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Mitsubishi Materials Cutting tools a key factor for unmanned lights-out production

| Author / Editor: Rhys Williams / Barbara Schulz

UK – Mitsubishi Materials provided the tooling and expertise that enabled Formagrind, an ISO9001 company with 26 employees based the UK to fulfil a challenging automotive machining contract. Software and cutting tools were among the key factors for lights-out production.

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Intricate details on titanium carrier bases.
Intricate details on titanium carrier bases.
(Source: Mitsubishi)

Formagrind, which was established in 1983, has been operating from a 1,000 m² factory since October 2015. Its equipment includes two new Hurco VMX30Mi machines, in addition to its Mazak, Hardinge and Gildermeister turning centres, Hurco VMCs and Sodick EDMs. It also has three i-Machining CAM software seats.

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Formagrind initially trialled Mitsubishi’s face mills, then implemented the Alimaster aluminium roughing end mill range on a long-term satellite project that had “brutal” material removal rates. The success of the face mills and the Alimaster cutters gave the company complete confidence in both Mitsubishi tools and the local engineer.

Machining hard-to-cut materials

The company machines molybdenum, titanium, Inconel and other hard-to-cut materials. It is now a consignment stock customer and has had an Autocrib vending system since April 2016. It has also made use of Mitsubishi’s expertise in setting of performance parameters and structures.

In February 2015 it received an order for over 100 complex titanium fixtures, each consisting of a carrier base and corresponding top plates that clamp electronic PCBs assemblies during their production and final assembly processes. They were required in a batch size of 105 bases and 160 cover plates. With over 14 hours of machining for each base and 110 minutes for each cover plate, Formagrind needed to run its new Hurco VMX30Mi machines 24 hours a day, seven days a week, for almost two months. With i-Machining optimising the process, the key factor for lights-out production was the cutting tools; Mitsubishi’s solid carbide end mills were selected.

Formagrind developed a fixture to clamp and process two 300 mm by 200 mm by 9.5 mm base plates at a time. The grade 2 titanium plates are first machined with an 8 mm diameter solid carbide four flute VQ Series end mill at 4.5 mm depth, with a 1.2 mm step-over and a feed rate of 1400 mm/min. After almost two hours, a 4 mm and a 3 mm diameter VQ end mill final details. Two, 3.5 and 4 mm diameter VQ end mills are used for rough and finish machining pockets that have already been waterjet cut. A 0.5 mm diameter MS2-SLB end mill handles fine details. Total machining time is nine hours for the top face. Formagrind changes the tools after each pair of bases; wear is hardly noticeable, even after 14 hours of machining.

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