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Productivity Offered By Mapal’s Neomill Cutter

Productivity Offered By Mapal’s Neomill Cutter

The radial NeoMill® standard milling cutter by MAPAL, stands for maximum productivity and cost-effectiveness, especially in series production.


What is the smartest way for a tool manufacturer to close a gap in its portfolio? With many years of experience in custom tools and thanks to the close collaboration with their customers, MAPAL was able to take a closer look at a wide range of milling processes enabling them to develop high-performance milling cutters that ensure excellent quality for machining of all tasks. “Custom tools have become standard tools that offer the highest productivity and cost-effectiveness”, says Heiko Rup, Product Manager for tools with indexable inserts.

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Milling Instead Of Grinding With The Hand Angle Miller

Milling Instead Of Grinding With The Hand Angle Miller

The wide range of milling discs, special techniques when milling by hand, as well as the use with hand angle millers and in (partially) automated processes. The milling discs are available in the three different kinds “milling disc”, “double sided milling disc” and “doubleworker”, which aim different areas of application.

For all of those the following applies:

The surfaces processed with the discs are metallic bright, and therefore prevent cavities while welding. While working, the discs produce neither (unhealthy) dust nor heat, and thus no structural changes that come with heat. The amount of material removed and the fineness of the result depend on the toothing. The fewer teeth, the coarser the chips and the greater the amount of material removed. The more teeth a disc has, the finer the chips and the smoother the surface, but less material is removed. The specific toothing depends on the material to be machined and the disc size.

The discs can be used for the following tasks:

  • The milling disc gets used for bevelling, deburr and flatten as well as working out weld roots.
  • The double sided milling disc (DMD) is used to open weld roots, according to the literal translation of the German original description, that would be “weld root opener”. Due to the teeth geometry, it is not made for the tasks performed by a single sided milling disc.
  • The Doubleworker (DW) combines the scope of single and double sided milling discs, without the need to frequently change the tools. The teeth geometry of the double sided milling disc had been adjusted to resolve the problem of chips getting stuck in the chip chamber.

Maija-Frästechnik GmbH, founded in 2012, develops, produces and sells high-quality milling tools made of hard metal. The company owns the patent for milling discs, which was registered in 2000 by the later company founder.

 

Freedom To Measure With Volvo

Freedom To Measure With Volvo

An automotive production plant for Volvo has boosted its productivity and efficiency with advanced measurement systems. Article by Hexagon Manufacturing Intelligence.  

With some 2400 employees, Volvo Car Body Components (VCBC) in Olofström is an automotive production plant that produces millions of car body parts every year. From hoods and roofs to doors and subassemblies, the facility is dedicated to pressing sheet metal into vital car components that are shipped whole or partially assembled to Volvo car factories around the world for final assembly and finishing.

The earliest production stages of the car design process at Volvo rely heavily on the development of the sheet metal stamping tools designed and manufactured by the Tool and Die team at Olofström. The team is first responsible for producing tool prototypes, and with up with up to 80 tools needed for a vehicle project this can be a four-to-five-month task. Each project typically runs for a year, and the remainder of the time is dedicated to producing the final tooling that will be used to press hundreds of thousands of car body components.

In 2018, the team decided it was time to introduce a modern metrology solution to their tool prototyping and production with the goal of improving productivity. They identified several key steps in their design, production and validation process that could potentially benefit from the introduction of advanced measurement devices. Having a large and well-equipped quality room already in place, the team was already familiar with a wide range of metrology hardware. One of their key considerations was identifying a solution that would be as at home on the shop floor as it was in the quality room.

Improving the Initial Casting

The first step in producing a designed prototype or final tool is the precision milling of a casted block of raw material. Casting is not a precise process, and the casted part is typically delivered with a lot of excess raw material that must be subsequently milled down to the correct size and shape.

A key step in setting up a casted part for milling is ensuring there is no collision between the milling machine and part as they are both moved into position. Such a collision can result in expensive and time-consuming damage to the CNC milling machine. Therefore, the operator must introduce a safety factor when setting things up – positioning the machine far enough away from the material that they are sure no collision will occur. Doing this by eye is not easy, and often means that the milling machine spends a significant amount of time at the beginning of its program milling nothing.

“When you can optimise the milling program to the actual size of the material, that’s the big time saving, because it doesn’t matter if the machine goes through the air or through the material, it’s the same speed,” said Kim Tingstedt, Tool and Die Operator at VCBC Olofström.

This optimisation was already being performed, but with the comprehensive data provided by a scanner, things could be much easier. This casting scan data can be used in other ways to improve production. Tool castings are extremely heavy and difficult to move, so any possibility to make them lighter improves their usability and reduces the amount of raw material required to make them. This means they have to be as small as possible – but not too small; if not enough material is left between the outside of the tool and the inside of its precision mould, it won’t be strong enough to withstand repeated high-power stamping.

Using scan data taken after casting, the casting of subsequent prototypes and final tools can be refined to ensure the minimum weight and raw material usage is achieved without diminishing the structural integrity of the tool. This also has the benefit of allowing the milling machine to begin its work closer to the final part shape with each iteration, compounding the time savings at every step.

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The Essential Guide To CNC Milling Machines

The Essential Guide To CNC Milling Machines

For those who may be a new entrant to the industry and would need a refresher, this article explains CNC Milling Machines, how they work, how they compare to CNC Lathes, and when to use such CNC machine tools. Article by Hwacheon. 

Focused on milling – the process of machining using rotating tools to gradually remove material from a workpiece – CNC milling machines are a mainstay for factories around the world. These machine tools make use of a variety of cutting tools along one or more axes to remove material from a workpiece through mechanical means.

CNC milling machines are often used in a variety of manufacturing industries: from industries like aerospace, shipping, automobiles, and oil drilling/pumping and refining, to medical, FMC manufacturing, and precision engineering sectors.

Also called CNC Machining Centers, the more advanced CNC milling machines can operate along multiple-axis. These may be fitted with automatic tool changers, advanced machine coolant systems, pallet changers, and advanced software to improve the efficiency and accuracy of machining processes.

In this article, we will be looking at the many different aspects of a CNC milling machine/machining center.

What CNC Milling Machines Are

CNC milling machines are machine-operated cutting tools that are programmed and managed by computer numerical control (CNC) systems to accurately remove materials from a workpiece. The end result of the machining process is a specific part or product that is created using a computer aided design (CAD) software.

These machine tools are normally equipped with a main spindle and three-linear-axes to position or move the part to be machined. More advanced versions may have a 4th or 5th rotational axis to allow for more precise shapes of varying dimensions and sizes to be machined.

CNC milling machines normally employ a process of material cutting termed milling or machining – the milling process involves securing a piece of pre-shaped material (also known as the workpiece) to a fixture attached to a platform in the milling machine. A rapidly rotating tool (or a series of interchangeable tools) is then applied to the material to remove small chips of the material until the desired shape for the part is achieved.

Depending on the material used for the part, as well as the complexity of the machined part, varying axes, cutting head speeds, and feed rates may be applied.

Milling is normally used to machine parts that are not symmetrical from an axial perspective. These parts may have unique curvatures or surface contours, which may require a combination of drilling and tapping, grooves, slots, recesses, pockets and holes to work on them. They may also form parts of the tooling for other manufacturing processes – for example in the fabrication of 3D moulds. 

Features of Advanced CNC Milling Machines

In the past, milling machines were manually operated. Operators had to use a combination of machines with different tools to machine a more complex part or product. Or they had to use various settings on one machine just to complete the job. 

With the advancement of technology such as CNC and automatic tool changers (ATCs), greater efficiency, flexibility and speed can be achieved – even for more convoluted parts. The provision of digital readouts and measuring systems has also improved the accuracy of CNC machining processes. 

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What Is Successful Milling?

What is Successful Milling?

Milling 101: What are the considerations when it comes to milling operations, and how can operators reduce vibration in milling? Read on. Article by Sandvik Coromant.

Milling has been evolved into a method that machines a very broad range of operations. In addition to all the conventional applications, milling is a strong alternative for producing holes, threads, cavities and surfaces that used to be turned, drilled or tapped.

There are different types of milling operations. They are: 

  • Shoulder milling
  • Face milling
  • Profile milling
  • Groove milling and parting off
  • Chamfer milling
  • Turn milling
  • Gear machining
  • Holes and cavities/ pocketing

The following are the initial considerations for milling operations:

  1. The milled configuration

The features to be milled have to be carefully considered. These can be located deep, requiring extended tooling, or contain interruptions and inclusions.

  1. The component

Workpiece surfaces can be demanding, with cast skin or forging scale. In cases of bad rigidity, caused by thin sections or weak clamping, dedicated tooling and strategies have to be used. The workpiece material and its machinability must also be analyzed to establish optimal cutting data.

  1. The machine

The choice of milling method will determine the type of machine needed. Face/shoulder or slot milling can be performed in 3-axis machines, while milling 3D profiles require alternatively 4- or 5-axis machines.

Turning centres today often have milling capability due to driven tools, and machining centres often have turning capability. CAM developments mean that 5-axis machines are increasingly common. They offer increased flexibility, but stability can be a limitation.

How to Reduce Vibration in Milling

Milling vibration can arise due to limitations in the cutting tool, the holding tool, the machine, the workpiece or the fixture. To reduce vibration, there are some strategies to consider.

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Horn Expands Gear Cutting Portfolio

Horn Expands Gear Cutting Portfolio

Paul Horn GmbH is expanding its range of gear cutting products. Horn’s new tool system for milling bevel gear teeth allows the complete machining of bevel gears on universal turn-mill centres. The system was created in cooperation with machine manufacturer INDEX and means that users no longer need any special machines to manufacture gears of this kind. It also allows all functional surfaces to be produced together with the gear teeth in one clamping. This enables high component precision, short lead-times, a very cost-efficient process and short machining times as a result of controlled machining cycles.

With a universal turn-mill centre from INDEX, components with bevel gear teeth can be efficiently and flexibly manufactured, including in small quantities. This also makes the process attractive to small and medium-sized companies that would previously have bought in gears or had them manufactured externally.

For the process, Horn relies on its S276 and S279 double-edged indexable inserts, which are screwed on tangentially. This makes it possible to achieve a stable insert seat, which is particularly important during form milling. The tool does not have to be remeasured after the inserts have been turned around or changed because the inserts are precision-ground on the circumference.

The milling body can be equipped to allow for different numbers of teeth and outer diameters when cutting gears. The process of developing the complete system (cycle, tool and clamping) called for a great deal of expertise on the part of both the machine manufacturer and the tool manufacturer. To implement the process, various types of INDEX machine with a “bevel gear hobbing” cycle are required. Horn offers the milling cutter bodies with the HSK-T40 and HSK-T63 interfaces. The profiles of the inserts are module-dependent and precision-ground.

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