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IMTS PRE-SHOW NEWS…BOOTH N-6737
Rattunde Corporation introduces the ACS + CFMcurve integrated sawing and machining center, an exciting new technology, at the IMTS show, McCormick Place in Chicago, from September 10-15, in the North Hall Booth #6737. A fully operational system will be producing a variety of parts, demonstrating the fully automated flexibility of this manufacturing center.
The ACS Sawing Machine is the new industry standard for cold saws. It utilizes a proprietary sawing algorithm with servo motor controlled feed to continuously adjust critical sawing parameters during each cut. The results are the fastest sawing times, best surface finish and longest blade life available on the market.
The CFMcurve machining center is a patented Rattunde process that simultaneously machines each workpiece end, using 12 independent servo-controlled axes. Machining options include: threading, boring, profile turning, grooving, radius edges and angled chamfering. Programming screens guide operators for quick setup on even the most complex part geometry. No special programming is required.
Precision parts are made in one continuous process with no operator intervention. Bundles of mill length stock, up to 16.5 meters (54’) long, are placed in an automatic loader, individually separated and fed to the sawing process. Cut parts are then transferred to the CFMcurve machine for precise finishing. Utilizing advanced CNC controls, linear ball screws and servo motors, all mechanical motion is seamlessly integrated into the machine design for full process control.
The technology incorporated on this manufacturing center delivers production rates and quality unmatched by the competition. For example, a tubular component of 70mm diameter, wall thickness of 5mm, material type ST52-3 BK, with a length of 150mm, machined with a 30 degree chamfer on the ID & OD with a faced end has a saw time of .96 seconds, a machined time of 1.86 seconds and the machine can produce 1,820 parts per hour, inspected for length and automatically packaged. Cut length tolerance of +/- 0.15mm at 1.67 CPK and a machined length tolerance of +/- 0.05mm at 1.67 CPK are maintained with consistency.
The operator interface saves part files for instant recall when changing parts. Servo motors move all cutting and machining tools to their exact positions and implement saved parameters. No tooling change is required in the ACS Saw within a diameter range of 10mm; there is a 5mm diameter range in the CFMcurve. Tooling change for the complete system takes less than 20 minutes, when necessary.
All critical sawing and machining parameters are monitored and controlled. Clamping forces and position, saw blade torque and vibration, plus machining insert torque are continuously displayed and monitored. Operating limits are set and machine functions stop when they are not met. Saw blade and tooling insert wear is predictable and consistent. Key data for each part produced are stored in memory for statistical evaluation. All guesswork is removed for the operator.
Rattunde sets a new industry standard for manufacturing with this machine, replacing slow and unreliable processes with a complete manufacturing center. Bar feeding lathe machines rely on a slow cutoff process, restrict the length of incoming stock and are not always capable of finishing both part ends simultaneously. Cutting in a conventional saw, dropping parts in a bin and eventually loading them to a conventional machining center is time consuming, labor intensive and creates excess inventory with a loss of process control.
Additional processes, engineered and manufactured by Rattunde, are easily integrated with the ACS + CFMcurve, including: part inspection stations, washing and drying, automatic packaging and automatic container changing, all available to further automate customer manufacturing. The system being exhibited at IMTS will include part inspection and automatic packaging.
The ACS + CFMcurve is available in three models with diameter ranges from 10mm to 102mm, 10mm to 136mm and 10mm to 169mm, with finished part lengths from 10mm to 3500 mm. All material types can be processed.
You can watch the machine in action at:Continue reading
Increasing demands made on precision and the push for the decrease of price of modern components is pushing traditional manufacturing processes to their limits. From September 10th-15th, 2012 at IMTS in Chicago, IL, EMAG will present three production technologies that complement or replace traditional processes such as turning, milling and grinding.
PECM for nickel- and titanium-based alloys
With its PECM technology (Precision Electro-Chemical Machining) EMAG presents a production process that opens up completely new fields of application. PECM is a process for the machining of high-alloyed materials, such as nickel- and titanium-based alloys. The disadvantages of traditional metal cutting – tool wear, mechanical stresses, micro-fissuring caused by heat, oxidization layering and the need for subsequent deburring operations – are eliminated, because this process is a non-contact one without heat input. All electro-chemical machining processes are characterized by stress-free material removal, smooth transition points and surfaces without ridge formations.
The advantages that the PECM process provides for different branches of industry are best shown with the example of a turbocharger for the automotive industry. The electro-chemical process is one that can be used to effectively in the machining of many high-alloy components, especially those in the high-temperature sector of the turbocharger – it also offers a much shorter and very efficient process chain. The typical clean-up operations necessary when traditional machining processes are used – such as deburring after milling – are no longer necessary. PECM machining operations are burr-free. And there is hardly any tool wear. The result: downtimes are minimal, when compared to milling (which requires regular tool changes). The process as a whole is sturdier and less prone to errors. And another important factor that our example of the turbocharger shows: the superb surface finish of the PECM process, where Rz-values of 0.3 micron can be achieved.
Will camshafts ever again be made of a single piece?
Another highlight is EMAG‘s heat-shrink assembly technology, a process that scores particularly well in camshaft production. The high degree of precision achieved with the joining process drastically reduces the number of cam profile grinding operations or – with the use of precision cams – avoids them altogether. Another benefit of the process is the ability to combine different materials in the construction of the shaft, such as forged cams (e.g. in 100Cr6) and sintered cams, which do not require regrinding. Accessory components, such as plugs and end pieces, can – like the shaft itself – also be made of better materials. This allows for the camshaft to be adapted to the requirements of the engine and to be optimized in load bearing capacity and manufacturing costs.
Operating costs reduced by 50 %
Production laser welding is already a highly productive process in the manufacturing of gearwheels. The use of diode-pumped solid-state lasers – such as disc or fiber lasers –reduces operating costs by up to 50%. EMAG has been involved with the use of solid-state lasers in the welding of powertrain components from an early stage and is considered a pioneer in the technology. EMAG again has fulfilled a promise to their users offering them the lowest possible cost-per-piece, by coming up with an innovative technology that brings true cost benefits.
For many applications, solid-state lasers allow welding without shielding gas. This not only reduces operating costs, it also avoids having to follow the annoying logistics imposed by the use of shielding and laser operating gasses. In many cases, the welding process can also be sped up considerably. This increases productivity and – through a reduction in energy input per unit length – reduces welding distortion, resulting in better component quality.
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Attention: Peter LoetznerContinue reading