P.O. Box 1438 - Middleboro, MA 02346
Phone: 508.946.4533 - Toll-free: 800.910.2352
Fax: 508.947.4686 - Toll-free: 800.910.2859
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hardinge turn mill

General Machining

  • Precision Machining of most Metals & Plastics
  • Nuclear & Sub Safe Part Machining
  • Production, Prototype & Quick Turn
  • Large Part Machining
  • Composite Molds and Preform Tools
  • Manufacturing of Large Shafts & Rolls
  • Precision Balancing of Large Rolls and Shafts
  • Refurbishing of Rolls and Shafts including Straightening
  • Centerless Grinding
  • Lapping Back, Lapping, Die Level Grinding and Precision Polishing and Diamond Sawing of Substrates Lapping
  • CNC Milling, Drilling & Turning
  • CNC Swiss Screwmachine parts
  • CNC 5 Axis Wire EDM
  • Laser & Waterjet Cutting
  • 3, 4 and 5 Axis Machining
  • Deep Hole Drilling

Producing components to tight tolerances is only the beginning of what precision machining means . In our view, a precision job isn't done until it is precisely in line with customer expectations for reliable delivery, component quality and world class cost effectiveness.

None of these outcomes can be successfully achieved without state-of-the-art Equipment.

  • Versatility - stainless steel, aluminum, titanium, brass and other metals and plastics, are used to meet needs of customers in defense, aerospace, high tech, medical, security, and more. See our Materials List.
  • Two-axis turning delivers peak cost efficiency in shorter volumes, as well as high capacity production of mechanically simple components
  • Multi-axis turning centers are extremely cost-efficient at higher volumes, and especially effective at replicating complex geometries
  • CNC Swiss is preferred by customers who need parts of exceptionally high precision and small size.
  • Deep Hole Drilling: 1/8 Dia. To 1 ¼ Dia. Up to 48" Deep.
    • "What is considered a deep hole?"
      In general any hole more than 4 to 5 times its Diameter, is considered a deep hole.

      Gundrilling is an very old process of drilling long or deep holes, first used in the making of gun barrels more than 100 years ago. Today's technology with refined machinery and tool design has made gun drilling a reliable high production method for drilling short holes as well as deep holes. The gundrill consists of a hollow tube with a " V" shaped groove or flute along its length, and a carbide cutting tip designed in such a way as to produce it's own guide bushing as it drills the hole. High pressure coolant is introduced into the center of the drill tube through the spindle of the gun drilling machine to help break and evacuate the chips along the "V" groove of the tool and out of the hole. Gundrilling provides very close tolerance straight holes with excellent surface finish. Gundrilling is able to produce holes as small as .031"

      With conventional drills such as twist drills several cycles or pecks would be required to clear chips from the flutes of the drill. With a dedicated deep hole drilling machine and proper tooling and fixturing the hole can be produced in one pass.

      Depth to diameter ratios of up to 300:1 can be achieved.

      Good surface finish and hole size may eliminate secondary reaming, or honing operations.

  • CNC 5 Axis Wire EDM, Laser & Waterjet Cutting
    • wire cut partWire EDM is a specialized thermal machining process capable of accurately machining parts of hard materials with complex shapes. Parts having sharp edges that pose difficulties to be machined by the main stream machining processes can be easily machined by WEDM process. Technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted non-contact technique of material removal with a difference that spark is generated at wire and work piece gap. Since the introduction of the process, WEDM has evolved as a simple means of making tools and dies to the best alternative of producing micro-scale parts with the highest degree of dimensional accuracy and surface finish. This paper outlines the development of a model and its application to optimize WEDM machining parameters. Experiments are conducted to test the model and satisfactory results are obtained. The methodology described here is expected to be highly beneficial to manufacturing industries, and also other areas such as aerospace, automobile and tool making industries.

    • laser cut gearsLaser cutting is a technology that uses a laser to cut materials, and is typically used for industrial manufacturing applications. Laser cutting works by directing the output of a high power laser, by computer, at the material to be cut. The material then either melts, burns, vaporizes away, or is blown away by a jet of gas, leaving an edge with a high quality surface finish. Industrial laser cutters are used to cut flat-sheet material as well as structural and piping materials.

      Advantages of laser cutting over mechanical cutting vary according to the situation, but two important factors are the lack of physical contact (since there is no cutting edge which can become contaminated by the material or contaminate the material), and to some extent precision (since there is no wear on the laser). There is also a reduced chance of warping the material that is being cut, as laser systems have a small heat-affected zone. Some materials are also very difficult or impossible to cut by more traditional means.

      Substrates can be laser drilled, scribed or cut to customer specifications.

    • waterjet part Waterjet Cutting
      An important benefit of the water jet cutter is the ability to cut material without interfering with the material's inherent structure as there is no "heat-affected zone" or HAZ. Minimizing the effects of heat allows metals to be cut without harming or changing intrinsic properties.

      Water jet cutters are also capable of producing rather intricate cuts in material. The Kerf, or width, of the cut can be changed by changing parts in the nozzle, as well as the type and size of abrasive. Typical abrasive cuts are made with a kerf in the range of 0.04" to 0.05" (1.016 to 1.27 mm), but can be as narrow as 0.02" (0.508 mm). Non-abrasive cuts are normally 0.007" to 0.013" (0.178 to 0.33 mm), but can be as small as 0.003" (0.0076 mm), which is approximately the size of a human hair. These small cutters can make very small detail possible in a wide range of applications.

  • For more information, see our Available Services.

Sub-Safe Machining:

SUBSAFE is a quality assurance program of the United States Navy assigned to maintain the safety of the nuclear submarine fleet; specifically, to provide maximum reasonable assurance that subs' hulls will stay watertight, and that they can recover from unanticipated flooding.

SUBSAFE covers all systems exposed to sea pressure or critical to flooding recovery. All work done and all materials used on those systems are tightly controlled to ensure the material used in their assembly as well as the methods of assembly, maintenance, and testing are correct. They require certification with traceable quality evidence. These measures increase the cost of submarine construction and maintenance.

SUBSAFE addresses only flooding; mission assurance is not a concern, simply a side benefit. Other safety programs and organizations regulate such things as fire safety, weapons systems safety, and nuclear reactor systems safety.

Vanguard Class

Machining for the Nuclear Industry under 10-CFR-50 Appendix B & Part 21 Regulations .

Large Machined Shafts and Rolls

  • CNC Turning - up to 24" x 150" Long.
  • Non CNC Turning - up to 48" x 500" Long.

Precision manufacturing of large shafting and rolls (up to 45" in diameter to 410" in length, or up to 3 tons) commonly used for paper and pulp production, power generation, mining, pharmaceutical/biotech, oil drilling, and turbomachinery. These and other shafting needs typically include large drive shafts, impeller shafts (including electropolished shafts), journals, rolls, and pump shafts. Also shafting requirements for keys, lock nuts, hardcoat plating, electropolishing, and stainless steel, brass and ceramic sleeves. Common shaft materials include 4340 alloy annealed and heat treated, 1141, 1018, and 316 SST.

Large Capacity Milling

Bevel 2Gear Cutting & Hobbing:

  • Bevel Gears-up to 12" Dia.
  • Helical Gears --up to 36" in Dia.
  • Internal Gears-up to 18" in Dia.
  • Worm Gears-up to 36" in Dia.
  • Spline Gears-External- 56" Long
  • Sprocket Gears-up to 36" in Dia.
  • Spur Gears-up to 36" Dia.
  • Timing Belt Pulley-up to 36" Dia.
  • Worm/Thread Milling 60" Long. x 12" Dia.
  • Worm/Thread Grinding 18" Long x 12" Dia.
  • Worm Whirling, .0005 TIR of PD. 6" length to .790 OD.
  • Thread Rolling - Sizes 0-80 to 7/8-20

Hobbing Machine:

A hobbing machine is a special form of milling machine that cuts gears. It is the major industrial process for cutting (as opposed to grinding) spur gears of involute form.

The machine forms the gear via a generating process by rotating the gear blank and the cutter (called a hob) at the same time with a fixed gearing ratio between hob and blank. The hob has a profile given in cross-section by the fundamental rack for the gear tooth profile and is in the form of a helix so that the sides of the teeth on the hob generate the curve on the gear. The helix has a number of cuts parallel to the axis to form the cutting teeth and the profile is suitably relieved to provide cutting clearance.

For a tooth profile which is a theoretical involute, the fundamental rack is straight-sided, with sides inclined at the pressure angle of the tooth form, with flat top and bottom. The necessary addendum correction to allow the use of small-numbered pinions can either be obtained by suitable modification of this rack to a cycloidal form at the tips, or by hobbing at other than the theoretical pitch circle diameter. Since the gear ratio between hob and blank is fixed, the resulting gear will have the correct pitch on the pitch circle, but the tooth thickness will not be equal to the space width.

Hobbing is invariably used to produce throated worm wheels, but it is not possible to cut all useful tooth profiles in this way; if any portion of the hob profile is perpendicular to the axis then it will have no cutting clearance generated by the usual backing off process, and it will not cut well. The NHS Swiss tooth standards give rise to such problems. Such small gears normally must be milled instead.

Flame Hardening:

Flame hardening is an oxy-acetylene heating process used to produce a hard case on the surface of a wide range of mechanical components. Burning fuel gas impinges directly on the surface to be hardened. When the surface reaches the austenizing temperature, the part is immediately quenched to produce a locally hardened surface.

Typical flame hardening applications include blades for turbine engines, gears for paper machinery, rolls for the printing and metalworking industries, cams for packaging machinery, machine tool beds, and automotive components.

Cost reductions occur as a result of the reduced distortion, allowance for straightening, and elimination of operations associated with flame hardening.

The use of flow controls, infra-red temperature sensors, and automated parts feeding insures conformance to your engineering specifications. Magnetic Particle Inspection is performed on a sample of all lots processed. Documentation is maintained for each order for a period of five years.

Induction Heating:

In the induction heating phenomena, a high frequency electric current is passed through a conducting coil surrounding the part to be heated. The electromagnetic energy created induces a current to flow on the surface of the part to be heated. By controlling the power, time, and temperature we are able to locally heat a wide range of components producing the correct metallurgical results to meet manufacturing requirements.

Induction heating is energy efficient and environmentally friendly. It also reduces distortion and improves the desired mechanical properties. Typical applications include tempering, annealing, hardening, brazing, and shrink fitting.

The use of microprocessor controls and infrared temperature sensing enables the heating cycle to be monitored for 100% of your components. A family of automated parts feeding equipment has been developed that allows the most efficient heating possible. New coil designs and the use of intensifiers allows for multiple part heating to increase productivity and reduce costs.

For each part inspected, there is documentation of the process. The heating time, part temperature, quench temperature, and voltage are recorded to insure the accuracy and repeatability of the operation. A sample of each lot is then Magnetic Particle Inspected to insure the integrity of the part. Laboratory facilities are available for metallographic studies.

Automated Hardening Process:

In an effort to enhance the productivity and control of the localized heat-treating process a wide range of automated parts feeding equipment has been integrated with optical infrared pyrometry. The PLC provides control of the sensing, location and motion for feeding and locating parts. The pyrometer provides temperature control of the parts during processing.

Typical applications of these technologies have allowed the ability to harden multiple parts in one operation. Flame hardening of mechanical components has been automated. Temperatures of each part heated can be controlled within a few degrees. Induction stress relieving cycles have been as short as 10 seconds and have reached 12 hours depending on the alloy processed. There is also the capacity to provide inert gas atmospheres to these operations. Charts can be developed for the process of each stress relieved item processed.

Computerized records provide the basis for certification as required by the customer.

TM Limited provides you with precision machining on most metals, as well as machining on intricate plastic parts.

Whatever your machining needs ... if you need the job done, you need it done right, you need it done quickly and at a competitive price, call us today at 508.946.4533 or e-mail us at tom@tmlimited.com

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