Omnitool, Inc. Reduces Machining Center Needs with Help from Kurt |
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One setup on one machining center does it all-high speed, 5-axis roughing, face-milling and tapping operations to create the intricate three dimensional features of a custom mold cavity. Production time is reduced up to 50 percent. Previously, the mold's upper and lower surfaces were machined on a vertical machining center, and then moved to a horizontal machine for machining on the other four sides. Conventional workholding limited machining operations to just three axes, hence the need for the second machine even though the vertical machining center has 5-axis machining capabilities. The new approach using the vertical machining center alone was made possible by Kurt's VB 5X100 Schenke 5.1 clamping system. This new, patented device allows continuous 5-axis cutting motion of complex pockets, sculptured and contoured surfaces and intricate 3-D features with repeatable precision in a single setup. The customer is Omnitool, Inc. of Minneapolis, MM, a high-precision manufacturer specializing in designing and building large thermoform molds and match metal trim dies. "For our 5-axis machining operations, the Kurt 5-Axis Schenke clamping system is ideal," said Dave Korton, Omnitool foreman. "It frees up a horizontal machining center for other jobs, and it allows us to really run the job fast on the vertical machining center at 270 inches per minute. Conventional workholding devices are restricted to three axes. The new Kurt system allows us to fully utilize the five-axis capabilities of our machines non-stop. There's no other clamping device out there that can handle this kind of 5-axis work." Omnitool has a long history of utilizing the latest machining technologies to achieve maximum productivity while delivering top quality results. Founded in 1976, Omnitool started out solving complex, tolerance centered, structural engineering challenges in the aerospace industry. Through the years, the company transitioned into a world leader designing and fabricating thermoform tooling systems primarily for the food packaging industry. The company has long term partnering relationships with almost all of the major thermoform producers nationally and internationally. To work successfully over time with these leading companies requires the best processes, equipment, engineering and toolmakers. Omnitool has all four, said an Omnitool spokesperson. "A key factor in Omnitool's precision machine work is part runs, which vary from just one to a high of 200 parts. These relatively short runs mean setups are frequent, time-consuming and with machining centers idled between jobs. Anything that can be done to reduce setups and increase machine utilization is a constant target for improvement," said the spokesperson. "We watch to see what's new in the workholding area to improve our productivity," said Korton. "Workholding is almost as important as the machining center. It can make a critical difference from one job to the next. The workholding has to suit the job as well as the machining center that's doing the work. They have to be the right match for each other. The Kurt 5-axis Schenke clamping system is new and I hadn't heard of it. Our programmer, Mike Beckmann discovered the vise on the Kurt website. We called our Kurt salesman, Mike Neeley, who brought one in. We tried it, bought it, and it paid for itself on the first two jobs." Initially used on an Okuma MU 400AV, the Kurt 5-Axis Schenke clamping system matches up well with its simultaneous 5-axis capabilities. The Okuma features a fixed spindle and trunnion table for optimum versatility and performance. Travel in each axis is as follows:
One specific day, Omnitool had the Okuma set up with the Kurt 5-axis Schenke clamping system to machine a 6061 aluminum part 6 x 8 x 10 in/l in. Calling for 120 finished pieces, the job was run at machine speed of 9000-RPM with roughing and face milling operations done at 270 in./min. "This job," said Korton, "was one of several that the new clamping system was used for, replacing conventional vises that are more restricted as to the size part they can clamp as well as the number of axes they can handle. That's because the Kurt 5-axis vise is adjustable to handle any desired clamping width, so it is limited only by the size of the Okuma's machine table. With two clamping jaws, one stationary and one movable, the jaws can be positioned at any desired distance from each other." Actual clamping width for this Kurt system is 0.0787 inch to 9.291 inch (2mm to 236mm) that can be extended with optional spindle screws, a clamping depth of 0.315 inch (8mm),height above the machine table of 6.889 inch (175mm) with extended height options to 7.874 inch (200mm) and 8.858 inch (225mm). The system is designed to mount easily on standard T-slot tables, location grid machine tables or custom fixtures. For Omnitool, it sets up like a standard vise on the Okuma's trunnion table in about the same amount of time, less than two hours, taking into account tweaking the setup and part program to avoid false starts and scrapped parts. The big thing with Omnitool's application is a second setup and machining operation is totally eliminated, said the company. Korton and his machine operators said they really like the rigidity of the Kurt 5-axis Schenke clamping system, which was proven on the first project. "We ran the machine at 9000-RPM (tops for the tool required for the task) with very aggressive roughing and finishing cuts at 270 in./min. We experienced no tool chatter or other part misalignment problems," Korton said. "Everything about the setup was rock solid." The reason for this rigidity is that the clamping system's design eliminates jaw deflection and/or part misalignment during these |
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high-speed operations. By locating the tension spindle directly under the workpiece, the clamping system's jaws do not flare out under tension and the machine table does not distort like conventional workholding. Also, the system handles a full range of workpiece configurations with equal rigidity including blank, machined, round and irregular shapes with repeatable accuracy. "We're very pleased with the Kurt 5-axis Schenke clamping system," said Korton. "Parts are machined complete in just one setup so we reduce production time by as much as half. We're getting the required tolerances of ±.0002 inch with no scrapped parts plus the system paid for itself on the first two jobs run." For more information contact: Omnitool, Inc. 3500 48th Avenue North Minneapolis, MN 55429 763-535-4240 Fax: 763-535-2064 E-mail: info@omnitool.com
Kurt Manufacturing Company Industrial Products Division 1325 Quincy St. NE Minneapolis, MN 55413 800-328-2565 Fax: 612-623-3902 E-mail: kurt@workholding.com
Seth Machlus Okuma America Corporation 11900 Westhall Drive Charlotte, NC 28273 704-588-7000 Fax: 704-588-6503
Southwest Carl Stelly Sales Manager Regal Machine Tool 4727 S Pinemont, Ste. 100 Houston, TX 77041 713-749-9600
Greg Kinney General Manager Hartwig Texas 5234 Bear Creek Court Irving, TX 75061 972-790-8200
Greg Taylor Manager Hartwig, Inc. 1913 West Reno Broken Arrow, OK 74012 918-259-0260
Southeast Jerry Rex President Machine Tool Systems 8334-E Arrowridge Blvd. Charlotte, NC 28273 704-523-6008
Dave Gordon President GOSIGER Southeast 2717 Rew Circle Ocoee, FL 34761 407-656-1411
Doug G. Schulte President R.O. Deaderick Company, Inc. 350 Electronics Blvd. Huntsville, AL 35824 256-461-8111
Northeast Randy Ditch President GOSIGER Mid/Atlantic 322 Commerce Drive Exton, PA 19341 610-524-7722
Brad Morris The Robert E. Morris Company 910 Day Hill Road Windsor, CT 06095 860-687-3300
Mike Tierney Morris Tristate 30 Chapin Road, P.O. Box 685 Pine Brook, NJ 07058 973-808-8335
Phil Rugari Morris Tristate North 800 Commerce Parkway Lancaster, NY 14086 716-684-7700
Midwest N. IL, WI, UP of MI John T. Murphy President Morris Midwest 9300 W. Heather Avenue Milwaukee, WI 53224 414-586-0450 Fax: 414-586-0453 E-mail: jmurphy@morrismidwest.com
Jim Gondeck Vice President Sales Morris Midwest 5200 Prairie Stone Parkway Hoffman Estates, IL 60192 847-649-1400 Fax: 847-649-0100 E-mail: jgondeck@morrismidwest.com
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