BlueSwarf High Performance Machining and
Lean Six Sigma Consulting
BlueSwarf (the “Company”) applies the science of Machining Dynamics to reduce cutting vibrations in the milling process. Reduced vibrations allow customers to run milling machines at higher speeds and deeper cuts significantly increasing metal removal rates and throughput, improving surface finish, increasing tool life, and allowing for part geometries not feasible in non-optimized machines. Customers using BlueSwarf enabled machines typically witness cost reductions in excess of 30%.
This optimization service is applied through a simple tap test of the machine, spindle, and tool combination at the customer site. The data is automatically transmitted wirelessly to the Company which develops and delivers an electronic file (“Dashboard”) that allows the customer to dynamically adjust machining speed and feed rates. Customers receive and have the ability to store Dashboards along with additional critical machining data within the BlueSwarf Tooling Cloud, a secure, online, proprietary cloud based environment.
The core BlueSwarf business model focuses on delivering a tapping kit (laptop and supporting equipment) at cost to end users, resellers, tool manufacturers and distributors who collect the vibration data onsite. BlueSwarf’s “value-add” is the proprietary, rapid conversion of this vibration data into useable solutions for customers. In this manner BlueSwarf is able to reduce its cost footprint and expand revenue and margin through increasing and optimizing its Dashboard production capabilities. Examples of our services are listed below.
Ancillary to the production of dashboards, BlueSwarf provides high-speed machining consulting services to address the complex problems faced in manufacturing environments. These services are intended to complement the primary growth model and are deployed typically in conjunction with Dashboards.
BlueSwarf’s consulting services are provided by the top milling, drilling and boring experts in the field. Many of our consultants hold PhD’s in advanced manufacturing and all have at least 15 years of industry experience. Our staff also include Master Six Sigma Black Belts and Lean Masters. Services provided range from the smallest individual machine and part optimization effort to large scale facility layout planning, manufacturing strategy and lean design. Experts at BlueSwarf have significant experience increasing throughput and reducing costs within the Automotive and Aerospace industries manufacturing chain and have been retained for multi-year engagements by top corporations such as General Electric, Ford, Boeing and Daimler.
ENGINEERING CONSULTATION SERVICES
Our world-class Ph.D.-level senior engineers are available for consultation, including; Machine Tool Assessment: Using our patented technologies, BlueSwarf can test various machine tool models for their appropriateness for a particular part process and determine the following: 1) Horizontal or Vertical Orientation, 2) HSK or Steep Taper Spindle, 3) Spindle Speed Required, 4) Torque Requirements, 5) Bending Moment Limitations, 6) Stiffness and Damping Requirements, and 7) 5-Axis Head or Trunnion Table. Vibration Analysis: Includes modal analysis, vibration monitoring and testing, forced and self-excited vibrations, and vibration monitoring systems. Metrology: Interferometric measurements, positional accuracy, repeatability, velocity ripple, pitch and yaw, thermal monitoring. Tool Design: Selection and modification of tooling systems, modification of current tool designs, design of specialized cutting tools. Process Planning: Hard-to-machine work pieces (flexible fixtures or parts), tool selection and management, part-programming strategies, machining of hard materials. Sensors and Controls: Control of vibration, active and passive damping, force and position control, spindle speed control, sensor filtering and signal processing. Workholding Analysis: Using modal analysis to fingerprint part as fixtured. Analysis will determine where support, additional clamping or damping is required. On-site support will require 2-day minimum and travel expenses.
ADVANCED ENGINEERING ANALYSIS FOR HOLEMAKING
We have developed a procedure for optimizing holemaking operations. It begins by identifying symptoms (Out of Round Holes, Lobed Holes and/or Vibration/Chatter). The appropriate data collection is carried out in the field by the BlueSwarf MetalMAX™ DC equipped end users or reseller. The choices are; 1) Harmonizer® to record a sound file to determine frequency, 2) SpinScope® for low-frequency vibrations or 3) BlueSwarf™ Tap-Test tool/part for mid and high-frequency vibrations. Following the analysis of the initial data, escalating solutions with additional data collection will be recommended. In addition to adjusting the machining parameters, a modification of the tool design may be appropriate. Finally, a Holemaking Dashboard™ is created for delivery to the customer.
The same BlueSwarf MetalMAX™ DC kits used for measuring cutting tool assemblies can be used to collect frequency data on workholding fixtures. A typical custom workholding fixture is shown at the left, required 22 data points, taking about one hour to collect. The analysis took 6 hours. The resulting report detected two unstable areas of the workpiece that was inducing vibration and causing scraped parts. The customer was instructed to add support in these two specific locations and the problem was eliminated. With fixtures costing tens of thousands of dollars, and no other corrective method other than trial and error, this is a cost effective service offering.
MARKET DYNAMICS AND BLUESWARF HIGHLIGHTS
We provide telephone-based and onsite consulting and training. Use of our MetalMax and Harmonizer technology enables self-serve data collection with remote analysis for lower costs and faster response in many machining operations. For inquires and rates please contact BlueSwarf at 1-888-811-3260, Extension 706, or email at firstname.lastname@example.org.