shop solutions s problem solving on the shop floor · with its optimized lubrication system, the...

April 2015 | AdvancedManufacturing.org 49

Outsourced Automotive Jobs Head Back Home

D ynamic Manufacturing (Melrose Park, IL) is a Tier One

vendor of transmission parts for GM and other major

automotive OEMs, Chrysler, Allison, and most recently Ford.

Dynamic has created an operational model that positions itself

Read more, P50

High-Feed Mill Faces Large Valve Flanges Faster

M any valve makers still do their flange facing by turning

with single-point stick tools. After all, valves are basi-

cally round and have two or more flanges to be brought

into tolerance and flatness specs.

Read more, P54

Untended Machining Fuels Aerotech’s Growth

D elivering geometrically complex parts cut from unforgiv-

ing superalloys—on time and on budget—requires the

coordinated efforts of an extensive team of talented individuals

with exceptional systems and equipment.

Read more, P120

sSHOP SOLUTIONSProblem Solving on the ShoP Floor

Dynamic Manufacturing’s machining modification of a GM

flywheel on a Doosan DNM 650 vertical machining center.

Aerotech has developed its expertise in multiaxis part workholding

solutions, which hold the key to efficient five-axis aerospace

parts machining.

Using live turning process tooled with Ingersoll Hi QuadF face mill, DeZurik

completes valve flanges in one-third the time of conventional stick turning

with a single-point tool . The Ingersoll Hi QuadF face mill works like a router.

50 AdvancedManufacturing.org | April 2015

to bid projects resulting from plant closures in

other countries and bring outsourced parts back

on-shore.

For example, on learning that GM is going

to close down a transmission works at Romas,

Mexico, where the 4L60 transmission is currently

made, a brainstorming session of engineering,

production, tooling, and fixturing closely examined

the requirement for 4L60 parts. How many pump

bodies, pumps covers, valve bodies, and 4L60

cases would be required? How have the parts

been made previously?

Today, manufacturing these critical parts is done

on multiaxis machining and turning centers, which

have replaced the 15 and 20-machine transfer lines

previously used. The result is greatly improved part

quality due to single fixturing, higher throughput,

and substantially reduced rejection rates—all done in greatly

reduced floor space. Dynamic, for example, might make the

transmission parts on one of its nine-axis Puma MX2600ST

turn-mill multitasking machines from Doosan Infracore

SHOP SOLUTIONSContinued from P49

Pete Motas, Paul Jensen, and Bart Kajaria (l to r) with a Doosan Puma

MX2600ST nine-axis with a B axis mill-turn running a hole-tapping operation

on a GM 4L60 transmission pump at Dynamic Manufacturing.


Machine Tools (Pine Brook, NJ). The Puma MX2600ST fea-

tures a tilting B axis, upper and lower turret and subspindle.

While Dynamic may be reluctant to refer to these installations

as “turnkeys,” the fact remains that much of Dynamic’s suc-

cess stems from the critical early plan-

ning meetings with suppliers, vendors

and especially with its distributor, 520

Machinery Sales (Schaumburg, IL).

“Three years ago, we outsourced

many of these transmission parts. At

that time we began to bring jobs back

in-house when we got involved with

Doosan,” said Paul Jensen, manager,

tooling and fabrication. “We actually

bought a used Doosan as one of our

initial pieces of equipment. It worked

so well, our quality improved so much,

and we were really so pleased with the

machine, that the company decided to

move more parts back home and buy

more machines.

“However, we decided that we

weren’t going to buy a fleet of machines

to run a single particular part. With

the nine-axis Doosan Puma MX2600

ST turn-mill multitasking machines we

could set up in such fashion as to run

multiple operations with a single fixtur-

ing. The parts that we’re running now

completely fill up the machine. We have

the front and rear spindles loaded up

and the B axis is moving all the time.

It’s a great machine for our company.

There’s no part handling from machine

to machine, no operator interven-

tion, no tolerance stack-ups, so part

consistency and machine flexibility are

remarkable, and the time and money

we save in not having to set up multiple

machines goes right to the bottom line.

Plus, we’re bringing jobs back as well.

In the last 2 1/2 years we’ve been able

to add 10 people,” Jensen said.

The machining area at Dynamic

covers about 40,000 ft2 (3716 m2) and

is equipped with two nine-axis Doosan

Puma MX2600ST turn-mill multitasking machines. Each

has an 80-tool automatic toolchanger, up from the standard

40-tool ATC. With this machine alone, Dynamic can produce

the 8000–10,000 transmission parts per year required by

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GM and do so cost effectively for Dynamic and GM. When

it acquired the first of its Doosan vertical machining centers,

Dynamic was able to bring 25–30 parts back in-house that

it had outsourced. Now, Dynamic has four Doosan vertical

machining centers—three DNM 650s and one DNM 500. As

well as producing new parts, they are being used

for remanufacturing transmissions which come

in and get disassembled and thoroughly cleaned

and inspected before being machined to meet or

exceed original requirements.

Initially, Dynamic put the Doosan VMC to work

making a solid torque converter for one of the

GM transmissions. “In the beginning, we had to

use steel billets because we couldn’t find a forg-

ing at that time, so in the beginning we had to

use these 150 lb [68 kg] hot-rolled steel billets,

and we said let’s see what the Doosan VMC can

do because we knew just by looking at it that

there would be a whole lot of metal removal. So

we put the billet in the VMC and we were able to maximize

material removal. Pretty soon we were doing 500 of these

torque converters per day, and now it’s basically an 8–10-

hr operation every day. And we’ve never had that machine

or any other Doosan break down,” said Jensen.

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SHOP SOLUTIONS

Complex automotive workpiece, a GM 4L60 transmission valve body

machined at Dynamic Manufacturing.


One of the first parts that Dynamic started working on

when it began this reshoring program was the differential car-

rier for the four-piece four-wheel-drive transmission, 4T40 and

4T65. The carrier is cast-iron and a major driving component

for the transmission. “It takes about 40

different tools to make this part on the

nine-axis Puma MX2600ST. If I didn’t

have the nine-axis machine, I would

probably have to quote this part on two

or three separate machines. That’s the

way the part was being made previ-

ously—on a sort of transfer line setup of

multiple machines,” Jensen said.

“Right now, we’re averaging between

60 and 800 GM 4L60 pump covers per

month. And this is done right now on

the nine-axis Puma MX2600. There are

probably 20 angular holes in this part

and there are three bores that also are

angular, and a lot of angled holes that al-

low us to use the B axis to put all those

holes in at one time and hold tolerance

of ±0.0002" [0.005 mm],” said Jensen.

To run a family of 4L60 valve bodies,

Dynamic brought in two Doosan HP

5100 horizontal machining centers, one

with an APC. “We are running these with

two four-sided tombstone fixtures. We

set this up in a fashion that we can run

lights-out, and thus far we haven’t had

any problems. In fact, we’ve accom-

plished this with one operator running

both a Puma MX2600 machine and one

Doosan HP 5100 horizontal machining

center. It’s our goal to get operators run-

ning multiple machines, as well as doing

spot checks for quality. With the pallet

changer we will have six open stations

so we can keep our 24-hr lights-out

operation up and running,” said Jensen.

A Doosan multiple pallet carousel

system with six different carousels

loaded with tombstone fixtures on them

allows Dynamic to load up six differ-

ent part families, depending on their

changing needs. “We have 180-tool

automatic toolchangers on both of our Doosan HMCs,”

Jensen said, “and we can set the MPS system so it can have

multiple valve bodies or multiple cases, so we can fixture

multiple parts or part families and with all the tooling we can

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set the machine up so that it runs continuously through all

the setups until it runs out of tools.”

The HMC can run untended except for the period where

Dynamic has to unload the finished parts and load new

blanks into the fixtures. “Generally, we load up in the morning

and let the two HP 5100 HMCs run until the afternoon, and

then we unload and reload and then restart, and that’s good

for all afternoon and into the evening. At this point we can

decide whether to unload and reload and restart the process,

running all night,” said Jensen.

“I can’t say enough about the support from Doosan and

their local distributor 520 Machinery Sales Group,” Jensen

said. “They are here absolutely when we need them. A JIT

[just-in-time] operation like ours can’t be down more than

24 hours. The machines are great, and the operators love to

work on them.”

For more information from Doosan Infracore Machine

Tools, go to www.doosanmachinetoolsusa.com, or phone

973-618-2500.

Continued from P49

High-Feed Mill Faces Large Valve Flanges Faster M any valve makers still do their flange facing by turn-

ing with single-point stick tools. After all, valves are

basically round and have two or more flanges to be brought

into tolerance and flatness specs. Glenn Hennen, a 15-year

veteran machinist at DeZurik-APCO-Hilton (Sartell, MN),

believed there had to be a better way.

Hennen’s idea took shape in June 2014, when DeZurik

moved production of their 42" (1066 mm) and 36" (914-

mm) valve bodies to a new Mazak e-1550V five-axis CNC

multitasking mill-turn machine. Until then, the company had

machined the flanges in a conventional turning process

at 650 sfm (198 m/min), 0.25 ipr (6.35 mm/rev) feed rate,

requiring about 18 minutes per side to complete.

Employing about 300 shop personnel and running 24/6,

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SHOP SOLUTIONS


DeZurik is a recognized leader in valves for municipal water,

hydropower, and processing applications. The company pro-

duces about 160 of each size per year, made to order, which

occupies about 20% of machining time on the new machine.

Not surprisingly, management listened to Hennen and

moved ahead quickly, bringing in their “go-to” tool vendor

Ingersoll Cutting Tools (Rockford, IL) to pursue his idea. As a

result, DeZurik reduced facing cycle time for the flanges from

18 minutes to 3 minutes. This saves

about $114 per part on the two valves

now running on the Mazak.

Based on that success, the com-

pany is standardizing on the process as

quickly as possible, anticipating savings

exceeding $100,000 a year. “A five-axis

machine is a big-ticket item with a high

hourly burden, so it’s vital to get the

most out of it,” said Chandler Commer-

ford, manufacturing engineer.

The solution, according to Commer-

ford: “Live-turn” the flange in a macro

helical mill-turn cycle and replace the

single-point stationary stick tool with a

multiedge rotating Ingersoll face mill.

“We now get 11 cutting edges working

at once, not just one,” said Commer-

ford, who handled all the programming

to make it happen.

“Live turning also gets two spindles

working simultaneously,” said Inger-

soll field engineer Bryan Winterlin,

who helped develop the solution.

“Two-spindle machining will almost

always remove more metal faster

than a single-spindle process.” The

method also reduces cutting forces.

On a rotating face mill, each cutting

edge takes off a tiny chip sequentially

to achieve the cumulative result. This

distributes the cutting forces evenly

over all the edges, protecting both the

tool and the machine.

The key to making the new process

work was using a high-feed face mill

that steps out of its comfort zone. The

tool that made the difference at DeZurik

is a 5" (127-mm) Ingersoll Hi QuadF

face mill, nominally a high-feed mill

involving high feed rates and shallow

cuts. It boasts an extra thick insert and

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SHOP SOLUTIONS


extremely rigid seating for durability plus free-

cutting geometry and 12° lead angle for lower

lateral cutting forces and enhanced stability. “Here

each pass removes up to 0.200" [5 mm], definitely

beyond the comfort zone for high-feed tooling. It’s

really an all-purpose tool,” said Winterlin.

In flange work, low lateral cutting forces are es-

pecially important for stability toward the outer edge,

which can be less supported. Unless the flange is

perfectly flat, leaks can develop in service. Winterlin

and Brad Dillinger of Black Hawk Industrials ran the

demo and helped the DeZurik team set the param-

eters for an initial test. It was the company’s first

experience with live turning.

The valve bodies are in cast iron or ductile iron and have

two flanges per part. Because of the variability inherent in cast-

ings, usually there is from 0.200 to 0.400" (5–10 mm) metal to

remove. The operation starts at the open bore and proceeds

outward along the Y axis to the flange circumference. As the

part turns slowly on the main spindle, the face mill rotates at

785 sfm (239 m/min) and feeds outward from the center at

0.561 ipr (14 mm/rev), or 403 ipm (10 m/min). It works much

like a router in woodworking. Synthetic oil cutting fluid is deliv-

ered through the spindle.

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Bore Depth

Cutting Time Comparison

Cutti

ng T

ime,

Min

utes

per

Hol

e

Material: 4140 SteelStarting Hole: 3"

Final Hole: 4"

Milling2" Face Mill, 5 FluteFeed/Tooth: .005"

Rough Boring4" SW 319, Stepped CuttingFeed/Tooth: .014”

kaiser 1921-02 ME_RoughBoring_Ad_v1.indd 1 3/10/15 1:26 PM

The team at DeZurik that changed to “live turn” with high-feed mills: (l to r)

Bryan Winterlin, Ingersoll field engineer; Chandler Commerford, DeZurik

manufacturing engineer; Glenn Hennen, veteran machinist who believed

there must be a better way.


The DOC setting averages 0.075" (2 mm)

but may be as much as 0.200" (5 mm), de-

pending on dimensions of the rough casting.

Those settings are established to complete the

flanges in two passes and leave the surface

finish well within the 250 μm spec. Edge life

averages one complete piece, or two flanges.

The only changes since the initial demo

and test were to probe the rough surface

to locate the starting point and switch to a

tougher insert grade. Probing reduced air

time enough to subtract another minute

from the cycle without changing machining

parameters. “That air-time saving matters

more in a three-minute cycle than it did in an

18-minute cycle,” said Commerford.

The tougher insert, Ingersoll grade

IN4005, improved edge life by 3 to 1 at

SHOP SOLUTIONS

Continued on P120

Indexing gives a good view of the Hi QuadF face mill that speeds up machining of

big valve flanges at DeZurik. Eleven cutting edges in free-cutting geometry with

12° lead angle reduce and distribute cutting forces for process stability and long

edge life at high removal rates. Though nominally a high feed cutter for fast feed

rates and shallow cuts, the Hi QuadF handles depths of cut up to 0.200” (5 mm)

in this application.


the same removal rates. Now, cutting edges last through

three complete parts (six flanges). The longer tool life stems

mainly from an advanced post-coating technology that

reduces microcracks and leaves a smoother, slipperier

cutting edge.

“The 4000 series inserts cost us 7% more but give us triple

the life,” said Commerford. “That’s a deal I’d take any day.

The larger saving is in reduced tool-change labor from the

longer service intervals. Each indexing costs us about $15.”

The aluminum oxide coating is deposited by a pressure vapor

deposition (PVD) process, which creates a more durable bond

between coating and substrate.

DeZurik believes in formal continuous improvement pro-

grams—as long as there’s room for spontaneity and open-

ness to ideas from the guys on the shop floor. “Some of the

best ideas have come from employees like Glenn,” said Tim

Kindel, manufacturing engineering manager.

For more information from Ingersoll Cutting Tools, go to

www.ingersoll-imc.com or phone 815-387-6600.

Continued from P49

Untended Machining Fuels Aerotech’s GrowthD elivering geometrically complex parts cut from unforgiv-

ing superalloys—on time and on budget—requires the

coordinated efforts of an extensive team of talented individu-

als with exceptional systems and equipment working toward

a common objective. Although technical and sophisticated,

aerospace manufacturing is a “people” business, too, ac-

cording to Joey Jones, owner of Aerotech Machining Inc.

(Bloomingdale, GA).

With 33,000 ft2 (3065 m2) of manufacturing space and

three, four, and five-axis systems capable of producing large

parts, Aerotech is a first tier supplier to aerospace OEMs, as

well as major agricultural and power generation equipment

companies. In the past 10 years, Aerotech doubled its sales—

twice—and has added several CNC manufacturing systems,

particularly those designed for untended machining. As a

result, Aerotech has increased its sales and support staff to

uphold its manufacturing capabilities and service levels. In the

meantime, the profit-generating engine of this business—the

shop itself—quadrupled its manufacturing output while adding

only a couple additional programmer/machinists.

Aerotech has managed to sustain its growth by having a

well-tooled shop, capable programmer/machinists, and an

exceptionally flexible computer-automated manufacturing

workflow, orchestrated via powerful and pervasive Master-

cam software from CNC Software Inc. (Tolland, CT).

“Workholding wins jobs. If you can hold it securely, then

you can make it efficiently on multiaxis equipment without

generating scrap, even when we are manufacturing on a

lights-out basis,” said Jones. “We know how to hold difficult

parts. Our customers know this and they send them to us.

We have hundreds of workholding solutions. We have a

fixture shelf 20' [6-m] tall and 20' [6-m] wide with five levels of

shelves on it and they are stacked with workholding solutions

that we have designed either in Mastercam or CATIA.

Short lead times keep work coming to Aerotech, which

quotes lead times of four to eight weeks, compared to eight

to 12 weeks, which are more common in the aerospace

manufacturing world. The company has developed the flex-

ibility to rearrange manufacturing schedules to accommo-

date special emergency jobs without falling behind on other

assignments. Part of this flexibility involves being able to

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SHOP SOLUTIONSContinued from P58


use the same Mastercam programs on many different CNC

systems in its shop.

Aerotech also has a number of trusted subcontractors who

can take CATIA models translated in Mastercam and use them

as the basis for creating part programs. Jones insists that

Aerotech’s subcontractors use Mastercam, so that everyone

is “speaking the same language.” Once the subcontractor has

been given a particular job, Aerotech’s intention is to leave the

work with that shop. However, Aerotech pays for the program-

ming time and owns the program, so it can pull the job back

in-house, if necessary, to meet tight delivery schedules.

At Aerotech, programmers are machinists. Aerotech has

six programmer/machinists who use Mastercam to gener-

ate programs for the company’s 25 CNC manufacturing

systems, including a Mazak Integrex and a Mazak Palletech

manufacturing system. “The business model of having a

programmer sitting in an office writing programs doesn’t

work anymore,” said Jones. “If you do it that way, you end

up sending drawings to the programmer’s office, he writes

a program and by the time he gets to the floor he has to

modify it 15 times because he’s not really sure how the setup

guy is going to hold it and run it. The whole key is having a

machinist who can program. He can think for himself. He

knows what that machine is supposed to do, so it’s a whole

lot easier to write that program.”

Lead programmers Chris Beatty and Bill Urbaniak have

extensive training in multiple levels of Mastercam from their

reseller CAD/CAM Solutions Inc. (Snellville, GA). The training

has been very comprehensive. They work closely with the

other four programmer/machinists, passing along what they

have learned and learning from them as well.

Advanced Mastercam capabilities have been instrumental in Aero-

tech Machining’s ability to pursue and capture high-end five-axis

aerospace machining work, according to Joey Jones, president.

See us at EASTEC Booth #5728


Aerotech’s programmer/machinists are creating pro-

grams for all of the CNC equipment that operates on the

10-hr day shift, and for an increasing number of machines

that operate untended on the 10-hr second shift. When

the programmers develop a program for a prototype that

will initially run on a single table mill, they are also emulat-

ing a program that will be able to seamlessly transfer to

their Palletech system if the part is ultimately needed on a

production basis.

Because much of the manufacturing takes place on the

untended second shift, the volume of programs created

has nearly doubled over the past five years. The team has

been able to keep pace with this requirement because of the

new tools provided in Mastercam to make each successive

generation of the software faster and easier to use for the

programmer/machinists.

“It really makes it easier on the programming side when

you can finish a product almost as efficiently as you can

rough it out. It works wonders,” said Jones. “Today, we can

program in half the time compared to five years ago. A lot of

the buttons I’m talking about show up in the five-axis stuff.

The five-axis drilling is really simple. Instead of having multiple

setups, you can just leave your part in the same spot and it’s

really simple to click the holes and drill your part. If you are

doing multiple parts, you have that one operation and you

just click, click, click, and you’re done.”

According to Jones, efficiency trumps throughput. When-

ever they can, his programmer/machinists do time studies

to ascertain the effectiveness of new machining approaches

introduced into the CAM software. Based on such stud-

ies, Mastercam’s Surface Rough Pocket toolpath has been

established as the go-to strategy for roughing. “This is one

of the best toolpaths for getting our part down to near net

shape as quickly as possible. You go into the model, put a

containment boundary around the tool, and let it loose to do

its thing. Instead of having 15 or 20 different operations to

run that part out, you have one,” said Jones.

Aerotech is now doing time studies on Mastercam’s tool-

paths incorporating Dynamic Motion technology with built-in

intelligence to adjust feeds and speeds according to the

condition of the material immediately ahead of the tool. For

example, Dynamic Peel Mill was recently tested for a titanium

job. Dynamic Peel Mill reduced an hour of cutting time down

to 40 minutes and tool life was better.

For more information from Mastercam/CNC Software Inc.,

go to www.mastercam.com, or phone 860-875-5006.

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SHOP SOLUTIONS

shop solutions s problem solving on the shop floor · with its optimized lubrication system, the...

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