Center Rock Uses GibbsCAM for Setups

Not many manufacturers can claim to have been cited in a State of the Union address. Center Rock Inc. of Berlin, Pennsylvania got nearly 200 words in President Obama’s speech to Congress on January 26. The maker of rock drilling tools produced the custom drills that were used to free the 33 trapped miners in Chile—the miners whose rescue was seen and celebrated around the world in October 2010
Brandon Fisher, Center Rock’s president and founder, was already back home from Chile by the time those men were freed. His company’s role in the drama was complete once the 2,000-foot-deep hole had been successfully drilled. At that point, Mr. Fisher, along with Center Rock’s Julie Fisher and senior engineer Richard Soppe, left the site to get out of the rescuers’ way.

This lathe machines the company’s larger rockdrilling bits, including some that went into drills sent to rescue the miners in Chile.

For the Center Rock team, that drama actually had begun back in the machine shop, on the day the Chileans accepted the company’s offer of assistance in the emergency. When news of this emergency became clear, Mr. Fisher committed his company to producing the drills needed for the rescue as quickly as physically possible—at the cost of putting every other active job on hold. Because the forged steel bits used in these drills were tailored to the demands of the rock composition in Chile, the bits were machined from scratch. One might think that a process involving seven different machine-tool setups, not to mention trips to subcontractors in the midst of the machining, could not possibly be responsive—but Center Rock proved differently.
The manufacturing drama at Center Rock is the subject of the latest episode of The Edge Factor, an online show about the excitement and importance of modern manufacturing. That episode is now playing at edgefactor.com. In it, Mr. Fisher describes his company’s involvement in a moment when manufacturing and machining became perilously significant to the lives of 33 men.
在智利矿难营救中,Center Rock公司生产的钻孔机与另两家公司生产的钻孔机不同,采用高压缩空气而非液压转动来驱动钻头,并清除岩石碎片。其它钻孔机通过碾磨钻凿岩石,主要使用牙轮钻头,用水或其他液体冲洗并清除钻头上的石屑。Center Rock公司生产的钻井机技术更先进,采用多个气动锤,随着钻孔机旋转,每个气动锤都能有规律地用力推动钻头击碎岩石,就像一组旋转式凿岩机。压缩空气除了驱动气动锤外,还能把钻头上的岩石碎片和灰尘向上吹散。这些最先进的DTM(潜孔钻机)开凿硬质岩石比液压系统钻孔机速度更快、效率更高。

在此次的智利矿难营救中,Center Rock公司使用三种不同型号的钻孔机把救援井打通至地下2067英尺,成功救出33名被困矿工。第一个是5.5 x 12 QL 120型扩孔器,用来把直径5.5英寸的通风孔加宽至12英寸,此通风孔还能作为其它钻孔机的导向孔。第二种和第三种钻孔机是LP井下钻孔机,直径分别为28英寸和26英寸,每台钻孔机分别配有气动锤和四个直径为7-7/8英寸的钨钢钻头。
LP井下钻孔机的机械部件包括如下:顶部的凸缘及接收器、平板、气动锤的卡盘以及一个长的锯齿状导向器或叫“感应器”。然而最硬的零件和最复杂的几何是LP井下钻孔机的钻头,Center Rock公司生产了各种形状的钻头以便于实际应用。除了车削加工外,每个钻头还需采用平面铣、轮廓铣、放射铣或轴向铣进行加工,有时还要在不同角度钻各种孔。这就极大地促使了他们采用多任务加工。Center Rock 公司的编程人员和机械师把GibbsCAM软件的MTM模块和斗山MX2500机床结合使用,在同一台机床上就能把一个零件完整加工完成,节省了多次装夹和浪费在装夹工件上的时间。
由于GibbsCAM软件集成了所有操作,在进行车铣复合编程和MTM多任务加工编程时,CNC编程人员在同一用户界面操作即可,无需退出现用模块后再进入另一模块。车削、铣削、钻孔和非切削操作,如换刀、刀塔移动以及两个轴之间的转换等,所有这些操作都能在同一界面完成。GibbsCAM MTM会自动在每个通道运动的相应位置插入等待代码并执行同步程序,同时控制每个通道刀具组之间的排列,这就使得优化刀路操作更为简单。GibbsCAM MTM模块还能在显示刀具运动和材料去除的同时验证刀路,因而编程人员可以在任何时候验证刀路:在每步操作完成后验证,在一系列操作完成后验证或在整个刀路都走完后验证。
Center Rock公司采用自己的技术及专业技能把智利矿难大营救的时间缩短了一半,从预期的5个月缩短至两个半月,GibbsCAM软件与此同功,Center Rock公司的编程人员和机械师采用GibbsCAM软件编程,应用到马扎克加工中心和斗山Puma车床以及MX2500 MTM机床上,大大提高了机床的生产效率,加速了钻孔机和钻头的生产,为大营救赢得了宝贵的时间。

Center Rock played significant role in the mine rescue in Chile

A drill sometimes includes many bits for cutting the rock, as is the case with this one about to be welded in the company’s fabrication area


Center Rock’s larger drill bits see the most setups. For one of these parts, the work of turning both ends, preparing the part for a holemaking operation, and detailing the machined hole together entails four lathe setups. The part then goes to an HMC from Mazak for spline milling, milling the rock-cutting face and drilling recesses that hold the carbide cutting elements. This machining center work requires three setups—two before heat treatment and one after.

该车削中心具有实时加工功能。另一个用于更小钻头的车削中心具有带电工具和辅助主轴。

As Center Rock shows, this capability is valuable for reasons that go beyond just single-setup machining. The freedom to perform more machining in one place enhances Center Rock’s production capacity, even if that freedom is not used to machine a part all the way to completion. For example, the smallest bits often receive stem-end turning, pilot hole drilling and spline milling in a single, efficient turning center setup. However, the cycle then stops.

Webber金属产品公司不断成长,在1994年,公司建立了卫星厂,距离威斯康星州普拉特维尔的总部1个小时车程,在1997年,原来的加工厂移至爱荷华州喀斯喀特占地120,000平方英尺的新址 。拥有67个CNC (另外一个VMC 正在购买中),这两处工厂进行枪钻、研磨、水射流切削、垂直和水平铣削和车削加工以及多任务加工,为各行各业提供各种材料的部件。自从1999以, GibbsCAM一直服务他们帮助他们成长。

Brackemyer说“除了对我们所有的机床编程外,我们都知道,GibbsCAM大大的缩短了我们的编程时间,减少了我们的设置和处理时间,我们花在编程上的时间比以前少的多了。”

Steve Bungard demonstrates one of the machining operations for a drill bit part in GibbsCAM, which the shop uses to program both turning machines and machining centers. More about Center Rock’s machining process is documented in the episode at edgefactor.com.


该公司开发了自己的工艺,在每一个钻头上钻深盲孔。这个过程的关键是Sandvik Coromant Corodrill工具,它允许冷却液和切屑通过工具从孔中抽出。

 

As seen in MODERN MACHINE SHOP Magazine

See Related Applications

Manufacturing

Production Parts

Shop Floor

Share:

Share on facebook
Share on twitter
Share on linkedin
Share on email

GibbsCAM Newsletter