NEWS & PR

Slicing Hours off Production Time

22 March 2006

Stellram's 7792VXD allows one tool to be used for facing, pocketing, slotting, and plunging. It reduces component costs by maximising metal removal rates and reduces processing time by allowing close-to-profile pocketing of 90º walls.

There is reduced vibration and improved tool economy. It also allows new productivity levels with virtually any material, including steels, cast irons, aluminium, titanium, and superalloys.

How much can the 7792VXD improve performance? Consider this: A manufacturer of precision stamping dies and special machines was looking for an effective solution to machine a 460mm x 1370mm x 89mm die-pressure pad made from 4140 steel, using a Matsuura vertical machining centre with a BT50 spindle. The flat-bottom blind holes were 51.5mm in diameter and 68mm deep. Due to the part configuration and fixturing, a 114mm-tool projection was required to produce holes. Cycle time was 15 minutes per hole, or 4 1/4 hours total.

Stellram’s 7792VXD modular head high feed cutter and anti-vibration heavy alloy modular shank were used successfully to create a hole by helical interpolation. Starting from a solid workpiece, the flat bottom hole was helically interpolated in just 1 minute 45 seconds with the high feed concept. Speed was 1500 rpm with a feed rate of 1.15mm per tooth.

The cutting action of the 7792VXD directs forces axially back into the spindle, producing less stress on the machine. The pad, which required 17 flat-bottomed holes, was completed without chatter.

Production time was reduced from 4 1/4 hours to a mere 30 minutes and is an optimum solution for many applications.