Easy NC Machine-Accuracy Measurement
For precise micro manufacturing, control of minimal shakes of cutting tools deserves utmost attention.
BLAZE User Example 1
■ Company name: KOUBUN KAKOU LLC.
■ Outline: Resin processing, 10 employees, located in Kawagoe-City, Saitama-Ken, Japan
■ Facility: machining center, NC lathe, milling machine, drilling machine, etc.
One November morning, I visited KOUBUN KAKOU Ltd., with Mr. Saito, president of Iriso Seimitsu, Co. Ltd. Mr. Kenta Kato (Manufacturing Technology Division) welcomed us, and later, Mr. Sachio Kato, president of KOUBUN joined us as well. Was BLAZE of any use?
■01■Please tell us about your company.
Mr. Kenta Taro: We are made up of a group of craftsmen and our focus is on resin processing.
You may think resin is soft, but some of it is used in space industries, and there are various hardness and characteristics.
There is no machine designed for resin processing, so our facility is similar to that of metal machining factories.
We do have some problems specific to resin, such as it tends to melt because of softness.
■02■ Tell us about the challenge you face.
Our clients are mainly in electronical parts business, and demands are rising for smaller parts, and more detailed processing have become necessary.
Tolerance are becoming stricter and stricter as well. Until recently the units were 0.1mm, 0.2mm, and so on, but nowadays the units are 0.01mm, 0.02mm, etc.
Cutting tools also. 0.5mm was good enough until some time ago, but recently sometimes we must use 0.1mm tool to meet the client’s demands.
There were times when we looked at the diagram they provided and we were not sure whether to accept the order or not, and sometimes we had to decline.
Yes, we do like to challenge new type of work, but since trial and error of changing various conditions and cutting tools takes time, and our time was limited.
I will confess that there was a time when we succeeded in some complicated resin processing, and we were happy, but we did not know why. This means we will not be able to accept order with confidence when there is similar order. This was when I had opportunity to visit Iriso Seimitsu with my father. My father told me that it was an interesting company, with various interesting things to see. I was still fresh in the company and wanted to learn anything possible. That was when I first learned about BLAZE.
■Q. So, you visited Iriso Seimitsu, and that was when you first found about Blaze?
■Q. What was your first reaction?
“It’s fishy, I thought!” (Everyone laughts.)
Saito of Iriso Seimitsu: ：I like your freshness and honesty. That was when BLAZE was just developed, and we were still considering price for the product.
I was told even hole drilling of 60 screw threads was possible, and it was hard to believe. Also, the test piece of BLAZE is aluminum, and we have never worked with it. I thought conditions were different for resin. The way cutting is done is different as well.
We tried it anyhow and was surprised to find BLAZE worked for resin as well. What I thought was only for aluminum worked also for resin.
Saito of Iriso Seimitsu:There is spindle runout that we cannot dismiss. The processing values listed in catalogues of cutting tools, such as rotation speed and feed speed are ideal values, but spindle runout is not considered there. Unless processing is done in big-sized companies with stable production facilities, these 50 or 20 microns cannot be achieved at factories. All the veteran craftsmen know this. Runouts do exist. Some people may think runouts of 50 or 20 microns are not so important, but we technicians do not. We must not take anything for granted, and question what sort of processing conditions do matter and influence each other. Mr. Kenta Kato realized this importance.
■Q. What sort of test did you perform with BLAZE?
First, we checked the runout value. We rotated the spindle with our hands and used the dial. This I learned is called the “First Runout”. We tried under neutral conditions, and the runout was more than we expected.
The “First Runout” is the runout found by manually rotating the spindle, just as Mr. Kato said. This is a very important step.
Then, there is the “Second Runout” of rotating the spindle, and the “Third Runout” of machining.
In BLAZE, it is possible to check the “First Runout” and the “Third Runout”.
As for the “Second Runout,” it is difficult to check unless a very costly device is used. But, if you drill holes, the related result is easily grasped. That is how BLAZE can be used to check the “Second Runout.”
Yes. After checking the “First Runout”, we used the BLAZE kit and drilled a total of 9 holes in 3 places, to check the “Third Runout.” We tried changing the rotation speed, at maximum machine rotation speed, and then 1000 lower each time, as advised.
We were pleased to find THE best rotation speed for the machine. It was the same speed as when we succeeded machining of the difficult task. It was very timely to be offered another similar difficult task but with different material, and now we can accept the order with confidence and pride.
■Q. That is wonderful to hear. Now that you have found out answers to your questions, there is no need to use BLAZE soon?
Yes, that is so.
But as long as we have this test result, BLAZE might become useful when we perform regular checkup every year or so.
Same machines differ in runouts, including spindle runout, holder grasping, collet, and so on. BLAZE will come in handy when we need to decide on the changing timing of machine parts, or when we need to verify new holders that we installed.