MIGHTY SOLID AT MELROSE METALWORKS

By: Tom Walsh

Things are looking Mighty solid at Melrose Metalworks, Inc. located in Melrose, Minnesota. According to owner Scott Kramer, 'Things are solid in more ways than one. We not only use a solids based CAM program, but we also use the most solid machine tools that I believe are on the market-Viper CNC lathe and VMCs from Mighty USA.'

Melrose Metalworks is a high tech precision machine shop that specializes in CNC milled and turned products and custom machined parts. Working out of a new 7,200 sq.ft. facility, they can handle both short and long runs as well as prototype projects. Many of their projects involve machining parts for hydraulic systems, and agriculture and mining equipment. Materials machined include aluminum, steel, bronze, stainless steel, cast iron, and even plastics.

Customer information comes in the form of print geometry data. Melrose Metalworks uses GibbsCAM '99 for importantion of solid model data. Melrose has dual capability within the Gibbs program- one for milling and the other for lathe work. Real-time part rendering lets the user see exactly what is taking place on the maching tool before cutting any chips. With this feature (Vertual Gibbs) Melrose Metalworks has saved countless hours of prove-out time and almost eliminates the scrapping of parts due to programming errors. 'As a result, ' stated Scott Kramer, 'Programming time has been greatly reduced as programs run much more efficient, and run much faster.'

MIGHTY SOLID MACHINES

'Equally important is having really solid machines,' said Scott. ' Originally, we were looking at used equipment, because many of today's machines are light weight- lightweight in construction and performance. However, after looking at Mighty, we found machines that are not only extremely durable and heavyweight, but reasonably priced as well. The machines we settled on are the VMC-950s for milling and the VT-25Bs for turing.

'The V-950 is the best machine available in its class. As mentioned, all Vipers are built without taking shortcuts or downsizing rigidity. For instance, Mighty does not substitute linear guideways for box ways. It has the fastest automatic tool changer and it also features speeds of 10,000 rpm. The capacity of the tool changer is 20 positions.'

The Viper V-950 weighs 15,440 lbs and has a travel of 40" x 20" x 24.8". Melrose has a FANUC O-MD controller for high-speed and accuracy.

In addition Scott stated, 'The PC based controller supports Windows and is extremely user friendly. If customized screens are required, I can use our GIBBs CAM software. The controller also supports tool management, production management, quality information, spreadsheets, and other commercially available software programs.'

In summary, pound for pound, you won't find a meaner, more productive, better built, or better built VMCs.'

VT-25B TURING CENTER

The VT-25B is built tough, with one-piece construction and 45 degree slanted bed with an integrated piping structure. Headstock, saddle, turret and tailstock are located on the same bed, preventing the miss-match of thermal growth on each component, which in turn ensures an accurate turning operation.

High precision P4 grade spindle bearings ensure precison turning and long-term operations, while the oil pressure monitoring system detects lubrication and pressure drops immediately, should they ever occur. The cooling tank is completely separate from the main slant bed, thus preventing any thermal growth from hot cutting chips.

The VT-25B relies on the FANUC 18-T controller for high-speed precise and efficient machining control. Scott stated, 'With FANUC's proprietary servo and spindle control and processor for high speed computation, the VT-25B is just right for turning operations.'

ROUNDING OUT THE OPERATION

Also important in any machining operation is tooling. Close tolerance work demands the very best in tools, machine and materials. This is especially true in the field of precision boring and this is why we use inserts with our boring head and tools. Inserts allow a semblance of standardization, something that is a definite requirement for machining many different materials and jobs.