Small-hole EDM is a growing area of interest for KLH Industries (Germantown, Wisconsin). The company continues to gain traction in aerospace applications, particularly in aircraft engines, because of the various hole sizes and shapes that can be produced by today’s advanced equipment. KLH machines small and even potentially microscopic holes with the low machining force of EDM, in which an electrode never contacts the workpiece, helping to Deep Hole Drilling Inserts maintain straightness and concentricity. 

Aerospace Focus

KLH is a precision parts manufacturer that specializes in EDM, CNC machining, waterjet cutting and contract inspection. The company has manufactured components for the International Space Station and is a machining supplier for the Boeing Space Launch System, a heavy-lift rocket capable of transporting crew and cargo beyond the moon and eventually to Mars. Additionally, it has produced components that aid in the guidance, navigation, control and communications of new and existing aerospace designs.

The “Hole” Problem

Today, multi-hole and multi-electrode operations have become the norm for KLH, says Davin Karvala, EDM business unit manager. However, an increase in these types of jobs meant the company WNMG Insert had to find a way to drill the holes quicker. This was difficult because machine operators were manually changing the electrodes out of the older EDM equipment every hour on the hour, a process that took too much time, Mr. Karvala says. The operator would have to wait for the machine to consume the electrode and stop, unscrew the collet from the machine, remove the spent electrode, add a new electrode, screw the collet into the machine and continue drilling.

This process required KLH to dedicate an employee on every shift to stand in front of the machine and make sure it kept drilling. If the operator was unavailable to tend the machine when the electrode was finished, it could result in the machine being idle for several hours. Mr. Karvala knew there had to be a better solution.

Automated Electrode Changes

To expand the company’s EDM capabilities by making electrode changes quicker, KLH invested in the Drill 300 hole-drilling EDM from GF Machining Solutions (formerly GF AgieCharmilles) of Lincolnshire, Illinois. This equipment helped make significant improvements to setup time, managing labor hours and providing faster turnaround for KLH’s aerospace customers. 

With the Drill 300, KLH operators now have a significantly faster and more effective solution to change electrodes. The Drill 300 is equipped with an automated electrode and guide changer that reduces setup time in an eight-hour shift down to just a few hours per day. The operator has the ability with this automation technology to load the electrode change once per shift, he says, freeing the operators to run other machines or start other jobs on the shop floor.

In addition to the reduced setup time, the efficiently controlled EDM processes on the new machine tool have led to faster throughput and less electrode wear. The machine’s breakthrough technology (related to when an electrode essentially “breaks through” the part to make the hole) has made it easier for the shop to manage the speed, consistency and precision requirements of its aerospace hole-making applications.

“We see a much slower rate of electrode wear than on other EDM equipment on the floor. There’s also less deviation in the hole diameter leading to a more consistent hole through the part,” Mr. Karvala says. 

This is accomplished with the machine’s Intelligent Power Generator (IPG). The IPG optimizes each electrode pulse to reduce electrode wear or control surface finish. This process control takes a fraction of a second adjusting and modifying each electrode pulse.

This reduced setup time, in conjunction with the machine’s control over the EDM processes, have led to a 50 percent increase in hole-making productivity. One block might require 2,200 holes, while the next could have 700. KLH once drilled more than 5,000 holes in a block, so the production time can vary greatly for each application.

The software for the Drill 300 offers additional benefits, Mr. Karvala says. “The AC HMI Drill software enables our team to stop in the middle of a program, run a different job and then pick up right where they left off. It can provide holes with different diameters and positions in a single setup. KLH team members can make generator adjustments at the machine to optimize drilling. That data is stored locally and can be called up for similar applications.”

GF Machining Solutions provided several pre-settings that KLH operators could work with, but additional programs were needed to meet certain customer needs. For example, the program couldn’t initially accommodate an application that required thousands of holes drilled into a 5-inch-thick piece of aluminum. Therefore, KLH tested and developed its own job program parameters for a component of that size and worked with engineers at GF Machining Solutions to ensure that the software was capable of handling a large quantity of holes like this in the future.

Mr. Karvala says the company has already drilled about 160,000 holes with the new machine. It was originally intended to complement its other EDMs, but has quickly become a stand-alone service that increased drilling capabilities, particularly in aerospace applications. He says that adding this machine has enabled KLH to become much more competitive in pricing due to the reduction in labor hours and the faster turnaround for parts. The plan is to invest in additional small-hole EDM equipment in the near future.

“If there’s work, we’ll continue to make the machine tool investment,” Mr. Karvala explains. “Perhaps we’ll invest in a machine with additional electrode capacity that can run over the weekend without any operator intervention.”

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As more and more manufacturers are seeking high-quality contour surface milling capabilities, Tarus Products Inc., a large U.S. machine tool builder based in Detroit, is rising to the challenge. Recently, it has made significant technology investments, spearheaded by its inclusion of the Heidenhain TNC 640 CNC on many of its large equipment offerings.

“We are excited about the changes made here over the last couple of years that give our manufacturing customers the edge they need to compete in today’s global marketplace,” explains Doug Greig, who co-owns Tarus with his brother Dave.

“Tarus has always been known to have great build on its machines, many say ‘strong bones.’ And we’ve now upped the game with machine performance levels of increased speed and accuracy highlighted by five-axis capabilities with the Heidenhain TNC controls and linear and rotary encoders, predominantly. We believe this is a great one-two punch,” Dave Greig says.

Established in 1969, Tarus serves the automotive, aerospace and mold and die manufacturing industries. Tarus’ bridge and gantry milling machines feature an average work envelope ranging from 7 by 10 feet to 14 by 60 feet. Besides large CNC milling machines, Tarus builds combination deep-hole drilling (gundrilling) and milling machines for moldmakers as well as specialized multi-spindle, deep-hole drilling machines used in the nuclear industry for critical steam generator tube sheets.

From the mid-1970s until 2008, Tarus developed and used its own CNC for its milling, gundrilling and measuring machines. After that, the company started building machines with customer-specified CNCs. In 2017, Tarus decided to make a shift to the Heidenhain TNC 640, with the first machines delivered in 2018.

Tarus has been a long-time customer of Etel, a supplier of linear and multi-pole torque motors, owned by Heidenhain. One of the signature innovations at Tarus is its development and use of Etel torque motors in a direct-drive ball-nut assembly found in its PMT bridge TNMG Insert and TBM gantry CNC machines. These torque motor assemblies are used to drive each machine axis (X, Y and Z) and result in improved efficiency, less wind-up and increased overall axis stiffness/rigidity.

“Tarus has some great machines with great features, but when it comes down to it, the customer really only cares about how fast they can complete their job, what is the uptime on their machine and how does their end product look,” explains Brad Kleinow, director of service. “The fast speed, strong reliability and superior surface quality that Heidenhain brings to the Tarus machines has proven to be a game-changer.”

According to Doug Greig, part surface finish tends to be smoother and cleaner with the TNC 640 when compared to the older Tarus machines equipped with the previous Tarus CNC. After Coated Inserts a thorough testing process in which the TNC 640 performed even better than expected, and due to the fact that many of the company’s main markets now require the Heidenhain, Tarus is now predominately using the new control on its large, high-performance machines.

“The TNC 640 control is our preferred choice for these applications because of the reliability and performance it provides as a result of pairing it with the Heidenhain motion control feedback encoders,” Doug Greig says. “We believe that this coupling allows us to be the best at serving our machining markets in the long run.”

Overall, the Heidenhain TNC 640 control is designed for mill-turning, high-speed cutting and five-axis machining on machines with as many as 18 axes. It is a workshop-oriented, high-powered and user-friendly control featuring numerous functions. For Tarus customers, some of those features include:

“The combination of features on the Tarus machines promises to provide users with increased performance, faster speeds, more flexibility, reduced setups and more uptime,” says Doug Greig.

“We believe the changed philosophies and revamping done here at Tarus over the last few years is exactly what the manufacturing industry needs to excel in today’s marketplace,” Dave Greig says. “We are proud of our long history and the successful use of Heidenhain encoders that were helpful during our transition to current improved five-axis control technology.”

In fact, the company expects to be involved with retrofitting many of its current machines in the field with these latest generations of Heidenhain controls, drives, motors and feedback, Mr. Kleinow says.

To support the overall increase of Heidenhain controls in the field, Heidenhain provides on-site application training at the end user by arrangement. Users can also attend TNC training classes at the TNC-CNC Academy in Schaumburg, Illinois.

The Greigs also mention that besides the new pairing with the Heidenhain TNC 640, their Tarus machines now also feature new cables, connectors and cable chains to improve reliability and simplify servicing. These developments, along with the culture shifts at Tarus and new quality and ISO 9001 certification processes now in place, are meeting the changing needs of today’s manufacturers.

“We are seeing much traction at Tarus starting now,” Dave Greig says. “We also have some new and exciting five-axis products currently in development that we expect to launch within the next year or so.”

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DThe M5F90 face-milling cutter ifrom Sandvik Coromant is designed for machining thin-walled aluminum automotive parts without burring, scratching or chipping. The two-in-one cutter can perform roughing and finishing in a single operation for faster and more efficient machining strategies.

The M5F90 cutter body’s diameter (25 to 80 mm/0.98" to 3.15") carries brazed PCD inserts that require no adjustment thanks to new production processes and therefore enable higher feed rates without vibration. Scratches, burrs and breakages on the machined part are said to be eliminated with a combination of optimal cutting angles, insert shape, edge preparation and Face Milling Inserts cutting parameters.

In terms of roughing, the tool works as a conventional cutter, with all rough-cutting edges positioned on the same diameter and height. The M5F90 can machine to a depth of cut measuring 4 mm (0.157"). With regards to finishing, this portion of the tool consists of radial and axial stepped cutting edges. Such a configuration promotes burr-free milling and good surface finish on thin-walled aluminum parts while enabling a close pitch-in order to avoid cutting vibration, according to the company.

“The inherent flexibility of being able to rough- and finish-mill makes it possible to machine different positions on the same part with just one cutter,” says Emmanuel David, global automotive product manager. 

Although designed for thin-wall milling operations on aluminum parts, CCGT Insert such as gearbox cases and housings, the M5F90 is also able to handle other aluminum automotive part features, the company says.

The M5F90 is described as completing Sandvik Coromant’s milling cutter offering for aluminum automotive parts, complementing the M5B90, M5C90, CoroMill Century/590, M5Q90 and M5R90 tooling solutions.

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Rem Sales offers the Tsugami S2Carbide Aluminum Inserts 06-II Swiss-type lathe with IMG 400LS laser cutting system. Developed by Innovative Machinery Group, Rem Sales’ sister company, the machine was originally designed to fast production of small, cylindrical parts for the medical industry but has potential applications in other industries that manufacture similar-sized parts.

The machine combines six-axis Swiss machining with laser cutting capability, making it possible to perform both operations in a single setup, reducing production time. The Tsugami S206-ii opposed gang-tool lathe features a Y-axis toolpost that enables the use of the back and main spindles simultaneously for machining complex parts. The machine is also convertible so that it can be run as traditional sliding headstock machine with a guide bushing or with a chucker. All laser cutting operations are Carbide Milling inserts programmed and driven from the Fanuc 32i-B control.

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Arch Cutting Tools Corp. (Arch), a manufacturer of high-performance custom tooling, is acquiring Custom Carbide Cutter Inc. (CCCI), a provider of cutting tools to manufacturers and distributors located in Cincinnati. 

"I am proud to announce the addition of Custom Carbide Cutter to the Arch Cutting Tools team,” says Jeff Cederstrom, Arch Cutting Tools divisional president. "Custom Carbide's experience in specialty carbide micro tools and high-performance burs sets them apart in the industry and compliments the Arch offering.”

Arch is based in Tungsten Steel Inserts Bloomfield Hills, Michigan, and serves the medical, aerospace, defense, automotive, energy, agriculture and general industrial markets. As a mid-sized, full service cutting tool manufacturer, Arch has facilities across the United States, and the company says it is dedicated to engineering high-performance standard and custom tooling.

“We are excited to offer these additional domestic manufacturing capabilities to the growing Arch customer base, especially the micro tool application expertise, as this is a rapidly expanding segment of the industry. Steve and Dena Long have assembled a talented team, and we look forward to building on Custom Carbide’s longstanding customer relationships with additional products and services,” Cederstrom adds.

CCCI was established in 1983 to provide cutting tools for local companies in the Cincinnati area but has since grown to service customers around the world. It specializes in serving the automotive Cemented Carbide Inserts and aerospace industries along with shipyards and medical facilities.

“The acquisition by Arch Cutting Tools will help us keep pace with this ever-changing industry,” says Steve Long, CCCI president. “It will give us access to additional support and guidance for our highly-skilled employees and help us continue developing our manufacturing processes.”

The Carbide Inserts Website: https://www.aliexpress.com/item/1005005920836723.html