Axiom’s investment in a double-head milling machine is bringing value-added service to customers needing squared to size machining material. This will save valuable machining time as the material arrives as machine-ready blanks and can be machined as soon as it is received.
One of the most time-consuming operations in a machining or fabrication shop is material preparation Axiom’s investment in a double-head milling machine is bringing value-added service to customers needing squared to size machining material.ing operations in a machining or fabrication shop is material preparation. Programming rough machining operations for efficient removal of material is crucial when preparing a workpiece for finished machining or fabrication. Ultimately, it can lead to large losses of material, especially if the material has to be scrapped because of incompetency. “These more mundane and less cost-effective operations occupy expensive equipment that should rather be performing the tasks that require micron precision,” explains Axiom Hydraulics director, Lance Tondolo. “For a busy manufacturer there can be few harder challenges to productivity in your machine shop than having to first prepare material on your expensive CNC machine before you can actually start machining, particularly when you do not have the equipment to do so. We should know.
“From idea to reality it all begins in our integrated manifold design centre. With an accumulative experience of over 120 years in the hydraulics industry, we have the expertise you need in designing high quality, durable manifolds. We design and plot all manifold functionality using schematical circuitry. Once the design has been approved, our engineers design intricate, integrated manifolds to suit your system’s requirements, using only the latest CAD-based build of Hydrosym, Hydroman and Inventor 3D design software and five three-axis CNC milling machines. We now also have our new double-head CNC milling machine with genuine Sun Hydraulics precision tooling.”
All raw manifold billets are high quality and certified ductile iron, imported from the USA. Axiom Hydraulics not only uses Dura-Bar for its products, but also stocks and distributes a comprehensive range of sizes in Dura-Bar ductile iron square and rectangular bar stock. Axiom has represented Dura-Bar in South Africa since 2001.
Dura-Bar’s superior machinability and minimal need for deburring means decreased cycle times, and therefore more parts per hour can be produced. It increases machining speeds by a minimum of 30%, and often as much as 50%. Increased feed rates are due to a reduction on spindle load, and less cutting force is required compared to steel. Consistent material structure and graphite content lead to an improved tool life.
Applications for Dura-Bar include machine bases, manifolds, pumps, and compressor components. Dura-Bar iron bar stock is frequently specified over steel for better machinability and lower part costs. For example, a spindle housing was recently converted from leaded steel to Dura-Bar 65-45-12 ductile iron, reducing parts costs by 33%.
From a process perspective, Dura-Bar’s continuous cast process is one of the main differentiators. The process begins with a water-cooled graphite dye that is machined to form the shape of the desired bar. The dye is mounted on a bar machine crucible, and then the bar is pulled horizontally from the crucible. The head pressure feeds molten iron into the dye, producing a fine grain cast bar. The process enabled the microstructure of the iron to be free from impurities such as slag, gas holes and other tool-wary inclusions, producing material that is a superior alternative to carbon steels.
The first obvious advantage is that Dura-Bar is 10% lighter than steel, which immediately saves money on the weight. Another advantage is the formation of chips when machining. When steel is machined, you get very sharp stringers that are not easy to handle. When machining Dura-Bar you will get chips that are more compact, lead-free, and easy to handle, and they are not sharp; and in Dura-Bar you will see a dense, fine-grain microstructure with a uniform graphite distribution, which makes the material easier to machine and leads to longer tool life.
“The double-head milling machine was purchased as a value-add service for customers wanting squared to size material. This saves valuable machining time as the material can be machined as soon as it is received. Average delivery time for squared material is one to two working days, in sizes not exceeding 190x190 x460 mm,” explains Tondolo. “A meaningful percentage of our business is the designing and manufacture of manifolds for the hydraulics market. The milling machine is used to square our internal material for manufacture, and for these manifolds.
“Prior to its arrival, we were using two manual conventional milling machines to perform the process of squaring. We have now deployed those machines to a different department and we estimate that we have now increased productivity three-fold. Additionally, there has been an upgrade to the throughput and quality of supplied product, and it has increased output and quality of production.”
Applications
Typical applications for Dura-Bar material are in the automotive industry for gears; in the fluid power industry for cylinder blocks, end caps, gear rack housings, glands, manifolds, pistons, rotors and valves; in the glass mould industry for bank moulds, plungers, machinery bushings, chuck bodies, die blocks, flywheels, gears, housings, journals, pulleys, rams, rotary tables, side frames, spindle housings, and tie rod nuts; in the power transmission industry for coupling hubs, gears, pulleys, and sprockets; in the pump and compressor industry for gears, housings, pistons, rotary screw, and rotors; and in the transportation industry for coupling hubs, gears, pulleys, rail spacers and sprockets.
Dura-Bar is stocked in several grades of ductile iron and grey iron, and also in additional non-stock grades which can be ordered in volume quantities. The type and distribution of graphite influences most of the properties, and results in the free machining characteristics, excellent noise and vibration damping, thermal conductivity and wear resistance.
“There is a myriad information on the Dura-Bar website, where you can find further information on the material and its uses,” he continues. “On the floor we have five CNC vertical mills and machines for spline hobbing, broaching, keyway cutting, lathes and manual drilling. If necessary, we can offer these processes for further machining, but we are mainly doing inhouse work on these machines. The effect of loadshedding has been mitigated by installing our own solar system, enabling us to maintain our supply chain and meet customer needs in the challenging times we find ourselves in.
“This investment has been an invaluable investment for our organisation, and depending on future growth, we are considering purchasing a larger version of the machine, and a band saw to give us more cut-to-length options.”
Axiom Hydraulics is one of South Africa’s leading hydraulic specialists, serving the unique requirements of a range of industries through a comprehensive range of hydraulic products. The company specialises in the design and supply of complete hydraulic systems, including hydraulic drives, integrated manifolds, power packs, oil cooling and braking systems. It also imports, supplies, repairs, reconditions and services hydraulic equipment from some of the world’s leading hydraulic technology brands, facilitating cost-effective, innovative and flexible solutions for southern Africa’s hydraulic requirements. The Axiom Hydraulics head office is in Wadeville, Johannesburg, Gauteng.
For more information contact Lance Tondolo, Axiom Hydraulics, +27 11 334 3068, [email protected], www.axiom.org.za
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