Page 28 - MetalForming August 2016

Progressive Stamping Dies
contribute significantly to rigidity. With the mill’s ample axes travels– 126in.onthex,95in.ontheyand35 in. on the z–Victory can machine large
parts inhouse.
“The bridge mill has significantly
expanded our machining envelope– our x-axis capability has been doubled and y-axis reach has been tripled,” says Meixell. “This gives us a large platform to set up each job one time to machine big die sets for the tools we build.”
Automatic Tool Changer Boosts Efficiency
“In previous years, it was not uncommon for us to outsource $100,000-$200,000 of work annually due to our inability to handle larger sizes,” explains Simonson. “Since we purchased the bridge mill, we have not outsourced any jobs due to workpiece size, and by keeping this work inhouse we have saved 30-40 percent in out- sourcing costs during one year’s time.”
Victory also takes advantage of the
mill’s versatility by running a range of jobs with a variety of workpiece sizes, from small to large.
To improve efficiency, in August 2014, a custom 90-tool automatic tool changer (ATC), the first of its kind installed in the United States, was added to the mill. The ATC has greatly reduced set-up times and increased efficiency to meet tight-tolerance spec- ifications versus Victory’s older machines, which only offer 24-tool selection. Typically, Victory uses 76 tools each day, so tool standardization is key to minimizing tool changes, sav- ing time and reducing required pro- gramming.
“Setups are much quicker because the tools are already loaded into the machine,” says Simonson. “We calcu- lated that we are saving more than $70,000 annually with the 90-tool ATC alone.”
Adds Meixell: “Most shops are trying to accomplish similar work with 30 or 40 tools. We have a dedicated set-up
crew that is very impressed with the time savings as well as the advantage the ATC brings in more efficiently meeting high-accuracy requirements.”
Part Complexity No Problem
Victory tackles many complicated jobs, such as large, progressive stamp- ing dies with tight tolerances and mul- tiple, complex features.
“Some customers give us die spec- ifications totaling 40 pages or more, so we have to be in close touch with them throughout the jobs in order to meet their part requirements,” says Meixell. “The complexity can be daunt- ing, but having efficient machining capability inhouse with the new bridge mill has significantly increased our throughput and accuracy. We can col- laboratively work with our customers who are confident with our capabilities, and so are receptive to our ideas that sometimes include alternative engi- neering/design methods.”
Acquisition of the Feeler mill has far exceeded Victory’s original expec- tations, with the company expecting an ROI of less than three years. Simon- son and his team are impressed with the rigidity and reliability of the mill, and are confident enough to run the machine unmanned.
“We set up a job before a shift ends and run it lights out–sometimes to 20 hr. unattended,” Simonson says. “This allows an operator to multitask, and work on other jobs.”
And, as word has gotten around in the metalforming industry about Vic- tory’s large bridge mill and its capability to take on a broader range of work, Victory is now taking on the machining of large plates.
“We are extremely pleased with our decision to bring in the bridge mill,” says Lynch. “Now we are able to take on new business and increase sales while reducing cycle time and scrap.” MF
Article provided by Methods Machine Tools, Inc., Sudbury, MA; tel. 978/443- 5388, www.methodsmachine.com. Information also contributed by Victory Tool, Anoka, MN; tel. 763/323-8877, www.victorytool.com.
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MetalForming/August 2016
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