There’s still plenty of good old fashioned metal (and material) removal going on in tens of thousands of US metalcutting shops and plants around the country. A visit to the huge South Hall at McCormick Place during IMTS 2016 is where you will find booths overflowing with advanced conventional turning and milling machines, multitasking CNC lathes, towering boring mills, and precision Swiss automatic lathes under power along with the automation needed to carve more-efficient production out of industries as diverse as aerospace, automotive, medical, job shop and contract manufacturing, and general engineering. In the two short years since the last IMTS, a lot has happened, but nothing more than the emergence of the disruptive technologies ushered in by the Internet of Things (IoT) and the potential of hybrid additive/subtractive machine technology. It all adds up to a revolution, not an evolution. Capturing real-time data from machines and processes facilitated by the MT Connect standard will significantly advance smart manufacturing and provide real-time intelligence about machine OEE, predictive maintenance, and ultimately plant-wide efficiency.
There’s probably more than one grizzled old metalworking industry veteran who would like nothing better than to be around long enough to see how smart manufacturing and hybrid AM technology will play out. Here’s some of what you can expect to see.
Mazak Exhibit Emulates Advanced Smart Factory
“Our booth will be symbolic of a Mazak Smart Factory, combining all the elements of advanced manufacturing technology,” said Brian Papke, chairman, Mazak Corp. (Florence, KY). “This year will mark the largest amount of advanced technologies we’ve ever brought to IMTS. We will demonstrate a host of new high-level developments in full digital factory integration, a Smart Box digital integration launch platform, and Industrial Internet of Things (IIoT) connectivity—in addition to new machining and automation systems—all of which will prepare manufacturers for the next industrial revolution.”
Mazak will show over 20 advanced manufacturing cells and systems. Among these will be the company’s latest developments in multitasking and five-axis machine tools with single-setup, done-in-one part-processing capabilities crucial for tomorrow’s smart factories. Additionally, the company will unveil the next generation of its hybrid additive/subtractive multitasking technology, along with new software and accessories that give multitasking machines even more functionality and multiple-process power. Various types and levels of smart factory automation will be demonstrated, including gantry systems, robotics, the proven Palletech system and the new compact Vertical Stacking System for standalone machining centers.
“We will demonstrate the user-friendly programming capabilities and processing speed of our Mazatrol SmoothX and Mazatrol SmoothG CNC controls,” said Papke. “Smooth controls feature new algorithms that result in faster speeds, finer accuracy, and better finishes, producing machining results that are as much as 7–30% faster with the biggest impact on the most complex five-axis machining.” For automated tool changing, Mazak is introducing its new Tooltech compact tool system that stores big, heavy and large-diameter tools within a very small amount of required floor space. As a shop’s tooling needs increase, Tooltech’s storage capacity can easily expand to as many as five levels and the capacity to hold 250 tools.
All the new and advanced machining and automation systems in the Mazak IMTS booth will be under power and running real-world part demonstrations. For example, Mazak will unveil its new Variaxis i-800T multitasking machine and demonstrate it cutting an aerospace jet engine blisk using 5ME’s cryogenic cooling system. Other applications experts from Mazak’s Value Inspired Partners (VIP) program will be on hand to discuss and demonstrate total manufacturing solutions and part-processing improvements.
Mitsui Seiki Strategy Based on High-Precision Machining
Mitsui Seiki USA Inc. (Franklin Lakes, NJ) will exhibit three machines that demonstrate its ability to provide high-precision technology that meets the most exacting machining standards for aerospace. “All three machines are our Vertex-style machines that machine a decimal point tighter,” said Scott Walker. “One machine will have a direct drive [DD] motor machine that is capable of grinding like a jig grinder in addition to precision milling capability. The second machine will be a single-blade Vertex milling machine aimed at the Ti-Aluminide market, and the third will be the new Vertex 55X-H additive/subtractive machine with a powder metal feeder and a laser assembly head with shield gas being demonstrated machining a damaged jet engine blade in need of repair.”
The Vertex 55X-H, which is making its debut at IMTS, is built on a precision Mitsui Seiki VMC platform with a spindle-adapted laser DED (Direct Energy Deposition) / powder feed nozzle. The nozzle loads into the toolchanger like any conventional tool and is changed automatically via the CNC program prompts. For milling the 3D-printed surface or internal feature, a milling/drilling tool replaces it and aspects of the workpiece are machined conventionally. The process is under full adaptive control as the part is made, moving back and forth between additive and subtractive while maintaining common center line integrity to produce the intended surface or feature with sub 15-µm accuracy within the work envelope. Users can choose either a CAT or HSK 15,000–30,000-rpm spindle. “The Vertex 55X-H hybrid machine is well-suited for the repair of a number of different types of airfoil parts, such as high-pressure turbine and compressor blades, low pressure blades, blisks/IBRs and impellers for the aerospace, power generation, and oil and gas industries,” said Walker. ”
Hurco Invites Visitors to Race to Profitability Indy-500 Style
Hurco will capture the spirit of Indianapolis, the headquarters location of the company since its founding in 1968, and the home to the single largest one-day sporting event, the Indianapolis 500. Visitors will be able to race RC IndyCars on a Hurco created scaled-down version of the Indianapolis Motor Speedway, complete with a blimp and leaderboard. Attendees can check www.hurco.com/imts to see what hours open racing will take place and/or to register for a spot to race competitively. Prizes will also be announced on the website.
“In addition to sponsoring IndyCar team Ed Carpenter Racing [ECR] with drivers Ed Carpenter and Josef Newgarden, the team uses our CNC machines at their machine shop,” said Maggie Smith, marketing manager. “Since we know that both racing and machining rely on speed, power, and precision to succeed, we thought the race to profitability theme would be a fun way to showcase how Hurco CNC machines make our customers more profitable,” said Smith.
Hurco will exhibit several new models of CNC machines in addition to their newest technology invention that will enable owners of Hurco vertical machining centers to transform their WinMax part programs to a 3D-printed rapid prototype directly on their CNC machine using an optional spindle-powered wireless accessory. The 3D print head adapter, which extrudes plastic PLA filament, will be exhibited at the Hurco booth and at the Additive Conference.
Turned Parts Complete in One Clamping
“Machining parts complete in one clamping from bar stock or castings is still the primary strength of much of today’s turning-based machining,” said Jeffrey Reinert, president and CEO, Index Corp. (Noblesville, IN). “Our technology enables manufacturers to drop precision parts complete in one setup, run untended, get more machining hours out of the week, 24/7, if they so desire, and be competitive globally. And that’s where our advanced technology for US-based companies comes into play with products like our new extended version of the Index MS16 Plus.” The six-spindle CNC lathe simultaneously accomplishes two or more operations, dropping complete parts in very short cycles. The machine features six independent liquid-cooled, hollow-shaft CNC spindle drives each capable of 7000 rpm, a main spindle drive with increased stiffness, and hydrostatic guide bushings on each carrier slide, which eliminate wear and transmission of vibration to the tool. “With liquid cooling, spindle and drum cooling is accomplished away from the work area, making the machine more stable, able to run at higher rpm, with more torque, if needed, according to the needs of the material being cut,” said Reinert. Typical applications for the MS16 Plus are found in the automotive, aircraft, hydraulics, and valve industries.
The new INDEX G220 Turn-Mill Center which will be demonstrated generating bevel gears, includes a motorized five-axis 18,000-rpm (max.) milling spindle and a tool turret with Y axis, providing maximum machining flexibility for turning and milling complex parts in a single setup from bar stock up to 90-mm diameter, chuck diameter of 210 mm. Users in the precision parts industries including automotive, aerospace, and mechanical engineering will benefit from the high-accuracy done-in-one capability of the machine.
The new TRAUB TNL32-11 sliding/fixed headstock automatic lathe, to be introduced at IMTS, has a headstock moving in the Z axis, an upper and identical lower turret with X, Y, and Z axes, and a counter spindle movable in the X and Z directions. The innovative machine offers a new front working attachment which sits on an additional cross-slide moving in the X and Z axes, providing the user with further, freely positionable tools and enables the use of up to three tools, simultaneously and independently of each other. The 11-axis machine saves machining time—especially for components with a high proportion of drilling.
DMG MORI Offers an Innovative Path to Production
DMG MORI (Hoffman Estates, IL) will demonstrate 27 high-tech machine tools and innovative technologies, including the US premieres of the Ultrasonic 20 linear and the Sprint 32|8 as well as the locally produced DMU 50 with PH 150 and NHX 4000 2nd Generation with RPP. “We want to show a path to production that gives visitors a broader view of how a common part can be manufactured using a number of different ways of automating the process,” said Adam Hansel, CTO, DMG MORI. “For example, one way might be using a turning center and three-axis machining center. Another way might be using a five-axis machine with a pallet changer, or the same mill and lathe tended by a robot with peripheral processes like deburring, laser marking, or gaging added. And still another might be with a mill-turn multitasking machine with a built-in NC robot.”
DMG MORI will highlight production in its North American manufacturing facility in Davis, CA, which has a production capacity of 100 machines per month that includes horizontal machining centers, five-axis universal milling machines, vertical mills, and CNC turning centers. At IMTS, customers will experience live demonstrations on locally manufactured machines and be able to take a virtual tour of the factory, discovering how DMG MORI builds its machines seamlessly from design to production.
To support its global customer base, DMG MORI will highlight its global Spare Parts availability with over $240 million worth of inventory and more than 275,000 unique spare part numbers in the global logistics network, DMG MORI guarantees a fast worldwide delivery directly from the manufacturer. The inventory includes new parts as well as replacement parts. There is also spare part availability for early models from 1970 or later.
Innovative areas include additive manufacturing with two DMG MORI machine models, the Lasertec 65 3D and Lasertec 4300 3D, hybrids that enable machining of complex components. In the field of additive manufacturing DMG MORI uses a blown powder deposition welding process with laser, as it has long been used in principle for repair work in the tool making or turbine technology branches. In this process the powder is melted onto the base material by the laser beam. DMG MORI also builds up layer by layer, but only uses the powder where it is actually needed. This reduces the necessary quantity of powder significantly.
Okuma Opens its Customers to Possibilities
Okuma America Corp. (Charlotte, NC) will exhibit 17 machines from its variety of high-tech and core product categories. “If you take the time to count, the machines have a total of 72 axes,” said Tim Thiessen, vice president-sales. “Inside of the booth, we will detail how our customers can benefit from the Open Possibilities that our OSP control and broad product line offer. Our high-tech products include vertical and horizontal multitasking machining centers and five axis machining centers and vertical turning lathes.” Okuma will have demonstration parts in the booth for aerospace and medical applications. “If we’re making an aerospace part on a Multus, we’ll also feature an automotive or medical on a video screen being machined on the same machine,” said Thiessen.
At IMTS, Okuma’s MU-5000V vertical machining center will be shown cutting an actuator and intake manifold on steel, aluminum and titanium. The MU-5000V is excellent for five-axis multisided machining. It features standard ball-screw cooling and a highly rigid left-right, mobile trunnion table to support high-precision and heavy-duty cutting power in a compact footprint. Maximum productivity is achieved with a wide array of automation options. The unique design places the pallet changes at the back of the machine, allowing easy connection to a Palletace flexible manufacturing system, pallet pool, large capacity ATC and robots to deliver high productivity in addition to high accuracy.
Simulators in the Okuma booth will demonstrate the intuitive nature of the OSP control. “We’ll also be showing our machine tool apps which can be made by the user, much like smart phone apps. We make a number of apps as do our distributors and customers. They are basically little applications that may address a certain need or desire to get certain information out of the control or create a special procedure like a lock-out procedure. We’ll also be showing our OSP Suite, which may seem to be like an app, but they are kind of like widgets on the control, a calculator, a materials calculator, messaging, or an eco-friendly suite recognizes that certain motors and pumps can be turned off if not needed to save money or be more energy efficient for savings,” said Thiessen.
Three A’s Hold Sway at Methods Machine Tools
According to Bryon Deysher, president and CEO, Methods Machine Tools Inc. (Sudbury, MA) focuses its product development focus on the three A’s: Automation, Additive, and Accuracy. “With builder partners such as Nakamura-Tome, FANUC, Yasda, Kiwa, Feeler, and now 3D Systems, we are in a unique position to bring the latest technologies to both subtractive and additive solutions for our customers serving aerospace, defense, medical, firearms, and automotive industries.”
To enable its customers to deal with the shortage of skilled labor in the manufacturing workforce, Methods Machine has expanded its Methods Automation group to provide customers with more unattended processes with Nakamura, FANUC Robodrill, FANUC EDM, and Feeler Products. Nakamura, Yasda, and Kiwa offer built-in automation.
“Additive manufacturing solutions in both metal and nonmetal composites from 3D Systems enable our customers to meet these demands of time-to-market pressure,” said Deysher. “We will feature the most advanced 3D Additive manufacturing solution with the new ProX DMP 320 Metal Printer. Feeler will feature a variety of prismatic part and full five-axis solutions, and FANUC will introduce new models in high productivity solutions on both EDM and Robodrill platforms—all intended to meet critical time-to-market requirements.”
Methods Machine’s expanded automation offerings will include FANUC robots providing automated deburring and inspection systems in addition to our normal machine tending solutions. “We will also be displaying a high-speed gantry system on a Nakamura WT150 platform and a Kiwa KMH300 six-pallet system as solutions with built-in automation,” said Deysher. “The Yasda PX30 will address both production high-accuracy requirements with positioning feedback resolution of 0.1 µm and untended capability with 33 pallets and full five-axis capability. We will also feature three Yasda Jig Borer class platforms for Die Mold and ultra-precision requirements.”
Machining Centers and Cells
Gantry-Style Five-Axis VMC
PG5 five-axis double-column vertical machining center is designed for large-size and heavy workpieces for aerospace, automotive, die and mold, and job-shop industries. The five-axis machining center has a built-in 60-hp (45-kW), 15,000-rpm, HSK A100 spindle, a maximum table load of 115,000 lb (52,163 kg). Table sizes are available up to 137 × 236″ (3.5 × 6.0 m). PG5 uses Hiwin C3 class ballscrews with dual ballscrews in the X and Z axes. All linear axes use ballscrews with cooling systems to avoid heat generation caused by ballscrew movement. Ballscrew cooling promotes dynamic three-axis performance by maintaining a constant temperature.
Mighty USA Inc.
Web site: www.mightyviper.com
Portable VMC for Second Operations
Trak 2OP portable VMC is designed for secondary machining operations, streamlining a shop’s workflow by bringing an additional spindle quickly and easily to reduce overall cycle/throughput times. It performs the secondary operation within the cycle time of the primary operation. The Trak 2OP improves labor utilization enabling an operator who is idled by the cycle time of his primary machine to simultaneously run a CNC secondary operation machine. Product planning/scheduling are reduced by having parts completed before they leave the workcenter. The Trak 2OP has a 2.5 × 4′ (0.76 × 1.4-m) footprint, contains an eight-station automatic toolchanger, and can run G-code. It uses proven ProtoTrak CNC technology with easy-to-learn and use conversational language programming. Programs can be generated either at the machine or remotely to perform tasks normally associated with secondary operations.
Web site: www.southwesternindustries.com
Horizontal, Vertical, Five-Axis Machining Centers
Mycenter-HX250iG HMC is able to drill, mill, bore, tap, thread, and turn light to heavy-duty materials in an ultra-compact 6 × 9.7′ (1.8 × 2.9-m) footprint machine with high-speed rapids of 2362 ipm (60 m/min). A two-station APC is automation-ready and field-expandable up to 10 pallets for untended operation potential. The standard full fourth-axis rotary table features a Direct Drive motor enabling speeds of 300 rpm (108,000 deg/min) rapids. Part cycle times are dramatically reduced and backlash eliminated on the rigid machining platform. A powerful, high-torque, 15-hp (11-kW) #30 taper, dual-contact spindle is standard. Control is supplied by Kitamura’s advanced icon-driven Arumatik-Mi CNC. Also being exhibited are the all-new Mycenter-2XD Sparkchanger VMC with 180° rotating two-station APC and Kitamura’s newest addition to their five-axis line-up, the Mytrunnion-4G simultaneous VMC.
Kitamura Machinery of USA Inc.
Web site: www.kitamura-machinery.com
Production Efficient Machining Centers
Two new machining centers, the QP5X-400 five-axis VMC machining center and the FVM-3016DCL II next-generation, premier double-column bridge machine, demonstrate increased production efficiency for automation. The new QP5X-400 is a 40-taper, high-speed VMC featuring five-axis simultaneous or 4+1 axis applications with 25-hp (18-kW) 12,000-rpm spindle. Tool capacity is 30+1. The machine provides fast interpolation, with a high-linear rapid speed of 1417 / 1417 / 1181 ipm (36/36/28 m/min) and features the FANUC 0iMF control. The new FVM-3016DCL II Series double-column bridge machine with a heavy-duty structure offers a 6000-rpm, two-speed gearbox spindle. The 35-hp (26-kW) motor, with a two-speed gearbox, can generate 719 N•m of torque, ample power output and a high-speed range for fine-cutting results. The FANUC 0i-MD is the standard control. The machine’s table size is 122 × 57″ (3.1 × 1.4 m) with a table load of 17,600 lb (7983 kg).
Chevalier Machinery Inc.
Web site: www.chevalierusa.com
Three Third-Generation VMCs
DNM series third-generation vertical machining centers feature faster spindle acceleration and deceleration rates and an upgraded FANUC 0iMF control for quicker processing speed. The new DNM series comprises three machines, the DNM 4500, 5700, and 6700, stepped up in size and capacity. In general the series offers larger cutting space by 6%, bigger table sizes by 14%, and heavier loads by 25% while maintaining the same overall footprint as the previous generation. Direct-coupled, through-coolant type spindles are standard, providing 8000 rpm (15/11 kW) and 12,000 rpm (18.5/11 kW). Other specifications include a Big Plus 40-taper tool interface and table sizes of 1000 × 450 mm; 1300 × 570 mm; and 1500 × 670 mm. Maximum table loads are 600, 1000, and 1300 kg. Rigid roller guideways and a new grease-based lubrication system require a refill only every 3–6 months.
Doosan Machine Tools America
Web site: www.doosanmachinetools.com
Multiaxis Machining Centers, 3D Print Head
New machines include the high speed double-column bridge type BX40i; the new open bed HTM30i CNC mill; the new five-axis VC600i CNC machining center; and popular models from the other product lines, such as the five-axis VMX42SWi CNC machining center, the three-axis VMX6030i, the trunnion style five-axis VM10Ui, the high-speed three-axis VMX24HSi CNC machine equipped with an Erowa robot, the general performance three-axis VM20i, the TMX10MYSi slant-bed lathe with live tooling and subspindle, and the general purpose TM6i slant-bed lathe. Hurco’s new 3D print head adapter that connects to Hurco CNC mills for accelerated prototyping will be demonstrated.
Hurco Companies Inc.
Web site: www.hurco.com
Productive Five-Axis Machining
Heller’s Power Cutting Universal swivel head unit provides 44-kW power and 242 N•m torque with HSK 63 spindle taper. Available in several machine models, the C head provides fifth axis for maximum process dependability with system availability over 90% without restrictions in terms of chip removal rate. Power is available at any spatial angle. As a result, the Heller machining centers are capable of heavy-duty cutting, combined milling and drilling operations or five-sided machining in a single setup in five-axis simultaneous milling. Machines are thermally stable due to the construction and achieve precision down to the micron range. This level of precision down to the micron range is provided by absolute encoded, direct measuring systems, high-resolution rotary encoders, and YRT bearings with integrated measuring system.
Heller Machine Tools
Web site: www.heller-machines.us
Gun Barrel Single-Point Rifling Machine
DeHoff CNC G536-C1 machine cuts rifling grooves into gun barrel blanks as an alternative to button rifling, creating the rifling groove using a single-point cutter without inducing any additional stresses into the barrel. The G536-C1 can perform cut rifling on barrels ranging from 22 to 50 caliber and from 4 to 30″ (102–762 mm) in length. Twist rates range from one rotation every 4″ (102 mm) to one rotation every 60″ (1524 mm). The custom-built machine can cut rifle at variable twist rates along the length of the barrel, also known as “gain twist.” Other programmable operations include traverse rate, depth of cut, and number of grooves. The bespoke machine features a cast-iron drillhead base with hardened and ground steel boxways, plus hand-scraped and fitted saddle, gibs, and strap for superior vibration damping, extended tool life, and improved accuracy.
Kays Engineering Inc.
Web site: www.kays-dehoff.com
Multispindle Horizontal Machining Centers
Samag machining centers include multispindle horizontal machining centers and deep-hole drilling machines that are used primarily for large block milling and deep-hole drilling for applications in the automotive powertrain, off-highway, moldmaking, and other industries. Multispindle machines include the MFZ Series for large workpieces; the smaller, modular WBM Series for up to six-spindle deep drilling; and the combination TFZ Series. The latter offers users the ability to bore and mill complex cubical workpieces on four sides with a single clamping. On the largest standard machine, large-scale moldmaking is possible, with a maximum drilling depth of 2300 mm, 65-mm bore, and a 50-ton capacity worktable. Samag machining centers are now available in North America from German Machine Tools of America (GMTA).
Web site: www.gmtamerica.com
T-Bed Boring Mills
T-bed boring mills with high accuracy and cutting capacity are designed and priced for job shops. T-bed or travelling column boring mills move the column in the Z-direction and the tables in X. Engineered for flat-floor installation, small footprint and low ceiling clearance, the first models of the machine are configured with a 10,000-kg capacity, 1250 × 1400-mm contouring rotary table. Optional 1400 × 1800-mm tables are available. The machines are sized to fit the smaller physical plant of most job shops and toolrooms. The new Giddings & Lewis RT 130 and RT 155 boring mills feature 130 or 155-mm diameter gear-driven spindles available with up to 45 kW and 3380 N•/m torque. All spindles are size 50-taper tool, and equipped with Giddings & Lewis’ exclusive spindle thermal growth compensation. Standard X-Y-Z axis travels are 2000, 1500 and 1600 mm with W-axis spindle travel of 750 mm.
Fives Giddings & Lewis LLC
Web site: www.fivesgroup.com
Adaptive Automation, Machining Solutions
Makino’s machining centers and engineering solutions merge to create adaptive automation systems for any market or production demand, including automotive, die/mold, aerospace, medical and general production markets. New versions of the a51nx and a61nx horizontal machining centers provide expanded machining capacity through productivity-enhancing features, including vision broken tool detection, enhanced levels of inertia active control and Geometric Intelligence technologies. For midsize part applications, the new a71nx is a high-speed 50 taper, 500-mm HMC with a standard direct-drive NC rotary table and other nx-Series next-generation technologies will be introduced. A Makino Machining Complex (MMC2) pallet-handling system with an a61nx five-axis horizontal machining center showcases high-mix, low-volume production with improved machine utilization and exceptionally high material-removal rates. A custom, automated system includes the newly updated a51nx horizontal machine with 60-tool magazine and Erowa robot multi-ERM system.
Web site: www.makino.com
Five-Axis Profiling and Head Porting
The UMC-750P is designed for profiling and porting five-axis machined complex parts. The 40-taper vertical machining center has 30 × 20 × 20” (762 × 508 × 508-mm) travels and a unique arrangement of the rotary axes. A powerful 8100-rpm inline direct-drive spindle (12,000-rpm optional) driven by a 30-hp (22-kW) vector drive system comes standard with a 40+1 tool side-mount toolchanger. High-speed machining control software is standard, and the machine includes Dynamic Work Offsets, Tool Center Point Control, and Haas Automation’s Wireless Intuitive Probing System to simplify job setup. Rotary axis configuration is well-suited for such complex shapes as turbine blades. Included A-frame support allows running parts in a tombstone setup, like on an HMC, by loading up multiple sides of a tombstone to gain more parts per cycle.
Haas Automation Inc.
Web site: www.haascnc.com
High-Performance Machining, Automation
Kao Ming double-column multiface KMC 421SR-H features four guideways, high-rigidity structure and double boxway construction to ensure performance and reliability suitable for both high-speed and heavy-duty cutting of extra large parts. New Quaser HX400 horizontal CNC machining center features advanced engineering design combined with 35-hp (26-kW), 15,000-rpm spindle, and 60-tool ATC system. One FMC system from Quaser for lights-out automation features high-speed HX-504 HMC with eight-pallet shuttle-type FMC system. The 40-hp (30-kW) spindle and 2360 ipm (60 m/min) feed rate offers notable cutting capability and efficiency. A second FMC system features a versatile MF-500U five-axis machining center with 28 pallets FMC system from Quaser that is ideal for machining complicated medical and aerospace parts.
Web site: www.ymtcnc.com
High MRR Five-Axis HMC
Toyoda’s FA1050 five-axis HMC delivers the highest removal rate in its class along with the lowest required maintenance for longer tool and machine life. Capabilities include all boring, end milling, finish cutting, threading, U-axis machining while maintaining accuracy. FA1050 five-axis machine begins with a solid cast iron base combined with full-plate clamping mechanism with up to 26,000 lb (11,793 kg) of table clamp force. Spindle support from four heavy-duty bearings include double-row cylindrical roller bearings and dual angular contact thrust bearings to eliminate vibration. The boxway machine accelerates rapidly and performs consistently with its 60-hp (45-kW) spindle drive motor at 6000 rpm of geared head cutting. The FA1050 Five-Axis’ solid structure delivers versatile and accurate machining on difficult materials such as Hastelloy, Inconel and Nichrome.
Web site: www.toyodausa.com
Multi-Way Production Cell
LSA 8-250 is a multiway production cell with horizontal indexing axis for three-sided machining in one clamping. The LSA concept arises from the clamping position of the workpiece, the required machine flexibility, accessibility and setup and the number of radial units that are adjustable and pivotable. They adapt to changing workpiece shapes.The unit is a trunnion rotary design with eight machining positions.
Web site: www.hydromat.com
Digital Five-Axis VMC
Bridgeport XT 630 F-Axis VMC is a digital machine tool meant to achieve maximum capacity and performance in aerospace, mold and die, medical and automotive applications. It is offered with a Siemens 840D-SL control. X-Y-Z axis travels are 762 × 630 × 600 mm. Standard are Big Plus CT40 spindle, 15,000-rpm direct-coupled spindle with oil chiller, coolant chip flush system, 40-tool swing arm, ATC prewiring for Renishaw part probe, through-ballscrew chiller, and A and C-axis encoder. Also exhibited are the Conquest V480 APC VMC with integrated automatic pallet changer and the Conquest V1000 with Mitsubishi M70V control with NAVI MILL programming.
Web site: www.hardinge.com
Electric Spindle Models
HES electric spindle models can be coupled with various spindle tapers and utilized in either dry or flood coolant cutting conditions. These spindles are integral motor/spindles and are not traditional geared speeder heads. Operating with NSK’s control, there are two models, one capable of up to 50,000 rpm and the other up to 80,000 rpm.
Web site: www.nskamericacorp.com
Low-Cost Production of Small Batches
New VM 9 modular turning machine covers a broad spectrum of applications with combined turning, milling, and drilling technologies and an intelligent machine design. The machining area and workpiece spindle, fitted at the bottom of the machine, ensure short tooling times and maximum flexibility for small-batch production of a wide variety of individual parts. Mineralit polymer concrete base provides excellent damping properties, and compound slides on the X and Z axes ensure machining quality, high-speed processing, and short idle times. The main spindle provides the 83-kW power rating and torque of 990 N•m. Chucked components up to maximum diameter of 450 mm can be machined. The tool turret can be fitted with up to 12 tool positions, depending on the tool interface (BMT or VDI) and can also be equipped with driven tools to carry out drilling or milling operations.
Web site: www.emag.com
Expanded Swiss Machines Introduced
Sprint 32|5 and Sprint 32|8 automatic lathes are equipped with a SWISSTYPEkit for machining bar material with diameters of up to 1.3″ (33 mm), which enables both short and long turning on one machine—with setup times of less than 30 minutes. To achieve this, the spindle stroke is lengthened from 4 to 10″ (101.6–254 mm). The Sprint 32|8 is ideally suited to machining of more complex workpieces. It has an additional Y axis for the second tool carrier plus a C axis for the counter-spindle. The Sprint 32|8 is equipped with a total of six linear axes and two C axes and has 28 tool pockets. This expansion option of the machine has a third independent tool carrier that is suitable for deep-hole drilling on the main spindle, for example, and that also enables four-axis machining on the main spindle.
Web site: www.dmgmori.com
Two Production Turning Centers
The new FBL-230+Gantry Robotics features a 45° slant-bed, rigid box ways structure. Its ribbed Meehanite cast-iron mono-blocking foundation provides excellent damping absorption during heavy machining. The series features an 8” (203-mm) chuck, 21.6″ (320-mm) maximum swing diameter, up to 12.2″ (310-mm) maximum turning diameter and a maximum turning length up to 15.9″ (404 mm). For running large quantity production, the servo gantry loader provides uninterrupted automatic loading/unloading of parts. The maximum part dimension is up to 6.7″ (170 mm) and 11-lb (5-kg) weight. The newly designed, multifunctional FNL-220LSY Series multiaxis lathe features turning and milling with first and second operations in one machine. The series features high-torque live tooling, with full C axis for the main and subspindle. Bar capacity is 2.0″ (51 mm) for the main spindle, maximum cutting diameter is 12.6″ (320 mm) with a turning length of 20.1″ (508 mm).
Chevalier Machinery Inc.
Web site: www.chevalierusa.com
Parallel Twin-Spindle Lathe
Compact CSD-300 twin spindle lathe is designed for quick and accurate turning of a variety of heavy parts Ø 200 x 100 mm, weighing 5 kg + with hydraulic clamping loader and 8–10″ (203–254-mm) capacity workholding chucks. The turret achieves speeds of 0.26 sec./index, while the CSD-300’s dual Ø 100-mm spindles (A2-6) are equipped with 15/20 hp (11/14.9-kW) high-output spindle motors. Robot alignment to spindle center line is achieved with the CSD-300’s three-axis gantry robot control. Environmentally friendly, the CSD-300 features an energy-saving auto shut-off LED light. User-friendly features include a rear or optional side-positioned discharge chip conveyor and maintenance items all conveniently located in one section on the machine.
Fuji Machine America Corp.
Web site: www.fujimachine.com
Sliding/Fixed Headstock 11-Axis Automatic Lathe
Traub TNL32-11 sliding/fixed headstock automatic lathe has a headstock moving in the Z axis, an upper and identical lower turret with X, Y, and Z axes, and a counter spindle movable in the X and Z directions. The new front-working attachment, which sits on an additional cross-slide moving in the X and Z axes, provides the user with freely positionable tools and enables the use of up to three tools, simultaneously and independently of each other. The front-working attachment features a CNC circular axis. By the interpolation of the rotary axis with the X axis and the C axis of the main spindle, the front-working attachment can also be used in the Y direction using an interpolated Y axis. The particular benefit: when a drilling tool needs to be corrected to exact center, the necessary corrections can be simply performed via the CNC controller.
Web site: www.indextraub.com
Laser Swiss Debuts
The new Tsugami SS207-5AX LaserSwiss is a 20-mm five-axis Swiss-type CNC lathe with B-axis control, which combines Swiss CNC machining with laser cutting on one machine in a single setup. All operations are programmed and driven from the machine’s FANUC 31i-B5 CNC and the machine allows manufacturers to consider part designs that couldn’t be machined with conventional methods. The Tsugami BW209Z, B0205-III and P034H machines are also new to the IMTS this year. The BW209Z is a 20-mm capacity split-slide CNC precision Swiss style lathe with a 10,000-rpm main spindle speed and a 12,000 rpm back spindle speed. The nine-axis machine can have three cutting tools, cutting the part simultaneously. The new B0205 is an enhanced version of the previous generation machine. The P034H is a 3-mm four-axis Swiss type lathe is designed for micro machining mass production of tiny precision parts.
Tsugami/Rem Sales LLC
Web site: www.remsales.com
Large-Part Swiss Machining
A new 10-axis Swiss-type automatic lathe is designed for machining complex, large-diameter parts with high efficiency. Rigid machine construction handles bar stock up to 1 1/2″ (38-mm) diameter. With B-axis versatility, complex parts can be produced in one operation with the precision and accuracy required by quality critical applications in a variety of industries. Star’s proprietary motion control system further optimizes machining operations and significantly reduces idle machine time. In addition, Star CNC will introduce two additional machines: the SV-20R and SR-32JII with upgraded capabilities.
Star CNC Machine Tool Corp.
Web site: www.starcnc.com
Blazing Fast Swiss-Type Lathe
Swiss DT 13 high-performance Swiss-type lathe features five linear axes, two C axes, and an array of productivity-enhancing functions. With its maximum feed rates of 35 mm/min and L-type kinematics, the Swiss DT 13 is fast, delivering remarkable chip-to-chip times. Its spindles can be operated at up to 15,000 rpm, a speed typically reserved for more high-end machines. The Swiss DT 13’s motorized synchronous guide bushing, which can reach maximum spindle speed, improves machining accuracy, workpiece surface finish, and can save valuable time when machining long parts. Many peripherals for the Swiss DT 13 are compatible with Tornos GT and ST machines, and the Tornos Machine Interface (TMI) is very user friendly.
Web site: www.tornos.com
Lathes and Mills
Precision 9–12″ (228–304-mm) metalworking lathes and mills utilize Meehanite bed castings, Allen-Bradley controls, German and Japanese precision-made bearings.
South Bend Lathe Co.
Web site: www.southbendlathe.com
Vertical Turning Centers
V Series vertical turning centers with six table sizes from 800 to 2500 mm are designed specifically for shops seeking a dependable, multipurpose lathe for pumps, valves, gears, bearings, compressors, wheel hubs, and jet engine housings, among others. “By adding the V Series, starting with 800-mm tables, to our existing VTC Series of vertical turning cetners, with swings up to 9 m, we are positioned to offer manufacturers the broadest and best range of turning solutions,” said Kevin Lichtenberg, Fives Giddings & Lewis president. High metal-removal rates and high-precision, the V Series lathes incorporate a hydrostatic ram to maximize rigidity for heavy, chatter-free cutting and improved part finish. Dual-scale feedback delivers precision and ensures parallelism while hydraulic cylinder elevation addes secure 100 k•N of mechanical clamping force per side.
Fives Giddings & Lewis LLC
Web site: www.fivesgroup.com
Compact Haas CNC Chucker Lathe
Ultracompact CL-1 CNC chucker lathe with an integrated bar feeder delivers high-volume machining of small precision parts like those found in the communications, aerospace, medical, and dental industries. The CL-1 is equipped with a 5-hp (3.7-kW) spindle that turns to 6000 rpm. The spindle’s threaded 5C collet nose easily handles bar stock up to 1″ (25.4-mm) diameter, and features an automatic air-closer. For higher torque applications, an optional 8-hp (5.9-kW), 6000-rpm spindle is available that provides double the torque of the standard spindle, as well as higher accel/decel rates. The CL-1’s high-speed cross slide and servo-driven eight-station turret guarantee fast chip-to-chip times and short cycle times, while offering quick setup and good clearance. The turret uses industry-standard gang-style tooling on 1/2″ (13-mm) centers. Machine X, Z travels are 12 × 8″ (305 × 203 mm), and brushless servos on both axes yield cutting feeds to 500 ipm (12.7 m/min) and rapids to 757 ipm (19.2 m/min). The user-friendly Haas control makes set up and operation up simple.
Haas Automation Inc.
Web site: www.haascnc.com
Large Vertical Turning Center
The EVC16100s is a large, rugged vertical turning center that has been designed for machining a variety of materials including cast iron, aluminum, steel, and composites. The EVC160100s has a 55″ (1397-mm) chuck and swing of 63″ (1600 mm). The machine has Z-axis travel of 39″ (990 mm) and a 60-hp (45-kW) motor. The machine weighs 55,000 lb (24,947 kg) resulting in rigidity and excellent part finish. Control is supplied by a FANUC 0i-TF CNC with a 10″ (254-mm) screen and USB, PCMCIA, and Ethernet interfaces.
SMTCL USA Inc.
Web site: www.smtcl-americas.com
CNC Turning Center Debut
Talent 51 MSY CNC turning center features the Hardinge quick-change collet-ready spindle which offers better part accuracy and surface finish than conventional spindles. The machine is equipped with five tooling, subspindle and Y axis for complete part operations. The Talent 51 MSY features a 5000-rpm, 25-hp (18.6-kW) main spindle with 2″ (51-mm) bar capacity. Turning diameter is 12.2″ (310 mm) and maximum turning length is 24.9″ (632 mm). The 12-station turret uses ¾” (19-mm) square shank and 1¼” (31.75-mm) round shank tooling, and 6000-rpm live tooling capability is standard. The turret provides one half station index for up to 24 tools. Control is the FANUC 0i-TF CNC.
Web site: www.hardinge.com
Multitasking with Cryogenic Technology
Variaxis i-800T multitasking machine significantly boosts productivity for aerospace applications. The Variaxis i-800T features full five-axis milling and turning capabilities and integrated 5ME liquid nitrogen cryogenics technology. Cryogenic cooling prevents the detrimental white layers typically generated when machining tough materials such as titanium, nickel, Invar, and other exotics. The machine features an 80-tool magazine for continuous uninterrupted productivity and a 10,000-rpm, CAT-50 spindle for milling speed and power. Trunnion-style tilting table and multitasking capability allow users to reduce the inaccuracies that occur when moving parts across multiple workstations, eliminating work-in-process inventory and increasing overall throughput. Mazak’s cryogenics freeze cutting tools from the inside out and keep their cutting tips/edges in a frozen state while workpiece materials remain in an ambient one. In doing so, absolutely zero heat or thermal affects transfer into workpieces so that they maintain their base material integrity.
Web site: www.mazakusa.com
Five-Axis Turn Mill Center
Index G220 Turn-Mill Center includes a motorized five-axis 18,000-rpm (max.) milling spindle and a tool turret with Y axis, providing maximum machining flexibility for turning and milling complex parts in a single setup from bar stock up to 90-mm diameter, chuck diameter 210 mm. Distance between spindles is 1280 mm, maximum turning length is 1000 mm. Users in the precision parts industries including automotive, aerospace, and mechanical engineering will benefit from the high-accuracy done-in-one capability of the machine. The G220 will be demonstrated cutting bevel gears from bar stock. The cutting method is similar to the Klingelnberg gear generating method and makes use of the G220’s Y-B axis provided in the milling head. The process is ideal for smaller, 0.6 to 4 module, size bevel gears as it can produce high-quality gears—front and back—faster than conventional bevel gear machines.
Web site: www.indextraub.com
Collet-Style Rotary Transfer Machine
Hydromat EPIC R/T 25-12 is a collet-style rotary transfer machine for precision metal cutting of stock sizes up to 1.0” (25.4-mm) round, 0.75” (19-mm) hex, and 0.50” (12.7 mm) square with a part length up to 4” (101.6 mm). This machine utilizes 12 horizontal tool spindles and has the capacity of up to six vertical tool spindles, featuring up to 18 tools in the cut at once. It also has the rigidity to handle all components and all material types within its work envelope. Hydromat’s non-rotating bar stock design provides quiet, vibration-free operation. The EPIC machine features advanced APM (Advanced Productivity Management) system software, a suite of data reporting platforms that provide 24/7 access to utilization, availability, performance, quality, and OEE information from any industrial asset on the plant floor.
Web site: www.hydromat.com
This article was first published in the August 2016 edition of Manufacturing Engineering magazine.