Manufacturing Equipment

Mitsui Seiki has introduced a small, vertical, Nd:YAG laser drilling machine in answer to aerospace companies’ wishes for a more accurate system to be used on engine components.

Mitsui Seiki has introduced a small, vertical, Nd:YAG laser drilling machine in answer to aerospace companies’ wishes for a more accurate system to be used on engine components Mitsui Seiki will be introducing its Laser Drilling Machine and its latest ‘Heavy Metal’ Horizontal and Vertical CNC Machining Centres at the USA’s IMTS 2008 machine tool exhibition

High accuracy laser drilling - Mitsui Seiki’s VLD-300 is a small, vertical, Nd:YAG laser drilling machine for 12in (300mm) cube parts.

The VLD-300 offers positioning accuracy and repeatability in X-, Y-, Z-axis of 0.00004in (0.001mm).

A-axis positioning accuracy is +/-6 arc sec; repeatability is +/-3 arc sec.

C-axis accuracy is +/-4arc sec; repeatability +/-2 arc sec.

X-, Y-, Z-axis acceleration rate is 1.5G.

This machine was developed collaboratively with several aerospace engine component manufacturers who expressed a need for a higher-speed and more accurate laser-drilling machine than what was currently available on the market.

Some workpieces, primarily jet engine high temperature alloy parts, require about 3,000 small diameter cooling airflow holes - each at a different angle - to be drilled in a non-contact manner.

Laser is often the best option for operations speed and to minimise material stress.

Typical metals are Inconel, Waspalloy, Hastalloy, and nickel-based titanium alloys.

Mitsui Seiki partnered with a European laser company for the Nd:YAG version of this new machine.

The VLD-300 is designed to also work with CO2, diode pump, and fibre lasers for different aerospace and other industry applications, such as certain electronics, medical, and automotive parts.

For rigidity and stability, the VLD-300 has a cast iron bed and linear motor drives.

A dust collection system, combined with an interior work area of smooth, highly sloped surfaces, keeps cutting debris from contaminating the work zone and equipment.

The Nd:YAG system offers a focal length of 200mm or 300mm with a height sensor for scanning and work offset probing.

The machine is ‘automation ready’ for devices such as pallets and robotic loading/unloading equipment.

A Fanuc 310iM control features the Microsoft Windows-based platform and seamlessly controls the machine, laser, and the auxiliary equipment.

* Machining centres - Mitsui Seiki’s line of ‘Heavy Metal’ CNC machining centres are the result of decades of experience and R and D in titanium and nickel alloy airframe and aerospace engine component machining.

The 4- and 5-axis horizontal machining centers in the advanced product line range from 500mm x 500mm to 1500mm x 1500mm square pallets (20in to 60in).

All the machines are designed for highest volumetric accuracy and stiffness.

The beds use a patented cast metal for rigidity and thermal stability.

Hand scraping is used to achieve the geometrical requirements now being demanded by progressive energy equipment manufacturers.

This, combined with positioning accuracies, measured in microns ensure overall volumetric component precision.

* Milling spindles - a variety of milling spindles are available, from ultra high torque geared units (essential for cutting tough materials in low rev/min, high frequency machining) to high speed direct drive spindles for super finish applications.

These machines are capable of handling large bending moments at the tool taper interface up to 35,000in.lb to increase productivity in roughing operations and stability in finishing operations.

* Mitsui Seiki at IMTS 2008, McCormick Place, Chicago, Illinois, USA, September 8-13, Booth 8767.

Weiler Corporation is offering a line of power brushes and abrasives designed for use on large and small right angle grinders

Weiler’s power brush line includes a wide variety of wire wheels, cup brushes and bevel brushes in a broad selection of diameters, wire sizes and types. Users can also choose from crimped wire for flexibility and light-duty applications or knot wire for a more aggressive brushing action. The abrasives offered for right angle grinders include Tiger Discs, Weiler’s premium line of coated abrasive flap discs designed to provide a high cut rate and long life and Vortec Pro flap discs which provide a high cut rate at a value price.

Application-specific flap discs include Big Cat flap discs for grinding and finishing curved and irregular surfaces and Tiger Discs for Stainless Steel grinding.

In addition, Weiler also has a complete line of resin fiber discs, surface conditioning discs, cut-off wheels and Type 27 and Type 28 wheels.

Abrasive fibre disc for high metal removal rates in stainless and mild steels in the welding and metal fabrication sectors removes metal up to 50% faster and lasts three times longer

3M achieves its highest ever performance in a Cubitron Fibre Disc, delivering new levels of productivity and value for the most demanding metal removal applications Global innovations company 3M has developed a brand new fibre disc for applications requiring high metal removal rates in the welding and metal fabrication sectors.

Effective with both stainless and mild steels, the new 3M 985C Fibre Disc removes metal up to 50% faster and lasts up to three times longer than competitive discs.

The 985C Fibre Disc contains 3M’s Cubitron ceramic abrasive mineral combined with a grinding aid to enhance heat removal while working difficult materials like stainless steel.

The robust vulcanised fibre disc and advanced 3M resins used to bond the abrasives to the disc help to maximise disc life in the most aggressive high pressure grinding applications.3M’s Cubitron grain is a sol gel mineral that sharpens as it wears due to its unique two-phase microstructure.

When a Cubitron grain fractures the fracture plane veers off course as it hits the microstructures or ‘platelets’.

As the microparticles break off, sharp new cutting edges are created.

These sharp cutting edges result in high cut rates, long life and amazing consistency.

‘Our tests have demonstrated exceptionally high material removal rates and our longest ever disc life in high pressure grinding applications,’ says Dinah Hughes, product manager at 3M Abrasive Systems Division.

‘Together, these factors deliver huge productivity benefits for users - benefits that go straight to their bottom line.’ To help users quantify the financial and productivity benefits of a switch to 985C Fibre Discs, 3M has developed a grinding cost calculator program that evaluates the savings made using the new discs in production applications.

‘We are encouraging users to run trials with 985C Fibre Discs on their toughest grinding applications,’ says Hughes.

‘Our programme will quickly tell them exactly how much time and money they will be able to save.’ 985C Fibre Discs are available in P24 (not available in 100mm size), P36, P50, P60 and P80 grades and in 100×16, 115×22 127×22 and 178×22 sizes.

Key applications for the new discs are expected to be found in weld bead removal, edge chamfering and anywhere where high metal removal rates and absolute productivity are a priority.

*Not available in 100mm size

A line of power brushes and abrasives designed for use on large and small right angle grinders includes a wide variety of wire wheels, cup brushes and bevel brushes in a broad selection of diameters

Weiler Corporation, the leading manufacturer of power and abrasive nylon brushes for the manufacturing industry, offers its line of power brushes and abrasives designed for use on large and small right angle grinders. Weiler’s high quality power brush line includes a wide variety of wire wheels, cup brushes and bevel brushes in a broad selection of diameters, wire sizes and types.

Users can also choose from crimped wire for flexibility and light-duty applications or knot wire for more aggressive brushing action.

The abrasives offered for right angle grinders includes TigerR Discs, Weiler’s premium line of coated abrasive flap discs designed to provide a high cut rate and long life, and Vortec ProT flap discs which provide a high cut rate at a value price.

Application-specific flap discs include Big CatR flap discs for grinding and finishing curved and irregular surfaces, and Tiger Discs for Stainless Steel grinding.

In addition, Weiler also has a complete line of resin fiber discs, surface conditioning discs, cut-off wheels and Type 27 and Type 28 wheels.

* About Weiler Corporation - Weiler Corporation, headquartered in Cresco, Pennsylvania, USA, an ISO 9001 manufacturer of power and abrasive nylon brushes, abrasives and maintenance products, provides world-class service and surface conditioning solutions.

Floor-to-floor time was reduced from 124 to 112s and the increase in grinding machine capacity was more than 12%, allowing production of 1.4 million camshafts during 2005 without any new plant.

Central to achieving the optimisation targets was the adoption of a newly developed Tyrolit CBN grinding wheel, which draws less spindle power as it is 60% lighter than conventional products.

Additionally, the new tool was better able to absorb vibration, allowing a harder bond to be used.

Together with improved dressing, it resulted in longer wheel life, leading to a significant reduction in cost per part.

Overall, the saving in cam lobe grinding was calculated at over GBP 300,000 per year over the lifetime of the project.

Said Ford Motor Company’s senior manufacturing engineer, Mike Jones, ‘The structured approach to this project was key to its success, especially the teamwork between our engineers and experts from Tyrolit.

It is a good example of our philosophy of working closely with partners and suppliers.

The successful outcome proves how extraordinary results can be achieved when innovative minds and production tools are at work.’

A line of power brushes and abrasives designed for use on large and small right angle grinders includes a wide variety of wire wheels, cup brushes and bevel brushes in a broad selection of diameters

Weiler Corporation, the leading manufacturer of power and abrasive nylon brushes for the manufacturing industry, offers its line of power brushes and abrasives designed for use on large and small right angle grinders. Weiler’s high quality power brush line includes a wide variety of wire wheels, cup brushes and bevel brushes in a broad selection of diameters, wire sizes and types.

Users can also choose from crimped wire for flexibility and light-duty applications or knot wire for more aggressive brushing action.

The abrasives offered for right angle grinders includes TigerR Discs, Weiler’s premium line of coated abrasive flap discs designed to provide a high cut rate and long life, and Vortec ProT flap discs which provide a high cut rate at a value price.

Application-specific flap discs include Big CatR flap discs for grinding and finishing curved and irregular surfaces, and Tiger Discs for Stainless Steel grinding.

In addition, Weiler also has a complete line of resin fiber discs, surface conditioning discs, cut-off wheels and Type 27 and Type 28 wheels.

* About Weiler Corporation - Weiler Corporation, headquartered in Cresco, Pennsylvania, USA, an ISO 9001 manufacturer of power and abrasive nylon brushes, abrasives and maintenance products, provides world-class service and surface conditioning solutions.

To avoid localised heating and abrasive ‘burning’ and the possibility of having to rework or scrap the job, a 0.75mm disc is claimed to be the thinnest on the market for cutting thin sheet metal

A thick cut-off disc can cause unwanted burring, localised heating and deformation when cutting thin sheet metal and other delicate materials such as profile and tube of small cross section. To avoid the problem and the possibility of having to rework or scrap the job, Tyrolit has introduced into its Secur Extra range a 0.75mm disc that is claimed to be the thinnest on the market.

The resin-bonded, fibre-reinforced disc is aimed at automotive repair shops, electrical equipment fitters and tinsmiths, but is also suitable for heavier work such as cutting steel rope and steel reinforcement.

The ultra-thin profile results in straight, clean cuts and effortless operation, making it especially suitable for working overhead.

The load on hand tool is also reduced.

Two sizes of disc are available, 115mm and 125mm diameter, for cutting mild steel, stainless steel and non-ferrous metals.

Both discs have a 42F depressed centre for strength and longevity, and may be used at peripheral speeds up to 80m/s.

Tyrolit manufacturing operations are recognised by the Organisation for the Safety of Abrasives (oSa), and the 0.75mm Secur Extra discs comply specifically with EN 12413, ANSI B.7.1., and BGV D12.