Magnetic attraction: General Industry Coverage

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END USER: The TMF Center, (765) 762-1000 CHALLENGE: Reduce setup and changeover times when machining large parts. SOLUTION: A modular magnetic workholding system. SOLUTION PROVIDER: Techniks Inc., (877) 354-3837, www.techniksusa.com

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The TMF Center, Williamsport, Ind., machines big parts in large volumes. The shop employs 96 CNC machines to manufacture steel and cast iron components for mining and construction equipment. Running three shifts, 7 days a week, the facility’s capabilities also include flame cutting, welding, painting, grinding and heat treating. Part size and volume make efficient workhandling and workholding key factors in maximizing overall productivity.

The company’s effort to streamline production of a family of large 1080 steel side plates for asphalt roller machines is a good example. The shop makes seven versions of the plates, which measure 8 ‘ to 12 ‘ long, 1¼ ” to 5 ” thick and 2 ‘ to 2½ ‘ wide. The plant produces about 25 of the parts per day.

TMF had been using a series of 12 toe clamps to hold the side plates for machining. Repositioning the clamps for each different part in the family took about 2 hours. Then, changeover from one similar part to the next during machining required about 20 minutes. That included loosening the toe clamps, removing the part from the machine, clearing the chips, loading the next part and retightening the clamps.

According to Jeff Martin, plant manager, TMF is “always looking for process improvements.” Seeking a way to reduce setup and changeover time, the shop consulted with longtime supplier Techniks Inc., Indianapolis.

Greg Webb, vice president of sales for Techniks, said, “Our company has worked with TMF for more than 10 years, and they’ve grown accustomed to us through our toolholders and boring products.” To hold the side plates, Techniks suggested its MagVISE magnetic workholding.

Webb said magnetic workholding was a good fit for TMF. “Their parts are very large and unusually shaped, and they have a lot of different sizes. They really needed something modular in its design and setup.” The MagVISE system enables users to selectively place the magnets as needed, he added. TMF decided to use 15 MagVISE ECB 120 magnets to hold the side plates. A turn of a handle activates or deactivates a 7 “×4 “×4 ” magnet. Each magnet provides a holding force of up to 2,640 lbs., depending on workpiece size and thickness.