Rotary Loading Automates Small-Batch
Transcription
Rotary Loading Automates Small-Batch
s SHOP SOLUTIONS Problem Solving on the Shop Floor A Honing System Hits Precision Gun Barrel Target H oning machine technology from Sunnen Co. (St. Louis) has replaced hand lapping in the manufacture of preci- sion rifle barrels for Pac-Nor Barreling Inc. (Brookings, OR) with impressive results. In competitive shooting, for example, where Read more, P42 Sunnen’s HTE hone has all but eliminated standard pre-rifling lap for Pac-Nor’s precision rifle barrels. Rotary Loading Automates Small-Batch Production A utomation of small-batch production poses particular challenges in terms of work processes, logistics, and availabil- ity. The Berger Group has reacted to the increasingly stringent requirements of its markets by rolling out rotary loading. Read more, P46 Liebherr’s pallet handling system RLS 800 is able to automate up to two machines for efficient small-batch production. Quick-Change System Gains Multiple Economies I n most cases, the installation of a quick-change system for holding turned parts creates savings by increasing produc- tion. For Milwaukee-based Charter Wire LLC, there were other unexpected savings. Read more, P116 Representative example of Hainbuch centroteX system. 40 AdvancedManufacturing.org | July 2016 SHOP SOLUTIONS winning scores may be separated by thousandths of an inch, a few millionths of an inch improvement in the uniformity of a Pac-Nor barrel may make a big difference for a skilled shooter. Manufacturing precision rifle barrels has always been something of an art that involves hand lapping of the bore surface twice, before and after the rifling profile is cut or swaged in by a rifling button. In fact, a bright, hand-lapped bore is considered one of the hallmarks of a precision rifle barrel, despite the inherent variations from manual work done by people who get bored and tired from the monotonous chore. More than a year ago, Pac-Nor Barreling set its sights on this issue and hit the X-ring with the newly developed HTE honing Barrel blanks are securely held in a three-jaw chuck with oil pumped into one end while the tool works from the opposite end. Sunnen’s Long Bore Tool uses metalbond diamond or CBN superabrasives to quickly remove reamer marks, waviness, tight spots, and other imperfections left by upstream processes. HighPerformance,PrecisionandProductivity HighPerformanceDrills HighPerformance EndMills HighPerformance EndMills Gettingthebestquality,performanceandcosteffectiveness fromyourproductionmachineryisnotjustaboutcuttingfaster, butmachiningsmarter. WhicheverM.A.Fordtoolingoptionyouchoose,youcanbeconfidentthat ourinnovativecuttingtooltechnologiesandover95yearsofexperiencewill optimizeyourmanufacturingprocessesandproductivityopeningupnew potentialforimprovementsinmachiningtime,qualityandfinish. TolearnmoreandexperiencetheM.A.Fordadvantage foryourself,contactusnow. C a l l 5 6 3 - 3 9 1 - 6 2 2 0 o r 8 0 0 - 5 5 3 - 8 0 2 4 • s a l e s @ m a f o r d . c o m • w w w. m a f o r d . c o m See us at MA Ford - Cutting Tool Engineering Advert BW 123x178mm.indd 1 42 AdvancedManufacturing.org | July 2016 Booth #W-2374 01/02/2016 16:49 machine from Sunnen Products Co. (St. Louis). The ma- and an Eldorado CNC twin spindle. After reaming, the bar- chine has all but eliminated Pac-Nor’s pre-rifling lap, which rels are gaged for size. Depending on the condition of the is the more difficult and time-consuming of the two laps. reamer, 0.0004–0.0007" (0.010–0.018 mm) of material is Pac-Nor is also producing as many custom barrels as ever, left in the bore. This must be manually lapped out or honed but with a slightly smaller staff. “Our objective with the hone was to build a better product with less labor, and the honing machine has exceeded my expectations,” said Pac-Nor Production Manager Casey Dichter. “The hone produces a consistency in bore diameter that is head and shoulders above lapping, within two to three millionths of an inch end-to-end when it’s really dialed in. This, in turn, improves the consistency of the rifling process by minimizing variation in the depth of the grooves. We still finish lap after rifling, but it’s easier because we just polish off the fine crosshatch finish that may be left after honing and rifling,” said Dichter. Pac-Nor Barreling is a true custom manufacturer catering to bolt-action rifle shooters. The company’s principal markets are law enforcement, military, competitive shooters and hunters. Started in 1984 by avid shooter and company President Chris Dichter, Pac-Nor is now in its second generation under his son, Casey. In addition to barrel manufacturing, the shop will rebarrel and install the barrel on a customer’s action, or add features such as muzzle brakes or fluting on bolts and barrels. The shop runs two shifts per day. A day shift of 10 people produces 30 to 40 custom barrels of different calibers in 416R stainless or chrome-moly steel. A night shift of three people produces one type of barrel—about 50 AR-15 barrels per day for a rifle OEM. Pac-Nor’s process starts with cutting and facing premium bar stock, followed by gun drilling, done by four Pratt & Whitney twin-spindle machines July 2016 | AdvancedManufacturing.org 43 SHOP SOLUTIONS out to final size for rifling. “Everyone who works here has We tried to shorten this, but when chatter marks get ironed done hand lapping. It’s an unpleasant job, particularly if the into the surface by the rifling button, the finish lap is even reamer is starting to get dull,” said Dichter. “Lapping may longer and more difficult, so there is no advantage. With take 10–45 minutes, depending on the caliber of the barrel. lapping, too, there is potential for variation, simply because it’s a manual process. Lapping can also be a production limiter and in our THE NEXT GENERATION HAS ARRIVED region we have a very small labor force to draw on when we want to grow.” The company had explored honing in the '90s, but revisited the idea when Sunnen introduced its HTE honing machine in 2014. The HTE is a horizontal machine that can hone small-bore rifle barrels with a diameter range of 0.150–0.790" (4–20 mm), and lengths up to 60" (1524 mm). Designed specifically for long SMARTER WORKHOLDING small bores, the machine features an extremely sensitive drive and tool feed system that provides maximum protection against tool overload/ breakage. Tool specific force limits Sealed, clamped, and ready to turn—the next generation of quick jaw change chucks has arrived. The KNCS-2G, offers the same superior flexibility, minimal set up times, and high repeatability as the original KNCS-N, but with added protection and efficiency, making it ideal for mass production applications. And with its optimized lubrication system, the KNCS-2G will save you time and money in repairs and upkeep. and run settings are stored in the touch-screen PC control, allowing the system to sense tight sections in the bore and correct them automatically. Sunnen also developed a new Long-Bore Tool (LBT) designed to take on industry’s most difficult honing challenges in small bores of .17 caliber rifle barrels. The tool quickly removes reamer marks, waviness, tight spots and other imperfections left by upstream processes. The LBT utilizes metal-bond diamond or CBN At SMW Autoblok, we have dozens of ways for you to hold workpieces better, stronger and smarter. Call or visit our website to learn more. superabrasives for high productivity, long life, and fast cycle times. Precision-machined of through-hardened tool steel, the LBT can produce bore accuracies of 0.000027" (0.0007 mm) Booth #W-1400 for diameter, roundness, and taper— from first part to last. Honing is an ideal replacement www.SMWautoblok.com 847.215.0591 for hand lapping barrel blanks before rifling. It quickly removes reamer scratches and surface waviness 44 AdvancedManufacturing.org | July 2016 without labor-intensive hand lapping. A typical 600-grit carbide rifling buttons and can provide different rifling styles, abrasive can produce a 6–10 µin. Ra (0.15–0.25 µm) finish including polygonal, per the customer’s choice. A button is in a reamed barrel blank. By producing a consistent bore di- attached to a rod and the rod is pulled through the barrel. The ameter of ±0.0001" (0.003 mm or less), parallelism, round- company’s hydraulic rifling machine utilizes a CNC machined ness, and surface finish end-to-end, honing yields more consistent performance from rifling buttons and cutters, resulting in a constant groove depth. The ideal bore geometry reduces distortion of the bullet shape for improved gyroscopic stability in flight. It’s all about Precision, Productivity, and Profit. One solution, fully integrated, from one company. Visit us at IMTS and let us show you how. Maverick McCourt prepares to install a rifle barrel on a receiver using Pac-Nor’s barrel press. “We are currently honing about 80% of what we make and will do more as we acquire the tools in different calibers,” said Dichter. “We have learned the quality of our reaming now does not TRUNNION Witzig & Frank by Hydromat is a leading brand for modular machine concepts and turnkey systems for metal cutting and forming applications The LSA is a multi-way production cell with horizontal indexing axis for 3-sided machining in one clamping. It features 4 to 8 stations with horizontal and radial units. Adjustable and pivotable, they easily adapt to changing workpiece shapes. EPIC ROTARY TRANSFER When it comes to multitasking, Hydromat is without peer. Whether it’s for lower volume production needs, improved design for tighter tolerances, high volumes, or tooling development for tougher materials, we have delivered better solutions to our customers for decades. Hydromat’s EPIC is the most efficient rotary transfer production system available. Bar none. MILL/TURN Designed with four machining stations and two dedicated loading/unloading stations, the ICON was developed around flexible machining principles. Equipped with a six position table, it shuttles pallets to four machining modules for fast, ultra-precision cutting. Engineered for maximum output in a small footprint, the ICON 6-150 the ultimate in productivity and flexibility. WITZIG & FRANK by need to be as critical because we have the hone. Although there is a tradeoff in cycle time and abrasive cost for additional honing, we are still able to run our reamers two to three times longer than when we lapped alone. With a hand lap, the time and effort increase when the reamer is getting dull.” After honing, the barrel is inspected www.hydromat.com Hydromat Inc. • 11600 Adie Road • St. Louis, MO 63043 p 314.432.4644 • f 314.692.5166 again before rifling with a pull-button. Pac-Nor makes its own Accu-Twist ME-Is half-HSL 3 Lines IMTS 2016.indd 1 July 2016 | 45 5/26/2016 11:25:09 AM AdvancedManufacturing.org SHOP SOLUTIONS twist bar with a helix angle that matches the twist rate request- followed by contouring of the outer shape and final, finish ed by the customer. The final twist rate is confirmed afterward lapping of the bore. “During the finish lap, you can really tell using a Barrel-Scan electro-optical twist measurement system. the difference between a bore that was honed before rifling The barrel is then stress-relieved in a tempering furnace, and one that was lapped,” said Dichter. “You can easily sense any remaining tight or loose spots in the bore. The diameter uniformity and roundness of the honed bore are superb. The lap also feels different Is A Crippa Tube Bender Right For You? Ask The Man Who Bought One Two Four Six Of Them in a honed bore.” For more information from Sunnen Products Co., go to www.sunnen.com, or phone 314-781-2100. Continued from P40 Rotary Loading Automates Small-Batch Production Brent Taylor is Vice President of the Metal Divisions of Jay Industries, a Midwest based metals and plastics manufacturer. He purchased his first Crippa machine in 1999 and has been a steady customer ever since. Today Jay Industries has a Crippa 532, 542, 976 and 980 at their Mansfield, Ohio plant and a 532 and 980 at Gadsden, Alabama. A utomation of small-batch production poses particular challenges in terms of work processes, logistics, and availability. The Berger Group has reacted to the increasingly stringent requirements of its markets by rolling out Liebherr’s Rotary Loading System (RLS) at its plant in Wertach, Germany. This now enables the contract manufacturer Here’s why. “The machines are very reliable in terms of uptime and capability and the service support is outstanding. Our service tech is extremely competent and he’s been an excellent resource for helping us improve our performance. “Basically, you cannot go wrong with a Crippa. Crippa’s technology, build-quality, capability and service all add up to excellent value and peace of mind.” to meet customer needs more flexibly, Crippa has been the world’s leading innovator in tube processing technology for more than 65 years. Brent Taylor knows why and so should you. quickly, and cost-effectively. Give us a call and let us show you why a Crippa tube bender is the right choice for your next machine. manufacturer of precision lathed and Air Conditioning the Berger Group is the world’s largest milled components. It is a full-service contract manufacturer with global operations and state-of-the-art machinery assets with more than 800 machines/ CRIPPA USA LLC 65 N. River Lane, Suite 209, Geneva, IL 60134 Ph: 630.659.7720 web: www.crippa.us Aerospace Established in 1955 by Alois Berger, Automotive Furniture Heating Ventilation installations and more than 2400 employees at 10 plants in five countries. The times, however, are changing. “The markets have become fasterpaced,” said Helmut Berger, who has been factory manager at the company. 46 AdvancedManufacturing.org | July 2016 SHOP SOLUTIONS “That’s why we have to keep adapting solution could provide. The company more and more quickly to changing decided to choose Liebherr’s Rotary market circumstances. The concept Loading System (RLS) to meet its small- applied in the past served its purpose batch and single-item production needs. but there was still a need to optimize. Featuring up to 24 storage bays, The issue of a suitable automation the system has an outstanding high solution had to be raised,” said Berger. storage density while requiring mini- A key reason for this: the compo- mal floor space. Plus, the design of nents to be manufactured—complex the storage module allows another components for innovative hydraulic machining center to be integrated into power units—feature different bore the system. That ensures the required and threading finishes and are there- degree of flexibility that may arise in fore available in a wide range of differ- the future. Given its modular design, ent versions. Even the manufacturing this automation can be matched to process itself is challenging. current production needs in no time at Staff at Berger’s plant, which manufactures components predominantly for mechanical engineering firms, spotted the potential which a suitable automation 48 AdvancedManufacturing.org | On Liebherr’s Rotary Loading Systems, the integrated setup space is located right next to the operator’s side of the machine for easy access and monitoring. July 2016 all. The two available sizes, RLS 800 / RLS 1500, cover a wide range of applications. Berger specifically operates an RLS 800. “Our focus was on reducing expensive setup times. We needed to significantly extend our machine-side tool storage capability,” said Philipp Schneider, head of department at this branch of the group. Thus, the tool storage was upgraded from 80 to a total of 320 spaces and the modular, flexible-configuration rack columns were designed to enable even customer-specific requests to be promptly met. The equipment featured an all-purpose design to provide as much flexibility as possible. During the period when the RLS was integrated into the existing solution, Liebherr worked closely with machining center builder Heckert. Together the two companies sorted out the interface issues between both systems. Another important point is that operators like working on the RLS. The integrated setup space is located right next to the operator’s side of the machine. The system’s special design enables users to access the automation unit easily. The surrounding window panels in combination with the well-laidout user interface provide an overview of what’s happening in and around the RLS. Through the intuitive-to-use cell controller software and the graphic user interface, the required functions can be conveniently activated via “drag and drop.” The software, like the entire system, features a modular design. A range of different add-on packages can be hitched onto the basic package to enhance functionality so Liebherr can adapt new applications to deliver process reliability without having to modify the existing computer system. The switch to the RLS for small-batch production is paying dividends for Berger, particularly in terms of efficiency, customer focus, and delivery capability. Given its newly acquired flexibility, the company is able to react immediately even to really short-notice changes in demand. Customers are supplied on time with exactly the models in the quantities they require and are therefore capable of reacting faster in changing market situations. The RLS has also reduced the manufacturing cost impact of setup times significantly and enables more productive use of machining center time cutting parts. The RLS allows operators to set up jobs in parallel with machining time. So the machine tool is not waiting on the next job, thus ensuring that setup costs are not absorbed in machine hour rates. This RLS concept optimizes spindle utilization and maximizes production output. Even an unmanned third shift would be feasible. Another effect of this changed production philosoContinued on P116 July 2016 | AdvancedManufacturing.org 49 SHOP SOLUTIONS For more information from Liebherr Automation Systems, Continued from P49 phy was that Berger was able to reduce its inventory. Regard- go to www.liebherr-us.com, or phone 734-429-7225. ing return on investment (ROI) the RLS acquisition is likely to have paid for itself within a comparatively short period. Continued from P40 Quick-Change System Gains Multiple Economies I n most cases, the installation of a quick-change system for hold- ing turned parts creates savings by increasing production. For Charter Wire LLC, a Milwaukee-based supplier of precision cold finish bar, cold-rolled steel, custom profiles, and shaped wire, there were other unexpected savings. Founded in 1936, Charter Wire supplies precision wire products to manufacturers around the world. An early pioneer in cold-rolling technology, Charter Wire and its sister division, Charter Steel, employ the latest in technological innovations throughout their manufacturing processes. As a result, Charter can furnish customers with products engineered with tailored mechanical properties, as well as custom shapes with tolerances up to 0.002” (0.05 mm). “Because we produce literally thousands of custom shapes, we create our own tooling dies for our rolling Cut the materials of today. Shape the products of tomorrow. mills,” said Cory Rockteschel, senior ALL WITH WATERJET. hardened to >50 Rc.” project engineer. “There can be some variation in the steels and shapes we use, and we typically use tool steels When Charter Wire recently ordered a new Mazak QTS 350M through Machinery Systems Inc. (MSI; Brookfield, WI), Rockteschel inquired about FlowWaterjet.com 1.800.446.FLOW fitting the machine with a quick-change system. John Schlevensky, MSI sales 116 AdvancedManufacturing.org | July 2016 SHOP SOLUTIONS engineer said: “In reviewing Charter Wire LLC’s application, Wire application required both high-precision OD turning and I immediately thought about the Hainbuch centroteX system ID turning. centroteX was the ideal choice given the part sizes and contacted Tom Buraczewski, midwest regional sales man- we were working with, which are primarily 4–10" [101.6–254 agerGeneral at Hainbuch Buraczewski “The Charter Grinder IslandAmerica.” Ad M.E. 7-16_Layout 1 said: 6/5/16 12:24 AM Page 1mm] in diameter, and the need for precision.” Although traditionally known for its line of chucks and workholding equipment Feature Machines of the Month The Industry Leader of Heavy-duty Surface Grinders designed to enable the fast change of collets, jaws, and other retaining devices, Hainbuch’s centroteX system extends the capabilities of the workholding system by facilitating the fast and easy changeover of a selection of chucks of various sizes. The interchange is made possible by a precision-machined adaptor/flange plate equipped with rapid-action screws and a bayonet coupling. This accommodates a variety of chucks and holding devices that are easily connected and locked by six simple fasteners. Typical changeover time ranges from 10 seconds to 15 minutes, and the clamping device ensures precision in the 6-µm Model CSG3A818 shown with optional dresser and coolant/dust system range each time a chuck is mounted. Model CSG1640ASDlll shown with optional paper/coolant system For large and heavy clamping A New Generation of Automatic Surface Grinders, The Precision ASDlll Series with the All New PLC Digital Control Panel devices, the Hainbuch Monteq spring- Clausing Precision ASDlll Automatic Surface Grinders Feature... flexibility during changeover. Chucks • Delta PLC Control with a 7.2" touch screen • Exclusive Clausing/Equiptop Picture Mode Operation is the easiest to learn and operate • Complete grinding cycle displayed in easy to read format – start point, end point, incremental downfeed, spark out and more • Brushless DC servo motor for step infeed and continuous cross traverse • Standard sizes from 6" x 18” to 32" x 120" • Optional Variable AC spindle drives available • Precision Hydraulic Surface Grinders: 6" x 18" thru 16" x 40" are hoisted into place by means of a lifting and mounting device for fast positioning and easy handling. In addition to accommodating the weight of the chuck, gradations on the device assist in alignment of the horizontal axis, and nonthreaded, quick-action bolts secure the device for loading or removal. Chucks are stored in a specially Clausing Offers A Full Range of Precision, Low-cost, High Performance Surface Grinders... • Precision Manual Surface Grinders: 6" x 18" and 8" x 18" mounted attachment offers speed and designed wheeled storage container that speeds selection and keeps them • Custom sizes and Cylinders Grinders available clean when not in use. The Charter Wire LLC project involved four chucks: one three-jaw chuck that was provided by Charter Wire LLC, and three more Call 800-323-0972 or visit www.clausing-industrial.com Celebrating A Century in the Machine Tool Business 118 AdvancedManufacturing.org | July 2016 that Hainbuch supplied equipped with an expanding mandrel for ID work. John Schlevensky said: “We worked with Hainbuch to ensure that their Powerful precision – Custom machine tools for XXL workpieces Engineered in Germany, produced in the USA – with their experience of more than 160 years, WaldrichSiegen and UnionChemnitz offer customized solutions that set the benchmark worldwide: Horizontal boring mills Portal milling machines Vertical and horizontal lathes Roll grinding machines In Ford City, PA, a team of highly qualified specialists manufacture, sell and service our machines. 101 River Street · Ford City, PA 16226 T: 724 763 3889 [email protected] · waldrichsiegen.com/imts [email protected] · unionchemnitz.com/imts Anzeige_IMTS_Manufacturing_Engineering_7x4,875.indd 1 30.05.2016 09:52:17 Charter Wire custom cold-rolled steel shapes. system and the Mazak lathe achieved maximum compatibil- existing chucks that will be repurposed. This will not only ity, and there were absolutely no difficulties.” The results were save them money but will ensure continuity with their cur- dramatic. According to Cory Rockteschel, “We have been rent process—a further savings in engineering time. It’s a able to save about 15 minutes per part. Formerly, we were win-win situation all around.” producing 600 parts per month, and we are now generating Mike Cekanor, CEO at Machinery Systems Inc., said: in excess of 1200 by replacing the old CNC machine with the “With the Hainbuch centroteX system with the latest in Mazak CNC Lathe/Hainbuch centroteX system. As a result, Mazak technology, we’ve been able to achieve a dramatic we plan to add two more Hainbuch systems on existing CNC improvement for Cory and the people at Charter Wire LLC. lathes in the near future.” And that’s what it’s all about.” Tom Buraczewski pointed out another economy inherent in the new installations: “The new systems will use two For more information from Hainbuch America Corp., go to www.hainbuchamerica.com, or phone 414-358-9550. July 2016 | AdvancedManufacturing.org 119