In order to maintain long-term competitiveness, manufacturers are striving to find a way to increase productivity and profitability without increasing costs. In addition, strong competitiveness and higher productivity help to shorten the lead time of the product while maintaining the number of existing positions and employees. To achieve these goals, tool manufacturers are working to develop new tools that have less cutting force, are more efficient, have no vibration, and have smoother chip removal.
With the continuous development of hole processing technology, the newly developed tool has a unique geometry and can achieve higher metal removal under the premise of lower energy consumption. The use of such tools not only reduces costs, but also significantly increases productivity.
Efficient machining and mass production of ultra-precision holes
The machining quality of the hole is affected by the depth of the hole, the rigidity of the workpiece clamping, the quality of the coolant, and the way the chip is removed.
As an upgrade to the previously successful product line CHAMDRILL and CHAMDRILLJET, the SUMOCHAM continues the characteristics of the quick-change tool head with its cutter head and sipe design. It has been improved with high metal removal rates and high economics due to replaceable cutter heads.
Beam magic chameleon drill
SUMOCHAM's innovative clamping mechanism increases the productivity while changing the number of cutters. The drill rod has a spiral inner cooling through hole for more durability and a more reliable structure.
Replaceable cutter heads with four different standard geometries for drilling steel, difficult-to-machine materials, cast iron and aluminum alloys. The SUMOCHAM has a diameter range of 7-25.9 mm and a depth of 1.5 xD, 3.5 xD, 8 xD and 12xD.
The unique sipe design of the SUMOCHAM makes better use of the cutting force through the mechanical structure. The cutting force is successfully converted into a clamping force, and the blade is clamped by the reaction force of the sipe. Therefore, it can be understood that the larger the cutting force, the larger the clamping force. The contact area produces less strain due to the clamping force and does not develop plastic deformation, which increases the number of replaceable cutters by at least three times that of existing chameleon drill bits. A more important advantage is that the new clamping structure increases productivity by 50%. Lower clamping torque reduces internal stress in the sipe and increases tool life. The joint of the cutter head has a cylindrical design, and the clamping portion of the joint portion is larger, and the thrust portion is designed to eliminate the possibility that the cutter head is pulled out and falls off.
In addition to the above characteristics, the SUMOCHAM series also features high rigidity, high spiral angle chip flute surface finish and smoother chip removal. Its cutting position has excellent chip control, which minimizes built-up edge and allows for high cutting levels while maintaining high precision. In addition, the cutter head clamping mechanism helps to extend tool life and allows the number of cutters for a single drill pipe to be replaced more and more economical.
A heat exchanger manufacturer asked Isca for a hole machining solution that required drilling 1,700 holes on SAE carbon steel tube sheets.
For this solution, Iskar engineers need to achieve two goals: first to shorten the processing cycle; secondly to improve production efficiency and profitability while ensuring the same level of accuracy.
Based on the above considerations, Iskar engineers used a 25 mm diameter beam-shaped chameleon drill (SUMOCHAM) in the program. Compared to the tools previously installed on the machine, the drill can increase cutting speed by 30%, feed rate of 25%, and feed rate of 33% of the table. The tool change time is only 10%. The end result is a 40% reduction in drilling time for individual workpieces and a 63% increase in productivity, and a total cost reduction of 21.4% due to a combination of factors. With all of these advantages in mind, heat exchanger manufacturers have no hesitation in promoting the application of this solution on their production lines and are very satisfied with the improvement in tool performance and productivity.
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