Production Machining

DEC 2014

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

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bushing support, having the option to run without ofers signifcant savings on production runs." Without the close tolerance setup of the guide bushing, barstock doesn't need to be ground and allows the shop to run cold-fnished bar and tubing in the chucker mode. Additionally, there is no need to set the guide bushing, saving setup time. Te remnants (80 mm) are shorter, so there is less waste on the chucker setup compared with 240 mm in Swiss mode. Having the convertible option not only helps Advance process its parts in the most efcient way; it provides the fexibility to run in either mode, which increases the number and kinds of parts the shop can bid on. Shifting Gears—a Little Advance's next addition to its Swiss department was a DMG MORI Speed 20-11. Te shop now has two. "Te Speed machines are Swiss only," Mr. Dunaway says. "Tey don't have the convertible guide bushing feature. However, as our volumes have increased, having the efciency of a third gang tool slide and three Y axes, which these machines have, being able to have three tools in the cut at one time reduces our cycle times for longer runs. Plus, there is additional milling capability for more complex part geometries." Te ability to bring an extra gang slide makes processing some of the materials used on the Speed, such as 1505 and 4031 stainless more efcient. Using a pinch turn or pinch milling method for better cutting and getting extra support from the guide bushing helps, too. "It is nasty material to machine," Mr. Dunaway says. "Likewise, we run quite a bit of hardened material (through hardened 40-45 Rc) across these machines for the same reasons. Pre-hardened materials have become a specialty for us." Choices Currently, Advance has four Swiss-type machines in its stable. Two Sprint 20-8 and two Speed 20-11 machines. Having only owned these machines for 2 years, Mr. Du- naway and his operators have managed to become fairly savvy about using the attributes of each model when as- signing jobs to them. One example Mr. Dunaway cites was the frst part run on the Speed. "Te frst part we ran across the Speed was an existing stainless job we processed in three opera- tions using our Sprint and then fnished up on one of our vertical machining centers. Te cycle time using the two machines, with handling, was 22 minutes. We then tried it on our frst Speed machine, and we were able to run it complete on the Speed in 7.5 minutes." What they have learned from working with these two models is that the Speed will provide 20 percent more efciency over the Sprint when there is signifcant milling required for more complex parts. Te key diference is the Speed machine's ability to bring three tools into the cut simultaneously. However, it takes the right application to take advantage of the additional efciency. "We run a variety of parts in the Swiss department, so we sat down and looked at various prints to determine which machine to assign them to," Mr. Dunaway says. "Te idea was to try and optimize the production in order to provide the best value for the customer in order to win more work. Having a choice between the Sprint, with its ability to run with or without a guide bushing, and the Speed, with a third tool slide, Y axis and milling capability lets us better match the job with the tool to provide the best economies for the customer." Zero to 40 in 2 Years As the Swiss department has grown at Advance, new market opportunities have opened for the shop. Medical, packag- ing, high pressure hydraulics and work from the fastener in- dustry has found its way into the customer base. "Te markets seem to be fnding us," Mr. Hamilton says. "With a diversifed base of customers and our increasing production fexibility, we manage to weather some of the up and down cycles of manufacturing and as a conse- quence, stay busy." Adding Swiss machining capability to its operational capability has been a boon to Advance. According to Mr. Hamilton, "Swiss machining now represents 40 percent of the company's revenue. Tat additional business has occurred in only 2 years from a standing start. It's about creating a support structure willing to look at new ways to move the business forward and fnding the talent to make it happen. It's working for us." For more information: DMG MORI :: 847-593-5400 Advance CNC Machining :: 614-539-3000 For more information about Swiss-type machining, visit PM's Swiss-Type Zone. LINK :: 34 PRODUCTION MACHINING :: DECEMBER 2014 SWISS-TYPE MACHINING

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