Metal Cutting: Turning Machines and Centers
Turned parts cover such a broad range, from slender shafts and tiny precision connectors to large-bore oil-patch tubing and huge turbine shafts, that it's hard to imagine how they fall under the same category of single-point metal removal.
Whether used in the toolroom or for rapid prototyping or for high-production applications, turning centers depend on the latest advances in machine design, control technology, software, and automating load and unload devices for their effectiveness.
Visitors to IMTS 2006 can expect to see technology solutions that reflect the demands of manufacturers for singlesetup production of more and more complex parts to ever higher levels of quality. Here's what visitors should look for:
- CNC lathes with live tools, C axes, subspindles and Y axis have the capability to drill and mill off center, and are much in demand for complete part processing in a single setup.
- CNC lathes approach full multitasking capability with a B axis that allows rotation around the Y axis for drilling at an angle or contour milling off the spindle centerline
- Classes of machines such as vertical turning centers and Swiss turns continue to enjoy demand because of growth in markets, including energy, aerospace, medical, and machinery.
For high-production applications, turning machines have evolved with multiple spindles, adding to the number of single-point tools that can be applied to the same part or machine multiple parts in a machine cycle.
Machines that add live (driven) tooling in the form of milling cutters, drills, and sundry other tools can perform turning and milling and other processes in a single setup, and approach true multitasking machines in capacity. Multitasking machines will be covered in the next section of our show preview.
Going to IMTS in search of your next turning machine involves adopting a strategy based on the volume and complexity of parts to be machined, the need for quick-change change workholding and tooling, desired quality of finished part, and ease of programming. It could be a simple two-axis lathe or a Swiss-turn capable of producing the most complex precision parts in as many as ten axes.
For medical applications, electronics connectors, and a host of similar precision-machined parts, Swiss turns that machine bar, typically to 32-mm diam, are following a number of courses in development.
"Manufacturers are requiring faster changeover, as businesses want smaller batches and smaller quantities," explains Tom Dierks, president, Tornos Technologies US Corp. (Brookfield, CT). "There is a need to set up faster and change over faster, relying on quick-change tooling or quick-change barfeeders with different bar sizes," Dierks says.
"Tornos has done a lot of things to its Swiss turns to overcome the limitations of the number of tools, for example taking a tool position and tooling it up to handle two or three tools to open up more tool positions on the machine. That's essential for more complex parts typically found in medical applications and some automotive and electronics parts," Dierks says.
For moderately complex parts, Tornos will exhibit its Deco 20s six-axis machine. It has been boosted to a 20 (25.4)-mm diam size and features a mirror image front to back sliding headstock on the front and sliding subspindle on the back, and gang slide on front and back. "It's a much less expensive option for the user who only requires five or six axes, and it can be configured a la carte or packaged with barfeeder and driven tools for under $200,000," says Dierks.
"IMTS attendees will quickly notice that today's machines are moving in two distinct directions," says Brad Morris, president of REM Sales Inc. (East Granby, CT). "Manufacturers are being driven to do more with less, looking at all of their processes for ways to reduce or eliminate operations while improving flexibility. In doing so, many are purchasing multifunction lathes, including Swiss turns, as solutions.
"In response to this market need, Swiss turn builders are producing more complex machines capable of simultaneous operation. Many of these new machines include turrets and driven tooling for milling, drilling, and other operations not typically performed on lathes," Morris explains.
"Attendees will see more machines than at any previous show capable of helping them consolidate operations in one machine and drop parts complete. At the same time, Swiss-turn builders are also developing simpler machines that are cost-effective solutions with decent capabilities for manufacturers producing parts that demand flexibility, but don't require complex machining operations," Morris explains.
"To an outsider, it might appear that these two strategies run counter to each other. In actuality, they are working together to help machine tool builders broaden their product offerings and provide more comprehensive solutions to their customers," Morris says.
REM Sales will debut the BH38SY Swiss turn, a combination turret/gang machine that delivers the benefits of a traditional Swiss turn with the flexibility and capability of a turret machine. The BH38SY features a 38-mm 15-hp (11.2-kW) main spindle and a 10-hp (7.5-kW) two-axis subspindle for shorter cycle times.
High-volume production of parts has been dominated by cam-driven multispindle machines that traditionally have required long setup times. "The current pace of change in manufacturing is such that job shops will not even have the luxury to move to the next step, the cam-driven multispindle with CNC slides," says Olaf Tessarzyk, president and CEO, Index Corp. (Noblesville, IN). Index, which is a leading supplier of multispindle machines, will introduce a machine at IMTS that will enable manufacturers to make that "next leap" in technology more easily. "I see CNC technology taking over almost completely. Flexibility is more and more an issue for our customers," he says.
"Shops that don't add value by manufacturing complex parts complete in one setup to the quality requirements of their customers will not survive," Tessarzyk says. These shops will have to be able to machine the difficult-to-machine materials such as stainless, very hard aluminum materials, and parts for the aerospace and medical industries. "The parts that are mostly brass, aluminum, or mild steel have probably gone to the Far East by now," he says.
Fadal Machining Centers (Chatsworth, CA) will introduce its new line of horizontal turning centers exhibiting three models. The Fadal PTC and TC turning centers are intended to offer manufacturers a range of options for creating integrated production systems using both turning and milling machine tools that Fadal supplies.
The show machines are a Performance Series PTC150-M, a PTC250-M, and a box-way series TC35-375L. The PTC machines with the milling (M) option can be combined with the sub-spindle (S) and a Y-axis option for complete machining flexibility. The TC35-375L Series machine is a box-way machine with a 375-mm chuck with a maximum turning diam of 540 mm. The L model has Z-axis capacity of 1600 mm. The TC series box-way machines are designed for high metal removal operations. The TC35-375 has a 30-kW, 2000-rpm spindle with a 102-mm through hole for bar-fed applications.
With the introduction of the Talent SV Series two-axis turning centers in 6" (152.4-mm) and 8" (203-mm) chuck sizes with 15-kW spindle drives, Hardinge Inc. (Elmira, NY) has expanded its CNC lathe product lines to meet what it perceives as all the turning needs of its customers from entry-level to high-end precision machining. The SV Series machines will be shown along side a diverse array of higher-end machines.
Hardinge has re-engineered the Elite Series II turning center for either machining small parts of 1.625 (41-mm) or 2" (50.8-mm) bar in a single setup, or for quick changeover to 6" (152.4-mm) or 8" (203-mm) chucking. The Elite II machines feature live tooling, C-axis contouring, rigid tapping and a subspindle option. One change made to both the 6/42 and the larger 8/51 Elite II machines is a new turret design that offsets the top plate in the Z axis, increasing tool length by 2" on the backside for live-tool machining operations on the optional sub-spindle.
Vertical turning centers continue to prove extremely versatile for production of small and midsized parts, as well as for machining large parts. They can supply their own part load and unload automation in inverted-spindle designs, or employ multiple spindles for higher production throughput. The VTLs are increasingly being offered with live spindles for milling, drilling, and other processing to complete parts without the need to refixture.
Manufacturers, who are looking for VTLs to add capacity or replace an older manual machine will have plenty of CNC versions to choose from, gaining both capacity and capability in the process.
"For large part machining, anything related to energy, aerospace, and heavy machinery such as construction equipment is very busy right now," says Steve Ortner, president, Absolute Machine Tools Inc. (Lorain, OH). "The key to our business today is that we are able to deliver VTLs in diam to 40" [1016 mm] and larger in a reasonable time. They are in demand for machining flange and oil-field workpieces, castings for heavy machinery and pumps, and, of course, jet engines," explains Ortner.
Absolute will exhibit the VTL-1600ATC-II You Ji vertical turning center, which tips the scales at 85,800 lb, (38,590 kg) with 100-hp (75-kW) spindle, 20-hp (15-kW) driven tools, and spindle load capacity of 17,600 lb (7990 kg) for the aircraft and power-generation industries. Maximum turning diam is 71" (1803 mm). An umbrella-style ATC stores 12 #50-taper tools. C-axis contouring with live tools for drilling and contouring is optional.
Ease of programming continues to be important, especially in job shops where operators may be called upon to program a short part run. GE Fanuc Automation Americas Inc. (Charlottesville, VA) has simplified programming and setup of complex lathe and milling applications with its Manual Guide i Software. For example, the software simplifies programming a variety of probe cycle at the machine tool without any operator knowledge of G code. Selections are available for probe calibration, toolsetting, setting fixture offsets, and basic metrology, among others.
Edge Technologies (Maryland Heights, MO) is making its debut with bar feeders, parts cleaning systems, and lathe automation products. Edge customers benefit from support from a team that has been together for 20 years as the bar feeder group of Hydromat Inc.
"Almost the number one concern of the customer today, besides having a good product, is to be able to operate the equipment at the lowest cost and have the most confidence that there is solid back up for an operator if something does go wrong," says Bruno Schmitter, Hydromat president. "All the customer has to do is pick up the phone and somebody will stop by to help solve the problem."
Edge Technologies will exhibit a variety of bar feeder solutions with economy in mind for feeding popular 3–20-mm diam round, square, and hex stock into CNC lathes. The Minuteman 320 12' (3.7-m) magazine bar feeder features a synchronization device for Swiss-style lathes that mechanically links the lathe's headstock Z-axis travel to the bar feeder's pusher to ensure synchronous movement and no loss of connection between bar stock and collet-pusher.
The FMB Turbo and Minimag automatic bar-loading magazine feeders for feeding round, square, and hexagonal bar material into CNC lathes are compatible with all types of sliding or fixed headstock, CNC or cam-operated lathes. Also from FMB, the SL80s short loader for processing bars in diam of 10–80 mm and 1250-mm long on CNC lathes will be introduced.
To make the search for that next productive turning machine as successful as possible, one industry observer suggests doing a little preliminary research about programming, quick-change tooling and workholding, and automating load/unload devices before approaching the machine tool builders. The reason: you'll know exactly what will work on the machine.
The equipment below is a sample of the turning technology that will be on display at IMTS 2006. — James Lorincz
Cycle Controlled Lathe
Proton 530 CNC lathes are controlled by the Fagor 8055 CNC cycle-control system that is simple to operate and allows convenient programming for production of complex parts without DIN programming experience. The Fagor system features integrated cycles for facing and plain turning, as well as radius, taper, thread, plunge cuts, and complete contouring. Turning diam is 21" (533 mm) over the bed and 11" (279 mm) over the cross slide. Bed width is 14.6" (370 mm) and the distance between centers is 59" (1498 mm) in two low-speed ranges.
Knuth Machine Tools USA
Ph: (847) 229-0600
Model DVH250i duo vertical pick-up turning center is designed for high-volume applications with a work envelope of 300 x 200 mm. The DVH350i duo turning can machine parts to 250-mm diam and has a shuttletype part feeder for fast part-loading times. Axis traverse rates are 45 m/min in the X direction and 30 m/min in the Z direction. A single part can be sequentially processed by moving it from spindle to spindle. In parallel production, typical parts can be machined at 200 parts/hr.
Ph: (586) 532-2500
Sprint linear series automatic lathes combine productivity and flexibility for producing short turned parts to 1.65" (41.9-mm) diam. Linear technology offers maximum speed to 1654 ipm (42 m/min). Integrated spindle motors on the main and counter spindles, both with Y axes, as well as the tool carrier and the 12 power tools make it possible to work with three tools and six axes simultaneously. A total of 24 tools are available for production.
DMG America Inc.
Ph: (847) 781-0277
The Elite Series II turning center is designed for machining either small parts 1.625" (41.2 mm) or 2" (50.8 mm) in a single setup or quick changeover to 6" (152 mm) or 8" (203-mm) chucking. Elite II machines are flexible and reduce setup time with live tooling, C-axis contouring, tailstock, and rigid tapping. New turret design on the 6/42 and 8/51 models offsets the top plate in the Z axis, increasing tool length by 2" on the backside for live tool machining operations on the optional subspindle.
Ph: (607) 378-4396
Turret-Gang Swiss Turn
Model BH38SY is a combination turret/gang machine that combines all the benefits of a traditional Swiss turn with the flexibility and capability of a turret machine. The BH38SY features a 38-mm main spindle capacity and two-axis subspindle. The main spindle is 15 hp (11.1 kW), and the 10-hp (7.5-kW) subspindle allows for shortened cycle times.
Twin-Turret CNC Turning
Model MJ200G is a twin-turret single-spindle CNC turning machine capable of simultaneous, four-axis machining operations, such as CVjoints and small shafts. The MJ200G features a high-speed three-axis CNC gantry loader for automation. Also being exhibited are the MW series twin-spindle CNC chuckers with gantry loading. GT models allow parallel loading of two parts from both sides of the machines. The GS model with 40 hp (29.8 kW) is for heavy-duty cutting.
Murata Machinery USA Inc.
Ph: (704) 875-9280
Gang Tool Lathe
Prodigy GT-27 gang tool lathe features a C-axis spindle and polymer base for fast and accurate small-parts turning. Spindle speeds reach 6000 rpm. Full C-axis indexing positioning in 0.01° increments is possible. As a result, live tooling can perform drilling and milling operations. The Prodigy GT-27 can handle both first and secondary machining operations in medical, automotive, commercial, ceramics, and fasteners applications.
SNK America Inc.
Ph: (866) 379-6068
VTLs are designed for high metal removal rates in machining wheels, disk brakes, flywheels, and hubs. The addition of a robotic, gantry, or conveyor-type carriage system allows partial or full-automation capabilities. Models come with either Fanuc OiT or 18iTC control. Gang-type, single-turret, or double-turret tooling configurations are available to meet various production requirements. Chuck sizes range from 8 to 24" (203–610 mm).
Chevalier Machinery Inc.
Ph: (800) 243-8253
Model HHLV-1 is a hybrid precision toolroom lathe that has a CNC control, but can also be operated manually. Distance between centers if 18" (457 mm) and the cross-slide travel is 8" (203 mm). Part swing over the guide rail is 14" (355.6 mm) with 6" (152.4 mm) over the cross slide. Spindle speeds are infinitely variable from 0–3000 rpm and the 5C collet nose accepts a variety of workholding options. Control is the Haas CNC.
Haas Automation Inc.
Ph: (805) 278-1800
Fit-to-part automatic loading systems can be added to a new CNC lathe or retrofit to keep production flowing at a steady and efficient rate with minimal operator intervention. The operator can swing the loader away from the lathe for programming and to accommodate short-run, manually fed projects. The system can be designed to run a family of parts by integrating multiple nests. The magazine can be adjusted to handle diverse sizes and unusual shapes of parts.
Toellner Systems Inc.
Ph: (262) 784-4900
CNC Lathe With Milling
NL Series lathes feature a directly coupled milling motor inside the turret that reduces tool spindle accel time by two-thirds and vibration and noise by one half. Models include 6", 8", 10", and 12" (152.4, 203.2, 254, and 304.-mm) chuck versions with the longest maximum turning length of 49.6" (1260 mm) on certain models. NL3000 handles bar work as large as 3.54" (90-mm) diam. NL machines have rigid triangle structure in the bed, the spindle, and the tailstock, and feature boxway construction.
Mori Seiki USA Inc.
Ph: (847) 593-5400
Model R07 Swiss-turn machines precision parts to 7 mm. The rotary guide bushing unit performs metal cutting at speeds to 12,000 rpm. The subspindle delivers 10,000 rpm. The R07 uses linear motors to drive slide and tool posts. Rotary tools are part of the gang-tool post, allowing small-diam parts requiring complex machining such as polygon turning and end-face drilling to be performed.
Marubeni Citizen-Cincom Inc.
Ph: (201) 818-0100
OD Turning Center
Model Lynx 220 for OD turning has three models: the 220A with a 6.5" (165-mm) chuck; the 220C with an 8.25" (209-mm) chuck, and a 220LC with an 8.25" (209-mm) chuck and elongated bed. All have 20-hp (14.9-kW) motor. The 12-station, heavy-duty turret is non-stop and bi-directional with a 0.15-sec station index time. Rapid traverses are 1181 ipm (30 m/min) on the X-axis and 1417 ipm (36 m/min) on the Z axis.
Ph: (973) 543-2004
Model HP multispindle machine with Cucchi bar loader will be exhibited. The HP features threading, back drilling, and back tapping. The machine will be tooled up with CJ Winter's Quick Change Tooling. Also exhibited will be the Servo B and Model B multispindle screw machines.
Ph: (800) 344-5748
Big-Bore two-axis horizontal CNC turning systems can machine bar and tube from 1 to 12" (25.4–305-mm) diam, such as piston rods and hydraulic cylinder bodies, in one operation. The Big-Bore line offers 12 or 15-station interferencefree turrets with optional live tooling. High spindle speeds to 3000 rpm are available with AC spindle drives of 40, 54, or 80 hp (29.8, 40.2, 25.4 kW). Bar and tube loading systems allow automatic magazine loading and handle incoming material to 40' (12.2-m) long.
Bardons & Oliver Inc.
Ph: (440) 498-5800
Vertical Turret Lathe
Model TVL8DC vertical turret lathe is a 24" (610-mm) chuck, 30-hp (22.4 kW) VTL with a 41.3" (1050-mm) swing and a 12-tool ATC. An 8" (203-mm) ram structure on the Z axis ensures heavy-duty cutting at maximum stroke. Two-speed gearbox provides power at the low end with full 30-hp (22.4 kW) at 46 rpm. Control is Fanuc-0iT. VTLs are available with chucks from 10 to 60" (254–1524-mm_diam tables with turrets, rotating tools, and ATCs.
Tong-Tai Seiki U.S.A. Inc.
Ph: (845) 267-5500
Horizontal Turning Centers
Three models of two new horizontal machining centers lines, PTC150-M, PTC250-M, and a box-way TC35-375L, will be exhibited. The performance turning centers series (PTC) include four models for production applications with chuck sizes of 6, 8, 10, and 12" (150, 200, 250, and 300-mm). All PTC machines, except the entry level PTC150-G unit, can be ordered with a powered turret milling option suitable for axial or radial rotary-tool operations. The TC Series machines feature box ways for highhorsepower, high-metal-removal operations.
Fadal Machining Centers
Ph: (818) 407-1400
Economical Bar Feeders
The Minuteman 320 is a 12' (3.7-m) magazine bar feeder with a 3–20-mm diam capacity that's designed for feeding round, square, and hexagonal bar stock into CNC lathes. The Minuteman is equipped with a quick-change polyurethane guide channel that is flooded with oil to create a hydrodynamic effect, resulting in higher rpm with reduced noise and vibration. Also being shown is the Rebel 120-Servo with 8–120-mm diam bar capacity and a large magazine capacity for long untended operation.
Edge Technologies, Div. of Hydromat
Ph: (314) 692-8388
Model VTL-1600ATC-II vertical turning center is built for heavy-duty turning of large parts. The VTL-1600ATC-II has a heavily ribbed Meehanite casting that minimizes thermal distortion and dampens vibration. Both X and Z axes are supported by oversized, hardened and ground box ways. The spindle's 60-hp (44.8-kW) Fanuc high-torque motor is coupled with a two-speed XF gear box. ATC stores 12 #5-taper tools. Spindle load is 17,600 lb (7983 kg) and spindle speed is 2–250 rpm.
Absolute Machine Tools Inc.
Ph: (440) 960-6911
Made by Haco-Fat, TUR MN/CNC lathes offer 45, 53 or 61" (1143, 1346, or 1549-mm) swing x 78*472 (1981*1199 mm) between centers. They come with Siemens 810D manual turn or Fanuc 18T manual guide controls, spindle speeds to 900 rpm, 5.5 to 17.7" (140*450-mm) spindle bores, load capacity to 15 tons (13.6 t), choice of tooling systems, and many other features. The TUR series features a 44" (1118-mm) wide bedway design that has an approximately 7" (178-mm) front way, resulting in improved stability. Tailstock features a 7.9 (200-mm) diam quill equipped with built-in live center.
Ph: (847) 301-3700
Manual Guide i software provides operators with simplified programming of complex lathe and milling applications. Part program editing gives users the flexibility to cut and paste, or copy specific sections of a program. The software provides guidance messages in G- or M-code comments displayed on-screen. M-codes can be registered for exclusive use with a specific machine. The software also offers a simple method for programming a variety of probe cycles at the machine for calibration, tool setting, setting fixture offsets, and basic metrology.
GE Fanuc Automation Americas
Ph: (434) 978-5000
Hydrobar Sprint 555 incorporates both hydrostatic and hydrodynamic principles, allowing users to cut 12' (3.6-m) bar stock at maximum spindle speeds without vibration to produce more precise surface finishes. The hydrodynamic principle allows loading a range of bar stock diam in one setup, fewer guide changes, and 2–8-min changeovers. Also being exhibited are chip conveyors and high-pressure coolant systems.
LNS America Inc.
Ph: (313) 528-5674
Twin-Spindle CNC Turning
The DNC line of twin-spindle lathes features two turrets and two spindles to offer the performance of two machines in a single machine. Systems are offered in two models, the DNC 300 and DNC 500. The main spindles move in Z-axis, automatically transferring the workpieces from the right to the left spindle. The right and left side of the workpiece is turned, drilled, or milled without any action on the part of the operator. Automatic loading and unloading of the workpieces is optionally possible, and complete machining reduces part costs. Storage and transportation is not necessary, reducing production time.
A. Monforts GmbH & Co.
Ph: 49 2161 401418 (Germany)
Vertical Boring & Turning
Model TUE-15 is single-column CNC vertical boring and turning mill with a table diam of 59" (1500 mm), maximum swing 71" (1800 mm), maximum cutting height of 59", and maximum table load of 17,600 lb (8000 kg). Table-drive motor of 40 hp (30 kW) achieves table speeds of 2–250 rpm. Positioning accuracy is +/- 0.009/500 mm and positioning repeatability accuracy is +/- 0.005 mm.
Toshiba Machine Machinery Co. Ltd.
Ph: (847) 593-1616
The Vturn-16 turning system features a small footprint for customers looking for a small lathe capable of handling a wide range of jobs and materials. This compact system handles a variety of jobs, from small chucking jobs to shaft work. A generous machining area ensures the machine is suitable for medium-batch production. High-speed spindle and rigid construction offer improved surface finish, eliminating many cases the need for post-machining grinding. Units feature a fast tool exchange time of just 0.7 sec, 6000-rpm spindle speeds, reduced setup time with 12-station turret, and a standard chucking diam of 6" (160 mm). Fanuc OT-C control also is standard, and standard Fanuc power up spindle motor offers high torque at low spindle speed.
Fortune International Inc.
Ph: (732) 214-0700
Two Lathes In One
Deco 20s Swiss-type machines are aimed at machining moderately complex precision parts to 25.4-mm diam for medical, automotive, electronics, and connector parts. The Deco 20s has almost an equal number of tools available for both the 3.7-kW main and counter spindles. Both tool systems have three fully independent axes for a total of six axes. A total of 22 tool positions are available. Live tooling can perform milling and drilling operations.
Tornos Technologies US Corp.
Ph: (203) 775-4319
The Centur CNC 30G is a two-axes gang-tooled turning center equipped with GE Fanuc 0i-T conversational control suitable for economic bar turning. The 30G comes with bar loader, parts catcher, chip conveyor, 5500-rpm spindle, and 10-hp motor. Unit features fast, efficient machining of bars up to 1.625" (41.3 mm). System offers manufacturers a rugged bar machine with hydraulic collet chuck and automatic parts unloading, as well as Ushaped cross slide gang tooling with T slots for toolholder positioning, allowing superior flexibility for tool setup for multiple applications. Suitable to a wide range of applications, the machine turns precision parts from bar swiftly and efficiently with fast changeovers and little operator involvement. Interactive programming screens make it equally adept at mixed-volume, short-run production as well as dedicated high-volume applications.
Romi Machine Tools, Ltd.
Ph: 877-ROMIUSA (877-766-4872)
Model 2SP-V60 is a twin-spindle vertical turning center design for high-precision turning of midrange parts. The 2SP-V60 features maximum cutting diam of 24.02" (610 mm), maximum cutting length of 25.98" (660 mm), and a maximum swing of 27.56" (700 mm). Spindle speed is 20–2000 rpm. Both column and saddles are designed for rigidity and accuracy. Like all single or twinspindle V-series machines, the 2SP-V60 has Fanuc CNC control system, integrated spindle/quill assembly, and is available with live tooling.
Ph: (847) 465-0160
The TRAK TRL 1730SX lathe featuring the ProtoTRAK SLX CNC is the smallest toolroom lathe in the TRAK line. The 1630SX can be operated manually for CNC with the optional TRAKing feature. The bedways are hardened and ground, and sliding surfaces are Turcite coated. The 1630SX comes with electronic handwheels and a jogstick and a spindle speed range from 150 to 2500 rpm.
Southwestern Industries Inc.
Ph: (866) 876-0601
The new three-turret Super NTY3 multitasking turning center Nakamura-Tome offers 100% stockon turning and machining that virtually eliminates lost productivity due to tool changes. With the system's three turrets each offering a Y axis in a relatively small 109.45 x 77.6" (2.8 x 2-m) footprint, the turning center can outperform single-tool multitasking machines, allowing one-pass complete turning/machining/finishing, reducing part cycle times. Units offer multipoint machining with process integration, combining turning and milling capabilities in one machine, and its three 6000-rpm milling motors can simultaneously machine two flat surfaces (top and bottom) on one spindle and one surface on the other. Each extremely rigid turret holds 12 driven or 24 stationary tools, for a maximum of 72 tool stations. Accelerating Y axes have travels of 2.44" (62 mm). Up to 29/20 hp is available for shaft/work turning with synchronized spindles (14.5/10 hp per spindle).
Methods Machine Tools Inc.
Ph: (978) 443-5388
Company will demonstrate Feeler's turning systems, which include the versatile FTC high-speed linear guide machines, featuring live tooling, Caxis, sub-spindles and dualturret options. The FT Series heavy-duty, 45° slant-bed and box-way construction are extremely effective for heavy metal removal applications. The Feeler FTC-10 turning center features a high-speed linear guide, 6" (152.4-mm) chuck diam, a 10-hp (7.5-kW) continuous drive system, and spindle speeds to 6000 rpm, while the FTC-20 offers an 8" (203.2) chuck diam, 20-hp (15-kW) continuous drive system, and speeds to 4500 rpm. The FTC-10 and FTC-20 both offer a Fanuc 0i-TB control.
GBI Cincinnati Inc.
Ph: (513) 841-8684
The 2SP/LF Series features a front-facing spindle with the Okuma LFS and LF Series offering an automation-friendly lathe for small-parts production. Systems come in two models, the LF150 and LF250. By moving the spindle off the side and incorporating the Okuma Gantry Loader into the production line, parts can be loaded and unloaded automatically. An extremely compact footprint improves floor space utilization. The popular dual-spindle option significantly reduces cycle time. An extremely fast and accurate sliding headstock creates precision parts in minimal time.
Ph: (704) 588-7000
Single-Bore Engine Lathe
Model B Series is a new line of geared-head engine lathes with a 4.5" (114-mm) spindle bore. B Series lathes have a D1-11 camlock spindle and a swing capacity of 22, 26, and 30" (558, 660, 762 mm). Their center distance ranges to 160" (4064 mm) between centers. Also being exhibited is the CNC ST-10 turning center with a swing capacity of 18.9" (480 mm) and maximum turning length of 13" (330 mm). CNC features include word-processor editing, multifunction jog handle, and Manual Guide i Programming.
Sharp Industries Inc.
Ph: (310) 370-5990
Manual Pallet System
Manual pallet system has universal applications on lathes, as well as fourth and fifth-axis rotary milling tables. Available in three pallet sizes, 8.5, 10, and 12" (215.9, 254, 304.8-mm) diam, the system utilizes a common receiver that holds any of the pallets. The M-RPC system utilizes a mechanical clamping system that doesn't require any air/hydraulic or power lines and has a clamping force of 6500 lb (2948 kg) with a repeatability of +/- 0.0001" (0.0025 mm).
Ph: (847) 593-8420
Model HL-25 CNC lathe can cut from 0.0625 to 9.84" (1.6–250-mm) diam to 23.62" (600-mm) lengths in a wide variety of materials. It comes with a 12-station servo turret for faster setup time and faster tool changes. The HL-55/110S CNC lathe incorporates box-way design for rigidity. With a large turret casting and an oversized curvic coupling, the CNC lathe can cut from 0.062 to 24.21" (1.6–614.9-mm) diam to 49" (1244-mm) lengths.
Ph: (714) 898-2066
This article was first published in the August 2006 edition of Manufacturing Engineering magazine.