Aluminum Extrusions – Time Study and Test
Click image to see the actual trial video
General
Observations
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We had a
limited time to do the trial on a local customer’s machine in
between their regular production and we only had one sample of
each aluminum extrusion, so we had no opportunity to refine our
approach prior to running each test.
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A new
operator on the customer’s machine had also unfortunately filled
up the coolant tank with undiluted coolant. The coolant should
be diluted 20:1. The foaming coolant on the trail videos is not
the normal situation and will not occur with the correct
dilution.
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We used a
regular drill bit sharpened for structural steel. We did not
experiment with drill geometry for aluminum.
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We reduced
the drill feed rate, and we increased the drill motor
RPM.
-
We also
reduced the clamping pressure to reduce the compression
on the extrusion; unfortunately we forgot to back off the
approach speed of the drill so there is a bit of product
movement on first contact. All these parameters are easily
adjusted by the user, so with more experience the ideal settings
could easily be achieved. It is also very easy to create you own
custom fixturing for long production run items.
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The customer
has a two year old Avenger that does not have the latest
Peddimat update for tubes installed. The older version of the
software retracts the drill after it has penetrated the first
side of the extrusion, and then sends in the drill again to
drill the far side. The newest Peddimat update sends the drill
through both sides before withdrawing. On this extrusion this
saves approximately 2 seconds per hole.
-
In a regular
production situation, the client will refine a more suitable
approach based on the products they are running
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A. Large Extrusion
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We did not
have an extended length drill available, and were thus not able
to drill the far side on two of the holes. With the extended
length drill bit this will be no problem. We added 14 seconds to
allow for the two additional holes on the far surface.
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Time taken to
drill 26 holes (13 holes through both sides of the extrusion)
was 197 SECONDS (3mins 17 secs)
-
With the new
software update drilling through both sides without retracting,
the time will be approximately 167 seconds (2 mins 47
seconds)
-
We believe
that this time can easily be further reduced with more testing,
using different drill geometry and different settings on the
Avenger.
B. Small
Extrusion
-
On the small
extrusion we were able to drill through both sides of the
extrusion with the regular length drill bit.
-
Since the
holes to the lower edge of the profile are located so close to
the edge, the drill bit would make contact with the table stops
designed to locate the profile. This is easily remedied by
adding a length of ½” flat bar under the profile to raise it off
the table.
-
The extrusion
calls for a tool change to drill tow different diameters. This
tool change adds 40 seconds to the overall drilling time, and if
the same drill diameter could be used for all holes this would
reduce the overall time by 40 seconds.
-
Time taken to
drill 24 holes (12 holes through both sides of the extrusion)
including the tool change was 202 SECONDS (3mins 22 secs)
-
With the new
software update drilling through both sides without retracting,
the time will be approximately 178 seconds (2 mins 58
seconds)
-
By using only
one drill diameter for the entire extrusion and using the new
software update, the time will be approximately 138 seconds
(2 mins 18 seconds)
-
We believe
that this time can easily be further reduced with more testing,
using different drill geometry and different settings on the
Avenger.
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