Ram EDM
Our conventional EDM department, equipped with seven EDM sinker machines and EDM Drillmate to provide a wide range of capacity and capabilities. The Sodick AD 55L C&C machine has orbiting features with extremely high accuracy. The EDM machines are equipped with the 3R system to ensure accuracy and repeatability. The other departments that manufacture and dress the electrodes also use the 3R system.
Our operators have the expertise to burn carbide as well as various tool steels used by customers. Whether a punch face is for miniature electrical contact or a large surface area with multiple features our operators are trained to achieve the best possible surface finish. The less the recast layer, the better the detail on the finished face. This helps avoid distorting the face features during the polishing process. We apply the same concepts when burning choke/step dies. Punch face electrodes are produced first using Mastercam and then cut on a Mikron Graphite Master high-speed mill with a remarkably high degree of accuracy.
Wire EDM
The Wire EDM department, equipped with two SODICK wire machines and one Makino, all capable of using .002 to .012 diameter wire for a variety of applications. With taper and auto-threading capabilities, they can run continuously to meet stringent delivery schedules. Integrating wire EDM into production in the 1970’s gave CTI employees 30 years of experience with the process. The machines are equipped with 3R and Erowa work holding systems to ensure accuracy and repeatability in the next operation.
Precision Machining
Along with eight lathes ranging in size from a small Hardinge high precision collet lathe to a NILES lathe with a swing capacity of 24 inches, the machining department consists of seven Bridgeport Knee Mills, a Cincinnati slab mill for roughing sizes and a Haas CNC Turning Center that can fit 12 inch diameter and 52 inches long.
The CNC department consists of two CNC mills for cutting shaped tooling. As with other CNC departments, these can be programmed at the machine by our highly skilled operators or using Mastercam for more intricate or complex parts and engraving. We work with DELRIN and other types of plastics, aluminum, and various PM tool steels.
Heat Treatment
Heat treatment is done using 3 Lucifer furnaces that can hold temperature up to 2400 degrees for an extended period of time. We oil quench if required by the part specifications. Our Rockwell tester is calibrated by an independent source.
We have highly skilled contacts to accommodate any specific requirements the part may have, for example Cryogenics (Freeze), Stress Relieving, Nitride and Black Oxide, etc.
CNC Jig Grinding
The CNC Grinding department consists of three Moore Jig Grinders. All three of our Jig Grinders are equipped with FAGOR CNC computer controls. These allow for shape grinding up to 9 x 16" with an absolute accuracy of +-.0001 over the entire range. All of the programs for these machines are created in house using Mastercam.
OD, ID, and Surface Grinding
A Tool and Die manufacturing facility is not complete without a strong OD/ID and Surface Grinding Department. While some may consider these operations basic, in reality they are equally important as any of the other manufacturing areas. Almost every item manufactured passes through this department and the individuals operating the equipment are working to the same close tolerances (+-.0001")
This department is equipped with two Chevalier Surface Grinders having a 16x26" magnet with a grinding tolerance of +-.0001. A Thompson Surface Grinder, Heald ID Grinder, Myford, for grinding between centers, two Brown and Sharpe, a K.O. Lee OD Grinder and a Zocca OD grinder. These machines range from 6 inches to 14-inch diameter and reaching 24 inches long.
Lapping and Polishing
Pristine and smooth surface finishes are integral to fitment tolerances between punches and die cavities. They are also integral to consistent and clean ejection and release of pressed green parts and prevention of residual powder build up on wear surfaces. Lapping can also provide finishing to dimensional requirements and corner sharpness tolerances that other machining methods are not capable of producing.
Optical Comparators and Measurement
The majority of the tooling we produce requires .0003 / .0005 inch clearances and tolerances of +- .0001. Evaluating parts produced to those standards requires equipment of even greater accuracy, so optical comparators are regularly used to evaluate accuracy of tooling profiles whether they are machined, ground, or EDM cut to size and finished.
Profile Inspection
Quality control of machined parts are determined not just by the methods and accuracy used to produce the parts, but also on the expertise and tools used to evaluate the finished tooling. Our inspection department uses various measurement devices, such as microscopes, a contour tracer, and Perthometer-surface analyzer to qualify parts with measurement, profile, and surface finish requirements specified by the customer.
Erowa and 3R Matrix Tooling
To produce tooling with the best possible alignment and positional accuracy possible, our processes utilize fixturing equipment compatible with Erowa and 3R Macro/Matrix (and Refix) tooling systems, chucks, and fixtures. On site sizes are Erowa chucks PM190 and PM128, and Macro 10 Ton, 20 Ton and Matrix 110, 142, 185.
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403 Wide Dr McKeesport, PA 15135 - (412) 751-3535
If you have challenging, novel, or complex tooling requirements contact us for consultation or quoting today.