temperatures of a gas turbine engine. However, the same characteristics make them extremely challenging to machine.
“ We invited Vericut to deliver a Force presentation at our premises,” says David Dudley.“ However, it sounded too good to be true, so we requested a trial of Force on a key component – a part designed for one of the largest IGT engines in the world.”
The component is machined from exotic alloy on a Kitamura Mycenter HX550iG four-axis horizontal machining centre. It features a long cycle time and carries high consumable cost, with several cutters typically requiring replacement before part completion.
After just two days of training, indicating the software’ s ease of use and shallow learning curve, ELE Advanced Technologies applied Vericut Force to its component.
Baki Huna, Senior Manufacturing Engineer at ELE Advanced Technologies, takes up the story:“ The great thing about Vericut Force is that you have a choice. You can reduce cycle time OR increase tool life, OR find an agreeable balance. For this component, reducing the cost of consumables was paramount, so we were delighted to find that Vericut Force delivered up to 20 % saving in tooling costs on
The great thing about Vericut Force is that you have a choice. You can reduce cycle time OR increase tool life, OR find an agreeable balance.
some products. As the cutters to machine these exotic materials are expensive, it’ s a significant reduction, particularly when multiplied over potentially thousands of components every year. Vericut Force also provided a cycle time saving of 11.2 %.”
Force of nature Most CAM systems do not adjust for changing cutting conditions. In particular, they fail to compensate for chip thinning. Chip thickness is the most important parameter when machining, not feeds and speeds, as many assume. Vericut Force automatically adjusts chip thickness for each tool operation using Vericutcalibrated materials and cut-by-cut tool engagement analysis. Force keeps the chip thickness as constant as possible by adjusting feed rates, block by block of NC code, even adding blocks if necessary to deliver ideal cutting. The result? Shorter cycle times and / or longer tool life.
Importantly, all of this is achievable without any compromise in quality, a vital factor for ELE Advanced Technologies and its customers. The company prides itself on the consistent delivery of high-quality products, carrying both AS 9100 and ISO 9001 quality management certifications. ELE is also NADCAP-approved for NCM( Non- Conventional Machining) and NDT( Non-Destructive Testing).
Sustainable way forward
Further advantages of applying Vericut Force to the component at ELE Advanced Technologies include better sustainability through longer lasting tools. The company is committed to driving sustainability and working towards net-zero targets, both in its day-today operations and the products it delivers. Furthermore, Vericut Force provides a better overall process as it is now unnecessary to stop the program for tool checks, while the toolholders no longer sustain damage due to worn cutters.
“ We estimate ROI for Vericut Force at less than 12 months,” states David Dudley.“ Our team of manufacturing engineers is now applying Force to several other milled components that currently demonstrate long cycle times and / or high consumable use.”
Potentially, all milled components at ELE could ultimately benefit, including graphite electrodes required by die-sink EDM processes.
“ We currently have three machines on site for this purpose,” he says.“ Vericut Force will help reduce cycle times and free-up capacity on these busy machines, subsequently avoiding the need to invest in another. We’ re currently doing everything we can to meet rising market demand for additional capacity, but spending our way out of it with new machines or more floor space is expensive. Force provides a far more cost-effective solution. It also demonstrates to customers that we’ re proactive and innovative about alleviating cost pressures from suppliers while avoiding the need to increase prices.”
For further information, please visit https:// vericut. com / en-gb /
Issue 77 PECM 101