CNC Machining of a spiral die at Zala Machine on our Mori Seiki NTX 2000 

North of 10k

It was +-.005", not really precise but just had to reach the back side and break thru in the center at an angle. I milled a start about 1/2" deep to the same diameter as the gundrill. That leads the gundrill to drill a straight and precise hole.

Thanks and yes I do program all my parts myself including this one.

My previous job was it to polish all these channels in a high-gloss surface ;)

operating the machine with the door open, that's how all the safety freak accident videos start.

No it was hand polished.

it doesn't have to be hand polished. high surface speed, depth of cut with the right geometry tip and you'll get a up to ra0.5

This is for plastic industry and customers require mirror finish even though it measures around 4rms in most spots. Any visible line is unacceptable.

Very nice work

All plastic extrusion surfaces require very smooth surface finish.

Ok no problem I think I can walk you through it. On head 1 go into settings and press 1 to go into the operation panel. Once there page down to the 2nd page and you will see an option (2nd spindle/tailstock) switch over to tailstock and exit back into settings screen. Now you should have a new option #22 for Tailstock. Go into #22 and you have to fill in the options for Thrust (how much kN you wanna push with) Thrust Position (where you are touching your work piece) Approach Position ( .2" away from the work piece) Retract Position (I do about 2" away from the part) and Thrust Tolerance (I set that to the max of .2") Then you use the Tailstock/2nd spindle buttons on the control (next to memory) to approach with your subspindle. Press once to get your retract position, 2nd time it should go to approach and then to the thrust position automatically. If you did everything right the light on the button for the subspindle movement will light up and the thrust on the tailstock screen will shoot up to whatever you set it at. Hope this helps. Any questions do not hesitate to ask.

Thanks heaps for the reply, i'll have a look in the control tomorrow morning! Do you use esprit for programming? i'm an adult apprentice and use esprit and an 12 month old ntx 2000. no one knew how to use it so i'm self taught for the last 6 months. steep learning curve

I though I was very good before this machine came in and I had at least a 6 month learning curve just make my first good parts, but yes I do program in Esprit. You have to be a good machinist to make good use of this machine. You can make very beautiful complex parts on the NTX. What kind of part you run?

Come to Jersey I am looking for someone that can run my machine. I'll teach you everything I know.

Black Market Machining haha I'm Australian else I would, so much I don't know. We get a big mix, defence contractor but get some mining and drilling. been running bronze for 2 months, 2000 parts. Got a heap of 4140 bushing and shaft work this week with a +0.00/-0.01mm call out. +/- 5 microns.. THAT will be a learning curve.

It depends on the specifics. If you have parts you need made send email to Sales@zalamachine.com

The steel was 4140 heat treated to 28-32 Rockwell. The Insert I use for finishing is a VNMG from Sumitomo. My feed is .004" per revolution and speed around 700 surface speed.

Marcin Zala man that was awesome

Marcin Zala what was the rpm at tapping the holes and what was the tap bit that u used and thanks a lot

Not a problem. The actual RPM of the tap was 300 rpm but I sped up the video a bit so it seems like it is spinning faster.

Marcin Zala. awesome man love ya

Hand polishing.

I run the part from blue print to final polish. Programming and all.

Invite me to India and pay for my trip I will teach you how to program this.

These small dies go for about $8-12K for just this one piece. We are doing larger ones for around $20k a piece. With that said we only do the smallest of the dies, our customers have in house capabilities that go much much bigger. The one in the video is an 8" dia single layer die. Our customer is doing a 96" dia 7 layer die.

Awesome.

Measured the door interlock key and made myself a handle with the key shape. I use it all the time when working on the Mori.

Thank you. I thought there is a hidden command or "bit" to set. I would like to use this only, when I wanna get in contact with the surface with jogwheels, to have a better view.

Not a problem and thanks for watching. When you make a nice part like that and video tape the machining of it let me know, I'll be sure to subscribe.

Its not about the destination, its more about the journey... As grumpy as Oscar is, i think he has a point.

Arrogant.

Oscar Faustino Costa o

Yes you're right, it would be nicer to see the machining of the whole part, than we can stare at our monitor for probably 4+ hours... :-)

Details please. But there's very little chance that I would leave what I'm doing right now. I like it too much.

It survived but chipped a bit. Resharpen and keep going.

you can't machine hardened steel

lmao :) not sure if you're joking or you've never tried searching youtube for "hard machining" or "hard turning" :)

Depends on the type of hardening. If you use Plasmanitriding (depending on the steel), there is only a hardening depth of maybe 0.1 - 1.5mm. So you just need to get through the hard area. Millers nowadays can do that easily.

And hard turning itself is no magic at all. We use CBN to finish the hardened parts and roughness below Rz1.5 are absolut possible.

Ingo you are correct and in the not so older days we used ceramic inserts. chronok it's only shiny because they polished it before doing the final mill work.

For a change.

Melted plastic flows thru the angled holes and out through the spirals.

It's used to produce plastic pipes ir plastic foil

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