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On Mfg - April

Counterboring Inserts; High-speed Milling Machine; Flexible Gaging System


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Counterboring Inserts for Precise Operations


What: Insert for counterboring applications, the E47

Who: Walter USA (walter-tools.com/us)

Important to note: The E47 counterboring insert geometry is designed for use with Walter’s own tooling systems, the BoringMEDIUM (for drilled holes from 20 to 153 mm) and BoringMAXI  (holes from 150 to 640 mm) (although they can also be used for turning).  According to Walter, while indexable inserts not specifically designed for counterboring operations are often used, this is not optimal.  For example, the inserts can have curved edges, which can result in shape deformations in short order.  The E47 geometry, which has a straight edge, provides precise dimensional accuracy.

Pertinent data: The E47 has a universal chip groove, positive rake angle, and cutting edge with zero-degree chamfer.  Depths of cut from 2.5 to 6.3 mm can be accommodated.  Various shapes (CC, WC, SC), sizes, corner radii, and grades (WSM20 and WSM30 for ISO S, M, and P applications and WPP20 for ISO P and K applications) are available.



High-speed Machine for Nonferrous Parts


What: The M8 Cube, a high-speed milling machine for processing nonferrous metals or composite materials



Who: Datron Dynamics (datron.com)

Important to note: The M8 Cube is designed to use small tools (0.1 to 20 mm in diameter) to produce parts from materials including aluminum and composites, parts like small molds, instrument panels, and rocker panels.  It is a compact machine, measuring just 69 x 69 x 77 in., yet provides a sizeable work area, measuring 40 x 28 x 9 in., X, Y, Z.

Pertinent data: The M8 Cube can be equipped with a high-frequency, liquid-cooled, 3.0-kW spindle that operates at up to 40,000 rpm.  It is designed to handle tools with HSK-E 25 toolholders.  There is a five-tool toolchanger for tools in the HSK-E toolholders.  The machine features a reinforced polymer concrete table with a steel frame that provides high levels of vibration dampening.  The gantry structure has Y-drives on each side.  In addition to the speed of the spindle, the  machine offers feedrates of up to 866 ipm.  Control is via a Windows-based software system that can be readily integrated with third-party software and automation systems.



Gaging System with Extended Capabilities


What: The Equator 300 Extended Height flexible gaging system

Who: Renishaw (renishaw.com)

Important to note: While gaging for high-volume parts is often performed on dedicated systems, not only are these systems limited to what they can do (i.e., they are part specific), but given that more and more manufacturing systems are flexible—making a variety of parts—this means that there can be a duplication of systems.  But the Equator 300 Extended Height system is designed so that it can inspect features on parts up to 300 mm tall.  The unit accommodates parts that are on fixtures, so it is easy to change from one part to another.

Pertinent data: The Equator 300 Extended Height has a maximum scanning speed of 100 mm/second, a maximum movement speed of 500 mm/second, a scanning rate of 1,000 points/second, a scale resolution of 0.0002 mm, and a fixturing requirement of ±1 mm to where the master was measured.  The system’s MODUS software allows pushbutton simplicity of operation yet comprehensive inspection recording as required. 





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