EQUIPMENT NEWS
Coating on small-part mandrels won’t flake
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Forming mandrels for manufacturing small-diameter parts feature a uniform fluoropolymer coating that is pinhole free and will not flake. APC PTFE Natural fluoropolymer forming mandrels made from stainless-steel or nitinol wire are available from Applied Plastics Company, Inc. (Norwood, MA, USA; www.appliedplastics.com). Capable of withstanding temperatures to 288°C in continuous operation and excursions as high as 370°C, they outperform parylene-coated mandrels in this regard. The gray forming mandrels exhibit a 0.05 coefficient of friction in testing to ASTM 1894.
Suited for fuse welding and tipping operations, this line of forming mandrels comprises lengths up to 3.66 m. The wires are offered in sizes ranging from 0.127 to 0.178 mm in diameter, and the fluoropolymer coating can be applied in a layer 0.00127 to 0.02032 mm thick. The supplier promises a final-diameter tolerance of ±0.00254 mm.
Milling machine given graphite capability offers flexibility
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A high-speed milling machine designed specifically for high-precision tool and mould applications has been enhanced to take on the extra challenges of graphite milling, increasing flexibility in the job shop. Like most high-speed machines from GF AgieCharmilles (Lincolnshire, IL, USA; www.gfac.com/us), the Mikron HSM 300 MoldMaster (MM) uses the versatile, workshop-oriented Heidenhain iTNC530 control system to achieve the speed and control necessary for performing the most complex applications. The machine has fast linear axes and a 30,000-rpm high-frequency spindle, its high dynamics and precision capability making possible high-quality workpiece surface finishes and very good accuracy while also ensuring time-optimized high-speed-cutting conditions. The polymer granite base provides the vibration damping and stability essential for high-speed milling. Single-casting construction maximizes machining accuracy, producing good thermal stability to optimize workpiece surface quality and minimize tool wear.
This machine’s graphite- dust extraction option, a package available previously on the manufacturer’s Graphite-Master products, is fully integrated in the machine base and ensures a clean and efficient machining process. Nozzles surrounding the machining spindle deliver focused air blasts directly to the work zone for optimal dust removal. In addition, constant underpressure in the full enclosure confines dust to the machining area so as to protect the guides and automatic tool changer.
Wire EDM is optimized for small parts of complex shape
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A wire-cutting electrical-discharge machine (EDM) is targeted at large-volume manufacturers of high-precision components, particularly very small, complicated parts for miniaturized devices such as compact medical equipment. Offered by Sodick Europe Ltd. (Coventry, UK; www.sodick.org), the AD325L EDM features linear motors in the x-, y-, u-, and v-axis drives and performs high-speed cutting at the high level of accuracy required by manufacturers of small medical devices, aerospace components, cutting tools, and the like. It is constructed to exhibit high rigidity and includes a variety of features to maximize manufacturing efficiency.
The machine’s efficiently designed discharge-circuit unit helps minimize installation space. This EDM is smaller than other wire-cutting machines of the same class, even with the incorporation of the linear-motor drive system, tension servo function, automatic fluid-depth control, and automatic wire threader. As an option, it can be supplied with an indexer. A square-shaped work stand and vertically sliding front door enhance machine operability. The standard Heart NC autoprogramming system enables even an entry-level user to machine a workpiece into a complicated shape easily.
Micromachining laser translates high power into high throughput
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A new model in an established family of micromachining UV lasers offers the highest power commercially available at its wavelength and repetition rate. The AVIA 355-28 ultraviolet (UV) laser from Coherent GmbH (Göttingen, Germany; www.coherent.com) delivers 28 W of output at 355 nm and 110 kHz. The high power and high repetition rate translates directly into increased throughput for a variety of micromachining applications, as well as a lower cost per part machined. Targeted at demanding high-throughput micromachining applications, this UV laser is suited for via-hole drilling in printed circuit boards and flip chips and for micromachining medical disposables.
In addition to higher power, the machine offers several features specifically designed to enhance its processing capabilities and minimize long-term cost of ownership. These include PosiLock, a proprietary technology for achieving highly repeatable spot positioning at the work surface; PulseEQ, which provides constant pulse energy across a wide range of rapidly varying pulse repetition rates; and an automated harmonic crystal shifter that maintains constant output power over the lifetime of the laser.
Machining system can produce an array of complex parts
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A milling/turning unit from Stama Maschinenfabrik GmbH (Schlierbach, Germany) is suited for the production of complex, high-quality parts. Equipped with up to 60 tools, the system can be used to fabricate an array of different parts from metals such as titanium and stainless steel. Among the applications of MC 726/MT machine are the manufacture of spinal implants including anterior distraction devices that can replace several vertebrae at once.
The system supports simultaneous five-side machining of bar material. Once the part is unclamped, it can be swiveled to machine a sixth side. Bar material can be processed with a length of up to 800 mm and with diameters ranging from 6 to 65 mm. The high-pressure system for the internal coolant can supply up to 70 bar of pressure to allow deep drilling of holes with diameters of less than 1.5 mm. The system is built to eliminate stray vibrations that might interfere with machining accuracy.
