Production Machining

OCT 2017

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

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process can be significantly reduced by performing hard turning and grinding in a single setup. e advantages of combining hard turning and grinding in a single handling lie in the ability to consoli- date the process stream. Eliminating multiple handling, including refix- turing, can positively affect cycle times and improve part quality. Rigidity is the key to successful hard turning and grinding on a single machine. All of EMAG's vertical pickup machines use a polymer granite base, specifically designed to meet the damping qualities necessary for hard turning and grinding. Cast granite bases provide a much smaller vibration signature than cast iron (as much as eight times) or welded bases, and it is this stability that allows the machine to accommodate more aggressive cutting forces from hard turning. Stability also allows the finesse necessary for precision finish grinding on a single platform. e inverted vertical design is highly flexible. In addition to its hard turning and grinding capability, the inherent advantages built into the machine's design can be configured for metalworking operations that include drilling, milling, hobbing and measurement all in a single part handling. Making it All Work With the multitasking capability available on these inverted vertical machines, it begs the question: what are the programming considerations that a shop needs to under- stand to take full advantage of what these machines can do? Creating the correct tool path is only one of the consider- ations for getting the most from these machines. Since seeing is usually the best way to confirm machine performance, EMAG has developed software called VirtualMachine. It provides simulation that takes into account the unique layout of these machines and enables a detailed observation of production processes, making it possible to optimize them long before the first real part is set up on an EMAG machine. is allows new workpieces to be set up quickly and reliably, already fully optimized. Jeff Moore, regional sales manager at EMAG, shared some insights. Sequencing Operations Typically, the operational sequences for an inverted vertical are the same as for horizontal lathes. Turning, milling, drilling and other multitasking functions are application dependent. Programming an inverted vertical machine differs from a horizontal lathe because it includes an integral auto- loading sequence using the machine's workholding chuck. Using the machine's on-board probe for position and dimensional verification, along with the CNC's tool life management software, machining operations for a simple finishing application could go as follows: 1. Raw part blank is moved to pick-up location. 2. Work part is picked up by main spindle. 3. With the part in the spindle and finishing tool selected, turn face 2-mm long at a known depth of cut (DOC), say 0.100 mm, to skim the part in Z. Do the same type of cut on the diameter for X. 4. Measure the Z and X axes using the probe. With the measured DOC value, compare it with the expected value and compensate the offset in X or Z if needed. Also, check to ensure the measured value is within the set target limits (for example, offset ±0.020 mm) if out of range; stop machine and alarm operator to investi- gate—the tool could have been set incorrectly. 5. Finish machining the part. 6. Probe finished dimensions to ensure offsets are correct and part is good. If the part is good, drop off to finished :: A turnover station is available for applications where op. 10 and op. 20 are required for part processing. VERTICAL TURNING 38 PRODUCTION MACHINING :: OCTOBER 2017

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