Factory Machinery Pics

Codger_64

Codger_64

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If you ever wondered how they put the "ser's" on a serrated knife, here is the serrator grinder from the Imperial Schrade factory at Ellenville. A lot easier than using a round file!
 
The machine shown was actually different from the other CNC serrators used at Schrade. All the other's used a shaped diamond wheel to "dress" the grinding wheel. This one used a diamond tipped probe and could be programmed for different shapes without the expense of the dressing wheel. The diamond probe cost less than $50, whereas a diamond dressing wheel could cost well over $1,000. I believe it was purchased by Benchmade at the auction.
 
I thought it interesting that air nozzles were used to keep it clear and cool. In the automotive factory and machine shops, we used a glycol spray or light oil, but usually, we were metal to metal in the CNC's. Some of our twin wheel stone grinders really heat up parts as they pass thru, and liquid cooling was essential. The glycol cooled and helped stave off rust until the next step, the viberatory, before plating.
 
well whatever all that mechanical stuff is it sure worked. Here is what they looked like when they came off that machine. Note the writing etched on the handle of one of them. LT
 
Thanks for the information gentlemen:thumbup:...quite interesting to see.

Bill
 
ISC_RIP said:
The machine shown was actually different from the other CNC serrators used at Schrade. All the other's used a shaped diamond wheel to "dress" the grinding wheel. This one used a diamond tipped probe and could be programmed for different shapes without the expense of the dressing wheel. The diamond probe cost less than $50, whereas a diamond dressing wheel could cost well over $1,000. I believe it was purchased by Benchmade at the auction.
Click to expand...

Last time I was in the Benchmade factory I saw one of the machines they used for cutting serrations, but that was 8 or 9 years ago, before they moved to their new facility in Oregon City. The last email I got from Les De Asis, he mentioned that they were just getting some of the Schrade machinery on line. However, he did not mention which machines they were.

Dale
 
The information I have at this point, not yet confirmed by Les, is that Benchmade bought a CNC hollow grinder, a robotic finishing cell, a flat grinder possibly, and they also bought a CNC hollow grinder from the auction of the Ireland plant's equipment. I am still looking for a preauction inventory list.
 
Ahh.... I just didn't see the catchment and filtering for recycling the coolant. In the bottom of the machine no doubt. We do use air in the machine shop for some operations where little heat is generated, like on brass, and where chip recycling is expected. The air is more for clearing than cooling.
 
In another thread, it was mentioned that some patterns (mainly 34OT, I think)were being glazed by robot in late production. Here is a pic of this being done. Glazing is the process of reducing the cover to meet the bolster, giving the two-tone effect as the dyed layer is removed and the base layer exposed. How many different operations were done with robotics? Did they have a "teach robot" in house? Or was the program done by the robot suppliers, or staff techs on the production robot? In the automotive plant, we used an offline teach robot for writing the programs for our paint robots, then proofed them on the paint line, checked film build, coverage, etc., and edited the program for duration and angles.
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Codger
 
Great pics Codger, where did you get them?
Thanks for the interesting info.
 
This is a HAAS "mini mill" milling machine. It is exactly like the Fadel units I use in the machine shop. Schrade had six of these at one time, and used them for milling covers such as the 6OTX, the Silhouette and the viper. They were also used to shape handles for the custom knives such as the AG Russell bowie. It was also used to put the rope pattern on the back of the Schrade Barnett blade and spring, and possibly the filebacks on the SDU15OTF?

You will notice that it is set up in this photo to run eight pieces per loading. The machine is programmable to run both left and right covers in the same operation, helpful if the operator does his/her job of keeping them seperated when unloaded and QC'd. In operations that run either a left or a right alone, you can wind up with a oversupply of one and not enough of the other if the tool experiences problems, or if long cycle times are required. Some parts can run a hundred cycles per hour, but more complicated items may run only thirty or forty cycles per hour. And operators loose an hour a day at least to breaks and lunch, factor in downtime for machine maintenance and cycle interuption for the human part of loading and unloading.

I cannot see the milling head in this shot, but our Fadels are set up to accept up to eight seperate milling attachments held and automatically indexed from a rotating holder to the 10,000 RPM milling head. Also, our units have a light curtain surrounding the operator opening as a safety feature. They will shut down the machine if the light pattern is broken by an operator reaching in without first stopping the cycle. I am sure these also have a similar feature not seen here. This is a great improvement over the old "pull back" safeties where a harness strapped to the operators wrist physically pulled their arms back during a cycle, or the interim whiz-bang safety, the pressure mat which sensed where the operator was standing.
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The second pic shows a bit better the fixture which uses vacuum to hold the covers in place. I have been told that the the HAAS machines had closing viewing doors which excluded operators and locked out the machine when open. Our CNCs have similar doors but were refitted with the light curtains. Messier operations require the doors to be used from time to time, as when liquid coolent is used, or metal chips fly.

Codger
 
He he, a parenthesis to talk about..... ping pong:

Here's one Robot that I know well, our trainer would set it to shoot balls to alternating corners and we had to return them all with our forehand, 200 balls, then it's someone else's turn, then 200 returns all with the backhand, kept us jumping from side to side.

Luis
 
Here a shield is being "heated in" to an undyed cover blank, checking fit of the shield with the sample cavity. You will notice that this is one of the anniversary banner shields. The gray heated element is seen just above the shield. It will heat the shield while pressing it into the formed cavity. Look ma! No glue!!
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Codger
 
But then what Micheal . why ahould your source be a secret??? Oh well it is your right. LT.
 
Why should they remain anonymous? Why will they not bring this and other information to the public themselves? These people do realize the historical importance of the knowledge they have acumulated, and want to share it with us. But they do not wish to subject themselves to publicity, and possible ridicule and scorn by appearing in a public forum themselves. They want to maintain their right to privacy, just as your friend Frank does, Richard. You respect his wish for privacy, as do we all. Knowing this is his wish, I have made no attempt to contact him, nor will I. The only difference with these people is that they do not want to take their first hand knowledge of Schrade to their graves.

They are proud of Schrade's history and the products, and their roles. For some, they still have jobs in industry, and some are still key players in the cutlery field. Some have taken menial jobs and squeek by, many had to move to other states to find better economic opportunities. A couple are in retirement now, and wish to enjoy it without being hounded. Some are still stinging with the life-altering events that we have only experienced as interested outside observors. A lot of litigation, and rumor of litigation is still flying around. None want to open themselves to liability, publicity etc., so they have asked me to keep their identities confidential. That is their right, and my obligation. If that disturbs anyone, just discount all I bring to this forum, including my own first hand observations.

I am personally pleased that people who had long time experience working at, or in some cases with Schrade have seen fit to contact me and let me make the information public. Each has their own reasons for not doing so themselves. When one comes along who wants to be publicly quoted, I shall gladly do so. Until then, I am satisfied that these people (there are quite a few, not just one as some might be inclined to believe) wish to share with us.

And I understand why many refuse to respond to my requests for information as well. A wealth of knowledge is out there to be discovered by anyone who is willing to seek it, if they are willing to maintain the trust and confidence of the people who hold that knowledge.

Michael Little
 
Like I said it is your right it is there right and I respect that. I am not disturbed by this and Your enthusiasm does bring a lot to the forum. It is nice that you have become the confident to these people. Frankly I thankyou for your explanation. There are other factors involved as well. However as I said I respect everyones rights. The difference involving Frank is that you know who he is. Again it does not matter. Even if your source was Mr Taylor it does not matter since it is pertinent information and Mr Taylor is simply a business man who does business with a government that some people find objectional. Which is quite normal and common in this era. I guess these sources will be the forums deep throat ( so to speak ). Whoever and whatever there motivations might be I wish them and you sucess in your pursuit. There have been some unusual happenings on this forum recently this is simply another one. Some i personally agree with some I don't, simply again an opinion. The important thing is that the subject now has a following and great input. A few years ago it was about dead. This is what I wanted. You and others have made it self sustaining. So for that I thank you all. LT
 
LT wrote: "A few years ago it (this forum) was about dead. This is what I wanted. You and others have made it self sustaining. So for that I thank you all."

How true.

I'm enjoying the pics and stuff.

Phil
 
After the Delrin handles are molded, sprues and gates (sometimes called runners) trimmed, they have to be dyed. Two heated dye tanks are used, one brown for OT covers, and an additional black for the UH covers. The tanks are heated to 180 degrees, far below the melt temperature of Delrin. but hot enough for the dye to penetrate the surface and set. I am not familiar enough with this particular dye to tell you what the color base material and mordant are, but most dyes (as with most paints) have mineral base ingredients. A mordant is a chemical (usually acid or alkali) which acts as a penetrating agent and carrier solution. Like the vinegar used with Easter egg dyes. In this case, it could well have another type of mordant. The covers are dumped into the first dye vat and an operator stirs the parts every few minutes to prevent the parts from streaking from dry spots, and weakened dye, or contact with the vat. They also occasionally lift some parts with the stir paddle to check the color. If the dye is fresh, time in the dye tank is about 25 minutes. When the dye is weakened from use, dying times are extended by the operator to compensate, until they judge the dye needs replacement. This whole operation was dependent upon the judgement of the operator. When the parts reach the desired color, they are removed from the dye vat with a shovel and are placed in a basket in the rinse tank. After rinsing clean, the basket is lifted and drained, and the parts spread on a drying table. Ours are perforated stainless with reversible air flow for updraft heated air, or downdraft cool air, depending on the part. At this point, the covers should be a uniform dark brown color. For the UH covers, they go from the brown dye (approx. 15 min, or until the proper reddish brown color is achieved) then to the rinse, then to the black dye tank for another 10 minutes or so, depending on dye strength. They are again rinsed, and go to the drying tables.

Now, considering the number of manual steps required, and the amount of objective judgement required by the operator, you can see why they were trying to streamline the process. (edited)

Here is a knife assembled with undyed covers, and one with the dye not reduced by glazing

radopd.jpg


Codger
 
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