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Published on Aug 31, 2016
Existing customer owning 3 local shops for machining, fabrication, welding and casting calls during the weekend asking for cnc machine control repair references. Needs to ship 12 trial run parts by the end of the week to a potential new customer for a very promising part future order annual buy.
Material already purchased and waterjet cut based on cnc lathe machining (facing, turning, chamfering and boring in multiple operations) and the split half weldment prep face and chamfer grinding.
But the cnc Mazak M5 lathe with a Fanuc 6T control is now down due to a malfunctioning motherboard and the inoperable serial RS-232 connector. Recommend a seasoned performer especially for the older technology on the rigid hand scrapped cast iron from the 1980s. But he couldn't make it until the following week. All other source solicited by the owner responded no quote.
Asked for an emailed drawing. Studied the pdf image and saw how similar it appeared to many others in weld fabrication component parts programmed in the past.
Recommended 3d wireframe milling also known called sweep or swept mill in the 90s by many CAD/CAM OEMs.
The M5 was the largest lathe the job shop had in any of the 3 locations but there were several VMCs available. All CAT40 except for one other Mazak V22 CAT50 with a M2 Mazatrol. However, it has down for a Y-axis drive. So recommended running an ISO machine code format program on any one of the open Mazak, Okuma, Haas or Hitachi Seiki CAT40 spindles.
Recommended milling both faces to clean up and to the 1/2" part drawing thickness and hold in a 3 jaw chuck with ID serrated jaws (standard job shop item) for milling the 1st OP. Big cost saving on future raw material buys too.
Next ask the owner to appoint his most qualified machinist to begin prepping for the alternate machining process. And, he did.
Found a couple 1' diameter solid carbide 4 flute ball endmills with 1-1/2" flutes which were perfect to start immediately.
And, we cut the 1st OP the following day.
While cutting, designed the OP2 and OP3 work holding fixture and began programming it the following day and started cutting chips the same day too.
During the 6 part run off of 6.50 hours per round invited a Kennametal Sr. Applications Engineer to view the cutting and recommend what he thought was their best tool for the application. He did.
Estimate the Kennametal high speed face mill to generate an 80% cost reduction. The ball is in the job shop owner's court. The bottom-line.
Enjoy the awesome current and developing technology.