James Engineering

"One-Time-Setup"

Standard Deburr Setups and the Max Advantage

With the variety of parts currently found in all areas of industry, it would stand to serve that there would be just as many technologies to deburr them. Many parts are simple and the machine setup involved will take moments and will be correct the first time. Other parts will have geometry that will require complex setups and a substantial amount of trial and error before an acceptable result is achieved. The net result is a significant investment of time, money and a trail of scrapped parts. Ideally, all machine/part setups would be a "one-time-setup" on a low cost machine, that is easy to program and stores the program indefinitely.

The term "one-time-setup" is often used in industry but rarely, honestly, represented. Many machine manufacturers refer to their machines as "one-time-setup" machines, when in reality, setup is required for each batch of parts run. In this particular scenario the expectation is that for every batch of parts that will be run on the machine the part data will be re-loaded for each run. The problem with this concept, although widely accepted in the industry, is if the part is complex, it may take several passes to get the setup right and part waste is inevitable. For every batch that is run, several parts will always be scrapped. This isn't an indefinite problem as the Operator becomes more skilled with the process; however, dependency on the Operator now becomes the issue. If the Operator is moved to a different job or leaves the organization, the trial and error process begins all over again.

CNC machining centers that utilize HAAS, Fadal, Mazak, etc. are also referred to as "one-time- setup" machines. CNC machining centers require the part data to be developed in, and loaded from, a CAM (Computer-Aided Manufacturing) software package. CAM software is a tool to help plot the path of the cutting tool. This software is usually operated by a skilled CAD (Computer-Aided Design) operator who exports the data for load to the CNC. The CNC then uses this information to identify where the part is located in the fixture and what operations to perform on the part. The bonus with this type of machining center is its' accuracy and repeatability. The downside is their cost and complexity. Aside from the high cost, there is a high level of difficulty and expertise required to create the program, which is truly overkill for deburring and edge breaking applications. Additionally, this type of machine is not designed to work with the abrasive dusts generally created in the deburring environment. The dust will often build up on the ways of the machine and between the chip seals on the machine ways. Once past the seals, the dust lodges between the sliding surfaces of the ways and quickly damages the precision surfaces.

"One-Time-Setup"- MAX System™ by James Engineering

The MAX System™ provides a unique offering to the deburring industry and truly is a "one-time -setup" machine. It acts like a CNC in that it is accurate, repeatable and stores the program but without the complexity or high cost. Also, The MAX System™ is literally a fraction of the cost of a CNC machining center. Because it is a true "one-time-setup" machine, the batch run scenario described above becomes an entity of the past.

The MAX System™ offers a user friendly interface that doesn't require a "rocket scientist" to create the program. The machine control is so intuitive in nature that many customers have elected to bypass training. It has the simplicity of a manually adjusted machine with the bonus of program setup storage.

The MAX System™ is the Operator who never leaves your organization taking valuable training time with them!

Once a setup has been created with "MAX", it is truly a "one-time-setup." "MAX" remembers…forever…The MAX System™, "one-time-setup", "cutting edge" technology.


2380 West Midway Blvd., Unit 1, Broomfield, CO 80020 • 303.444.6787 • info@James-Engineering.com
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