Quality Magazine
Case Study

Falcon CNC: A "Gem" for Mastertech Diamond Products

November 2, 2012
Vision Engineering’s non-contact measuring system “ticked all the boxes” on manufacturer’s wish list.
 
vision engineering falcon CNC
The Falcon CNC from Vision Engineering.
Source: Vision Engineering
The Mastertech Diamond Products Company (Mentor, OH), designs, manufactures and distributes a comprehensive range of high-quality cutting tools that are capable of undertaking the most challenging of machining applications. In addition to producing a wide variety of standard format tools, Mastertech is able to manufacture and design specialized tools and inserts to customers’ own specifications.
 
Mastertech specializes in the production of diamond tooling for cutting aluminum alloys and other non-ferrous materials. Polycrystalline diamond (PCD) inserts and cutting tools are rapidly replacing carbide cutting tools in many nonferrous machining applications, and Mastertech’s expertise in the field ensures that the company is kept busy satisfying the burgeoning demand for these extremely cost effective cutting tools. Mastertech’s PCD products deliver increased metal removal rates, faster cycle times, reduced scrap levels, tighter dimensional control and improved component surface finish.
 
Further improving the efficiency of Mastertech’s PCD and CVD (Chemical Vapor Deposition) inserts and cutting tools, the company now offers customized, laser-etched 3-D chip breaker geometries. Mastertech’s advanced chip-breaking geometries help overcome the problematic build-up around tools and workpieces that can be encountered when turning aluminum and other non-ferrous materials.
 
The company’s laser-etched 3-D chip breakers give users a long list of advantages, including extended tool life, reduced tools breakages, improved surface finish and increased machine tool utilization.
 
The nature of the challenging industries supplied by Mastertech means that the quality of the company’s products is of paramount importance. To help ensure the continued delivery of premium quality cutting tools and inserts, in addition to utilizing a range of state-of-the-art machine tools, Mastertech also makes regular investments in the best available quality control technology.
 
Mastertech Production Manager, Kathy Miner explained, “As it is vitally important to precisely adhere to the dimensional specifications of our cutting tools and inserts, we use a range of sophisticated, non-contact inspection technologies in our climate controlled facility. This advanced metrology capability also allows us to verify the absolute accuracy of the complex geometries of our products.
 
“An increased demand for our products has lead to a potential bottleneck in our busy inspection department, to avoid the possibility of inspection hold-ups and to help guarantee our fast delivery times, we recently carried out a search for an efficient measuring technology. The required system needed to provide extremely accurate and repeatable results in 3-axis, across our range of high precision measuring applications. In addition, given our ever increasing volume of work, we also wanted a measuring system that had an increased level of automation.
 
“Having thoroughly investigated the available alternatives, we purchased a Falcon CNC non-contact measuring system from Vision Engineering. Although the other systems performed adequately, the Falcon ticked all of the boxes on our wishlist and proved the easiest to use. It was also a bonus that the advanced Vision Engineering option was one of the least expensive systems that we considered.
 
“Now in constant use, our new Falcon CNC has freed up an employee from standing in front of a comparator and inspecting each cutting tool or insert. Most of our products are now simply loaded on to a pallet and, as the machine does the inspecting, the employee is free to perform other duties.
 
“The flexibility of the Falcon allows us to quickly recall our part programs and to perform very accurate, multiple cutting-tool inspection routines in a rapid CNC mode. Among other characteristics, we measure features such as Radii, I.C., H.O.B dimension, angles, height and centrality of holes to I.C.”
 
Kathy Miner concludes, “As the Falcon CNC is so easy to use and Vision Engineering’s software is so intuitive, our operators had a very short learning curve before they became proficient in the system’s operation. Our Falcon CNC is now making an excellent contribution towards ensuring the absolute quality of our products, as it can quickly inspect large amounts of high precision work in a CNC mode, we anticipate a rapid return on our investment.”
 
Vision Engineering
(860) 355-3776