A success story

[gcode]

We've got a production part that's been running for years in batches on 10 to 15 pieces.
Theya are big steel casting and have about 200 tapped holes in each part.
There are 120 5/8-11 blind holes   12 radial bosses with 10 holes each
 
Running old school on our old HBM's it took about 2 to 3 hrs to tap these holes depending on the motivation of the operator.
(blow out the hole.. add tapping paste , tap,   check  threads,  clear chips off the tap ... repeat )
 
Friday we tried this on a modern machine
Sandvik through coolant tap
Sandvik rigid tapping collet and collet holder
1000 psi through spindle coolant
90 sfm = 554 rpm @ 50 ipm
 
the machine has torque monitoring and Sandvik provides torque values
new tap, time to change ... and breaking torque
this particular tap is rated at 1300 holes at 90 sfm in 4140 steel
if the machine hits the torque limit it backs out of the hole and stops
 
the operator set it up and got ready to run it..
I got called away to answer a phone call...and missed the whole show
 
120 holes in 18 minutes and every hole gages perfectly
 
the boss's jaw was on the floor
 
It will be interesting to see how this proccess holds up long term

[CADCAM3D5AXIS]

Its great to get out of the stone age with new Tech and new Machines. but Some bean counters just do not get it. you drag them kicking and screaming to the show they dont want to see then when you get to show them they say why didn't you tell me about this stuff sooner !

At least some do anyway .

Way to go G

[gcode]

as an official old guy who started his carreer on old leather belt driven WW2 vintage bench lathes and shapers,,

the fact that they can build machine tools that powerful, that fast and that accurate is just plain amazing.

the physics involved in a rigid tapping cycle moving at those feeds and speeds is mind boggling

[Mick]

That is a great example of modern technology coming together. I'm a big fan of Sandvik Coromant. I've always found their level of expertise, and technical backup, combined with the quality and performance of their toolholders and cutting tools second to none.

 

Out of curiosity g, what machine was that cut on? (Now that I have seen your shop ) 

[gcode]

That is a great example of modern technology coming together. I'm a big fan of Sandvik Coromant. I've always found their level of expertise, and technical backup, combined with the quality and performance of their toolholders and cutting tools second to none.

 

Out of curiosity g, what machine was that cut on? (Now that I have seen your shop )

Okuma MU-1000 of course..

We've had it 2 years now... and it still makes me shake my head in wonder some days

[Mick]

Okuma MU-1000 of course..

We've had it 2 years now... and it still makes me shake my head in wonder some days

 

Good stuff That sure is an impressive machine!

[tancuda]

Okuma MU-1000 of course..

We've had it 2 years now... and it still makes me shake my head in wonder some days

Is this machine on the okuma website ? can't see it 

[Mick]

Is this machine on the okuma website ? can't see it 

 

http://www.okuma.com/mu-10000h

 

There it is

[Jayson Kramer]

That is really cool. I love that technology keeps moving forward on machining and we still after all these years in the game can still be amazed. Thanks Gcode for sharing and that was a nice machine. thanks for showing us the shop.

[Bob W.]

Now imagine what that machine just did for your shop rate.  8 hours worth of work (and billing) done in 18 minutes.  That is why I loved moving projects from my Haas machines over to the Makino HMCs

[Newbeeee™]

http://www.okuma.com/mu-10000h

 

There it is

Doesn't look *that* big on the website...

[Del.]

I wasn't all that impressed on the video with the 6 inch cutter on 4140.

[gcode]

I wasn't all that impressed on the video with the 6 inch cutter on 4140.

that demo was shot on the machine we bought

when I went to Charlotte it was still set up and they ran a pass for me

It's much more impressive in person, but not nearly as cool as the stuff

I'm doing with it 2 years later

[Del.]

that demo was shot on the machine we bought

when I went to Charlotte it was still set up and they ran a pass for me

It's much more impressive in person, but not nearly as cool as the stuff

I'm doing with it 2 years later

Yeah, I know its a hell of a machine.

[gcode]

I wasn't all that impressed on the video with the 6 inch cutter on 4140.

That is a 8" cutter taking a 6" wide x .375" deep cut at 23 ipm

[tancuda]

That is a 8" cutter taking a 6" wide x .375" deep cut

[Newbeeee™]

That is a 8" cutter taking a 6" wide x .375" deep cut

I wouldn't want to pay your electric bill

[gcode]

I wouldn't want to pay your electric bill

I suspect it's brutal

We have 150k square feet of air conditioned manufacturing space

and a fleet of VTL's pulling up to 200 horse power

A man could live large on our monthly power bill

[Del.]

I suspect it's brutal

We have 150k square feet of air conditioned manufacturing space

and a fleet of VTL's pulling up to 200 horse power

A man could live large on our monthly power bill

Our Production shop has 140,000 sq ft with 30 CNC machines. None as big as the ones you got though. That building is used only for production parts.

[YoDoug®]

I suspect it's brutal

We have 150k square feet of air conditioned manufacturing space

and a fleet of VTL's pulling up to 200 horse power

A man could live large on our monthly power bill

 

You are still using electric company utilities? You could be running all of those VTL's off of solar powered Tesla batteries.

[gcode]

You are still using electric company utilities? You could be running all of those VTL's off of solar powered Tesla batteries.

by the time Governor Moonbeam is done, we'll probably be running a herd of rats in treadmills

[Rocketmachinist]

Is that an off the shelf tap or something that they made up for you special?

[?Mark]

If anyone is interested we could possibly consider unloading our okuma m800vh. Runs great and never crashed 

[Newbeeee™]

Our Production shop has 140,000 sq ft with 30 CNC machines. None as big as the ones you got though. That building is used only for production parts.

What a waste of space.

We have 2k sq feet and 11 cnc's and a cmm and a canteen

[Del.]

What a waste of space.

We have 2k sq feet and 11 cnc's and a cmm and a canteen

It was more than they needed but gave them plenty of room for expansion. Personally I have never been in it. A few years back when it was a plastics plant a worker went in and killed 6 persons including self and I don't like bad Ju Ju.