Understanding Swiss Screw Machines

Swiss Machine

HISTORY OF SWISS MACHINING

The first-ever Swiss Screw machine was developed in Switzerland back in the 19th century. This machine quickly made its mark as the premier lathe for the production of small and complex parts.

Swiss machines differ quite a bit from conventional lathes, as Swiss machines move the bar stock through a bushing using a sliding headstock. The headstock moves the material forward and backward, exposing only the portion of the material being machined.

When it comes to utilizing the gang tool and guide bushing, it provides close proximity to the cutting device to the material being cut, minimizing deflection and delivering an increased precision while holding tight tolerances. As with other machining processes like lathes and mills, the Swiss CAM automatic machine has led CNC Swiss machines to better-streamlined automation.

WHAT’S THE ADVANTAGES IN A SWISS PRECISION MACHINE?

PRODUCTIVITY

Currently, the Swiss Screw machines in use will rely on a computer numerical control (CNC) unit to process the parts designed to meet specifications by following a coded, programmed instruction without a manual operator.

With room for over 20 different tools and the ability to perform multiple operations concurrently, complex parts can now be completed in one operation on the machine as opposed to multiple operations that traditional lathes requiring.

CNC Swiss machining also offers the capabilities for a secondary process such as milling, slotting, cross-tapping, and cross-drilling, and eliminating the need for any additional machining once the parts that are turned come off the machine.

HIGHER VERSATILITY

Swiss machines usually work in diameters under 1 ¼” and, with the majority of work that is performed is smaller than ¾”, but they also excel at producing tons of different parts with lengths greater than the diameter. The ability to make slender, more extended parts while reducing deflection is a huge benefit to running those larger length-to-diameter parts on a Swiss machine.

LARGER COST SAVINGS

The new Swiss machines required smaller work-pieces, which allows you to use a smaller bar stock. The lower cost of these materials turns into lower overall production costs, all without sacrificing any product quality.

The Swiss machines can now achieve greater accuracy and precision, even in complex and intricate designs. With a good bar stock quality, the swiss machine will allow for tight tolerance, often eliminating the need for any outside grinding service. Additionally, once your machine has been set up and provisioned, you will notice that some parts will allow for an unmanned runtime; this will increase your labor efficiency in the shop while cutting down lead times for your customers.

APPLICATIONS USES OF SWISS MACHINES

Swiss WatchesThe machines were originally created a long time ago to manufacture screws for the watchmakers and their industry; over time, machines have evolved across multiple industries. While these machines still create parts for high-end watchmakers, they also can be found making screws for a range of applications, including:

  • Medical components
  • Industrial components
  • Aerospace and defense industries
  • Components for musical instruments

With the ability to machine many different types of metals with tight dimensional tolerances, there is next to nothing that the Swiss machines cannot do when it comes to machining parts.

WHAT MATERIALS ARE USED IN SWISS MACHINING?

A swiss machine can employ a variety of materials depending on the specifications required from the components. These range from common materials like exotic alloys:

  • Aluminum
  • Brass
  • Bronze
  • Carbon Steel
  • Copper
  • Plastics
  • Stainless Steel
  • Steel
  • Tool Steel
  • Titanium
  • Exotic Alloys

TYPES OF SWISS SCREW MACHINES

Swiss screw machineThere are a few types of swiss machines on the market today.

Swiss- and Turret-Style Machines

The Turret-type screw machine produces very similar results to the Swiss-style machines. One advantage of the new CNC Swiss screw machine is that many more tooling fixtures can now be applied, and, despite screw machines typically being “single spindle,” the possibility is also thereof using it as a double spindle machine. This time-saving feature effectively cuts out the operator.

This part is automatically transferred from the screw machine to another machine for the secondary operation saving in labor cost for which an operator would generally have to be there to complete. Turret-style screw machines also come equipped with a transfer attachment that can also perform this function for you.

The Turret type, also known as Brown & Sharpe, named after its first manufacturer, mounts the work-piece on a vertical ram, which works into the lathe. The Swiss-type was originally named after its place of origin where swiss watchmakers used it for precision components, mounts the work-piece on a rotary slide. While these two types function differently, their benefits and output are essentially the same, although the Swiss screw machine is better at more precise work.

CNC Swiss Machine – Applications

The other is Computer Numerically Controlled (CNC) machines, and these use a CNC unit to control all of the tools, which allows parts to be made to exact specifications.

The CNC Swiss screw machine, which is also known as CNC lathes, can work on multiple axes for fast results. Both machines, automatic and CNC driven, will take some time to configure but are cost-effective when producing various parts in volume. They are not typically the ideal solution for your small one-off prototyping. However, because of the variety of metals they can work with, they are a great choice when it comes to creating parts from different types of metals.

Benefits of the CNC Swiss Machine

When it comes to the CNC machines, they offer a level of control that may not be possible with a standard automatic Swiss screw machine. The CNC unit allows the use of tools on multiple axes, allowing more tooling for both milling and turning. Cycle times of the machines are reduced, and more detailed parts can be created with the use of the abilities provided by the CNC machines.

Operations can be performed in a shorter period when using a CNC Swiss machine. This screw machine can rotate parts at up to 10,000 RPM with an accuracy level ranging between 0.0002 to 0.0005 inches. In addition to being extremely precise, the CNC Swiss lathe also reduces waste and gives more flexibility when machining a specific part.

Swiss machining is a viable manufacturing process for many industrial application needs. Compared to traditional turning processes, it offers greater precision, versatility, productivity, and cost-effectiveness.

Screw machines are automated lathes that are used to machine turned parts. The appellation “screw machine” might be misleading, as they don’t screw anything in, nor do they thread materials, although this is one of their functions. Basically, the machine components by spinning on a very quickly rotating lathe, which shaves the metal down to the desired size.

With over two decades of experience, we have the knowledge, skills, and tools to fulfill any CNC Swiss precision turning need. To learn more about our services and capabilities, contact us today for pricing details.

If you are looking for a partner for your next Swiss machining project, turn to the experts at Salco Global.

Understanding AS9100D

AS9100D

 

Salco is thrilled to have received the AS9100D certification in February 2019. This latest certification applies to our Denver facility. It symbolizes Salco's dedication to continuous improvement and the desire to exceed any customer quality expectations.

What is AS9100?

The term AS9100 is an aerospace Quality Management System (QMS) standard. This is based on the international QMS standard ISO 9001 and provides additional requirements directly specific to the aerospace industry.

This sector is governed by the FAA, space, and defense regulations. Having an AS9100 QMS, it is used to help businesses adapt to the evolving needs and demanding requirements put in place by the aerospace industry.

Not only does it provide a needed framework for businesses to operate by, but it also provides your customers with confidence about the quality and reliability of the products they purchase from your company.

What is AS9100 Rev D?

The international QMS standards are updated often in order to stay relevant to the industry needs and also adapts to emerging trends. The most recent update that went from Rev C to Rev D of the AS9100 was released back in September 2016, and companies were given until September 2018 to transition to the new Rev D standard.

The revision also coincides with the AS9100 standard's newest revision of ISO 9001 released back in 2015. The current version of AS9100 Rev D emphasizes companies creating value for their customers by integrating the QMS requirements into their business processes.

In this latest update, the major revision areas pertain to product safety, risk management, counterfeit prevention, configuration management, and human factors.

Salco's commitment to quality

Salco was first added to the AS9100 certification, and it's the list of quality certifications back in 2007 to help support the dynamic needs of the aerospace industry and the customers served, like Boeing.

Salco underwent an extensive upgrade audit at its manufacturing location to obtain the AS9100 Rev D certification. Conforming to the new revision of the AS9100D represents our compliance with the most current requirements based on the aerospace standards.

Conformance to these standards in place helps to ensure that Salco maintains the highest quality products and process control in our manufacturing facility.

The AS9100d standard also includes the ISO 9001, the quality management system requirements that define additional aviation, defense, and space industry requirements, descriptions, and notes.

The requirements are specified in the standards and are complementary (not alternative) to the customer and applicable statutory and regulatory requirements.

If there becomes a conflict between the customer and the standard's requirements, the regulatory requirements, or the applicable statutory, the latter shall take precedence.

The International Standard is set to layout the requirements for a quality management system and is defended as when an organization:

a. needs to show its ability to consistently provide products and services designed to meet the customer and any applicable statutory and or any regulatory requirements, and

b. aims to increase the overall customer satisfaction through a practical application system; this includes improving the system and the assurance of conformity regarding the customer and applicable statutory and any regulatory requirements.

The requirements of the International Standards are designed to be generic and are intended to be applied within any organization, regardless of its size or type of products or services they provide.

ISO 9001 – What is it and why is it so important?

What is ISO 9001?

ISO 9001 is recognized as the international standard for creating "Quality Management Systems" (QMS). This was created by the ISO (the International Organization for Standardization).

This well-known standard had its most recent updated back in 2015 and is now referred to as the 9001:2015 version of the ISO. For this version to be updated and made effective, it first had to have been approved by most member countries to be known as the current updated to the internationally recognized standard.

What is quality management systems?

According to the ISO definition, quality management systems are the standard in which a company's QMS requirements are defined. This system creates the processes, policies, and procedures necessary to provide products and services designed to meet customer and regulatory demands and improve overall customer satisfaction.

Quality management systems are the foundation of any quality assurance activity.

Why is it critical to have?

ISO 9001:2015 is known internationally as the recognized standard for creating, implementing, and maintaining a company's quality management system.

This standard was designed to be used by companies, no matter their size or industry. As the international standard, 9001 is recognized as the basis behind any company that wants to create a system that is designed to ensure customer satisfaction. As such, many corporations today require this certification from their suppliers.

Having the certification provides your customers the needed reassurance saying you have implemented a Quality Management System in place that is created on the seven quality management principles.

This certification is such an influential and essential industry standard that industry groups often use parts or all of the 9001 standards, such as the ISO 13485 for the medical devices industry, the AS9100 for the aerospace industry, and the AITF 16949 for the automotive industry are just a few examples.

A recent survey performed in 2017 for ISO certifications under 900 1 showed that, despite the global recession, the total number of companies that have implemented the ISO 9001 standard is still growing worldwide.

What is the current ISO 9001 standard?

The current ISO version is 9001:2015. The ISO 9001 2015 standard is often called ISO 9001 revision 2015. This version was released back in October 2015 and replaced any of the previous revision ISO 9001:2008.

This update includes many of the processes from the previous revisions to the ISO standard, with a greater emphasis on understanding the context of the organization and risk-based thinking.

Is ISO 9001 worth it?

The benefits behind having the certification cannot be overstated; companies of all sizes have used the standard to significant effect, securing cost savings and additional revenue.

Here are just a few of these benefits:

Improve your image and credibility – If your customers see that a recognized certification body has certified you, it will show them that you have implemented a system focused on meeting customer requirements and improvement.

This will improve their trust that you will deliver what you have promised, and it will help you get new clients.

Improve customer satisfaction – One of the main principles behind the ISO 9001 QMS is the concept of improving customer satisfaction by identifying and meeting customer needs and requirements. By providing this, you will grow your repeat business.

Fully integrated processes – By using the ISO, you look at the individual functions within your organization, but you also interact with those processes. By doing this, you will discover areas for improvement and savings within your organization.

Use of evidence-based decision making – Ensuring that you and your team are making decisions based on factual evidence is key to success. Ensuring that your choices are based on accurate information will help you target the resources to correct any problems and improve your organizational efficiency and effectiveness in a timely manner.

Create a culture of continual improvements – With ongoing continual modifications as the main output of the QMS, you can saving time, money, and other resources. By making this the culture behind your company, you can focus on your workforce by improving the processes that they are directly responsible for.

Is ISO 9001 a legal requirement?

No, there are no legal requirements, even though the certification is a requirement for many contracts. There are even awards, such as the Malcolm Baldridge National Quality Award.

Click here to view our proud certification

What Exactly is Metrology

Metrology is defined by the International Bureau of Weights and Measures (BIPM) as “the science of measurement, embracing both experimental and theoretical determinations at any level of uncertainty in any field of science and technology”.

Metrology is how companies guarantee certain comparisons of global measurement results. As an example, metrology is used to help ensure that the parts in the vehicles we drive are accurately and precisely measured, manufactured, and assembled despite the different manufacturing processes language barriers, and measurement systems (such as US and metric) that are used by the manufacturers.

Metrology also incorporates precision measuring tools like the coordinate measuring machines (CMMs) also the precision measurement sensors.

Globally Standardizing Precision Machined Parts
Today’s global supply chains are using the international measuring standards to help precisely manufacture, distribution, and assembly machined parts through out the world.

All different types of factories from different countries can precisely machine identical parts from CAD or drawings. Each manufacturer’s measuring instrument is calibrated with the same specific thresholds.

These calibrations are designed to ensure that all of the parts created will fit together and work as they were intended to. After the calibration phase is over, the production machines are then set and the quality assurance and controls are confirmed.

Types of Metrology Equipment
A coordinate measuring machine is a system that measures the testing product by combining a probe with the coordinate system to measure the geometric physical points of the product.

In addition to accurate measurements, CMMs have the advantage of providing real-time information on the condition of the manufacturing process to the CMM operator. All global CMMs must comply with the ISO 10360 international measurement standards and can be controlled by either an operator or a computer. Five major types of CMMs are used in today’s metrology:

Cantilever:
This is used primarily for measuring master parts.

Bridge:
Most popular with digitizing and scanning jobs for the mold, stamping, and machining markets.

Gantry:
Used for measuring heavy, large parts such as large dies and molds.

Horizontal Arm:
This is used to measure parts in industries such as defense, aerospace, and appliances.

Portable (PCMM):
Handheld 3D and geometric tolerance and dimensioning measurements which can also be ISO 10360-certified.

Touch-trigger:
Touch-trigger probes are the most commonly used type of probe in metrology because they remove touch bias and can be used with computer control.

There are also two major groupings of probes: contact and non-contact. Contact or tactile probes include:

Hand Probes:
Hand probes are designed to measure curved surfaces, but one must watch out for tactile differences that can be caused by the operators.

Touch-Trigger Probes:
This is the most popular type of probes. It simply removes touch bias and can be used by direct computer control.

Analog Probes:
Use CAS technology to measure irregular shapes and contorted surfaces, like sheet metal. Non-contact probes are used for large, complex geometric, flexible parts. They include:

Laser Probes:
Laser probes are a triangulation with a beam of light designed for high-speed component measurements.

Vision Probes:
Vision Probes are designed for high-speed measurements of small, 2D parts with images taken from a camera.

As previously noted, manufacturers from all over the world need to meet or exceed the set specified tolerances of each item tested so they will fit and work exactly as they were designed to.

This quality assurance covers components manufactured from medical devices to rocket engines and everything in-between. In fact, precision measurement technology is used to ensure the quality assurance of measurements up to one-thousandth of a millimeter.