A Built Up Edge while machining Titanium will result in a white recast layer in the workpiece and create poor micro-finishes.
Machining Efficiencies can resolve this machining problem and bring a better awareness of world class machining practices to your plant and management personnel.
MEI techniques ensure that all of the manufacturing disciplines are investigated for sub-optimization. Managers, engineers and operators will understand which sub-optimized discipline is creating high costs, poor tool life or high scrap rates.We generate evidence to reinforce the learning experience.
Average process cost savings are typically 20% and often much higher.
These techniques are used effectively on all chip making operations such as: Broaching (involute, helical, pot, surface) Hobbing Drilling Tapping Reaming Turning Milling Threading Shaping Grinding
Send us your worn tools for a report on what sub-optimized practices are causing tool failure.
Based on a comparison of thousands of reference photos, we examine your tools to identify the failure mode and probable causes. This insight will enhance the information you get from your tool or metalworking fluid supplier.
This technique also reveals issues with your machine/tool setup, coolant, filtration, tool geometry, coatings and substrate choices.
These techniques deliver process improvements every time they are applied. Use them to establish process baselines and measure continuous improvement.
Use these techniques to develop educational programs for your operators and engineers. Contact us for more details.
Overview of Seminars & Programs These programs are designed to address the gaps in basic and advanced application knowledge related to machining and grinding operations.Focus is on optimizing the performance relationship between metalworking fluids and tools.The entire package is a fresh, holistic approach to improving your manufacturing conditions.
Coolant Action in the Cutting Zone This educational seminar covers the performance of coolants in the cutting zone, emphasizing effective application, and practical approaches.It reviews basic knowledge often overlooked in manufacturing practice.Broach tools are used as the model due to their relative high cost, long delivery dates and fast wearing characteristics.
* Designed for any level machine operators, floor supervisors, skilled trades and process engineers responsible for machining and grinding with straight oil and water based lubricants. The program is a prerequisite for getting the most out of the other programs. The Cost of Manufacturing This short program covers all costs of a specific process, culminating in an actual cost per piece produced.Included are the costs of chemical and water, manpower, filtration, disposal, tools, regrinds, scrap, downtime, and depreciation.A spreadsheet is made available to help compare different metalworking fluids, tools, filtration, and maintenance techniques.It can be used to monitor continuous improvement in a specific manufacturing system. * Designed for line supervisors, department managers and process engineers, who are responsible for a particular stage of the cost of the part being manufactured.Used for following the continuous improvement, focusing on central coolant systems. Troubleshooting Coolantsin Central Systems Problems covered are odor, rust and stain, loss of filter efficiency, poor emulsification, residual films, dermatitis, foaming, poor tool or wheel life, poor microfinish, poor part size control, paint removal, smoke or excessive misting, clinkering of chips and swarf, fungal growth, seals or V belt failures, and stringy chip problems. * This interactive workshop is for those group leaders and members who wish to optimize the performance of their central coolant system and manufacturing conditions.It is for those central system managers who cannot determine how their problems are related to current floor practices or system maintenance.
Tool Wear Patterns & Process Improvements This advanced program covers the various failure mode patterns found on broaches, drills, taps, reamers, shapers, hobs and disposable inserts.It can be customized using the worn tools from a specific process, making it very effective for continuous improvement.Specific remedies are suggested for each type of wear pattern.Persistent follow up is available to ensure proper execution of the recommendations.
* Tool engineers, process engineers and their management will gain an understanding of why tools are failing and what should be investigated to correct it.Anyone seeking to bridge the knowledge gap between cutting lubricants and tools will gain from this seminar.
Services:
Tool analysis of wear patterns and diagnostic services, including microphotographic evidence, problem analysis, and recommended actions.
Process recommendations to reduce your costs of manufacturing.
Persistent follow up to ensure success to reduce the cost of manufacturing
Other services available through MEI 1. Job element sheets for specific machining processes 2. PFMEA’s 3. Control & reaction plans 4. Custom Manufacturing Process Optimization Programs 5. Tool, coolant, & machine data evaluation programs 6. Manufacturing problem anticipation & resolution 7. Continuous Improvement Programs - Kaisen events 8. Training programs - General and specific machining processes 9. ISO 9001:2000 consulting, coaching, and guidance.
