Greenleaf Corp.’s proprietary insert, cutter and machine adjustments helped OCCO reduce crankshaft machining costs up to a quarter of the original cost.
Job: Machining locomotive and tugboat crankshafts from steel forgings that measure between 95-165 inches long and range in weight from 2,000-6,200 pounds. Machining one shaft was taking between 4-6 hours with one shaft machined per two indexes of the triangular carbide inserts.
Greenleaf consultants were called for consultation
The cutting tool supplier altered the cutter bodies to encapsulate a segmented design, which allowed for more insert pockets. Greenleaf also altered the triangular design The machine could apply 25% more inserts, the total now being 48. The redesign also led to faster feed rates. The heat and wear resistance of Greenleaf’s GA5036, a CVD-coated carbide grade, now used is well suited for high-speed milling of the forged steel. OCCO upgraded its American GFM model FKP45 crankshaft milling machine to allow for higher cutting speeds.
These improvements reduced the cycle time for machining crankshafts to under two hours, with four shafts machined per index of the carbide inserts (earlier one shaft for two indexes).
https://www.mmsonline.com/articles/greenleaf-boosts-occos-cutter-and-insert-productivity
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https://www.youtube.com/watch?v=QYyXODNxRxE
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