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First Mitsui Seiki Blue Arc Machine Installed At Aerodyn Engineering

First Mitsui Seiki Blue Arc Machine Installed At Aerodyn Engineering

Mitsui Seiki has produced the first commercial CNC machine tool that incorporates the Blue Arc HSEE (High Speed Electro Erosion) material removal process technology that is exclusively licensed by General Electric. The first “HW63TD BA” machine has been installed at Aerodyn Engineering, Indianapolis, IN. There, the two companies – Aerodyn and Mitsui Seiki – are partnering on multiple process development applications for their existing and prospective customers in aerospace, outer space, mold and die, power generation, oil and gas, and other critical component industries.

Fundamentally, Blue Arc HSEE is a non-conventional rough machining process utilising a controlled thermal metal removal method using a high-speed beam of electrons to erode and remove metal, driven by an electrical pulse between a tool electrode and a workpiece. Where EDM delivers a single point of material discharge, Blue Arc generates a multiple point discharge event resulting in rapid material removal. Blue Arc technology eliminates the need for high-powered spindles, highly engineered cutting tools, and reduces wear on the machine kinematics. It is known to be an extremely efficient roughing metal removal method for hard, difficult to machine alloys, such as nickel and titanium alloys as well as stainless and tool steels. Certain alloy components are being rough machined in a fraction of the conventional milling time and with less stress on the machine as Blue Arc is a non-contact method. The process can cut machine-tool capital costs by 30 percent or more and cutting tool costs by 70 percent, according to the company.

“We are excited to have the revolutionary Blue Arc technology in our facility to continue its development and showcase its remarkable benefits to manufacturers of hard metal parts,” said Robb Hudson, president and CEO of Aerodyn Engineering.

Providing more details about the specific Blue Arc machine installed at Aerodyn, the Mitsui Seiki HW63TD BA machine is a high performance 5-axis machining center platform featuring a standard CAT50 spindle. Basic specifications include an X, Y, Z axes work envelope of 1000mm (39.38”) in X and 850mm (33.46”) in Y and Z. The B and C rotary axes are driven at speeds of 60 and 90 rpm respectively. The machine also includes Fanuc drive motors and a Fanuc F30iM-B control system.

Mr. William (Bill) Malanche, COO of Mitsui Seiki USA, said, “There is a solid team in place at Aerodyn that is solely dedicated to the Blue Arc initiative. Both Robb Hudson and Cameron Perkins were both heavily involved in the development of the process and the machine with our company and GE when they were on staff at Mitsui Seiki. They have a deep understanding that will serve customers well to determine the optimal and most efficient applications for Blue Arc. From Mitsui Seiki’s perspective, having the BA machine installed at Aerodyn makes perfect sense for all involved, and it’s a thrill to see the machine ready, willing, and able to take on suitable projects.”

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Sandvik Coromant Upgrades CoroPlus ToolPath For PrimeTurning Software

Sandvik Coromant Upgrades CoroPlus ToolPath For PrimeTurning Software

Cutting tool and tooling system specialist Sandvik Coromant has upgraded the CoroPlus ToolPath for PrimeTurning software to help manufacturers speed up their operations and planning processes. Part of the Sandvik Coromant digitally connected CoroPlus suite of solutions for machine shops, the software facilitates maximum turning productivity and output.

Introduced by Sandvik Coromant through the unique PrimeTurning concept, the all directional turning methodology enabled increased metal removal rates, offered significant time savings and boosted productivity while eliminating many of the misconceptions associated with small entering angles and chip control. The concept proved especially beneficial in mass production industries such as the automotive sector. It was also ideal for short batch production—for example in aerospace and oil and gas—of components in difficult-to-machine materials that require frequent set-up and tool changes.

To get the best out of the process, including more efficient and faster programming, the company launched its CoroPlus ToolPath for PrimeTurning software, which has now been enhanced with a host of new features, functions and an easy-to-use interface. Available in stand-alone and CAM-integrated versions, the software provides the correct grade, geometry selection, and cutting data while ensuring optimal productivity and tool life as well as maximum output. It is also compatible with a wide range of CNC turning machines that use ISO codes, thereby providing automatic storage for component profiles.

The CoroPlus ToolPath for PrimeTurning now supports profiling and facing for external turning in addition to existing programmable support for longitudinal turning. The software also enables CAD models to be imported (in STEP and IGES formats, amongst others) and offers 3D simulation with collision detection.

A key new feature is an improved and intuitive interface for machinists who don’t have CAM software with PrimeTurning support or those doing shopfloor programming, with the option of operating on desktops or mobile devices. The user is able to generate NC code in few quick and easy steps. After the user specifies the operation, machine parameters, workpiece details and material information, the software automatically recommends the right tools to use along with the cutting data. The operator can simply use the suggested solution or alter parameters to get customised results.

Before creating the final NC code, the PrimeTurning tool path software enables the user to run a simulation to verify no collisions and change any parameters as required, then generate a new programme within seconds and run another simulation until the user is satisfied enough to produce the correct code. The software enables the user to stop anywhere they like in the process, running a simulation block by block or going back into the code if preferred.

 

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Walter’s HU5 Geometry Enhances Capabilities Of Cutting Machines

Walter’s HU5 Geometry Enhances Capabilities Of Cutting Machines

Walter AG has launched new single-sided indexable inserts with HU5 geometry for ISO M and S materials, helping users produce more components using the same number of machines.

The HU5 has a larger contact surface to the tool holder, increasing the stability and allowing for greater cutting depths, feeds and a larger metal removal rate—specifically, in the practical test, this comes to 18.36l/h instead of 10.71l/h. In addition to the stable fit, the decisive factor behind this is the combination of the geometry and Walter Tiger·tec Silver cutting tool materials, which allows for increases in tool life of up to 75 per cent. The geometry itself has been specially developed for heavy roughing of stainless steels and high-temperature alloys. It is typically used for applications in the oil and gas industry, for instance, in large valves made from AISI 316 material, or in the aerospace industry with Inconel 718 or titanium materials.

The main cutting edge, which is protected by a negative chamfer, prevents fractures when machining hard edge zones and optimises the performance for hard scale, for example, of forged parts. Components with interrupted cuts and other demanding machining operations are equally feasible.

The curved cutting edge and a deep chip breaker groove produce low cutting forces with high feed rates, consequently reducing the machining temperature. The variable rake angle in the area of the corner radius allows for soft chip reforming and increases the tool life. Available in standard CNMM, DNMM and SNMM, Walter rounds off its vast product range in the areas ISO S and M with the HU5 geometry. Walter now offers a total of 12 geometries in six grades as well as tools with precision cooling and ceramic or CBN inserts.

 

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