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Hoffman Estates, IL, United States

Burley J.,BIG Kaiser Precision Tooling Inc.
Manufacturing Engineering | Year: 2014

Aerospace is unique among industries in its thirst for component accuracy. Today, standard boring tools can usually be supplied with radii as small as 0.1 mm, or up to 0.79 mm. An operator has to make very tight, incremental changes to the tool. A tool has to be very rigid, and be able to cleanly cut a small amount of stock without any rubbing or smearing in order to hit surface finish requirements. Specialty carbide inserts are expensive, and are not cheap to carry in inventory as standard. Many boring tool manufacturers only offer metric scale tools, which have a conversion. Aerospace manufacturers are often asked to machine intricate workpieces, and it is not always possible to complete a bore with a standard boring tool.

Vacio G.,BIG Kaiser Precision Tooling Inc.
Cutting Tool Engineering | Year: 2010

Gerard Vacio, BIG Kaiser Precision Tooling, informs that machine tool accessories need to be used to maximize machine performance. These accessories can offer economical solutions to many tooling and machine setup issues. Accessories can help improve productivity and reduce machine failures when used in combination with a machine that delivers the speed and features a shop needs. Gerard Vacio states that a retention-knob pull-force gage needs to be used to test the drawbar force on a regular basis. A gage bar tests runout and spindle accuracy and is a perfectly concentric steel cylinder that measures spindle rotation against its centerline. Use visual inspection and gages need to be used to check spindle geometry and the internal geometry that establishes the spindle centerline needs to be free of defects and contamination.

BIG Daishowa Mega Technical Center in Awaji, Japan has undertaken several tests to determine the acceptable runout. A 3mm diameter, solid-carbide drill with 0.00008'' of runout produced 148 holes at 3 times diameter until the primary cutting edge experienced 0.008'' of wear, at which point tool life was considered to be over. A second 3mm diameter carbide drill with 0.0002'' of runout under the same conditions produced just 125 holes using the same tool life measurement. The results showed that carbide has the highest sensitivity to diminished tool life due to runout. HSS tools were slightly less sensitive than their solid-carbide counterparts to diminished life. Dynamic runout gages are useful for high-speed machining. When the spindle is rotated at low speeds, centrifugal forces runout is actually unacceptable if the shop wants to improve tool life. Shops should check their spindles regularly for runout using a precision gage bar.

Vacio G.,BIG Kaiser Precision Tooling Inc.
Technical Paper - Society of Manufacturing Engineers | Year: 2013

Composite materials can be easily damaged during machining. To improve the repeatable performance of the machine and the cutting tools, care should be taken during all facets of workpiece preparation and the material removal process. Dull cutting tools generate excessive heat and cannot shear the material, so they should never be used. Even when using the sharpest cutting tools available, there can still be problems with delamination, splintering, fracturing, and fiber pullout. Composites are unlike refined metals and have very different machining characteristics. While composite machining is best done on a dedicated machine, conventional CNC machines can fill the need for many machine shops. Recommended cutting speeds and feed rates based on optimum cutting conditions and for the specific composite materials being used should be followed, and the workpiece and the cutting tool need to be held as rigidly as possible.

Kaiser C.,BIG Kaiser Precision Tooling Inc.
Manufacturing Engineering | Year: 2014

The KAISER Precision Tooling apprenticeship program is active in Switzerland, admitting two or three new apprentices each year. These trainees learn to master each machine in the Rümlang, Switzerland boring tool factory. For those who aren't looking to work on the machines, opportunities are available to work off the floor in the production office and R&D department. With the extensive hands-on work, apprentices leave the program with a highly specialized and marketable skill set. The first two years of the apprenticeship consist of two days at school and three days of shop work. For the following two years, apprentices attend one day of classes and spend two nights each week learning supplementary skills from external seminars. Roughly 50% of participants are offered a job with KAISER after completing the program.

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