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Metalcutting: Machining Centers and Cells

 

 

How to do more with less

        

The overall theme of the machining center and cell technology being exhibited at IMTS 2004 would have to be "Doing More with Less." Users are looking for more parts, with better quality, in less time and with less labor.

"In a nutshell, business owners want to make more money in less time," says Bob Burrows of Haas Automation (Oxnard, CA). "You achieve this by paying less for the initial investment in equipment, reducing or eliminating labor, and keeping future costs--service, maintenance, spares, downtime, etc.--to a minimum."

Haas's new machine offerings feature faster rapid traverses, spindle speeds, and toolchangers than previous generations. Many have automatic part loading and pallet changers that help users minimize labor input and provide untended machining capability. 

For example, visitors to the company's exhibit at IMTS will see the VM-3, a high-speed vertical machining center designed for moldmakers. The machine has a 12,000-rpm, inline direct-drive spindle and high-speed control with full look-ahead capability.

 

"We also are trying to reduce the cost of ownership by designing low-cost--affordable, not cheap--machines, while maintaining quality by using economies of scale and common components," Burrows says. Value-added services, such as same-day service, 90% first-call completion rate, and spare parts price and inventory are also important, he adds.

Makino (Mason, OH), has found that production of machined parts is shifting to contract manufacturers. "As auto parts, for example, move more from being OEM-produced to being outsourced to a tier-level production shop, our focus had to change," explains the company's Tim Jones.

According to Jones, contract manufacturers in North America are being compelled to invest in new technology due to five major factors.

  • A shortage of skilled craftsmen in the tooling and machining area. "Shops are being forced to look for alternative resources, and automated and integrated technology is a solution to enhanced productivity," Jones points out.
  • Global competition, which makes it imperative to balance quality human resources with automated technology. "In actuality, automation and technology will end up saving jobs, not taking them away," he says.
  • A move toward high-mix, low-volume part production means traditional setup times can no longer be tolerated. "Automation is no longer a 'perk' of the large OEM operation; it is becoming a requirement for tier-level and smaller operations," Jones says.
  • Ongoing demands for shorter lead times, faster production, and reduced cycle times. According to Jones, "Everyone wants everything today, and often untended machining with automation and cell integration is the only answer."
  • A need to address shorter product life cycles by expanding machining data and knowledge bases. "Industry cannot continue to redevelop processes and procedures for new parts. We simply cannot re-invent the wheel with every new widget," he says.

Jones says Makino has restructured much of its machine technology to be more cost-effective in terms of both initial capital investment and cost of operation. At the show, this emphasis on value technology will take the form of the a81 HMC, which features a high-torque spindle Makino says is the most powerful integral-drive spindle in the world. The proprietary 50-hp (37.3-kW), 50-taper spindle produces 744 lb-ft (1009 N*m) of torque from 0 to 392 rpm and still maintains fast accel/decel rates.

 

But, Jones adds, users also expect service, training, and ongoing process improvement efforts from machine suppliers. "The burden of R&D and training is also on us," he concludes. "We have to be educators for the life of our customer relationship. You cannot just build a machine tool, drop it off, and ride off into the sunset. You need to work with customers to transfer skills and knowledge, and support your technology with an in-depth skill and training base."

 

Another potential solution to increasing demands for improved metalcutting productivity is a cellular system built around HMCs, according to David Austin of Mori Seiki (Irving, TX). The company offers both carrier pallet pool (CPP) and linear pallet pool (LPP) systems.

"A CPP is a preconfigured flexible system, and an LPP is a modular, expandable flexible system," he explains. "The benefit of these systems is that we find HMC utilization typically increases to 85%, and even better in some cases. This results from the elimination of setup time from the HMCs in the system."

Mori will also showcase its latest machining centers, which feature the Driven at the Center of Gravity (DCG) technology optimized at the company's Digital Technology Lab (West Sacramento, CA). Use of dual ballscrews on selected machine axes is said to hold down costs while improving part accuracy, surface finish, and tool life by reducing cutting vibration. "Vibration destroys tooling, so decreasing vibration increases tool life," Austin explains. "In one of our cutting tests, a DCG machining center yielded a 3.7 X increase in tool life versus a conventional machine. Considering perishable tooling can represent up to 50% of the cost to machine a part, this reduces overall costs dramatically."

Mori's DCG machining center lineup includes the NV4000 DCG, a VMC with five ballscrews--one on the X axis and two each on the Y and Z axes--as well as larger 5000 and 6300 series machines.

According to Toyoda Machinery USA (Arlington Heights, IL), controller software and pallet handling is as important as machine technology for metalcutting cells. The company will exhibit a three-level stacker system that uses a new high-speed rail-guided vehicle to move 12 pallets.

The cell will be under the control of Toyoda's latest Mach III cell controller software, a Windows-based system said to increase machine and operator productivity by up to 90% by determining the most efficient production schedule and automating multiple tasks.

For large and/or complex components, combining five-axis capability and high-speed machining can lead to big increases in machining productivity, according to Mal Sudhakar, vice president, Mikron Corp. (Lincolnshire, IL).

"Shops are looking for ways to combine more operations on one machine. While turn/mill centers and multitasking machines are offering more capabilities and becoming more prevalent, the use of five-axis machining centers is also increasing. Five-axis machining centers that provide multisided machining in one setup are available in the market at more affordable prices, and many shops are getting into this technology."

And, Sudhakar notes, the definition of high-speed machining is changing as spindle and axis speeds continue to increase. "A few years ago, machining centers had top spindle speeds of 8000 rpm, feed rates of 400 ipm, and acceleration of 0.1 or 0.2 g. Today, many high-performance machining centers are available in the market with spindle speeds up to 20,000 rpm, feed rates of 1600 ipm, and acceleration of 0.5 g," he says. "A further step above this are machines with spindle speeds up to 60,000 rpm, feed rates of 3000 ipm, and acceleration of 1 g and higher."

Mikron is attempting to address these needs, as well as requirements for increasing automation, with technology it calls smart machining. "Smart machining can improve reliability, optimize machining performance, and allow reliable unmanned operation," Sudhakar explains. "Examples of smart machining technology are real-time monitoring of spindle vibration in a high-speed machining process, automatic compensation for thermal drift in a machine, and communication of the operating status of a machine from the CNC to a PC or cell phone."

A case in point is the UCP 600 Vario, a five-axis, high-speed machining center that embodies all the above trends. The machine is equipped with a 20,000-rpm spindle, rotary/tilt table for five-axis/five-side machining, laser tool measuring system, part probe, integrated table chuck for palletization, an integrated seven-position pallet changer, and vibration monitoring and thermal control modules.

Following is a listing of machining center and cell products scheduled for display at IMTS.       

 

 

 

Product Previews

                                                                                                                                                                                                                            

Horizontal Production Center

Model SPN501 horizontal is a 20" (508-mm) pallet machine that produces parts as large as 31.5" diam X 39.4" tall (800 X 1000 mm). A three-point-mount machine, it features rapid traverse of 2362 ipm (60 m/min), and three choices of 50-taper spindles at 8000, 12,000, and 15,000 rpm. Its synchronous-swing-motion tool-change system generates tool change for a 44-lb (20 kg) tool of 1.4 sec, and chip-to-chip time is 3.8 sec. Chips are evacuated from the rear of the machine, and pallet exchange time is 7.0 sec.

SNK America, Niigata Machinery Div.
Ph: 847-364-0801

 


 

Flexible Automation

Called Cellmaster, this automation system attacks bottlenecks in mid-to-high-volume part making. It decouples processes in a production line, eliminates bottlenecks on existing lines, and reduces capital investment in new lines by eliminating extra machines. The flexible system uses three stacks of parts. An operator removes a finished stack while the other two are used to load and unload the machine tool. The worker does not handle parts, or load/unload the machine. The operator is converted from machine tender to production controller.

Wes-Tech Automation
Ph: 847-541-5070

 


 

Twin-Spindle Machining Center

Model MCT 160 and MCT 250 twin-spindle machining centers feature a dedicated B axis for each spindle. Shared X axis is integrated into the column, and the shared Y axis is a vertical slide. Independent ram-style Z axes are integrated in the Y slide.

Working envelope for each of the smaller MCT 160's spindles in X/Y/Z is 450 X 450 X 450 mm, maximum part diam is 450 mm, and maximum part height is 600 mm from the pallet surface. Rapid traverse in the X axis is 60 m/min at 1 g.

Heller Machine Tools
Ph: 248-288-5000

 


 

Robots

The Windows-based NX100 controller builds on the company's patented Multiple Robot Control Technology, which is said to reduce the complexity of multirobot installations. Many application-specific robots will be displayed, including: the ArcWorld V-6300, three wall-mounted EA1400N welding robots with an extra heavy-duty headstock/tailstock positioner; RoboBar II, a UPJ3D dual-arm robot with a NXC100 controller that will serve various beverages; and the six-axis PX800 robot, the small model in a family of high-performance painting robots.

Motoman
Ph: 937-847-3202

 


 

Traveling-Column VMC

On the Vcenter-205 VMC, a C-framed traveling column with rapid feed of 30 m/min reduces spindle idle time and provides easy access to load/unload components. A long, fixed worktable ensures evenly distributed loading. The machine features uniform accuracy at full X-axis travel even when oversized parts or off-center parts are loaded. Central partition guarding permits machining on one side of the table while the operator loads parts on the other side.

Fortune International Inc.
Ph: 732-214-0700

 


 

Automatic Pallet System

Series 15SD side-mounted automatic pallet system is intended for use on small VMCs and CNC drill and tap centers. For lights-out manufacturing, the four-pallet Dual APC allows users to fixture all pallets the same. A cast-iron receiver (clamping unit) offers up to 20,500 lb (91 kN) of clamping force and includes the company's dual air blast feature for chip removal. This design offers ±0.0001" (0.003-mm) repeatability. Pallet exchange time for all of the manufacturer's line of APCs begins from about 8 sec.

Midaco Corp.
Ph: 847-593-8420

 


 

Vertical Bridge Machining Center

Intended for the die/mold shop, the FP-66A bridge-style machining center has a 30-hp (22-kW) integral spindle capable of speeds from 60 to 16,000 rpm.

Machine features include: Heidenhain optical scales on all three axes, oil/air-mist spindle bearing lubrication system, spindle-cooling system, and 24-tool swing-arm-type ATC system. Travel in X, Y, and Z is 26 X 20 X 15.75" (660 X 508 X 400 mm). This network-capable machine employs a Fanuc 18iMB CNC with a 64-bit RISC processor.

YCI Inc.
Ph: 562-906-6118

 


 

Upgradeable VMC

The QP-Series VMCs are designed to accommodate future upgrades with features that include prewiring for the fourth axis, and hoses and fittings for the spindle chiller and coolant-through-spindle. They utilize the Fanuc Oi-MB controller. Standard features include a 24-tool arm-type ATC, and a 10,000-rpm, 20-hp (15-kW) spindle with coolant circulation (12,000-rpm spindle optional). Machine specifications for the QP2026 include travel of 26 X 20 X 20" (660 X 508 X 508 mm) in X, Y, Z. For the QP2033L: travel of 33 X 20.5 X 20" (840 X 520 X 508 mm). Cutting feed rate peaks at 394 ipm (10 m/min). Toolchange time is 5.5 sec chip-to-chip.

Chevalier Machinery Inc.
Ph: 562-903-1929

 


 

Five-Axis Machining

The Millac 800VH machining center from Okuma & Howa has an 800-mm-square pallet and a standard 22-kW spindle that operates at 10,000 rpm. Full CNC indexing table (C axis) uses a curvic coupling equipped with scaled feedback as standard. The tool magazine holds 80 CAT 50 tools, and toolchange time is 4 sec. An X, Y, Z-axis of 1020 mm permits handling of oversized parts and allows space for robotic loading.

KGK International
Ph: 847-465-4476

 


 

Two-Spindle CNC Module

Called the Specht duo, this two-spindle module gives automotive suppliers a system intended for volumes in the 500,000-part range. It can be configured for wet or MQL machining. The module features X, Y travels of 710 mm and Z travel of 600 mm, a work zone with 710-mm clearance diam, and a 16,000-rpm spindle with a 37.4-kW output. Each spindle has its individual Z-axis drive. Its chain-type magazine holds 71+1 tools (84+1 is optional) with +1 designated for single-spindle operation (e.g. during setup).

Cross Hüller
Ph: 586-566-2400

 


 

Horizontal Machining Center

By using its 2953 ipm (75 m/min) rapids, 50-rpm B axis, 2-sec tool change and 12-sec pallet change, the HM800S HMC reportedly optimizes noncutting efficiency. The 800-mm pallet feeds at 1575 ipm (40 m/min) with travels of 41.33 X 35.43 X 34.64" (1049 X 900 X 880 mm) in X, Y, and Z, and has 2645 lb (1200 kg) max loadable weight. It combines a 50-taper, 12,000 rpm, 40-hp (30-kW) spindle, and core-chilled ballscrews. Static accuracy is ±0.0001" (0.003 mm) and repeatability is ±0.00006" (0.0015-mm).

OKK USA Corp.
Ph: 630-924-9000 ext. 219

 


 

Dual-Zone Machining Center

The DFT X-Mill is a fast (60 m/min), long-travel (6-m) VMC. It has a monolithic bed with dual stationary tables, a high-back-wall swarf-containment compartment, and a raised bed for either a single or twin-spindle module that moves the spindle in all three axes. Its tool-centered feed-force design centers the axis feed-force line of action on the cutting tool. The machine's long-bed design allows long and short-part machining in either single or dual work-zone mode. Options include fourth and fifth-axis contouring table.

Bertsche Engineering Corp.
Ph: 847-537-8757

 


 

"Smart" Machining

Company will exhibit equipment for "Smart Machining," which it says can improve high-speed machining process reliability, optimize machining performance, and allow reliable, unmanned operation. Making its North American debut will be the UCP 600 Vario, which will be equipped with a tilting, rotating table and a 30-position ATC as well as thermal control. Also on display will be the HSM 600U five-axis machining center for machining of large workpieces. It will be equipped with a 36,000-rpm, high-torque spindle; optional pallet changer; and integrated 30-position ATC.

Mikron
Ph: 847-913-5300

 


 

Machining Center

Linear-motor-driven high-speed machining center offers high dynamic response with 1g acceleration rate and a 40,000 rpm spindle. It's available in two sizes. Model MC 430L has X, Y, Z axis travel of 16 X 14 X 8" (406 X 356 X 203 mm) axis travel, while model MC640C offers axis travel of 24.5 X 16 X 12" (622 X 406 X 305 mm).

Sodick
Ph: 847-310-9000

 


 

Multiaxis Machining

The Variaxis 730-5X combines five-axis capability with a 50-taper spindle to enable significant productivity gains in machining of castings, forgings, steels, and stainless steels. Compared with the company's 40-taper Variaxis, the machine achieved cycle-time reductions of 24% in cutting tests on identical workpieces. Features include a high-precision table with 150º of tilting range; 10,000-rpm, 40-hp (30-kW) spindle; 1575-ipm (40 m/min) rapid traverse rates in the three primary axes; Mazatrol Fusion 640M CNC with conversational programming; and a standard table size of 24.8 X 19.7" (630 X 500 mm). Machines equipped with a two-pallet system get 19.7" square pallets. The machine also has reduced air consumption and produces less tramp and waste oil, which extends coolant life by 50%.

Mazak Corp.
Ph: 859-342-1700

 


 

Multiaxis Modules

Available in three sizes, FlexCenter can be integrated with dial, transfer line, and cell applications. The multiaxis modules come with a horizontal or vertical spindle, horizontal or vertical turret, or a basic platen (flat mounting surface). The FC350, the smallest model, features a 14" (356-mm) work cube, and can be configured with a 40-taper or HSK63 tool interface. Model FC450 has an 18" (457-mm) work cube and can be configured with 40 or 50-taper, HSK50, 63, or 100. The FC630 has a 25" (635-mm) work cube, and can be configured with 50-taper, HSK63, or HSK 100 tool interface.

Setco Sales Co.
Ph: 800-543-0470

 


 

Rotary Transfer Machines

EPIC R/T rotary transfer machines use Embedded Motion Control (EMC) technology, which incorporates plug & play programmable valves into each toolspindle unit. This approach is said to virtually eliminate use of conventional valves and simplify CNC components and wiring, reducing potential failures and facilitating troubleshooting. Integrated modem connections also speed problem solving. Featuring full CNC programmability and quick-changeover capability that makes them suitable for small, medium, and large production quantities, EPIC R/T machines are priced similarly to the company's previous generation of rotary transfer equipment.

Hydromat Inc.
Ph: 314-432-4644

 


 

Fast HMC

FH-S horizontal machining centers are said to increase throughput by pairing high spindle speeds with faster non-cut operations, resulting in 30% faster cycle times than previous machines. The modular HMCs feature a high-gain spindle that reaches full speed in 2.3 sec. Users can select either a 15,000-rpm, #40 or #50 taper spindle or a #40 taper, 8000-rpm spindle. Other machine features include roller bearing linear guides for rigidity and vibration-dampening, Fanuc 30i CNC with Field Bus technology, 550-mm square pallets capable of handling workpieces to 790 kg, and a 40-tool ATC that can use tools weighing up to 27 kg.

Toyoda Machinery USA
Ph: 847-253-0340

 


 

Machining Center Lineup

The HW63A box way horizontal machining center for high-speed and precision applications. The machine incorporates double ballscrews on all axes for high speed and positioning accuracy. It features a 1000 X 800 X 800 mm machining envelope. Also on display will be the new VU65A-SH five-axis contouring VMC for production of complex aerospace, gear, cam, and automotive components, as well as the revamped HU63A-5X HMC, with a trunnion system redesigned for easier workpiece access, a more compact footprint, and a larger range of motion and higher torque on the A-axis drive.

Mitsui Seiki (USA) Inc.
Ph: 201-337-1300

 


 

Verticals and Horizontals

Four models in the new VMC XP3 line of vertical machining centers are differentiated by size, spindle speed and power, taper sizes, and acceleration rates. The largest machine, the 1500 HPD, has an X-Y-Z work envelope of 60 X 26 X 24" (1520 X 660 X 610 mm), a two-speed gearbox, and a 7500-rpm, 40-hp (30-kW), 50-taper spindle. Also on display will be three new horizontal machines representing the HMC 700 line. All three machines are supplied with 290-psi (2-MPa) through-spindle coolant systems, GE Fanuc CNCs, and a 60-position ATC with chip-to-chip toolchange time of 5.5 sec. Available options include a six-pallet changing system.

Bridgeport Machines Ltd.
Ph: 203-929-5570

 


 

Graphite Machining

Designed for machining graphite EDM electrodes, the VM1 vertical machining center can also handle plastics and light metals at spindle speeds to 30,000 rpm. The machine features a 26 X 14 X 18" (660 X 355 X 455 mm) work envelope, 30-taper spindle connection, Hurco's UltiMax conversational control, and a swing-arm ATC. Refrigerated coolant provides thermal stability, and metal telescoping way covers have positive air flow to minimize dust contamination. The machine can be modified to accommodate an optional vacuum dust collection system. Also shown will be the VM3 vertical machining center, designed for low and medium-quantity jobs. The machine offers travels of 50 X 18 X 18" (1270 X 455 X 455 mm), a 20-hp (15-kW), 8000-rpm spindle motor, and the UltiMax CNC.

Hurco Cos. Inc.
Ph: 317-298-2622

 


 

50-Taper HMC

The design of the NH6300 DCG horizontal machining center was digitally analyzed, resulting in a machine that can deliver the long tool life and smooth machined surfaces, as well as minimized noncutting time. The machine features the company's Driven at the Center of Gravity (DCG) technology, which directs net driving force through the center of the axis. Twin ballscrew drives on the X and Z axes reduce vibration without sacrificing speed; the Y axis gets a single ballscrew. Other features include a box-in-box structure that increases rigidity, a standard 60-tool rack-type ATC with options to hold up to 330 tools, and 10,000-rpm spindle. A center trough design allows placement of the coolant tank on the floor underneath the spindle, simplifying maintenance tasks.

Mori Seiki
Ph: 972-929-8321

 


 

High-Speed VMC

Designed for mold and die work, the VM-3 has a 40 X 26 X 25" (1000 X 660 X 635 mm) work cube, a 54 X 25" (1370 X 635 mm) table, and a high-speed control with look-ahead capability. Cast-iron construction with extensive internal ribbing increases rigidity and damps vibration, while linear guides on all axes further increase rigidity and stiffness. Other features include a 12,000-rpm, 40-taper, direct-drive spindle said to reduce vibration, heat, and noise compared with belts; coolant circulated through a jacket in the machine's head casting to remove heat generated by the spindle; and a side-mounted 24+1 ATC. Also on display will be the OM-1 Office Mill, a compact machine for prototype shops; medical, dental and research facilities; schools and training facilities; or even hobby shops.

Haas Automation
Ph: 805-278-1800

 


 

High-Performance VMCs

CFV vertical machining centers are designed with a high-strength cast iron structure, 540 mm of Y-axis travel, and a standard 25-hp (18.6-kW) spindle. Users can select from four models with X-axis travels to 1300 mm, and from two performance packages: Xi, with a 12,500-rpm spindle and 30-tool ATC for high-production machining applications; and Si, with a choice of 20,000 or 40,000-rpm spindle for die/mold or aerospace machining. Users also have a choice of GE Fanuc or Siemens controls. Also debuting at IMTS will be Mega series horizontal machining centers and new high-production, small-footprint horizontal production centers for mid- to high-volume flexible manufacturing.

Cincinnati Lamb
Ph: 859-534-4600

 


 

High-Torque Spindle

A high-torque spindle said to be the most powerful integral-drive unit in the world will be demonstrated on the a81 horizontal machining center. The spindle's proprietary design eliminates the geared head used in other high-torque units. The result is fast accel/decel with 744 lb-ft (1009 N*m) of torque from zero to 392 rpm and 50 hp (37.5 kW) continuous from 2000 to 5000 rpm, making the CAT-50 (optional HSK-A100) spindle good for machining stainless steels, titanium and nickel-base alloys, and cast irons. Also on display will be several other new machines, including the A66E-5XD, a five-axis machine for production of critical aircraft engine components such as blisks, inducers, and impellers. Features include a single-casting B and C axis that minimizes moving mass and tool interference, a direct-drive motor on the rotary table, and a patented core cooling system and under-race lubrication that cool the spindle from the inside out, eliminating the need for a warm-up cycle and keeping the spindle cooler than its housing.

Makino
Ph: 800-552-3288

 


 

Universal Machining Centers

Designed for parts in the mid- to large-sized range, the U 1130 machining center features a head configuration that utilizes offset spindle placement to provide improved access to parts and minimize the need for extensive fixturing and riser blocks. The machine features X-Y-Z axis travels of 1300, 720, and 630 mm respectively, a table loading capacity of 1000 kg, choice of 12,000 or 18,000-rpm spindles, 16-pocket chain ATC (optional 28-pocket ring unit), and mineral cast base. The head can be activated via CNC or manually over a range of +5º to -95º.

Hermle Machine Co.
Ph: 414-421-9770

 


 

Five-Axis Machines

Three different models of high-speed, five-axis machines for aerospace, automotive, and architectural curtain wall/door and window manufacturing will be on display. PBZ NT and PBZ LC series machining centers are available in standard length up to 14 m, and are equipped with fully programmable and flexible vises that are said to eliminate the need for hard tooling. UBZ NT series machines are built using a modular concept, and can be custom configured for each particular application. All machines offer automatic tool changers, Siemens 840D CNCs, and spindle speed/power options to 30,000 rpm and 134 hp (100 kW).

Handtmann CNC Technologies Inc.
Ph: 847-808-1100

 


 

High-Speed Machines

The Mycenter-3XiF is a vertical machining center said to offer fine surface finish capabilities as well as precision, rigidity, and high-speed cutting capability. Hardened and ground solid box ways on all axes contribute to ±0.000078" (2-µm) positioning accuracy and ±0.000039" (1-µm) repeatability. Other features include a four-speed geared spindle, 18-hp (13.4-kW) AC motor that drives the standard spindle 15,000-rpm spindle (10,000 and 20,000-rpm units optional), Kitamura-Fanuc 16iMB control, and axis travels of 30 X 17.9 X 18.1" (760 X 455 X 460 mm) in X, Y, and Z axes, respectively. Users can select either 180º rotating or side-shuttle style pallet changers, each with two pallets.

Kitamura Machinery of USA Inc.
Ph: 847-520-7755

 


 

Digital Control

Vertical machining centers from Fadal are now available with a choice of three controls, including the GE Fanuc Series18i MB, Siemens Sinumerik 840D, and the new Fadal 104/D digital control. The latter, a standard feature of the company's new VMCs, is a proprietary digital control based on the Windows 2000 Professional operating system. In testing, the 104/D has allowed cutting feed rates up to 10 X those of previous controls without deviating from part tolerances. Other features include an integrated Ethernet connection, on-board data storage capacity of 4 GB, a 15" (380-mm) LCD display, and a new mounting system that provides improved pendant positioning and operator ergonomics. The control can be retrofitted to older VMCs.

Fadal Machining Centers
Ph: 818-407-1400

 


 

Linear Axis Drives

The DMC 75 V Linear vertical machining center uses linear motors on all axes to provide very good dynamic response, contouring precision, and part surface quality. Acceleration of 2 g and rapid traverse speeds of 90 m/min are possible, and position accuracy is enhanced by direct-displacement measurement on all axes. A Heidenhain iTNC 530 CNC and 18,000-rpm, 25-kW (continuous) spindle are standard. Options include a swivel axis in the spindle head and CNC rotary table for simultaneous five-axis machining, as well as ATC software, which tunes the linear feed drives at the push of a button. A larger machine, the DMC 105 V Linear, is also available.

DMG America
Ph: 704-583-1193

 


 

Near-Dry Machining

Chipmaking using a patented Minimum Quantity Lubrication (MQL) system will be the focus at this company's exhibit. The MQL system reduces cutting fluid flow by more than 1000 X versus conventional flood coolant. Coolant flow is measured in milliliters per hour, not gallons per minute, resulting in significant cost savings versus conventional wet machining. Two machines, both built for specifically near-dry machining, will be on display. Making its debut at IMTS is the model RM80H-40 fixed-column horizontal machining center for high-production CNC machining of larger parts. It features an 80-mm diam, 8000-rpm spindle; 40-station ATC; and built-in pallet changer.

Marubeni America Corp.
Ph: 734-354-7940

 


 

Agile VMCs

The V-Star vertical machining center is produced in two models: one for automotive machining, and one for aerospace manufacturing. Equipped with linear motor on all axes, the machines are available in multispindle, three-axis or five-axis versions. Also on display will be the ModuMill, designed for mold and die work. A large gantry-type VMC, the machine is said to achieve metal removal rates of 700 cc/min in steel with a 35-kW (45-kW optional) spindle that operates at speeds to 24,000 rpm.

Forest Liné Machine Inc.
Ph: 973-838-5611

 


 

Vertical Machining Center

The QVM1100 vertical machining center features a casting, ways, ballscrews, and spindle designed using finite-element analysis to improve stiffness and minimize heat effects. The machine's Fanuc 18i MB CNC provides the speed and look-ahead capability to maneuver small block motions and corners at high speeds. The control also features software to allow users to adjust time constant values required for various high-speed machining operations, giving programmers flexibility to adjust finish, accuracy, and cutting time. The machine has a 24 X 43 X 20" (610 X 1100 X 510 mm) work envelope, and is provided with either 12,000 or 20,000-rpm CAT40, BT40, or HSK-63A spindle.

Tong Tai Seiki USA Inc.
Ph: 845-267-5500

 


 

New HMC

The DHP 5000 horizontal machining center combines a 40-hp (30-kW), 14,000-rpm spindle; a 60-tool ATC with 1.5-sec tool-to-tool changes; 1890-ipm (48 m/min) rapid traverses; and a rotary shuttle system that changes the machine's 19.6" (500-mm) square pallets in 7.8 sec. The machine's 40-taper cartridge spindle is supported by four precision-class, permanently lubricated bearings. A cooling system circulates refrigerated oil around the spindle, drive shaft bearings, gears, and motor flanges. Other features include heavy-duty linear motion roller guideways; high-torque, directly coupled servos on all axes; a rear or side-mounted chip conveyor and coolant tank; oil cooler; flood coolant system; through-coolant; and Fanuc 18i-MB CNC.

Daewoo Heavy Industries America
Ph: 973-618-2500

 

This article was first published in the August 2004 edition of Manufacturing Engineering magazine. 

 


Published Date : 8/1/2004

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