5 AXIS MACHINING is the future. Our latest acquisition is the industry coveted DOOSAN DVF-5000 with a 8 PC PALLET CHANGER. The DVF is a newly designed 5-axis vertical machining center that’s fully packaged to handle diverse 5-sided or simultaneous 5-axis applications to meet a variety of customer needs. These VMCs offer a diverse range of tailored options and automation that make them ideal for unmanned machining. They come automation-ready and supplied with an optional/retrofittable AWC (Auto Work piece Changer) that provides additional productivity by offering up pallets to feed the machine for unattended machining. The 5000 will hold 8 pallets.
Does your company currently rely on 3-axis machining? While 3-axis machining has its benefits, it does pose certain manufacturing limitations. The primary difference is that 5-axis machining introduces the element of rotation of the A and B axes. In addition to enabling faster production of complex shapes, the 5-axis parts production process results in a higher-quality surface finish. Other important 5-axis CNC machining benefits include:
The enhanced capabilities of the 5-axis machine results in decreased production times, which translate into shorter lead times for your production projects. This allows you to provide better service to your customer base.
5-axis machining and milling offers a level of precision that 3-axis processes cannot replicate, which is crucial if your finished products must adhere to strict quality and performance specifications. 5-axis machining also eliminates the need to move the workpiece among multiple workstations, thereby reducing the risk of error.
It is feasible to produce high-quality 5-axis machined parts with the use of shorter cutters, which can reduce the vibration that frequently occurs when machining deep cavities with a 3-axis process. This typically results in a smoother surface finish. The use of a shorter cutting tool also allows for a higher cutting speed without putting excess pressure on the tool.
Many companies find that 5-axis milling increases the types of products and services they can offer to their customers and prospects. This enables them to capture a larger segment of the market and take their entire business operation to a whole new level.
As many as 60 percent of the parts produced in CNC shops these days require five-sided machining. As such, 5-axis milling and machining services are in high-demand for various applications in a wide range of industries. A primary consumer of 5-axis machining services is the aerospace industry, where machined parts must be designed to conform to the aerodynamic shapes found in most types of aircraft. 5-axis production parts are also key components when manufacturing products for the food processing, pharmaceutical, medical and energy production industries
WIRE EDM is a cutting operation that utilizes a Computer Numerically Controlled and electrically charged brass wire to “burn” through a raw block or stack of material, producing an extremely accurate cut and clean finish suitable for aerospace and medical applications.
A1 JAYS MACHINING has the capability to manufacture production parts and tooling components of tight tolerance by utilizing Wire EDM. We specialize in production runs of precision components and tube cut offs, creating fixtures, building spare tooling for metal stamping dies, and sharpening shaped die components.
We use Wire EDM for customer contract work as well as our internal requirements. A1 JAYS MACHINING can assist your company with its Wire EDM needs from design assistance to final completion. Fixtures used for production runs are designed by our talented Design Engineering Team and built by our experienced toolmakers. Our programmers use CAD information to produce high-volume and low-volume Wire EDM parts in our state-of-the-art Wire EDM machines and to our customer’s custom specifications.
Wire EDM @ A1 JAYS MACHINING is a core machining capability of ours. We specialize is extremely complex FLEXURE manufacturing using this technology while holding extrmely tight tolerances.
Wire EDM @ A1 JAYS MACHINING is a core component of our Tool & Die maintenance and repair capabilities. Our Wire EDM department supports our Maintenance Department by providing sharpened or replacement tooling components in order to repair a worn or damaged tool. All jobs that enter our Wire EDM department are analyzed by our Quality Assurance Department to ensure that all dimensions are correct and geometries have been met. Blocks are checked for squareness and absolute size. In-process SPC data collection is utilized to maintain quality in production modes.
We currently run 4-axis machines capable of wire diameters from .004″ to .012″ Our machines have a cuttable travel (XYZ) of 20.5″X 14.5″X 12.0″and minimum corner radius of .0023″ as necessary. We have the capability of working with material in our machines up to 2200 pounds. Wire EDM machine accuracy to within .0001″ repeatability to .00005″ A1 JAYS MACHINING also has one CDM Drill which allow holes to be drilled as small as .012″ or as large as .250″with a maximum work piece height of 8.0″
LAPPING MACHINES are a type of precision finishing machine. Lapping is a loose abrasive machining process that differs from honing or grinding because the abrasive action comes not from a solid abrasive (like a grinding wheel) but from a slurry--abrasive particles mixed with oil or water. The slurry forms an abrasive film between the underlying lapping plate and the parts to be lapped. The part stock is gradually removed through the rolling and sliding action of the abrasive grains between the lapping wheel and the workpiece. The slurry, along with the removed stock, drains away from the table.
Lapping machines create truly flat surfaces--normally up to 0.001mm, with surface finishes of better than Ra.01. Overall, lapping produces extreme dimensional accuracy, corrects minor imperfections of shape, refines surface finish, and produces close fit between mating surfaces.
Lapping machines may be beneficial whenever absolute flatness, parallelism, or surface finish is essential. Since it is a loose abrasive process, irregularly-shaped or non-magnetic parts can be easily accommodated. Lapping removes stock quickly, with no clamping or heat distortion, no expensive tooling required, and virtually no maintenance. Inspection and production costs are also lower, since the machine can be run by semi-skilled operators. Parts can be run as easily in small batches as in production processes.
The process eliminates warping, since parts are not clamped and very little heat is generated. Lapping produces no burrs and actually removes light burrs. Any part the machine can accommodate can be lapped, regardless of thickness or shape. However, lapping requires a level of experience and skill, and trial and error may still be needed to get the optimum results.
We @ A1 JAYS MACHINING currently run 3 LAPPING machines capable of wire diameters from .004″ to .012″ Our machines have a cuttable travel (XYZ) of 20.5″X 14.5″X 12.0″and minimum corner radius of .0023″ as necessary. We have the capability of working with material in our machines up to 2200 pounds. Wire EDM machine accuracy to within .0001″ repeatability to .00005″ A1 JAYS MACHINING also has one CDM Drill which allow holes to be drilled as small as .012″ or as large as .250″with a maximum work piece height of 8.0″
LASER MICRO-MACHINING is one of the core competencies of our business. Thin wall tight tolerance part manufacturing is the specialty of our LASER LAB. Tube or Flat application - ON-AXIS or OFF-AXIS. We can execute. Prototypes in 3-5 business days flat. We strive to meet your desired price point and timelines on each and every project we undertake. Our fully function and equiuped LASER SOLUTIONS APPS LAB is capable of quick run prototypes as well as high volume production runs