MICROMACHINING
MICRO
MACHINING TECHNOLOGY FROM MAKINO
Latest Die/Mold Applications and Innovations Highlight IMTS
Exhibit
AUBURN HILLS, MI—September 2006—Micro
manufacturing new processes and applications are being pushed into the market
on a daily basis, and only a handful of die/mold shops are able to take
advantage of the market potential.
Makino
technology can provide the machining and applications support for any die/mold
shop to enter into this exciting and vibrant market. “This highly technical,
design focused marketplace is dependent upon investing in skilled craftsmen and
modern machine technology,” according to Lee Richmond, micro machining product
manager for Makino.
“Part
tolerances of five micron or less are commonplace today. Makino has actually
had machining requests to hold +/- 0.1 micron shape accuracy. While
seemingly impractical in today’s world, history shows this may well be reality
within 5 years.”
“Without an
investment in advanced technology and the skill set of quality employees,
die/mold shops may not be able to compete in the micro machining market,” says Richmond. “Shrinking
tolerances and shrinking lead-times dictate change in order to stay
competitive.
“This is
the next step in the manufacturing evolution. It is necessary to satisfy the
dynamic requirements of the medical, telecommunications, defense and consumer
electronics markets.”
Visit Booth
# D-4110 in the EDM Pavilion during the 2006 International Manufacturing
Technology Show (IMTS) at McCormick
Place in Chicago,
Illinois, September 6 through 13
to
see demonstrations on equipment and processes that meet the demand for
micro-dimension milling and ultra-high precision EDMing. Also plan to visit
Booth # 8301 in Hall A of the South
Building at IMTS to learn
more about other technological innovations.
Market
Changes
“In 2000, the
majority of milling was done in tool steels like P20 or H13 reaching 50 HRC.
Today, more machining is done in hard steels that exceed 60 HRC such as A2, S7
and D2 steels,” says Richmond.
“Between this and the growth of micro machining applications, less inserted
tooling is being used and technology has turned toward coated solid carbide
tools. In fact, it is not uncommon now to use a 3 mm ball end mill as the
roughing tool. While this is not considered a micro application, it does show a
shift in our industry.
“As these
smaller tools are used for creation of tighter part definition, this in turn challenges
the supporting CAD/CAM systems. Smaller step-overs and tighter chordal
tolerances equate to larger toolpaths, requiring more accuracy in the hardware
and ‘cleaner’ geometry upfront. Because part size is getting smaller --
look no further than your cell phone or iPod -- die/mold shops are now
acquiring smaller machines and looking for solutions that offer the level of
performance and accuracy needed.”
The
stiffness and rigidity, vibration absorption and accuracy of Makino milling
machines make them great options for micro machining operations. A low
vibration spindle, thermal stability and the highly accurate SGI.4 controller
provide ultra fine finishes and quality.
Test
Cut Example
To satisfy a
customers’ need to refurbish expensive welded assemblies, Makino engineers
recently utilized the UPJ-2 horizontal wire EDM. A 20-micron diameter tungsten
wire was used to cut through a 50-micron spacer that separated the two critical
components in an assembly measuring just 3.8 mm in diameter.
The machine’s
integrated rotary C-axis was utilized to “turn and burn” this work piece, a
machining process that resulted in re-useable, burr-free parts. This unique
feat was achieved in only 19 minutes in 718 inconel.
The UPJ-2
uses an oil dielectric system that provides for much finer control of the machining
spark gap in wire EDMing. Makino’s patented PowerWIZARD Adaptive Power
Control Technology provided excellent part accuracy and increased work piece
quality.
Ram EDM
technology from Makino can also provide 1 micron positioning accuracies in
micro machining, as well as 2 micron machining accuracies. Internal corner
radii of .005mm are now possible for the manufacturing of molds, a real benefit
to such markets as the electrical connector industry.
Micro hole drilling
capabilities are also advancing in the Ram EDM arena. The use of 20-micron
diameter rod is readily available, as is 100-micron diameter “pipe.” Makino’s
generator and machining technology creates a consistent process, producing
superior roundness and surface quality in fine hole applications. This can
be run in an unattended operation and can be integrated with automatic tool
changing and robotic capabilities, all of which helps reduce setup and cycle
times.
Makino is a global provider of advanced machining technology and
application support, where new thinking takes shape for the
metalcutting and die/mold industries. Makino manufacturing and service
centers are located in the United States, Japan, Germany, Singapore,
Italy, France, Korea, Taiwan, Turkey, China, Mexico, Brazil and India,
and are supported by a worldwide distributor network. For more
information call 1.800.552.3288, or visit www.makino.com.
# # #
For
additional releases and media information, visit www.makino.com/media.
Makino
logo: JPG
Media Contact
Brandon Rhoten
HSR Business to Business
513.346.3588
makino@hsr.com