Tooling Dictionary…

Rel-e-gate (verb) ; consign or dismiss to an inferior rank or position

Example: The customer relegated the inferior boring heads to the cart while the Kaiser heads stayed in the machine making round bores that did not taper from top to bottom.

We ran 112.118 Kaiser finish boring heads in 303 Stainless steel on a Cat 40 Haas Mill, holding .0005″ tolerance and .0001″ roundness. Excellent results with the new Alcona coated inserts. Note in the photo below how the competition’s heads have small – difficult to read adjusting dials. Additionally, note how the boring bars mount on the head, fixed at a great distance from the main body.

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2011 RECAP

This blog has been quiet for a while, I broke my own promise to keep updating as the new projects came in.  What I was not expecting was the increase in business from about the middle of the year on – it became one of the best years for sales ever. I’ve attached some data from the Association for Manufacturing Technology. The numbers are nothing short of amazing – but we have to remember how bad it was from  late 2008 through mid-2010. I think 2012 will be more of the same for the first half of the year, a little tempered in the latter half. Click On An Image To Enlarge

AMT / AMTDA Orders Through November 2011

Midwest Order Numbers

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New Big Kaiser Boring System Rewrites The Rules

An Elk Grove Village based aluminum die-cast house and machining operation isn’t afraid to go all in with their tooling. In a highly competitive market seconds count in any operation. One place most wouldn’t look to be able to save time is with an 11.75″ diameter bore on an older BT40 mill, but with a new tool from Big Kaiser the rules have changed. Why can’t we run faster on larger diameters and on smaller taper machines ?  Tool weight is the key: too heavy to get the SFM’s up, too heavy to tool change. With the new series 318 boring system from Big Kaiser, both of these questions were answered with an off the shelf tool. Series 318 uses anodized aluminum components for the strength of steel with a substantial decrease in tool weight. Additionally, the new system allows for integral slide components to further reduce weight and the additional cost of multiple components. When the customer asked what we might have available for the application, it could not have been better timing for this product. Here are the net results in the customer’s email to me after the tool test. The only issue they had was clearance in the magazine with a large tool on a BT40 machine:

“That tool is awesome. We had to modify pot in, pot out sheet metal and  that’s it.

Ran a part 2400rpm @ 19.2ipm with the regular inserts (carbide) you set up, looks beautiful! “

That’s 2400 RPM on an 11.5″ diameter..do the math on the SFM’s yourself. I think many, many,  large production bores are now up for review.

11.755" diameter on a BT 40 flange. Tool weight approx. 15 pounds

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Fullerton G3 Makes The Grade

Fullerton Tool’s new Alumamill G3 tool proved itself to be the class leader in high performance aluminum endmills at a Chicago area contract shop. The details:

5/16″ diameter standard length tool

6061 Alum   /  .880 deep slot  / Took .220 at a time   / 1500 SFM    / 54 IPM    / 500 Parts

The customer used 3 end mils on this job instead of an other 3 flute tool from a national distributor. Production was tripled.

The key to the performance was the wiper flat on the bottom of the tool, providing superior surface finish even at high speeds and feeds.

Contact me for your no charge test today

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Applications Wanted…

Fullerton Tool has just introduced a new tool to the market, the AlumaMill G3. It’s a hybrid rougher/finishing tool with superior wall and floor finish capabilities. The team at Fullerton’s experience and r&d capabilities helped to develop and deliver this tool to set the bar for high performance aluminum milling. Applications are wanted, test tools are available on a guaranteed performance basis. I’ll be posting results as we get this product rolling, feel free to contact me for a sales flier and additional performance specs.

The AlumaMill G3 Is Here

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Extended Heule Defa Tool Saves Scrap

An aerospace contract shop had an expensive problem – producing a front and back countersink by hand on a magnesium housing resulted in parts being scrapped. At $15,000.00 a part, the problem needed to be corrected more than fast.. Just to make thinks more interesting, the location of the countersinks on the part required over 14 inches of reach from the top of the tool to the face of the holder for clearance. Using a stock standard Defa front and back chamfering tool from Heule Precision Tools allowed the customer to machine the 90 degree countersink in their horizontal machining center, solving the problem. We provided specs to the customer to help them build their own extension, I’ve attached a few photos of the tool. Heule Precision Tool’s twin bladed Defa tool allows for adjustment of the chamfer diameter on the tool and allows for toleranced chamfers and countersinks from 4mm to 44.5mm.

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Speroni Delivers Under the Covers…Competition, Not So Much.

This may be a bit of a long post and sorry for the bad tag line but hang in there…

I installed a new Speroni Magis presetter at a customer in the Chicago area last month. While it was good fortune for me and the customer is very pleased with their new machine, it was a bit of a tough pill for them to swallow. They purchased our new presetter due to the almost constant breakdowns to their only three and a half year old existing unit. Why did they have to replace such a relatively new piece of equipment? Well, I had the opportunity to take a look under the covers of my competitors unit and to say I was a bit surpised is an understatement. I’ve attached a slide show of some pics of the competition’s unit and I would like to point out a couple of  design features that over time, proved to be their undoing.

First, take a look at the large voids in both the base and column castings. My customer felt that with larger, heavier tools in their 50 taper spindle, the machine would not repeat. I can understand this due to a lack of support from the castings. Trying to hold tenths with lack of stability is hard to achieve. Secondly and where the customer had multiple problems, is the completely unprotected gold colored glass scale strips along the x and z axis. Even with the covers and bellows installed, contaminants were making their way into the machine and causing the scales to misread. The readout would jump by as much as .010″, the guys in the tool crib were actually using a 20 year old height gage at the end to set lengths out of fear of crashing tools due to bad measurements. My customer machines a lot of stainless and still had contamination problems – good luck in a cast iron shop!

Needless to say, the quality of construction that goes into both table top Speroni Magis and floor model Esperia presetters could never allow for these pretty glaring deficiencies. Solid castings, massive guideways and sealed Heidenhein scales are the foundation for constructing a machine that is designed to last decades, not months on the shop floor. If you’re coming to IMTS 2010 and in the market for a presetter, stop by Big Kaiser at booth W-1600 for a look at the Speroni machines. We’ll give you a look under the covers.

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