Milling Steel Gear with 150 teeth on the Hurco VMX at a depth of cut of 3mm at 2,000 mm/min / 79”/min by Air Turbine Spindles® 650DIN40. Cycle times reduced from 75 minutes with standard 12,000 rpm Hurco Machine Spindle to 5 minutes with the 40,000 rpm Air Turbine Spindles® 650DIN40.
ESK Mechaniks in Peiting, Bayern, Germany was faced with a problem.
ESK had been offered a contract of up to 20,000 steel gear wheels per year, but a pattern portion of the program alone took 75 minutes to finish. How could ESK produce the parts and make money?
The gear wheel: http://goo.gl/T4n1ln includes 150 teeth with a radius of 0.75mm and a tolerance of 0.01mm - a great challenge to machine. ESK's production team tried different manufacturing methods, but the parts could only be produced by milling.
The owner of ESK, Mr. Unsal, contacted the application engineers from Air Turbine Tools® for a suitable solution. After a short conversation it was clear that this was an application for an Air Turbine Spindles®. A test was scheduled on ESK’s Hurco and Haas machines.
The governed 40,000 rpm 650DIN40 Air Turbine Spindles® reduced the production time to 7 minutes from 75 minutes. With a change of cutting tool the gear program was optimized for under 5 minutes cycle time.
Visit http://goo.gl/mZ9Vlk to view video of the powerful governed 650DIN40 milling on a Hurco VMX Machine at 2,000 mm/min / 79”/min with a 3 mm depth of cut. The difference is the powerful governed constant high speed does not materially drop while cutting with our patented spindles.
Calculation of ESK Mechaniks return on investment shows the dramatic effect on costs:
Comparative Production Costs
Standard 12,000 rpm Hurco Machine Spindle
500 parts with a standard machine spindle:
500 x 75 minutes = 625 hours
Governed 40,000 rpm 650DIN Air Turbine Spindle®
500 parts with an Air Turbine Spindle®
500 x 5 min = 41.6 hours
Saving = 583.4 hours per 500 Batch Order!
Price of the 650DIN40 spindle with patented TMA Autochanger in Germany = € 4,950.
ESK Mechanics was able to accept the order and increase their profits on the job.
This is one of many examples of the results delivered on all types of CNC machines (standard blocks available for Hurco, Makino, Hermle, DMG, Doosan, Brother, Fanuc, Haas, Hwacheon and more) with full automation of loading from the CNC magazine.
Visit http://goo.gl/8GhCnQ to view the 650 Series constant governed high speed spindle range.