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<blockquote data-quote="Trickymissfit" data-source="post: 456838" data-attributes="member: 25383"><p>Oh BOY!! Electron beam welding!! What brand of machines did you use? I had one electron beam welder, and hope to never ever see another again! The one we had was used for a single operation and was fully automated. Welded a steel hub to a hydroformed plate (kinda looked like half of a torque convertor) that had gear teeth cut on it. There was a hydraulic press in the system that pressed the steel hub into the plate. Then sent it strait to the welder. The welder was purely robotic in nature, and used a rotorary table so the orfice was lined up exactly right with part. It would spin the part to check to see it it was strait, and then weld the hub with a weld that was about 12mm wide with very deep penitration. This took about 20 seconds from the time the hub entered the box till everything retracted. When I first went out there I asked them what all those grey stickers were that they had stuck up all over the place (you know the answer). They were the same stickers they use in nuclear subs to detect radiation leakage!! Now I ready to get outta there in a hurry. They assured me all was OK (I never did believe them), and even went so far as to bring out a gieger counter to prove it. There were lead shields all around the box, and it looked like whoever built the thing did it upside down. The problem (as usual) was lack of vacume in the orfice. That machine was the single most expensive machine to keep running in the entire corporation, and a good week for it was seven days strait without going belly up! They sold the machine to a sub contractor, and I built a wire welding complex that used several banks of Miller welders. A welder was junk after about ten days, and there were four of them. I thought they were nuts, but they showed me the paper work, and they were a half million dollars ahead in twelve months. </p><p> </p><p>I leveled all my machine centers with a Federal electronic level after roughing them in with 12" machine levels to where they were within .0005" a foot. On a Devlieg Jig Mill the spec for the x axis was was .000020 max in 12 feet. I thought they were nuts, but found out that the currunt draw for the motors was about 25% of what it was at .0005". Bad thing about doing an axis that close is that things change over night, and you have to keep tweeking the leveling pads till the frame quits changing. You can't get there with a laser, but an autocolumator will also work. After a year of setting those beasts up you get a real good education on machine tool alignments. Ever get to play with Tyco Way Bearings on a slide? Or do any work with ceramic super precision ball bearing sets? That's a whole new education in itself!</p><p>gary</p></blockquote><p></p>
[QUOTE="Trickymissfit, post: 456838, member: 25383"] Oh BOY!! Electron beam welding!! What brand of machines did you use? I had one electron beam welder, and hope to never ever see another again! The one we had was used for a single operation and was fully automated. Welded a steel hub to a hydroformed plate (kinda looked like half of a torque convertor) that had gear teeth cut on it. There was a hydraulic press in the system that pressed the steel hub into the plate. Then sent it strait to the welder. The welder was purely robotic in nature, and used a rotorary table so the orfice was lined up exactly right with part. It would spin the part to check to see it it was strait, and then weld the hub with a weld that was about 12mm wide with very deep penitration. This took about 20 seconds from the time the hub entered the box till everything retracted. When I first went out there I asked them what all those grey stickers were that they had stuck up all over the place (you know the answer). They were the same stickers they use in nuclear subs to detect radiation leakage!! Now I ready to get outta there in a hurry. They assured me all was OK (I never did believe them), and even went so far as to bring out a gieger counter to prove it. There were lead shields all around the box, and it looked like whoever built the thing did it upside down. The problem (as usual) was lack of vacume in the orfice. That machine was the single most expensive machine to keep running in the entire corporation, and a good week for it was seven days strait without going belly up! They sold the machine to a sub contractor, and I built a wire welding complex that used several banks of Miller welders. A welder was junk after about ten days, and there were four of them. I thought they were nuts, but they showed me the paper work, and they were a half million dollars ahead in twelve months. I leveled all my machine centers with a Federal electronic level after roughing them in with 12" machine levels to where they were within .0005" a foot. On a Devlieg Jig Mill the spec for the x axis was was .000020 max in 12 feet. I thought they were nuts, but found out that the currunt draw for the motors was about 25% of what it was at .0005". Bad thing about doing an axis that close is that things change over night, and you have to keep tweeking the leveling pads till the frame quits changing. You can't get there with a laser, but an autocolumator will also work. After a year of setting those beasts up you get a real good education on machine tool alignments. Ever get to play with Tyco Way Bearings on a slide? Or do any work with ceramic super precision ball bearing sets? That's a whole new education in itself! gary [/QUOTE]
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