Cnc Machines

CNC automatic lathes are fast to program

2008-09-23T23:15:00.001-07:00

Precision turned parts subcontractor said Star CNC automatic lathes are fast to set and program, so they are back in production quickly for the next batch run.

UK precision turned parts subcontractor, BGT Automatics, is steadily changing over from using cam-operated automatic lathes to using sliding-headstock, multi-axis CNC lathes Established in Aldershot in 1965, BGT increased the number of Star machines on its shop floor in 2007 by 30% The company acquired a Star SR-20RII, with extensive facilities for driven tool work, and an SV-32 that extends the subcontractor's sliding-head capacity to 32mm.

The other Star CNC automatics used by BGT have bar capacities of 12, 16 or 20mm diameter.

The machine tool supplier, Star Micronics, said that the SV-32had filled a capacity gap between the smaller automatic lathes and a 52mm bar capacity, fixed-head, CNC turning centre. Manager of the family-run company, Carol Naismith, said that the additional lathes and a more even spread of maximum bar sizes enabled BGT to offer a more comprehensive service.

Naismith commented: "It is the policy of large manufacturers and multinationals not to award contracts to subcontractors whose turnover is below a certain level, so we have been missing out on some of the bigger turned parts contracts, even though we would be perfectly capable of fulfilling them".

So BGT decided to increase its capacity to expand the business and raise company turnover.

Naismith added: "It also puts us in a stronger position to handle overflow work from larger subcontractors that may be struggling to fulfill large contracts, or that may not have sliding-head mill-turning capacity".

BGT has only replaced half of its cam automatics.

Eight of these are used to cost-effectively machine relatively simple components very cost-effectively, allowing the CNC automatics to machine the more complex, close-tolerance work.

BGT's customers are spread across many engineering sectors.

The company said two-thirds of its output is in machining stainless steel (303, 304, 316, 321).

Aluminium (HE30, FC1), steel and brass are also turned.

The Aldershot facility runs 24h/day, producing batches ranging between 100- and 50,000-off.

Machining tolerances down to 10 micron total are routinely held.

Less 'second operation' work is needed owing to the twin-opposed-spindle configuration and extensive driven tool capabilities of the Star CNC automatic lathes, and of the fixed-head lathe.

All of BGT's CNC lathes are able to perform in-cycle cross and reverse end machining.

Naismith related something of BGT's history: "Our father, Peter Ball, took over BGT Automatics in the early 1980s and shortly afterwards bought the first Star CNC lathe.

It was a JNC-16 and is still running today, so we have stayed with the same supplier ever since".

She continued: "We find the Stars fast to set and program, so they are back in production quickly for the next batch run.

This is important to us, as machine downtime would eat into our profits".

CNC sliding head turn-mill centres aid Adaero

2008-09-23T23:15:00.000-07:00

Citizen Machinery has revealed how its CNC sliding head turn-mill centres have helped Adaero Precision Components secure lucrative components contracts.

Adaero Precision has two Citizen machines installed in its newly extended facility at Crediton, Devon; an M32-III and a mid-range L20 with the high pressure Coolblaster 2,000 lb/in2 coolant system The machines produce batches of 500 or so parts in Acetal, aluminium, brass and a variety of stainless steels Such is the complexity of some of the single operational cycles - for instance, an optical focus component that uses 24 tools on the Citizen M32 - that while cycle times can be relatively long at 5.5min, the overall benefits are significant through combining operations and shortening lead times.

Indeed, it was the purchase of the Citizen L20 in June 2007 that led Adaero to win an important medical contract for three variants of an air flow adjuster in 316 stainless steel for anaesthesia equipment.

Consistency of production from the two Citizens has never been an issue, resulting in the company's high level of confidence for long periods in limited manning and unattended running.

Such is the level of setting expertise that requirements to maintain grinding tolerances can be met when turning on features such as seal diameters and grooves, that are then monitored using the latest optical inspection equipment to ensure full compliance to drawing requirements.

Changeover normally takes between two and three hours depending on the complexity of the batch but, according to Mark Pearson, engineering sales manager at Adaero Precision Components, this time is minimised due to machine's flexibility in being able to accommodate different tooling layouts.

Also, as most programming is performed offline and most jobs have been previously run, efficiency is high, keeping lead times short.

The 13-axis Citizen M32-III is able to hold up to 80 tools.

Common tooling can be left set on the vertical tool platen and drilling station for back machining as well as on the Y-axis fed, 10-station turret that is able to accommodate up to 50 tools by using its half index capability and special tool holders.

What is CNC Controlling

2008-09-10T01:50:00.001-07:00

Since we are dealing with machines that do work for us, we need to control those machines somehow. We need to control them for safety reasons as well. If you give a machine improper commands it can easily get out of control and cause harm to you or the part you are machining. We want to give good commands to our CNC machines, at the right times so they are not “out of control”.

The language that these machines use is called GCode G-code has been around since the early 60’s. There are a number of variations of G-code, but most are very similar to one another. See the previous section for a sample of G-Code.

We need a computer to interact with our CNC Router. Our computer will send signals to our CNC machine. In-between our computer and our CNC machine sits a controller. A controller converts commands into signals that are used to control the motion of our machine.

As these signals are sent out of the controller, they go to either stepper or servo motors. This is how we create motion. These cnc motors drive our various axis on our machine. While we are moving our axis, there is generally a cutting tool of some sort removing material. This is the machining process coupled with CNC.

Here is a brief description of the two types of motors generally used in CNC:
Stepper motors:
Simple design
Easy
Generate torque at low rpm
Do not know their position in relation to the program

Servo Motors:
Generate torque at high RPMs
Generally need gearing of some sort to be effective
More sophisticated
Can maintain their relative position, thus, they can be more accurate

CNC Machine Controls
Controllers generally stand alone near the CNC machine. They act as a translator between your cnc control computer and your machine. Generally, they add quite a bit of cost to a CNC machine as well. Controllers can cost anywhere from $1000-$20,000 or more depending on their sophistication.

CNC Community Site:
If you need more information about CNC, click over to http://www.CNCInformation.com You can join for Free and you get two free CNC ebooks. One is a GCode Quick Guide and the other is the CNC Info Site eBook. You also get access to the Free Video Series…Image to CNC Art when you join the community.

CNC Water Jet Basics and CNC Machines

2008-09-10T01:50:00.000-07:00

CNC Water Jet Information has just been added to the website that already has plenty of CNC Information. In addition to all of that CNC Information, you will now find a complete page full of CNC Water Jet Cutting Information. Learn the basics of CNC Water Jet Cutting from A to Z by visiting this new Computer Numerical Control webpage on CNC Water Jet Cutting at: CNC Machines

Its very odd for one to think of a Computer Numerically Controlled Water Jet that is Cutting some sort of material or fabric. Usually, when a person thinks of cutting something, a Jet Stream of water doesn’t come to mind. However, Computer Numerically Controlled Water Jet Cutter is actually in use in a lot of industries today. You can find various articles that Ivan Irons has added to the webpage that talk about the different uses for having a Computer Numerically Controlled Water Jet in your shop. The CNC Water Jet website can be visited by clicking on this link: CNC Machine

Some of the reasons that a CNC Water Jet is used instead of another kind of machine is that is does a very good and precise job at cutting metals, glass, or fabric. The cutting that happens during the CNC Water Jet process is actually an abrasive cutting that happens by eroding the material away with the pressure of the Water Jet. Now its not just the water that cuts the object, usually there is another additive in the water that helps with the cutting. You can find more about CNC Water Jet Cutting by visiting Ivan’s dedicated webpage that is all about CNC Water Jet Cutting at: CNC Machines

About CNC Information: CNC Information is a community CNC website that brings user into a deeper understanding of CNC.

CNC Machines Including CNC Mill

2008-09-10T01:49:00.000-07:00

CNC Mini Mill Basics have now been made available on CNC Information’s Website Category page. There you can find information on CNC Mini Machines of all types including CNC Mini Mill information and CNC Mini Lathe information. Since Computer Numerically Controlled machines have made their way into the home shops of Do-it-Yourself Hobbyist, a new market has come into play and they are called CNC Mini Machines. Just like their name says, these CNC Mini Machines are miniature versions of their older siblings. Since these Mini Machines are gaining popularity, Ivan has decided to make a complete page on this CNC Information website that is dedicated to Computer Numerically Controlled Mini Machines. A user can visit this new CNC Mini Machine site for free by visiting the following web address: CNC Mill

What is interesting about these CNC Mini Machines is that they make it possible for more and more people to get involved in Computer Numerical Control. Before, in order to get into the CNC Machine marketing, you had to have a signification time and financial investment, not to mention a separate garage or space that can be dedicated just to your CNC Lathe or CNC Mill. Read more at the CNC Mini Machine Page on Ivan’s website: CNC Mill

Now, with the new market for CNC Mini Machines, there is a lot less time, money, and space invested. Not to mention, the makers of these mini machines have made the learning curve a lot less steep than a curve for a large sized CNC Mill or CNC Lathe. This is such a unique market and Ivan has plenty of additional information on his website page that is dedicated to the CNC Mini Machines. Visit the Webpage at: CNC Mill for more information on CNC Mini Machines.

About CNC Information: CNC Information is a community CNC website that brings user into a deeper understanding of CNC.

Penny Slot Machines

2008-02-14T01:11:00.000-08:00

Playing slot machines with only one penny seems awfully cheap. Actually, it is cheap but it is exactly what the casinos want you to think.

Gone are the days of the simple 3 reel slot machine, today’s machines are gigantic multiline slot machines who have been developed to include any money making trick known in the book. In the comfort department, today’s slot machines have improved to accept dollar bills instead of only coins and can give prizes in the form of redeemable tickets, all in order to make the player as comfortable as possible.

The biggest change in modern slot machines is the addition of many more pay lines (a modern slot machine will have at least 20 pay lines and some reach a lot higher) which of course requires many more coins in order to activate all of them. With machine that costs 50c per spin but offers 20 pay lines, the cost per spin can easily reach 10$, and suddenly the old “pay less win more” slot machine has become a financial burden on the average gambler. For those who say “play only the minimum lines”, we will remind that in order to win the biggest prizes (and the jackpot, of course if available) you must play the maximum number of lines or your profits will be very slim.

In order to make the players less aware of the cost of playing these slot machines the casinos have come up with 1 penny slot machines. That’s right, 1c per spin. This has become the hottest trend in the casino’s slot machine floor and the low denomination has attracted numerous gamblers who now think that playing slot machines has become much cheaper. The focus though has turned into the multiple pay lines which require multiple points in order to maximize profits. Machines exist which will require more than 1500 coin per spin! This makes the average spin cost almost the same as the regular 50c machine.

Are Penny slot machines a sucker’s bet? Not necessarily. These machines are perfect for a player who came to the casino with the intention of spending a few hours of fun without committing too much money to the casino. On the other hand, those who like to suck every ounce of edge out of the machine and will never settle for anything than less the maximum payout will find better options elsewhere.

By the way you might have noticed some famous jackpots being offered in the penny slot machines, be assure that all in all playing the jackpot in a 1 penny machine and 1 dollar machine has no difference as the total amount required to gamble to be eligible for the jackpot is the same.

Why Rowing Machines Are Used in Gyms

2008-02-14T01:10:00.000-08:00

Some of the oddest machines in the gym are the rowing machines and, although they are somewhat rare, it is not uncommon to see a skiing machine, too. Many people wonder why these sports have been singled out as being such great exercise – why is there no tennis machine, or swimming machine, for example? The answer is that both rowing and skiing exercise your body in a way that other sports don’t.

If you’ve ever met a rower, you’ll know that they have huge amounts of upper-body strength, and there’s a reason for that. Rowing is, in many ways, the ultimate upper-body exercise, comprehensively exercising your arm and chest muscles.

The situation is much the same with skiing and your legs. Because of all the leaning and balancing that is needed to ski successfully, almost all of your leg muscles get a workout from skiing.

While rowing and skiing machines are no match for the real thing, either in terms of how much fun they are or how effective they are as exercise, they serve a useful purpose, because we can’t all go rowing and skiing every day. If you use both the rowing and skiing machines in one day, you will get an all-over body workout to more than rival the one you might get on the various weight machines, and the chances are that it will be quicker for you too.

However, with rowing machines especially, you need to be careful about overdoing it. Because rowing tends to feel easier on your muscles than it actually is, it’s tempting to set too-ambitious targets and tire yourself out completely, perhaps even pulling a muscle. For the sake of your health, take it steady, keeping track of how many repetitions you do on the machine on each visit, and gradually increasing, instead of going all-out one day and doing hundreds more than normal.

Interesting Facts:Coffee Machines

2008-02-01T05:46:00.001-08:00

Drinking coffee is a pastime of millions of people all over the world. Coffee machines make it possible to meet the demand of all these people. Without coffee machines, it would not be possible for millions of people around the world to enjoy a good cup of coffee.

The first coffee machine was invented in 1818 by Mr. Laurens. The machine was continually modified over the years. New versions of the coffee machine continued to emerge until 1960. This is when the first paper filters for coffee machines were put into place. This simple change created an unbelievable increase in coffee machine sales. People had always wanted the product, but didn’t like the time it took to clean up and prepare with the cloth filters. The paper filter saves people time and hassle which makes the coffee machine more appealing.

Coffee machines have changed in design as well over the years. The early ones were just created to do the job; no one really cared what they looked like. Today’s coffee makers come in all colors and sizes to accessorize nicely in any kitchen or living room. There are also many different brands of coffee machines, as each has their own unique looks and design to attract consumers.

Mr. Coffee has been the leading coffee machine in the United States for centuries. This is because the company continually changes or adds new products to meet the needs of the consumer. Bunn coffee makers lead the industry in commercial coffee maker sales.

Snack Vending Machines are Profitable and a Quick Fix to Hunger

2008-02-01T05:44:00.000-08:00

You are in a hurry, perhaps for school, work or a business meeting. You are not even familiar with the place and you’re stomach is churning. You need something to eat. That is the magic of a snack vending machine. It can give you the benefit of grabbing a snack whenever you are in a hurry and needs something to eat fast.

A vending machine is an apparatus that doles out food, drinks or snacks whenever an individual drops money, coins or paper bills. Verification of money is usually identified by a currency detector.

A snack vending machine is a piece of equipment which dish out different snacks and beverages whenever people drop money in to it.

Snack vending machines come in various shapes and sizes. A full size machine is where one can just let it stand on the floor. Some are small, where machine owners can hang it on the wall. A number of snack vending machines are electrically operated. Several are just manually operated. There are snack vending machines that are see-through or have fronts which are glass-made. Various snack vending machines can only dispense as little as six or ten types of snacks or it can sell a wide range of snack and beverage choices.

Different snack foods are available on vending machines. Vending machines display different kinds of chips, candies, peanuts, biscuits, and other finger foods. Commonly, snack vending machines also sell different kinds of beverages such as bottled water, bottled or pouched juices, bottled or canned sodas, hot or cold chocolates, and tea-based drinks.

Locations of snack vending machines are commonly found next to an establishments’ entrance or exit. You can also find it in workplace or school break rooms and corridors, next to other vending machines, and in waiting areas. These places are strategic site where people will most likely buy and grab some snacks.

Snack vending machines are beneficial due to the following reasons:

* Snack vending machines are located where individuals can immediately get to them. You can spot snack vending machines at your workplace, bus or train stations, airports, and other public places.

* Unlike with your ordinary store, you need not search for the right coin. The currency detector can detect what amount you dropped. It will give you your change if change is due. Additionally, there are snack vending machines operated by money cards, wherein you just insert the card and any commodity purchased will be deducted on that cards remaining value.

* Prices of the snacks in snack vending machines are reasonable.

Snack vending machines have their disadvantages.

* If the snack vending machine is electricity-operated, then there will be a problem when power is out.

* There are instances when owners of snack vending machines are not diligent in replacing used up products.

* Malfunction of machine. Sometimes your coin will get stuck or your bill is not accepted.

Snack vending machines are everywhere. You can always count on them whenever you need something to ease your hunger or thirst.

Fax

2008-01-30T00:09:00.000-08:00

Fax is one of the many forms of telecommunications technologies in widespread use today. You can find a fax machine in almost every office anywhere in the world. The word “fax” is short for facsimile, which is Latin for “make a copy.” Fax technology basically works by transmitting copies of documents through a telephone network using a device called a fax machine. In simple terms, a fax machine works as if you sent pieces of paper documents to a receiving end almost instantaneously.

A fax machine is basically a scanner, modem and computer printer all rolled into one. The fax process begins with scanning the graphical images from the document inputted into the fax machine. As the sender feeds paper documents into the machine, a sensor scans the document for the white and black spots that comprise it. This data is then encoded so that it can be transmitted through a phone line. At the receiver’s end, the fax machine’s mechanism marks the heat-sensitive paper with a reproduction of the original document sent.

Fax machines are indispensable office equipment. Today’s fax machines have evolved from simply sending documents to and from, to integrating various functions all into one device. Some fax machines also feature advanced handset functions and can work as the chief phone of a small office.

Multiple functions are also common to many modern fax machines. For instance, a fax machine can also work as a copier, a scanner and a printer. These multi-use fax machines virtually eliminate all other electronic machines and offer their functions all in one package. At present, even though various innovative telecommunication technologies have been introduced, fax machines continue to be an integral part of office equipment. Also, fax machines and fax services continue to evolve to better serve the needs of today’s users.

Embroidery Machines

2008-01-30T00:08:00.000-08:00

Creativity, imagination, and hands and finger skills are the keys to unlocking the success of embroidery. This art form started during the early times as a means to put designs on bare pieces of fabric by sewing or weaving pieces of threads to come up with a certain design or pattern. Anyone has to go through the painstaking process of needlework to produce the desired work of art. It was first done by drawing figures or any desired pattern on the fabric which will serve as the guide as to what types of stitches or threads were to be used.

The same creativity and imagination the paved way to the invention of embroidery machines which can be traced back in 1800s through Joshua Heilman who laid the foundation of the embroidery machine industry. It was later on followed by more advanced embroidery machines that made use of the shuttle embroidery and chain stitch embroidery methods. Embroidery sewing machines are still operated manually using the hands and fingers through the aid of other types of fabrics and materials like plastic, wire, metallic strands, and leather.

Further advancement in technology brought corresponding improvements in the embroidery industry through computerized sewing embroidery machines that can automatically come up with a design from a built-in pattern program. Using computerized embroidery machines is much easier and less costly as compared to hand and manually operated sewing machines.

Aside from the ready-made designs, users can use their creativity and imagination to make their own designs and patterns. Ready-made patterns are transferred in the computerized embroidery machines in varied means and ways, although it may depend on the design file format of the machines. CDs, special cards with features similar to compact cards, floppy discs, or cables are just a few of the things that can be used.

A Look at Soda Vending Machines

2008-01-29T05:15:00.000-08:00

Soda vending machines come in a number of sizes. You can get soda vending machines in a system that holds just four or six selections, or you can get machines that dispense dozens upon dozens of cans. Choose a smaller size if you’re looking to save money or space. Choose a larger size if you think the customers will be diverse enough in their tastes, and if you think total traffic will merit the greater number of selections.

Soda vending machines can be the closed-box type, where you can’t see the beverages, or the glass-front type, where the beverages are visible. The advantage to the closed-box type is anonymity; the customer can’t see what’s missing, and you don’t have to clean out the inside as often to make it presentable. The advantage to the see-through machines, however, is that the customer can see exactly what they’re buying. Sometimes just displaying the product clearly is enough to make the customer want to buy it.

Some machines are customizable for either cans or bottles. The bottles can be plastic or glass (although today, more manufacturers have found it more economical to offer soda in plastic bottles and glass is becoming increasingly rare). To adjust for cans or bottles, there are a number of possible mechanisms. Some are as simple as pushing or pulling a panel in the back of the machine, to simultaneously adjust all slots. The advantage to this is that you can switch up product styles to find out which style maximizes your profits at any given time. These adjustable machines also allow you to adjust the price, as with all vending machines.

Soda vending machines vary widely in price. If you want to buy new, your advantage is that there is less that is likely to go wrong, you will have warranty coverage, and you might even have service coverage on your soda machines.

Long Arm Sewing Machines

2008-01-29T05:14:00.000-08:00

Long arm sewing machines are different from models such as light weight sewing machines, medium-duty sewing machines, heavy duty sewing machines, and special purpose sewing machines.

Long arm sewing machines are Compound Feed sewing machines. They can be used for sewing medium and heavy weight materials. Features include: 18 inch long arm, auto lubrication by pump, selection of special needle gauge, safety clutch device protecting hook, vertical-axis twice large rotary hook etc. Long arm sewing machine also includes Zig Zag TONY H-301L Zig Zag Sewing Machine (Large Hook) for Mid & Heavy Material. It is used for making leather bags, shoes etc. It is also used in garment industries.

The Ontarian 300 is a long arm sewing machine produced by OSA (Ontario Sewing Automation). This long arm sewing machine has the speed of a standard 11" sewing machine. It gives the clearance under the arm of up to 72 inches. This machine is used for stitching tents, greenhouse covers, truck tarpaulins; reinforced swimming pool safety covers etc.

Juki TL98Q long arm sewing machine has the following features: easy bobbin replacement, extended sewing area, automatic needle threader without eye strain, knee lifter lever helps to lift the presser foot without using hands, sews heavy weight materials easily, machine, foot pedal switch for thread trimming increases sewing efficiency, even feed foot helps this type of machine to produce beautiful seams when sewing velvet and georgette.

Some long arm sewing machines have free space measuring 420mm width which allows the operator to handle a large sewing product easily.

Delkar Machine Company produces long arm sewing machines. These long arm sewing machines are used to stitch golf bags, filter bags, car covers, airplane covers, parachutes, aircraft fabric covers, awnings etc..

Long arm sewing machines can be purchased on-line or from local stores. Payment can be made using credit card, Master card etc.

Office Machines

2008-01-07T06:01:00.001-08:00

Finding office machines can be a real problem is the budget is tight. But the problem can be solved when you shop smart. And let’s face it, furnishing an office and finding high quality office machines on budget can be a little bit of a challenge. But with a little more effort, nothing’s impossible. Usually, a cubicle in an office can fully furnished within $6,000...but let’s just say that if you shop smartly, you can get furnishing for each cubicle done for under $3,000! And who doesn’t know you can get office machines from eBay at low prices?

First off, determine the space that you have and the budget that you have got to work within. Discuss the style that you want on the furnishings and the kind of office machines that you will need. Once you’ve got that all settled, you’re ready to get going.

Now, one way to save cost on furnishing your office is by purchasing used workstations and used office machines. Used furniture is not always drab and dirty. In fact, some used office furniture and office machines are almost brand new. They sell the office machines off cheap. There are tons of used office machines in the market, so, navigate through the flood of used office machines and furniture carefully. Although the price of the used office machines and furniture is of utmost importance, the quality and condition of the office machine and furniture should be taken into serious consideration.

Another way to get cheap tasteful office furniture and high quality office machines is to buy refurbished office machines and furniture. Refurbished office machines and furniture are, essentially used office machines and furniture, but they have been refurbished or repaired to an ‘almost new’ condition. Be careful to test out the office machines and furniture before you buy them because refurbished office machine and furniture may look fine and dandy on the outside but it may already be worn out on the inside. So, if they don’t allow you to test the office machine and furniture out, don’t buy.

Of course, another way of getting your office furnished is to lease the office machine and furniture instead of buying them right off. This helps free up some cash for the daily operations of your business. Most of these office machines and furniture leasing companies have a wide range of office machines and furniture for you to choose from and they are mostly top-of-the-line.

As you can see, furnishing an office need not be an expensive feat. The only condition is that you look at the right place at the right time. In fact, if you find someone with good contacts with office machines and furniture dealers, they may give you a big discount if you buy the office machine and furniture in bulk.

Dakota Caudilla, journalist, and website builder Dakota Caudilla lives in Texas. He is the owner and co-editor of http://www.office-machines-plus.com on which you will find a longer, more detailed version of this article.

Fax Machines Guide - Some Guidelines About Fax Machines

2008-01-07T06:00:00.000-08:00

A telecommunication tool that sends and receives documents or graphics via telephone lines is known as ‘fax machine’. Fax machine is basically a package of image scanner, a modem and a computer printer. Scanner is used to convert the content of physical documents into digital image whereas modem sends image data via phone line and printer is used to make a duplicate of original document.

Sometimes fax machines are used to scan documents into a computer and to take a print of documents from computer. Fax machines converts a picture into zeros and ones format so that data can be easily transmitted like normal computer data while on the other side it reads the data and translates zeros and ones back into dots and reprints the picture.

Fax machines are affordable and easy to use devices. Fax machines transmit data at speed from 4,800 bps to 28,800 bps. Fax machines with a speed of 9,600 bps transmit one page within 10-20 seconds. Several fax machines use thermal printer that needs special paper to print the best pictures. Thermal paper mostly comes in two sizes such as 8.5 inches wide and 10.1 inches wide.

Some fax machines come with vast variety of dialing features. It enables you to set a program to send a document at future time. Another important feature of fax machine is that you can send multi page document without feeding each and every page manually in the machine.

Latest fax machines are a bit faster than the old ones. You should determine quality, price and other important features at the time of purchasing a fax machine. You can select ‘fax modem’ in case you want to send faxes but not receive them. Choice of fax machines depends on your requirements.

Grinding shop steps up to CNC machining

2007-04-24T22:37:00.000-07:00

Rob Murnyack had been turning his professional life upside down in a quest to use CNC machining at his shop. He'd been working for his father for more than 20 years in what had become a successful grinding operation. However, Mr. Murnyack wanted to take the company to the next level--using CNC machining.

"We couldn't gather a powerful enough argument to nudge my father over the line," Mr. Murnyack says. "I can't blame him. He's 65 and has built a solid business around manual operations, and for him to invest $150,000 to $200,000 to move in a new direction was a tough sell."

Mr. Murnyack worked out a deal with his father, setting up a kind of "beta site" operation. He took several of his father's employees, a number of established customers and four manual grinding machines and began Absolute Grinding (Mentor, Ohio) in May 1994. Then, 4 months later, he found himself in Chicago, Illinois at the International Manufacturing Technology Show (IMTS).

"I wasn't making a salary at this point," he says. "Here I was looking at machines that cost $200,000 and more. I thought I was nuts. But at the same time, I realized I needed to make the investment if I wanted to shift gears to CNC."
Advertisement

Obviously, a lot rode on his first plunge into CNC machining. He chose a Studer S35cnc universal cylindrical grinding machine from United Grinding Technologies (Miamisburg, Ohio). It had a choice of a straight or angular infeed with the grinding wheel mounted left or right; wheel dressing and profiling with continuous path control; automatic grinding and dressing cycles; automatic change-over from external to internal grinding; and an automatic swiveling wheelhead. It also allows the use of up to three grinding wheels in a single workpiece program, as well as a special workhead with a C axis that permits form and thread grinding.

Mr. Murnyack notes that none of his employees were familiar with CNC, so in that respect, the new machine had to be easy to learn. "We literally self-taught ourselves," he says. "The programming was that easy."

Three years after he entered the CNC arena, Mr. Murnyack added an S36cnc, a universal cylindrical grinding machine for medium-sized workpieces. His objective was to find a quality machine that could do internal and external grinding for less than $250,000.

One of the bonuses of the grinding machine, according to Mr. Murnyack, was that it allowed the company to do random wheel shapes and more intricate configurations of the grinding wheel and of the grinding cycle. In general, it gave Absolute the ability to tackle complicated projects.

The latest addition to the company's fleet of Studers is the S31 cnc purchased in 2001. Mr. Murnyack thought he should investigate the new generation of CNC machines, which are more flexible than their predecessors and would allow the company to handle a wider variety of parts with a reduction in setup time. The S31 took care of this, with a drive-spindle power of 10 hp, grinding wheels with a maximum diameter of 20 inches, a width of 3.15 inches and an infinite B axis. It permits grinding ID, OD and tapered ID's on one machine.

"We do four or five setups a day," he explains. "This is a job shop. We can't spend 4 hours on a setup. My guys can switch from an ID operation to an OD operation on a different part in an hour with the S31. With other machines, I hear from people in the field that they might spend 4 hours just writing the program. It takes us just 5 minutes to write these programs on the CNC machines."

Because of the significant time savings the company has discovered when using CNC machines, Mr. Murnyack and his shop employees understand what a difference they can make in a shop's efficiency. Not only are these machines easy to operate, but they also provide quality machining to complicated projects. They also allow one machine to perform many tasks, rather than wasting time using several machines.

Orscheln's Screw Machine Division Installs Two New CNC Lathes

2007-04-24T22:36:00.000-07:00

Orscheln's Screw Machine Division (formerly known as Qualico Precision Products), Moberly, Missouri has recently installed two new CNC lathes.

This Orscheln location offers screw machine products, plating and coatings and is a QS9000 registered company.

The two new lathes, EmcoTurn 420MC plus models, feature two spindles with two sub-spindles and auto bar-feeders.

"These lathes represent the newest technology available," stated Orscheln's Plant Superintendent Daryl Duchesne. "They will replace several manual screw machines as well as secondary equipment since they produce finished parts. This will improve our efficiency and help lower our costs, especially on machining-intensive parts."

The company has 35 other screw machines (single and multispindle) and various secondary equipment. It specializes in high volume, long run, precision screw machine components, but is capable of low volume orders as well.

The screw machine operation works with steel, brass, aluminum, copper, stainless steel and plastics up to 1.25" diameter in round, hex, tube and square stock.
Advertisement

Over 20 variations of plating are offered at Orscheln. Its plating lines utilize barrels 36" in length and 16" in diameter.

Coatings offered include dipspin Magni-Coating, Elisha's EMC (Electrolitic Mineral Coat) process and powder coating.

The company serves a diverse range of customers in such industries as: automotive, off-highway, furniture, computer, marine, aircraft, military, lawn & garden, heavy truck, recreation, construction and agriculture.

Efficient CNC flexible system transfer saves time and money

2007-04-24T22:35:00.001-07:00

Since its organization in 1994, American Axle & Manufacturing (AAM) (Detroit, Michigan) has been proving to the industry that a U.S. manufacturer can be competitive on cost and quality. The company attributes its success to its investment in manufacturing technology and training.

To meet quality and volume requirements from a customer who hoped to increase the torque and load-bearing capabilities of its full-size pickup trucks and SUVs, AAM engineers developed a process to produce a new rear differential gear carrier. It was the largest the company had ever produced, at 118 pounds.

The process initially used a series of large horizontal machining centers (HMCs) to meet the demand for the 11.5-inch carrier. Then, using the same process, fixtures and tooling, AAM ramped up using a CNC Flexible System Transfer (FST) line from Heller Machine Tools (Troy, Michigan) when volumes went from 35,000 to 240,000 parts annually. The process and the equipment permitted the plant to respond quickly and cost-effectively to the change in demand while consistently achieving quality goals.

In developing the carrier design, AAM paid special attention to details that would positively affect the part's perceived noise, vibration or harshness characteristics, and would thereby provide an advantage to customers in the pickup truck and SUV market.
Advertisement

Once the parts were designed, the company conducted simultaneous engineering programs with three machine tool companies to evaluate each vendor's approach to its manufacturing challenge. In each case, AAM was interested in flexible manufacturing cells to handle relatively low initial production volumes. The company also looked for machine tool vendors that used Hirth couplings on their rotary tables, which AAM felt would help it meet critical tolerances. The purpose was to prove that the critical dimensions could be consistent on a machining center.

Carrier housings and differential case housings are two important axle components, which AAM machines and supplies to its customers. These parts have been produced by a number of different machining processes: for example, carrier housings were machined on single-spindle horizontal machining centers and dedicated transfer lines, as well as CNC lilt-and-carry transfer lines. The differential case housing was produced on single-spindle HMCs and lathes.

Rather than using 11 to 12 HMCs to produce the housings, AAM invested in a single Heller EST. In the experience of its Three Rivers facility, the FST has proven to be a reliable high production system and to be more cost-effective than HMCs. According to AAM, the FST has the benefits of using less floor space (in this case, about 30 percent less) and has capital costs of up to 25 percent less than conventional transfer lines.

The facility uses the 14-station FST to machine the 11.5-inch carrier housings. These operations include face milling, drilling pan holes, and machining pads for end-cap seating and rough-boring the axle tube bores. The FST then completes the boring process, maintaining the perpendicularity of bores in the carrier. Each bore is completed in three passes. Once the part is finished, it is unloaded and put on a conveyor to a robot-loaded machining center cell, where the remaining holes are drilled and tapped in the carriers. Empty fixtures in the FST are returned via an overhead conveyor to a washer and then back to the load station.

Six Heller MCP-H250 HMCs are also incorporated at Three Rivers. All the machines have HSK 100 spindles, making it possible to use the same tooling in both types of machines when necessary. A hydraulic workholding system uses swivel pads and locator points on the casting to ensure repeatable clamping. The HMCs are also capable of being retooled and refixtured for other components or to supplement production of the FST.

The FST concept uses predesigned modular units mounted on standardized bases with independently controlled stations. Three basic pre-engineered machine sizes cover component dimension, power and technology applications. System components can be combined to create the system best suited to the application. Because all interfaces between the units are standardized, engineering time is reduced and assembly is accomplished quickly, the company says.

The FST was fully assembled and run off on the Heller assembly floor in Troy prior to the delivery to the company. This allowed the FST to be fully operational and on the plant floor in a third less time than a transfer line usually demands.

CNC grinding machine

2007-04-24T22:28:00.000-07:00

The company has released its OpenCNC grinder for CNC ID, OD and centerless grinders. The grinder consists of hardware, software and documentation and has been engineered to meet the needs of machine builders, integrators, end-users and retrofitters who specialize in CNC grinding machines, the company says.

The grinder maintains the flexibility and power of open architecture, while providing ease of use and built-in features of a standard package, the company says. It is said to allow machine builders and end-users to easily upgrade or interchange machine hardware, software and peripheral components without having to re-engineer their existing machine logic.

The part programming features include: 11 wheel dressing routines, eight grinding sequences, advanced grinding wheel offset tools and an online help system. Each part program can contain as many as 20 grinding sequences.

The hardware/software package comes with wiring diagrams, documentation and pro-written PLC logic that allows machine builders or integrators to complete a control retrofit without having to spend weeks writing and debugging special machine logic, the company says.

CNC features important for lathes used on oil valves

2007-04-24T22:22:00.000-07:00

Kimray, Inc. (Oklahoma City, Oklahoma), a manufacturer of control valves and related equipment for oil-and gas-producing companies, reports a 40 to 50 percent increase in its machining efficiency, achieved largely as the result of CNC-based production equipment. Control features that simplify programming and setup on the company's latest CNC lathes contribute to this productivity trend.

Founded in 1948, Kimray operates a 125,000 square-foot facility and employs more than 250 people to serve its expanding customer base. The company machines iron, steel, aluminum and thermoplastic materials to build its line of control valves, thermostats, energy-exchange glycol pumps, gas-operated pilots and other control devices. Its products are used to control vessel and lead line temperatures, the liquid level inside pressurized vessels, pressure drops and liquid/gas flow.

The company maintains a turnkey manufacturing facility that includes dozens of lathes, grinders, turning, milling, sawing and bore finishing honing machine tools, almost all with CNC systems on board. The newest arrivals are Emco Maier Emcoturn 420 MC Pills and Hyperturn 665 MC Plus lathes, each equipped with Sinumerik 840D CNCs and Simodrive 611D drive packages from Siemens (Elk Grove Village, Illinois). Kimray operates a host system for file storage and backup on all part production data.
Advertisement

The company has been especially pleased with the CNCs. One operator explains that with the Sinumerik 840D, programming and cut and paste operations are possible even while the machine is running.

"Each screen allows you to be very detailed about what you're doing, such as separating your mains from your subs with your part and workpiece programs,' he says. "I use the Siemens CNC for axis and spindle movements on both machines. My programs and data can be accessed easily and transferred back to the machines [from the company's main host system] as needed."

He can run operations, such as milling and stenciling, out of the sub programs, he adds. "I use the parts program as my way to transfer files and folders to the main system and back again."

He commented further on the controls. "On a typical setup, I like the sensitivity. Being able to move the axis only a ten thousandth at a time to a hundred thousandth at a time comes in bandy. I also like the program test feature, especially on new programs. Each tool has its own geometry page and up to four offsets, making things less complicated."

Kimray typically machines barstock of 303, 304, 310, 316 and 17-4 stainless steel, as well as D-2 tool steel, 6061-T6 aluminum, brass and Teflon. Cast iron, ductile, steel, stainless steel and aluminum are also machined by the company.

The 665 Hyperturn machine enables four-axis machining plus full C-axis capability on both the main and counter spindles. The 665 uses some of the same programming features, plus the same digital drive systems as the 420, but in a larger package.

CNC machine for turning, drilling, milling and grinding - Modern Equipment Review

2007-04-13T04:24:00.002-07:00

The company recently introduced the Hardpoint 300, a CNC machine that combines turning, drilling, milling and grinding. It is a modular concept machine and can be configured with up to four main spindles and a variety of tooling combinations, depending on user needs. The machine can machine the front and rear faces of a single part; machine a single face on two parts simultaneously; machine the front and rear faces of two parts simultaneously; or machine a single face on four parts simultaneously.

The company says its product represents a flexible and economic machine concept for high-quality, complete machining of small components. The axes is variable, with up to ten possible. The machine offers fully automatic, synchronous complete cutting of complex workpiece geometries, up to a diameter of approximately 3" x 3" (80 mm x 80 mm).

The modular machine concept is said to ensure machining efficiency and flexibility. The various platforms are said to allow several cutting processes to be combined, thereby eliminating the need to operate multiple machines. The company says this reduces floor space requirements and operation costs. The machine incorporates an internal gantry loader. External loaders are also available as is a post-process measuring system.

Steering to greater flexibility: re-tool aging dedicated machines? For this plant, it makes more sense to spend a bit more to replace them with new, m

2007-04-13T04:24:00.001-07:00

Sure, a dedicated machine delivers faster cycle times, but when it goes down, production stops until the machine is repaired. And for what it costs to re-tool that dedicated machine for another job, you can almost buy a new, more flexible, CNC machine that is better suited to today's production requirements." If you get the feeling from the above remarks that dedicated machine tools are on the way out at Visteon's Chassis plant in Indianapolis, Indiana, you're right.

The plant, which specializes in the production of power rack and pinion steering gear assemblies for passenger cars and trucks, has eliminated about half of the dial index machines used to produce input shafts, a critical component of a power steering valve. And as the input shaft jobs running on the remaining dial index machines end or change, the plant expects to retire them, rather than re-tool them, as well.

The input shaft is a cylindrical steel component, about 6 inches long by 1 inch in diameter, machined from barstock. It requires numerous operations, including an "Op 80," in which multiple holes (hydraulic fluid passages) are drilled through the OD to a main bore running the length of the part.
Advertisement

At one time, the input valves were drilled almost exclusively on automatic dial index machines. Recently, however, the Visteon plant received an order for a new rack and pinion steering gear assembly with an input shaft that required an unusually small (1.5-mm diameter) hole. At a staff meeting to discuss the new job, the drill supplier advised that the small hole would have to be drilled at a higher rpm than the dial index machines were capable of, so the staff began considering alternate ways of producing the hole.

"We have a large number of dedicated machines in the plant, and there was a growing awareness that the time and cost involved in setting up the machines for different jobs greatly limited our efficiency and flexibility," explains Wahid Kapadia, a member of the Forward Models Engineering department. "We started looking for a CNC machine to drill the small hole for a number of reasons. First, many CNC machines offer the spindle speeds that we needed to drill the hole. Second, small drills are vulnerable to breakage, and CNC machines offer the tool control needed to minimize the problem.

"Third, we are very concerned about maintaining production rates," be continues. "When a problem arises on a dedicated machine, production stops and does not start again until the problem is solved. On the other hand, when production is spread over several standard CNC machine tools, if one machine develops a problem, the other machines continue to make parts, and although production is affected, it isn't completely stopped."

The plant first considered a CNC lathe with live tooling. However, it was unable to find a machine that offered the drilling speed required for the small hole.

Next, the plant looked at standard CNC drilling and tapping machines. Several such machines would be needed to satisfy the production volumes involved. However, because the machines would run in a largely unattended mode, some add-ons would be required to equip them for the job. One or more robots would be needed to automate the loading-unloading of parts. An indexing workholder would also be needed to index the input shaft in 90-degree increments for drilling. The prospect of buying the machines and fitting them with the workhandling equipment needed for the job was becoming daunting. A simpler solution was desired.

After more research, the plant investigated the A-Series machining centers made by Wasino Corp. U.S.A. (Rolling Meadows, Illinois). The A-Series consists of four-axis (X, Y, Z and C) machining centers with secondary turning capability. Configured more like automated turning machines than conventional machining centers, the series has a horizontal, 4,000-rpm spindle with a C axis that is programmable in 0.0001 inch increments. The spindle is served by a tool turret, which can accommodate a rotary or turning tool at each tool station.

The A-Series machines also feature an integral gantry loader that takes parts to be machined from, and returns machined parts to, a compact, carousel-like staging area at the rear of the machine. The machines come with chucks up to 10 inches (for the largest model) for handling discrete parts, as well as a spindle bore that permits feeding barstock or extrusions to the machine from a bar feeder.

One of the most important features of the machine to Visteon was that the tool turret could directly drive (with no gearing) rotary tools to speeds up to 10,000 rpm, providing the speed to drill the small hole needed for the new input shaft. Accordingly, the plant purchased the A-12 model (for 12 turret tools). To make certain that the plant would have adequate drilling speed for current and future jobs, it purchased the machine with a speeder head that doubled the maximum speed capability to 20,000 rpm

CNC multispindle - Spotlight: workholding

2007-04-13T04:23:00.000-07:00

The company has recently introduced the MultiDeco 20/8b. This machine is configured for machining parts up to 20 mm in diameter. It has eight spindles and comes equipped with an integrated bar feeder. The machine is also available in a 2 x 4 configuration. This model can be a traditional eight-spindle machine, or a two four-spindle machine to produce two relatively simple, separate parts at the same time. The model is said to combine the advantages of cam-controlled and CNC machines through the use of TB-DECO software and its PNC control.

As an eight-spindle machine, this model can produce highly complex parts featuring cross milling/drilling with 23 simultaneous axes, six cross slides and spindle and counter-spindle stops, the company says. The counter spindle has two axes capability, permitting complete machining of a part. The machine features different spindle combinations, including single-speed, two-speed and two-speed with stopping.

Rapid Planning for CNC Milling-A New Approach for Rapid Prototyping

2007-04-13T04:21:00.000-07:00

This paper presents a description of how CNC milling can be used to rapidly machine a variety of parts with minimal human intervention for process planning. The methodology presented uses a layer-based approach (like traditional rapid prototyping) for the rapid, semi-automatic machining of common manufactured part geometries in a variety of materials. Parts are machined using a plurality of 2 ½-D toolpaths from orientations about a rotary axis. Process parameters such as the number of orientations, tool containment boundaries, and tool geometry are derived from CAD slice data. In addition, automated fixturing is accomplished through the use of sacrificial support structures added to the CAD geometry. The paper begins by describing the machining methodology and then presents a number of critical issues needed to make the process automatic and efficient. Example parts machined using this methodology are then presented and discussed.

Keywords: CNC Machining, Rapid Manufacturing, Rapid Prototyping, Process Planning, Computer-Aided Manufacturing
Advertisement

Introduction

The cost of producing small numbers of parts has been driven by the cost required to process-engineer the part(s). Traditional computer-aided process planning (CAPP) systems have reduced the time required to plan machined parts, but the cost for one or two-of-a-kind machined parts is still dominated by the cost of planning the part. The current use of CNC machining for these small quantities of parts is further limited by special tooling costs and machine setup.

The typical approach to planning parts for CNC machining has been to define the "features" of the part and match these features and tolerances to a set of processes that can create the required geometry to the specified accuracy. This approach has worked reasonably well for medium to high-volume parts, but it has had marginal success for the production of very small quantities of parts. In most cases, the time required to plan the part, kit the required tooling, and set up the machine (both fixture and tooling) has limited the use of CNC for these applications. The result is that rapid deployment of CNC machining has been relegated to a simple set of part geometries. The promise of minimal process engineering is a major factor that has driven the use of freeform rapid prototyping (RP) techniques. Unfortunately, many of these processes have been restricted to a small variety of materials with limited geometric accuracy.

In the literature, process planning is often approached with a set of goals driven by high production levels of parts-that is, a set of plans that strives for cost effectiveness through maximizing feeds and speeds and creating repeatable setups that can be paid for through economies of scale. Process planning for CNC machining includes tasks such as fixture planning, toolpath planning, and tool selection. There is a considerable amount of work in the literature pertaining to these three areas (Maropoulos 1995; Chen, Lee, and Fang 1998; Joneja and Chang 1999). The concept of flexible fixturing has been the topic of much research, though a completely autonomous fixture design system has yet to be developed (Bi and Zhang 2001).

Some exploration into the use of CNC machines for rapid prototyping has been published. Chen and Song (2001) describe layer-based robot machining for rapid prototyping using machined layers that are laminated during the process. The process is demonstrated using laminated slabs of plastic, machined as individual layers upon gluing to previous layers.

A hybrid approach using both deposition and machining called shape deposition manufacturing (SDM) continues to be developed (Merz et al. 1994). For each layer, both support and build material is deposited and machined in a combined additive and subtractive process. Sarma and Wright (1997) presented Reference Free Part Encapsulation (RFPE) as a new approach to using phase-change fixturing for machining. The approach was discussed recently in conjunction with high-speed machining (HisRP) (Shin et al. 2002). RFPE, in combination with feature-based CAD/CAM was proposed as an RP system (Choi et al. 2001).

Another approach is to use CNC machining for prototyping dies, an area called rapid tooling (Radstok 1999). One approach to rapid tooling uses machined metal laminates stacked to form dies (Vouzelaud, Bagchi, and Sferro 1992; Walczyk and Hardt 1998).

Many of these methods utilize CNC machining but do not address the fundamental problems of automating a fully subtractive rapid machining approach. This paper presents a method for "feature-free" CNC machining that requires little or no human-provided process engineering. The methodology described in this paper is a purely subtractive process that can be applied to any material that can be machined. The method described herein was developed in response to the challenge of automating as much of the process engineering as possible. The ultimate goal is to generate both the NC code and an automatically executed fixturing system by the touch of a button, using only a CAD model and material data as input. The process is perfectly suited for prototypes as well as parts that are to be produced in small quantities (~1 to 10)

CNC Grinding Machine optimizes CBN in shaft production

2007-04-04T02:39:00.001-07:00

Designed for volume production of round and non-round shaft parts, Zeus M has grinding length to 950 mm, max diameter of 430 mm, and center height of 220 mm. Product handles workpieces up to 80 kg and combines cylindrical, non-round, plunge, and high-speed peel grinding (HSP) in one machine. It employs polymer Granitan machine bed, galvanic-bond and ceramic-bond CBN grinding wheels, and 130 mm rotary diamond dressing.

********************

MIAMISBURG, OH - United Grinding Technologies, Inc. (UGT) announces the Zeus M, the latest high-performance CNC universal grinding machine for round and non-round shaft parts from Studer Schaudt.

The Zeus M is designed for volume production of camshafts, crankshafts and gear shafts, as well as steering assembly parts, eccentric shafts, axle components, turbo rotors and others. With a grinding length up to 950 mm, a maximum diameter 430 mm, and a center height of 220 mm, the Zeus M handles workpieces weighing up to 80 kg. The Zeus M combines cylindrical, non-round, plunge and high-speed peel grinding (HSP) all in one machine.

A polymer Granitan machine bed provides optimum vibration dampening and thermal stability. The sliding Z-axis with digitally controlled ball screw drive and X-plus Z-axis with hydrostatic guideways offer ultra-precise axes positioning and repeatability for precision shaft grinding. High-frequency motor spindles combined with galvanic-bond and ceramic-bond CBN grinding wheels from 70 mm to 650 mm diameter enable constant circumferential grinding wheel speed of up to 200 m/sec.

The results are short grinding times, long-lasting tool life and optimum grinding performance. The 130 mm rotary diamond dressing form roll is positioned next to the tailstock for easy access, while assuring precise dimensional accuracy between the dressing tool and the grinding wheel.

CBN and compressor shafts

In most cases, gray cast iron compressor crankshafts are ground with corundum tools under optimized processing conditions, a situation that provides very little room for process improvement. However, the use of CBN as a grinding medium opens up new possibilities.

Earlier attempts to introduce CBN failed for a number of reasons - excessive cost, high wear and tear resulting from slow cutting speeds, unsuitable dressing tools and a low degree of machine rigidity.

The Zeus M has been designed and optimized specifically for the use of CBN. Cutting speeds of 200 m/sec, rotating diamond dressing tools and superior machine stability make the Zeus M an ideal CBN machine. And compared to conventional grinding approaches, CBN considerably increases the intervals between dressing and grinding wheel changes.

Clamping chuck

Another problem confronting users of more conventional process solutions is clamping the crankshaft in the eccentric chuck in order to machine the lift pin. The crankshaft is clamped eccentrically into the chuck so that the crank pin can be centered and ground cylindrically. As a certain amount of adjustment is necessary for eccentricity, expensive clamping devices and large chucks are often required.

Special chucking is no longer necessary with the Zeus M. The workpiece is clamped with ease in a central clamping chuck, and the pin is cylindrically ground using a programmed path operation. The eccentricity changeover takes place in the machine control, and manual adjustments are no longer necessary. All of this adds up to higher precision, more flexibility and shorter changeover times.

Features

The Zeus M workhead has a C-axis speed range of 1 to 300 RPM. Spindle torque is 25 Nm. The work center is typically MT 4. Tailstock quill stroke is 150 mm.

Depending on the application task the optimum guideway system can be selected accordingly. This could be the cost-effective linear anti-friction guide-way system for cylindrical grinding, the ball bearing system or the hydrostatic guide-way with hydrostatically threaded spindle for camshaft grinding.

For the two-slide versions the concept of the guide-way systems allows the movement of the two slides right next to each other with only a very small safety gap for the grinding wheel protection covers. As a result, even cams or journals positioned closely to each other can be ground simultaneously.

State-of-the-art Siemens digital control and SIMODRIVE axis drive components are at the heart of the new Zeus M. Machine operation, setup, changeover, dressing and programming of even complex parts are easily accomplished through an innovative step-by-step, on-screen operator interface developed by Studer Schaudt. The Siemens Sinumerik 840D control package features application-specific software routines. WOP (work oriented programming) system permits automatic generation of speed profiles from just a few parameters. Remote diagnostics, process control and trouble-shooting via standard telephone line and machine modem link are easily facilitated.

CNC Machine suits rotary deburr or grinding applications

2007-04-04T02:38:00.000-07:00

Developed for plier grinding applications, CNC Rotary Deburr/Grinding Machine consolidates 3 stations on single dial. Hand operations or single station rotary belt grinding operations can also be performed. Standard features include belt speed of 4,000-7,500 fpm, self-contained coolant system with filtration and magnetic separator, speed modification capabilities at each station, real-time head position and pressure monitoring, and Ethernet capability.

********************

Ultra Tech Machinery's has developed a CNC Rotary Deburr/ Grinding Machine. The technology incorporated into this machine positions it as one of the highest production machines of its type on the market. The machine was developed specifically for a plier grinding application, but the design can be utilized in any CNC rotary deburr or grinding application.

The equipment consolidates three stations on a single dial, tripling plier production. In addition, hand operations or single station rotary belt grinding operations are all performed by this diverse machine. Completing all operations in one fixturing resulted in improvements in consistency, quality and productivity.

CNC retrofit improves accuracy and productivity for aerospace components

2007-04-04T02:28:00.000-07:00

Stellex Monitor Aerospace Inc. (Amityville, New York) has completed a total CNC retrofit on the fifth of its ten Cincinnati Milacron gantry-style milling machines, which are used in the production of titanium and aluminum aerospace components. The turnkey retrofits were provided by the Siemens Machine Tool Business (Elk Grove Village, Illinois).

Originally equipped with Acramatic "Big Blue" controls, these machines now have Siemens digital servomotors and drives, Sinumerik 840D CNCs running on a Windows XP platform with 3D five-axis cutter compensation and full five-axis real-time kinematical transformation. According to Stellex Vice President Gary Kahrau, the results have already been documented to include reduced setup time, improved surface finish, reduced secondary finishing operations and significant improvements in overall productivity.

The company operates a 250,000 square-foot modern facility. There, it produces struts, spars, landing gear, bulkheads, crown beam assemblies and other medium to large parts from titanium, aluminum and stainless steels for commercial and military aircraft and aerospace vehicles, including space shuttles.

Mr. Kahrau elaborates on some of the 840D features that are benefiting the company. "The open architecture of the control allows us to create our own screens and integrate with our ERP system," he says. "We store all of our own data on a proprietary ERP system. The data files are dispatched to the CNC, where our custom Shop Workstation program resides. It handles the handshake of the data files with the control. This program is fully integrated with the control's tool management system as well."

With the real-time five-axis kinematical transformation called Traori, the 840D control can directly accept the part's workpiece definition data.

"With the extreme metal removal rates, deep pockets and long contours typically encountered in aerospace production, this feature of the CNC has demonstrable upsides every day for Stellex," says Mr. Kahrau.

He further expands upon the open HMI of the CNCs being retrofitted on the Stellex machines. "A cutter diameter compensation and customizable tool management system onboard the 840D give operators quick and accurate information in real time, plus it has the capability to accept additional features as the application demands," he explains.

Siemens also provided Stellex with an advanced dynamic machine engineering analysis called Mechatronics. First, it collects critical real-time machine performance data, and then it establishes optimized parameterization of the CNC and servodrives. Finally, the analysis verifies optimized performance of the machine. Mr. Kahrau cites the servo analysis, ball bar tests, acceleration/ deceleration tests, bi-direction compensation work-up and other protocols as being key to the end results. "Our machinery accuracy is better now than when the machines were new, our five-axis gantry has never performed so well and the rotary axis error was literally cut in half."

CNC grinder helps start a business

2007-03-29T03:59:00.001-07:00

With the economy beginning to head south, many manufacturers were searching for ways to cut costs during the late 1990s. To many, this would seem to be an inopportune time to start a niche grinding business. However, viewing the proverbial glass as being half full, Joe Scolaro saw this period as a window of opportunity.

At the time, Mr. Scolaro was a manufacturing department supervisor at a Cleveland plant, and he felt he'd "hit the ceiling" as far as potential for career advancement. He met a machinery dealer who had a used manual Studer from United Grinding (Miamisburg, Ohio) on his floor. Mr. Scolaro bought it, leased a 2,500 square-foot space, and, along with partner Dale Stebner, began knocking on doors. Thus began Venture Grinding, Inc. (Cleveland, Ohio).

Since that first used manual Studer 6 years ago, Mr. Scolaro and Mr. Stebner have bought three others--an S21, an S36 and the latest model, the S31 with a full B axis, which permits combining several operations in one chucking.

Adv

Mr. Scolaro says he started Venture Grinding to fill a niche. "Most machine shops don't have a grinding department," he says. "They do extensive turning and milling, but when it comes to grinding, most send the job out, primarily because grinding is a specific and highly variable discipline. Hardness, grit size, makeup, the dressing method and coolant are among the many aspects to be considered.

"You can teach programming relatively easily, but in a grinding operation, you must take your eyes and ears out on the floor," he continues. "Listening and feeling for vibration can indicate how a part is running. For instance, the operator can ascertain if the wheel is too hard, if the part is getting too warm or if the coolant concentration needs to be modified.

"I don't want to call grinding an art form, but there's certainly more involved in finishing a ground part than in turning or milling a part," Mr. Scolaro adds.

According to Mr. Scolaro, the last 4 years have been rough. A lot of shops Venture Grinding's size and larger have not survived. The companies that have remained, the OEMs and the bigger machine shops, have had to make every possible effort to reduce costs.

"I knew someone was still going to be making small lots of complex parts, and we stepped up our sales efforts and won jobs," Mr. Scolaro says. "Being a startup, leasing shop space, having the best machines and having low overhead, we were able to give customers a more competitive price. Sometimes we were offering same-day turnaround to get the business. That's something that companies who went overseas with their parts gave up--quick response."

One of the many factors Venture Grinding attributes to its success is the communication between the company and its customers. Mr. Scolaro explains that, in most cases, grinding is the last in a series of several operations. For instance, many jobs the company receives are from heat-treating operations. If the upstream processes fall behind in schedule, it's difficult for the company to make up the difference.

"We try to maintain a schedule, while still being flexible," Mr. Scolaro says. "If we get an order with a few days notice, it's not a problem. Because of the flexibility and reliability of the Studer machines, we can run jobs as small as two pieces to lots comprised of as many as 10,000 pieces." The Studer pictogramming and the quick-set programming feature makes rotating the B axis; maintaining the relationship between the wheels and the part; and change-over, setup and training relatively easy.

Another strategic tip Mr. Scolaro offers is the 20 percent rule. He says he tries to never have more than 20 percent of his work tied to one customer; in fact, 20 percent makes him nervous. It's not that the company turns away large orders, but it continues to look for new customers so that it is never in a position where there will be serious problems if a customer sends work overseas.

Currently, Mr. Scolaro says the company has about 16 or 17 percent of its work tied to one customer. However, he notes that taking this percentage rule too far in the other direction--for example, having less than 4 percent or 5 percent tied to each--would be unfeasible. "It would be impossible to keep track of who was doing what for whom and when, which would make scheduling problematic," explains Mr. Scolaro.

Verify CNC program correctness

2007-03-29T03:58:00.000-07:00

All CNC programs must be verified. While new programs present more challenges than proven programs, operators must be careful and alert during every step of a program's verification.

Step 1: Verify the correctness of the CNC program. This step is required for new programs or for programs that have been modified since the last time they were run (possibly because of engineering changes). It is also necessary to do this step if there is any doubt as to whether you are working with the current version of the program (after making changes at the machine the last time the job was run, perhaps the setup person forgot to save the program).

The objective of Step 1 is solely to confirm the correctness of motions commanded in the program. Other potential problems will require further verification at the machine; however, when Step 1 is successfully completed, the setup person will have confidence in the motions made by the program.

Some operators perform this step on the CNC machine during setup, which requires time. Many current model CNC machine tools have built-in toolpath displays, and as long as you verify the new program while the machine is running, you won't interfere with production. Not all CNC machines allow you to view one program's toolpath while another program is running. In this case, Step 1 will add to the setup time. If mistakes are found, the time it takes to correct them will also add to setup time.

Not all CNC machines provide toolpath display, and it is difficult to see a program's true motions by watching a CNC machine run a program. You may not be able to achieve the objective of Step 1 in this case because there might be serious mistakes to be found and corrected in Steps 2 and 3.

With the affordable off-line G-code level toolpath verification systems available, Step 1 can be performed for upcoming jobs, while the machine is running production shortly after a CNC program is created or modified. With these desktop computer-based systems, users can gain a better view of the program's movements than they could by watching the machine move.

If using an off-line system, the programmer is usually responsible for this step. They will perform this step shortly after the program is created. While most CAM systems have toolpath verification that is done as the CNC program is created, if changes are made to the G-code level program, many CAM systems cannot display the changes.

Even if changes are not made to the G-code level program, I recommend using a G-code level off-line program verification system to check the program's motions. If nothing else, this gives the programmer another way to see the motions a program is going to make before it is run on the CNC machine.

It takes a watchful eye to catch mistakes with an off-line system. Because the job is not currently on the machine, there is no real urgency, so mistakes can slip by. It might help to have someone else perform this step (another programmer or a setup person). Because the original programmer is so familiar with the job, he or she might not catch obvious mistakes. A setup person can be the best bet, since he or she will be responsible for actually running the program at the machine.

Many off-line systems don't show the location of clamps and other obstructions, so the person verifying the program must be able to visualize the placement of workholding components around the workpiece. The more problems they catch, the fewer problems there will be for the setup person to find and correct.

There may still be problems with the program's motions alter Step 1 is completed, but these problems should not be severe. Even with a toolpath display, it can be difficult to catch small motion mistakes. Some solid model-type program verification systems allow performing measurements on the virtual workpiece machined in the system; however, you must suspect that a problem exists before taking a measurement. For instance, with a mistake of less than 0.01 inch, it is likely that you may not suspect that anything is wrong.

Software aids in wheel design for CNC tools and grinders

2007-03-29T03:57:00.000-07:00

Suited for X Class range of CNC tools and cutter grinders, Wheel Editor v27 includes key hole punch software for creation of punch geometries from library of shapes. Software also enables creation of customized contours and punches with concave and convex shapes. Additional features include Delta-C R850 drill point sharpening function and Profile Pivot Editor function to optimize feedrate.

********************

Melbourne - ANCA has recently released version 27 for their X Class range of CNC Tools and Cutter Grinders. This version is packed with new innovative features that make the performance of an ANCA machine more efficient, provide significantly extended flexibility and enhance the possible spectrum of applications. The two main new features with version 27 are the addition of Key Hole Punch software and Delta-C R850 Drill Point. This increases the applications on version 27 to more industries. The Keyhole Punch software allows creation of punch geometries from a library of shapes and also allows creation of customised contours. Unlike standard punch grinders this solution is able to create punches with concave and convex shapes. Once the shape is designed the software will specify the wheel shape required to grind the punch. This wheel shape can then be loaded into the ANCA Wheel Editor. The Delta-C R850 drill point has been implemented in iGrind and is available in the drill wizard. This is a proprietary drill shape. Version 27 enables sharpening of this drill shape under license.

Version 27 has a wide range of applications, which enable users from many different industries to utilise its broad and flexible functionalities. Some of the more common applications which have been improved are:

Profile

Profile Pivot Editor function is a new feature of profile software. This option changes the way in which nine o'clock grinding positions the wheel. If full control is selected then the pivot angle can be specified at the start and end of each profile element. An option has been added in profile grinding that allows the feedrate to be optimised to maintain a constat passage of the grinding point across the profile.

Step

The wizard has been added to the Step editor operation that will allow a single DXF file to be split into multiple step sections. A new menu has been added to the Step Editor operation that allows geometry to be displayed and selected in iView.

Mist Collectors For Enclosed CNC Machines - Brief Article - Product Announcement

2007-03-24T02:03:00.002-07:00

The model F-275 Filtermist mist collector, designed for use primarily on enclosed CNC machines with an internal volume between 28 cu. ft. and 80 cu. ft., will be exhibited.

The 6" diameter intake results in very low intake velocity, reducing the likelihood that chips and large droplets will be drawn into the unit, the company says. Though designed to be mounted directly on the top of a machine, this model can be modified to be mounted on a stand or to be suspended above a machine.

The units are designed specifically for oil mist and smoke produced by machine tools such as lathes, mills and grinders. These mist collectors are intended to protect personnel from these pollutants.

A CNC Solution For Cells, Lines And Machines - C64 CNC, advanced hardware technology - Brief Article

2007-03-24T02:03:00.001-07:00

The company has developed the C64 CNC, which is designed for control of manufacturing cells, transfer machining lines and rotary index machines. Along with the ease of integration to line applications, the C64 incorporates all the features and specifications expected from a high-end CNC. Incorporating a high level of PLC technology, the C64 CNC allows for reduction in man-hours for design work with built-in PLC functions. Also, the line dedicated graphic user interface function shortens the debugging time. Moreover, the improved diagnosis function is said to minimize equipment downtime.

The advanced hardware technology has up to 14 axes of control, and using the multiple system function, one C64 CNC is capable of controlling up to seven program paths simultaneously, thus reducing overall machining line cost. Multiple C64 CNCs can be connected to the same control network to control unlimited module machines in a control line. Operating ease and work efficiency are both enhanced through the use of the "selective machining" and "process machining" functions, making it possible to graphically select only the processes and machining steps that are to be executed, according to the company. The open connectivity to major networks such as the MELSEGNET/10 and CCLINK, as well as Ethernet, Profibus, and Devicenet allows the C64 to interface with other peripheral devices, including remote IO as well as existing shopfloor management schemes.

Extended instructions broaden the control range to provide control. PLC instructions have been increased. "Multiprogramming" allows design sharing and process-by-process design. A multiple number of PLC programs can be entered and executed, enabling program design sharing and structural division by function, process or designer. With the GPPW programming tool, editing of PLC programs within the C64 can be done concurrently without stopping the built-in PLC. PLC loop control can be performed for each axis of multiple systems, using a one-axis program to save program development time and minimize the number of steps.A high-resolution 12.1" LCD, Windows CE touchscreen terminal increases functionality and flexibility. By using this terminal, the machine builder can use the standard interface or create a customized interface utilizing Visual basic or Visual C++. The terminal carries an IP65 rating and is 55mm deep, allowing for installation in severe environments and in shallow enclosures.

METALCUTTING: Turning Machines and Centers

2007-03-24T02:01:00.002-07:00

Turned parts cover such a broad range, from slender shafts and tiny precision connectors to large-bore oil-patch tubing and huge turbine shafts, that it's hard to imagine how they fall under the same category of single-point metal removal.

Whether used in the toolroom or for rapid prototyping or for high-production applications, turning centers depend on the latest advances in machine design, control technology, software, and automating load and unload devices for their effectiveness.

Visitors to IMTS 2006 can expect to see technology solutions that reflect the demands of manufacturers for singlesetup production of more and more complex parts to ever higher levels of quality. Here's what visitors should look for:

* CNC lathes with live tools, C axes, subspindles and Y axis have the capability to drill and mill off center, and are much in demand for complete part processing in a single setup.

* CNC lathes approach full multitasking capability with a B axis that allows rotation around the Y axis for drilling at an angle or contour milling off the spindle centerline
Classes of machines such as vertical turning centers and Swiss turns continue to enjoy demand because of growth in markets, including energy, aerospace, medical, and machinery.

For high-production applications, turning machines have evolved with multiple spindles, adding to the number of single-point tools that can be applied to the same part or machine multiple parts in a machine cycle.

Machines that add live (driven) tooling in the form of milling cutters, drills, and sundry other tools can perform turning and milling and other processes in a single setup, and approach true multitasking machines in capacity. Multitasking machines will be covered in the next section of our show preview.

Going to IMTS in search of your next turning machine involves adopting a strategy based on the volume and complexity of parts to be machined, the need for quick-change

change workholding and tooling, desired quality of finished part, and ease of programming. It could he a simple two-axis lathe or a Swiss-turn capable of producing the most complex precision parts in as many as ten axes.

For medical applications, electronics connectors, and a host of similar precision-machined parts, Swiss turns that machine bar, typically to 32-mm diam, are following a number of courses in development.

"Manufacturers are requiring faster changeover, as businesses want smaller hatches and smaller quantities," explains Tom Dierks, president, Tornos Technologies US Corp. (Brookfield, CT). "There is a need to set up faster and change over faster, relying on quick-change tooling or quick-change barfeeders with different bar sizes," Dierks says.

"Tornos has done a lot of things to its Swiss turns to overcome the limitations of the number of tools, for example taking a tool position and tooling it up to handle two or three tools to open up more tool positions on the machine. That's essential for more complex parts typically found in medical applications and some automotive and electronics Darts." Dierks says.

For moderately complex parts, Tornos will exhibit its Deco 20s six-axis machine. It has been boosted to a 20 (25.4)-mm diam size and features a mirror image front to back sliding headstock on the front and sliding subspindle on the back, and gang slide on front and back. "It's a much less expensive option for the user who only requires five or six axes, and it can be configured a la carte or packaged with barfeeder and driven tools for under $200,000," says Dierks.

"IMTS attendees will quickly notice that today's machines are moving in two distinct directions," says Brad Morris, president of REM Sales Inc. (East Granby, CT). "Manufacturers are being driven to do more with less, looking at all of their processes for ways to reduce or eliminate operations while improving flexibility. In doing so, many are purchasing multifunction lathes, including Swiss turns, as solutions.

"In response to this market need, Swiss turn builders are producing more complex machines capable of simultaneous operation. Many of these new machines include turrets and driven tooling for milling, drilling, and other operations not typically performed on lathes," Morris explains.

"Attendees will see more machines than at any previous show capable of helping them consolidate operations in one machine and drop parts complete. At the same time, Swiss-turn builders are also developing simpler machines that are cost-effective solutions with decent capabilities for manufacturers producing parts that demand flexibility, but don't require complex machining operations," Morris explains.

"To an outsider, it might appear that these two strategies run counter to each other. In actuality, they are working together to help machine tool builders broaden their product offerings and provide more comprehensive solutions to their customers," Morris says.

CNC Software is built on open control architecture

2007-03-24T02:01:00.001-07:00

OpenCNC[R] v6.5 enables manufacturers to integrate off-the-shelf hardware and software technologies. Set of lathe macros helps saves programming time, while hand-wheel feed feature lets user hand feed job stream up to programmed cutting and traverse speeds. Software also provides compiled HTML help menus, lead screw compensation for rotary axes, and Sercos SoftSERCANS support. With winPlot, users are provided with clear, 2D plot of machine moves.

********************

Manufacturing Data Systems, Ann Arbor, MI, announces the release of OpenCNC[R] Version 6.5 with a host of features that saves programming time and improves usability across a wide range of machine tools.

OpenCNC software, the first production-proven, unbundled, software CNC built on an open control architecture, enables manufacturers to save cost and keep up with rapidly advancing technology by integrating off-the-shelf hardware and software technologies. It was introduced to the market in 1990 and is installed on thousands of machines across a range of industries.
New set of lathe macros, including profile definition, finishing, grooving, roughing, and tool definition saves programming time, delivering the maximum machine motion for minimum programming time.

o The new Hand-Wheel Feed feature allows the user to hand feed a job stream up to the programmed cutting and traverse speeds. Handy for debugging programs, this feature allows the user to control machine motion and watch the machine tool follow a programmed path and avoid potential collisions or misfeeds in the program.

o Help menus are now compiled HTML allowing for easier searching and navigation.

o Improved lead screw compensation for rotary axes reduces complexity in set up, saving programming time and contributing to machining accuracy due to improved positioning.

o A low-cost assist for analog servos, a new driver for Sensoray526 card also will be included in the new OpenCNC release. The Sensoray526 card is an economical reader of an encoder input used to run a servo.

o Broadened Sercos SoftSERCANS support with the addition of drivers that will run more variations of Sercos drivers in use on machines today, making OpenCNC even more widely applicable to more different machine tools.

SERCOS (SErial Real-time COmmunications System) is an open, fiber-optics-based, CNC-to-digital drive interface standard. Interfacing a completely open, all-software CNC with an open digital communications standard allows the power and tuning of a servo drive to be managed entirely in software from a single PC, with just one fiber optic cable and a passive communication card between the PC and the drive.

The benefit of the OpenCNC SERCOS interface for machine tool builders and end-user manufacturers is enhanced servo performance, improved part finish, and the cost savings associated with using standard digital interfaces and non-hardware-based open solutions for communications to the machine tool versus using proprietary digital or analog drives.

Other new features include:

o The new winPlot feature allows users to display the machine coordinates during operation for diagnostic and prove-out purposes. The feature provides a clear, two-dimensional plot of machine moves.

o The winSevView feature makes it easy to search and view specific patented Significant Events / files. Significant Events are time-stamped events stored in the control in order of occurrence. With this new tool users can quickly review significant events from any time in the machine's operating history.

Unlike proprietary CNC controls, OpenCNC requires no proprietary hardware or motion control cards. Combining a soft CNC and soft PLC in a single application, OpenCNC is well suited for new equipment as well as machine control replacements and allows the easy and regular installation of software updates. OpenCNC also provides essential software tools and diagnostic features for customizing servo, spindle, ATC and other hardware interface options.

"In an industry dominated by proprietary hardware CNC solutions, MDSI has proven that high-end, multi-axis CNC machine tools can be controlled entirely from software-without any motion control cards, proprietary hardware, or embedded firmware," said an MDSI spokesperson.

OpenCNC provides a common control technology across a full range of machine tools: single- and dual-turret lathes, single- and multi-spindle precision drills, routers, mills, grinders, gear hobs, dial index machines, and gantry machines-all from a single operating system, running from a single processor.

Waterjet Machines work with EDM technology

2007-03-24T02:00:00.000-07:00

Available in 3 models, Waterjet series include stainless steel tanks, dedicated nano control, and 15 in. waterproof screen. Featuring 2D CAD-CAM software, 2-3 axis Classica offers accuracy of [+ or -]0.004 in. Suprema 4-axis' software includes Intelligent Tapering Control that corrects tapering of cut and achieves [+ or -]0.001 in. wall straightness in 1/2 in. thick steel. Evolution 5-axis' 3D System uses rotation point device to maintain constant distance from nozzle to workpiece.

********************

Wood Dale, IL - Mitsubishi introduces the first waterjet line designed specifically to work hand-in-hand with EDM technology. The Waterjet line brings speed and flexibility to EDM shops, while maintaining the level of reliability and accuracy required in EDM manufacturing.

Mitsubishi experts have played an active role in the Waterjet machines' design, making sure they're engineered specifically to work with EDM technology. Mitsubishi engineers are constantly delivering ways to increase efficiencies and boost productivity. The machine's speed is ideal for reducing production times attached to roughing and bulk material removal before finishing on EDM. For example, a time study showed a 28% time savings on materials roughed with Waterjet versus an EDM machine.

The Waterjet series is available in three different models to best fit every shop's needs. These include the 2-3 axis Classica, 4-axis Suprema, and 5-axis Evolution.

The machines feature stainless steel tanks for easier maintenance and cleaner cutting conditions. A solid base construction and custom-made table for accepting tooling systems allows Waterjet and EDM to easily work together.

The Waterjet line is powered by Mitsubishi Electric, giving it more programming capabilities than other waterjet manufacturers. The Mitsubishi 700 Series Control provides unprecedented productivity and operating comfort. Dedicated Nano control helps achieve high-precision machining. The unit is controlled on a 15-inch water-proof screen, with improved graphics and NC design to simplify operation.

The 2-3 axis Classica features 2D CAD-CAM software with nesting capabilities, and accuracy and repeatability of [+ or -] 0.004".

The 4-axis Suprema's software features (ITC) Intelligent Tapering Control, which correct tapering of the cut automatically. The CNC tilts the high-pressure water jet [+ or -]2 degrees which allows for increased cutting speeds in a contour. The ITC system can achieve [+ or -]0.001" wall straightness in half inch thick steel.

The Exclusive 5-axis Evolution 3D System uses a self-positioning rotation point device on the material to automatically maintain a constant distance from the nozzle to the workpiece. This protects the nozzle through a working range from flat work to a contoured interpolation of [+ or -]69[degrees].

The Mitsubishi Experience is providing customers with the ingenuity and innovation to stay competitive on all levels. We deliver industry-leading technology and integrated solutions to help you reach new manufacturing heights. The Mitsubishi Experience is the unparalleled support of our sales and service teams, the knowledge of our application engineers, and the expertise from specialists dedicated to maximizing your productivity.

Tecumseh sets its course: a very different kind of CNC software paves the way for creating an integrated manufacturing environment

2007-03-24T01:59:00.000-07:00

A journey of a thousand miles starts with a single step."

This ancient Chinese proverb is good to keep in mind when thinking about how a factory begins to move toward a plant-wide electronic production monitoring system. The vision of the future destination may be luminous and compelling, but turning this vision into reality is no hop, skip and a jump. It has to be taken earnestly and carefully, step by step.

In the end, plant managers will be able to access the system and get instant, up-to-the-moment reports summarizing the OEE (Overall Equipment Effectiveness) rating of the whole plant, separate production lines or even individual machine tools. Analysis of the collected data used to calculate this rating will pinpoint where problems or opportunities for improvement appear.

Here is an example of what is to come when a production monitoring system is in place: Managers are alerted to a report showing that a certain machine in one of the machining lines needed an average of 3 minutes cycle time during the last shift when it should have been closer to 2 minutes at programmed feed rates and spindle speeds. Reviewing the log of events that occurred during this shift shows that a grinding wheel was not cutting as aggressively as intended and had to be replaced at 50 percent of its expected life as a result of excessive wear. A recent change in wheel grade is recorded in notes entered by the manufacturing engineer. At the start of the next shift, a message to the cell operator gives instructions to install a harder grade wheel. Cycle times monitored during the day show a return to the required output. Problem solved.

This vision is not new. It's been talked about and dreamed about for years. In fact, the software and hardware to make it happen not only exist, but they also have a proven track record. What is becoming clear is that making the transition to this future state will be neither quick nor effortless. The first steps are the toughest, but that is where the journey begins, as the proverb reminds us.

Tecumseh Products' compressor plant near Tupelo, Mississippi, has taken those first steps, and the benefits are already clear and substantial. The plant has installed software-only CNCs on several "bottleneck" machine tools and is running key portions of a bidirectional production monitoring system that integrates the CNCs with the plant's existing computer network and ERP software. Plant management is taking the results of these initial installations as proof that these steps are definitely moving in the right direction.

Under Pressure

Although Tecumseh Products is best known for its small engines found on leading brands of lawn mowers, snow blowers and similar products, the company is a major producer of compressor motors for refrigerators and air conditioners. Consumers are not likely to be aware that the reason these products run so quietly and efficiently is the unseen presence of a Tecumseh-built compressor inside, yet the reliable performance they enjoy is dependent on the quality of those compressors. Because many of the major brands of refrigerators and air conditioners have moved production offshore, Tecumseh has had to redouble its efforts to maintain profitable operation of its compressor plants in the face of the cost pressures brought on by the severe contraction in U.S.-based appliance manufacturing.

In Tupelo, Tecumseh operates three main machining lines that feed an assembly line on which the various compressor models are built in a mix that is determined by a schedule of firm customer orders. This plant houses about 100 active metalcutting machine tools. A shop control system that relies on manual data entry allows managers to monitor production, but the information is at least 1 day old by the time it is available for analysis and response. The system tells managers basic information about labor input, machine output and scrap rates. This gives them a somewhat sketchy picture of where the bottlenecks are and when part shortages may affect the assembly line. It is adequate to tell them how to react but rarely helps them anticipate and avoid shortages that hamper the assembly line. It can't tell them what is happening inside each machine to reveal the causes of bottlenecks.

Four-Spindle CNC Lathes

2007-03-24T01:56:00.000-07:00

To maximize productivity, SB Machine Tools (Schaumburg, IL) offers Kitako four-spindle CNC lathes. With the four-spindle concept, zero loading/unloading time and virtually uninterrupted productivity come true. With their independent spindles housed in an indexing carrier and working in pairs, two preloaded chucks are continually cycled through the machining compartment. Upon completing each cycle, the carrier indexes at 180°-the two loaded spindles go to the machining area and the two "job-done" spindles go to the loading and unloading area.

Two independent turrets work on the two different, or identical, parts simultaneously, providing broad flexibility. Employing either manual loading or an automatic servo-driven loading system, the part loading process is accomplished during the machining cycle. It is very possible for just one operator to run two machines, which is equivalent to the productivity of almost five to six single-spindle CNC lathes. Kitako technology is available in both horizontal and vertical models covering 4-22" chuck sizes. Each is capable of being customized to maximize its productivity and profitability.

Contact SB Machine Tools, 1300 Remington Rd., Unit K, Schaumburg, Il 60173; Ph: 847-882-9600; Fax: 847-882-9800; or Circle 454.

Reaching New Depths And Greater Accuracy

2007-03-08T04:47:00.001-08:00

Just when you thought high speed machining or hard milling would steal the best applications from ram-type elertrical discharge machines, linear motor technology is taking "sinker EDM" to levels unattainable with any other metal removal process.

Mike Province, the vice president of Clarich Mold (Westchester, Illinois) had planned to take a vacation over the Christmas holiday but that was not going to happen. He needed to burn one more mold on his CNC ram-type (sinker) EDM. The electrode, about 4 inches wide by 6 inches long, had complex geometry and deep ribs. Instead of using those four vacation days, Mike got stuck at the shop "babysitting" the EDM process--constantly adjusting the cutting conditions and the flushing ports. Almost a year later that same job came through the door again, only this time, Mr. Province burned the job on his new EDM with linear motors. Instead of spending four days burning the mold, he spent only 15 hours. The new machine completed the job faster because it did not require any special flushing setups.

Adapting linear motors on machine tools has created a lot of interest in the last few years. This interest was apparent at Chicago's International Manufacturing Technology Show in September 2000. Several major machine builders including Cincinnati Machine, Mazak and Sodick unveiled various types of machines with linear motor drive units. Other manufacturers of servomotors or control units such as Fanuc, Mitsubishi Electric, Yaskawa and Siemens also displayed linear motor technology.

Linear motors are not a new invention. Rather, they are an innovative adaptation of an existing technology. It is, in fact, the very same technology that propels roller coasters and bullet trains to record speeds in Japan. What makes the current linear motor units so intriguing is their entry into mainstream machining operations. Many industry observers believe that linear motors will have a dramatic impact on the design of machine tool axis motion, outmoding the present technology much like CNC did to control systems a few years ago.

Linear motors are rather simple. On a CNC ram EDM, two series of magnetic plates are mounted on the Z-axis quill, along with fixed magnetic coils on each side of the axis. The basic components of a linear motor are shown in Figure l. A linear scale with very fine resolution is mounted to the Z-axis quill in order to detect axis movement location. As the control signals the Z axis destination, electrical current is introduced into the copper coils, which are adjacent to the magnet plates. The resulting difference in polarity between the plates propels them in opposite directions. Because the one set of plates is fixed, the other set is driven rapidly along its path. The more current that is introduced, the faster the moving axis will travel. The Z axis can travel more than 1,400 ipm, or nearly 22 times faster than a traditional ballscrew equipped EDM.

No Backlash

With conventional motors, before any movement is realized, the electrical motion (rotation) must be converted into mechanical (linear) motion through the use of belts, gearboxes or ballscrews. All of these conversions introduce issues of mass, inertia, backlash, lag-time, overshoot, friction and heat. Even in the case of direct-drive systems (where the motor-shaft is mounted directly to the ballscrew), it must first overcome the mass, inertia and friction of the ballscrew mechanism before it encounters the mass, inertia and friction of the table and the workpiece weight. Then of course, to stop this motion, the same amount of time and energy is required. With linear motors, most of these issues are reduced or eliminated because no conversion from rotational to linear motion takes place.

Although a linear drive produces less torque at low speed than conventional drive systems do, EDM machines don't have high-torque, high-load requirements as chip cutting machines do. Therefore, this characteristic is not an issue for EDM. Because EDM is a non-contact machining process, it is a perfect fit for linear motor technology. Unlike machining centers that take advantage of the table speeds of linear motors, EDM uses linear technology's speed for the Z axis (ram stroke) in order to create its own flushing capability. EDM also uses the speed of linear motors to react to changes in the spark gap. Linear motor EDMs will excel in difficult-to-flush applications.

Retrofit Increases Productivity And Reduces Capital Outlay

2007-03-08T04:46:00.001-08:00

Monitor Aerospace Corporation of Amityville, New York, is a producer of aerospace structural components for companies such as The Boeing Company. The company invested heavily in the 1970s in large expensive machinery, but more than 20 years later these aging machines were no longer keeping up with productivity demands. The older controls on these machines had limited functionality, and operators had to continuously tweak the machines to compensate for wear. Moreover, maintenance costs were soaring and downtime was increasing.

Gary Kahrau, director of manufacturing engineering, and Chris Nagowski, facilities manager, had a dilemma. They needed to address the machines' performance problems, but they did not have access to the enormous capital outlay necessary to replace them. Mechanically the machines were in fairly good condition, so they decided to explore retrofitting the machines with new controls as a solution to their problem. They knew that new controls would provide more flexible functionality, higher reliability and less downtime, but they also hoped that newer error compensation capabilities would help make up for some of the machines' wear related tolerance problems.

As Mr. Kahrau and Mr. Nagowski explored their retrofit options, their first task was to decide on a control. They wanted a control that would give them ease-of-use, high reliability, and sophisticated capabilities such as five-axis movements and advanced error compensation. Just as importantly, however, they wanted an open control that they could integrate into their existing plant system architecture and that would be poised for integration with undefined systems of the future.

Traditional controls offered the motion and compensation sophistication they were looking for but did not offer the flexibility and integration capabilities they wanted. On the other hand, purely PC-based controls, which offered the integration and operator flexibility they wanted, did not offer the motion sophistication they needed.

As their search went on, Mr. Kahrau and Mr. Nagowski spoke with CNC Engineering, Inc. (Enfield, Connecticut) and learned about CNC Engineering's PC-based Open Vision HMI system for the GE Fanuc series of controls. This system provides a hybrid solution that ties together a flexible and powerful PC-based front-end with the motion and compensation capabilities of a GE Fanuc control. Based on GE Fanuc's HSSB, and using an industrial PC for the operator interface, Open Vision HMI provides access to all of the control's native functions through intuitive touch screen menus. And, since the operator interface is on a PC running Windows NT, custom screens and options are readily available, and advanced network and system connectivity is fully supported.

The first machine Monitor decided to retrofit was a three-axis Cincinnati Bridgemill. This was a sound machine, but the X-axis gearboxes were worn, and the machine was not holding tolerances well. Rebuilding the gearboxes would be an expensive undertaking, and Mr. Kahrau and Mr. Nagowski thought that this expense could be avoided by applying some of the advanced error compensation functions available in a newer control. Working with CNC Engineering, a specification was developed for the control. For this application, Monitor decided to use a GE Fanuc 15MB control with CNC Engineering's standard Open Vision HMI Software. (The front-end software would run under Windows NT Workstation, and the PC initially would be connected to Monitor's Local Area Network via a standard Ethernet topography.) Since the GE Fanuc control had many options that might help compensate for the worn gear boxes, it was decided to add compensation features one at a time and perform accuracy tests after each feature was implemented to quantify the results.

Monitor has tight production schedules, and it could not spare the machine for the protracted period of time associated with a full in-field retrofit. CNC Engineering's CPR (Certified Pre-assembled Retrofit) package solved this problem. Under the CPR program, engineering and design specifications were worked out in advance during an initial site visit. During the site visit, detailed measurements were taken of the machine, and new component placement was finalized. The engineers at CNC Engineering spent considerable time working with Monitor to specify the optimum operators' pendant for the application. In this case, the original operator console was removed, freeing up a large amount of floor space, and a new three joint operator pendant was designed for maximum operator convenience. With the information from the site visit the entire retrofit package was engineered, designed and assembled at CNC Engineering's facility. During the engineering and assembly phase all necessary electrical schematics, cable lis ts, panel layouts, mechanical prints and ladder programs were developed. The exact equipment that was to be installed at Monitor was then assembled, wired and powered up. All parameters were loaded into the control, and the entire package was then tested exactly as it would be on the machine--right down to servomotors with their custom length servo cables. Once testing was finalized, the package was shipped to Monitor for field installation. For this machine the installation took 3 weeks.

Techno trucks: Roush racing

2007-03-08T04:44:00.000-08:00

I'n a western suburb of Detroit, the Roush Racing NASCAR Craftsman Truck teams have been busy all winter preparing for the 1999 season opener in Homestead, Florida. The snow-shrouded shop could be mistaken for any other factory in a row of commercial buildings that line the service drive of a major expressway leading into downtown Detroit. But inside lies one of the most organized and complete shops in racing.

Don't tell Jack Roush that NASCAR teams must be located in the Carolinas to be competitive. The Roush truck teams have been extremely successful operating right out of Michigan, thank you, with third and eighth place overall standings in the 1998 series, almost identical to 1997. And don't tell Roush he has to purchase his chassis, engines or other components from someone in the South. If it can be done at all, it can be done well by Roush Racing.

Perhaps this formula has been the secret to the success of Roush's NASCAR teams over the last few years. (Roush Racing campaigns five Winston Cup and two Busch Grand National cars, in addition to the trucks.)

Part of the credit, however, must be given to the vast amount of technology used in this operation. Everywhere I looked I saw laptop computers used for reference and data recording. Nothing is left to human memory or the possibility of miscommunication.

The Teams

The two truck teams consist of the No. 50 Grainger Ford, driven by Greg Biffle, and the No. 99 Exide Battery Ford, now piloted by Mike Bliss for 1999.

I was given a shop tour by Matt Chambers, Crew Chief for the No. 99 truck and Randy Goss, Crew Chief for the No. 50 truck. I asked them what it was like, working in close proximity to another team.

"The two teams eat their lunches together and share information and communication. It keeps everybody together," said Goss. "It's an advantage."

"Randy and I work together closely, comparing notes and finding out what works and what doesn't," Chambers added. "It saves us a lot of time." Chambers prefers working in the NASCAR Truck Series rather than the Winston Cup or Busch Grand National cars. He's been on Winston Cup and Grand National teams and thinks the trucks are the best, "especially here with Roush. This is the best team I've been on," he continued, "and I find it's a lot of fun. In Winston Cup, there's tremendous pressure to please sponsors. We know we still have to make them happy,' but the pressure doesn't seem as bad in the Truck Series. We're also very fortunate to have great sponsors, as well as great ownership."

"We still have fun," Goss chimed in. "We race hard and take it seriously, but we still enjoy ourselves. Plus, when we leave home, we know we've got a chance to win. Some teams can't say that, and it takes all the fun out of it."

The huge facility is large enough to house both teams, with plenty of space for several built-up trucks, plus the offices and fabricating and storage areas. There's even a "wall" area for practicing pit stops. Each team has bays to work on five or six trucks that are in various stages of completion. Located in the fabricating area is a machine shop, a shop where oil pans and coolers are made, a shop for making headers, a chassis-building section and a shop to create the steel body shells. Outside, the transport trucks for each team wait to be loaded for the trip to Homestead.

Technology Abounds

I visited with Kevin Caparella, an experienced shock man who builds the shock absorbers for both teams. He creates a computer profile of each track on the schedule, compares it to last year's results and prebuilds the shocks for each truck accordingly. Caparella says short tracks with higher banks, like Bristol, create his biggest problems, because "a lot is happening in a short distance"-lots of bumps and turns. He then prepares several sets of shocks for each of the two trucks, which can then be fine-tuned at the track during testing and qualifying.

Caparella logs the mileage of each component and records the changes on his laptop computer. He inspects the shocks after every race and rebuilds them after three races. He uses a dynamometer that's specially made for testing and proofing the shocks before returning them to action. Again, the dynamics of each shock are recorded on his laptop for later reference.

Brian Hoye builds the transmissions and differentials for the truck teams. He has 22 Jerico four-speed gearboxes in his inventory and prebuilds several boxes prior to each race. Hoye usually prepares a tranny and two spare boxes for each truck, while the parts truck hauls two extra units, just in case. Having eight transmissions for the two trucks gives him the flexibility to rebuild quickly at the track to suit the driver's needs.

Eight-axis CNC turn/mill machines—EMCO Maier, booth A-8540 - Turning Equipment - advertisement - Brief Article

2007-03-05T22:37:00.000-08:00

The Hyperturn 645/665MCplus, an eight-axis CNC turning-milling machine with Y and B axes is said to feature an crgonomically designed work area with straight chip drop, fully covered guideways and optimum lighting. According to the company, both dynamic spindles are powered by integrated spindle motors with synchronization and have a wide speed range, high torque and high drive power. The main spindle also has a bar capacity with a maximum diameter of 45/65 mm. The 12-station, upper tool turret Y axis and B axis (Quickmill or Powermill) have 12 driven tools and are for use on both spindles. The lower tool turret, which is also used on both spindles, features VDI quick-change system, 12 driven tools and alignment-free toolholders. The machine's control is a Sinumerik 840D with LCD color monitor.

This B-axis configuration of the Hyperturn QuickMill allows the upper turret to swivel to any position within a 45-degree arc. The combination of axial holder, radial holder and 45-degree holder can reach any angle within a 180-degree range. Its tool-change time is 0.14 second.In the configuration of the Hyperturn Powermill, a milling spindle with hollow-shaft motor takes the place of the upper turret. The B axis travels 210 degrees. The tool carrier is a 24-tool station magazine with Capto-C4 holders (48-tool stations optional). The Y axis of the machine is designed to divide the cutting forces over two guide planes. The result, the company says, is rigidity for all turning and milling operations. Travel of [+ or -]50 mm permits off-center milling and drilling. The company will show examples of its machine tool line. Some additional models on display include the Hyperturn 690 and Emcoturn 325-II.

CNC needs CNC support - computer numerical control machines

2007-03-05T22:36:00.002-08:00

Outdated secondary-operation machines were strangling the productivity of a Chicago-area screw machine shop's impressive battery of CNC screw machines. Now, CNC drilling and tapping machines and turning centers are providing secondary machining efficiency that has raised the firm's performance to a level few competitors can match.

When you drive past the building, with its concave front and narrow, close-set, floor-to-ceiling windows, you would guess an insurance firm, or an engineering or architectural firm, or perhaps an association office. In fact, the distinctive exterior pictured in Figure 1 houses the operations of General Automation, Inc., one of the most impressive screw machine shops in the country.

General Automation specializes in, among other things, Swiss screw machine parts, that is, workpieces with high length-to-diameter ratios. The firm produces them on numerous Swiss-type cam automatic screw machines, arranged like spokes on large wheels, bar feeds toward the center. (The arrangement makes the most efficient use of floor space and makes it easier for the operators to load the machines and tend their operation.)

Although cam-operated screw machines have been around for generations, they remain a very competitive method for producing workpieces in large quantities. They can produce workpieces in less time (a shorter cycle) than by most other methods.Screw machine shops are aware of the advantages of CNC screw machines; many have one or two in order to remain competitive on prototype work, short run jobs, and jobs where fast turnaround and/or high quality are critical. However, few shops are in a position to invest in enough CNC screw machines to comprise a separate department.

General Automation is one of the few. The firm operates some 63 Nomura CNC Swiss-type screw machines--the largest concentration of such machines in the U.S. The CNC Swiss-type screw machine offers a number of advantages over the older cam automatic screw machine. As its name implies, the cam automatic's cutting tool movements are controlled by a set of cams specially made for the workpiece being produced.

The CNC screw machine needs no cams. Tool movements are automatically determined by data from the dimensions of the part, fed into the machine's CNC unit. The workpiece can be programmed on the CNC right at the machine. Or, as is more often the case, the program can be prepared on a programming system located off the shop floor, and loaded in the machine's control when required. The control's "memory" is capable of storing dozens of workpiece programs; preparing the CNC screw machine to produce a different workpiece simply involves calling up the program for the next job, minimizing machine downtime between jobs.

Because CNC machine tools handle job change-overs much faster than manual or automatic machines, they are usually thought of as "short-run machines." By contrast, cam automatics, which are noted for their very rapid cycle times, are considered "production machines," ideal for producing large quantities of workpieces over long periods of time.

However, General Automation's CNC screw machines are faster than its cam automatics, so the company benefits not only from fast, easy machine setups, but from fast workpiece cycle times as well. According to General Automation president Max Starr, the CNC Swiss-type machines are frequently the most economical choice for complex workpieces, regardless of the length of the run.

Other advantages of the CNC screw machines are their greater accuracy and piece-to-piece consistency. Both are important to today's product manufacturers who demand parts machined to finer dimensional tolerances--and that those parts be within tight statistical process control parameters.

Another big advantage of the CNC screw machines--important to any job shop concerned about controlling costs--is that operator responsibilities are reduced to monitoring the machines and keeping their bar feeds filled. This enables General Automation to use less skilled operators at lower hourly rates.

Plugging into STEP NC - Emphasis: CNC - CAM software firms offer programs for CNC machines

2007-03-05T22:36:00.001-08:00

CAM software companies are offering software programs that allow their users to read STEP-NC files info their existing CAM software to generate the tool path and output for specific CNC machines. These "plugins" make many of the benefits of STEP-NC available to the average machine shop today.

The concept behind STEP NC is simple. It enables a product model database to serve as direct input to a CNC machine tool. No separate files of tool paths. No G or M codes. No post processors.

This is a radically different approach to CNC programming. It has far-reaching implications for the emerging possibilities of "e-manufacturing." Recent developments, however, promise to make it easier for CNC machine shops to make the transition to this technology Without scrapping existing machine tool and CNC programming technology, shops now have a way to implement key aspects of STEP-NC.

Several leading CAM software companies have made it possible for STEP NC files to be used with their own software. This makes their users ready to participate in supply chains that are turning to global data exchange standards to streamline the flow of digital information over the Internet. According to STEP Tools, Inc. (Troy, New York), a leading supplier of STEP software toolsets for application software developers, design firms and manufacturing companies, STEP NC offers significant savings to machine shops and their customers. The company estimates that, by fully implementing STEP NC, machine shops can reduce the time it takes to get jobs onto their machines by 35 percent if they can seamlessly read the 3D product geometry and manufacturing instructions of their customers. Likewise, original equipment manufacturers can reduce the time they spend preparing data for their suppliers by as much as 75 percent if they can seamlessly share the design and manufacturing data in their databases.

STEP Tools also estimates that STEP NC will reduce machining time for small- to mid-sized job lots by as much as 50 percent because STEP NC compliant CNC units will be capable of optimizing speeds and feeds with very little intervention from CNC programmers or machine operators. This factor could make it easier and safer to program high speed and five-axis machines, the company says, making it more likely that they will be used for small- to mid-sized job lots.

STEP NC In A Nutshell

STEP NC is an extension to STEP, the STandard for the Exchange of Product model data. STEP is the international standard that specifies a neutral data format for digital information about a product. STEP allows this data to be shared and exchanged among different and otherwise incompatible computer platforms. STEP NC standardizes how information about CNC machining can be added to parts represented in the STEP product model.

By using STEP NC to capture instructions on what steps to follow for machining the part, the "producability" of this part would not be affected by the availability a certain brand of control unit, programming system or post processor. Figure 1 compares the key features of STEP NC to current conventional approaches to creating CNC machine tool input.

If equipped with a STEP NC compliant CNC, any suitable machine tool could be designated to make the part. Because a product model database can be made accessible through the Internet, this designated machine tool could be linked to this global network virtually anywhere on earth. For manufacturing enterprises participating in a highly competitive global supply chain, this kind of flexibility is crucial. With the Internet acting as a global DNC system, the world becomes one big job shop.

Step Rather Than Leap

The availability of STEP NC software plug-ins for CAM software puts STEP NC within the reach of many shops. Currently, plug-ins are available for Gibbs CAM from Gibbs and Associates (Moorpark, California) and for Mastercam from CNC Software (Tolland, Connecticut). A plug-in for Esprit from DP Technology(Camarillo, California) will be completed soon. With these plugins (or "add-ins," as they are also called), a shop can take in a customer's STEP NC files and produce parts on existing CNC equipment.

A full implementation of STEP NC would involve equipping machine tools with CNCs customized with special software. This software enables the CNC to interpret the STEPNC data directly and use the information to machine the part without a conventional G-code program. This software is currently under development.

Machine tools with PC-based open architecture control systems may be able to install this software to upgrade to STEP NC compatibility rather effectively. The conventional input/output (I/O) structure and the servo system of the CNC machine do not need to be modified under STEP NC.

Slat cleaner removes flatbed laser slag build-up

2006-12-23T02:26:00.000-08:00

A new award-winning product from Trumpf’s Power Tool Division was shown for the first time in the UK at MACH 2006. The TSC-1 slat cleaner provides an easy method of removing the slag that builds-up during laser processing from support slats and pallets of the flatbed machine. It saves time, costs and enhances workpiece finish.

The TSC-1 is a first.

There is no other dedicated cleaning tool for this purpose and Trumpf’s innovation in this regard has resulted in it receiving the coveted 2006 UK German government Award for ‘Outstanding Innovative Achievement’.

The TSC-1 underwent rigorous assessment before being declared the winner by the Munich and Upper Bavarian Chamber of Trade.

Until now, dirty pallets either had to be replaced or manually pounded with a hammer to remove the slag build-up.

It was a process that was time-consuming, not wholly effective and certainly not beneficial to the operator’s health.

With the new TSC-1 it takes just 20 min to clean a standard slat measuring 1500mm x 3000mm.

Water jet glass cutting is quiet, easy to use

2006-12-22T02:26:00.001-08:00

In the design and construction of modern automotive vehicles such as passenger cars, buses, coaches and goods transporters, the need to integrate large sheets of glass requiring intricate, often complex cut-out areas, has presented manufacturers with problems both technical and expensive in time and money. Now a breakthrough has been established by the leading Polish automotive glass supplier Saint-Gobain Sekurit HanGlas Polska, who have found that the installation of a high-accuracy Water Jet Sweden cutting machine at their Zary Plant has enabled them to cut-out any size or shape of area easily and economically. * Traditional method - traditionally, automotive safety glass is cut to size by first using automated profiling machines with diamond wheels to slit or score the surface for subsequent snapping off by skilled workers.

Straight-line work is easy, but contours and geometric shapes call for greater skills.

It has also long been possible to make holes in glass of reasonable diameters.

What has not been so practical, until now, has been the ability to produce internal cut-outs of any desired size or complexity.

The breakthrough has come about with the advent of water jet cutting equipment.

* Simple solutions - the Zary plant took delivery of the WJS NC3020S machine 18 months ago and technical director Marek Sulik with Wojciech Lipinski’s project development team immediately set about making the process suitable for their particular needs.

Glass, by its very nature, shows up any defects that would probably not be evident no matter if present in other materials and so surface finish is of the utmost importance.

It was found, for example, that the conventional knife-edge ‘wave formation’ table normally recommended for use on the machine caused ‘ricochet’ marks on the underside of the glass and so a lot of thought and energy was put into finding an alternative means of support for the glass while being cut.

A highly-satisfactory solution was found that appeared delightfully simple in retrospect.

The table-top is positioned below the water level, but the glass sheets are supported well above it by a large number of freely positioned spacers in the form of rubber collars mounted on top of large-diameter plastic tubes.

This simple idea was immediately successful as it is now possible to quickly position the supports clear of the cutting path for any desired profile with the result that products are totally unmarked every time.

* Computer control - at a more detailed level, the development team naturally devoted much time to establishing the optimum combination of dynamic values for the various operating parameters of the abrasive water jet equipment.

These included: nozzle diameter, jet pressure (up to 4,000 bar) and rate of ramping it up, grit size (120 mesh garnet), traversing speed, including acceleration/ deceleration, and positioning.

In establishing most of these, the GE Fanuc 160i MB NC computer control system fitted was found to be extremely effective and, although it being the first controller from this supplier to be used at Zary.

Project engineer, Rutkowski, says it has been easy to program and, like the WJS machine itself, has been highly reliable.

The control panel is conveniently mounted on a swing-arm at one corner of the machine and is linked to the company’s CAD/CAM facility, so that programs for any of the many parts to be produced can be called up instantly - important where jobs are for short runs and are ordered on a JIT basis from all over Europe.

* Fast, easy and environmentally friendly - in operation, the WJS machine was found to be clean, quiet and easy to use.

After the operator has lifted a sheet of glass from the vertical storage rack, located by the workstation, with the aid of its vacuum lift cradle, it is rotated to the horizontal plane and laid on the table against the positioning stops.

This takes just a few seconds and is all that is needed to be ready to cut.

The water jet cutting machine is then switched on and will run entirely automatically as it cuts the desired internal profile(s) in the glass.

Generally the tinted glass sheets involved are up to 2200 x 1900mm in size, well within the machine’s 3.0 x 2.0m capacity, and the glass sheets may be as thick as required.

In a direct comparison with a situation where the production of windows with internal ‘holes’ was previously possible, the water jet cutting method enabled productivity to be increased by more than 300%, from 3 to 10/h.

Using the water jet system, both cut-outs and holes can be performed in a single setting without the need to transfer to a drilling machine.

* WJS accuracy attracts new business - as well as offering increased scope to designers for incorporating distinctive internal hole shapes within sheet glass, the system can also do things not possible by any other means.

For example, one designer wanted a pattern of 78 holes of 6mm diameter to be incorporated but such small holes (very close to each other) could not be drilled.

Thanks to the extremely small radii that the WJS machine can perform and its 0.1mm tolerance capability, the work could be taken on at Saint-Gobain Sekurit HanGlas Polska and, in fact, many jobs will now find their way to Zary because radii of less than 5mm are required.

Reasons for seeking internal cut-outs in vehicle glass, apart from the obvious ones of needing to position integral door handles, window latches etc, can be for enabling structural elements to pass through, for entire rear light clusters to be mounted in a back window, fuel pipe access and so on.

Ultra-high pressure waterjet systems

2006-12-22T02:26:00.000-08:00

Jet Edge, a leading manufacturer of ultra-high pressure waterjet systems, will demonstrate its latest waterjet cutting technology at the Experimental Aviation Association’s Oshkosh AirVenture, at Wittman Regional Airport in Oshkosh, Wis. During AirVenture, Jet Edge sales engineers will showcase the remarkable versatility of waterjet and abrasive waterjet cutting and discuss their many applications in the aviation industry. Jet Edge also will introduce special guest, Pilot Dave Willcock of St Catharine’s, Ontario.

Willcock has built a successful business manufacturing aircraft parts with a Jet Edge system.

His business, Profile Waterjet Cutting, has been featured in Canadian MetalWorking and Canadian Industrial Machinery.

Waterjet cutting is ideal for making aviation parts, Willcock said, noting that aircraft are a compilation of flat, thin parts.

He read a lengthy list of parts he had made for just one customer.

It included 22 items ranging from gussets and flanges to power distribution panels and custom wine racks.

‘There are hundreds or even thousands of parts,’ he said.

‘The number of parts you can make will just stagger you.’ Willcock, who owns 10 aircraft, contends that home-built aviation enthusiasts could greatly increase their productivity by using waterjet instead of conventional cutting tools.

‘Most of the stuff is made with bandsaws, hacksaws and files,’ he said.

‘If you were building an aircraft from scratch, you would save months of work in constructing a project.’ Aircraft enthusiasts also could save money by making their own specialty tools at a fraction of their retail cost, Willcock added.

Flexibility, productivity and lights out running

2006-12-21T02:25:00.001-08:00

E and R Moffat is one of the largest UK-based designers and manufacturers of commercial catering equipment. The company’s stainless steel products for the preparation, display and serving of food can be found in schools, hospitals, cruise ships, oil rigs and gourmet restaurants the world over. Although it still appreciates the value of craft skills for certain aspects of its production, it has not been slow to invest in advanced technology and purchased a Trumpf L3030 laser system with LiftMaster automatic sheet handling.

The Trumpf system not only provides flexibility, productivity and lights out running, but running costs for high speed cutting are slashed by using compressed shop air instead of high pressure nitrogen.

As R and D Technician Scott Hamilton explains, ‘We do a lot of one-off bespoke equipment such as ranges and serveries where the architect or chef will specify exactly the layout they want - so you can end up with some quite fancy cut shapes.

We have Cat Eye on it as well which means we can put a sheet back on and make further modifications if the customer decides to change their specification.’ Before the laser was installed this work was done on a Trumpf TC500 punch press, and as Scott says, using tool rotation they could cut almost anything on the TC500 that they can on the laser, but on the type of work they are doing the laser is much quicker.

‘The speed is unbelievable,’ says Scott.

‘The normal thickness for our stainless counter tops is 2mm and with normal shop compressed air we can cut this at around 12 to 13 metres per minute.

On lighter gauge material - and we go down to 0.9mm - we are cutting at up to 28 metres per minute.

‘When you cut with shop compressed air you get a gold finish on the edge rather than the conventional edge you get with high pressure nitrogen.

These edges are perfectly acceptable for welding without any further preparation, but most of our edges are turned under anyway, and once they are hidden it doesn’t matter.’ What does matter though are the cost savings.

Production cell based laser technology

2006-12-21T02:25:00.000-08:00

Remaining competitive whilst improving quality and expanding capability is a challenge that all ambitious companies face. Propbrook, one the UK’s leading privately owned elevator engineering companies is no exception. It firmly believes that continued investment in production cell based laser technology is the future for its type of work, giving it the edge on finish and unit cost.

Propbrook has always invested in high technology manufacturing to ensure that improvements in quality and productivity go hand in hand.

It was the first UK customer for TRUMPF’s TC2020R punch press and also for the L2510 2D laser cutting machine.

Although punching still has an important role at Propbrook, the company’s commitment to laser technology is clear.

Its latest acquisition, TRUMPF’s L2510, complements established L2503 and L3030 machines ‘We are very much involved in bespoke marketing,’ explains Chairman David Yates.

‘Batch sizes range considerably.

We work in anything from 20 gauge to 12mm, producing small parts through to panels in mild steel and stainless.

So we need the versatility of laser to respond quickly to the needs of our customers.’ Lights out production is the aim for Propbrook now.

‘The longstanding support relationship we have with TRUMPF and the build quality of its machines are important factors here,’ David Yates continues.

Servo-controlled high speed press brake

2006-12-20T02:25:00.001-08:00

LVD will display a PPEB servo-controlled press brake featuring the Easy-Form Laser adaptive bending system and high-speed turbo package at MACH2006, Hall 4, stand 4665. The PPEB-EFL Turbo 80/25 - 80 Tonne by 2.5 metre model will be exhibited. In process Advanced Angle Measurement with Easy-Form Laser The PPEB press brake displayed at MACH2006 will feature LVD’s Easy-Form Laser adaptive bending technology.

Easy-Form Laser is a unique angle measurement device that uses a laser to monitor and correct the angle in real time during the bending process, producing accurate bending results from the first piece.

Easy-Form Laser uses symmetrical measurement at the front and back of the die to determine the exact value of the angle of the workpiece.

The system projects straight lines composed of multiple light points onto the workpiece and the vertical part of the die, providing a measurement calculation every 20 milliseconds.

The sensing device transmits information in real time to the CNC control unit, which processes it and subsequently recalculates the correct depth adjustment to obtain the correct angle.

The bending process is not interrupted, and no production time is lost.

Unlike mechanical angle control systems, Easy-Form Laser does not extend the cycle duration and provides accurate results consistently.

It does not require calibration after each set-up.

High-speed Turbo The press brake displayed at MACH2006 will be equipped with a high-speed turbo hydraulic system, which is now available on PPEB press brakes up to 350 tons.

The turbo system increases the approach, pressing and return speeds of the press brake ram by as much as 30 percent compared to standard machines of the same size and type.

Increasing the operating speed of larger capacity press brakes improves flexibility and provides the ability to produce parts that would typically be assigned to smaller machines with higher performance.

Faster pressing speeds improve the output of higher tonnage press brakes particularly when using wide dies that require deeper penetration of the punch and longer ram travel.

LVD’s PPEB series of precision press brakes are equipped with state-of-the-art hydraulics and electronics and are offered in multi-axis configurations.

PPEB press brakes are built on a rigid frame design to ensure accuracy.

PPEB press brakes are available in working lengths from 1.5 to 15 m with tonnages up to 3000 tons.

Powerful CADMAN CNC Control and Software All PPEB press brakes feature the exclusive CADMAN control.

CADMAN is a powerful PC-based control complete with Windows operating system and the CADMAN-B 3D programming software.

The high quality design of the press brake coupled with the CADMAN control help ensure the consistency of the bend over the entire part length.

The CADMAN control, equipped with an Intel Pentium microprocessor and a 2-gigabyte hard drive, creates and stores interactive databases for bend allowance, angle corrections and spring-back.

These user-generated databases, created by actual bending results, are searched and applied each time a part program is generated.

This automatic optimization of the part program eliminates trial bending, and reduces the time required to produce a quality part.

CADMAN-B 3D software is standard in the machine control and is available as an offline programming system.

The databases developed and maintained in the PPEB press brake can be duplicated and downloaded to the offline system.

Having actual bending technologies available prior to part creation eliminates unwanted errors in the actual blank generation prior to bending, and assures accurate part tolerances throughout the process.

The LVD group based in Gullegem - Belgium is a leading worldwide designer, manufacturer and distributor of a comprehensive range of sheet metal / plate working machine tools and software solutions, including laser cutting systems, punch presses, press brakes, guillotines and automated flexible manufacturing systems - all supported by its’ CADMAN PC-based, Windows compatible programming system for punching, laser cutting and bending.

5kW linear CNC laser cutting machine

2006-12-20T02:25:00.000-08:00

Being shown for the very first time in the UK LVD will introduce the Axel 3015S 5Kw Linear CNC laser cutting machine at MACH2006, Hall 4, Stand 4665. The Axel 3015S 5kw Linear provides advanced laser cutting capabilities and high-speed part processing combined with integrated automation to maximize machine productivity and facilitate unattended operation. The laser cutting machine incorporates the most recent advancements in linear drive technology, laser power and control systems to provide superior cutting capabilities, greater flexibility and ease of use.

The Axel 3015 S offers optimum performance when processing both thin sheets and thick materials.

A high pressure (clean cut) cutting head is available for 5′, 7.5′ or 10′ cutting lens.

The high-pressure cutting head produces exceptionally clean cuts and is equipped with a safety system that protects the head from collision with the workpiece The Axel 3015 S on display at MACH2006 will feature a 5 kW laser source.

The high beam quality of the 5 kW laser allows processing of thin material at extremely high speeds up to 40 metres/min in 1.0mm material and thick material with high quality surface finishes.

A new 10′ cutting lens allows the Axel to process thick mild steel10 mm to 15 mm,10 to 15 percent faster.

The 10′ lens permits processing of 25 mm mild steel with a 4 kW laser source.

Using the 10′ lens, 20 mm mild steel can be processed at 1000 mm/min, 10 mm mild steel can be cut at speeds of 2000 mm/min.

The laser source, CNC and servomotors are integrated and interfaced as a complete system to optimize machine performance, offering high speed and reliability, low operating and maintenance costs.

The monoframe design incorporates high precision hardened guideways and optimal driving system to achieve high-speed acceleration and positioning speeds.

The Axel 3015 S boasts an improved frame design with increased stiffness.

The rigid frame construction minimizes deformation caused by high acceleration, improving overall machine accuracy.

LVD’s Axel 3015 S features a constant beam length system that keeps the diameter of the laser beam constant and consequently always maintains a fixed focal point position.

This results in higher cutting speeds and superior cut quality maintained over the entire working area.

The Axel 3015 S is now available with LVD’s exclusive Win-Executor software.

The software further simplifies machine use by providing an explanation of error messages, automatic calculation of stand off distance, and graphic display during the cutting process.

The Axel laser system combines high-speed part processing with integrated shuttle tables for continuous, uninterrupted part processing.

The shuttle table design allows one table to be loaded while the machine is cutting on the other table, maximizing uptime.

The Axel 3015 S features a newly redesigned shuttle table drive system with double-driven timing belt for improved machine performance and reliability.

Table change time is now three times faster and is completed in 15 seconds.

Shuttle tables are driven by a coupled toothed belt, which also provides faster and smoother pallet changing.

The laser system’s working area is enclosed with a protective plexiglass cabin that provides a clear view of the cutting process.

The manually operated rotating door also allows easy access for machine maintenance.

The LVD group based in Gullegem - Belgium is a leading worldwide designer, manufacturer and distributor of a comprehensive range of sheet metal / plate working machine tools and software solutions, including laser cutting systems, punch presses, press brakes, guillotines and automated flexible manufacturing systems - all supported by its’ CADMAN PC-based, Windows compatible programming system for punching, laser cutting and bending.

CNC turret punch press with automated load

2006-12-19T02:25:00.001-08:00

Being shown for the very first time in the UK LVD will introduce its high speed, high productivity Global 20 1225, a 200 kN CNC turret punch press, with Automated Load - Pick and Sort System at MACH 2006, Hall 4, stand 4665. The Global 20 1225 is part of LVD’s Global 20 series of high performance turret punch presses. The machine combines high production technologies to address the fabricating requirements of job shops and O.E.M.s around the world.

Its unique contemporary design provides a rigid base for precision punching.

Key features include large sheet processing capability, a 30-station turret with large auto-index capacity, and state-of-the-art GE Fanuc CNC control.

The Global 1225 on display at MACH2006 will feature a Robot Automated Load and Pick-Sort system for fast, cost effective cut-part unloading.

The robotic system handles cut part dimensions up to 1000 x 2000 mm with an unload time of 12 seconds per part.

The Global 1225 processes workpieces up to 2500 x 1250 mm.

Working area capacity with one repositioning is 5000 x 1250 mm.

The punch press has an advanced hydraulic press drive optimized for high-speed operation.

This high-speed hydraulic system delivers up to 400 hits per minute on 25 mm centers and is capable of producing at 1000 strokes per minute in continuous nibbling mode.

The hydraulic ram also offers the flexibility of electronic adjustments and features that take advantage of the intuitive control interaction.

Users can apply custom settings or alterations to stroke elements such as depth offset, dwell and ram speed, to further maximize machine capabilities.

Fully programmable stroke profiles and the exclusive Smart Stroke feature also maximize punching performance and provide flexibility for punching and forming applications.

Smart Stroke maximizes the productivity of the Global 1225 without operator or programmer intervention.

Smart Stroke automatically optimizes the punch cycle by determining the hover height based on material thickness and distance between holes.

The Global 20 1225 features a 30-station turret with station-to-station tool change in less than 1 second.

Replaceable, hardened steel guide bushings eliminate turret tool bore wear.

The turret punch press is available with up to four dia 88.9 mm auto-index stations.

Three auto-index stations are standard with the machine.

Turret capacity can be further increased with the addition of 3- or 8-station indexable Multi-Tools to expand the number of auto-indexable tools.

Full Wheel tool capabilities (cutting and forming) together with thread tapping also expand turret flexibility.

The Global 20 1225 is equipped with three programmable, relocatable work clamps, which can be programmed to a position on the X carriage and individually relocated to a new position within the part program.

Applications for the water-jet cutting process

2006-12-19T02:25:00.000-08:00

Flexible water-jet cutting technology can be used in practically all sectors of industry - an article by Peter Longman, Area Manager, KMT Waterjet Systems. The aerospace, building and construction, mechanical engineering, glass industry, wood, textiles and paper manufacturing sectors are all taking advantage of this versatile process. In addition, the automotive and its supplier industries, as well as the electrical, electronic and food processing and defence industries have all emerged as markets for some of the more novel applications of water-jet.

High-speed prototyping and flexible, just-in-time production are well suited to water-jet whilst new applications including cleaning, recycling and decommissioning.

Unlike traditional thermal cutting methods, water-jet cutting technology has major advantages in terms of its high level of cost-effectiveness and flexibility.

The most diverse materials can be quickly and precisely worked using a high-pressure jet of water.

Material thicknesses of 150 mm or more present no difficulties for this cutting processes.

The water-jet achieves optimum cut-edge qualities on both simple and extremely complex contours.

Water- jet cutting falls into general 2D and 3D applications.

2D include the cutting of sheet metal such as: stainless steel, carbon steel, high-alloy nickel steels, aluminium, titanium and copper.

Construction materials include decorative stone, marble, granite, tiles, plasterboard, glass and mineral wool.

Glass covers: laminated glass, safety glass, and bulletproof glass.

Foodstuffs can range from baked goods to deep-frozen products and fish.

Paper, cardboard, corrugated cardboard, printing papers together with miscellaneous materials such as: plywood, leather, textiles, composites, rubber, plastics, sealing materials and foams are also typical 2D applications.

3D and robot applications cover abrasive cutting of titanium, aluminium and stainless steel motor-vehicle components; turbine blades, decorative stone or marble.

Pure water cutting can be used for motor-vehicle components such as carpets, door-trims, fenders, dashboards, instrument panels, rear shelves.

The essential benefits of the water-jet cutting system are the fact that there are no heat-affected zones, no thermal hardening and no material stresses.

From a health and safety point of view there are also no gases and no production of dust or fumes.

Production benefits include the fact that there is no need to sharpen tools whilst high cutting speeds.

high cutting accuracy and high surface quality can be achieved.

Secondary operations such as deburring can be omitted and re-working becomes unnecessary.

Burr-free cut edges, a narrow cutting gap and low tangential forces exerted on the component also provide user benefits.

Waterjet can be used for both cleaning and removing layers of materials from the surface of products.

KMT’s Streamline pump range can provide high pressure to the Rotojet nozzle so that cleaning can be undertaken in an environmentally friendly way without any gases.

The base material’s integrity is not affected and the process is therefore ideally suited to applications such as jet engine turbine blade decontamination.

As part of the restoration and repair of gas turbine jet engine components undertaken by Wood Group Component Repair, coatings need to be stripped from turbine components prior to re-application.

In order to refine the coating removal process, Wood Group is currently carrying out development work using a KMT waterjet system.

This significantly speeds up the process without affecting the base material.

Hundreds of different coatings are applied to the turbine component parts by plasma arc deposition - mainly on to casings and seal areas where the ceramic or other coating is intended to wear in preference to the mating part.

At present the plasma sprayed coatings are removed by conventional machining, acid bath and grit blasting.

This is a very time consuming operation and some of the base material is removed during the operation.

These problems are eliminated by the waterjet process comprising of a Streamline SL IV 50Hp pump that produces 3,800bar (55,000psi) working pressure.