I must cut off 260 mm of 3 mm spring steel generated from coil stock. The tensile strength of the steel is 200,000 lbs. per square inch. The straightness requirement is 0.005" per inch. I must make a groove at the end of the part. Quantity: 20,000 per week.
I am looking to run the part on one machine but I will settle for a two-machine solution if I must. Tool life is an issue with this material so I need an optimal tooling package.
Esco is the way to go--For coil it has the straightner and can be used to push the 11 inches over several open collet and drop the head back a 2nd time. Might need 3Xs for 11 inch.
The spring steel is very hard on tools, Any thoughts on how to get greater tool life off the escomatic?
Try using OTEC precision edge honing equipment for your cutting tools. OTEC's drag finishing process increases tool life up to 16 times. Contact Dempsco at info@dempsco.com for more details.
An Esco D6 with the GL long feed attachment or the 643 CNC would be the way to go with this part as they will run coiled stock and hold the straightness. 20,000 per week should be no problem. As for tool life, have the tools TiCN coated to increase tool life and use a coolant made for tough material. As you start the job, see how long you can go between tool sharpenings/changes and log it a few times, then you can come up with a schedule to change your tools every certain number of pieces. I would make 10 of each tool (ie #1, #2 & #3), have them TiCN coated, and change them each time instead of sharpening them. Make each tool number identical, then they will be like changing inserts. When they are all dull, regrind them (you must grind every edge) and have them recoated. Good Luck!
This looks like a classic Escomatic job to me. I would also use coated carbide insert tooling. 20,000 pcs / week on ONE machine should be very practical.
Jim Buchanan
This is a GREAT JOB for an Escomatic D6 or their CNC 647. This machine has more rigidity than the Escomatic D2 and has a better selection of RPM. We just finished running 50,000 pcs of .094" dia. of Hastelloy X with a tensile of 212,000 psi. This was a pin .250" long which cycled at 16pcs/min., at 3500 RPM. Tool sharpenings occured every 10,000 pcs. using Micro 100 carbide.
Hope this helps,
Gregg Foster
All Pins Mfg.
Gregg. Where are you. Maybe my client will want to contact you. You can call me at 708-535-2200.lloydgrafftmw@yahoo.com
I would recommend having the tooling cryogenically treated to strengthen, increase wear resistance. For higher carbon steel and carbides, it will significantly increase useful life. Dave
dkimmel@300below.com
The wire should preferably be straightened first through a series of rollers as it's being fed.
Use abrasive cutoff or shear to length. Or the blanks could be cut slightly longer, then straightened in a mini bar straightener.
The groove and chamfer are best plunge ground in one pass. Dress wheel to shape or use CBN.
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