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OSG on cutting aluminum auto parts with Micro Technology

Micro Technology Inc., Tullahoma, Tenn., makes parts that are used to mount to automotive engine blocks to be robotically transported through assembly lines. The company uses HAAS VF-3 with CAT40 taper tools. One part is 6061 Aluminum with a tolerance requirement of +/- 0.002" and was being machined with a face mill at 3,000RPM 120IPM with 1.25" axial and 1.2" radial depth of cut. The challenge: Improve productivity without sacrificing quality and accuracy. OSG Tap & Die describes their solution in a recent web feature:

What's shakin'? Seco Tools on vibration control

Seco Tools looks at passive and dynamic vibration control in a recent technical article on the company's web site. In metalcutting, vibration is generated by the changing forces that occur when making chips. The intermittent forces are apparent in the interrupted cutting process of milling and also appear in turning operations when the toolholder bar is periodically loaded and unloaded as chips form and break. A passive/dynamic approach to vibration control for tools involves application of a tuned mass damper concept.

Shop Operations: A fresh look at 1-2-3 blocks

08/25/2017
Author:
Tom Lipton
Many machinists fondly remember their early training or apprenticeships when they made 1-2-3 blocks from scratch under the watchful eye of a master toolmaker. These young machinists carefully machined the blocks oversize, heat-treated them and then ground them to size. They quickly learned that precisely holding size and geometric features to close limits is more challenging than it seems at first glance.
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Three steps to optimizing machining

09/05/2017
To profitably machine high-quality parts, many manufacturers follow a similar path, beginning with tool selection and application and then solving any problems that arise in a reactive way. However, research suggests that manufacturers should examine the entire machining process before cutting begins, focusing on eliminating rejected parts and unforeseen downtime.
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How to keep from scrapping parts

08/31/2017
Author:
Scrap happens. By scrap, I mean parts that are out of tolerance and, therefore, useless. Unlike other by-products of the manufacturing process, such as chips, shavings and drops, you generate scrap only through mistakes. 

So the challenge of reducing scrap comes down to preventing mistakes.
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