May 2008 Edition

SPOTLIGHT: SWISS TURNING

The Right Tool for the Right Job Shop

When a shop landed a big customer, it purchased a Swiss turning machine to meet its needs. It fit the bill so well that when demand increased, the shop bought two more.

With nearly 24 years as a metalworker under his belt, Jay Lundberg was ready for his next career challenge: starting his own business. He had such faith in his abilities to find work and perform it, that he leased about 5,000 ft² of space before landing his first customer.

"It was a ‘now or never’ situation," he said. "There are dreamers and doers. I did it."

After taking that first big step, Lundberg faced the second step: choosing the right machine to do the work he didn’t yet have. He knew he needed a machine that offered maximum capability yet was flexible. After an extensive search, he selected a twin-spindle CNC lathe with 1.25" bar capacity and live tooling.

"The bankers must have thought that I was crazy, applying for a machinery loan before I had my first customer," he said. "I think they considered my experience in the industry when they agreed to finance the purchase."

With a location and a machine, Martin Precision of Rockford, IL, officially began business.

New Client, New Machine

Initial efforts to market to OEMs and other shops were disappointing. Online quoting systems that let Lundberg bid on jobs from all over the country amounted to a lot of quoting with few results. Selling a new business without a track record was a formidable obstacle.

"We discovered that online quoting was only part of the answer; I made the decision to pursue a more aggressive and direct strategy," Lundberg said.

This approach proved more effective, and the shop began to win jobs. Jim Lundberg, Jay’s father, landed one of the first jobs: shafts for a customer serving the communications industry.

"The initial job of 70,000 pieces required us to machine a series of parts ranging from 1/2" to 4' in length," Lundberg said. "The CNC lathe was not practical; all of them were less than 1/2" in diameter."

It’s down from a 40 hour run to 15 hours. That’s like a conventional work week down to less than a day and a half.

Recognizing the potential for long-term growth with this account, Lundberg informed the customer he intended to purchase a Swiss-style machine to handle the work.

With the customer’s approval, Lundberg discussed his needs with Rem Sales, Windsor, CT, the North American importer of Tsugami machine tools. Having worked with Tsugami in the past, he was familiar with the machines’ capabilities.

"Almost all of the bar fed machines at my previous employer’s shop required constant repairs to keep them running. The Tsugami machines really stood out since they just kept making quality parts with few service calls," Lundberg said.

After a review of part requirements and capabilities, he purchased a Tsugami BO12B Swiss-turn machine. Easy to set up and operate, the BO12B featured seven turning tools, two cross rotary tools, and up to eight ID tools.

A Backlog Brings Two More

With the Tsugami producing parts, the shop’s customer list expanded, and the need for small parts with tight tolerances grew. The Tsugami was operating at near maximum capacity and fully engaged while the CNC lathe was often idle.

"We had a backlog of more than 100,000 parts waiting to be cut on our Swiss machine, while our CNC lathe was running less than a shift per day," Lundberg said.

As a small lean shop, Martin Precision relies on unattended manufacturing. The CNC lathe required frequent intervention, making lights-out work impractical.

"The lathe was a solid machine – it helped launch our business – but it was not the solution to customers needs," he said. "We couldn’t afford to have a machine running just one shift."

To handle the overflow work, he added a Tsugami BS19B, which expanded capacity to work 3/4" in diameter. Additional driven cross and ID tools gave the company the ability to handle parts that required heavy milling and contoured end work. Once installed, the new Tsugami was kept busy as customer demand increased. It wasn’t much later that Lundberg began to plan for his third Swiss-turn, a Tsugami BN20.

"We liked the fact that it offered a completely modular tool zone and seven-axis capability," he said. "The split slide would let us pinch-turn, greatly increasing our capabilities."

Keeping in mind skillful expansion of the company, Lundberg looked at ways to acquire the new lathe without incurring debt.

"We were able to work out a trade with Rem Sales," he said.

In January 2008, Martin Precision acquired its third Tsugami by trading in the CNC.

A Swiss-shop by Customer Demand

The three Tsugamis are now in continuous operation. Lundberg, who doubles as chief manufacturing engineer, runs the shop during the day. He then loads the magazine bar feeders before heading home for dinner, then returns around 9 p.m. to check part quality and load the bar feeders again. He is experiencing at least a 50 percent improvement in cycle times.

One run, a hex broach part, required ID threading on its back side. On a conventional turning center, the total cycle time was three minutes. Using the BN20, it dropped to 1.5 minutes. In another case, a 4" shaft with double keyways, the cycle time dropped from 3.5 minutes to 1.45 minutes.

"Multiply that by 600 to 6,000 parts in a run, and there’s a significant efficiency improvement. In the first case, it’s down from a 40 hour run to 15 hours. That’s like a conventional work week down to less than a day and a half."

Although he didn’t set out to establish a Swiss-shop, Lundberg let customer demand guide his decisions.

"Our customers are looking to produce complex parts with tight tolerances. Swiss technology lets us produce complete parts in one setup," he said. "Our operations remain lean, while our customers are able to achieve lower overall unit costs." Tsugami Rem Sales, LLC

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Swiss-type Turning Centers Offer Rapids of 1,600 ipm

The Maier MLK 125 Linear Automatic Series of Swiss-type turning centers offer accurate, high volume production of parts for electronic component manufacturing and a broad range of other small part applications. The Linear Series feature 1,600 ipm rapids in all axes, reducing production lead times, part costs, and cycle times. The Linear Machines can accelerate up to 2g. Spindles – main and opposed – are driven by built-in 3 hp integral motors that can reach a speed rate of 15,000 rpm. Maier USA, Webster, MA

For more information (click here)

System Locates Bar in Less than 0.004"

The Multidec Micro-Bore system locates micro boring bars in the holder for micro-boring bar changes. The boring bar incorporates an angled back that locates the bar less than 0.0004" against a positive location pin in the bar holder. Hand-tightening a fine pitch threaded knurled nut applies the force needed against boring bar snap ring. No wrenches are needed, limiting micro-boring bar breakage from slipping wrenches in tight tooling areas. The boring bar necks feature a multi-faceted surface for reduced harmonics, resulting in improved surface finishes and contributing to longer insert life. Genevieve Swiss Industries, Inc., Westfield, MA

For more information (click here)

Small-diameter Spindles for Swiss Turning

High-speed milling and drilling spindles in 20mm and 22mm diameters are available for Swiss turning applications. Using synchronous, DC motor technology, the spindles operate up to 100,000 rpm with 260W continuous power and high torque. Suited for machining applications involving micro-milling and drilling tools, as well as engraving and fine milling, these spindles feature high rigidity and precision – less then 2µ – to enhance surface quality, machining accuracy, and reduce the need for secondary operations. Models are available in standard length and shorter length models to better suit compact tooling areas as well as 90° versions. IBAG North America, North Haven, CT

For more information (click here)

Broaching Tool Holder for Swiss-type Lathes

The Adjustment Free Rotary Broaching Tool Holder is stocked in four sizes of the tool; 0.625" shank, 0.750" shank, 12mm shank, and 22mm shank. These sizes are designed for Swiss-type lathe and screw machines. Swiss-type tools are popular due to their use in aerospace and medical applications, such as with orthopedic bone screws and custom fastener products. The adjustment-free design lets the operator use the tool holder without the need for centering. The rotary broaching tool holder’s sleek design eliminates interference and clearance problems, and provides easy access to the grease fitting for maintenance. Slater Tools, Inc., Clinton Township, MI

For more information (click here)

Turning System Designed for Job Shop

The Sigma 20 Pursuit offers Swiss stability through its one-piece core motor direct drive spindles, 5/8" tool shanks, 7 hp drive, synchronous rotary guide bushing and one-piece cast iron base with built-in pre-cast cooling channels. It offers simultaneous machining on front and back spindles, high cutting speeds and 1" stock capability. The unit has a sliding headstock turning center designed to meet the demands of the North American general engineering industry. It offers features designed for today’s job shop. It comes pre-loaded with attachments and accessories needed to turn parts for the electrical, consumer goods, automotive, aerospace and defense industries. The machine has three double live spindles for a total of six axes for cross milling front or back. Tools such as angle drills, polygon milling tools, and saw mills can be added to the machine. The design of the Sigma 20 Pursuit is based on the done-in-one concept. Parts can be machined to completion in one setup, without requiring deburring or secondary finishing operations. An arrangement of tools can be loaded in a single setup. The machine accommodates eight to 16 front tools and eight backworking tools, all of which can be used in any combination. Tornos US, Lombard, IL

For more information (click here)