Forging Ahead

 

FORGING AHEAD
SNC Demo Summary

Superior Surface FinishThe objective of the demonstration is to show 3-axis contouring with Super Geometric Intelligence machining.

Process Benefits

With Super Geometric Intelligence it is possible to produce a highly accurate, complex graphite electrode with a superior surface finish eliminating the need for costly handwork.

Depending upon the geometry being produced, the SNC High Speed Graphite Machining Center can produce electrodes as much as ten times faster than conventional machining. This is important in maintaining production schedules as well as preventing costly downtime of expensive EDM equipment.

A clean working environment is maintained regardless of the volume of graphite dust produced. Machine upkeep is minimal since machining is always done dry. Baking electrodes to prevent arcing or fracture is also eliminated.

Specifications

 

MATERIAL: POCO-200
TOOLING : Roughing 1/2" ball end mill
  Finishing 1/4" ball end mill
SPEED: Roughing 10,700 rpm
  Finishing 13,000 rpm
FEEDS: Roughing 150 ipm
  Finishing 300 ipm
PROGRAM: 02420 Roughing 160.5 kilobytes
  02421 Finishing 12.14 megabytes
STEP OVER: Roughing .1"
  Finishing .0005"
TIME: Roughing 6.9 min.
  Finishing 2 hrs. and 54 min.
TOTAL CYCLE TIME: 3 hrs. and 1 min.

 


EDM Forging Demo Summary

The test cuts were performed on Makino’s EDNC65 RAM EDM machine cutting with 120 Amps, utilizing two electrodes of the same dimensions, one for roughing and one for finishing.The cavity was machined to a 12 5 Rmax finish. In forging, it’s possible to finish a cavity with only one electrode because of geometry demand and surface finish requirements.Two electrodes were used on this cavity to show high accuracy and very fine surface finish. The combination of Makino’s power supply and aggressive standard machine cutting parameters achieves very low wear.

Process Benefits

Forging CavityBy utilizing MaxAdapt adaptive control, an operator can set up the workpiece, look up the cutting parameters, and start the cut. This leaves the operator free to work on other projects. MaxAdapt also allows an operator to program the next job while machining the present one.

Specifications

 

MATERIAL: POCO-200
FLUSHING USED: None
SURFACE FINISH: 12 5 Rmax
ROUGHING TIME: 2 hrs. and 3 min.
FINISHING TIME: 2 hrs. and 11min.
TOTAL CYCLE TIME: 4 hr. and 14 min.

 


Trim Die Demo Summary

The demo shows a time efficient manufacturing approach for trim dies for the forging industry. A typical trim die would be made in a much heavier plate, ranging from 4" to 6" in thickness. The entire machining process shown in this demo may be performed in an unattended manner, which is made possible by auto-wire threading for cutting and rethreading of the wire at multiple locations.

Process Benefits

Trim DieAdvantages of this process include unattended operation, made possible by automatic wire threading and extremely large workpiece capacities (up to 3,300 lbs. and 12.8" tall). You also have the ability to machine in a submerged or non-submerged state, depending upon workpiece girth, which is provided for by the programmable rise and fall work tank.

 

Specifications

 

Cut 1 degree die relief on geometry profile for 4" thickness: Approx. time 4 hrs. per profile
Perform cutoff to remove primary slug: Approx. time 5-7 min.
Cut profile to leave .50" die land around perimeter: Approx. time 2.0 hrs.
TOTAL CYCLE TIME PER OPENING: 7.8 hrs.

 


Cavity Demo Summary

Connecting Rod CavityThe demonstration shows Flush Fine (FF) cutting in 50 HRc-13, machined on the 40 horsepower MC98 equipped with Super Geometric Intelligence and a Jet 50 spindle. Micro grain carbide cutters with TiAlN coatings were used to completely machine a cavity at 15,000 rpm and up to 120 ipm feedrates.

Process Benefits

FF machining of hardened H-13 at 50 HRc from CAD data produces a forging die that eliminates subsequent benching. FF applied to forging dies typically reduces overall cycle time by 75%. EDM finishing processes are also eliminated.

Specifications

 

MATERIAL: H-13, 50 HRc
TOOLING: Tool 1 6mm B.E.M.
  Tool 2 3mm B.E.M.
FEEDRATE: Tool 1 110 ipm
  Tool 2 120 ipm
SPEED: Tool 1 10,500 rpm
  Tool 2 15,000 rpm
CYCLE TIME: Tool 1 39 min. (rough)
  Tool 2 56 min. (finish)
TOTAL CYCLE TIME: 1 hr. and 35 min.