Modern Machine Shop

DEC 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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Page 30 of 140

28 MMS December 2017 RAPID TRAVERSE Machining Technology in Brief under 200x magnification as an additional quality control measure. This attention to detail ensures that once the tool has been set up, no fur ther height adjustments are required when replacing a worn insert. Horn μ-Finish inserts are manufac- tured with a center height tolerance of ±0.0001 inch to ensure this accuracy while indexing. Horn's S274 μ-Finish system, as well as its Supermini and DS micro end-mill system, was used to machine the tiny shaft component shown on page 26, which has a length of 0.08 inch. The first facing operation with the S274 system was per formed with a cutting speed of 80 meters per minute and a feed rate of 0.003 millimeters p e r r e v o l u t i o n. T h e s a m e to o l s y s te m w a s Understanding Electropolishing E D ITE D BY M AT T DA N FO R D Horn USA Inc., call 615-771-4100 or visit u s e d fo r l o n g i tu d i n a l tu r n i n g, g ro ov i n g a n d parting-off operations. For internal-profiling operations (for a diam- eter of 0.009 inch), the Supermini system was used at a cutting speed of 12 meters per minute and a feed rate of 0.003 millimeters per revolu- tion. Mr. Smoody says the Supermini cutting tool's new substrate, coating and edge prepara- tion increase tool life. For example, he says the EG35 grade has demonstrated as much as 60 pe rce nt longe r tool life whe n tur ning cobalt chrome at 1,000 N/mm 2 . This grade enables the tool to machine diameters ranging from 0.008 inch to 0.268 inch in tough materials while increas- ing return on investment. In addition to sharp, clean, chip-free edges, maintaining the proper feed rate will help keep chip removal problems at bay, he adds. A fter a certain threshold, deburring gets easier. That is, when part sizes are small enough and volumes are high enough, lots of hundreds or even thousands can be cleaned up at once, whether by tumbling against one another, a dif- ferent media or both. However, volume isn't the only factor to con- sider when choosing a high-volume, metal-part deburring process. The smaller the burrs and the more delicate the part, the greater the advan- tages of removing these raised, sharp protrusions via non-me chanical me ans. Spe cif ically, via electric charges that are naturally drawn to the high points on a sur face, similarly to lighting striking a tall tree. This process is known as electropolishing, and the "lightning strike" occurs not in the open air, but in a chemical bath. A rack full of workpieces, positively charged to serve as the anode, is sub- merged in this electroly te solution along with negatively charged cathodes. Drawn toward the cathodes via the process of electrolysis, minute A close-up look at a razor blade before and after electropolishing.

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