Challenge Machine continues to add high-speed equipment for the increasing amount of micromachining work it is performing. Here are some lessons it has learned along the way, using tools as small as 0.001 inch in diameter.
What’s interesting about Challenge Machine is the range of equipment—and available spindle speeds—this shop has added over the years to perform micromachining work. In fact, two of the shop’s machines have 100,000-rpm spindles, enabling them to effectively use end mills as small as 0.001 inch in diameter (one-third the diameter of a human hair). For most micro-milling work, Challenge Machine uses end mills from Performance Micro Tool. Improvement in micro-tool geometries and finishes have been key to enabling the shop to get the most out of its high-speed equipment. Once a shop finds its niche, it is essential that its staff keeps up with the latest technology for the favorite process and learns tips and tricks along the way to stay competitive and efficient for its customers.
IQ300 Micro Milling Machine for Ultra Precision Performance
Makino also offers their iQ300 Precision Micromachining Center that incorporates the latest advancements in machine and spindle design, and unparalleled component temperature control. This machine also utilizes 0.005 micron scale feedback for superior sub-micron accuracy. The iQ300 is the ideal precision micro milling machine for manufacturers of LED tooling, optic surface finishes and other high-tolerance machining applications. The machine delivers wide ranging capabilities from sub-micron machining accuracy and repeatability up to macro-scale machining applications.
The iQ300 micro milling machine is built with a state-of-the-art linear motor design, 0.005-micron scale feedback and unparalleled component temperature control. Together, these features provide precise and predictable machining results, eliminating continuous process parameter adjustments due to tool positioning error and thermal distortion. The machine can effectively measure tool lengths to sub-micron levels of accuracy and repeatability, providing for simple and predictable tool blends with various cutting tools, spindle speeds and machining depths. Its large work envelope, wide-ranging travels, and flexible spindle design provide for high utility in micro part production, as well as groundbreaking research and development.
The iQ300 features a 45,000 rpm HSK-E32 spindle equipped with a patented core-cooling, under-race and jacket spindle temperature control system that virtually eliminates thermal growth, deflection or vibration, even during long hours of high-speed machining. To ensure microscopic blending and matching of surfaces when machining with different tools, the iQ300 integrates the proprietary Hybrid Automatic Tool Length Measurement System (ATLM). A 40-tool magazine assures a wide variety of tooling to address an extensive variety of projects. The worktable measures 600 mm x 400 mm (23.6 in x 15.7 in) with X-, Y-, Z-axis travels of 400 mm x 350 mm x 200 mm (15.7 in x 13.8 in x 7.9 in), respectively. This large work table and ample travels assures the capability to do multiple set-ups and utilize precision chucks and vices.
Tornos SwissNano – Micromachining on a CNC Swiss Lathe
The Tornos SwissNano, a micromachining lathe with curved front-access window and tablet control. The Swiss Nano is intended to be a resolutely, uncompromising watchmaking machine and its kinematics enable it to produce 75% of the moving parts in a watch. The 4 mm capacity machine has a frontal design for easy access to the machining area. The graphic tablet displays all the basic production data (workpieces, products, machine, bar changeover, fleet monitoring). At a glance, the operator can access all the data for a specific machine or for a whole fleet of machines.
The SwissNano includes a precision tool setting system using a sensor and feeler probe, with the aim of this being to provide a user-friendly system able to position the tools to within 3 to 8 micron, according to bar diameter. With a footprint of 1.8 by 0.65 by 1.6 m (LWH) and a maximum workpiece diameter of 4 mm, the Swiss Nano incorporates an X1/Y1 tooling platten with seven turning tools having maximum shank dimensions of 8 by 8 mm. The Swiss Nano also has the capacity for three end-mounted tools having a diameter up to 16 mm, as well as another two end-mounted tools for counter-operations. To meet the specific needs of the end user, the Swiss Nano is available with optional extras, such as a gear hobbling device, transverse drilling, HF spindles and polygon tools.