A processor of coiled metal wanted to reduce handling time and automate machining operations. The problem was that several different widths and thicknesses of material and hundreds of different milling patterns were combined to produce the company’s thousands of products.
Originally the milling operations were done after the material was cut to length. The machine envisioned would position a length of material while still connected to the coil and mill a specific pattern. The company wanted to eliminate the handling and fixturing required for machining after cutting to length.
After intensive analysis of the multiple operations required downstream of the cutting to-length operations, it was determined that the milling operation would be better performed before the material was cut off from the coil. To meet all requirements, this custom machine tool was designed to be adjustable in five axes. The material strip is processed continuously as it moves through the machine.
The multi-tooth milling head is first fed into the material in two axes. Second, the material is fed through the machine and into the milling head for the required distance. Belt driven spindles are used for the milling operation. The “Y” and “Z” axes hardened way slides feeding the spindle are controlled by hydraulic cylinders. The “X” axis is a dovetail slide used for manual adjustments of the two spindles relative to each other. The fourth and fifth axes are for adjusting milling angles and material widths. The machine has been a tremendous success. Hundreds of complicated and error prone operations have been eliminated. Productivity has increased, and the company has been able to expand its product offering with no additional machinery or personnel required.
Not only is the design and operation of the machine successful, but the Gilman USA components that made it possible are all stock or standard products. This use of existing designs kept the project cost low.
By using stock and started components to achieve the customer’s design goals, cost and delivery time were both minimized.
