MICROMACHINING
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 for
the metalcutting and die/mold industries, dedicated to driving out more costs
from your manufacturing operation than any other competitive machine tool
manufacturer. 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.
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Media
Contact
Brandon Rhoten
HSR Business to Business
513.671.3811
makino@hsr.com