Modern Machine Shop

OCT 2017

Modern Machine Shop is focused on all aspects of metalworking technology - Providing the new product technologies; process solutions; supplier listings; business management; networking; and event information that companies need to be competitive.

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mmsonline.com October 2017 MMS 89 FEATURE boring bar used to counterbore the deep center- hole. Other wise, the tool would crash when a smaller cutter on the same turret engaged for subsequent operations. Overall, processing on the turn-mill has reduced total machining time on the fuel pump extension from about 3.5 hours to about 40 minutes, Mr. Anderson says. On the blower pulley, machining time has been reduced even further, from more than six hours to roughly 40 minutes. FIVE-A XIS AND BEYOND The shop's most advanced milling machine is a five-axis Okuma MU-6300V that spends most of its time cutting cylinder heads. Unlike the castings common to commercial vehicles, these compo- nents start as 130- to 135-pound aluminum billets. With complex, contoured features on all sides, operations are complex. Tilting and spinning the part through various operations both consolidates setups and ensures quality by facilitating the use of shorter cutting tools than would be possible otherwise, Mr. Warga says. However, DSR was milling these parts in five axes before it purchased the five-axis machining center. The first evolution of the process involved moving the parts away from five dedicated VMCs Twin spindles for automatic hand-off and angled machining with the upper milling turret significantly improved productivity on the supercharger pulley visible in the workzone of DSR's new turn-mill. This supercharger bearing housing (left) and fuel pump extension exemplify the kinds of parts produced on the turn-mill pictured above. with rotary fourth axes (those five machines are now used for repair operations). The primar y reason is that even with the four th a xis, the operator had to intervene nine different times for every part, whether to reposition the workpiece or the clamps themselves, Mr. Warga says. Moving the parts to a horizontal machine (in this case, an Okuma MA-600) enabled accessing more of each part by merely indexing the tombstone. Nonethe- less, consolidating setups for complex operations

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