A happy plug for AB Tools

March 18, 2017, 11:50 am

≫ Next: How to machine inside torx at cnc lathe?

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Hi All:
I just got a set of form cutters from AB Tools for milling a conical Oring seat in 316 SS on a production job.
I couldn't be happier with what they made for us!!!
Normally I grind or wire cut all our own formtools, but since this is a moderate volume production job and we needed really tight consistency from cutter to cutter, we decided to go with an outside vendor.

Alfred and his guys did a brilliant job on these.
I gave them the material spec, and the profile geometry and asked them to use their own judgement on what to make for us: we got back a 3 flute cutter, uncoated with about 5 degrees of positive rake.

These things cut slicker than snot and leave a beautiful finish; better than I was able to achieve with the form cutter I ground to do the process planning and prototyping, and I took a fair bit of care making that first cutter because of the tight finish requirement.

So all of you that need form cutters...go to Alfred at AB Tools!

Cheers

Marcus
Implant Mechanix • Design & Innovation > HOME
www,vancouverwireedm.com

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How to machine inside torx at cnc lathe?

March 18, 2017, 12:55 pm

≫ Next: High Speed Tooling

≪ Previous: A happy plug for AB Tools

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Hi people,
i have to machine 5000 parts with this inside torx at them. Material is X30Cr13 (420F). I do not know any tool capable of doing it as fast as it would be appreciated. In fact, i do not know how to do it...
Any advice, method, tool advice i will be very appreciated. Thanks.

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High Speed Tooling

March 18, 2017, 9:07 pm

≫ Next: heidenhain tnc 530 axis overload error

≪ Previous: How to machine inside torx at cnc lathe?

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Looking for thoughts on high speed endmills, face mills etc.

what do you guys go for when working on 4140, 1018, D2, A2, 6061 etc.

In particular trying to figure the type of tooling you see on youtube where they are running it fast as hell taking large chunks out of these materials.

thanks

heidenhain tnc 530 axis overload error

March 19, 2017, 2:30 am

≫ Next: Cadem free dnc

≪ Previous: High Speed Tooling

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hi all
we have 6 years TOS KURIM fuq 150 ,heidenhain 530 TNC , and we generally use FANUC for machines,but heidenhain is new for us. When we re using the machine , all parameters are true ,tool cut the part rapidly app. 2 mm and after that tnc protect itself,and all of the axis are locked right now, and when we turn on the machine and drive for axis , machine does not goes to references , also we ve got error 241 and 243 for z and x axis overload, error 66 md is max.
Can anybody help me ?

Cadem free dnc

March 19, 2017, 4:05 am

≫ Next: Actuator Runout - SQT

≪ Previous: heidenhain tnc 530 axis overload error

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I "bought " the Cadem dnc but I can't find the file which is associated with my machine, a First mcv 300 with Fanuc oil Mate MB.I was given a 3 conductor cable with the machine. Machine end has 25 pins the computer end has 9. Any idea about where to get the details about this machine and the proper cable? :crazy:

Actuator Runout - SQT

March 19, 2017, 7:18 am

≫ Next: inco718 plate stock bowing

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The actuator on my SQT 18MS has a good bit of wobble to it. It didn't have it before I removed everything to replace the scale a few weeks back. Now it does. I've indicated on the C axis brake rotor and it shows .002" runout. By the time you bolt the actuator on you're 16" or so from the spindle so any runout is amplified quite a bit. I can't run above 2500 rpm or vibration becomes a problem.

I unbolted everything, cleaned up all mating surfaces, and tried to get it dialed in but nothing wants to move. Is there a way to indicate these that I'm missing? Pics below.

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inco718 plate stock bowing

March 19, 2017, 8:18 am

≫ Next: 5 Axis Length Comp

≪ Previous: Actuator Runout - SQT

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Hi,
I have some 5"x 5" x.250 thick inco 718 plate stock I need to mill to .160" thick.
I have cut 1 pc and I am getting a bowing after machining.
I need a 32 finish with a flatness of .004" on one side.
do I have to keep flipping over and over again with short depths of cuts or
do i need to get this material stress relieved 1st?
any help appreciated.

this is my 1st post
*why does it say 'plastic' in my header

5 Axis Length Comp

March 19, 2017, 2:09 pm

≫ Next: Basic question on gear hobber on cnc lathe

≪ Previous: inco718 plate stock bowing

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How does Length Comp work on a 5 Axis machine where Spindle Rotation is the B Axis. If length comp is active when the B Axis is at negative 90 degrees. Will it comp in the X axis direction?

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Basic question on gear hobber on cnc lathe

March 19, 2017, 4:11 pm

≫ Next: Tungaloy twisted TDX indexable drills vs the Sandvik 880's

≪ Previous: 5 Axis Length Comp

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Hello,

This week I am going to be trying a wto gear hobber out on a Puma 2600sy cnc lathewith fanuc 30i control. After quite a bit of back and forth with the machine tool supplier we have managed to get my test program to run in the air. (we had to set some parameters).

I am very comfortably with the machine but I know basically nothing about gear machining, and especially nothing about hobbing. The gear I want to make is a spur gear(straight teeth). I have the hob and I will run my test in a nice soft piece of uhmw....hopefully this will keep me from annihilating the hob!! I am unsure of something right out of the gate. Should I angle the head of the gear hobber by the lead of the hob or can I leave it at 0 degrees?

I will run my test and more than likely have more question afterwards as i don't have any support other than the internet right now. Thanks for your time.


Here is a link of about the same hobber I will be using.

Gear-hobbing machine with adjustable angle / finger joint / for turning center - WTO - Videos
Brad

Tungaloy twisted TDX indexable drills vs the Sandvik 880's

March 19, 2017, 4:13 pm

≫ Next: Doosan Puma TT1800 SY opinions

≪ Previous: Basic question on gear hobber on cnc lathe

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Our company recently began manufacturing more of our parts. We needed to drill 3,4, and 5xd holes in 17-4 Stainless steel with an indexable drill, and we talked to Tungaloy representatives in our area, including one individual who staffed the Tungaloy booth at last years IMTS show in Chicago.
The reps recommended Tungaloy Twisted drills. They showed me a drill- the drill really looked impressive- nice nickel plated finish, nice geometry etc. We bought 7 or so of the twisted drills at their recommendation.

It took us ~4 months to begin making chips on the machines these were intended for. We hired a 20+year mill-turn machinist to lead the new turning cell. Our machines have 25HP main spindles and 1000PSI M30-70 chip blasters, running Master Chemical Trim E206 coolant at 10% concentration [we've been thinking about going to Qualachem Xtreme Cut 292 but haven't yet]. We had a lot of trouble getting the Tungaloy drills to perform consistently. After about 4 days working with the drills, having damaged one TDX340W40–4 4Xd holder body and replaced it with a TDX340W40–5 5xd body, we had them at about 290SFM, pushing a feed of about .0041”/Rev. We had tried speeds up to 450SFM, and feeds .0035-.0059/rev. The smoothest we could get the drills to be, they screamed like an apparition, and made the machines vibrate in the 3-5Xd depth region. At their worst, they made the concrete vibrate and the machines seemed about ready to start walking around on the floor. We really felt like we were beating up our brand new machines using the TDX drills. Some insert edges would go 20 minutes, others 7 or 13, and the process was so unstable the machinist couldn’t really leave 1 machine to check a part at another. After drilling a few hundred holes, we realized part of the insert used in the initial cut would later be used and part of another edge. So there really were only 2 ACTUALLY CLEAN insert edges per insert set. (This doubles the cost of a pair of inserts). The marketing suggested 4 edges, but our practical application showed 2 real indexes per insert set. That probably was the condition causing spotty insert life. The production rate was slow under ideal conditions with the Tungaloy drill, and slower with the machinist second guessing and checking the insert condition, having to stop machines when inserts chipped or failed prematurely etc.

We switched products to the Sandvik 880-D3400L40-05, and instantly the unstable process stabilized. We tuned the drill in only 2-3 cuts (25 minutes of production time) and settled on 391SFM at .0055/rev. The drilling time per hole decreased by 45% [51 seconds faster per hole]. The 880 gave us Fanuc tracked tool life of 13 minutes per insert edge, and gave us 4 predictable indexes. The machine vibration was gone. Spindle loads dropped substantially. Feed loads dropped 30%. We drilled over a thousand holes on one body, and our machinists were able to operate 3 machines and get their focus and efficiency back.

Production speed greatly increased, and we drilled over a thousand holes on the Sandvik 880-D3400L40-05 without an issue. Our second Sandvik drill to go into a machine- a A880-D0625LX19-03, was tuned in 2 cuts, and produced 1500 holes.

The Tungaloy product for us was a waste of time and money. The first drill body was destroyed in a couple dozen holes. The tuning time cost us $1000 of payroll, and probably several times that in lost production time. Sandvik mops the floor with the competition. It’s not really even comparable. The only negative point for Sandvik is the higher insert cost. The drill body costs are comparable, but the insert pricing makes them a little less attractive. We’ve had trouble getting decent discount pricing on sandvik inserts and tools so we do as little business with Sandvik as possible unfortunately. Iscar is where we currently do probably 60% of our purchasing.

Doosan Puma TT1800 SY opinions

March 19, 2017, 4:28 pm

≫ Next: Effect of Look-ahead in radius-compensation mode?

≪ Previous: Tungaloy twisted TDX indexable drills vs the Sandvik 880's

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What do you guys think of the Doosan Puma TT1800 SY machines you have or have experience with?

From the outside looking in, they look nice.

Effect of Look-ahead in radius-compensation mode?

March 19, 2017, 7:34 pm

≫ Next: Review on DMG Mori CMX 800 V for mould making application

≪ Previous: Doosan Puma TT1800 SY opinions

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In the radius compensation mode, it is believed that there should not be two (or more) consecutive non-movement blocks in the plane of compensation; otherwise, it would lead to error in compensation. I was wondering if this rule applies also when a large number of block are pre-read.

Review on DMG Mori CMX 800 V for mould making application

March 20, 2017, 1:57 am

≫ Next: Fanuc 16i Ma Parameter Password... Trying to crack it

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We are about to buy a new VMC for our captive toolroom to make dies & moulds for rubber & plastic industry. So expert comments based on following information will be much appreciated.

Currently we are considering CMX 800V DMG Mori which is an entry level VMC by DMG Mori & came after Ecoline series.

CMX 800 V Specifications -

C frame type

Ball Screw : Size Dia 40 x 12 make Steynmeyer, Germany in all linear axis
LM Guideways : Size 35 mm make THK, Germany in all linear axis , Roller type in Y & Z Axis and ball type in X Axis, Distance between rails X- 374 mm, Y-473 mm, Z- 286 mm

X movement on feed table, Y & Z movement on spindle.
What is possible advantage of having Y axis movement on spindle rather than conventional X & Y both movement on feed table?


Table size - 800 x 560 x 510

Seimens 840 D controller

Please let us know if this is good choice for injection mould making where precision & finish is important.

Thanks

Fanuc 16i Ma Parameter Password... Trying to crack it

March 20, 2017, 6:49 am

≫ Next: Guhring Mill / Drill Huge Issues with Breakage and Tool Life

≪ Previous: Review on DMG Mori CMX 800 V for mould making application

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I bought this 1997 Robodrill from a man who bought it (like a dealer/trader) from Danaher (Matco Tool).

I got it up and running but the previous company put a password into the parameters. I called and talked to someone who might possibly know, he said the password would be 1111 or Kingsley. I have entered 1111 into the keyword and still can't get past it.

Another person on the internet claims to be able to crack the password if I send the SRAM back up.
Apparently the "a" version of the 16i control requires a genuine SRAM card (bought 2mb card from cnc-specialty-store.com for $130) and did an SRAM back up. But I can't figure out how to get SRAM to my PC as a send able file. CNC Specialty has a reader/writer for $405.

I may need to bite the bullet, but any ideas would be great. My understanding is the only way to get the control password free is to either crack it or wipe it. If I wipe it and I don't have all the 9000s output and certain parameters, I may end up with a fast, 4-axis, boat anchor.

Thanks for any help.
Greg

Guhring Mill / Drill Huge Issues with Breakage and Tool Life

March 20, 2017, 12:56 pm

≫ Next: Fanuc Output Module Failure

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Hello all,

I'm new to this forum and coming to the forum with a crucial issue to our shop (desperate). We are going through Guhring mill / drills at an alarming rate. I have inherited this process and it has always been known to be a tool breaker, but it is at a serious point where we need to look at cost savings. Since start of production this year we have consumed 720 drill bits at a cost of $38,000 and 320 end mills at a cost of $5,500.

It is an outer race with a spline. Two oil holes are milled and drilled into this outer race from the spline side. The material is SAE 1060 Rockwell C 26-36

This operation runs 1,900 parts per shift, 2 shifts a day, 5 days per week. There are 3 robodrills that perform this operation 2x per part. Based off of that, each machine performs each operation 1,267 times per shift.

The operation is appears to be a 2mm depth of cut with a 2mm mill to form a pilot and then a 2mm drill operation thru cut which appears to be about 6mm in travel.

Machine: Fanuc Robodrill Alpha-T14iE

Operation 1: Carbide Mill 2.0mm Guhring 16,000rpm at 190 mm/min 2mm depth of cut Guhring

Operation 2: Carbide Drill 2.0mm Guhring 14,000rpm at 720mm/min 6-8mm thru cut Guhring



Does anyone think this existing tool can be saved with feeds/speeds or if I should pursue a different tooling supplier?

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Fanuc Output Module Failure

March 20, 2017, 1:01 pm

≫ Next: What's your preferred toolholder for tapping?

≪ Previous: Guhring Mill / Drill Huge Issues with Breakage and Tool Life

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Late Friday afternoon one of our lathes went "boom" .... pretty loudly.
It was an electrical boom to be sure, but there was very little to no magic smoke to be found.

2 banks of units. Bank 1 = basic machine. Bank 2 = Options.
CRT said error on Z, but bank 1 had no alarms at all on the amps.
Bank 2 had an alarm on .... ???? the Power Supply I think....
No alarms @ Control On
Machine would come "up" and then throw the alarms, but stay "up". No movement.

Took out all (7) P/S's and Amps today - expecting to find a big blow hole somewhere.
No signs on first eyeball tour.
Went back through then with the meter, and found one Output Module that shows bad, but it is visually OK. (I ordered replacement(s) )

Checked motor leads with meter (just ohms) and all seems fine there too.


I've replaced a module or two just like this on other machine before, but not sure if I heard them "go" before. (May not have even been in the building at the time)
Does that seem right that it could make "that much" noise, and not let out magic smoke or appear blown? (bulging or ??? like I have seen the snubbers when bad)


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Think Snow Eh!
Ox

What's your preferred toolholder for tapping?

March 20, 2017, 2:08 pm

≫ Next: Aluminum S20 Collet Pads?

≪ Previous: Fanuc Output Module Failure

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I've been speaking with several customers lately about tooling for new machines (machining centers) and the subject of toolholders for taps keeps coming up.

I'm curious to hear everyone's thoughts on what they prefer.

I've personally used floating tap holders, rigid tap-holders with quick-release tap-collets, ER collet chucks with dedicated tap-collets, and plain ER/collets.

What's everyone prefer? I'm personally in the "keep it simple" camp and tend to default to ER collet chucks & collets, because I'm lazy.

Who out there prefers dedicated tap-collets?

Aluminum S20 Collet Pads?

March 20, 2017, 7:05 pm

≫ Next: 2005 Haas VF-6/50 w/ 210TR and approximately 1500 hrs for titanium & copper?

≪ Previous: What's your preferred toolholder for tapping?

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As the title says, looking for aluminum collet pads OR some other way to keep the pads from scratching the OD of a part as I slide it in/out for the 2nd op. I broke the sharp edges but not good enough I guess.

Really I should tear into the sub to see if it's a through hole or not so I could avoid the 2nd op all together. I'm guessing Mazak could tell me that as well.

2005 Haas VF-6/50 w/ 210TR and approximately 1500 hrs for titanium & copper?

March 20, 2017, 8:00 pm

≫ Next: Bulova CNCs?

≪ Previous: Aluminum S20 Collet Pads?

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Greetings, future friends! I seek advice regarding whether I am getting a decent deal for a good machine - or about to make a huge mistake!

I am ready to step up from a Tormach PCNC1100, which has been terrific for learning and proving my ideas, to a 5-axis machine with vastly improved rigidity and throughput. My primary product lines are titanium firearms, specialty scientific incubators and phase-change heat pumps, robotics, and upmarket furniture and fixtures. I use Siemens NX for all CAD/CAM. Most of my mill work is on titanium 6al-4v and copper, but approximately 20% is other random stuff, such as mild steel, aluminum, stainless, etc. Business is good, and it's time to get serious.

I located a 2005 Haas VF-6/50 for sale with 4th and 5th axis support enabled and a TR210 table. The TR210 table was used only once, and the VF-6 has approximately 1500 hours on it. The seller is looking for somewhere between $90k and $120k for everything.

My research indicates that this is a decent deal, but I am putting a lot on the line. Although my energy, ambition, and determination are second to none, I am new to this field, and I lack experience. Any comments, questions, or opinions would be welcome. Thanks!

Bulova CNCs?

March 21, 2017, 4:11 am

≫ Next: lathe job: bar feeding parts 3/4-10 thread, able to chamfer both sides?

≪ Previous: 2005 Haas VF-6/50 w/ 210TR and approximately 1500 hrs for titanium & copper?

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While looking for a used VMC I came across a Bulova VMC-4220B for sale. I was wondering if anyone here has any experience with them or has at least seen one in person?

They appear to be rebadged Campro (Taiwan) VMCs. CPV-B-CAMPRO

I remember seeing ads for them a few years ago, but I haven't heard anything about them since then.