The Alpha Group based in Statesville NC, a division of R.P. Machine Inc, has both products and services that are very unique and competitive in the industries and markets they serve. The Alpha Workholding business unit (AWH) markets, manufactures and sells magnetic Workholding systems and lift devices that are marketed and sold globally. The Alpha Machining and Grinding (AMG) business unit supports OEM manufactures with value added metal removal processing on large and small parts and programs.
By incorporating AWH magnetic Workholding products into their work cells, AMG has been able to improve throughput, reduce or eliminate fixture costs, and help customers be more competitive in the world economy. The flexible magnetic A-POD system allows the engineer to instruct the operator where to position the pod for safe clamping without interfering with the tool path. It also reduces costs of the projects by eliminating the need for fixture design, build and testing. General Manager Marty Murawski states, “We can significantly reduce the time required to achieve first part inspection approval and begin production. What an advantage.” However this was not where AMG’s quest ended.
AMG produces several lines of large to mid-size Blanchard ground and machined plates for products sold and used globally. The machining operations became the focus of a cost reduction program that would enable AMG to remain competitive in an ever changing market. The target product line requires full perimeter prep and a multitude of pocket milling both through and blind. “While our AWH A-POD electro perm magnet system provided flexible Workholding, one second clamping and allowed for machining five surfaces without clamp or fixture interference, we still needed more throughput in order to beat our foreign competition,” Murawski said.
By working with AMG’s local distributor, Operations Manager Greg Thibodeau was able to incorporate the advanced technology of another American made product to again enhance throughput. “The ‘Gorilla’ brand end mills were introduced and tested, and the results were outstanding,” Thibodeau added.
Gorilla’s roots are in Waukesha, Wisconsin, making this the ideal product for an American manufacturing and metalworking facility. The “Gorilla” geometry is not only variable flute but also encompasses a variable pitch design. It is a patented geometry to the “Gorilla” brand. Harmonics are not seen with this geometry. The Gorilla product in a 5 flute configuration for perimeter work and a 4 flute configuration for slotting and pocketing, make it hard to beat. An added bonus is the proprietary coatings applied by Gorilla in their facility. Gorilla also offers specialized three flute technology for non ferrous materials and a broad offering of aviation grade specialized geometries as well as commercially standard end mill geometries and coatings. Their drill program features lengths of 3XD, 5XD and 7XD with proprietary high performance coatings. Additional services offered are re-sharpening and recoating in-house at competitive rates. The returning reconditioned product exhibits the same quality as the virgin product with outstanding turn around. AMG constantly has product in the float to further achieve cost targets.
Even with the more aggressive material removal features of the “Gorilla” mills, the AWH A-POD system held the work piece firmly in place. “We were concerned that with this aggressive material removal, chip evacuation might be a concern with the magnetic method of Workholding. But the AWH A-POD system’s minimal magnetic flux penetration into the plate did not impair the chip removal. We were very pleased with the final result,” stated Thibodeau.
Thibodeau subscribes to the theory that tooling cost must be measured in cost per cubic inch of material removed, not the cost of the tool itself. Learning the Gorilla product was also the price leader in variable flute technology added a measure of additional value. The advertising surrounding the brand attracted AMG’s attention, and the fact that AMG takes pride in being a global competitor while producing their product exclusively in America seemed to be matched by the Gorilla brand.
Proof that two innovative American companies were able to work together to evolve a vertical machining center into a world class work cell was amazing to see. AMG’s product maximizes the ability to eliminate moving clamps and five surface machining, and the Gorilla tool performance maximizes metal removal rates with the lowest possible cost per cubic inch. This advantage assisted AMG and their customer to bring back a 3,000 EAQ product line from an offshore manufacturing supplier!
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Alpha Magnetic Workholding and Alpha Machining and Grinding of Statesville, NC have both unique and competitive products to sell in the global marketplace. AMW focuses on a mature product line of lifting magnets while AMG produces a unique product line of pod magnets designed to fixture a work piece in a vertical machining center to permit maximum utilization of time and materials.
Greg Thibodeau recognized the value of unique tooling to take further advantage of his unique work holding methods to maximize through- put production coupled with the value, not the cost of added value tooling. Greg subscribes to the theory that tooling cost must be measured in cost per cubic inch of material removed, not the cost of the tool itself. Learning the Gorilla product was also the price leader in variable flute technology added a measure of additional value.
By fixturing his product with the use of pod magnets, he is able to place the pods to permit full perimeter work and pocketing work without mechanical chucks and a continuing need to re-fixture to complete his machining paths.
We were introduced to the “Gorilla” brand end mills and drills by a local distributor, says Greg. The advertising surrounding the brand attracted our attention, and frankly, the fact that we pride ourselves in being a global competitor while producing our product exclusively in America seemed to be matched by the Gorilla brand. Perimeter finishing and pocket milling was never more aggressive with any competitive world- manufactured end mill nor more cost competitive.
The “Gorilla” geometry is not only variable flute but also encompasses a variable pitch design. It is a patented geometry to the “Gorilla” brand. Harmonics are not seen with this geometry. Gorilla’s roots in Waukesha, Wisconsin make this the ideal product for our American manufacturing facility. Our product maximizes our ability to eliminate re-fixture handling and the Gorilla tool performance maximizes our metal removal rates with the lowest possible cost per cubic inch states Marty Murawski.
An added bonus is the proprietary coatings applied by Gorilla in their facility. Among the services they offer are re-sharpening and recoating in- house at competitive rates. The returning reconditioned product exhibits the same quality as the virgin product with outstanding turn around. We constantly have product in the float to further achieve our cost targets.
The typical product machined at the facility is ground plate requiring full perimeter prep and a multitude of pocket milling both through and blind. The core penetration into the plates does not yield magnetism to the product or impair the chip removal. The ability to achieve this in a single fixturing gives Greg and AMG the competitive edge they need to be a global competitor within our domestic market. The Gorilla product in a 5 flute configuration for perimeter work and a 4 flute configuration for slotting and pocketing, make the two a team that’s hard to beat.
Gorilla also offers specialized three flute technology for non ferrous materials and a broad offering of aviation grade specialized geometries as well as commercially standard end mill geometries and coatings. Their drill program features lengths of 3xD, 5XD and 7XD with proprietary high performance coatings.
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