Complete CNC Information

CNC Cutting Machine

2008-08-22T02:58:00.003-07:00

A good quality CNC cutting machine has a cutting table that covers the area bounded by a length of four feet and a width of eight feet. A quality table can handle satisfactorily a standard 4 x 8 plate of metal, wood, plastic, glass, or stone. A table that lacks a sufficient length or width will make it necessary for the operator to repeatedly reposition the plate. Operators of the CNC cutting machine refer to such repositioning as indexing.

A good basic CNC cutting machine does both plasma and oxyfuel cutting. Refinements on a basic cutting machine might provide it with the ability to perform other functions, functions such as:

-spotting holes for drilling

-drilling aluminum

-cutting a shape in the sides or end of tubing

-routing wooden shapes

Other modifications on a CNC cutting machine might be directed at installation of the equipment for laser or water jet cutting.

The selection of a CNC cutting machine will be primarily determined by the nature of cutting that will be performed by the machine operator. For some operations, it will be necessary to do only straight cutting. For other operations, the cutting machine must perform bevel cutting. Bevel cutting allows the operator to trim, reduce, shave, and pare the material in the plate.

Both types of cutting will subject the CNC cutting machine to a fair amount of wear and tear. The manufacturer therefore needs to purchase a machine with adequate customer support. Such support should include the availability of spare parts. An absence of spare parts could require that the electronics of the CNC cutting machine undergo a retrofitting.

A need for retrofitting would deprive the operator of important production time. The need for retrofitting would diminish the quantity of goods that could be sold to the consumer. The need for retrofitting leads to a decrease in the amount of time that the operator will be spending at the CNC cutting machine. That is why the availability of spare parts for a malfunctioning CNC cutting machine remains one of the two chief concerns of the manufacturer. A second prime concern is the size of the cutting table.

The operator of a CNC cutting machine that needs to spend a large percent of time indexing will not have much time to spend on the actual cutting. Hence, the manufacturer will have much less product. Fewer products from the manufacturing facility translate into fewer products on the shelf. Consequently, the need for operators to spend time indexing can prove a detriment to the company’s bottom line. A good sales volume reflects the well-planned purchase of a CNC cutting machine.

Peter Vermeeren is the owner and webmaster of: Machines and Tools and Airsoft GOT | Tactical Gear | Military Supplies

Article Source: http://EzineArticles.com/?expert=Peter_Vermeeren

Controlling CNC and You

2008-08-22T02:58:00.002-07:00

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 appropriate commands to our machines, at appropriate times so they are not "out of control".

The language that these machines use is called G-code. 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 will need to use a computer to talk with our CNC machine. 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 motors drive our various axis on our CNC 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 to use

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

Machine Controllers

Controllers generally stand alone near the CNC machine. They act as a translator between your control computer and your CNC 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.

Don is active in G Code and CNC Milling.

CNC Machine is part of his expertise.

Article Source: http://EzineArticles.com/?expert=Don_Edge

The Mini CNC Machine

2008-08-22T02:58:00.001-07:00

The mini CNC machine gives the manufacturer a way to reduce cycle time. The mini CNC machine helps the manufacturer to avoid a long void between the end of one operation and the start of the next operation. The manufacturer who decides to purchase a mini CNC machine has chosen to apply the principles of cycle time to the area of production machinery.

The nature of the mini CNC machine creates three ways by which miniaturization can pave the way for cycle time reduction. This article will list three ways by which a manufacturer can reduce cycle time. It will also provide details concerning how the mini CNC machine permits the manufacturer to apply the principles of cycle time reduction to the operation of the mini CNC machine, and ultimately to the process of machine production.

The effort to reduce the manufacturers cycle time begins with an attempt to minimize the amount of time that operators spend loading and unloading various materials. The operator of a CNC machine will work more efficiently if he or she is able to minimize the workplace loading and unloading. This minimization is achieved through use of the mini CNC machine.

The operator of the mini CNC machine can save time by using large bed sizes and a small footprint. The operator of a mini CNC machine will save money by loading into the machine a wide piece of material and then limiting each process (cutting, engraving, routing, and drilling) to a small footprint.

The operator of a CNC-based piece of equipment can reduce cycle time by reducing the tool maintenance time. Such a reduction is made possible by the mini CNC machine. The small size of the miniaturized machines facilitates the creation of multiple design options. The large number of options leads to creation of a generous number of spare parts. Meanwhile the surplus of spare parts guarantees the ready replacement of any malfunctioning parts.

The operator of a mini CNC machine also reduces cycle time by decreasing the program execution time. The clamping of small elements to the mini CNC machine and the automation of the tiny machine parts leads to a lowering of operator intervention. Whenever operators can afford to devote less time to matching the quality of a previous result, then the manufacturer saves money.

It thus becomes obvious that the characteristics of the mini CNC machine guarantee the application by the operator of the principles of cycle time. Three aspects of any CNC program fall under the control of the product manufacturer.

1) The time required for workplace equipment to accomplish the loading and unloading of the material that requires a transformation (a cutting, drilling, routing or engraving),

2) The length of the program execution time,

3) The length of the tool maintenance time.

The ability of a mini CNC machine to substantially alter any of the above three aspects could lead to a reduction in cycle time. A reduction in cycle time could improve performance of the process machinery.

Peter Vermeeren is the owner and webmaster of: Machines and Tools - Airsoft GOT | Tactical Gear - Kamikaze Martial Arts.

Article Source: http://EzineArticles.com/?expert=Peter_Vermeeren

Conseco, Pioneer Financial complete merger; Conseco executives exercise options to purchase common shares

2008-02-15T03:56:00.001-08:00

CARMEL, Ind.--(BUSINESS WIRE)--May 30, 1997--Conseco, Inc. (NYSE:CNC) today completed its merger with Pioneer Financial Services, Inc. (NYSE:PFS). As a result of the merger, PFS is now a wholly owned subsidiary of Conseco.

In the merger, each outstanding share of PFS common stock was converted into the right to receive 0.7077 of a share of Conseco common stock. First Union National Bank of North Carolina will act as agent for the conversion. Appropriate forms for presenting PFS stock certificates will be mailed shortly to all PFS stockholders of record. For further information, holders may contact First Union at (800) 829-8432. Each $1,000 of PFS's 6- 1/2% Convertible Subordinated Notes due 2003 will be convertible into 35.385 shares of Conseco common stock. Conseco also announced that its chief executive officer and executive vice presidents exercised outstanding vested stock options to purchase approximately 8.6 million shares of the company's common stock. The options exercised would otherwise have remained exercisable for approximately seven years. As a result of the exercise, the company will be able to realize a tax deduction of approximately $225 million, equal to the aggregate tax gain recognized by the executives as a result of the exercise. No cash was either received or paid by the participants in the program; participants paid for the exercised options by tendering approximately 2.9 million previously owned shares and Conseco withheld approximately 2.6 million shares from the exercise proceeds to cover federal and state taxes owed by the executives as a result of the exercise transaction.
As part of the inducement to exercise the options, the Compensation Committee, composed entirely of nonmanagement directors, also granted new options at the current market price to the executive officers equal to the number of shares surrendered and withheld for the exercise price and taxes.

Net of withheld shares, the participants received a total of 3.1 million shares of common stock in the program. As a result of the program, the number of shares owned by executives increased and the dilution attributable to stock options decreased, Conseco said. The program also made it possible for the executives to avoid having to sell a large number of shares in the open market to pay the tax obligations generated by the option exercise, thereby eliminating a potentially adverse effect on the market price of Conseco stock.

Conseco is a financial services organization headquartered in Carmel, Ind. Through its subsidiaries, Conseco is one of the nation's leading providers of supplemental health insurance, retirement annuities and universal life insurance.

NOTE TO EDITORS: There is an "at" symbol between "ir" and "conseco.com" below. That symbol may not appear properly in some systems.

Remote oil filter adapter

2008-02-15T03:54:00.000-08:00

Stef's now offers a remote oil filter adapter machined out of 6061 T6 aluminum billet that bolts to the stock filter mount and can be used for a remote oil filter or oil cooler. It is a high-flow compact design that eliminates chassis clearance problems common to other remote adapters. Stef's remote filter adapters are black anodized to prevent corrosion especially in marine applications.They come as a complete kit with grade 8 Allen-head bolts, Buna-N-- Silicone O-rings and your choice of -10 or -12 hose fittings. Installation takes just a few minutes and Stef's quality CNC-machine finish ensures a leak-free installation. Stef's offers remote oil filter adapters for most popular big- and small-block Chevy applications. For information, write to Stef's Fabrication Specialties, 693 Cross St.,Lakewood, N.J. 08701, or call (732) 364-6700; website, www.stefs.com.

Exhaust systems for GM trucks

2008-02-14T03:02:00.000-08:00

Dynatech's new SuperMAXX exhaust systems for Chevy/GMC trucks and SUVs are engineered for a direct bolt-on fit, are fully OBD-II compatible, and retain all emission connections. These precision-- crafted, complete header exhaust systems feature CNC mandrel bent long tube headers, dual stainless-steel hi-flow cats, and NASCAR-style 2-1 racing merge Ys. All SuperMAXX systems use stainless steel materials throughout and aerospace T-304 polished stainless header tubing. Recent dyno testing showed improved stump pulling torque and 17 more rear-wheel horsepower on 5.3L engines. One system fits '00-'03, 4.6L and 5.3L, two- and four-- wheel drive, Chevy Silverado/GMC Sierra 1500 pick-ups, Avalanche, Suburban, and Tahoe/Yukon. For information, callDynatech, (800) 848-5850, or log on to www.dynatechheaders.com.

Linear motor drive translates to high velocity

2008-02-14T03:00:00.000-08:00

The company's SVC 2000L vertical machining center is driven by a linear motor, with acceleration and axis positioning from 4,724 ipm in the X axis to 1,969 ipm in Y and Z axes.

The table size is 133.86" x 20.08". A 30-hp integral spindle can achieve a top speed of 12,000 rpm in 0.8 seconds. Other features include a 40-taper tool shank and standard 30-tool magazine. Chip-to-chip tool change time is 4 seconds. The company says that the top area of the door opening is completely open, which enables the user to load and unload workpieces with an overhead crane.

The unit comes equipped with the Mazatrol fusion 640M CNC. Programming is conversational, and existing programs can be modified with editing, which makes for reduced programming time and length.For more information from Mazak Corp., call (859) 342-1700 or enter MMS Direct code 278VB at www.mmsonllne.com

Advertsing To Spending Seniors

2008-02-02T02:45:00.000-08:00

Advertising to seniors about groceries. - Do you eat food? So do seniors? Do you buy products? So do seniors. In fact, as a group, seniors are tremendous consumers of grocery-related consumables. Seniors—and advertisers know this—are tremendously interested in health-care related products such as vitamins, dietary supplements, and nutritional aids. Alongside of advertisements, Today’s Senior Magazine includes information about the type of news and information seniors want.

Advertising to seniors about health products - Seniors are concerned about their health. That’s why marketing to baby boomers for prescription medication and other health-related products makes complete sense. Seniors are looking for advertisements that will lead them to quality health products. Amidst advertisements for health-related issues, Today’s Senior Magazine also provides informative articles on health issues.

Advertising to seniors about travel – Seniors typically have the discretionary income and leisure time to travel more than other age groups. Focusing advertising efforts on traveling seniors makes complete sense. Today’s Senior Magazine provides advertisements on senior travel coupled with informative articles on popular travel destinations and pastimes. Advertisers offering air, RV, or cruise information will find Today’s Senior Magazine a great resource.

Advertising to seniors about leisure – Seniors have leisure time, so here’s an advertiser’s dream opportunity. Those that are 50+ spend time with pets, grandchildren, preparing scrapbooks, and photo albums. If you’re an advertiser attempting to sell any products or services, marketing to seniors should be considered. Advertising to the baby boomers isn’t just about the things they must buy, but also the things they want to buy.

Today’s Senior Magazine is an advertiser’s answer to how to reach baby boomers and those 50+. Whether you are promoting an online business or a brick-and-mortar store, seniors will be seeing your advertisements both online and in print.

Paid Online Surveys -- Two Tips for the Tricks

2008-02-02T02:43:00.000-08:00

It’s excitingly easy to spend your free time doing online surveys…and it may pay quite well, too. Paid survey companies are competing for your attention and are ready to pay from a couple of dollars to $75 to grab and file your opinion. Online surveys have also become a legitimate source of income for hundreds of thousands of people worldwide. Getting paid to complete online surveys is simple and rewarding.

What should you expect once you register with a paid survey database? First, you will receive email invitations to complete upcoming surveys. You should be careful to check the survey availability as soon as you can, because very often survey companies gather the required number of survey responses very quickly and close the particular survey. If you can’t complete the survey short from receiving the invitation email, you stand a chance that the number of consumer responses needed has been reached before you get to complete the survey. Even though completing paid online surveys is easy and simple, lazing about may help you miss a lot of profitable and exciting opportunities. Second, do you need to worry about the questions survey companies ask at registration? Many beginner survey takers have worried that they should answer specific questions about their household, income and interests. This is standard procedure, no need to worry. Even though not every survey company will require these answers, they help build your user profile and boost your relevancy to a larger number of future surveys. Some survey companies have optional categories – you may complete the “Interests” section only, and skip the “Financial” information. However, this may limit the diversity and hence the number of surveys you receive. You may get the surveys about golf and CD players, but not the surveys about mortgage plans, car lease or loan repayment schemes. While general surveys are definitely fun, the more particular and complex surveys are normally the highest paid ones.

Keeping in mind these two pieces of advice, you are ready to maximize your return on time investment in paid online surveys. To access a database of reliable paid surveys options, visit http://www.surveysponsors.com.

Applying for Nursing School Grants

2008-02-01T02:30:00.000-08:00

If you are planning to attend nursing school, one of the biggest factors you have to consider is the cost of tuition. The obvious question is, will you be able to afford it? If you lack the resources, do not lose hope. Like millions of others who are in a similar situation, you can get financial assistance through nursing school grants.

Nursing school grants are like gifts, which means they are free, given by various organizations to help those interested in a nursing career to get the necessary education. Majority of nursing school grants are needs based, which means eligibility depends on your financial need. Other eligibility requirements such as good scholastic record depend on the agency.

The US Government provides an excellent program known as Free Application for Federal Student Aid or FAFSA. Through FAFSA, you can start your application for nursing school grants and other forms of financial aid. Most organizations that provide financial assistance to students use the information in this application form to determine if a student is qualified to receive a grant.

Some of the information and documents you will need to complete your FAFSA are your Social Security Number, driver's license, income tax return, recent bank statements, and if you are not a US national, a permanent residence card. You will be more efficient in your application, if you secure all the documents you need first before filling out an application.

It is very important that you provide complete and accurate information on your application. If the school or the government verifies that you have provided misleading information, your application will be denied or you will be obligated to pay not only the amount of the grant but other fines as well.

FAFSA forms are available in high schools and colleges, the education department offices in your state, many community libraries and on the FAFSA website. You can send your filled-out and signed FAFSA form to a processing unit or, alternatively, submit an application online.

Time is of the essence when applying for nursing school grants. It is critical that you complete and send your application on or before the deadline. Deadlines vary for each state, school, or agency so be sure to find out the exact deadlines. Many financial aid counselors recommend that you send your applications a year early. Do not wait to apply after you have already started school, as processing takes time and funding for grants do have a limit.

Washington D.C. Car Insurance - Where to Get the Best Rates

2008-02-01T02:28:00.000-08:00

Have you compared prices on your Washington D.C. car insurance lately? If you haven’t, you're probably not getting the best rate you can. With a little fast and easy research, you can get the best rates and save hundreds of dollars on your auto insurance.

Visit an Insurance Comparison Website

To find the best rates on your Washington D.C. auto insurance, begin by visiting an insurance comparison website on the Internet. An insurance comparison website lets you quickly and easily compare auto insurance quotes so you know you're getting the best rate.

If you have any questions about your auto insurance, the best insurance comparison websites have an online chat feature so you can get your questions answered by insurance professionals.

Complete your Insurance Information

At the insurance comparison website you'll complete a form with information about your:

* Driving habits, such as the number of miles you drive each year and any tickets or accidents you've had.

* Vehicles, such as the year, make, model, and safety features.

* Personal information, such as your name, address, and age.

* Coverage amounts you want. The higher you set your coverage limits, the higher your rate will be.

* Deductibles for comprehensive and collision coverage. The higher you set your deductibles, the lower your rate will be. If your auto is more than five years old, you may want to drop comprehensive and collision coverage altogether.

Compare Your Quotes and Choose the Best Rate

Once you've completed your form, you'll soon have multiple auto insurance quotes from A-rated companies to choose from. You can then compare the quotes and choose the company with the best one.

By taking a few minutes to shop around and compare quotes, you'll be able to find the best Washington D.C. car insurance rate.

Ultimate Wealth Package Review - Will It Bring You Ultimate Wealth?

2008-01-31T03:45:00.000-08:00

Ultimate Wealth Package is a complete internet marketing course by Guru Mark Warren. There are hundreds if not thousands of internet marketing courses on the internet, most of which are useless. But is Ultimate Wealth Package different? I set out to find out.

The first thing I noticed when opening Ultimate Wealth Package was the table of contents. The chapters looked like they covered everything. But a lot of courses I had read looked complete and were really full of air. So I continued.

I found that the course is well written, full of information and easy to follow. And definitely has something in there for veteran internet markers as well as beginners. For the beginners, it has everything you need to know to start working from home.

Mark literally takes you by the hand and walks you through the world of internet marketing. Every step of the way he shows you exactly what to do – leaving nothing to the imagination. It really is a complete guide.

Ultimate Wealth Package also has an 8 week risk free money back guarantee so you don’t have to worry about wasting your money. Mark also offers an amazing 108 bonus items with the course as well as a ready made marketing website, ready to use so you can start earning straight away.

So, does Ultimate Wealth Package do what it says on the tin and really bring you ultimate wealth? Well as with anything you need to put some hard work into it but if you do it delivers. Ultimate Wealth Package is definitely one of the most comprehensive and complete internet marketing guides on the internet and as well worth your time.

State Criminal Records

2008-01-31T03:44:00.000-08:00

State criminal records include abbreviated conviction and arrest information from most county and state government agencies. County criminal records are not always reported at the state level. Some state courts make their records available on the Internet, but some states exclude the sensitive personal information online in their criminal records. State courts have to ensure a balance between privacy and accountability while providing criminal data online.

While some state courts offer comprehensive access of their records free of charge, some state courts charge a prescribed fee for online accessibility. The accessibility of the court records online to the public users allows them to monitor the fairness and the equality of operations in the judicial system. The criminal records that are provided by state courts online are in different forms ranging from state services to single jurisdictions. Moreover, if the state courts provide the cost-free, uniform, consistent, and user-friendly information via Internet, it will be useful to the public. They should consider these facts while granting electronic access of their records. So providing online accessibility of criminal records is a great challenge to the state courts.

Statewide searches of criminal records require 3 to 5 days in most states. Strictly speaking, a county level criminal record check is a better option when compared to a state check from a practical perspective because receiving information from a state court takes much more time to have a complete history of felonies and misdemeanors. Indeed all the state criminal indexes receive their date from the counties only. If any error is there in a county criminal record, then obviously state records may not be genuine and complete. Therefore the best option is searching both statewide and countywide indexes.

A Complete Body Sculpting Routine for Men

2008-01-30T01:41:00.000-08:00

When you're looking for a complete body sculpting routine for men, you have a number of routes to take. You might hire on a personal trainer to help you formulate a plan. Or you might look to books or websites for your information. While all of these methods can give you a sense of what to include in a complete body sculpting routine for men, you need the exercises that will really work to improve your fitness levels. Here in this article is a no-nonsense body sculpting workout plan that will help you achieve your goals.

The first portion of a complete body sculpting routine for men is the upper body routine. Because many men are already comfortable with exercise for this area of the body, it's generally the part of the body that's well-defined and toned. Here are some simple exercises that can be used for the upper body:

* Pushups – targets the entire upper body and upper back

* Military presses – take a barbell or dumbbells in each hand to lift the hands above the shoulders, pressing towards the ceiling. You can also alternate one arm at a time to help protect your low back.

* Bench presses – lying on a weight bench, you will push the weights up from the shoulders

* Bicep curls – take a weight in one hand and lift into a curl position to the shoulder

* Tricep dips – on a weight bench, place your palms behind your body, slowly lower the upper body down

But many men forget that a complete body sculpting routine for men should include lower body exercises as well. This will help the body be balanced in its tone and symmetry – no sense in having great arms if your legs are skinny and underdeveloped. Here are some exercises that will work well for a complete body sculpting routine for men:

* Squats – either with weights in the hand or with squat machine

* Calf raises – standing up on your toes as far as you can, hold and slowly lower again

* Quad extensions – on a weight machine, sit and then extend your leg until straight

* Hamstring curls – using a machine or simply standing, bend your leg towards your buttocks

A complete body sculpting routine for men is a great way to define your whole body in a short amount of time – without needing a lot of equipment or background. And don't forget to add some abdominal work to your complete body sculpting routine for men too.

Without Hassle You Can Get No Call Faxless Payday Loans Help You Get The Funds You Need FAST

2008-01-07T05:39:00.000-08:00

If you're looking for a way to have complete privacy, with no person-to-person contact no call faxless payday loans may be your solution. The loan application is completed online, without having to make any personal contact whatsoever. You loan application is usually evaluated within minutes and your loan is accepted or denied.

Before you go online to complete the application for faxless payday loans, its a good idea to have some basic information ready. Youll need information to verify your identity, your employment, and your home address. Social security number, and drivers license number is required, so have it handy if you dont remember each.

No Call Faxless Payday Loans Gather Your Information Before You Apply

Youll also need specific information to verify your employment and a copy of your most recent pay stub. This information will be verified, so make sure to enter it accurately.

Therell also be specific bank information required, such as routing number and your account number. In most cases you must be the owner of the account where the loan amount will be deposited.

Once youve entered all the information and your loan is approved, the money will usually be deposited into your account within twenty-four hours.

The process is simple and easy to complete. What happens afterwards may not be so easy. Its important for you to understand that the interest rates charged on many of these no call faxless payday loans can be very high. Some ay be as high as thirty dollars per hundred borrowed.

This interest is monthly. For example, lets say you borrowed $100.00. At the end of the first month you would owe $130.00. Interest continues to accrue at this rate until you pay the balance owed.

These types of loans can be very helpful during times of emergencies. Sometimes we all get into desperate situations. One way to avoid regular use of faxless payday loans is to try to work a different payment schedule with your creditors. If theres an unusual occurrence in your life, explain the situation. Many times creditors are willing to work with you as long as you talk with them.

Using no call faxless payday loans as a regular source of borrowing is not recommended. The amount of money youll wind up paying in interest can be very high. Make sure you understand the full amount youll be paying back before you choose this type of loan

ERP for the Little Guy

2008-01-07T05:38:00.001-08:00

Most of the news and information you hear on the web or read in print about ERP relates to SAP, Oracle and other large systems. There is a derth of information on ERP for the small shop or for the under 10 million dollar manufacturer. What then do people do when they have graduated from Peachtree or Quickbooks? Is it possible to get a complete integrated system that manages their entire operations and finance areas?

Well fortunately, there are a few solutions that will not break the bank and will provide end-to-end functionality for a small manufacturer or distributor. These software are surprisingly complete. In fact, there are often features and functionality that beat the main-stream big systems.

One such system is called IntegrateIT. This system provides a well rounded set of features that allow the small manufacturer the ability to run the company with a complete understanding of what is in inventory, what am I making today, what should I buy today, where is my cash position and am I profitable? Surprisingly, this software has modules that many larger ERP systems do not have, such as Field Service. It is amazing the amount of power that these smaller systems have. This link is one such example of how this system saved a company thousands of dollars.

Another solution is DBA Software. Having gone through a major rewrite of their core solution, they are both complete in functionality and have a very current underpinning of technology. This solution provides a very easy to use system for the smaller firm.

What makes these systems perfect for the smaller enterprise? The fact that they get more done with fewer screens. On a mid-tier solution, there maybe 2 to 5 screens needed to process a transaction such as entering a voucher or creating a work order. These smaller solutions tend to do it in one to two screens with all the information you need at your fingertips. The idea is that in larger companies, there is a delegation of work. In the smaller company, you may have one person wearing many hats and they need efficiency in transaction processing.

So the when you are thinking of integrated software solutions, remember that big isn’t necessarily an answer. Amazing things often come in small packages.

ERP for the Little Guy

2008-01-07T05:38:00.000-08:00

How They're Made - Gates Underwater Video Housings

2007-12-19T22:18:00.000-08:00

Ever wonder what goes into manufacturing a Gates Underwater Video Housing? We did, so we took a trip to San Diego to answer that question for ourselves. Gates Underwater Products has long been known for their durable and dependable housings, the following article will show you what goes into the manufacturing of their housings and what makes the Gates name synonymous with reliability and durability.

Design

To begin, the housing goes through an initial design phase, which includes taking very detailed and accurate measurements of every aspect of the camera. This information is input into the design software, so the team can determine exactly what they want the housing to look like and how it will function. All Gates housings use mechanical controls, so this portion of the design is crucial.

Once a design is chosen, the Gates engineers will begin working on a prototype. The process used for making prototypes is exactly the same as that used for the final product. Prototypes allow them to test the product and incorporate changes well before the housing goes into production.

Machining

Each housing is machined out of a solid block of 6061-T6 Aluminum, as shown in . 6061 is the grade of aluminum, and T6 is the temper process which imparts strength. Without the T6 temper, the aluminum would be much softer and flex under pressure. The T6 temper is a necessary component of achieving the 450ft depth rating, which all Gates housings have.

The machining of these aluminum blocks is done on a CNC (computer numerical control) machine. The CNC is operated by a computer "controller" that reads G-code instructions and drives a machine tool, which selectively removes metal according to the design parameters entered into the machine. Not only is the main body of the housing created during this process, but the holes for controls are also completed. Using CNC for this step ensures the accurate placement of controls.

Compared to extrusions and castings, which can have porosity and warping issues, the machining process allows Gates to maintain very close tolerances with very high accuracy between each part.

Assembly

Once the machining process is complete, the aluminum sections of the housings undergo a Type III hard black anodize finish. (Anodizing uses controlled electrolytic oxidation to develop an aluminum oxide coating on the surface of an aluminum sheet or finished part. The resultant coating is dense and file-hard.) Of the three major types of anodizing, Type III produces the best wear performance and is highly heat resistant.

Once anodized, the housings are delivered to the assembly room for control placement and final assembly. During the final process, all housings controls are manipulate with a camera installed, to ensure proper control placement and operation.

Testing

After assembly is complete, every housing is tested to ensure structural integrity. The housings undergo three separate tests; Once in water and twice under a vacuum. During the vacuum tests, the controls are manipulated to ensure o-ring integrity and control operation.

Summary

Although new features and improvements are designed into virtually every Gates video housing, the manufacturing process remains basically the same. This enables Gates to maintain the highest level of quality between housing models and ensures that, regardless of which model you buy, your Gates housing is guaranteed to be reliable and durable. That's why they say:

CNC Machines - The Leaders In Precision Technology Machines

2007-12-19T22:17:00.000-08:00

The evolution of computer numerically controlled technology, leading to higher speeds and more reliability allowed the development of machine controllers adapted to new production systems. Most of the controllers are developed in agreement with the CNC technology of the correspondent machine tool manufacturer. As a consequence; the characteristics of the CNC and the microcomputer are combined. Some researchers have addressed a flexible structure of software and hardware allowing changes in the hardware basic configuration and all control software levels.

Camware software is an integrated program to execute certain functions in these CNC systems. Today, CNC technology is a major contributor to the production capacity of industrial companies. A complex network of post-processors is therefore needed for the basic functionality of CNC systems. The necessary knowledge transformations from the vendor specific software domain to the conceptual model space are essential. This will eliminate the requirement for postprocessors. Consequently, resources will be interchangeable and interoperable, adding to the strategic agility of the manufacturing network.

CNC tool cutter and grinder chosen by leading industries are high precision tools and reliability is paramount. Whether you manufacture standard high precision cutting and drilling tools, need to sharpen standard or special tools or manufacture parts for very special applications, the camware software provides the toughness and flexibility you require. This software enables application support in all markets and can offer services that will allow you to accept special projects and deliver results in a short period of time. You can be confident that as your business expands into new application fields. Again Flexible manufacturing systems (FMS) can be created by combining any of this CNC machines with any of vertical articulated robots. The robot can be mounted on a linear slide base to provide mobility and increase its work area. Additional devices, such as storage systems and part feeders, can be added to expand the range of tasks performed by the system. FMS station in CIM system Enriched with advanced technologies generated by the company's industrial activity, and supported by effective didactic methods.

Regardless of how advanced a technology is it can only fully benefit from its advantages when the user masters it perfectly. Increasing competitive pressure demands optimized production. But how can the productivity be increased significantly? How can setup times and machine downtimes be minimized and any fault analyses and fault corrections be made as easily as possible? The solution: CNC technology. CNC machining allows you to integrate your machine tools faster and more securely in your production network - for the smooth planning, scheduling and execution of your production using data that is always current. This gives you the decisive information for significant, increased productivity. Ideal solutions for every functional area Motion Control Information System provides a complete spectrum of powerful software modules for the acquisition and optimization of your production processes. These software modules guarantee simple integration of the machines in your ERP environment. The software is modular and uniformly matched with each other. This allows the system to always be customized to your production - independent of the size and requirements profile.

A lathe that doesn't turn the workpiece

2007-07-25T04:36:00.000-07:00

The essence of turning on a lathe is to rotate the workpiece as a rigidly held cutting tool is brought to bear along the length or across the face of the workpiece. One class of lathes, however, holds the workpiece steady as the toolhead rotates around it. Cams or CNC servo units within the head move two or more cutting tools to perform a variety of lathe-type operations. This configuration allows such a machine to produce "turned" parts that would be difficult, more costly or slower to produce any other way.
The concept of holding the stock steady while rotating a toolhead around it was developed more than 50 years ago by a parts maker in Switzerland. Esco, the Swiss company formed to build machines embodying this concept, continues to design and manufacture these unusual lathes as part of its Escomatic line. Although all of these machines follow the Esco turning concept, the line includes standard and customized versions, several of which incorporate units for machining the front end and/or the back end of the part to produce it complete on one machine. In North America, Tornos Technologies (Brookfield, Connecticut) is now responsible for service, sales and application support of new and existing Escomatic lathes.

One of the most important benefits of rotating the toolhead around the stationary workpiece stock is that it can be fed as bars or coils from 0.02 mm to 12 mm in diameter. Round or profiled material can be used. Large coils of material allow continuous machining for extended periods without downtime. The stock is held in place by feed rollers and a set of guide bushings as material is removed by cutting tools in the rotating wheelhead.
For coiled stock up to 6 mm in diameter, a straightening unit must be used to straighten the incoming material before it is fed into the rollers and guide bushings. A rotating straightener is standard on the Esco machine line. It revolves around the stock, straightening it with a combination of moves as the stock passes through five bushings. The center bushing is adjustable; it cambers the stock as the unit rotates. For material from 6 mm to 9 mm in diameter, a roller straightener is available.

After passing through the straightener, the material is clamped between a set of grooved rollers, which rotate to feed the material into the cutting zone. The grooves can be round for wire or contoured to match profiled stock. By locating the rollers close to the guide bushing, small diameter wire can be machined without bending or whipping.

Depending on the model, the toolhead rotates between 8,000 to 12,000 rpm. The toolholders pivot into the workpiece stock rather than entering directly along the radial axis. The resulting tool stroke follows an arc, helping to compensate for the outward thrust of centrifugal force. The tool stroke is very short, minimizing cycle time. After the machining cycle is complete, a counter collet supports the workpiece for cutoff. Supporting the part produces a flat, clean end with no nib at the center.

Workpieces that lend themselves to production on these machines include automotive parts, connectors, components for watch making, jewelry, parts for lock manufacturing, medical and dental components.

Software Technology Links Motion Control to PC-based System

2007-07-25T04:35:00.000-07:00

In traditional automation systems, the tasks are clearly distributed. A programmable logic controller (PLC) links inputs and outputs, and the CNC coordinates the motion of the axes. Today, parts of the drive control are performed by either corresponding PLC functions or special positioning mpdules, or they are delegated to a lower level within the position controller itself as in the case of servo amplifiers. With the advent of local intelligent power electronics, the entire control circuit and the integral profile generator are often embedded in the drive. Units such as these are now only parameterized by the higher-level control system, and usually receive their jobs via a field bus.
In contrast, other systems feature central control systems that assume the power control of the individual drives. In these cases, it is essential to have a fast bus connection between the power and monitoring sections and the control system, which is connected to a high-performance computer.

The strength of a motion control system stands and falls with the performance, flexibility, and scope of functions offered. In particular, the convenient, simplified handling of the software blocks that control the drive technology is a key advantage. Sophisticated, specialized motions, whose direct programming would be highly intricate in the DIN language of CNC, can be easily realized by using function blocks. In such cases, operator control is simplified and more understandable, especially if the necessary communication between function blocks takes place in the background, without involving the user.

Enhanced CAD/CAM Software—PartMaker Software/IMCS Inc., booth 5441

2007-07-04T03:34:00.000-07:00

Intended for use with CNC mills, lathes, wire EDM, turn-mill centers and Swiss-type lathes, PartMaker version 7.8 features a range of expanded functionalities, including enhancements to the Surface Machining Wizard (SMW) module, 3D simulation and the introduction of a production milling module. The latter of the three modules is designed to provide improved simulation capabilities for multi-axis milling attachments, including fourth-axis and fifth-axis rotary tables and tombstone fixtures. For cylindrical parts, chucks can be created and simulated as well.Calculation of surfacing tool paths using SMW is faster in this latest version when compared to previous releases, says PartMaker Software/IMCS Inc. In addition, new surfacing capabilities have been incorporated to support four-axis milling for setups that support continuous rotary milling on a CNC mill, turn-mill or Swiss-type lathe.

CAD/CAM Software facilitates staircase design/production

2007-07-04T03:32:00.000-07:00

Incorporating a wealth of new features for faster and simpler operation, the modular CAD/CAM system, comprising staircad and staircam, provides everything needed to enable staircases to be designed, costed and manufactured quickly and effectively.

Both alphastair V6 modules feature a completely revised Graphical User Interface (GUI), which enables operators to rapidly add or delete toolbars, as well as tailor screen layouts to their individual requirements. Staircad and staircam also share a fully integrated database with single point data entry, and the system's new graphically based menus allow all relevant information to be specified and updated simply and accurately.
Advertisement

In-built checking routines within alphastair ensure that all designs conform to latest Building Regulations in the UK and can be adapted for other countries. In addition, staircad automatically provides fully detailed 3D CAD drawings and materials lists, along with accurate costings and ready-to-sign quotations printed on company branded stationery, if required.

Revisions to the product design, material specification, overhead and margin can all be accommodated instantly by the software, with costings and quotations recalculated at the click of a mouse button.

Close integration between staircad and staircam provides automatic generation of CNC machine code directly from the system's common database, using either pre-configured or user specified tools, speeds and feeds. Staircam also supports manual nesting of components on the machine tool bed, for maximum raw material and enhanced tool utilisation. Similarly, the system will provide board assembly lists and glue-up schedules on demand, for optimum manufacturing efficiency.

Direct linking of alphastair V6 with alphacim and alphacim lite business management systems enables sales order processing, the calculation of cutting lists and invoicing all to be automated. It also provides information for built-in bar coding and part labelling, as well as a comprehensive variety of management reports to further streamline the operation of order-based joinery manufacturing companies.

Like other alphacam CAD/CAM software releases, alphastair V6 will be available world-wide in all major languages. It will also be backed by local customer helpdesks, advanced on-site or remote system support, comprehensive product training programmes and the company's networking, installation and IT consultancy services.

About alphacam

Alphacam, along with radan, jobshop and cabinet vision, are principal brands of Planit Holdings plc. The organisation's product range encompasses design to manufacturing applications and Enterprise Resource Planning software solutions for companies operating throughout the metal, woodworking, stone and sheet metal manufacturing sector. In addition, Planit International offers leading retail design software. The group is a multi-million pound global business, with operations in Europe, the Americas, Taiwan and Japan, as well as a network of approved distributors and dealers throughout North and South America, Asia, the Middle East, South Africa and the Pacific Rim.

System Measures Surface Finish And Profiles - Lemforder Corporation production information - Brief Article

2007-06-19T02:03:00.000-07:00

Lemforder Corporation, a Lancaster, South Carolina, company, is a full-service supplier of steering components and suspension systems for trucks and buses. Its engineers work closely with large-vehicle manufacturing customers, offering prototype development and manufacturing.

As a quality systems supplier, Lemforder imposes strict internal quality demands on its components. Many machined parts feature bearing surfaces that will come into moving contact with mating parts made of metal, plastics or powder metal. These bearing surfaces, which can have complex geometries, must meet certain surface finish requirements to ensure product functionality and durability.

Lemforder machines many round components with varying diameters, complex surface contours, tight surface roughness specs and internal features. The company's previous surface measuring machine, while capable of performing satisfactory surface measurements on round parts, bad several limitations.

According to Sri Burugapalli, quality manager at Lemforder, "It was beyond the capabilities of the machine to measure straight or non-round surfaces."

Testing protocols required technicians to run the surface-measuring probe across a reference standard that matched the particular surface finish that was being inspected. The quality laboratory maintained a number of these reference standards. To identify surfaces of blind holes or through-holes and internal threads, quality technicians were required to "feel" for these features using a probe. "In some cases, we had to inspect blind holes and internal threads destructively," explains Mr. Burugapalli.

Occasionally, quality engineers required more detailed information than the surface finish machine and comparator could provide. This required sending the part out to an inspection vendor.

The company found it needed greater quality verification on surface finish and profile measurements of the machined components going into its automotive suspension systems. When searching for better ways to measure surface finish and part profiles, Mr. Burugapalli expected he would have to buy two separate pieces of equipment. "We talked to a number of suppliers. Most offered these capacities in two separate machines, a comparator for profiles and a surface finish measuring system for the surfaces. They may have one computer that linked the two machines, but you were limited to using only one measuring system at a time and had to move the parts from machine to machine."

Although the initial search revealed that most suppliers could not provide both capabilities in a single unit, the Surftest SVC524 from Mitutoyo America Corporation (Aurora, Illinois) proved to be a pleasant surprise. This single instrument made it unnecessary for quality technicians to move parts from one measuring system to another to complete an inspection. Only two probe heads are needed to satisfy these measuring requirements. The new system eliminated the costly requirement of cutting open sample parts to inspect internal features and profiles.

The Surftest altered Mr. Burugapalli's expectations. "It offered us both these measuring functions in a small footprint, had more capabilities then the other systems, and the price was very competitive. It represented a $20,000 savings versus the cost of having to buy two different machines to perform the respective measurement functions." To perform both measuring functions, the Surftest requires only two interchangeable heads.

According to Mr. Burugapalli, the system gives Lemforder many measuring advantages. "Its ability to perform internal profiling was extremely attractive. Also, it gives us the flexibility to use the surface gage or the comparator to check external features and profiles."

Today, quality technicians use the Surftest to measure threads, canduct surface measurements of corners, radii and merging arcs. "We can measure exact profiles of these types of parts," says Mr. Burugapalli. "If we have three or more circular features in a small area, a wave feature for example, the Surftest measures it very accurately." Quality technicians can inspect all surfaces: straight, round, contoured and wavy. "We can perform linear checks, no matter what the surface shape is," adds Mr. Burugapalli. "As long as the scribe can access a feature, the machine can measure it."

These measuring capabilities give design engineers at Lemforder greater confidence in their ability to design and build steering and suspension components and systems. "Buying the Surftest gives us confidence and verification about our machining processes," says Mr. Burugapalli. "The benefit is we know we can meet internal demands for producing quality components and products."

Now, setup times are shorter for some parts. "Occasionally a part might need both surface finish and profile measurements," says Mr. Burugapalli. "With a few basic adjustments we can do both in one setup." To change over from one inspection method to the other, the technician simply switches probe heads and tells the computer which head is now installed.

Case Inserts and Tote Liners utilize PNP technology. Identification For Positive Component Control, Accountability

2007-06-19T02:02:00.000-07:00

Available in fabricated foam, laminated composite, and conductive/anti-static materials, case inserts and tote liners feature PNP (Part No. in the Pocket) labeling technology, which ensures positive component identification and protection. PNP labeling technology, located in bottom of tool or component silhouette pocket/cavity, is protected by clear, plastic laminate and aids in inventory control, component accountability, organization, and security. GEORGETOWN, MA-UFP Technologies, Inc., a leading manufacturer of custom engineered packaging materials, introduces its new PNP (Part # in the Pocket; US Patent #08034462) technology for positive component identification. UFP's Case Inserts and Totes, when used with PNP Technology ensure positive component identification and protection for the industrial, medical, military, automotive, EMS and shipping/packaging industries. Applications include military, medical/surgical instruments and kits, assembly, production, manufacturing, material handling, distribution fulfillment kits, electronic components, production tools, field maintenance tools, sales samples and many other industrial applications.

The Part Numbers in the Pocket are located in the bottom of a tool or component silhouette pocket/cavity and are protected by a clear, plastic laminate. PNP are ideal for reordering components or specialty tools and allow the user to know the exact part number when requesting a replacement.
Advertisement

Available in a wide variety of materials such as fabricated foams, laminated composites and conductive/anti-static materials, UFP's case inserts and tote liners with PNP labeling technology enhance inventory control, component accountability, organization, security and aesthetics. Case inserts or tote liners can be water jet cut or CNC routed, which make them easily revised without tooling, providing a cost effective solution for low to medium volume applications. Offered in a variety of colors to enhance product appearance and accessibility, UFP's case inserts can be designed to meet individual customer specifications and budgets, as well as more stringent applications such as use in a clean room environment.

UFP provides both single and multiple material/process turnkey solutions, from durable functional case inserts and totes for applications ranging from rough duty uses such as field maintenance and emergency response kits, to high aesthetics sales sample kits featuring one or more attractive colors. UFP's engineering also team delivers turnaround design and prototyping services. For applications demanding organization, asset management and/or increased productivity, two color shadow box foam organizers are designed for the storage and protection of tools and instruments.

About UFP Technologies, Inc.

UFP Technologies, Inc. (NASDAQ-UFPT) is a converter and fabricator of foams, plastics and natural fiber materials. The company serves the medical, consumer, automotive, industrial, electronics and military markets from its 10 North American manufacturing facilities. UFP specializes in custom solutions using foam fabrication, foam molding, laminating, plastic thermoforming and molded fiber/pulp.

No wires, no worries: is it safe to make your shop floor a "hot spot" for wireless DNC and other data communication? This shop's experience shows that

2007-06-18T05:28:00.001-07:00

According to Mike Carrier, Miller's engineering manager, that experience convinced the company to install a wireless network for downloading data such as NC programs to machines on the shop floor (a procedure often called DNC for direct or distributed numerical control). This wireless network replaces the cables that physically connect the machine tool CNCs. "Fortunately, we had only three machines active at the time, or we might have lost more from the lightning strike," Mr. Carrier says. The shop had been planning to connect all of its CNC machines to this network, but the expense and difficulty of stringing wire across the factory to reach additional machines had delayed further progress.

A network that does not need wired connections obviously avoids that obstacle and would make it possible for Miller to use DNC on all of its CNC machines. Wireless connections (often called WiFi for "wireless fidelity" in computer circles) also promise to make it simpler, easier and less costly to move this equipment. That was an important consideration because Miller is a growing, changing company that increasingly relies on its ability to respond to its customers' needs by adding or relocating production assets.

Switzerland is learning to be lean: earlier this year, Modern Machine Shop visited a cross section of metalworking manufacturing companies in Switzerl

2007-06-18T05:25:00.000-07:00

What do prosperous job shops in the heart of Switzerland look like? How do Swiss machine tool builders cope with the high cost of manufacturing in their country? Why is lean manufacturing being embraced by Swiss companies that already enjoy a reputation for efficiency and precision?

Answers to these questions, along with many other interesting observations about manufacturing in Switzerland, can be found in "Lean Manufacturing, Swiss Style," an MMS Online Exclusive. The article profiles eight companies in the metalworking industry. The list includes two very distinctive job shops (C-mill Technologie AG and Fribosa), two builders of grinding machines (Studer and Magerle), a manufacturer of machine tool spindles (Step-Tee), a builder of high-performance machining centers (Mikron), a builder of electrical discharge machines (Charmilles) and a manufacturer of collets and toolholders (Rego-Fix). For a link to the complete article, visit www.mmsonline. com/articles/060604.html

Rotary Broach Head suits limited-space applications

2007-06-07T05:34:00.000-07:00

Designed for CNC Swiss-type and gang style lathes, PCM[R] 2160 eliminates need to indicate broach to center and thereby facilitates setups. Product, which measures 1.1 in. in dia and 2.42 in. long, is suited for sub-spindle applications. Each holder has extra long shank, eliminating need for bushing and minimizing vibration. Capable of withstanding 2,200 lb of push force, broach head is offered with shank sizes of 16, 20, 22, and 25 mm as well as 5/8, 3/4, and 1 in. dia.

Designed specifically for the Swiss-type and gang style lathes, the PCM[R] 2160 Rotary Broach Head eliminates the need to indicate the broach to center making setups faster and easier.

The compact size of this broach holder fits into even the tightest of machines without loosing adjacent ID stations. The head diameter is only 1.1" and the head length is only 2.42" making it possible to use for sub-spindle applications where there is limited space.

Each holder has an extra long shank, eliminating the need to add a bushing, thereby reducing vibration, increasing rigidity, and providing better tool life. This also allows for modification to each specific machine and application.

Capable of withstanding 2200 lbs of push force, this broach head uses a special bearing design making it the most compact medium duty broach holder available.

Software aids in wheel design for CNC tools and grinders

2007-06-06T06:14:00.001-07:00

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.
Advertisement

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.

About ANCA

ANCA was founded in 1974 to design and manufacture high technology Computer Numerical Controls (CNCs) for the machine tool and metal-based industries. Today, ANCA has become a leading designer and manufacturer of complete, precision CNC tool and cutter grinding machines in a global niche market. With its core values of precision, innovation, quality and technological excellence, ANCA is today an international organisation of more than 300 employees with a robust set of technological and entrepreneurial skills. Offices are located in major cities in Europe, North America and Asia; with dealerships represented in over 25 countries. ANCA continues to understand market demands and produce products and services to benefit its customers.

Lots of CNC. . - Shop Talk - CNC Programming Handbook - book review

2007-06-06T06:13:00.000-07:00

A new guide to CNC programming has recently been published. The 600-page book, CNC Programming Handbook, presents material on most all CNC programming subjects in great detail and discusses CNC milling and turning operations. Written by Peter Smid, the book is geared toward a CNC programmer working in the field.he book is also suitable as a basic text in a CNC training program. The book presents complete information on various programming techniques, including illustrations, tables, formulas, tips, shortcuts and real-world examples. Organized like an encyclopedia, the book makes it easy for a reader to look up a specific subject. CNC Programming Handbook is available

CNC Lathe combines turning and machining

2007-06-06T06:11:00.000-07:00

ERLANGER, KY - Romi Machine Tools, Ltd, an industry leader in turning machine technology, has built a reputation providing customer-driven solutions to a broad array of precision turned-part challenges. The M Series of Combination lathes is yet another step in providing these solutions ever-more flexibly. The M Series is ideal for today's mixed-volume, short-run, JIT operations as well as dedicated, high-volume applications.

With a swing of 20", the M 20 combines high performance turning and large machining capacity within a compact 124.02" x 64.96" space-saving footprint. Rapid traverse rates of 394 imp (X axis) and 295 (Z axis) mean accelerated machine cycle times and reduced non-cut time, which increases overall throughput. Also increasing cycle time is an optional automatic electric turret offering a fast 0.48 second index, station-to-station. The turret holds eight tools with pockets for square tool holders and bolt-on I.D. tool blocks.
Advertisement

The M 20 has a rigid cast iron "H" bed design. All guideways are induction hardened and ground. They feature a Turcite-coated carriage and cross-slide that move smoothly on the solid bed and saddle guideways, thus ensuring superior rigidity, accuracy, cutting tool performance and long machine life. The M 20 offers three bed-length options: M 20 by 40, M 20 by 60 and M 20 by 80. Distance between centers is, respectively, 43.15", 62.84" and 82.52"

The spindle. A new belt-driven cartridge-style gearless headstock featuring a high-torque 15 hp AC GE Fanuc "P"-type spindle motor with a variable speed drive permits full horsepower at spindle speeds as low as 275 RPM. Three spindle options allow you to match the spindle speed and size to specific production needs. A2 spindles feature rigid mounting, larger through-hole capacities and higher RPM, while Dl Camlock spindles offer quick chuck changing between three- and four-jaw chucks. The A2-6" has a through hole of 2.56" and a speed range of 3 to 3,000 RPM, while the A2-8" and Dl-8 have a through hole of 3.15" and a speed range of 2 to 2,200 RPM.

To assure the rigidity required for heavy-duty cutting, the spindle is supported by angular contact ball bearings at the nose and a double row of cylindrical roller bearings at the rear. The spindle cartridge is lubricated for life, and the spindle design eliminates the need for oil recirculation or a refrigeration systems to maintain spindle temperature. The result is years of reliable performance with reduced operating and maintenance costs.

CNC Grinder handles various part features in same machine

2007-06-02T03:29:00.000-07:00

Landis Evolution CNC Grinder enables precision plunge and traverse peel grinding of multiple part features in same cycle. High-speed spindle permits grinding wheel speeds to 250 m/sec with part rotation to 7,500 rpm. Grinder incorporates granite base, workhead spindle-mounted rotary diamond dresser, and 5 mm wide CBN wheel to contour complex part shapes. Programmable unit offers less than 1 min part-to-part changeover time.

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

Chicago, IL, September 6, 2006 - Cinetic Landis Grinding Corp. (Waynesboro, PA) has introduced its Evolution high-speed CNC grinder at IMTS-2006 in booth B-7045 at McCormick Place. This exceptionally fast, rigid grinder enables precision plunge and traverse peel grinding of multiple part features in the same cycle. The Landis Evolution was developed to meet the demand for high throughput to reduce piece costs, along with flexibility to accommodate multiple part features and many part families. The machine incorporates a high-speed spindle to permit grinding wheel speeds up to 250m/sec with the part rotating at up to 7,500 rpm.

Outfitted with a narrow, 5 mm wide CBN wheel, the Evolution grinder can contour complex part shapes much like a lathe but with grinding accuracy and surface quality. Grinding at such fast speeds produces smaller chips that help improve surface quality on critical parts like transmission shafts. Various part features including faces and grooves can be accomplished in the same machine, which eliminates additional processes and avoids parasitic time for part handling. And the machine can be programmed to handle a large family of parts with part-to-part changeover in less than one minute.

No part drivers are required with the new Evolution grinder. The machine features a granite base and incorporates a workhead spindle-mounted rotary diamond dresser. A choice of Siemens or Fanuc CNC control is offered.

Complete information on the new Landis Evolution high-speed CNC grinder can be found on the company's web site at www.landis-us.com or by contacting Cinetic Landis Grinding Corp., 17 East Sixth St., Waynesboro, PA 17268, telephone 717-762-2161.

Cinetic Landis Grinding is a part of Cinetic Industries, a leading global supplier of manufacturing solutions.

CNC Bandsawing System minimizes set-up process

2007-06-02T03:19:00.000-07:00

Completely automating bandsawing processes, MBD[R] Model 4340 offers infinitely adjustable material clamp and max capacity of 60 x 20 x 14. Servo controlled feed table guides bandsaw blade along cutting path and through material. Machine eliminates need for templates and marking, automatically sawing block and panel materials. Automated process optimizes raw material yield, productivity, part quality, and accuracy.

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

Warsaw, IN - Warsaw Machinery, Inc. offers the new MBD[R] Model 4340 CNC Automatic Bandsawing System for cutting parts quickly and accurately. This bandsaw system offers complete automation of the bandsawing process, automatically sawing block and panel materials.

The Model 4340 bandsawing system replaces several manual bandsaws and eliminates the need for templates and marking, virtually eliminating set-up. The automated process provides greater raw material yield, increased productivity, improved part quality and accuracy along with reduction of finished parts inventory. A servo controlled feed table guides the bandsaw blade along a cutting path and through the material. This system offers an infinitely adjustable material clamp to 14" thick and a maximum capacity of 60" long by 20" wide by 14" thick.

Warsaw Machinery, Inc. offers bandsawing, clamping, cutting, routing and material handling machines and also provides equipment, parts and services for Tyler[R] woodworking equipment, MBD[R] bandsaws and Handy[R] clamps. Custom industrial machines are also available.

For more information, please contact Warsaw Machinery, Inc., 610 South Detroit Street, Warsaw, IN 46580. Telephone 574-267-5355. Fax 574-267-5366. Web site: www.warsawmachinery.com. E-mail: sales@warsawmachinery.com.

Hydrostatic grinder uses linear motor drives

2007-04-21T05:13:00.001-07:00

Precision profile grinding machine has linear motor drives and adjustable hydrostatic slideway technology to generate new orders of flatness and straightness within 0.3 micron over 300mm.

Developed to provide a compact, self-contained production or toolroom grinding process as an alternative to creep feed systems, optical profile grinding machines or even wire EDM, the Okamoto UPG 31Li Ultra Precision profile grinding machine incorporates linear motor drives and adjustable hydrostatic slideway technology. Unlike creep feed methods, the process is able to generate new orders of flatness and straightness within 0.3 micron over 300mm even when grinding a profile out of solid material by utilising a rapid reciprocating table movement. Now available from 600 Centre of Shepshed, Loughborough, UK, the compact Okamoto UPG 31Li is able to ensure component geometry, surface finish and very competitive process times on smaller components up to 30mm by 25mm such as carbide inserts for punches, high precision slots used in the connector industry, and parts requiring face contouring or edge profiling features to be ground.

The process enables components to be progressively ground by rapidly reciprocating the machine table at up to 650 passes per min as a viable alternative to more traditional creep feed methods that use high wheel speed and a slow progressive feed rate.

One major advantage of the new Okamoto method against creep feed is that it does not require the added machine complexity involving high pressure coolant and special dressing systems.

Controlled by Fanuc 31i Model A, the machine uses high speed linear drives to provide the rapid acceleration/deceleration to power the high speed reciprocation of the table.

The table is supported on dual hydrostatic slideways that are adjusted automatically to maintain a constant oil thickness to create a stable and consistent bearing condition.

This configuration of the table overcomes any forces input by the linear drive and removes any tendency for table lift or pull-down during the grinding process.

It also eliminates any effects of thermal growth that could otherwise be influenced by the rapid table movement and the linear drive system.

Positioning is via linear scale measurement.

The 2.2kW, 20,000 rev/min wheelhead is able to tilt +/-5 deg and is available with programmable dressing.

Both carbide disc and pre-formed diamond wheels can be used.

Rapid traverse rates are 1000mm/min and feed rates programmable between 1mm/min and 1000 mm/min.

The machine has a longitudinal travel of 280mm and cross travel of 170mm with a magnetic chuck of 170mm by 105mm.

Daylight between wheel and table top is a maximum of 400mm.

CNC surface grinder exceeds requirements

2007-04-21T05:12:00.002-07:00

CNC surface grinding machine exceeded all requirements for grinding a diverse range of cylindrical mould tooling from 292mm) to 711mm diameter to be used in timing belt system manufacture.

The Gates Corporation of Denver, Colorado in the USA was established in 1911. Formally known as the Gates Rubber Company, they are now one of the largest high precision automotive timing belt manufacturers in the World. Recently when needing to ramp up their production facilities in support of new business growth, they contacted Jones and Shipman and asked them to review a project they had on the table.

It consisted of a very specific and demanding set of criteria that had to be met in support of a new range of Gates high precision timing belts.

The challenge was to grind a diverse range of cylindrical mould tooling from 11in (292mm) to 28in (711mm) diameter.

Soon after an initial contact Jones and Shipman's application engineers provided an in depth application assessment report confirming that a model in their ProGrind range was capable of not only achieving their requirements, but also exceeding them in all departments, accuracy and process time, plus giving them the requested larger capacity.

Jones and Shipman is not traditionally known as a manufacturer of large capacity production surface grinders.

However with the introduction of their award winning Dominator range, with its three dimensional grinding capabilities and more recently a high accuracy ProGrind range, most applications can now be fulfilled.

The Jones and Shipman (J and S) ProGrind is designed to marry physical size with high precision, high productivity and incredible flatness.

Incorporating Jones and Shipman's simple to use and quick to set 'Easy' software via a GE-Fanuc Touchscreen control and A.C.

Digital Servos with Heidenhain 'Absolute' linear scale feedback, it proved to be the ideal machine for the Gates Corporation.

Having established from the initial feasibility study that a ProGrind 1267 was the grinder of choice, design and process optimisation commenced.

A Nikken CNC Rotary indexer and heavy-duty hydraulic tailstock was chosen to support and drive the mould tools, each of which would be held between centres.

With all mould blanks being produced from alloy steel and of a fixed length of 17in (450mm), J and S recommended twin high precision diamond discs as the optimum wheel dressing option.

The discs, accurately lapped with 0.004-5in (0.1-0.125mm) radii, where chosen to complement the mould tooth profile accuracy and mounted on a J and S custom disc dressing unit for easy of use.

After machine build in the UK, grinding trials commenced on sample mould blanks to prove out the form and optimal wheel dress frequency.

The wheel form profile and the mould tooth profile being initially optically checked against master overlays.

Further verification of the form being obtained via a ground tooth form test piece on a CMM.

Having established the initial wheel dress frequency and grinding parameters, the machine was accepted following a 'lights out' run of a Gates mould and shipped to Gates Corporation's, Denver, facility for on-site commissioning and final grinding acceptance trials.

Operator familiarisation and training with the Easy software quickly progressed through dressing and grinding flat forms on a test mould.

From this point training moved on a pace and the first test blank a 115-tooth profile mould, was set and run with a roughing cut.

As the ProGrind is a 24/7-production grinder the machine ran unmanned for the next day.

After inspection the wheel was redressed for a four-hour finishing cycle.

A full inspection by CMM of all geometry including size and profile angularity confirmed that all features where well within tolerance.

The ProGrind was then set to grind a 100-tooth mould; this took a day to rough grind.

Their existing machine, an Okamoto, which had started an 80-tooth mould one-hour after the ProGrind, was still grinding with three teeth left after a day and a half.

In fact the CEO of the mould customer who was visiting at the time remarked on how efficiently the ProGrind was operating.

Final acceptance was signed and the ProGrind passed over to the Gates Corporation in Mid July 2006.

High speed machine grinds in one set-up

2007-04-21T05:12:00.001-07:00

A high-speed grinding machine, delivered to a transmission manufacturer, combines high productivity associated with CBN and the flexibility derived from contour grinding.

Danobat has recently supplied a high-speed grinding machine to a transmission manufacturer, where the high productivity associated with CBN and the flexibility derived from contour grinding are combined. * Danobat FG-600 - with the new grinding machine, Danobat achieves the complete grinding of the part in one clamping, increasing productivity, reducing stocks and in short, significantly improving the production costs and delivery times for the end customers. The FG-600-3BS model has a rotating wheel head that can incorporate up to three high-speed grinding wheels.

Two of the grinding wheels are CBN and contour grind at speeds ranging from 100-120m/s, which enable the complete grinding of all the diameters of the parts.

The third wheel is a conventional abrasive wheel and grinds a thread starting from the previously turned diameter.

The diameters to be turned have IT5 tolerances and the roughness attained by the contouring grinding process is always under Ra 0.4 micron.

Wafer grinding machine is easy to use

2007-04-21T05:11:00.001-07:00

A horizontal enhanced wafer grinding machine is easy to operate for individual and small quantity wafer loads and offers improved functionality, such as centre-wheel coolant delivery.

Engis' enhanced wafer grinding machine, the EHG 170AV, is now available to UK customers. This small footprint, horizontal grinder is particularly suitable for surface grinding advanced materials including, wafers and windows to the highest level of flatness. The launch of the EHG 170AV demonstrates Engis' commitment to develop technology specifically for customers in the advanced materials processing market, to which it brings its unrivalled expertise in superabrasive and lapping technologies.

Developed from the very successful, earlier EHG-150AV, the newly designed and technically enhanced machine remains a competitively priced and easy to operate horizontal grinder for individual and small quantity wafer loads, but offers improved functionality including centre-wheel coolant delivery to ensure optimal coolant dispersal, an updated operating system and an enlarged capacity cooling system.

Specification options include a coolant cooling unit, a cartridge filter and flow sensor and a magnetic or vacuum chuck.

The grinder offers automatic sizing and three-way motion to provide reduced surface and sub-surface damage and edge-chipping - providing an increased yield in operation.

* EHG-170AV Machine specifications are as follows.

Wheel speed - 4000 rev/min variable.

Work speed - 400 rev/min, 0.75kW, 200V 3-phase.

Maximum work size - 170mm.

Wheel motor - 1.5kW, 220V, 3-Phase.

Work motor - 0.75kW, 220V, 3-phase.

Wheel size - 170mm.

Dimensions - 1246mm x 650mm x 1260mm (WxDxL).

Weight - 1000kg net.

Precision optics grinder covers spheres, aspheres

2007-04-21T05:10:00.000-07:00

A versatile CNC machine tool that is adaptable to turning as well as grinding is tooled for grinding spheres and aspheres in BK7 optical glass.

Accura Technics has successfully launched launch of their MicroTol product line. The first machine is now in production at a precision optics manufacturer near Rochester, New York, USA. With other applications in bearings, aerospace and automotive industries, the MicroTol is a versatile CNC machine tool adaptable to turning as well as grinding.

The lead-off machine is tooled for grinding spheres and aspheres in BK7 optical glass.

A cross-axis approach is used with the axis of the work spindle horizontal, and the axis of the wheel spindle vertical.

The workpiece is routed around the periphery of the grinding wheel by X and Z-axis interpolation to produce either a spherical or an aspherical shape.

Spherical shapes can be programmed as a single parameter - radius.

Aspherical shapes, such as paraboloids, can be programmed as a point table or with a parametric equation.

Tool radius compensation features are used to adjust for wheel diameter.

'Optical components require tight tolerances while maintaining rapid throughput,' said Patrick Hurst, president of Accura Technics.

'The MicroTol can generate excellent geometry and surface finish while minimizing the grinding time prior to polishing operations.' The work area consists of a hydraulic chuck supported by Accura's proprietary hydrostatic work spindle.

Hydrostatic bearings provide added damping and robustness not typically found in work spindle designs.

The X and Z-axis slide system is supported by hydrostatic slide bearings and driven by high performance linear motors with glass scale feedback.

The 20,000 rev/min air bearing wheel spindle is rigidly mounted to the machine base on a micro-adjustable column.

The grinding operation is performed with a metal bond diamond wheel.

The MicroTol has a large, configurable work area that is totally enclosed for coolant containment.

Standard X-axis travel is 8in (200mm).

Standard Z-axis travel is 4in (100mm).

Rough and finish wheel spindles on a rotary table can be added for grinding small optics and molds.

Expanded capabilities include match grinding and match turning for sub-micron fits.

The machine can be fully automated with robot loader and conveyors.

Accura Technics is a certified Fanuc Robotics integrator.

Accura Technics' other products include the 1210G vertical axis, multi-surface grinder; and a compact cylindrical OD grinder.

CNC lathes investment wins new business

2007-04-14T03:34:00.002-07:00

Investment in two CNC lathes has produced significant business benefits to a subcontractor including the winning of its first contract in the aerospace sector.

First investment in CNC machine tool technology creates solid platform for SB Engineering to take-off in manufacturing precision components for the aerospace sector. Leicester - based precision subcontract specialist - SB Engineering - has recently invested in two Hardinge 6/45-SV CNC lathes. The machines, both installed at the company's facility in November 2006, are the first CNC machines purchased by SB Engineering.

In only two months the machines are delivering significant business benefits to a company that has high ambitions and which, (owing to its recent machine tool investment), has just secured its first contract in the aerospace sector - machining complex high-precision titanium fasteners for aircraft wing sections.

SB Engineering is a family business run by three brothers - Sat Bhamra, Harj Bhamra and George Bhamra.

The company was first established in 1984 and was initially involved in machining parts and components for knitting machines.

To undertake this work the company invested in a range of manual machine tools - milling, turning and grinding, etc.

Whilst SB Engineering today still handles this type of general precision subcontract work - the company has raised its ambitions significantly - and sees its future in manufacturing complex, high precision components.

Said Sat Bhamra, director at SB Engineering: 'We have the skill, the commitment and now the technology to realise our ambitions.

The investment in Hardinge CNC technology is just the start.' He continued: 'We have made a real step change in the way we operate.

We knew we needed CNC capability and we chose Hardinge for two major reasons.

Firstly their machine tools, in terms of performance and price are second to none.

Secondly, they provided excellent pre-sales support - and their technical, applications and after-sales services cannot be faulted.' The aerospace contract won by SB Engineering is vindication of the company's machine tool investment programme and long term strategic aims.

The parts (titanium fasteners) manufactured on the Hardinge lathes vary in size and batch quantity.

Typically part dimensions can be from 5mm to 25mm - and quantities are required in hundreds or even thousands per week.

Both Hardinge lathes are used to make a complete finished part - and some 8 separate cutting operations are involved.

The first operations (on one of the Hardinge lathes) involve fine turning on the components back end - to remove the 'blue' oxidation layer on the titanium and to bring the part into tolerance - +/-0.001mm.

Secondary operations on the second Hardinge lathe involve drilling a small bore in the centre of the part - plus high precision chamfering and grooving operations.

Each part is completed (including set up) in 45 - 50s.

In addition to the Hardinge lathes - SB Engineering has also invested in inspection equipment to fulfil the demands of the aerospace sector - and is well on the way to achieving ISO:9001 (2000) certification.

Concluded Sat Bhamra: 'We are changing rapidly to ensure that we can exploit the business opportunities that exist in high-precision and high-growth sectors.

We have plans in the pipeline to relocate our business in the near future to a new and bigger site.

The investments we have made in Hardinge CNC machines will help us take on more profitable work - and will enable us to consolidate our position within the aerospace and other precision manufacturing sectors.' * About the Hardinge 6/45-SV lathe - the Hardinge Talent 6/45-SV lathe is a compact and rigidly constructed 2-axis machine.

It is equipped with a 15kW spindle drive (with Fanuc control) and includes a three-jaw power chuck as standard.

The machine also has an A2-5 (6,000 rev/min) spindle with 45mm through draw bar capacity.

Rotation time for the Talent's bi-directional 12-station VDI-30 turret is 1s (unclamp/index/clamp) to an adjacent station.

The non-rising turret index is achieved using a separate brushless servomotor and the turret positively locks into position using a three-piece curvic coupling.

Rapid traverse rates for the X and Z axes are an impressive 30m/min and maximum X-axis travel is 153mm and maximum Z-axis travel is 406mm.

The lathe has a ribbed 45 deg slant bed base that provides superior rigidity and durability.

All structural components and castings are qualified by finite element analysis (FEA)-a proven, highly-technical procedure that ensures a stiff, structurally-sound machine tool design.

UK subcontractor to expand CNC machine tool park

2007-04-14T03:34:00.001-07:00

Having to increase its manufacturing capacity, a subcontractor has invested GBP 250,000 in CNC lathes and a vertical machining centre to meet growing oil/gas/subsea components demand.

UK subcontractor to expand CNC machine tool park Having to increase its manufacturing and size machining capacity, a subcontractor has invested GBP 250,000 in CNC lathes and a vertical machining centre to meet growing oil/gas/subsea components demand. Investing more than GBP 250,000 in a package of Colchester-Harrison CNC machine tools from 600 Centre of Shepshed, subcontract precision machinist Ultimate Precision of Jarrow, Tyne and Wear sees the purchase of five machines as important in increasing its capacity to cope with 60 to 70% increases in production demands from oil and gas and subsea sectors. The order, involving progressive installation of a Colchester-Harrison Combi 6000, MultiTurn 4000 and 2000 flat-bed CNC lathes, a Tornado T8, two-axis lathe and a Storm VMC 1300 vertical machining centre, is part of the company's planned increase from small to medium size part machining into high specification parts up to 1m cube and up to 1m diameter by 4m long.

The company, under managing director Ken Davidson, employs 30 people and has grown from its formation in 1997 supplying aerospace, automotive, medical and general engineering sectors.

It has recently added 55% to its turnover from contracts gained from subsea and offshore industry customers.

Said sales and marketing manager Andy Hey: 'We still produce batch work for existing customers and continuous production for the automotive sector, which tends to have very tight margins, but the new areas are really very challenging in materials, tolerances and machining knowledge so we need production equipment that is reliable, accurate and very flexible.' The company investigated the machines available and while managing the growth of the business, value for money against equipment performance and flexibility were key markers on the comparison spread sheets.

'Here,' said Hey, 'The performance of the Combi and its specification fitted our requirements exactly against machines costing 45% more.

We also have the factory in Heckmondwike, West Yorkshire providing a close lifeline for support because our philosophy is not to let customers down on delivery.' In addition to general materials, Ultimate Precision also produces parts from exotic materials and bespoke alloys, such as Duplex and Super Duplex, stainless steels and ceramics.

Tolerances run into a few microns on certain dimensions and high orders of surface finish are commonplace.

Here programming was a key element in judging the flexibility ranking of the machines and by standardising on Fanuc control, which is a key part of the 600 Group machine's specifications, means the setters on the shopfloor are quick to adapt to the new installations.

In addition to the machines from 600 Centre, the company has installed Fanuc's FAPT off-line programming and made good use of the on-machine interfaces and macros developed by Colchester-Harrison.

Altogether, the CNC plant list at Ultimate Precision has 21 machines and three co-ordinate measuring machines.

Powerful CNC lathe installed at subcontractor

2007-04-14T03:33:00.001-07:00

A 26kW CNC lathe now located at a leading sub contractor in Devon features a swing over the bed of 750mm, a turning length of 1440mm and a fully cast slant bed design.

MTL is pleased to announce the recent installation of the largest cutting capacity Feeler CNC lather ever ordered in the UK. The FTC50L CNC lathe now located at a leading sub contractor in Devon features a swing over the bed of 750mm and a turning length of 1440mm. The machine features a fully cast slant bed design, with a powerful 26kW/35HP spindle motor coupled with a two speed ZF gearbox.

The hydraulic chuck fitted to the machine is 375mm dia.

with larger options available, the FTC 50 also has the advantage of a 117mm diameter through spindle bore.

A programmable tail stock, swarf conveyor and bucket comes as part of the standard specification of the FTC50 as does the 12 station block turret.

There are several other machines in the FTC series encompassing a 150mm chuck or bar feed machine, through to 300mm, all available with the industry standard Fanuc 0i control fitted with manual guide conversational software.

Feeler feature a very comprehensive range of CNC 2-,3-, and 4-axis lathes with their latest introduction being the FTC 350LY Y-axis CNC lathe, coupled with a vast range of CNC machining centres the scope and range of the equipment is one of the largest available.

Twin-spindle, front load lathe is automated

2007-04-14T03:32:00.000-07:00

A twin-spindle, front-loading style CNC lathe, with fully integrated high speed 150m/min gantry loader, provides a fully automated production cell for first and second operation component cycles.

Developed by Fuji Machine Tools to meet demanding automotive and bearing industry requirements, the PMD-2000 twin-spindle, front-loading style CNC lathe, with fully integrated high speed 150m/min gantry loader, provides a fully automated production cell for first and second operation component cycles in a very compact and rigid machining environment. Now available from Fuji Machine Tool's European distributor, 600 Centre of Shepshed, Loughborough, UK, the PMD-2000 is able to machine components up to 120mm diameter by 100mm long and has two identical eight-station turrets to serve the two 6in (8in option) chucks. The 7.5kW, 4,000 rev/min zero-centre design spindles are mounted on independent X-axis slideways each having 200mm stroke and the horizontal axis turrets on independent Z-axis slideways having 150mm travel.

Control is by Fanuc 180i-TB.

The high rigidity base, with a compact footprint of 1650 mm by 1725 mm, is designed as two individual handed carcases in order to prevent any influence from spindle to spindle during cutting.

For instance, witness marks could result when one spindle is engaged on roughing or intermittent cutting and the other on high tolerance or close surface finish machining.

And, from its automotive ancestry the design of the machine means excellent access is available to serviceable items, swarf control is paramount and highly efficient, with chips falling unhindered onto a central conveyor for speedy exit at the rear of the machine.

Central to maintain high levels of productivity, the machine and its ability to run under limited manning or unmanned situations is the Fuji developed high speed three-axis LX-10S gantry robot.

Available with single or double gripper it has a loading time of 4.5s and minimum cycle time of 24s.

This can be reduced to 12.5s for the twin gripper version.

Rapid traverse speed is fast at 150m/min in the X-axis, with 115m/min for vertical axis and 50m/min in the Z-axis.

Controlled via the Fuji MAX SPI robot control system, data entry is via touch screen from which the software automatically computes the most fluid and shortest time for movement.

A range of work stockers with 10, 12 or 20 stations can be integrated to input and exit stations with interfaces to measuring devices with feed back correction.

CNC punch press tooling catalogue published

2007-03-27T03:43:00.002-07:00

Euromac punch press users will find the new and expanded 36 page Mate Euromac tooling catalog helpful in planning their fabricating projects. This catalog contains a comprehensive overview of each of the tooling systems that are compatible with the Euromac punch press, including the following. * Thick Turret - Ultra TEC, Ultra TEC Fully Guided, Ultra TEC Heavy Duty, Ultra Light, Ultra XT, and Original Thick Turret style.

* Trumpf Style - Trumpf standard style, and Mate QuickLock tooling system.

* Multi Tool - tooling to suit Euromac's exclusive range of four-station, six-station, and 10-station multi tool assemblies.

The Thick Turret 'Product Selector' overview of each tooling system compatible with Euromac punch presses has nine different ratings.

They are charted for each tooling system, comparing factors such as quick set up, interchangeability, grind life, ease of use, value and purchase price.

Also included in the new catalog are a full range of forming tools.

These include: cluster tools, countersinks, electrical knockouts, and ventilation louvers with detailed explanations of what each form is used for.

Suggestions for appropriate material type and thickness range for each application are also included along with additional ideas on how to achieve superior results.

Fabricators will find that integrating formed features into sheet metal components using these tools greatly expands their ability to add value to the punching process.

CNC punch press choice based on experience

2007-03-27T03:43:00.001-07:00

A generous specification for a cost-effective price and a short delivery time led to the choice of another CNC punch press by a switchgear manufacturer, based on past experience.

Howarth Switchgear has built its business on providing exactly what customers want when they want it, and to give it the capacity and flexibility to meet these demands it has just invested in a new LVD Parma 1212 CNC punch press. Director Chris Howarth says that the key arguments for the Parma were that it gave a generous specification for a cost-effective price and a short delivery time. He was also convinced it would be reliable, as the company had been running a punch press from LVD's predecessor Shape Machines for the past twenty years with very few problems - and those problems that did occur were fixed very quickly.

'The Shape machine has worked well for us with very few breakdowns, but we thought it was time to move on,' he said.

Howarth's business is building electrical switchgear systems for all kinds of non-domestic premises - from banks and call centres to chemical plants, food processors and military installations.

And even though they try and incorporate standard elements, no two systems are the same.

'Every building is different and the system requirements in buildings are changing all the time,' said Howarth.

'If you are refurbishing a building you are going to need 100 to 150% more power because everything now is IT-oriented.

And if you have more computers you need more air conditioning to deal with the heat they give out.

The result is that they end up trying to get much more switchgear into the same space as they used before.

So it all has to be specially built.

The other problem is that sometimes the switchgear may be in a basement or on a roof and you have to design it in sections so that you can get it through the existing services.' Co-director Anthony Howarth added, 'Because we have a bespoke product we feel we have to do all of our own sheet metal.

Although systems may look similar there are always small differences that would make it very difficult for someone working with standard cut parts or bought-in frameworks.

If we relied on anyone else's casework we wouldn't be flexible - we give the customer what they want rather than what someone else stocks.' As well as this flexibility, the other factor that allows Howarth Switchgear to offer a premium service is its speed of delivery - and again, the only way to ensure that is to manufacture the critical components in house.

'We are mass producing one-offs, but that is what you have to do.

The Parma might seem quite a big machine for what we do, but the way we see it is that if you can do what the customer wants and react more quickly you will get more work in.

Because we can deliver on time with what the customer wants, they will be able to get the plant up and running sooner.' The LVD Parma punch press offers the speed and flexibility of programming and production that Howarth Switchgear needs.

With a 21-station turret including three direct-drive 50.8mm auto-index stations it gives a wide range of options with a standard tooling setup - and it needs it as Howarth designs and makes around 250 new parts every month.

The Parma 1212 features GE Fanuc 0iP CNC control, and rugged frame and table design to achieve tight tolerances and consistent punching accuracy.

LVD says that it can deliver up to 300 hits/min on 25.4mm centres, and nibble at up to 650 hits/min with a finished part accuracy of +/-0.1mm and +/-0.05mm finished part repeatability.

As Anthony Howarth explained, 'Auto-indexing isn't new technology but it will offer a lot more possibilities, and the programming is much more flexible and faster.

We aren't stubborn and are very prepared to grow into the capabilities of the machine and the software.

One of the things I liked about the Parma was that the punch press and the software came as a package, and the Cadman P 3D software has an unfolding module so that you can flat pack your parts from a 3D file.' The speed and quality of the manufacturing process is extremely important to Howarth's work and cash flow, said Chris Howarth.

'These can be really large installations and a considerable amount of cash (in components) can be tied up on the shop floor.

What we were looking for with the Parma was performance and flexibility at a cost effective price and we are now applying the Parma's advanced technology to speed up our work flow which in turn can only benefit our customers.'

Slitting die tooling offers longer regrind life

2007-03-27T03:42:00.000-07:00

Slitting die tooling system for CNC punch presses uses a tough and wear-resistant premium tool steel for the slitting die blade to offer twice the regrind life of standard tooling.

The Wilson 2-4-1 Slitting Die system is the latest innovation developed by Wilson Tool. The 2-4-1 Slitting Die system offers twice the regrind life over a standard solid die. The Slitting Die blade is manufactured from Ultima, a premium tool steel which is tough and resistant, excelling in applications which demand long-term wear resistance and toughness.

Ultima can further extend the tool life by up to 400% compared with a standard die, representing considerable cost-savings on replacement tooling.

The special die insert, exclusive to Wilson Tool, is fully supported by the die base which is made of a special shock-absorbent steel designed to resist the repeated impact that can sometimes cause conventional dies to crack.

As the die insert is reground, the shims supplied with the assembly can be used to return the die assembly to the correct height.

When the die insert wears out, a new 2-4-1 insert can be purchased for less than the price of a standard replacement die.

CNC punch presses have large turret capacity

2007-03-27T03:41:00.002-07:00

Robust, thick turret tooling style CNC punch presses, 200 and 300kN, offer a large turret capacity with a versatile mix of stations and the largest feed clearance in the industry.

LVD introduces the Verona Series of CNC turret punch presses offered in 200 and 300kN models (20 and 30 tonf). Verona turret punch presses are robust, full-featured machines designed for high production demands. These Thick turret tooling style punch presses offer a large turret capacity with a versatile mix of stations and the largest feed clearance in the industry.

Powerful control capabilities and programmable features make Verona punch presses easy to set up and operate.

Engineered for high productivity and long life, Verona punches materials up to 6.4mm with a maximum hit rate of 1000 hits/min at 1mm pitch.

A state-of-the-art positioning system combines heavy sheet carrying capacity with accurate motion control to produce a finished part accuracy of 0,10 mm with a repeatability of 0.05mm over the entire table.

Bridge frame construction provides accuracy and durability.

LVD's latest punch presses handle workpieces up to 1524 x 2500mm depending on model.

Larger workpieces are handled with clamp repositioning.

Smart Clamp, a standard feature, automatically determines exact clamp locations to provide the smallest possible no-punch zone.

* Advanced hydraulic ram technology - an advanced servo hydraulic press drive and easy-to-use interactive software optimize Verona's high-speed operation while reducing noise and shock.

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

Smart Stroke automatically optimizes the punch cycle by determining the hover height based on material thickness and distance between holes, maximizing productivity without operator or programmer intervention.

Up to 48-station turret capacity - Verona's large and versatile double-track turret provides flexibility and easy set- up.

Every station accepts shaped punches and dies, reducing set-up time.

A unique mix of turret stations provides exceptional capacity.

Verona 20 tonf models offer a 34-station configuration with four 88,9 mm auto-index stations.

The 30 tonf machines offer 48 stations with three 88.9mm auto-index stations and one fixed 88.9mm station or 114.30mm station.

The 114.30mm station is ideal for producing large louvers, special forms or using full-size parting tools.

Turret capacity can be increased with the addition of indexable Multi-Tools to expand the number of auto-indexable tools.

* Feed clearance of 25mm - Verona also provides enhanced forming capabilities with a full 25mm feed clearance between the upper and lower turret.

This generous feed clearance allows for the production of higher forms such as lances, louvers, embossments or card guides.

The punch press accommodates the latest in tooling technology for high-performance fabricating.

These capabilities further reduce set-up time, enhance productivity and promote long life with minimal maintenance costs.

Wheel tooling, including rollcut and rollform capabilities, permits quick and efficient cutting and/or forming of straight or curves shapes without nibbling.

Verona machines also employ part marking technology for part number or sheet marking requirements and can utilize tapping tools.

* Powerful PC-based control - Verona is equipped with a state-of-the-art, PC-based GE Fanuc 180i control that speeds set-up and delivers powerful features such as diagnostics, increased program storage capacity and networking.

Optional CADMAN programming software provides full support for all standard and advanced punching functions, including Auto-Index stations, Multi-Tools, standard and special punches, forming, embossing, tapping, stamping and wheel-style tools.

* Robotic pick-sort material handling system - material/part handling can be automated with the addition of an automatic sheet loading/unloading system and parts sorting device.

LVD's automatic load/unload system reduces manual worksheet handling and provides fast, efficient processing of materials up to 3.5mm thick.

Verona may be integrated with a robotic Pick-Sort material handling system.

The robotic system loads full size sheets and automatically retrieves and stacks individual punched parts with dimensions up to 1000 x 2000mm.

The Pick-Sort system converts the Verona into a freestanding, lights-out production cell.

* About LVD - LVD is a leading manufacturer of a comprehensive range of sheet metal/plate working machine tools and software solutions, including laser cutting systems, punch presses, press brakes, guillotine shears and automated flexible manufacturing systems, integrated and supported by its CADMAN PC-based Windows compatible software.

Tool systems fit punching requirements

2007-03-27T03:41:00.001-07:00

Danobat punch press users can select from a full range of high performance Mate tooling systems to fit the exact nature of their punching requirements. These include Mate Ultra TEC, Mate Ultra XT, Mate original style thick turret tooling, and the Mate Ultraform forming tool system. Mate Ultra TEC is a full-featured, highest performance thick turret punching system that increases tool performance and flexibility, offers extended tool life, and allows interchangeability with existing systems.

Features of the Ultra TEC system include: premium high speed tool steel, quick tool change, easy click length adjustment (no shims or tooling required), grooved guides for best lubrication, Slug Free Die design, and relieved strippers for extended grind life.

Mate Ultra XT is a new tooling alternative with more features than original style thick turret tooling but not as full-featured as the Ultra Tec line.

Designed to give press operators extra setup convenience, the system is another choice to achieve the highest quality punching at the lowest cost per part.

Ultra XT has these high performance features: premium high speed tool steel, quick tool change, easy click length adjustment, grooved guides for best lubrication and Slug Free Die design.

Mate Original Style Thick Turret Tooling is an economical thick turret tooling system that is fully OEM compatible with design enhancements that include: premium high speed tool steel punches, hexagon shaped 1/2' A and 1-1/4' B station punch heads for easy adjustment and maintenance, and Slug Free Die design.

All three tooling systems are available in sizes for 1/ 2' A station, 1-1/4' B station, 2' C station and 3-1/2' D station.

All Mate Tooling systems are 100 percent unconditionally customer satisfaction guaranteed.

Danobat users can gain a competitive advantage by using exclusive Mate Ultraform special assemblies to expand their fabricating capabilities while eliminating expensive secondary operations.

Examples include the new Mate HexLock system, which provides an alternative to self-clinching fasteners, and the Mate SnapLock assembly, which creates fabricated joints without secondary welding operations.

Abrasive waterjet saves fabricating time

2007-03-22T23:20:00.002-07:00

Large Massachusetts job shop invested in an abrasive water jet system on which CAD/CAM software has helped it reduce waste by enabling it to tightly nest multiple parts in a single program.

Located in Attleboro Falls, Massachusetts, USA, Metfab Engineering is a large full-service job shop that provides metal fabrication and machining services to businesses around the world. Metfab's services include CAD engineering and layout, machining, waterjet and laser cutting, welding, assembly, painting and finishing. The company's customers represent nearly every business sector, including the semiconductor, energy, defense, security, medical, pharmaceutical and chemical industries.

Like most successful job shops, Metfab Engineering can trace its roots back to a simple three-car garage and owner Edward Urquhart's vision to build a business from the ground floor.

Thirty-five years after its humble beginning, the thriving company occupies a 50,000ft2 modern manufacturing facility and employees 60 people.

Metfab's longtime manufacturing engineer Bruce Weeman attributes the company's success to Urquhart's willingness to invest in his business.

'His philosophy is if we can buy a piece of equipment that makes the job easier and faster, then buy it,' Weeman noted.

Seven years ago, Metfab did just that when it invested in a precision abrasive waterjet cutting system manufactured by Jet Edge of St Michael, Minnesota.

The company selected Jet Edge's 6ft by 10ft High Rail Gantry System (1.8m x 3m), which it powered with a 50HP Jet Edge 55-50B intensifier pump rated for 60,000 lb/in2 (4,100 bar) The system is controlled by Jet Edge's AquaVision motion controller, which produces consistent-quality finished surfaces and cuts 'We looked at all the major manufacturers and I saw demos from each one,' Weeman recalled.

'I met some of Jet Edge's engineers and heard what they had to say, and it seemed like the construction and maintenance of the machine was exceptional.' Weeman explained that his company originally bought its waterjet system to cut laminated panels, but quickly discovered its usefulness for other projects.

With its Jet Edge system, Metfab is able to cut parts from virtually any material, including materials considered 'unmachinable' with conventional cutting tools.

Metfab cuts materials up to 6in thick and maintains a tolerance as close as +/-0.005in (+/-0.13mm).

Weeman said that the Jet Edge system's CAD/CAM software has helped Metfab reduce waste by enabling it to tightly nest multiple parts in a single program.

The company also is able to cut smaller parts out of material it once would have considered scrap.

In addition, the Jet Edge system also has helped Metfab increase its productivity by allowing the company to cut parts on the waterjet that it once would have had to make in its machine shop.

This has freed up the machine shop for other projects and, since the waterjet leaves no burrs or heat-affected zones, has eliminated the need for secondary finishing.

The Jet Edge system also has allowed Metfab to take on projects it once would have had to sub out, giving the company more control over its delivery dates, Weeman added.

'We use it a lot more than we thought we would,' he said.

'It's brought in a lot of new work that we couldn't do before, and when these customers come into the building and see what we do, it leads to other different types of work.' Weeman noted that Metfab has saved several customers months of fabrication time with its Jet Edge system.

When a natural gas company needed to have a valve customized with a difficult-to-machine hole, and they needed it quickly, they called Metfab.

Metfab's waterjet operator manually raised and lowered the waterjet cutting head and was able to drill the hole into the contoured valve within minutes.

'They said if they had to buy the piece, it would have taken two months to get,' Weeman said.

'It took us a half hour between programming and cutting.' Metfab also has used its Jet Edge system to cut fragile stained glass pieces for a local window company, Weeman said.

The owner of the window company initially was skeptical that the waterjet could cut the pieces, some of which would have been impossible to cut by hand.

'He didn't think we could cut it, and we cut it out and handed it to him,' Weeman recalled.

'He said for a million dollars he couldn't have cut that by hand.

Parts it would have taken him six months to cut by hand, we did in four days, and out of 200 sheets of stained glass, I think we cracked three sheets handling them.

He said he usually has a 25 to 30% break ratio.' With his Jet Edge system still running smoothly after several years of intense use, Weeman said he has been very happy with Jet Edge's quality and commitment to service.

'It's been great,' he said.

'It's simple to use.

We're able to train new operators in fairly little time, and have sent two or three operators to Jet Edge's free lifetime training program'.

'If we call service, they are usually very quick, and the parts department is exceptional.

Jet Edge occasionally brings potential customers in here and we've recommended Jet Edge to everybody they've brought in.

Jet Edge has always been there when we needed them.

Downtime has been almost non-existent.

Everyone, from sales to service to parts has been excellent.'

Drill prepares for waterjet cutting

2007-03-22T23:20:00.001-07:00

A pneumatic self-feeding drill - available in stationary or laterally adjustable models - quickly pierces sensitive materials prior to cutting them with waterjet.

Jet Edge is pleased to introduce a pneumatic self-feeding drill for its precision waterjet cutting systems. The drill is available in stationary or laterally adjustable models. The air drill gives waterjet operators the opportunity to expand their cutting capabilities and take in new types of work by enabling them to quickly pierce sensitive materials prior to cutting them with waterjet.

It also can be used for reaming holes to a precise diameter.

The drill works with any manufacturer's waterjet system.

Its heavy-duty, corrosion-resistant design ensures a maximum operating life.

The drill features a hydraulic feed control unit, feed stroke adjustment, exhaust collector and PLC interface manifold.

A flexible bellows cover is mounted to the front of the drill to protect it from foreign material.

All controls are internal; there are no limit switches.

The drill has a free running speed of 3,300 rev/min and can be set for any stroke from 5/16 to 3in.

It is supplied with a 1/4in stainless steel drill chuck.

The drill requires an air supply of 27ft3/min at 100 lb/in2 and a control voltage of 24V DC.

All control valves are contained within a NEMA-rated electrical enclosure.

* About Jet Edge - Jet Edge is an ultra-high pressure waterjet technology company with a global presence.

Jet Edge's primary business includes designing, engineering, manufacturing and servicing ultra-high pressure intensifier pumps, precision waterjet and abrasive waterjet cutting systems, surface preparation and coating removal products, as well as high-pressure cutting heads and related products, parts and components.

Jet Edge products are used in a wide range of industries, from the world's leading airlines to automotive, aerospace and industrial manufacturers and machine and job shops.

Headquartered in St.

Michael, Minnesota, USA, the company has distribution partners throughout North and South America, Europe, Asia and the Middle East and serves customers in over 100 countries.

Gantry water jet cutting machine is precise

2007-03-22T23:19:00.001-07:00

The High Rail Gantry waterjet cutting system, with a stable overhead design, can hold an accuracy of 0.005in with a repeatability of 0.001in over the entire work envelope.

Jet Edge will demonstrate its latest waterjet cutting technologies at the WESTEC 2007 Exposition and Conference, March 26-29 at the Los Angeles Convention Center in Los Angeles, California, USA. During this global manufacturing event, Jet Edge will showcase its versatile High Rail Gantry precision waterjet system and its new iP60-50 ultra-high pressure intensifier pump. Look for Jet Edge in booth 5729.

Capable of producing complex parts out of virtually any material, the High Rail Gantry features a stable overhead design that allows full access to the work envelope and raises critical components out of the process environment.

The High Rail Gantry can hold an accuracy of 0.005in with a repeatability of 0.001in over the entire work envelope.

It is available in 2-foot increments from 4ft by 4ft to 24ft by 14ft.

Custom sizes are available, and the system can easily be expanded in place as a business grows.

The gantry's mechanical components are protected by stainless steel enclosures versus traditional bellows that can puncture and tear.

In addition, Jet Edge uses a filtered blower on each enclosure to introduce a constant positive air pressure that ensures there is no chance of a negative pressure condition in the enclosure system.

Jet Edge High Rail Gantry systems are powered by the company's legendary line of intensifier pumps, which range from 30 to 260HP and are rated for 60,000 lb/in2 (4,100 bar).

During WESTEC, show participants will have the opportunity to see the iP60-50 intensifier pump in action.

Featuring an extended life hydraulic system and tie-rod design, the 50-horsepower iP60-50 is rated for 60,000 lb/in2 (4,100 bar) and is capable of producing output pressures from 1,000 to 55,000 lb/in2 (3,800 bar) with flow rates of 0 to 1.1 gallons (5 liters)/min to a variety of cutting, surface-preparation or cleaning tools.

The iP60-50 provides easy access for all service and maintenance.

It features non-threaded high-pressure components in the high-pressure cylinder, an improved performance check valve, and low torque values.

The Jet Edge iP60-50 intensifier pump leads the industry with ease of operation and low operating cost.

It requires very few tools to maintain.

Jet Edge waterjet cutting systems are controlled by the AquaVision Di motion controller that guides users through the process from job set-up to production.

With the AquaVision Di, single parts, part arrays, mirroring, scaling, rotation, and plate alignment are right at users' fingertips.

The AquaVision Di is fully networkable, allowing part programs to be generated offline and easily transferred to the system's hard drive for production.

Feed rate and acceleration are automatically varied, based on known features of a specific job.

Dynamic tool offset, or 'cutter compensation', is employed real-time, and an optional real-time pump control allows remote starting and stopping of the pump, dual pressure set points for piercing hard-to-pierce materials, and unlimited data logging of every process parameter imaginable.

The AquaVision Di includes a full-featured hand-held pendant that allows feed rate override, return-to-path, program zero set points, and XYZ axis control.

* About Jet Edge - Jet Edge is an ultra-high pressure waterjet technology company with a global presence.

Jet Edge's primary business includes designing, engineering, manufacturing and servicing ultra-high pressure intensifier pumps, precision waterjet and abrasive waterjet cutting systems, surface preparation and coating removal products, as well as high-pressure cutting heads and related products, parts and components.

Jet Edge products are used in a wide range of industries, from the world's leading airlines to automotive, aerospace and industrial manufacturers and machine and job shops.

Headquartered in St.

Michael, Minnesota, USA, the company has distribution partners throughout North and South America, Europe, Asia and the Middle East and serves customers in over 100 countries.

Fabricator has UK's largest water jet profiler

2007-03-22T23:18:00.002-07:00

Sheffield-based subcontractor fabricatorclaims to have the largest water jet cutting and profiling machine in the UK, which has a 9m x 4m capacity.

Fabricator has UK's largest water jet profiler Sheffield-based subcontractor fabricatorclaims to have the largest water jet cutting and profiling machine in the UK, which has a 9m x 4m capacity. Leading subcontractor, Sheffield-based Charles Day Steel, now established for more than 30 years supplying a large range of steel profiles to UK industry, can now boast having the largest waterjet cutting machine operational in the UK, following the recent installation of a new Water Jet Sweden 9m x 4m-bed profiler, to complement its already existing battery of large flame and laser cutting machines. * Customer base transformed - installed only six months, the Water Jet Sweden profiler, designate 3015EB-NC, has already extended the business to an astonishingly-wider customer base, to include applications never dreamed of before.

Whereas in the past the bulk of business was that of profiling large sheets of metal, the company now finds itself at home profiling plastic figures for table decoration at corporate events, or can be called upon to produce individually-designed fashion belt buckles that look like lace - or indeed profiling anything from dense materials like granite or glass, to low density materials such as plastics and soft, flexible materials such as rubber and foam.

Moreover, the Company now profiles thick stainless and aluminum to customer specification.

Clearly, Charles Day is one of those firms that have stayed the course by keeping faith with its traditional customers while simultaneously moving with the times by extending the application of its expertise to fresh markets.

Indeed, with the addition of the Water Jet Sweden machine, it is probably the first company in the UK to offer a choice of flame cutting, CNC laser cutting or CNC waterjet cutting from within a single site.

* Massive capacity - the machine chosen, in spite of its massive 9m x 4m bed, is a near-standard type Water Jet Sweden product, except that its Z-axis capability allows slabs as thick as 300mm to be profiled, as against the 20mm maximum of the laser profilers installed at the company.

The table loading capacity is a very substantial 1.2 t/m2.

Another feature is the inclusion of triple abrasive heads to boost productivity by offering simultaneous cutting of identical smaller items wherever the opportunity arises.

Charles Day's managing director, Phil Wooffinden, whose first major project this has been since he was promoted to the top spot in 2003, said: 'I not only saw waterjet as a good fit between the flame and laser methods, but I also recognized that it could go beyond the scope of lasers, especially where thick aluminium sheet is involved.' Additionally, it appears, he could see waterjet as a means of bringing much needed added value to products, as the company increases its lead as a specialist in the profiling business.

* Economic advantages - Wooffinden was previously the company's financial director and company secretary and so was in a strong position to assess the all-important financial aspects of such an investment.

No surprise then that he reckoned to have considered about ten different machine suppliers before opting for Water Jet Sweden with whom he 'felt comfortable'.

Reassured by the domestic support capability offered from this supplier's own UK office, run by managing director Chris Baker, at Boston Spa (Lincs), Wooffinden says that the UK steel market suffered severely, some six years ago, as so much fabrication work went to Eastern Europe or even further afield.

It became imperative that Charles Day broaden its customer base.

Bringing the WJS machine into commission has helped do this in no small measure and it is available for production for up to 20h/day.

* Competitiveness improved - other economic advantages in adding waterjet to cover the full spectrum of profiling processes are that the company's fixed costs are now shared more widely, making it possible to apply more attractive hourly rates to each machine, thereby improving competitiveness.

* Quality advantages - among the many highly-rated advantages cited by Charles Day for the waterjet process over other profiling methods, are the elimination of distortion or heat-effected zones and, thanks to the application of minimal cutting forces, tension free processing.

These features, along with the excellent finish exhibited by cut faces, greatly reduce the need for any secondary finishing operations to be carried out.

* Advanced CNC system ensures precision - operating under the control of its jointly-developed Fanuc 160i MB CNC system, the WJS machine offers customers such exceptionally high degrees of precision as to enable Charles Day to quote a general tolerance of +/-0.25mm and, even more impressive, the tolerances achievable for positioning (+/-0.05mm per 1000mm) and repeatability (+/-0.025mm).

The fine jet orifice used permits a minimum slit-width (kerf) as small as 0.5mm to be achieved when required and any or all of the three nozzles can be used with water-only for soft materials or with the garnet supply programmed for abrasive cutting of hard materials.

The WJS profiler is equipped with a single, but substantial, 50HP KMT SL-V pump to provide the necessary supply of water at 4,000 bar.

* Versatility - the versatility of applications to which the waterjet process is applied at Charles Day is impressive.

Where else in the UK might one see thick (110mm) armour plate for military use being profiled on the same machine that, minutes before, could have been cutting complex shapes from thin plastic or even rubber sheet?

One shift might start with a substantial batch of 1.2m2 S275 (mild steel) sheets in process and then be followed by rubber or bakelite to be profiled.

Then, on to fine geometrically profiled 'combs' of 2mm thick stainless steel before finally dealing with a 7m x 2m ABRO steel sheet.

* Ease of operation - this 'all in a day's work' capability is made possible, in part, because the WJS profiler is so easy to program, either through calling up previously loaded programs directly from memory or, where simple shapes are called for, programming on the machine.

Another great plus factor is the way that sheets need only to be laid on the bed, without the need for fixtures, clamps or other tooling.

A reference point is quickly established on-screen, with or without the need to position against set stops.

Charles Day has ample craneage within its Sheffield facility to make light work of even the most sizeable metal sheets.

* Operator training in Sweden - three of the Charles Day's operators received training at the Swedish HQ of WJS, while others were taught either on-site or at a German waterjet user.

Wooffinden is proud of the high level of training afforded to staff within his company and says that all 42 employees have obtained NVQs in subjects relevant to their work.

* Brighter future in prospect - clearly, from a customer's point of view, the availability of a sub-contractor able to offer the best process for any particular job, without prejudice towards any one of the three major methods, has to be a good thing.

Add to this the positive way in which the original objective of attracting a wider clientele is succeeding, the company can look forward to a brighter future than many that were reliant on Britain's heavy fabrication industry a decade ago.

Pneumatic drill expands water jet cutting usage

2007-03-22T23:18:00.001-07:00

A pneumatic self-feeding drill for use with water jet cutting systems aids piercing and can be used for reaming holes to a precise diameter.

Jet Edge is pleased to introduce a pneumatic self-feeding drill for its precision waterjet cutting systems. The drill is available in stationary or laterally adjustable models. The air drill gives waterjet operators the opportunity to expand their cutting capabilities and take in new types of work by enabling them to quickly pierce sensitive materials prior to cutting them with waterjet.

It also can be used for reaming holes to a precise diameter.

The drill works with any manufacturer's waterjet system.

Its heavy-duty, corrosion-resistant design ensures a maximum operating life.

The drill features a hydraulic feed control unit, feed stroke adjustment, exhaust collector and PLC interface manifold.

A flexible bellows cover is mounted to the front of the drill to protect it from foreign material.

All controls are internal; there are no limit switches.

The drill has a free running rpm of 3,300 rev/min and can be set for any stroke from 5/16 to 3in (8mm to 75mm).

It is supplied with a 1/4in (6.5mm) stainless steel drill chuck.

The drill requires an air supply of 27 ft3/min at 100 lb/in2 and a control voltage of 24V DC.

All control valves are contained within a NEMA-rated electrical enclosure.

* About Jet Edge - Jet Edge is an ultra-high pressure waterjet technology company with a global presence.

Jet Edge's primary business includes designing, engineering, manufacturing and servicing ultra-high pressure intensifier pumps, precision waterjet and abrasive waterjet cutting systems, surface preparation and coating removal products, as well as high-pressure cutting heads and related products, parts and components.

Jet Edge products are used in a wide range of industries, from the world's leading airlines to automotive, aerospace and industrial manufacturers and machine and job shops.

Headquartered in St Michael, Minnesota, USA, the company has distribution partners throughout North and South America, Europe, Asia and the Middle East and serves customers in over 100 countries.

Water jet removes castings from runners

2007-03-22T23:17:00.001-07:00

A water jet cutting system is enabling a prcision foundry to remove remove components from the casting runners more efficiently before machining.

The capability of the McKenna Group - the Worksop, UK-based manufacturer of high precision cast components has been enhanced following installation of water jet cutting equipment supplied by Power Jet Systems of Wolverhampton. Power Jet Systems has recently supplied equipment from its 'Minijet' range to enable McKenna to more efficiently remove components from the casting runners prior to subsequent machining, heat treatment, etc. The PJS 'Minijet' system supplied to McKenna incorporates an abrasive management system which meters abrasive powder into the water jet cutting head to enhance its cutting ability.

The head operates on a cantilever system and is able to traverse a cutting area of 1.0m x 2.0m.

A cutting speed of up to 15m/min can be achieved with an accuracy of +/-0.1mm.

The motion system uses high precision rack and pinion drives and linear bearing systems.

The water jet is produced by a 30HP ultra high pressure generator capable of achieving a maximum operating pressure of 3,800 bar (55,000 lb/in2).

This UHP generator - together with the abrasive delivery system - was sourced from KMT, world leaders in water jet component technology.

The PJS equipment was supplied to McKenna as a complete 'turnkey' system including all hardware and operational software.

McKenna Group is a major supplier of components to a range of high integrity industries including orthopaedic, medical, aerospace, defence, oil and gas.

Its components are made using the 'lost wax' investment casting process in materials including stainless and cobalt chrome steels, aluminium and non-ferrous alloys.

Rotary shear included in cut-to-length line

2007-03-22T23:16:00.002-07:00

A large cut-to-length line with a rotary shear allows for cutting different forms, from rectangles to trapeziums, curved sided formats, 'chevron' and ribbed formats.

An important Russian service centre has chosen Fagor Arrasate, Spain, for the installation of a large cut-to-length line with a rotary shear. This type of machine, a Fagor exclusive design, allows for cutting different forms, from rectangles to trapeziums, curved sided formats, 'chevron' and ribbed formats, etc, with an investment 50% lower than that necessary for a press cutting line. The new line, similar to the one in the photograph, can process coils weighing up to 20,000kg with widths up to 1850mm and thicknesses up to 2.8mm.

The maximum cutting rate is 160 blanks/min and the maximum blank length, 3500mm.

However, as the stacker has two stations that can work together, packages of up to 7000mm long can be made.

The cut trapezium angles can be 30 deg.

The line includes a coil magazine, loading carriage, motor operated decoiler, tip preparation system, automatically interchangeable double cassette leveller, rotary shear and electromagnetic stacker, two station starting/stopping.

The installation does not require an accumulator loop and therefore no ditches need to be made in the foundations, further reducing the total investment.

The cost of the project is close to EUR 4 million.

Fagor Arrasate has increased its product range with the incorporation of Gamei (of which it has purchased 100% of the shares), as an equipment supplier for steel and non ferrous metal forging.

Gamei keeps its trade mark, workforce, sales channel and manufacturing programme strengthened by Fagor Arrasate's technical, commercial and design capacity and guarantees the service, quality and customer service from its new market position.

Slitting/cut-to-length line runs at 140 blanks/min

2007-03-22T23:16:00.001-07:00

The advanced design of Fagor's rotating shears allows a slitting, cut-to-length and banding line to operate at up to 140 blanks/min.

A large Australian Service Centre group has chosen Fagor Arrasate to supply its new cutting lines. The group in question is Smorgon Steel. The new project, amounting to EUR 4 million, includes a slitting line, a cut-to-length line and a banding line.

Victor Esteban represented Fagor in the signing ceremony.

The cut-to-length line will process 1525mm wide and 3.2mm thick coils at a speed of 140 blanks/min.

This high production rate is obtained by the advanced design of Fagor's rotating shears, with big advantages in productivity, precision and reduced investment, as the occupied space is much less and foundation costs are reduced to the maximum as no pit is needed.

In addition, the line has equipment for processing delicate coated steels and includes a high precision leveller for steels with a high elastic limit.

The slitting line, on its part, will process coils weighing 15 tonnes with thicknesses of up to 4mm and at a speed of 250m/min.

It includes a quick tool changing system in the circular shear that allows for starting a new cutting programme in only 4 min.

This is a big advantage, as the bottleneck in a slitting line is the low availability due to downtime.

With Fagor's new systems, this problem has been solved and users achieve an extremely high return for their money.

In 2006, Fagor Arrasate has become the undisputed world leader in the cutting line sector for the iron and steel industry and service centres, with almost fifty lines supplied over the year.

Water jet cutting expands its applications

2007-03-22T23:15:00.002-07:00

A south-of-England company shows just how easy it can be to use a top waterjet profiler for an exciting and apparently unlimited range of applications. When first launched, many in the manufacturing industry thought waterjet technology would be largely used as an alternative to laser and plasma cutting devices in the sheet metal field. Its ability to cut cleanly through thick slabs of marble and granite were thought of as some sort of interesting spin-off.

What may come as a surprise to traditionalists is the remarkable take-up of the process by those in the architectural, building and ceramics industries and, more recently, even by those with very clear artistic ambitions.

* Enterprising expansion - charged with the task of installing a highly-individual surround to the luxury swimming pool at the multi-million pound residence of a world-renowned football club owner, the hard-working tiler involved found himself having to source a means of cutting grills into the stonework.

Having seen an existing Water Jet Sweden user in the North of England and the ease with which the cutting contract was fulfilled, the tiler was convinced that he was on to something with huge potential and persuaded his business partner, who also happened to be his father, that the purchase of one such machine could revolutionise their own local tile distribution and contracting business.

Waterjet machines such as those supplied by WJS do not, by UK sales manager Chris Baker's own admission, come cheap, but so totally convinced was the customer that he had 'seen the future', he was prepared to mortgage his own home to grasp the opportunity he visualised.

* Ingenious uses already featured on national television - installed earlier this year, the WJS 3015EB has now been featured on national television on the 'National Geographic Channel' in their programme 'What You Didn't Know About Water'.

Already the new installation is pulling in business from an astonishingly wide customer base, including applications that might seem bizarre to those more accustomed to its hitherto industrial applications.

Who would have thought, for example, that the self-same equipment that might be totally at home profiling marble friezes for the St Paul's cathedral refurbishment, in London, and granite slabs, would be called upon to produce individually designed leather fashion belts that look like lace - or would even be hired out by the hour for the production of fashionable jewelry accessories to design students?

Peter, the younger of the partnership, says that he considered several makes of waterjet profilers but, as somebody with absolutely no experience of such equipment, good support would be absolutely vital.

After meeting with Baker, managing director of Water Jet Sweden UK, and visiting the Swedish manufacturer's factory, he was in no doubt that it had to be a WJS machine or nothing.

* Standard model - the machine chosen, a standard 3.0 x 1.5m cutting size, has twin heads for flexibility, enabling it to cut two identical parts at a time or, as some users tend to do, leave one head for use for water-only cutting and the other for abrasive cutting.

It was found that a 0.2mm orifice for the former and a 0.7mm orifice for abrasive works were ideal.

There seem to be no 'typical' applications here but probably the most frequent tasks are the profiling of artistic patterns in ceramic tiles for architectural, domestic or commercial building work and, in this connection, the distinction between commercial products and art is becoming quite blurred.

It would not be too much of an exaggeration to say that the waterjet cutting process is capable of bringing art into the homes and lives of people who might never otherwise have the pleasure of enjoying it in their daily lives.

The fact that this success can be profitably achieved by someone having no previous experience, and on a perfectly standard machine, says a lot both for the WJS 3015 and its user.

Probably the two key factors in all of this are the customer's own open-minded approach and the choice by WJS of using a Fanuc 18i-MB CNC computer control system to operate the machine.

* One week training course in Sweden - the one-week course offered by WJS in Sweden as part of its sales package, rapidly enabling learning how to use the programs involved, particularly the GEMS R5 that enables drawn shapes to be entered into the system, get the user off to a great start: 'Programming is easy!' says the user but the way he has introduced so many fascinating designs is probably as much a testimony to his own abilities as it is to the system itself.

After all, other companies may require operators to have a clutch of 'qualifications' before letting them loose on such a high-value piece of production machinery.

* Stunning effect - a couple of highly-stylized 'designer chairs' are examples of new, imaginative entreprise having been assembled from 25mm-thick plywood profiles.

It is worth mentioning that, when producing shapes such as these, the 'nesting' facility within the CNC program can be used to ensure the maximum yield from the sheets of material provided, thereby holding down costs.

Other examples include ceramic motifs using contrasting colours that are then inlaid to one another to stunning effect.

* Industrial applications - this installation is just as much at home providing a cutting service for industry.

As an alternative to EDM, laser and plasma cutting, or even machining, parts such as cycle chain wheels in steel, large stainless steel washers, and many engineering components in materials ranging from aluminium to zinc, including carbon fibre, are handled.

An ability to leave as little as a 1mm wide piece of material in thick sheet is another advantage to industrial users as has been the ability to meet whatever degree of accuracy (0.3mm) that has been asked for so far.

Shop fitting and display sectors call for the use of plastic materials, while glass profiling requests are just as likely to come from heavy industry, such as automotive, as from designers of giftware for top retailers.

Said the user: 'The applications are only limited by your imagination.' In truth, after years spent on his knees tiling and then suffering physically as a result, he is now flying free and looks forward to every new day to see what exciting challenge it might bring.

* Television appearance - a recent pleasant surprise was to be featured on an edition of the National Geographical TV channel's 'I didn't know that!' program.

Last word goes to Baker who has sold waterjet machines to many UK users.

'I have always been aware of the broad markets open to this technology, but it is always a pleasure helping open-minded customers like this to get the most out of their investment and I never cease to be surprised at the things they achieve'.

Coil loading cars retrofit easily into lines

2007-03-22T23:15:00.001-07:00

Low cost, easy to install coil loading cars have been designed for easy retrofitting to most de-coilers found in coil processing lines.

A series of new, low cost, easy to install coil loading cars from the Rotobloc-PSP division of the Dimeco Groupe is available from Shear-Form Machine Tools, Coventry, the sole UK representative for the French coil processing equipment manufacturer. These new coil cars CCM.3 (maximum load 3,000kg), 4 and 5 (maximum load 4,500kg) have been designed for easy retrofitting to most de-coilers found in coil processing lines and require only a minimum amount of floor space. They are very economical to use as they only require an air supply line to operate the lifting carriage to load coils with a maximum diameter of 1500mm and maximum width of 1500mm.

For narrow coils, four holding pins can be supplied as an option.

A small electric motor fitted to the end of the rails is used to move the carriage in and out.

They do not require any hydraulic link to the decoiler They operate on a set of two-rails, which are designed to fit under the feet of the decoiler.

The rails are bolted to the floor thereby reducing any tilting and de-railing to an absolute minimum.

All models have a very low height at bottom dead centre (BDP) of 315mm and the maximum lifting height is 500mm for loading and unloading of coils.

Automated CNC shaft lathe machines cylinders

2007-02-15T21:14:00.002-08:00

Latest CNC shaft lathe, designed for the automated, high-precision, internal and external machining of large shafts and pipes, is machining hydraulic cylinders..

A new breed of CNC shaft lathe - purpose-built by Dean Smith and Grace of Keighley, West Yorkshire, UK - for fully automated, high-precision, internal and external machining of large shafts and pipes, is helping the resurgence of Precision hydraulic cylinders (PHC). PHC is a Cramlington, Northeast-based manufacturer of mechanical rams for the fork lift truck and earth moving machinery markets. Designated 'SE' (Special Equipment), the lathe incorporates a 4000mm length bed, Fanuc 18i control, and fully automated chucking and steadying equipment for rapid loading and set-up.

The delivery of the lathe marks a remarkable turn round for PHC, whose premises were levelled to the ground in a devastating fire in May 2003.

Over the last three years the company, starting from the floor up, has totally rebuilt itself, and, the loyalty it showed to its customer base has been, in the most part, fully repaid.

Now, with the commissioning of the Dean Smith and Grace lathe, the fortunes of PHC have 'turned almost full circle'.

The lathe has been specifically purchased for handling 240mm diameter x 4000mm long hydraulic cylinders for earth moving machinery.

Delivered in March this year, the lathe has certainly impressed the person chiefly responsible for recommending the purchase of the machine, industrial engineer David Smith.

Smith commented: 'Because of the specialised nature of the application and our requirements for automated loading, the lathe was always going to be a 'special' - and we asked several major machine tool manufacturers to quote.

Unfortunately, because the lathe was a virtual 'one-off', however, the quotes I received were, quite frankly, unrealistic and way beyond our budget.' He continued: 'I then noticed an application story in one of the machine tool magazines concerning a bespoke lathe manufactured by Dean Smith and Grace of Keighley and found the article quite interesting, so I decided to give them a call.' He said: 'From the outset, all of the staff at Dean Smith and Grace - from managing director Nigel Grainger down - was very easy to work with and PHC had considerable input in designing the lathe,' added Smith.

'The finished build standard rivals any machine tool on the market and most pleasing of all, it came in at a quarter of the price of some of its rivals.' The process for setting up the large cylinders is now operator friendly, so that the cylinders can be quickly loaded and set-up with just one operator, at a stroke slashing floor-to-floor times for what has historically been a difficult and labour-intensive task.

Assisting the quick loading and set-up, is a fully automatic SMW KCNS 400 hydraulic, quick release, chucking system; complemented by an SMW type SLU-Z-4 three-point roller steady with mechanical positioning.

The three-point roller steady can traverse the full length of the bed - under operator's control or automatically - to find the optimum position of support, while hydraulically operated jaws clamp to the workpiece or retract as required.

The chuck and steady work in conjunction with an automatic tailstock designed and manufactured 'in-house' by Dean, Smith and Grace.

The tailstock utilises hydraulic power and the lathe's rack and pinion drive to automatically position at pre-set locations programmed by the operator.

Other features of the 'SE' include: Sauter 12-station auto indexing VDI turret, slat-type swarf conveyor, Fanuc digital motors, precision ball screws and Vogel/Sterling automatic lubrication system.

Operator Mike Smith (no relation to David Smith) is impressed both by the accuracy of the lathe and the auto loading: 'With some 4m bed machines, there tends to be small dimensional discrepancies when machining end-to-end, as we are with the current job.

Not so with the 'Deans' - accuracy is absolutely 'spot-on'.

Also, the automatic chuck, three-point steady and tailstock work well together to make loading a very simple operation.' David Smith summed up: 'Having been in service six months, we are very impressed with the performance of the Dean Smith and Grace CNC lathe and it is proving ideal for the application for which it's designed.

Commissioning and service response have also been pretty good, and, all-in-all, the purchase of the 2817 x 150 'SE' has proved an excellent investment.'

CNC lathes and VMC put firm back in business

2007-02-15T21:14:00.001-08:00

When a subcontract machine shop succobs to fire damage, close support and help from a machine tool supplier with re-establishing the business is very welcome.

In a little under two months PG Components has literally risen from the ashes and, with a move to new premises now completed - combined with the commitment, desire and skill of its management and workforce - plus shrewd capital investment in new and advanced Hardinge technology - the company is (once again) up and running - and is ready to face the future with confidence. Precision engineering subcontractor - PG Components (PGC) was first established in the UK in 1991 and today employs 15 staff. The company manufactures precision components for a diverse range of customers operating in the scientific instrumentation; medical and pharmaceutical; and steam valve and control industries and sectors.

Since its creation - the company has devoted considerable time and effort in developing strong and mutually-profitable relationships with its customers.

And, whilst these relationships were undoubtedly 'tested' after the fire - they were not broken - a testament to the skill, commitment and dedication of PGC's management and staff.

Said Mark Hall, managing director at PGC: 'Clearly the fire created headaches for us - but the loyalty shown to us by our customers was fantastic - it spurred us on to get ourselves back in business as soon as possible.' With a whole host of issues to sort out, such as managing customer's work-in-progress, securing new business, making the insurance claims, searching for new premises, keeping staff up to speed with developments, etc (to name but a few), the company also had to make plans to quickly acquire new machine tool technology.

Continued Hall: 'We had a number of tasks that we had to deal with concurrently.

Because we had no premises and no machines either - it was critical that we resolved these two issues urgently.

We ultimately made our decision regarding the machine tool supplier - not only on the price and the performance of the machines themselves - but also on the business approach adopted and understanding and sensitivity to our position shown by the machine tool supplier too.

And that's why we selected Hardinge.' Hall said: 'Right from the outset Hardinge appreciated what we were trying to achieve.

They took time to find out about the materials we machined (Inconel, stainless steel, aluminium, etc.) and the tolerances (down to 10 micron or better) and surface finishes (4 micron Ra required; they appreciated the type of manufacturing we were involved in (low to medium batch production) - and that we needed manufacturing speed and production flexibility to succeed as a business.' Hall added; 'Their approach was consultative and supportive throughout - whereas other suppliers just saw it as an opportunity to make a 'quick' sale.' * The purchase decision - PGC has recently installed (August 2006) - three new Hardinge machine tools at its new Cheltenham facility.

These machines - two Talent CNC 8/52 lathes and one vertical machining centre (VMC - Bridgeport) 650 BP3 milling machine have been further augmented with Hardinge tooling/workholding equipment worth over GBP 30,000.

The Hardinge Talent lathes have a 52mm bar working capacity and the machines are driven by 11kW 6,000 rev/min spindle producing 136.9Nm torque.

The Talent lathes' powerful cutting capability is complemented by their automation - 12 station turret ATC with 1 sec tool change; bar feed capability and sophisticated swarf (conveyor) systems that all enable trouble-free unattended and overnight production to occur.

The Bridgeport 650 BP3 is a heavy-duty and highly-rigid 3-axis VMC that provides PGC with unrivalled cutting performance.

The machine is equipped with a 10kW 8,000 rev/min BT 40 spindle; a 20 position ATC and delivers 30m/min rapid feeds on all axes.

Owing to the nature of PGC's work (not too many tools required for most jobs) - the BP3's tool changer contains sister tooling and probes - to ensure round-the-clock, high-accuracy machining.

The investment in Hardinge tooling and workholding (toolholders, collets, chucks etc) also includes rotary indexing (5C and 16C) systems that enable PGC to perform quick and high precision (360 deg/s) second operations work - drilling, tapping, contouring, etc.

PGC's investment in Hardinge technology has helped the company streamline its design-to-manufacture operations.

From the company's CAD department - CAD/CAM data can be sent directly to the new Hardinge machines (control systems) - speeding up and making more accurate (due to less operator involvement) the whole data transfer operation.

Concluded Hall: 'It's certainly been a year to remember for PGC.

Despite the problems we encountered with the fire during the summer - we're back in business and, thanks to Hardinge - we're better and stronger than we were in the past.'

CNC lathe offers rigidity and durability

2007-02-15T21:13:00.002-08:00

A compact and rigidly constructed C-axis CNC lathe, with live tooling, has a as a ribbed 45-deg slant bed base that provides superior rigidity and durability.

Radical Sportscars' well-resourced machine shop, already dominated by Bridgeport 3 and 4-axis vertical machining centres, which are used to manufacture complex engine parts and engine, transmission and suspension components for Radical's SR3, SR4, SR8 and ProSport racing cars - will soon be joined by a new addition from Hardinge's portfolio, a Talent 10/78 live tool C-axis lathe. Overview of products - Radical Sportscars, first established in 1996 by company directors Phil Abbot and Mick Hyde and now employing over 80 people, comprises three integrated companies - Radical Sportscars, Powertec Engineering and Amicom Engineering. All housed under one roof - the company designs, builds, tests and develops its own racing cars.

Radical manufactures up to 120 cars per year.

To ensure the high quality and performance of its racing cars Radical has made (and continues to make) significant and strategic investment in its manufacturing processes, systems and technologies.

The company has sophisticated CAD/CAM capability (SolidWorks); impressive component machining facilities; unrivalled engine building expertise and comprehensive fabrication and assembly capabilities.

Engine and transmission testing is carried out on Radical's 'rolling road' - situated on-site and aerodynamic analysis is undertaken at the nearby MIRA wind tunnel.

2007 is a big year for Radical and will see the company running a number of racing championships for its different racing cars - which include: Dunlop Radical Enduro Championship; Dunlop Radical Biduro Championship; Radical Powertec Cup; Radical Challenge Portugal; Swedish Radical Cup; US Radical Cup East; US Radical Cup West; Gulf Radical Championship; Radical German RaceCup and Radical World Cup.

Hardinge machine tool technology is, and will, be used extensively in the manufacture of racing car engines and components for all of these events.

But Hardinge's relationship with Radical and its racing cars does not end there.

The 2007 Dunlop Radical Enduro Championship, held at a number of UK race circuits and the Spa Francorchamps circuit in Belgium - will feature the Hardinge Motorsport SR-8 factory racing car driven by drivers Nigel Greensall and Helen Ray.

The Hardinge Motorsport SR8 was unveiled at the recent autosport Show (NEC, Birmingham) in January 2007 - and the car was used by Radical Sportscars (whilst still on the Hardinge stand) to launch the 2007 SR8 Championship itself.

The SR8 Championship has a large following - and interest looks set to rise with still further with the races being televised on Motors TV.

* The SR8 - the SR8 is powerful and sleek.

The car boasts new bodywork and has world-class handling characteristics.

The car weighs only 650kg and produces more downforce than the combined weight of the car and the driver.

Impressive grip and a paddle-operated semi-automatic gearbox provide a true racing (Le Mans) experience.

The SR8 has a powerful 2.6 Litre 363 BNP Powertec V8 engine (10,500rpm) that comprises Suzuki GSXR cylinder heads mounted on a dedicated dry-sump crankcase.

A flat-plane steel billet crankshaft transmits power to the gearbox and a gear-driven shaft drives 4 scavenge pumps ensuring that the engine operates at optimum efficiency.

The engine's induction system features a twin-butterfly plenum chamber which allows cooled air to be fed directly into the engine whilst also maintaining good aerodynamic flow to the rear wings.

A significant percentage of the SR8's complex and high-precision engine and car components are manufactured using Hardinge milling machines.

They are manufactured from a range of materials - aluminium, alloys, steels etc; - and are machined to high accuracy and equally high surface finish.

The parts often exhibit complex profiles and forms and feature intricate detail - thin walls, deep bores - and are required (and manufactured) in low-to medium volumes.

To cope with these manufacturing requirements Radical relies on Hardinge milling machines and, in the very near future, Hardinge turning technology too.

* Talent 10/78 lathe - the Hardinge Talent 10/78 C-axis lathe, due to be installed at Radical's production facility in Spring 2007, is a compact and rigidly constructed machine.

It is equipped with a 18.5kW spindle drive (with Fanuc control) and includes a three-jaw power chuck as standard.

The machine also has an A2-8 (3,500 rev/min) spindle with 78mm through draw bar capacity.

Rotation time for the Talent's bi-directional 12-station VDI-40 turret is 0.78s (unclamp/index/clamp) to an adjacent station.

The non-rising turret index is achieved using a separate brushless servomotor and the turret positively locks into position using a three-piece curvic coupling.

Through-tool coolant and headwall coolant capability is standard and can accommodate water- or oil-base coolant.

Heavy-duty ball-type linear guideways are used for X- and Z-axis movement, providing added stiffness, damping, and increased surface contact area produces a very stiff, durable and reliable machine.

Rapid traverse rates for the X and Z axes are an impressive 30m/min and maximum X-axis travel is 271mm and maximum Z-axis travel is 600mm.

The lathe has a ribbed 45-deg slant bed base that provides superior rigidity and durability.

All structural components and castings are qualified by finite element analysis (FEA)-a proven, highly-technical procedure that ensures a stiff, structurally-sound machine tool design.

The 2220kg machine base is constructed from high-quality cast iron that contributes to overall stability and rigidity.

Said David Andrew, sales and marketing director at Hardinge: 'The Radical SR8 racing car looks fantastic - and it's great to know that our machine tools have been instrumental in building such a world-beater.' He said: 'Hardinge Motorsport is sponsoring the SR8 factory car in the forthcoming Dunlop Radical Enduro Championships - and we have high hopes that our drivers - Nigel Greensall and Helen Ray - will race away with it.

We have a long-established relationship with Radical and we are delighted that they have continued their investment in our machine tool technologies with the new Talent lathe.'

Classic lathe maker reinforces internal team

2007-02-15T21:13:00.001-08:00

The continuing success of Keighley-based Dean Smith and Grace has led to the company welcoming two new people into the organisation to strengthen its internal workforce. Richard Sanderson, 45, joins the company as Internal Sales Executive. Keighley-born Richard brings to the role 28 years' worth of machine tool and sales experience and is the key man for processing initial sales enquiries and preparation of quotes.

Being a local man he is keen for the company to return to its former glories: 'I remember as a child watching literally hundreds of people leaving the factory at end of shift, and, though those days are gone forever, I hope to do my part in ensuring the company continues its current progress.' Richard is joined by another locally-born man, Roman Hrabar, who is appointed company buyer.

From ball bearings to balls of string, Roman is the man who can source them, consolidating his experience in previous machine tool sector buyer posts with Newall Aerospace and Binns and Berry.

Roman too, relishes the opportunities that Dean Smith and Grace offers: 'I feel the company has a real buzz about it and genuine potential for the future.' Away from work Roman is a champion crown green bowler, being a former British Parks champion and Yorkshire Parks champion on several occasions.

Both men join a company that has been rejuvenated over the last two years.

After an initial makeover of the Dean Smith and Grace branding and livery, incoming managing director, Nigel Grainger, has overseen a complete overhaul of the complete product range - including the launch of new aerospace and pipe lathes, which entered their respective markets at the very highest levels.

Links with the rest of the world have also been strengthened, with Dean Smith and Grace authorised agencies having recently been established in Australia, New Zealand, France, Pakistan and the USA.

Latest CNC turning ups blow mould productivity

2007-02-15T21:11:00.000-08:00

A long-bed lathe is helping a manufacturer of blow moulds to increase its productivity and maintain its competitive advantage by reducing set-up time for turning complex cavities.

Solent mould tool (SMT) - the UK's largest independent blow mould manufacturer has recently invested in a Hardinge Talent 10/78L (long-bed) lathe. The machine, installed at SMT's Waterlooville facility in August 2006, is helping the company increase its productivity and maintain its competitive advantage by reducing time (and resources) spent on job set ups as well as reducing machine cycle times (both by as much as 50%) - when machining complex cavities in mould tools. The net results for SMT through its investment in the Hardinge lathe are shorter lead times and improved part accuracy - which, in the world of complex mould tool manufacture, are very welcome.

* Comprehensive production capability - Solent mould tools was established in 1986 and today employs over 40 people.

The company designs and manufactures blow moulds (up to 2 tonnes) for a range of sectors and industries.

The company provides a total systems solution service to its mould tool customers.

This does not just include the manufacture of complex moulds but also involves working in close consultation with customers to develop and design mould tool concepts and prototypes prior to production sets being manufactured.

SMT also provides comprehensive mould tool repair and modification services to customers.

In addition to investing in the new Hardinge CNC lathe - SMT has also made significant investments (over recent months) in a number of 5-axis and high-speed machining centres used to mill slots, recesses and pockets, etc, in a single set-up.

The company has impressive CAD/CAM capability and, via DNC links, ensures fast data transfer between its design and production operations.

SMT's moulds are used by customers in the UK and throughout Europe and increasingly within the USA - which demonstrates the truly global nature of this market.

The company's moulds are made mainly from aluminium although in some instances steels and alloys - Alumex - are used.

SMT moulds are used in the volume manufacture of plastic bottles (PET, HDPE, PP, PVC etc.) for mineral water, soft drinks and fruit juices, carbonated beverages, cosmetics, toiletries etc - and in total the company manufactures in the region of two thousand mould tools every year.

The mould tool industry is highly competitive with price, quality and lead time reduction being of critical importance.

The decision by SMT to invest in the Hardinge Talent 10/78 lathe was in response to these market demands.

* Cycle times reduced by 50% - the Talent lathe is being used to machine the internal cavities in the mould and has been installed adjacent to an older Hardinge Cobra lathe that is used to machine external features on the mould tool.

Using high-density and diamond tip tooling - the Talent is able to perform heavy-duty cutting operations to high accuracy and repeatability.

Said Andy Thorpe, shop floor chargehand at SMT: 'The Talent lathe has provided us with additional capacity and capability - and has helped us become more productive.

Typically machine cycle times have been reduced by some 50% and the fine surface finishes we are able to obtain, which includes the elimination of blend lines, also means less time spent on secondary polishing operations.' * Check-out the Talent CNC lathe - the new Hardinge Talent 10/78L is a long bed lathe (1050mm between centres) designed for heavy duty turning applications.

Classic lathe maker reinforces internal team

2007-02-10T02:43:00.003-08:00

CNC lathe offers rigidity and durability

2007-02-10T02:43:00.001-08:00

Radical Sportscars' well-resourced machine shop, already dominated by Bridgeport 3 and 4-axis vertical machining centres, which are used to manufacture complex engine parts and engine, transmission and suspension components for Radical's SR3, SR4, SR8 and ProSport racing cars - will soon be joined by a new addition from Hardinge's portfolio, a Talent 10/78 live tool C-axis lathe. Overview of products - Radical Sportscars, first established in 1996 by company directors Phil Abbot and Mick Hyde and now employing over 80 people, comprises three integrated companies - Radical Sportscars, Powertec Engineering and Amicom Engineering. All housed under one roof - the company designs, builds, tests and develops its own racing cars.

Radical manufactures up to 120 cars per year.

To ensure the high quality and performance of its racing cars Radical has made (and continues to make) significant and strategic investment in its manufacturing processes, systems and technologies.

The company has sophisticated CAD/CAM capability (SolidWorks); impressive component machining facilities; unrivalled engine building expertise and comprehensive fabrication and assembly capabilities.

Engine and transmission testing is carried out on Radical's 'rolling road' - situated on-site and aerodynamic analysis is undertaken at the nearby MIRA wind tunnel.

2007 is a big year for Radical and will see the company running a number of racing championships for its different racing cars - which include: Dunlop Radical Enduro Championship; Dunlop Radical Biduro Championship; Radical Powertec Cup; Radical Challenge Portugal; Swedish Radical Cup; US Radical Cup East; US Radical Cup West; Gulf Radical Championship; Radical German RaceCup and Radical World Cup.

Hardinge machine tool technology is, and will, be used extensively in the manufacture of racing car engines and components for all of these events.

But Hardinge's relationship with Radical and its racing cars does not end there.

The 2007 Dunlop Radical Enduro Championship, held at a number of UK race circuits and the Spa Francorchamps circuit in Belgium - will feature the Hardinge Motorsport SR-8 factory racing car driven by drivers Nigel Greensall and Helen Ray.

The Hardinge Motorsport SR8 was unveiled at the recent autosport Show (NEC, Birmingham) in January 2007 - and the car was used by Radical Sportscars (whilst still on the Hardinge stand) to launch the 2007 SR8 Championship itself.

The SR8 Championship has a large following - and interest looks set to rise with still further with the races being televised on Motors TV.

* The SR8 - the SR8 is powerful and sleek.

The car boasts new bodywork and has world-class handling characteristics.

The car weighs only 650kg and produces more downforce than the combined weight of the car and the driver.

Impressive grip and a paddle-operated semi-automatic gearbox provide a true racing (Le Mans) experience.

The SR8 has a powerful 2.6 Litre 363 BNP Powertec V8 engine (10,500rpm) that comprises Suzuki GSXR cylinder heads mounted on a dedicated dry-sump crankcase.

A flat-plane steel billet crankshaft transmits power to the gearbox and a gear-driven shaft drives 4 scavenge pumps ensuring that the engine operates at optimum efficiency.

The engine's induction system features a twin-butterfly plenum chamber which allows cooled air to be fed directly into the engine whilst also maintaining good aerodynamic flow to the rear wings.

A significant percentage of the SR8's complex and high-precision engine and car components are manufactured using Hardinge milling machines.

They are manufactured from a range of materials - aluminium, alloys, steels etc; - and are machined to high accuracy and equally high surface finish.

The parts often exhibit complex profiles and forms and feature intricate detail - thin walls, deep bores - and are required (and manufactured) in low-to medium volumes.

To cope with these manufacturing requirements Radical relies on Hardinge milling machines and, in the very near future, Hardinge turning technology too.

* Talent 10/78 lathe - the Hardinge Talent 10/78 C-axis lathe, due to be installed at Radical's production facility in Spring 2007, is a compact and rigidly constructed machine.

It is equipped with a 18.5kW spindle drive (with Fanuc control) and includes a three-jaw power chuck as standard.

The machine also has an A2-8 (3,500 rev/min) spindle with 78mm through draw bar capacity.

Rotation time for the Talent's bi-directional 12-station VDI-40 turret is 0.78s (unclamp/index/clamp) to an adjacent station.

The non-rising turret index is achieved using a separate brushless servomotor and the turret positively locks into position using a three-piece curvic coupling.

Through-tool coolant and headwall coolant capability is standard and can accommodate water- or oil-base coolant.

Heavy-duty ball-type linear guideways are used for X- and Z-axis movement, providing added stiffness, damping, and increased surface contact area produces a very stiff, durable and reliable machine.

Rapid traverse rates for the X and Z axes are an impressive 30m/min and maximum X-axis travel is 271mm and maximum Z-axis travel is 600mm.

The lathe has a ribbed 45-deg slant bed base that provides superior rigidity and durability.

All structural components and castings are qualified by finite element analysis (FEA)-a proven, highly-technical procedure that ensures a stiff, structurally-sound machine tool design.

The 2220kg machine base is constructed from high-quality cast iron that contributes to overall stability and rigidity.

Said David Andrew, sales and marketing director at Hardinge: 'The Radical SR8 racing car looks fantastic - and it's great to know that our machine tools have been instrumental in building such a world-beater.' He said: 'Hardinge Motorsport is sponsoring the SR8 factory car in the forthcoming Dunlop Radical Enduro Championships - and we have high hopes that our drivers - Nigel Greensall and Helen Ray - will race away with it.

We have a long-established relationship with Radical and we are delighted that they have continued their investment in our machine tool technologies with the new Talent lathe.'

CNC lathes and VMC put firm back in business

2007-02-10T02:42:00.002-08:00

In a little under two months PG Components has literally risen from the ashes and, with a move to new premises now completed - combined with the commitment, desire and skill of its management and workforce - plus shrewd capital investment in new and advanced Hardinge technology - the company is (once again) up and running - and is ready to face the future with confidence. Precision engineering subcontractor - PG Components (PGC) was first established in the UK in 1991 and today employs 15 staff. The company manufactures precision components for a diverse range of customers operating in the scientific instrumentation; medical and pharmaceutical; and steam valve and control industries and sectors.

Since its creation - the company has devoted considerable time and effort in developing strong and mutually-profitable relationships with its customers.

And, whilst these relationships were undoubtedly 'tested' after the fire - they were not broken - a testament to the skill, commitment and dedication of PGC's management and staff.

Said Mark Hall, managing director at PGC: 'Clearly the fire created headaches for us - but the loyalty shown to us by our customers was fantastic - it spurred us on to get ourselves back in business as soon as possible.' With a whole host of issues to sort out, such as managing customer's work-in-progress, securing new business, making the insurance claims, searching for new premises, keeping staff up to speed with developments, etc (to name but a few), the company also had to make plans to quickly acquire new machine tool technology.

Continued Hall: 'We had a number of tasks that we had to deal with concurrently.

Because we had no premises and no machines either - it was critical that we resolved these two issues urgently.

We ultimately made our decision regarding the machine tool supplier - not only on the price and the performance of the machines themselves - but also on the business approach adopted and understanding and sensitivity to our position shown by the machine tool supplier too.

And that's why we selected Hardinge.' Hall said: 'Right from the outset Hardinge appreciated what we were trying to achieve.

They took time to find out about the materials we machined (Inconel, stainless steel, aluminium, etc.) and the tolerances (down to 10 micron or better) and surface finishes (4 micron Ra required; they appreciated the type of manufacturing we were involved in (low to medium batch production) - and that we needed manufacturing speed and production flexibility to succeed as a business.' Hall added; 'Their approach was consultative and supportive throughout - whereas other suppliers just saw it as an opportunity to make a 'quick' sale.' * The purchase decision - PGC has recently installed (August 2006) - three new Hardinge machine tools at its new Cheltenham facility.

These machines - two Talent CNC 8/52 lathes and one vertical machining centre (VMC - Bridgeport) 650 BP3 milling machine have been further augmented with Hardinge tooling/workholding equipment worth over GBP 30,000.

The Hardinge Talent lathes have a 52mm bar working capacity and the machines are driven by 11kW 6,000 rev/min spindle producing 136.9Nm torque.

The Talent lathes' powerful cutting capability is complemented by their automation - 12 station turret ATC with 1 sec tool change; bar feed capability and sophisticated swarf (conveyor) systems that all enable trouble-free unattended and overnight production to occur.

The Bridgeport 650 BP3 is a heavy-duty and highly-rigid 3-axis VMC that provides PGC with unrivalled cutting performance.

The machine is equipped with a 10kW 8,000 rev/min BT 40 spindle; a 20 position ATC and delivers 30m/min rapid feeds on all axes.

Owing to the nature of PGC's work (not too many tools required for most jobs) - the BP3's tool changer contains sister tooling and probes - to ensure round-the-clock, high-accuracy machining.

The investment in Hardinge tooling and workholding (toolholders, collets, chucks etc) also includes rotary indexing (5C and 16C) systems that enable PGC to perform quick and high precision (360 deg/s) second operations work - drilling, tapping, contouring, etc.

PGC's investment in Hardinge technology has helped the company streamline its design-to-manufacture operations.

From the company's CAD department - CAD/CAM data can be sent directly to the new Hardinge machines (control systems) - speeding up and making more accurate (due to less operator involvement) the whole data transfer operation.

Concluded Hall: 'It's certainly been a year to remember for PGC.

Despite the problems we encountered with the fire during the summer - we're back in business and, thanks to Hardinge - we're better and stronger than we were in the past.'

Sliding head automatics are misunderstood

2007-02-10T02:42:00.001-08:00

In the past few years we have seen more and more parts in the smaller size range produced on 25 to 32mm capacity sliding head machines. These machines are designed to produce long slender components - and for that type of part nothing can beat them. But people have run away with the idea that they are designed for all types of small turned parts.

For most parts above 20mm in diameter, and for many smaller parts too, a fixed head, multi-turret machine may be able to make them in half the time with less waste.

The reason for this is that, with one or two exceptions, the fixed head machine manufacturers have neglected this size range and left the field wide open to companies offering sliding head machines.

In the last couple of years Nakamura has moved to redress the balance by introducing fixed head machines specifically designed for the highly productive manufacture of small components.

Nakamura initially introduced the WT-100, a 42mm capacity machine specifically designed for producing parts down to less than 10mm.

It has two turrets, a Y-axis on the top turret, twin spindles for simultaneous machining of first and second operations - and a lot more power than a sliding head machine.

With up to 7kW on the driven tools and 11kW on the spindles we can use modern tooling technology to its utmost potential and really attack cycle times - literally halving them in many cases.

More recently, the company introduced the Super NTY3 twin-spindle machine - with three driven-tool turrets, each with Y-axis machining.

This means that up to 96 tools are immediately available, including 36 driven tools, for simultaneous cutting with three tools.

You've not just got two turrets that are truly flexible to either spindle, you've now got a third turret that can work between the spindles as well.

So with three Y-axis turrets you have a unique and absolutely flexible capability.

The cycle time improvements are not the only reason for choosing fixed head machines.

The beauty of the sliding head machine is that the part is supported by a bush, so the tool is cutting right up against the bush, which means it is very rigid when you are producing shaft-like parts.

But once you have fed the material through the bush you can't go back to it - so you generally have to produce the finished diameter in one pass.

That means that you have to compromise on the cutting conditions.

If you are going from 32mm down to 5mm, yes you can do it, but you may have to use lower feed rates and this will lead to problems with swarf.

This is why the fixed head machine is so much better on the majority of turned parts.

Another cost advantage of the fixed head machine is that there is no need to use high-quality bar as raw material because it is being held in a conventional chuck rather than passing through a precision bush.

There is also a lot less waste.

On a fixed head machine the waste at the end of a 3m bar is literally the length of the component and the grip length of the collet, whereas on a sliding head machine you can lose up to half a metre of material per three metre bar.

That's maybe not such an issue at the smaller sizes, but it can be on larger diameters, and when you are working in expensive materials such as brass.

Given these lower operating costs, combined with the lower capital cost of the Nakamura machines, 'UK turning' can add substantially to its 'bottom line'.

* About the author - Richard Turner is with Turning Technologies UK - distributor for Nakamura-Tome high precision turning centres and CNC lathes.

Vertical turning lathes can be customised

2007-02-10T02:41:00.004-08:00

Webster and Bennett International - based in Warwick, UK - is building standard and customised CNC vertical turning lathes from 1000mm to 2500mm diameter capacity. Using standard modules, the company can offer very simple or very advanced, 'tailor-made' machines at attractive proces. The company also builds a universal vertical turning, machining and grinding centre - a very cost effective product.

In the very busy aero engine rework sector, companies are already buying Webster and Bennett standard machines tailored to suit the requirements of this market.

Second rams for grinding - built into the CNC swivelling saddles, are one new benefit.

Another innovation allows eliptical turning.

* About Webster and bennet International - Webster and Bennet is a daughter company of the Ogepar group, which has manufacturing and trading companies throughout Europe and Africa.

The group includes Pegard Productics, Balliu, ABC Diesels - both based in Belgium - and KBB in Dresden, Germany.

pegard productics builds very large, precision horizontal boring and milling centres.

Balliu builds laser machine tools while ABC Diesels build marine diesels, locomotive power units and power generators.

KBB manufactures turbochargers.

Webster and Bennett has achieved success - 13 orders - in the German market and orders from UK, Belgium, The Netherlands, Canada and Egypt.

CNC machine tools complete in one set-up

2007-02-10T02:41:00.003-08:00

Yamazaki Mazak attendance at Southern Manufacturing 2007 will be used to emphasise the all-round capability of the Mazak CNC machine tool range, which encompasses everything from two-axis lathes, manufactured at its state-of-the-art European headquarters in Worcester, through to the world-leading Integrex series of multi-function machine tools. Actually on the stand, under power, will be an Integrex 100 IV ST multi-tasking machine and a VCN 410A vertical machining centre. In addition, members of Mazak's engineering and sales teams will be on-hand to discuss how best Mazak can improve your productivity.

The Mazak Integrex range is central to the company's 'Done in One' manufacturing system, whereby components are machined complete in a single machine set-up wherever possible.

This system allows lead times to be greatly reduced while at the same time reducing dramatically the value of work in progress, the number of machine tools required and the overall manpower levels.

All of which have major impacts on the bottom line, irrespective of company size.

'Yamazaki Mazak has always been at the forefront of multi-function machine development and the concept of Done in One was originated by us.

We are, therefore, extremely pleased that this concept is now being considered as a cost-effective option for many small- to medium-sized companies.

Our range of machines offers a cost-effective solution to the machining of virtually any component,' said Dr Damien Cleugh, European Marketing, Yamazaki Mazak UK.

Mill-turn centres get faster programming

2007-02-10T02:41:00.001-08:00

The GMX 200S Series linear turning and milling centres from DMG are designed to provide the highest performance for 6-sided complete machining for standard workpieces up to 1185mm in length and 400mm diameter as well as for bar up to 102mm diameter. Key features include an X-axis linear drive, a 6-channel machine bed, a 12,000 rev/min milling spindle with a long Y-axis and an interpolating B-axis. Additional features absolute measuring systems and a 36-tool disc magazine.

Now both the GMX 200S and 250S linear machines can be specified for even faster and easier shop-floor programming - up to 70% reduction in programming time in comparison to DIN.

This introduction makes mill-turn programming as easy and reliable as that for a universal lathe.

When teamed with ShopTurn on Siemens 840D solutionline, the GMX 200S is fully equipped for graphic programming, simple cycle selection and uninterrupted programme monitoring on the shop-floor.

It also provides 3D workpiece simulation for all turning and milling operations extending to the B-axis contour.

This development turns the GMX 200S linear into a highly cost-effective machine for serial production as well as a flexible multi-purpose centre for smaller batches and jobbing work with no limit on geometric complexity.

The GMX 250 linear with its TurnPlus system on the Heidenhain Plus iT controller builds on this flexibility by providing dual channel control for the shop-floor.

It allows the milling/turning spindle and the turret to be programmed with simple dialogue via a menu-based interface.

Features include multi-channel slide display during automatic operation and a detailed machining time readout giving main and idle time.

Small turning centre gives power and precision

2007-01-04T02:21:00.001-08:00

At the AMB in Stuttgart, Germany, Emco Maier will unveil its new CNC E25 turning centre for the first time. This machine represents an impressive rounding off at the 'bottom end' of the model scale of the successful E range from Emco. The E25 with a spindle bore of 25mm will be the successor to the popular Emcoturn 325 in the Emco portfolio.

However, the new E25 is anything but just a mere updated version of its predecessor.

Whilst holding to the maxim 'design to cost', which is adhered to for the whole E range, the E25 is a completely new development.

The aim of the development work was an ambitious one: improving the performance, quality and precision at the same time as radically reducing costs.

The first tests have shown that the Emco developers have managed to achieve what the international market expects of the new E25.

The machine offers uncompromising quality levels right down to the last screw - and all this at an unbeatable price.

The standard version of the E25 costs only EUR 39.990.

For their money, customers will get the very best in European technology, with precision, a long service life and an excellent performance.

Emco is expecting a similar run on the E25 as it experienced with its sister model: 'Since we managed to match the low-cost offerings from the Far East with the E45 and E65 in terms of price and performance, many of our customers have been waiting for the continuation of the E range into the compact class,' said Emco's 'upbeat' product manager Gerhard Meisl.

* Impressive technology - the E25 will be available in four different variants - starting with the basic version and including the tailstock version as well as the top-of-the-range model with driven tools and a C axle.

All of the variants are equipped with a 12-head turret with VDI 16 shaft.

The E25, with its very small footprint, offers everything that is good about and expensive in modern machine tool building: a very solid machine bed made from machine casting, a thermo-symmetrical headstock with a precision spindle bearing, pre-stressed roller guides in all of its axles and a fast switching Sauter tool turret.

The customer can choose between a Sinumerik 810D and a Fanuc 0iTC control unit - including dialog programming with ShopTurn or ManualGuide.

And if anybody needs any more convincing about the Emco E25, then they should know that it offers a perfectly aligned bar loader package, that costs just EUR 8.950, inclusive of an alarm lamp and interface.

And any user that needs to feed the E25 with longer bars, will be very pleased to hear about the new Emco Top Load 4-25/3300 bar loader for 3m bars.

Fast facts about the Emco Emcoturn E25 include the following.

* chuck size 25mm.

* Center distance 405mm.

* Speed up to 6300 rev/min.

* Main drive power 5,5kW.

Mill-turn flexibility frees up machining centres

2007-01-03T02:20:00.000-08:00

Addmore Engineering has built a reputation for manufacturing complex and difficult to machine components to the highest standards of quality and precision. As a subcontractor it produces a wide variety of parts, including spinal implants for medical applications, hydraulic valves for earthmoving equipment and couplings for the oil industry. Frank Vasquez, proprietor of the company, is a committed entrepreneur and has formed and run a series of successful engineering companies, including Kelgate Engineering, which specialises in the manufacture of caliper braking systems for competition karts.

Kelgate brakes have an enviable reputation in the racing world, and out of the 35 runners in 2006 Le Mans 24h Pro Kart Enduro race, 26 were fitted with Kelgate equipment.

Furthermore, the winners in each of the three race categories, 100cc, 125cc Rotax and Biland all used its braking systems.

The complexity of the brake components led the company to re-evaluate its manufacturing methods in order to cut costs and speed up production.

Vasquez and Rob Dewar - managing director of Addmore - chose to install a Mori Seiki NL2500 SY 6-axis lathe with driven tooling and Y-axis, at the Addmore Engineering factory in Stewartby, UK.

Vasquez commented, 'Previously some of our components required six operations.

With the Mori Seiki we were able to reduce this to one.

The innovative milling capability of the machine is unique.

The direct drive in the spindle gives it more power than other mill/turn machines.

Additionally, it is competitively priced and we can achieve extreme quality.

On one part we reduced the cycle time from 1.25h to 15 min.' Reducing the number of operations has generated further advantages as less handling and resetting of the job has reduced the chance of introducing errors between operations.

'With one operation we can immediately see if the job is right.

With multiple operations an error may not be detected until several parts have been partially manufactured.

We are finding that components manufactured on the Mori Seiki are spot on,' he continued.

The Mori Seiki NL2500 SY achieves its accuracy through the rigidity of its construction and active measures to reduce vibration and thermal distortion.

This has been arrived at by static and dynamic analysis of the frame construction, which exclusively uses Japanese manufactured castings; the use of direct drive motors in the turret; and measures to control heat dissipation including oil cooling jackets around the spindle, milling turret and ball screw bearings.

Vasquez added, 'You can see how stable the machine is just from its weight.

We are very pleased with it and have just purchased a second to increase our capacity.' The machines will feed 80mm bar, and have been used to cut parts up to 380mm diameter in the chuck and, thanks to their rigidity, the company finds it easier to machine difficult materials such as Duplex, NiBRON and Marinel 220.

Once the first machine had been installed, Addmore's existing customers realised the possibilities for their components.

One customer has now subcontracted parts to the company which it previously made itself, due to the quality problems it experienced with previous subcontractors.

Vasquez said, 'We have experienced a 20% increase in business as a direct result of installing the two Mori Seiki machines.' The flexibility offered by the new machines has enabled Addmore to examine how it manufactures existing components.

It has been able to transfer significant amounts of work from its machining centres onto the Mori Seiki NL2500 SY's as a direct result of their spindle power and machining envelope.

The change has released extra dedicated milling capacity which the company has already filled up.

Addmore Engineering and Kelgate Engineering both operate at the top end of the quality spectrum, and for them the reliability, rigidity, and accuracy of the Mori Seiki NL2500 SY perfectly matches their philosophy of excellence.

Frank Vasquez concluded, 'Our investment in Mori Seiki machines has been a very good decision.

We have achieved some valuable cost reductions and added considerably to our turnover and profit whilst maintaining our high quality standards.' * About Mori Seiki (UK) - Mori Seiki UK, the UK arm of Mori Seiki Co, services and supports Mori Seiki and Hitachi Seiki machines in the UK market.

Machine tool specialist bought by management

2007-01-02T02:19:00.000-08:00

The Directors of Leamington-based machine tool specialist, Mills Manufacturing Technology , have successfully completed the management buy-out of the company which was first established in 1998. Under the new arrangement which secures 100% of the equity, Mike Jenkins becomes the Chairman, whilst retaining his position as Managing Director. He is joined by fellow Directors and shareholders - Andrew Jack, Nick Frampton and Nav Ahluwalia - who, collectively, form the senior management team and are responsible for the future strategic direction of the company.

Funding to facilitate the exit of Close Investment has been provided by Barclays Leveraged Finance, supported by significant personal investment from the Directors.

Dave Davies, manager within Barclays, commented: 'We are delighted to have been able to support the management team in taking this significant step in the development of their business.

We look forward to working with the new owners as they continue to cement their market-leading position in the UK machine tools market.' Says Mike Jenkins: 'This is fantastic news for our staff and for our customers.

Our business is looking good for the future.

We have the funding, the resources and the people in place - and our sales performance, once again, is well ahead of the market.

Whilst it's certainly a case of 'business as usual' for customers and staff - we have exciting plans to grow the company in the future and are confident about our success.' The deal, finalised October 13th 2006, sees Close Investment - the Venture Capitalist who originally provided the finance for the management team to acquire the business - end its relationship with the company after 8 highly-successful years.

Mills Manufacturing Technology is the fastest-growing machine tool company in the UK.

The company has enjoyed consistent growth over a sustained period of time - and in the last 3 years has seen its sales rocket by more than 40%.

Mill-turn centre has B-axis for complex work

2007-01-01T02:18:00.000-08:00

Specialist contract machinist, PG Technology, has installed a B-axis mill-turn centre at its factory in Mitcham, Surrey. Supplied by NCMT, the Okuma Multus B300-W is the first twin-spindle mill-turn lathe on site and increases the contract machinist's turning capacity to 630mm diameter by 900mm long. It also extends considerably the complexity of in-cycle prismatic machining that may be carried out.

Business development manager, Clive Evans, stated, 'The addition of the Okuma machine to our existing, high quality CNC turning department will give the company a strong competitive edge in the UK and Continental European market place.' He added: 'With the Multus, we can make in one operation components that are normally machined in three to four ops.

So we are able to be even more competitive in delivering the right price for our customers, with which we have built up excellent working relationships based on high quality and rapid delivery.' Evans recently mentioned an aircraft hydraulics component in stainless steel that was previously quoted at GBP 118 and which could now be supplied for GBP 85.

There is a good chance that PG Technology will win this work next time around.

Another mill-turn job that will shortly take advantage of the 11kW milling spindle on the Multus is a stainless steel, eccentric cylindrical component that currently needs four operations on a lathe and a machining centre.

It will be machined in two operations and to very high accuracy, the position of some drilled holes being tied up to 3 microns relative to the bore centreline.

Installed at the end of August 2006, the Multus was first used for pure turning applications to give the operators a chance to familiarise themselves with the Okuma OSP P200L control and the machine's 7-axis CNC technology - X, Z, Y, B, C1, C2 and W (longitudinal travel of the opposed spindle).

On these jobs, the combination of the 15kW turning spindle, HSK A-63 tooling, 40m/min rapid traverse in X and Z and synchronous pick-up by the opposed spindle has on average allowed PG Technology to halve both the number of separate operations and manufacturing times, according to Evans.

Vincent Bootes, owner of PG Technology, commented, 'I am delighted to support the company with substantial new investment in the latest technology when I see the enthusiasm and commitment of the business to progress and strive for the ultimate accolade of world class supplier.' Concurrent with the new mill-turn centre installation, PG Technology purchased several seats of EdgeCam software, version 11, from Pathtrace to generate complex cutter paths.

A further development will be relocation of the factory in the first quarter of 2007 to new freehold premises nearby in Mitcham.

This will see the present 24h, 5 days/week operation go to 24/7 working, subject to recruitment of extra skilled people, which Evans complained is always a challenge.

He concluded, 'The Okuma Multus has already strengthened production of rotational components.

It brings turning in line with the highly advanced machining centre capacity we have, which includes full 5-axis capability.' 'The only way to compete these days is to invest in modern, capable production equipment like the Okuma Multus and it does not stop there, as we are currently looking into another 5-axis milling centre

Large mill-turn centre has extensive probing

2006-12-31T02:18:00.000-08:00

When Manthorpe Engineering takes delivery of the largest machine installed by DMG in April 2007, the colossal 3.4m bed DMU 340FD mill-turn machine will make the Derbyshire, UK-based aerospace specialist the envy of not just UK manufacturers, but also those throughout Europe and the rest of the world. From humble origins some 30 years ago as a precision machinist providing subcontract services to the mining industry, Manthorpe Engineering has emerged as one of the UK's premier suppliers of components to the aerospace, defence and power generation sectors. The past 10 years has seen Manthorpe maintain continued investment in new plant and machinery, which will culminate in the completion of a new 25,000ft2 machine shop late in 2006.

Some of the company's milestone investments include Unigraphics NX3 CADCAM in 2004, followed a year later by the arrival of Manthorpe's first multi-tasking machine tool.

'The installation of the DMU 340FD next April, along with a DMC 160FD twin pallet duoBLOCK mill-turn machine, will take our total number of multi-tasking machines to five and increase our machining capability to 3m diameter from our existing 2m limit,' explained sales director Chris Bowley.

The DMU 340FD mill-turn centre combines two technologies in a single machine, allowing workpieces weighing up to 7000kg to be machined using five axes simultaneously in a single set-up.

This complete solution not only saves time and money but also achieves greater flexibility and accuracy.

The new 2.5m, direct drive NC-rotary table offers 40kW of power.

It can provide rotational speeds of 120 rev/min, torque of 10,000Nm and a holding torque of 15,000Nm.

This highly productive unit masters a previously unattainable range of horizontal and vertical mill-turn applications.

During the evaluation process, the impressive capacity and specification of the DMU 340FD led Manthorpe to investigate further, first by attending the EMO 2005 machine tool exhibition in Hanover, and then by visiting the DMG assembly line in Pfronten.

Suitably convinced, Manthorpe officially signed the order for the GBP 1.25m package at the recent MACH 2006 exhibition in Birmingham.

'The DMU340FD is a strategic purchase that will allow us to widen our portfolio of parts both from a size and range perspective in the markets we already serve and hopefully also open up new ones,' explained Bowley.

'At the moment the large majority of our customers are UK-based although we are supplying parts to Belgium, the US and Canada, and are actively looking at other export markets.

The DMC 160FD will allow us to consolidate best practice manufacture on current and new parts where we are continually being asked for price and lead-time reductions.' Manthorpe Engineering will be using both of its new DMG machines to produce components such as air intake casings, compressor casings, turbine casings, rings and seals in a single set-up from materials including carbon steels, stainless steels, aluminium and exotic alloys such as nimonic, inconel and titanium.

The gantry-design DMU 340FD, with three-point support for quick installation, is a mill-turn machine featuring an XYZ of 2800 by 3400 by 1600mm respectively.

The universal, swivelling milling head features a controlled, driven B-axis, while the 180-pocket tool magazine comes complete with an automatic horizontal changer.

When large, high value billets of material are involved, the cost of scrap or rework is not an option in today's highly competitive manufacturing arena.

For this reason, the package selected by Manthorpe features the inclusion of several on-machine probing/measuring options.

These include: a Renishaw OMP 60 infrared measuring probe; a combination measuring tool for the machining area (Blum laser for milling tools, Renishaw TS 27R for turning tools); mechanical tool breakage control; and a Zoller TDS tool identification system.

All of the systems are linked to the machine's Siemens 840D Powerline control (Heidenhain iTNC530 available as an alternative).

Turning centre for subcontract machine shop

2006-12-30T02:17:00.000-08:00

Continuing its inward investment programme, Qualiturn Products has purchased yet another Miyano Turning Centre. The innovative subcontract machine shop has always kept one step ahead of the competition - and the Miyano BNJ-42SY is the next progressive step in the company's development. Implementing a strategy of innovative production techniques and high levels of quality through investment in CNC bar-fed lathes, the 7-Axis Miyano BNJ-42SY fits in well with Qualiturn's vision.

The Miyano BNJ-42SY will suit the subcontractor's 24 hour a day operation and will compliment the 16 Star sliding head turning centres already on site The sliding head lathes accommodate parts up to 32mm, so the company has purchased a Miyano BND-42S and BNJ-42S in the last four years to enable turning up to 42mm capacity.

The BND-42S and the BNJ-42S both boast 6 revolving tools and 12 tool turret stations that provide exceptional capability and reduced set-ups on a rigid machine base.

However, it is the new BNJ-42SY that will be the jewel in the crown with its Y-axis that offers vastly improved capabilities.

Qualiturn Director Mr Nick Groom comments: 'The Y-axis on the Miyano BNJ-42SY will give us the capability to conduct off-centre cross tapping and helical milling to name a few difficult tasks.

This will immediately enable us to bring more work in-house as opposed to subbing it out.

It will eliminate a lot of second operations on alternate machines thus improving productivity.' This is not the only advantage, as Mr Groom continues: 'The BNJ-42SY will enable us to quote for work that was either outside our scope or could not be produced in one-hit.

This new machine will change all that.' When looking for added capacity and capability, the Miyano was a straightforward choice as Mr Groom says: 'We researched the marketplace and the Miyano machines appeared to be a huge success wherever they were employed.

We were familiar with Macro CNC; and the capabilities of the Miyano's combined with the excellent service of Macro CNC were major contributors to our decision.

Another factor was the ease of use.

Our operators are familiar with the operating system of the Japanese Star machines we have.

Transferring this skill base to the Japanese Miyano machines was never an issue.

Our operators needed very little training!!' The Miyano will be used to manufacture anything from 5 to 10-offs to batches of 10,000+.

Working with a wide variety of materials including steels, aluminium and brass; material selection becomes a less expensive exercise due to the Miyano.

Mr Groom visited Miyano in Japan in late 2004 to witness the exceptional build quality of the Miyano brand and recalls: 'When I visited the Miyano manufacturing plants in Japan, the investment in developing innovative new products was immediately apparent as was the build quality.

It is this quality that gives the machines their robust and rigid nature that when combined with the high power will enable us to work with tougher materials at much improved metal removal rates.' The ISO registered manufacturer works with the demanding aerospace, electronics, military and medical industries and has little doubt that its new acquisition is guaranteed to be a huge success.

5-axis control vertical machining centre

2006-12-29T02:16:00.000-08:00

Mori Seiki has released the NMV5000 DCGTM 5-axis control vertical machining centre, which combines all of our accumulated original technology. In recent years there has been growing demand for a 5-axis control machining centre which offers both high-speed, high-precision machining and ease of use, due to the increasing complexity of shapes and the need for high added value in the parts machining and die and mold industries. In response to these requests, Mori Seiki has released our NMV5000 DCGTM 5-axis control machining centre, which allows machining which could not be done on 3-axis control machines, as well as process integration during high-speed machining with 5 axes.

Due to the 5 axes and 5 sided machining, complex components up to 300kg can be produced.

This means: 5 axes milling technology with MORI SEIKI quality with a large range in automation solutions.

The NMV5000 DCGTM achieves high rigidity by using Mori Seiki's unique technologies, DCGTM (Driven at the centre of Gravity) and Box-in-Box Construction.

The DD (Direct Drive) Motors on the B and C axes which turn the table eliminate backlash and allow high-precision positioning.

Turning is also possible, with a C-axis rapid traverse rate of 120 min-1 as standard and 500 min-1, 1,200 min-1 as options, dramatically increasing productivity through multi-axis machining.

What's more, as well as making it easy to use when performing the basic functions, we overcame the difficulty with setup which is characteristic of 5-axis control machines by paying particular attention to the operator's access to the table.

As a support function to make 5-axis control machining even more efficient, it uses the new generation MAPPSandnumber8546; operating system, which offers a real-time interference check function and specialised high-speed canned cycles for multi-axis machining.

Measuring microscopes for industrial inspection

2006-12-28T02:15:00.000-08:00

he new Olympus STM6 series of microscopes has been specifically designed for a wide range of industrial inspection and measurement applications. The range features a variety of models that covers increasing user demand for new measuring capabilities and offers more system versatility and higher performance than ever before. The STM6-LM is used for fast inspection of larger samples, and the STM6 offers the most compact microscope in its class with exceptional levels of precision and durability for today's broad research and industrial environments.

The new Olympus STM6 range of industrial measurement and inspection microscopes has been designed to perform the most demanding measuring and inspection tasks of industrial parts and electrical components.

Both the STM6-LM and STM6 models offer outstanding features with motorised focusing - a world first, highly advanced UIS2 (Universal Infinity System) infinity-corrected optics, and a high-rigid body with integrated counters.

Motorised focusing has been introduced to the STM6 series for quick and precise Z-axis measurement.

This dramatically improves operation in both focusing and the measurement of height and depth, and is equipped as a standard feature.

The Z-axis control box, which is conveniently located by the operators hand, allows both coarse and fine focusing movements to be carried out.

In addition, the auto focusing unit makes it possible to obtain stable measurement results by minimising the dispersion caused by different operators.

The space-saving body of the STM6 series is the smallest in size in this class of measuring microscopes despite its numerous versatile functions.

The highly rigid frame and measuring stage offers solid stability over long periods of operation in manufacturing environments.

The stages are embedded with glass scales for reliable and accurate measurements, and are available in three different types, 50mm x 50mm, 100mm x 50mm and 100mm x 100mm, to accommodate various sizes of samples.

The STM6-LM is equipped with a clutch-type stage which provides a large measuring area (250mm x 150mm), and all X and Y movements are clutch-controlled.

This allows the user to change quickly between coarse and fine movements by simply moving a lever, and free movements on the X/Y axis and X/Y plane allows larger samples to be accurately inspected.

It is also possible to measure mulitple samples on the stage at the same time.

A precise read-out counter (0.1 and 0.5um) has been integrated with the column of the microscope body, with the display comfortably positioned at the ideal observation eye-point.

The operator can confirm the measuring value with only a slight change in eye angle, allowing easier concentration on the sample observation and positioning.

The STM6 stand also accepts fibre optic cold illumination for minimising the heat effect on the sample and microscope body.

Turning centre deploys 80 tools without a magazine

2006-12-27T02:14:00.000-08:00

The new, German-built Traub TNX65/42 mill-turning centres from UK agent, Geo Kingsbury Machine Tools, are of twin-opposed-spindle configuration and may be equipped with two, three or four disc turrets, each capable of holding 10 driven or static tools on both faces using double toolholders. So up to 80 tools can be accommodated in this conventional design of lathe. Normally for a CNC lathe to deploy such a large number of tools, its design is based on a single-station turret head with automatic tool change (ATC) from a magazine outside the working area.

As a conventional turret tends to be more robust than its ATC counterpart, higher accuracy machining may be achieved, added to which the 10-tonne TNX65/42 is constructed on a heavily ribbed, cast iron slant bed that dampens vibrations and promotes close tolerance machining.

Tool change is faster with a disc turret than when cutters are exchanged from a magazine, leading to higher productivity as well.

Balanced turning of slender workpieces or two dis-similar machining operations performed at the same time are established advantages of twin-turret turning, which is achievable at both spindles simultaneously.

The TNX65/42 takes the technology a stage further, however, with the possibility of tools in three turrets cutting simultaneously at either spindle.

In addition to travels in X and Z of 650mm and 175mm respectively, there is +/-40mm of Y-axis movement on each turret, enabling keyway milling, off-centre drilling, side face milling and similar operations to be carried out.

Even more complex components may therefore be completed in one hit, with all attendant benefits including less work-in-progress, shorter lead times, zero fixture costs and reduced manning overheads.

The result can be cycle times so quick that they would normally be associated with a multi-spindle auto.

Of symmetrical design, the machine has its turrets arranged on independent slides above and below the spindle centreline, giving maximum versatility for optimising cycle times.

Furthermore, the headstock is thermo-symmetrical and the synchronous, C-axis motor-spindles are of identical rating at 24kW / 5,000 rev/min for the 65mm bar capacity machine and 28kW / 7,000 rev/min for the 42mm bar model.

Hybrid bearings are fitted as standard for increased service life.

Control is provided by the TX8i-s running, as usual, Traub's in-house developed software.

It is optimised to the manufacturer's lathes and is backwardly compatible, allowing programs to be run that were created on earlier controls.

Realistic 3D simulation shortens set-up time and avoids collisions when producing first-off components.

Abrasive machining ousts milling and broaching

2006-12-26T03:50:00.001-08:00

Broaching is a notoriously expensive and time-consuming manufacturing process, with machines costing up to GBP 2 million and suppliers quoting lead times as long as two years. Consumable costs are also high. The technique dates back to the industrial revolution and if you asked most production engineers which machine tool they would most like to eliminate, it would be the broach.

Its main benefit is that it has been used for decades, so the metallurgy of broached components is known precisely.

This is important when manufacturing safety-critical parts such as turbine and compressor discs and blades, and broaching has long been approved by companies building aero engines and turbines for power generation.

Makino-NCMT Grinding Division has been making significant strides towards replacing broaching with grinding for critical part production.

The British firm is a recognised world leader in so-called VIPER (very impressive performance extreme removal) grinding, introduced in 2001 as a replacement for creep feed grinding of inconel and other nickel-based alloys using CBN wheels.

While grinding is traditionally regarded as a low-stock-removal, finishing process, the VIPER process has also been shown to be 10 times faster at removing metal than milling.

Rolls-Royce in collaboration with Japanese machine tool builder, Makino, its UK agent NCMT, and Austrian grinding wheel producer, Tyrolit, developed the patented VIPER technique.

VIPER uses inexpensive, vitrified aluminium-oxide wheels of small diameter, typically 220mm diameter by 40mm wide, mounted in the spindle of a horizontal machining centre (HMC).

They are up to eight times faster than CBN when machining long-chipping, sticky, nickel-based alloys and set-up times are faster, lowering economic batch size.

High-pressure coolant is employed, both through the spindle and via a programmable coolant nozzle (PCN) to direct it accurately to the point of cutting.

The process is gradually being adopted by the major aero-engine companies and their subcontractors to replace some, if not all, broaching and milling operations.

Land-based turbine producers have been quicker to change, as their components are not so safety-critical.

Rolls Royce has for many years employed VIPER grinding on Makino HMCs for the manufacture of compressor blades, turbine blades and engine casings.

More recently, a land-based power generation company has invested in the technology for rough grinding instead of broaching the root form of nickel alloy turbine blades for power generation, and is close to replacing the finish broaching operation with grinding.

It is noteworthy that metallurgical analysis by Makino-NCMT shows lower residual stress in a ground component compared with its broached equivalent.

A big advantage of VIPER grinding is that it is carried out on an HMC using small grinding wheels that may be interchanged from the tool magazine.

A milling cutter, drill or other driven or static tool for turning can also be exchanged automatically into the spindle during a cycle, allowing second and subsequent machining operations to be carried out in the same clamping.

Multi-functional machining including VIPER grinding as one of the operations was pioneered by the Japanese machine manufacturer, whose UK agent, NCMT, was appointed earlier this year to market the technology not only in the UK, but also across Europe.

It follows the completion of many successful VIPER turnkey installations by NCMT in the UK over the past five years.

Versatility is almost unlimited using the Makino-NCMT solution owing to the ability to mix and match machining processes.

Maximum advantage is taken of the VIPER process for roughing and semi-finishing.

If finishing is not appropriate using the technique, perhaps because a grinding wheel cannot access some features, or a manufacturer's 'lifing' engineers do not accept grinding for the final operation, then milling or broaching can complete the machining cycle.

Related areas that have been researched by Makino-NCMT to achieve required process capability and throughput include gear grinding software, flexible fixturing, and manual or in-cycle part measurement, verification and truing.

In addition to aerospace and land turbine components, VIPER grinding is also suitable for cost-effective manufacture of medical components, especially as their increasing complexity is making manufacture more difficult on conventional or modified tool and cutter grinders.

Internal and external machining simultaneously

2006-12-25T03:49:00.000-08:00

Hollow shafts and similar components, on which the alignment of bore to external diameter must be of the highest precision, are being complete-machined, ready for assembly, on the HG 208 CD Center Drive Grinder. Examples of this type of work include the gear shafts used in modern direct transmission systems in passenger cars. The machine simultaneously grinds the shafts inside and out in a single set-up.

This process is far more accurate than alternative methods or producing the component on two separate grinders.

The HG 208 CD Center Drive Grinder simultaneously grinds hollow shafts of up to 400mm length internally and externally.

The top equipment specification for the machine features two internal and two external spindles mounted on two compound slides with B-axis.

This configuration allows for the internal machining of bores and end faces as well as of conical surfaces and slots.

The two external grinding wheels can also be used to grind diameters and adjoining end faces.

Depending on machine requirements the grinding technology used can be conventional and/or CBN.

A profiled dressing roll ensures that seats are ground without leaving tool marks.

The work spindle operates on modern, maintenance-free AC motor technology.

The chuck diameter is usually 160mm.

An integral loader loads and unloads the workpieces and also serves upstream and downstream equipment components, such as the storage sections for raw-parts and finish-machined components, measuring devices, cleaning stations, workpiece recognition and orientation equipment, marking devices, the data collection for the statistical process control SPC and so on.

The HG 208 CD is based on the HG series of grinders, to which were added certain components from the VSC series of combined turning and grinding centers, many hundreds of which are in use across the globe every day.

Workholding and automation equipment too are made by Emag.

This allows for the HG 208 CD and its peripherals to be assembled strictly in accordance with customer requirements, using a range of well proven machine modules - all of them from a single source.

Upstream processes, in particular soft turning operations, as well as downstream processes, in particular the precision machining of hardened tooth profiles, are also covered by Emag, the supplier of complete process streams and manufacturing systems.

The after-sales and service network of the Emag Group spans the globe, offering the user a high degree of security.

The financial advantages the user can enjoy with the HG 208 CD are the result of the following.

* Exceptional concentricity of external diameter to bore.

* Low cycle and idle times.

* High degree of machine availability.

Modular cylindrical grinders can be customised

2006-12-24T03:47:00.000-08:00

Modular concept grinding machine is ideally suitable for medium to large components and medium volume production applications. Danobat Machine Tool Co displays at IMTS 2006 the latest universality concept in medium - heavy duty grinding machines. Several machine configurations are available in order to satisfy market needs.

Customers worldwide, OEM and subcontractors, have already designed and developed their own HG grinder suited to their specific requirements and have experienced first hand the flexibility through partnership policy Danobat establishes with its customers.

Some of the most demanding applications, such as printing rolls and aerospace shafts, have relied on the multi diameter absolute measuring system (DAN MDM) to guarantee process precision and control.

This Danobat-developed system is a step forward in efficiency and process control.

It can be used either in-process or post-process applications, controlling part dimensions and measuring roundness and cylindricity on continuous or interrupted diameters.

The DAN MDM system is a highly value added tool for a single setup work process in medium to heavy parts when microns matter.

This system helps the operator avoid multiple manual measurement checks and offset changes that were traditionally required on the larger bulky close tolerance parts.

In addition it gives the operator the ability to in-process gauge virtually every critical diameter on the shaft, therefore reducing the overall cycle time and required operator intervention significantly.

The software is very intuitive and user friendly with its management and display conveniently integrated in the operator panel on Siemens or Fanuc CNCs.

This IMTS Special Edition HG 72-1500-B1 is the smallest of the HG product range series and is capable of handling parts up to 3300 lb and 63in in length, with a maximum diameter of 18in.

It has been equipped with a B1 wheelhead configuration (24in x 3.15in x 12in wheel) and the DAN MDM multi diameter absolute measuring system.

According to Harvi Chana, Danobat Grinding Division managing director, 'This compact footprint HG-72 rebounds maximum flexibility in configuration possibilities combined with rigidity, precision and productivity.' Chana emphasized in the HG product range potential in medium-heavy application markets, 'On structural big parts, when microns matter, our machines feel at ease guaranteeing outstanding performances, it is their job and customers will not expect less.' * HG product range overview - machine base and slideways - wheelhead infeed slide (X-axis): displacement of slide on hydrostatic slideways.

Direct drive transmission by servomotor and positioning controlled by linear encoder with 0.000004in resolution.

Table slide (Z-axis): displacement on V and flat slideways by automatic lubrication with indirect drive transmission by servomotor controlled by linear encoder.

Single block or double body available.

It is equipped with air cushion system for easy manual swiveling when the double body is used.

CNC universal grinder can mill and drill

2006-12-23T03:46:00.000-08:00

ANCA will debut its latest development, the TX7+Xchanger at the IMTS exhibition in September. The new machine has been designed with extensive customer input and incorporates an ANCA TX7+ universal grinder with a wheel pack exchanging system and magazine. The magazine holds 16 wheel packs instead of the customary two only found on most CNC grinders, which means the operator now has up to 64 wheels to select from.

This expanded selection holds productivity and cost-saving benefits for companies seeking to maximise automation in mass production of cutting tools or grind complex components that require several different wheel packs to complete.

Having multiple wheel packs set up in the Xchanger magazine provides several new benefits not possible with most grinding machines including the following.

* Immediate follow-on in mass production when the wheel pack needs to be changed due to wheel wear.

This means longer unmanned operation can be achieved.

* No downtime to change wheel packs when switching from one tool type to another, increasing production flexibility.

* Improved occupational health and safety conditions for operators as manual handling of wheel packs is reduced.

This limits exposure to oil and carbide and handling of heavy wheel packs.

* Minimal downtime to set up wheel packs as coolant manifolds and pipes are changed with the wheel pack.

Set-up is done off the machine in a set-up rig, which means production does not have to be interrupted.

All of this adds up to the possibilities of extended unmanned operation, which will deliver greater levels of productivity and lower-cost tools without compromise on precision.

To further increase the flexibility of the TX7+Xchanger, ANCA also built in milling capability.

Tools such as drills and endmills are driven by the spindle using standard Big Plus wheel arbours.

As the milling tools are also stored in the magazine and therefore also changed automatically, features such as holes, keyways and dovetails prove no problem for the TX7+Xchanger.

Although the new machine will be the flagship of ANCA's IMTS exhibit, it will certainly not be on its own.

Other products on show will include the following.

* TapX dedicated tap grinding machine, which can manufacture a complete tap.

* CLX compact loader, which provides an economical automated solution.

* iQual automatical wheel qualification system.

* iView tool measurement and compensation system.

* RX7 compact grinder demonstrating small diameter grinding and the VCS Precision V-block clamp and steady.

* About ANCA - ANCA is an Australian owned company that was founded in 1974 to design and manufacture high technology Computer Numerical Controls (CNCs) for the machine tool and metal-based industries.

Low-cost dust extractors introduced for grinders

2006-12-22T03:44:00.000-08:00

Low-cost dust extractors introduced for grinders Low-cost dust extractors for an extensive range of metal grinding machines feature electronic start and stop delay and there is an optional motor brake for decelerating the grinding machine. In order to meet customers' requests, 'Flott' has developed two new low-cost dust extractors for the extensive range of metal grinding machines. The metal dust extractor MA 400 D has been designed for connecting to a 400V power supply and extracting dust from three-phase AC machines, whilst the metal dust extractor MA 200 W has been specifically designed for 230V operation.

Dust is extracted through two transparent PU spiral hoses with a diameter of 50 mm.

The extracted air is filtered via a progressively compacted, matted non-woven fleece (filter class G3 according to EN 779), which features not only a high degree of separation but also has a high dust storage capacity.

The change intervals for the filter insert were thus reduced considerably.

Both metal dust extractors feature electronic start and stop delay; they may be equipped with an optional motor brake for decelerating the machine connected to the unit.

CNC cylindrical grinder improves product roundness

2006-12-21T03:41:00.000-08:00

Accura Technics announces advancements in precision grinding applicable to aerospace, automotive, bearing and optics manufacturing. In capability tests, Accura's Model 1210G CNC grinder produced 0.000010in (0.25 micron) roundness in ball bearing outer races and 0.000006in (0.15 micron) roundness in inner races. This multi-surface grinder was delivered to the USA's Adcole Corporation (Marlborough, Massachusetts; Pompano Beach, Florida) for grinding spindle components for camshaft and crankshaft measuring machines.

Roundness of these components directly impacts axial and radial run-out of the assembled spindle.

Excellent run-out is crucial to the measuring machines' performance.

Upon inspection of the first spindle processed on the 1210G, Adcole's general manager, Patrick Cole, said, 'Needless to say, we are impressed.

And it will only get better from here.' The 1210G is equipped with a hydrostatic bearing workhead, and two wheelheads: an air bearing ID/OD spindle, and a ball bearing rotary surface spindle.

The two wheelheads are mounted on independent CNC axes.

These axes are driven by ball screws and servomotors while the X-axis is driven by a linear motor.

The three slides are mounted on a thermally stable, natural granite base.

'Customers turn to us for creative solutions to their precision grinding needs,' said Patrick Hurst, president of Accura Technics.

'We work with our customers to develop robust processes that deliver higher precision at a competitive cost which saves them time and money.' The 1210G has a 12in (300mm) swing and 10in (250mm) workpiece height capacity.

Standard X-axis travel is 14in (350mm).

Standard Z-axis travel is 12in (300mm).

The machine can be fully automated with robot loader, conveyors and gauging.

Optional features include C-axis for non-round grinding and acoustic emission monitoring system.

Accura Technics other products include the MicroTol - a machine tool platform suitable for optics machining, hard turning, shoe centerless ID grinding, and miniature bore grinding.

Accura is also developing a larger vertical grinder with 30in (750mm) diameter capacity for applications in the aerospace, bearing and heavy equipment industries.

* About Accura Technics - Accura Technics designs and builds super-precision machine tools at their factory in Keene, New Hampshire, USA.

Creep-feed grinding gets quicker change-over times

2006-12-20T03:43:00.000-08:00

The current surface/creepfeed production environment demands high productivity, accuracy and the minimum cycle times associated with CNC grinding. But many components whilst being perfect for CNC are currently machined on conventional machines due to a variety of reasons, such as smaller batch requirements which necessitate more frequent set ups, shortage of operator skills, or no budget for high cost CNC solutions. Jones and Shipman already a major supplier of CNC surface/creepfeed grinders has used this customer feedback to produce a grinder that has the required performance levels and also overcomes these perceived shortfalls of traditional CNC.

This machine, the Dominator 624 Easy, offers quicker changeover times, a very easy to use touchscreen control, is priced lower than traditional CNC and is now available and was shown in the US for the first time at IMTS 2006.

Jones and Shipman's latest model in the combined Surface and Creepfeed grinder market the Dominator 624 Easy, is ideally suited to either short batch or long production runs in industries as diverse as aerospace, automotive, electrical, medical and mold and die.

Control in either 3 or 4 axes gives the precision, repeatability and reliability of traditional CNC, for it employs the same axis motion control elements, precision ballscrews driven by GE-Fanuc AC digital servomotors coupled with 0.000004in (0.01 micron) Heidenhain 'Absolute' linear scale feedback.

However the Dominator Easy is faster and simpler to set up via the GE-Fanuc touchscreen using Jones and Shipman icon based grinding and dressing software.

This provides Easy models with the capabilities to interpolate axes simultaneously to provide precision grinding of complex shapes, angles, radii and surfaces, with quick and easy set-up.

Even operators with little or no CNC knowledge quickly become familiar with the 'self teach' software and are soon able to precision grind complex components as well as more standard multi surface work.

Once set up, fully automatic dressing and grinding cycles permit unmanned operation.

Alternatively as with all 'Easy' controlled models the Dominator can function as a simple manually controlled machine with manual dressing and no set-up procedures.

Completed programs can be simply and quickly uploaded to or downloaded from a PC, PDA or Network as required, using JandS software, for storage or recall.

The Dominator Easy is available as a standard model or can be tailored to suit the requirements of individual applications.

A wide range of optional equipment is also offered, including permanent or electro-permanent magnetic chucks, wheel dressers and rotary indexing units.

Wheel dressing is by table mounted fixed diamonds, diamond disc dresser or via a diamond roll dresser.

Rotary indexing units include inline, vertical or cross table mounting, with tailstock if required.

On start-up, the Easy control offers the operator three simple options: Manual mode, Dress mode or Grind Cycle mode.

In manual mode, the Dominator Easy operates as a simple hand operated machine with control for the table and infeed via an electronic handwheel with position shown via a readout on the touchscreen.

Work speeds and feeds are also easily adjustable via the touchscreen, should the operator wish to set an area grind, or auto downfeed in place of manual movement.

When formed diamond rolls are not used to dress the wheel the operator can access Dress mode which offers five standard wheel shape macro's including flat, slot, facing, Vee form and full ISO with one or two diamond discs.

Dressing increments, speeds and frequency allow for roughing and finishing to optimise wheel performance.

A feature in the full software package is 'intelligent roughing out' of the wheel, - the system can automatically quickly and efficiently 'chop out' the basic form and then finish dress using the exact profile.

Wheel dressing can be initiated In or Out-of-Cycle and Dress-On-Demand for plain or complex wheelforms is standard.

The 'Dress-On-Demand' feature basically means that the operator can press the Dress button at any time and the machine will stop wherever it is, dress the wheel with full compensation and return to continue from where it left off.

Grind mode allows from One to 20 grind cycles to be linked as the complexity of the component dictates from cycles including plunge, multi plunge, area (intermittent or continuous), face grind, plunge and face, multi plunge and face, and plunge and creepfeed with or without taper.

The linked grind cycles function enables the Dominator Easy to be loaded with and to grind, different facets of the same component, or even different components, in one loading.

Machine construction is a unique, award winning, patented design incorporating a substantial cuboid machine bed, with the table mounted on the Y axis supported from the front end face on widely spaced pre-loaded slides.

Production/toolroom grinding made much easier

2006-12-19T03:42:00.000-08:00

The Jones and Shipman 524 Easy surface and profile grinder meets the requirements of the production environment as well as the accuracy, quick set up and change over demands of the toolroom. It also fulfils the criteria of both CNC and manual operation thanks to a GE-Fanuc control system and Jones Shipman 'Easy' software. Complex shapes, angles, radii and ultra flat surfaces can be precision ground quickly and easily.

Even inexperienced operators can obtain immediate improvements in set up and changeover times and in overall productivity for more complex work.

This is due to the combination of GE-Fanuc Touchscreen technology with Jones and Shipman's proprietary 'Easy' icon based software, which offers numerical control without the inherent complexity or cost penalties of traditional CNC systems.

In fact the 524 Easy can function as either a simple hand/hydraulic controlled machine with manual dressing and no set-up procedures or, once set using the easy-to-use 'self teach' software, can perform fully automatic dressing and grinding cycles.

With levels of functionality comparable to CNC but at lower cost all 'Easy' models are fast and simple to set-up via the touchscreen and easy-to-use Jones and Shipman icon-based software.

The control possesses the capabilities to interpolate two axes simultaneously to provide the creation of complex shapes, angles, radii and surfaces, with quick and easy set-up.

Y and Z axis control is via ballscrews driven from GE-Fanuc AC digital servomotors with 0.000004in (0.01 micron) Heidenhain 'Absolute' linear scale feedback.

On start-up, the 'Easy' control offers the operator three simple options: Manual mode, Dress mode or Grind Cycle mode.

In Manual mode the 'Easy' operates as a simple hand operated machine with hydraulic or manual table movement and handwheels for the crossfeed and downfeed which show position via a scale readout on the screen.

Work speeds and feeds are simply adjustable via the touchscreen should the operator wish to set an area grind or auto downfeed in place of manual movement once he has touched on.

Dress mode offers five standard wheel shape options flat, slot, facing, Vee form and full ISO with one or two diamonds as needed.

Dressing increments, speeds and frequency allow for roughing and finishing to optimise wheel performance.

A great feature when the full software package is incorporated is 'intelligent roughing out' of the wheel, - the system will automatically 'chop out' a basic form and then finish dress using the exact profile.

Wheel dressing can be initiated in or out of cycle and dress-on-demand for plain or complex wheel forms is provided as standard.

Dress-On-Demand allows the operator to press the Dress button at any time and the machine will stop wherever it is, dress the wheel with full compensation and return to continue from where it left off.

Grind mode allows from one to 20 grind cycles to be linked as the complexity of the component dictates including plunge, multi plunge, area (intermittent or continuous), face grind, plunge and face and multi plunge and face.

The 524 Easy has been designed from scratch to give improved productivity.

With a new bed, saddle, table, column etc, it offers increased precision, geometry and rigidity and continues a long-established tradition of excellence in manufacture.

Generously proportioned high-grade cast iron major units all combine to create greater rigidity for optimum performance in terms of grinding accuracy and repeatability.

The wheelhead slide moves vertically on low friction, preloaded ball and roller bearings, thereby ensuring extreme sensitivity, while the hand scraped table and saddle slideways are Turcite coated and lubricated automatically to reduce friction to the minimum possible.

'Sliding dogs', which are simply moved by hand without the need for tools, set the table reversal length, their positions being detected by proximity switches sited in the saddle.

Innovative design, high build quality and a rigid and stable machine structure combine to ensure accuracy and productivity and makes this the product of choice for both old and new to the art of precision surface grinding.

The 524 Easy forms the cornerstone of Jones and Shipman's all new range of Surface Grinders.

All models benefit from 'self teach' touchscreen technology, coupled with a highly stable robust mechanical design to give the highest levels of productivity, and are now offered in an extended grinding capacity range from 20in x 8in up to 40in x 20in (500 x 200mm up to 1000 x 500mm).

Entry-level tool grinding and inspection

2006-12-18T03:36:00.000-08:00

The trio of new Walter Helitronic tool grinding and Helicheck tool inspection machines announced by Kandoumlrber Schleifring UK of Honiley near Kenilworth not only reinforces Walter's position as a world leader in the tool grinding and inspection field, but the developments also address user demands both for entry-level tool grinding and inspection equipment plus a machine specifically to grind micro tools. The new machines are: The Helitronic Basic - a budget-priced five-axis tool grinder; The Helitronic Micro - for the consistent production of tools of 0.1 mm to 12.7 mm diameter; and The Helicheck Basic - an entry-level, high-accuracy tool measurement machine. The new machines are based on similar high-quality construction principles to Walter's existing models and, likewise, also incorporate the company's renowned tool grinding software.

But importantly, the new machines feature CNC and drive hardware from Fanuc - 'ultra-reliable and globally standardised technology', says Neil Whittingham, sales director of Kandoumlrber Schleifring UK.

A derivative of the highly successful Helitronic Power, the new Helitronic Basic tool grinder offers an unrivalled route for cost-effective tool regrinding.

With Fanuc 310i CNC and 15 inch touch screen monitor, the machine features a 70 mm grinding spindle powered by 7 kW drive plus worm gear drive in the A axis.

As standard it is supplied with Walter Window Mode P1 and P3 grinding programs (end mills and drills), and options include coolant tank, Eco tool loading system, automatic clamping and worktable.

The new six-axis Helitronic Micro, on the other hand, has been developed from a clean sheet and is designed to meet the increasing production demands by, for example, the medical and electronics sectors of micro tools of 0.1 mm to 12.7 mm diameter.

Tools from 2 mm to 12.7 mm diameter can be reground.

Featuring an HSK 40, 5 kW spindle and utilising Fanuc 310i CNC that incorporates Walter's 'what you see is what you grind' Helitronic Tool Studio software, the machine's double-ended grinding head (optionally three-spindle, with one 5 kW and two 1.5 kW drives) has integrated cooling that combines with linear drives and torque motor (with integral cooling) and the machine's mineral cast base to help generate high precision, excellent surface finishes and longer wheel life.

An integrated Fanuc robot (double gripper) loading system also features, for fast - less than 10 secs - tool change, in conjunction with the four-pallet Pallet load system.

This provides unmanned working of up to 300 tools per pallet - three pallets for unground tools; one pallet 'empty' for ground tools - of tools from 1 mm to 6.9 mm shank diameter and 120 mm long.

Larger tools of 7 mm to 12.7 mm shank diameter and 120 mm long can be handled at 108 tools per pallet.

An optional, additional manual X axis is available to reduce grinding traverses, where appropriate.

The new Helicheck Basic tool inspection machine occupies 30 per cent less floorspace than the Toolcheck it replaces (by adopting vertical design principles rather than horizontal) and, like its stablemates the Helicheck and Helicheck Pro, it offers 3C Direct View camera technology with cameras for back, front and top light illumination.

The back light provides magnification of 50x, front and top of 100x; and combined with the solid granite base plate for temperature resistance and high stability, the result is a repeatability of 1.5 micron and an absolute accuracy of +/- 2.2 microns at a measuring length of 10 mm (VDI/VDE 2617: E1 = 2.2 microns + L/300).

These new machines are complemented by a new grinding wheel/electrode wheel changer for the Helitronic Power Diamond two-in-one machine for grinding/eroding PCD tools - where up to eight electrodes/wheel sets, with coolant distributor, can be changed in 10 secs - and follow hard on the heels of recently-announced the Helicheck Plus tool inspection machine for measuring standard and micro tools down to 0.1 mm diameter.

Cylindrical grinding machine finishes in one pass

2006-12-17T03:36:00.000-08:00

The New ShapeSmart NP4 by Rollomatic is a reinforced version of the existing CNC148P4 cylindrical grinding machine with a patented method of rough and finish grinding in one pass. This machine is ideal for cutting tool blank preparation and grinding precision punches and molding components. The grinding size range is from 16.0 mm (5/8') down to micro scale, with blank length capacity up to 300 mm (12') for automatic loading and 350mm (13.8') for manual loading.

The two grinding slides have been designed with a New technology known as the BoxSlide system, which enhances stability.

To eliminate any run-out on the grinding wheels, the ShapeSmart NP4 features a New arbor system called Perfect Arbor, which uses material compression as a means of centreing the arbor into the spindles.

The NP4 also features the user-friendly tool design software, P4Smart.

With drop-down windows that allow you to edit program text and graphically check the movement of both grinding wheels during machining, it's easier than ever to grind precision blanks, punches and pins.

Super abrasive peel grinding slashes cycle times

2006-12-16T03:34:00.000-08:00

Holroyd has employed its super abrasive machining technology to reduce the cycle time for producing turbo charger stators from 5.1/2min to just 46s. These improvements have been achieved using Peel Grinding of the stator shaft, removing as much as 5mm a side in a single cut. In addition, the super abrasive wheel used in the Holroyd process lasts up to 200 times longer than tool inserts used with in twin turret turning, providing a life of at least 10,000 parts to minimise tooling and machine set-up costs.

One of the direct results of Holroyd's expertise in helical rotor production is that the company has established itself as one of the leading suppliers to the turbocharger and supercharger industries; both as a manufacturer and supplier of high precision machine tools, and as a sub-contract manufacturer of components using the self-same machines.

Recently, Holroyd was approached by one manufacturer concerning a cycle-time problem with the machining of turbocharger stators.

The stators comprise an Iconel impeller attached to a mild steel shaft.

Previously, the time to machine the shaft, and the faces and OD of each impeller was 5.1/2 min; this being achieved using twin turret lathes.

However, there were a number of problems with this machine set-up.

First, the cycle time was too long to enable the manufacture to achieve his desired component cost.

Second, although a twin turret lathe was used to ensure full depth of cut on the shaft - without bending, this did not account for the resulting upset of the shaft during the deep machining process.

Third, the depth of cut required - 5mm a side - from the twin turret lathe, and the resulting chattering of the tools in operation, meant that the life of tool inserts was extremely poor, with commensurate high costs for replacement.

Holroyd's approach to solving these problems centred on its super abrasive machining capability: in particular the use of an Edgetek Super Abrasive Turning (SAT) Centre.

The Edgetek SAT employs CBN wheels to achieve productivity rates far in advance of those obtained with hard turning.

It is designed to remove stock from the OD of cylindrical parts (slot, groove, and forms) in all types of materials (from soft to hard) at rates 40% faster than a conventional lathe.

Because productivity with the SAT system goes far beyond that typically obtained with hard turning, the machines are ideal for machining inconel and heat treated powder metal workpieces with interrupted cuts.

They can be used for such typical turning applications as machining slots, interrupted cuts on impellers, gears, splines and facing cylindrical parts.

The use of thin CBN wheels means that the SAT machines are especially well suited to Peel grinding, where high wheel speeds and high workpiece speeds result in very high stock removal rates with low grinding forces.

Thin CBN wheels used in this way have cutting edges similar to turning tools, thereby reducing the cutting forces required between the wheel and the work piece.

Compared to conventional grinding processes, Peel grinding typically removes three times the stock with half the force within the same time frame, and allows contour-grinding of a part in the same way that conventional machining does.

Holroyd applied its SAT Peel grinding technology to the tubocharger rotors with impressive results.

The overall cycle time for machining shaft, faces and impeller OD was reduced from 5.1/2 min to just 46s - a reduction of nearly 88%.

In addition, the improved burn threshold qualities of the Edgetek SAT machine result in a lower finished surface temperature of the workpiece, which means no upset and no undesirable friction weld rings generated during the super abrasive turning process.

Finally, toolwear and, consequently, tooling and set-up costs, are much lower using the Edgetek SAT machine: the life of the CBN wheels extending to an average of 10,000 parts before re-tooling and machine set-up is required.

Three 5-axis machining centres suit medical sector

2006-12-15T02:13:00.001-08:00

Milling machine tool specialist - Mikron - part of AgieCharmilles GF has recently launched three 5-axis machining centres into the UK market. The machines - the UCP 600 Vario ProdMed; the HSM 400U ProdMed and the HSM 400U ProdMed Dental - as their names suggest - are all aimed at the rapidly- growing medical sector and, in particular, at precision engineering companies specifically involved in the manufacture of medical devices (surgical and general instruments) and implants (dental and orthopaedic, etc). The medical sector is buoyant.

Increased life expectancy and the phenomenon of ageing populations (developed countries) - coupled with the rapid advances made in, and concomitant rise in demand for, cosmetic and reconstructive surgery and treatments - have created significant business opportunities for precision component manufacturers operating in the sector.

However, the sector is highly competitive - and, because medical components (implants), etc - are bespoke and are required in small batches (often one-offs) as well as being manufactured from tough materials - titanium, stainless etc - conventional machining technologies are often not up to the job.

The three machining centres span both High-Speed (HSM) and High Performance (HPM) milling technologies - and the machines provide users with the best of all worlds - increased productivity via automation, greater manufacturing flexibility, improved process reliability, high accuracy, optimised removal rates and excellent surface finish.

Here are some of the main highlights of the MedTech range of machines.

* Automation - on all ProdMed machines - integrated and high capacity tool changers (up to 220 position) and workpiece pallet changers (up to 48 pallets) ensure maximum productivity for low-to-medium volume production runs (characteristic of precision medical component manufacturing).

Such automated ATC and APC capability and capacity help manufacturers increase work throughput by reducing time spent on job setups and increase machine utilisation via unattended operations - resulting in reduced lead times and improved cost competitiveness.

Five-axis machining technology - the machines' 5-axis capabilities too (enabling 5-face and/or simultaneous 5-axis and one-hit machining) - clearly also helps speed up production - and ensures greater precision and better finish by shortening part cycle times and reducing time and resources spent on setting up, fixturing, etc - all critical in making customised part manufacture economically viable.

* Spindle technology - irrespective of whether high, accurate material removal or fine finishing is required - the ProdMed machines with their StepTec high-performance, vector-driven HSK spindles (ProdMed Vario 20,000 rev/min and both 400Us at 60,000 rev/min) - can be relied upon to deliver.

The choice of spindle when manufacturing medical components is critical.

Workpiece materials - exotic alloys, titanium, aluminium, high chrome steels - are all difficult to machine.

The medical applications themselves and whether the requirement is for high material removal or super (polished) surface finishes or both - all mean that spindle speeds need to be optimised to the workpiece material and components in question.

The new MedTech machines, through their standard specification and options enable such optimisation to occur.

* Lubrication - ensuring that medical components are ultra clean is clearly of critical importance.

Depending on the materials to be machined and the application itself - customers have a choice of lubricant and lubricant delivery systems on the MedTech machines - water or oil-based.

* Swarf management - because of their integrated automation (ATC and APC) - the MedTech machines can run unattended - including 'lights-out', weekends etc However, to ensure that these productivity gains can be realised and to avoid problems such as workpiece and/or cutting tool damage due to poor chip evacuation and part contamination - the machines are equipped with sophisticated swarf management and chip removal systems.

* SMART technology - the MedTech machines are supplied with Mikron SMART technology software to optimise machining and ensure improved process reliability - by enable the user to make decisive interventions in the machining process in 'real time'.

Said Mikron product specialist, Steve Burrows: 'The new MedTech machines have created huge interest in the medical sector - and to date we have already taken significant orders from a number of first tier medical manufacturers'.

Five-axis machining centres get linear drives

2006-12-14T02:11:00.000-08:00

Introduced to the UK is a family of new 5-axis CNC machining centres from Nottingham-based, CMS UK, part of the Italian worldwide group specializing in solutions for machining all kinds of non ferrous materials. Typical applications include composites, carbon fibre, model block, aluminum etc, as used in many manufacturing industries including aerospace, motor sport, automotive, marine, rail transport, construction and buildings. * linear drives - the standard Antares 5-axis CNC machining centre and its range of larger format Ares companions are now also offered with optional linear motor drives to X and Y axes for those seeking the very latest in production technology.

The Antares provides strokes of 2600 x 1500 x 1200mm while the larger Ares has three standard size options and can machine components requiring strokes of up to 6000 x 2600 x 1200mm.

The larger Ares machines, utilising a form of portal construction, are available in six different variants and permit the physical separation of the load/unload area from the cutting zone so that both operations can be carried out in tandem, thereby achieving maximum machine utilization.

* Design philosophy - according to CMS UK general manager, Toni Nagiel, the Ares/Antares concept deliberately tends towards a degree of 'over-engineering' in order to provide such a high degree of robustness, reliability and accuracy that the machines can be used with confidence for a wider range of applications than might previously have been envisaged.

This confidence in their capabilities is, he says, is being borne out by their increasing use in the high-tech industries.

* Aerospace - similarly, the materials regularly machined now extend through the more familiar mould, model and pattern-making, comprising wood, aluminum, epoxy paste and polyurethane to include structural light alloys and carbon fibre components as used, for example, in aircraft production.

* Pneumatic brake - one result of this design philosophy is to afford a far higher degree of stiffness to the 5-axis cutting head than is normally associated with machines of this type.

This useful attribute is further enhanced by the inclusion of a pneumatic brake that can be programmed to clamp the B- and C-axes during operations that do not require fully active 5-axis interpolation.

The PX5 universal head, with all five axes acting under simultaneous remote control from a GE-Fanuc 18i MB5 CNC system has, in addition to the three basic axes, a fourth axis that rotates around the vertical and a fifth that inclines the spindle in the vertical plane.

The highly specified NC control comes complete with PC Office integrated in the electrical cabinet.

* High speed - drawing on the parent company's 35 years of experience, a particularly strong spindle shaft, made in-house, is mounted on two pairs of pre-loaded bearings - ceramic type for the front pair and steel for the rear pair.

This high-speed spindle (24,000 rev/min max 12kW or 27,000 rev/min maximum 6kW) is liquid cooled.

Fast positioning speeds of 70-80m/min are achieved along with acceleration rates of up to 3.0m/s2.

Automatic tool changing is linked to a tool-holder magazine located on the front face of the traverse and has an eight-tool magazine as standard or a 16-tool option.

According to CMS, the combination of a very high performance, powerful electro spindle and the machine rigidity assured by the mobile bridge-type construction, offer users 'unmatched quality on a wide range of materials'.

CNC punch press has 3D forming capability

2006-12-13T23:42:00.000-08:00

The new Trumatic 1000 Rotation from Trumpf has a rare combination of attributes. No other punching machine is as easy to install, operate and program. It is therefore the ideal choice for those new to automated sheet metalworking.

However despite being a low-priced, entry-level machine the TC1000 is no low-end performer.

The TC1000 has the same process capability as a larger Trumatic including three-dimensional forming and tapping.

It can also produce 'extrusions' (formed profiles - Ed) quickly, easily and economically in one machine set-up.

Although primarily aimed at those with little or no programming experience the TC1000 is also an excellent stand-alone, supplementary production unit for established users.

It has a working range of 2070 x 1280mm without repositioning and can accommodate materials up to 6.4mm thick.

A key feature of this new addition to the Trumatic range is the simplicity of programming.

This is the first machine to include a new Trumpf navigation system that transparently guides beginners through the programming of simple parts and into the use of the ToPs 300 basic software.

The ToPs system allows more complex features to be added.

An NC programme is generated automatically in just three steps even for complex contours.

Having guided the programmer through the process of creating a drawing the software assists in the definition of the sheet layout to minimise material wastage.

The system then recommends the optimum tool path and process sequence.

Machine operation is via touch screen.

Naturally the control system has a modern user interface with a selection menu that is tailored to the operator's exact needs.

The hydraulic single station punching head featured on the TC1000 allows the use of angled punching tools to optimise punching force.

As all tools can be rotated a full 360 deg fewer tools are needed, set-up costs are reduced and higher processing speeds achieved.

Tools are changed in just 4s and with Multitools exchange time is even quicker; their use allows up to 150 tools to be held in the machine's linear magazine.

The TC1000 can achieve stroke rates of 600/min for punching and 1300/min for marking.

Ram guidance ensures high dimensional accuracy by ensuring the punch and die are always exactly aligned.

Continuous card guide tool does more work

2006-12-12T23:38:00.000-08:00

Mate Precision Tooling simplifies producing card guides in electronic assemblies with its new Continuous Card Guide Tool. Any length card guide now can be fabricated, eliminating the need for multiple tools and secondary operations. Mate's Continuous Card Guide Tool extends the punching capabilities of existing punch presses in the following ways.

* Card guide length can be customized to the printed board's length to give it maximum support in the electronic assembly.

* Eliminates the need to buy multiple tools for different applications.

One tool does the work of many, reducing tool inventory and tooling setups.

* Fabricates oversized card guides that previously required secondary operations.

* No special programming software is required.

Designed for fast and efficient punching, the Continuous Card Guide Assembly produces an initial form.

During the return cycle of the punch press, the integral stripping springs in the card guide assembly remove the work piece from the assembly.

The punch press then incrementally advances the sheet and the process is repeated until the desired card guide length is formed.

The distance between forms varies depending on the length of the initial form, which depends on the station size used.

Like all Mate tooling, the Continuous Card Guide Tool is designed for extra long life.

Its robust construction includes: polished tool steel inserts for reliable operation, steel spring upper and lower stripper mechanism, and fully interchangeable replacement parts for maximum convenience.

Mate's Continuous Card Guide Tooling is available for use in most popular CNC turret presses including those using Thick Turret, Trumpf style, Thin Turret, 112, 114, Nova and Salvagnini tooling.

Mate's Continuous Card Guide Tooling is an ideal addition to Mate's other application specific tooling for producing hinges, bends, interlocking components and custom markings, to name just a few.Mate Precision Tooling simplifies producing card guides in electronic assemblies with its new Continuous Card Guide Tool. Any length card guide now can be fabricated, eliminating the need for multiple tools and secondary operations. Mate's Continuous Card Guide Tool extends the punching capabilities of existing punch presses in the following ways.

* Card guide length can be customized to the printed board's length to give it maximum support in the electronic assembly.

* Eliminates the need to buy multiple tools for different applications.

One tool does the work of many, reducing tool inventory and tooling setups.

* Fabricates oversized card guides that previously required secondary operations.

* No special programming software is required.

Designed for fast and efficient punching, the Continuous Card Guide Assembly produces an initial form.

During the return cycle of the punch press, the integral stripping springs in the card guide assembly remove the work piece from the assembly.

The punch press then incrementally advances the sheet and the process is repeated until the desired card guide length is formed.

The distance between forms varies depending on the length of the initial form, which depends on the station size used.

Like all Mate tooling, the Continuous Card Guide Tool is designed for extra long life.

Its robust construction includes: polished tool steel inserts for reliable operation, steel spring upper and lower stripper mechanism, and fully interchangeable replacement parts for maximum convenience.

Mate's Continuous Card Guide Tooling is available for use in most popular CNC turret presses including those using Thick Turret, Trumpf style, Thin Turret, 112, 114, Nova and Salvagnini tooling.

Mate's Continuous Card Guide Tooling is an ideal addition to Mate's other application specific tooling for producing hinges, bends, interlocking components and custom markings, to name just a few.

Tool marks sheet anywhere under CNC punching

2006-12-11T23:41:00.000-08:00

Mate Precision Tooling will exhibit the latest in tool system technology at euroblech 2006, Europe's largest sheet metal processing technologies event, October 24-28, in Hannover, Germany. * Mate Sheetmarker Tool marks parts with assembly codes and numbers - Mate Sheetmarker tools permanently mark sheet metal parts with assembly codes, serial numbers, names and etchings. The tool is ideal for companies with quality programmes requiring part traceability by marking parts with data such as pallet number, machine number, sequential serial number, time and date.

The Sheetmarker is a ruggedly designed tool that can be programmed to mark anywhere on the sheet without marking the underside or deforming the material.

Images are smooth and consistent.

The mark depth is variable, which allows for precise control over logos or names.

The tool is not limited by material type or thickness.

Because the tool is designed with a backing spring, variations in sheet flatness or warpage are automatically adjusted for by the tool to retain even and consistent marking.

* Mate Rollerball Tooling makes stiffening ribs in light sheet metal - Mate Rollerball tooling forms ribs, flanges and raised areas across the entire work surface of light gauge sheet metal.

These offsets and embosses are not limited to the station range.

The Rollerball provides the benefit of making forms not possible with single hit forming tools.

The tooling is designed to take advantage of the extended programming capabilities of hydraulic punch presses where the ram can be held in a down position.

More applications can be run on the punch press than ever before.

Since the Rollerball uses a ball or sphere to create a deformation in the sheet metal, no restrictions are imposed as would be if there were an axis.

With the Rollerball, ribs can be formed with an NC program to create near right angles without lifting the tool from the sheet metal.

* Mate NEXT Insert Tooling has quick set-up and extra long life features - Mate NEXT tooling is designed with interchangeable, highly abrasion and adhesion resistant punch inserts that install easily and quickly into NEXT insert punch holders.

These holders combine the functions of a conventional punch shank and alignment ring into a single assembly.

The integral alignment design of the holder provides precise tooling orientation and makes installing the punch fast and without the need for additional fixtures or devices.

Mate's NEXT insert tooling delivers longer life.

M4 high speed steel is used for increased toughness in punch inserts with a diagonal dimension from 0.036in (0.80mm) to 1.181in (30.00mm).

Punch inserts with a diagonal dimension over 1.181in (30.00mm) are manufactured of M2 high speed steel.

Both tool steels are highly abrasion and adhesion resistant to maximize the interval between regrinds.

In addition, the NEXT insert tooling system allows the introduction of a shim between the punch insert and the punch holder.

After 0.118in (3.00mm) has been removed from the punch insert from regrinding, the punch assembly returns to its original length instead of requiring replacement.

This means that one Mate insert will outlast several conventional punches.

Another advantage of Mate's NEXT insert tooling system is that it is interchangeable with other popular alternative tooling systems and features quick, push-on urethane strippers that lock onto insert holders.

Thick turret punch press tooling lengthens life

2006-12-11T23:40:00.000-08:00

Mate leads the punch press tooling industry with another tooling first - the new MXC tooling system. Designed for all thick turret punch press brands and models, the MXC system provides extra long life and tooling interchangeability benefits. 'With MXC tooling, Mate now becomes the premiere alternative source for all thick turret tooling needs,' reported Andy Spence-Parsons, marketing manager for Mate.

'The MXC Tooling system brings to thick turret press users everything they need to replace existing tool components with Mate's proven longer life tooling, backed with its unparalleled reputation for high quality products, reliable delivery and service excellence.' Mate's MXC tooling systems consist of punches, strippers and Mate slug free dies for all five thick turret station sizes: 1/2in A, 1.1/4in B, 2in C, 3.1/2in D and 4.1/4in E stations.

All components are manufactured to Mate's exacting standards for guaranteed performance, long life and quality with the following designed in features: MXC Punches are manufactured of Mate DuraSteel.

Proven for its toughness and wear resistance, DuraSteel is air-hardened tool steel with increased vanadium and tungsten carbides.

This unique steel formulation adds durability and increases wear resistance while maintaining toughness.

Additional MXC punch features include a minute back taper with near polished punch flanks that reduce friction and heat build-up during the punching cycle.

For extreme applications, Maxima punch coating is available to further withstand abrasive materials and materials prone to galling.

Two versions of the 1/2in A station and 1.1/4in B station punches are available.

One version includes lubrication ports for compatibility with tool holders that integrate with machine tool lubrication systems.

The second version for 2in C station, 3.1/2in D station and 4.1/2in E station punches are designed for use in both lubricated and non-lubricated systems.

For maximum flexibility, all MXC punches are compatible with existing thick turret tooling systems including Mate's Ultra TEC and Ultra XT tooling.

MXC Strippers are manufactured of 4150 tool steel for added toughness and resistance to distortion during punching.

Precision grinder eases punch/die maintenance

2006-12-10T23:40:00.000-08:00

Mate Precision Tooling announces the expansion of its range of MPG grinders designed to precisely and automatically regrind punches and dies in order to maintain optimum condition for the highest quality punch press fabrication. Easy to set up and operate, Mate MPG grinders feature multiple user-specified grinding programs for grinding consistency. Highly accurate, the grinders allow for material removal in increments as small as 0.0002in to provide precise sharpening while avoiding overgrinding.

Precise roughing and finishing feed and speed controls ensure optimum grinding conditions for a full range of tooling applications, from the narrowest punch to the largest die.

A typical grinding cycle takes just 2 to 5 min for perfect re-sharpening.

The Mate MPG Grinder is available in two versions.

The original MPG grinder allows manual adjustment of the grinding wheel relative to the top of the tool component.

The new MPG grinder features a laser sensor to automatically detect the wheel position relative to the tool.

Both models feature a fully enclosed work area, which make them ideal for use in close proximity to punching machines.

Each version is equipped with long-lasting CBN grinding wheel for optimal grinding finishes across a wide range of tool steels.

Additional Mate MPG Grinder features include: universal grinding fixture that locates the widest variety of tool styles and station sizes; graduated angle plate to allow punches with shear to be ground; ergonomically designed keypad facilitates fast programming; control panel with touch pad has easy-to-read LCD screen; automatic coolant control delivers coolant to the grinding wheel; universal design accommodates all tooling styles including thick and thin turret, Trumpf style, multi-tool systems and more.

Mate Precision Tooling has appointed Baeumler

2006-12-09T23:38:00.000-08:00

Mate Precision Tooling has announced the appointment of Frank Baeumler to the dual position of Vice President European Operations and Managing Director of Mate Germany. Jack Schneider, President of Mate Precision Tooling, announced the appointment and said that Baeumler will strengthen Mate's long-term position in the European market by integrating the strengths of both organisations. 'With over 11 very successful years in his previous position at Mate USA as Vice President of Marketing, Frank is ideally qualified for this new dual position,' stated Schneider.

His mission is to understand and develop systems that utilise and combine the strengths of both Mate USA and Mate Germany in order to better serve Europe and the worldwide precision sheet metal market'.

Born in Nuremberg, Germany and fluent in German, Baeumler also was Mate's International Marketing Manager for 7 years.

During his 18-year tenure in marketing with Mate, the company doubled in sales volume and expanded globally with presence in virtually all manufacturing markets worldwide.

Prior to joining Mate, Baeumler was Education Coordinator with the Minnesota Trade Office, State of Minnesota Department of Economic Development for 4 years, and was head coach of the British Royal Navy Alpine Ski Team for 2 years.

Baeumler holds a BA degree in International Relations from the University of Wisconsin and an MA degree in International Relations from the University of Wyoming.

He served as board member of the Minnesota US Export Assistance centre, as board member of the Minnesota World Trade organisation including one term as President, and served on committees of the Association for Manufacturing Technology

Turret punch press has regenerative braking

2006-12-08T23:37:00.000-08:00

An all-electric, CNC turret punch press incorporating regenerative braking technology and energy management software in the controller was installed in mid 2005 at the Southport factory of leading commercial beverage-making equipment manufacturer, Instanta. The principal reason for the company choosing the press, a Finn-power E5, was that at average punching speeds the machine draws only 4.5 kW, which is around one third of the power consumed by a hydraulic punch presses of 200 kN punching capacity. The dramatic energy saving is a result of using capacitors to store energy from deceleration of the machine axes, and redirecting that energy to power other machine functions, rather than wasting it.

Supplied through Finn-power's sole agent, Press and Shear Machinery, the press not only minimises consumption of increasingly expensive power, but also avoids wasting and disposing of 150 litres of hydraulic oil every year.

Service is less expensive, as there are no seals or disposable filters to replace, and the risk of oil spillage has been eliminated.

In addition, the machine's elecronically controlled, servomotor-driven roller and cam arrangement for ram actuation is quieter in operation than an equivalent hydraulic press.

Instanta implements an environmental management system to BS EN ISO14001 and has long been an adherent to ecologically friendly business practices, as a brief visit to the relevant page of its web site will attest.

In any case, from a purely practical point of view, the factory was close to its maximum power consumption and a hydraulic press would have taken it over the limit, necessitating an increase in the capacity of the incoming electricity supply.

Of seven presses originally evaluated, the E5 was the only servo-electric model shortlisted, as it had a long and verifiably sound track record in this relatively new area of technology.

In addition, the machine's ability to use wheel-type tools and its proven and highly controllable upforming capability fitted in well with Instanta's wish to incorporate more strengthening ribs and decorative features into its products.

All of the stainless steel internal tanks, for example, are embossed in four to six places to support a baffle plate.

Spill trays are also embossed, allowing the fitting to be recessed so that water is not trapped.

The punch press also had to be highly productive to cope with increasing throughput, volumes having taken a sharp upturn recently with the introduction of a range of wall-mounted beverage makers alongside the counter-top types.

Over 7,000 beverage makers per year are currently produced and each contains 15 to 20 sheet metal parts.

Said operations director, David Wilson, 'We were surprised at just how quick the E5 was - it has exceeded our expectations.

The machine eats work, so much so that we are always ahead now and hold buffer stocks of our sheet metal parts.

'Before the Finn-power was installed, the factory worked to the pace of our old CNC turret punch press, as its speed was limited and if the machine stopped, the factory stopped.' All parts at the Southport factory are produced on the Finn-power E5 from 2.5 x 1.25 m or 2 x 1 m sheet, avoiding having to guillotine them into smaller sizes, as was necessary with the old punch press, and allowing larger batches of components to be nested and produced in one uninterrupted punching, nibbling and forming cycle.

Verify CNC turret punch press precision

2006-12-07T23:36:00.000-08:00

Mate Precision Tooling announced introduction of a new and improved model of its Pilot Tool Calibration System. Designed to verify and restore the angular and concentric alignment of punching stations of most popular thick turret punch presses, including those with eccentric turrets, this system is highly accurate and easy to use. With the newly designed Mate Pilot, users of thick turret presses can verify and align upper and lower tool holders to maintain top performance while safeguarding tooling and eliminating scrapped parts because of turret alignment problems.

The new Mate Pilot system with interlocking design and tri-color LED indicator lights is available for 1.1/4in B, 2in C, 3.1/2in D and 4.1/2in E stations.

The alignment tools for 1/2in A stations and Finn-Power Multi-Tool stations use a twin dowel pin design.

The Mate Pilot system is also available in two packages to suit thick turret and Finn-Power punch presses.

* Concentric and angular tool component alignment assured - the newly designed Mate Pilot consists of a matched set of upper and lower turret interlocking components with a new spring loaded lock pawl mechanism.

This mechanism keeps the two halves of the assembly apart until the station to be aligned is rotated into the punching position.

The system operates in two modes: Verification mode - confirms the precise concentric and angular alignment of the punch press turret to maintain high quality piece part production and maximum tool life; Alignment mode - restores the concentric and angular alignment of each station with the same precision as the initial machine installation.

* System is easy and fast to use - simply install the two halves of the calibration instrument into the press turret station to be aligned.

Then rotate the turret to position the station to be aligned under the machine's ram.

Tighten the integral adjustment handle, which draws the two halves of the calibration instrument together.

As this engagement occurs, the interlocking design of the interface causes the loosened die holder assembly to draw precisely together into concentric and angular alignment relative to the upper bore of the turret.

During this process, tri-color indicator lights on the top of the instrument signal alignment.

When the indicator shows: Red - system is not yet aligned; Yellow - system is aligned angularly and concentrically within 0.012in (0.030mm).

Adequate for most punching applications; Green - system is aligned angularly and concentrically within 0.0003in (0.008mm).

Recommended when punching materials are 0.048in (1.20mm) thickness or less.

* High precision components ensure accuracy, long life - like Mate's high precision, long-life tooling, the Mate Pilot Tool calibration system is quality manufactured to provide years of alignment service thereby ensuring top punch press and tool performance.

Each calibration instrument is machined from a single piece of the highest quality tool steel.

Tooling produces CNC punched, burr-free parts

2006-12-06T23:36:00.000-08:00

Two new tools, two patents filed, one purpose - thanks to the innovations of the roller deburring tool and the deburring MultiTool, sheet metal parts come out of the punching machine burr-free. This means that reworking in a separate manual stage, which was often necessary, is no longer needed. In the case of coated sheets and formed parts, this significantly reduces throughput times.

Both tools have something in common: they displace the burr and chamfer the edges (about 0.1mm).

The roller deburring tool uses a specially formed embossing roll for long edges and contours with a radius of more than 20mm.

In connection with the MultiShear tool (punching tool for outer and inner contours without disruptive nibble marks) the tool produces excellent edge quality as a result - for example in service openings of finished parts.

The three-way deburring MultiTool is suited to handle smaller radii, intricate geometries and corners in a single stroke or in nibble mode.

Various embossing contours take over this task as inserts in the die.

Both tools are suitable for sheet thicknesses of up to 2.5mm in steel, stainless steel and aluminum.

They are controlled by the TruTops Punch programming system.

The innovations submitted for patent protection have an additional benefit: the risk of injury is reduced when handling parts.