Overcome a weighty issue: General Industry Coverage

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END USER: Whirlpool Corp., (269) 923-5000, www.whirlpool.com. CHALLENGE: Eliminate damage to toolchanger arms on vertical machining centers when replacing a step tool that exceeded the weight capacity. SOLUTION: A lighter, module-style, combination cutting tool. SOLUTION PROVIDER: Mapal Inc., (810) 364-8020, www.mapal.us.

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A twin-spindle vertical machining center always boosts productivity compared to a single-spindle VMC except when the twin-spindle machine is down for avoidable repair work. Benton Harbor, Mich.-headquartered Whirlpool Corp. experienced unintended downtime after purchasing two Chiron twin-spindle VMCs to machine zinc Classic Gearcase cover plates for KitchenAid-brand mixers and applying the same tools the company previously used in single-spindle VMCs.

The tools, which machined four different part features, consisted of a reamer for finishing a 30.048mm-dia. bearing bore and a step tool for machining the 132.2mm-dia. part face, a 98.42mm-dia. bearing bore and a 81.0015mm-dia. clearance bore. The step tool had one insert per cutting diameter on an adjustable cartridge.

However, the 17.6-lb. step tool was too heavy for the twin-spindle machines, which have a tool-weight capacity of about 15.5 lbs., noted Christopher A. Cornelius, senior project engineer, KitchenAid Div. “We experienced a high level of broken toolchanger arms,” he said. “The arm is a multiple-piece design that Chiron refers to as a ‘basket.’ “

Images courtesy of Mapal

Mapal’s module-style tool (above, in both spindles) meets the tool-weight capacity requirements for the twin-spindle Chiron VMC while replacing the reamer and step tool (below) Whirlpool previously applied to machine four features in a cover plate for a mixer.