The HAAS VF6 Vertical Machining Center

The tool changer frees up the machine operator for other duties and allows for lights-out operation. "Since the machine can be run unattended for the completion a part, it has been possible to organize our work so we can do the shorter jobs during the day and the longer jobs at night," says Tim Droese, the machine operator. "Before, we couldn't run at night without a second-shift machine operator. This is much more efficient use of workers and machine time." We are seeing labor savings of as much as 80% with benefits to the customer of shorter lead times and lower tool cost.

The tool magazine can hold 25 tools and change tools in 2.8 seconds. The extra large 60" X 30" table allows for multiple set-ups, as well as larger work pieces.The machine is also more accurate and can hold tighter tolerances than with the equipment we used previously.

"An important characteristic of the new machine is its compatibility with new tools with through-spindle coolant capability," says Tim. "Coolant is fed in through the cutting tool itself which allows faster, less interrupted tool travel and also blows out chips automatically. Instead of running a 1/8" drill at 900 rpms and cutting at four inches/minute, the VMC can run it at 5000 rpms and cut at 30-35 inches/minute. And it's accurate to a tenth."

An example of a job that has benefited from the Haas is the machining of hot-rolled steel plates, which we have been producing for a local company for several years. Each requires, among other things, circular placement of several 4-inch diameter holes accurate to within .0002 of an inch in size, as well as ±.0005 in location. Using our old processes, each plate took 3.3 hours;. machining the plate in the VF6 takes one hour - a reduction of 70%. And it is much more accurate and consistent than in the past.

Punch holder, hot-rolled steel plate

Punch Holder Base

Another example is a punch holder base that we have been making for several years using conventional technology. This was previously drilled and milled in one machine (our Pratt & Whitney CNC), then tapped and chamfered in the drill press,
then sent through our wire-EDM department to accurately
finish dowel locations and sizes. This is now finished
completely in the VMC except for the chamfering of the
bottom sides of holes. This is done in the drill press. We were
able to reduce machining time by 66%.

Our goal is to cycle 90% of our die sets, strippers, punchholders, and die blocks through the VMC.

A specialty tapping machine by Ultra Tool (above)

--Box lug (left)

We produce a part called a "Box Lug" with a threaded hole (see photo) for a current customer. This part is used on an electrical enclosure. We produce about 150,000 of these parts a year. Our original technique was to hand load the stamped parts onto a turntable, position the table, and cycle the machine to cut the threads. We could produce 544 parts per hour. When production began in 1996, volume requirements didn't justify fully automating this process. As requirements increased, it became appropriate to apply our automation expertise to reduce cost. We developed a specialty machine using a vibratory bowl feed and a Speedycut tapping machine to automate the process. It orients the parts, positions them for tapping, taps the hole, and ejects the part. Electronic sensors detect malfunctions to provide zero defects.

The machine will tap 800 parts an hour unattended. All the operator has to do now  
is load the hopper and is then free to do other things. We expect it to save Ultra as much as $15,000 a year. At that rate, the machine will pay for itself in about two years. This investment will eventually allow us to reduce the parts price to our customer.

This is the type of machine design/build that Ultra is particularly good at. Let's discuss
your needs and what we can do for you.