. e programmers send the tooling requirements to the presetting department, where tooling data is tracked and maintained. e company pays close attention to tool wear and tool life expectations and applies its experience in predicting tooling performance in future work. A high- accuracy measurement system is used for the presetting geometry. e information, including diameter, tool tip and tool life, can then be written to an RFID chip, which is embedded into the Capto toolholders. By the time the tooling reaches the machines, the only concern for the operator is following the prepared script to place it into the correct turret positions, as all of the tool data is automati- cally read and captured by the Okuma control. Micro-Mechanics is driven by the idea of digital manufacturing, always seeking opportunities to reduce user error by eliminating data entry. Automatically establishing tool offset and geometry data via embedded RFID hardware and Okuma control software significantly reduces one of the most common sources of error. e company also worked with Okuma to develop a process to eliminate errors associated with calling the appropriate program from a traditional paper ticket. Okuma's software team created an app, called the Micro-Mechanics Program Management Interface, that uses a barcode scanner and QR code to automatically call up the appropriate program information. As added protection, the QR code automatically imports 3D models of the part, tooling and workholding into Okuma's Collision Avoidance System (CAS), which monitors machine position in both manual and automatic operation modes to avoid crashes. First-run parts for each job are handled in the engineering department, where the setup and production process can be refined without slowing other jobs that are running on the production machines. A traveler is drawn up that commu- nicates the raw materials that will move through the facility with the job and all the operations that will be applied to it until it is a finished part. At the top of this traveler is a QR code that is used to identify the part that is being made. When the job is ready to be run in the production environment, the operator scans the QR code to access the company's network and find all the setup documentation and modeling related to the part. e imported informa- tion includes the part program, the collision avoidance model data, the tooling that is in the turret, the features to be inspected, and any additional documentation that the operator will need. e operator can view the informa- tion on an external monitor that mounts to the side of the Okuma control, providing a much larger viewing area. With the latest version of the setup data automatically loaded, CAS is able to virtually check for interference and SHOP MANAGEMENT SOFTWARE 36 PRODUCTION MACHINING :: DECEMBER 2018

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