One of the key demonstrations at the 2017 Okuma Partners in THINC Winter Showcase, Dec. 5-6, in Charlotte, (NC), will feature a modular approach to enable manufacturers to generate high-precision five-axis parts without investing in a dedicated five-axis machining center.
The part chosen is a representative aerospace landing gear component and will utilize the combined products and capabilities of Okuma, which will supply an Okuma Genos M56O-V machining center, Hainbuch America’s precision workholding, Kennametal’s tooling, Haimer-USA’s shrink fit toolholders, MP Systems’ high-pressure coolant and chiller systems, Lyndex-Nikken’s 5-axis rotary tables, Blaser Swisslube’s mineral oil based coolant, and Siemens Product Lifecycle’s (PL) systems software.
“This is the sixth year of our Partners in THINC Winter Showcase, and over that time we have seen how, working together, we not only solve specific application problems, but also advance technology as a whole,” said Wade Anderson, Okuma product specialist and Tech Center manager. “If I had to summarize why our partnership has worked so well, it is because all of us are intent on delivering ‘the best from the best.’
“This demonstration, and the others that will be presented, provides a vivid example of the success that can be achieved when companies that are unquestioned leaders in their fields work together to create optimal solutions to defined customer challenges,” added Anderson. “Much of the current manufacturing environment is characterized by the need for complex parts produced in small to medium batch quantities. As parts requiring five-axis machining have become more in demand, manufacturers are faced with the problem of justifying a dedicated five-axis machine for a limited number of parts or parts families. Working together, our Partners in THINC have devised a solution that will enable their customers to achieve five-axis capability and high precision without incurring a prohibitive financial commitment.”
According to John Soukup, team leader and regional sales manager at Hainbuch America Corporation, the part that was chosen for the demonstration is representative of landing gear components used in the aerospace industry.
“Constructed of 7075 T-6 heat treated aluminum, the part will be clamped on the ID by a Hainbuch Mando Adapt workholding system affixed to an 8-inch Nikken five-axis rotary table,” said Soukup. “The Hainbuch system is versatile in that the unit can be used for both ID and OD applications. The ID application features a system that incorporates both hardened steel clamps and patented elastomer segments that provide maximum clamping force without marring the part finish. The Nikken rotary table is equipped with a carbide worm screw and an iron-nitride worm wheel that hold accuracies of +4 sec.”
The Kennametal tooling package includes the 7792 high-feed cutters with 6-mm inserts, carbide end mills with TiB2 coating, a Romicron boring system for the large bore application, as well as drills of various diameters. Comprehensive tool management will be achieved through the use of Kennametal’s Novo digital tools. Tooling will be equipped for delivery of high-pressure coolant.
Precision performance will be ensured through the use of Haimer shrink fit toolholders and balancing equipment. The balancing process reduces vibration and results in longer tooling life, better finishes, and improved boring performance.
For the demonstration, Blaser Swisslube has selected Vasco 6000, an ester based “Liquid Tool” chosen for its effectiveness in high heat hard machining operations. A high-pressure coolant and chiller system from MP Systems operating at 1000 psi and 8 gallons per minute (gpm) will facilitate faster cutting and drilling by evacuating chips while maintaining thermal control to prevent distortion.
Siemens PL NX, an integrated CAD and CAM platform will ensure correct geometries and provide full digital modeling capabilities. In the event of any changes, the system will reconfigure tool paths and ancillary modifications.