Integrated Sawing and Machining

The ACS + CFMcurve integrated sawing and machining center simultaneously machines each workpiece end, using 12 independent servo-controlled axes to do machining options that include threading, boring, profile turning, grooving, radius edges and angled chamfering.

Rattunde Corporation (Grand Rapids, MI) introduces the exciting new ACS + CFMcurve integrated sawing and machining center in Booth N-6737 at IMTS 2012. 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 m (54 ft) 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 70 mm diameter, wall thickness of 5 mm, material type ST52-3 BK, with a length of 150 mm, machined with a 30 deg chamfer on the ID and 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 ± 0.15 mm at 1.67 CPK and a machined length tolerance of ± 0.05 mm 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 10 mm; there is a 5 mm 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.

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Rattunde replaces slow and unreliable processes with this 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 2012 will include part inspection and automatic packaging.

The ACS + CFMcurve is available in three models with diameter ranges from 10 mm to 102 mm, 10 mm to 136 mm and 10 mm to 169 mm, with finished part lengths from 10 mm to 3500 mm. All material types can be processed. www.rattunde-corp.com