Drilling, Tapping and Threading Holes
Take a look at some of the newest equipment and tooling that are helping shops make their holemaking operations more productive and profitable.
Posted: February 4, 2015
OFF-CENTERLINE DRILLING, TAPPING
Fives (Fond du Lac, WI) brings off-centerline turning, drilling, milling and tapping capabilities to its Giddings & Lewis vertical turning centers with a new Y-axis attachment that combines a C-axis head with table and X- and Z-axes motions. This powerful package offers a wide range of motion, with power and torque equal to standard, heavy-duty right-angle heads and no limits in cutting performance relative to speed. This is an affordable way to reduce setups and free up machine time on horizontal machining centers and boring mills that used to be required to produce these same features on turned parts.
The C-axis head provides ±45 deg rotation, creating a machining range of Y-axis features of ± the VTC table radius. The continuous power 22 kW (29 hp) attachment has a maximum spindle speed of 2,200 rpm and continuous torque of 875 Nm (645 ft-lb) and can be loaded manually or automatically via the machine’s automatic tool changer. A live spindle accommodates standard Kennametal KM80™ or Sandvik Coromant® Capto C8 tooling. Coolant delivery via external nozzles on the face of the attachment or thru-the-spindle coolant is provided. The preloaded, high-efficiency, C-axis drive and high-stiffness roller bearings ensure accuracy. The attachment’s integrated measurement system allows for accurate machining of part features.
Fives Giddings & Lewis, 142 Doty Street, Fond du Lac, WI 54935, 920-921-9400, Fax: 920-906-2522, www.fivesmsi.com.
FAST HOLE EDM DRILLING OF FILM COOLING HOLES AND DIFFUSER SHAPES
Makino, Inc. (Mason, OH) offers the EDBV8 fast hole EDM drilling machine for the production of film cooling holes and shaped diffuser holes in blade and vane segments. The need for EDM drilling with advanced capabilities in blade and vane components has grown substantially due to new production requirements, as turbine engine manufacturers strive to improve engine performance and reduce fuel consumption. The development of this machine marks the first expansion of the EDBV-Series (electrical discharge blade and vane) product line, and it provides blade and vane manufacturers with the flexibility to accommodate a wider range of part sizes for any high-volume fast hole EDM drilling application.
The EDBV8 machine provides manufacturers with the speed, flexibility and reliability to effectively produce a wide range of hole shapes and sizes with a single electrode process. This approach significantly reduces tooling costs while improving cycle time, part quality and production efficiency. Its uniquely designed tooling system integrates the electrode and die guide into a common assembly for quick and reliable automated exchanges, and provides programmable control over electrodes and electrode diameter size changes.
The EDBV8 offers X-, Y-, Z- and W-axis travels of 800 mm, 600 mm, 750 mm and 500 mm (31.5 in, 23.6 in, 29.5 in and 19.7 in), respectively. The machine is also equipped with a 2-axis rotary table that can accommodate a maximum workpiece size of 500 mm (19.7 in) diameter by 635 mm (24.96 in) long, and a maximum payload of 150 kg (330 lb). Its rotating C-axis head features an EROWA compact chuck that enables automatic changing of electrode diameters from 0.2 mm (0.008 in) up to 6.0 mm (0.236 in) with rotation speeds up to 1,000 rpm.
The EDBV8 uses a rigid guide-arm assembly to hold, locate and support the die guide, which can be alternately used as a programmable axis (W-axis) that runs parallel to the Z-axis. An integrated “middle guide” system is also contained within the W-axis and is used with long small-diameter electrodes to prevent whipping, bending and vibration of the electrode. Additionally, the middle-guide “fingers” automatically retract as the electrode tube reduces in length, maximizing the productive useful length of the consumed electrode.
The EDBV8 features improved flushing through fully submerged machining, greater machining stability and part accuracy, and faster cycle times with the equipped 10 MPa (1,450 psi) flushing capability for higher productivity of deep-hole features. The machine also contains a fast response break-through detection circuit to prevent back-striking or back-wall impingement (damage to the inner cavity) during blade and vane cavity wall penetration. This highly sensitive breakthrough detection circuit, which uses a combination of different adaptive process-monitoring techniques, is accomplished while delivering maximum speeds.
An advanced EDM generator technology produces excellent metallurgical quality and integrity on high-nickel alloys such as Inconel®. Reliable and repeatable machining results are maintained using the machine’s on-board water quality control system that consists of a filtration system to clean the water, a deionization system to control water conductivity, and a chiller unit to maintain the water temperature at the same level as the machine casting.
For unattended burning of varying film cooling hole diameters, the EDBV8 features automatic tool change (ATC) and automatic guide change (AGC) systems. The patented tooling system combines the electrode holder and die guide together into a common assembly, providing enhanced reliability with simple and precise automated exchanges. Together, these features enable ATC and AGC exchanges in less than 1 minute, and they offer a unique combination of process flexibility while minimizing non-value added machine motions.
The EDBV8 employs several proven software technologies used in Makino’s fine-hole sinker EDM machines. Makino’s Model Plan system is integrated into the controller, providing user-friendly input screens with direct G- and M-code programming formats. An electrode length management system provides electrode wear tracking and automatically exchanges electrodes when lengths become too short. The controller contains several canned cycles for hole drilling and simple diffuser shape machining, and custom G-Code profiles can also be imported and easily used in the machine.
The EDBV8 has been designed for easy operation, and it offers the operator unparalleled access to the work tank with its three-sided rise-and-fall work tank. The EDBV8 is also capable of on-machine probing to determine workpiece locations and offsets. Electrical touch-sensing probing or a conventional mechanical touch probe can be used to capture location data points. The standard configuration of the EDBV8 includes a 24-station tool carousel and 24 tool assemblies to fully stock the machine for maximum productivity.
Makino, Inc., 7680 Innovation Way, Mason, OH 45040-8003, 513-573-7200, Fax: 513-573-7360, www.makino.com.
CORDLESS 4-SPEED DRILL/DRIVER FOR EXTREMELY HARD MATERIAL
FEIN Power Tools, Inc. (Pittsburgh, PA) has a series of cordless hand-held drill/drivers for use by metal fabricators. One tool in particular, the ASCM QX drill/driver, is ideally suited for drilling and driving fasteners in steel and extremely hard material in fabricating and industrial applications. The ASCM QX drill/driver is built to perform non-stop under the most rigorous conditions. Its brushless, dustproof PowerDrive DC motor and electronics provide extremely long service life with 30 percent more efficiency than comparable DC motors.
Its four-speed, all metal gearbox can be set to 400 rpm, 800 rpm, 1,950 rpm or 3,850 rpm with 15 torque settings that provide adjustable depth stops preventing stripping or breaking screw heads. When using the 400 rpm speed, the unit develops a 796 in/lb torque for driving 3/8 in X 15.75 in fully threaded screws. A side handle gives it added stability.
It comes with two, 18 V, Lithium-Ion batteries and a rapid charger that will provide full-day continuous use. Each battery will operate under full load use for about 30 minutes while the second battery recharges in the same amount of time. FEIN SafetyCell technology protects the batteries from overload, overheating and deep discharge through a communication link. A time saving feature of the ASCM QX model is its quick-action interchangeable Rohm chuck and separate bit holder. The chuck with spindle lock has a 1/16 in to ½ in tool capacity with steel jaws for optimal tool holding. The twist-on, twist-off chuck and bit holder are easily changed out without the use of tools.
It also has variable speed finger control for precision drilling and fastening. A high-performance LED light is aimed to provide perfect illumination of the work area without any chuck or bit shadows. The drill/driver weighs 3.75 lb (1.7 kg) with the 18 V battery. A 14.4 V battery is available reducing the unit weight to 3.25 lb, but at a sacrifice of 44 lb torque. It comes standard in a plastic carrying case with interchangeable chuck and separate bit holder, two batteries, rapid charging unit.
FEIN Power Tools, Inc., 1030 Alcon Street, Pittsburgh, PA 15220, 412-922-8886, www.feinus.com.
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