On The Radar

Tube Bending Machine Delivers Cost Savings and Productivity
The Elect XL all-electric 12-axis tube bending machine brings levels of productivity, flexibility, and accuracy to the bending of large diameter tube – up to 150mm/6", making it the ideal choice for many demanding automotive, machinery, aerospace, and hydraulic applications.

Flexibility and productivity are both enhanced by the fact that the Elect XL is a multi-stack bender, capable of holding up to eight tool sets, permitting rapid processing of complex parts and faster changeovers, benefits that are not generally associated with the bending of large diameter tubes. The machine can be converted into right- or left-hand configurations, and features both fixed or variable radius bending.

Changeover times are further reduced because all critical machine settings, such as clamping, pressure die, mandrel, etc., are automatically established by Elects XL’s VGP3D software, and managed by the CNC control. The fact that there is no longer any need for time-consuming manual adjustments during setup, results in less scrap.

BLM Group U.S.A. Corp.
Wixom, MI
blmgroup.com

ExpandING Capabilities Offered for ID Grinding
With the recent addition of the Studer CT internal cylindrical grinding machine series, United Grinding has substantially increased their ID grinding capabilities. UGT’s wide range of ID grinding machines now include eight Studer CT machines, as well as the Studer S120, S145, and S151. This ID grinding product line is complemented by the Studer S33 and favoritCNC, both of which feature ID and OD grinding but are configured by many customers as dedicated production ID grinding machines.

Studer’s S120 features a compact footprint, cross-slide design for up to two internal grinding spindles, easy automation, C-axis, a large selection of multi-application spindles, and modular configurability, making this machine ideal for applications like carbon sleeves, hydraulic valve components, fuel injector parts, and other small precision components.
The Studer S145 is perfect for the machining of medium-sized workpieces up to 200mm (7.9”). This machine is especially suited for workshops producing prototypes and small runs, or those involved in toolmaking.

The powerful Studer S151 grinds workpieces up to 300mm (11.8”) in diameter. The sturdy workhead and spindle turret, with up to four grinding spindles, offer a wide variety of application possibilities and are suitable for complete machining in one setup.

Studer’s CT product line is ideal for small- to medium-sized internal cylindrical grinding applications such as die plates, spring collets, toolholding fixtures, hydraulic components, and thread ring gages composed of hard materials like tool steel, carbide, ceramics, and glass.

United Grinding Technologies Inc.
Miamisburg, OH
grinding.com

User-Friendly, Web-Based Tool Selection Software
Profitability from machining a part is dependent on the machine type, cutting tool, cutting conditions and the interaction between them. ITA (Iscar Tool Advisor) is a user-friendly web-based tool selection software that is constructed upon a unique mathematical algorithm. The importance of tool selection is paramount in maximizing productivity and should be, based scientifically, on objective and empirical technical data rather than any conventional intuitive method. 

The ITA application provides an effective process of narrowing down all possible tooling scenarios, taking into account cutting conditions, machine power, metal removal rate, and cutting time. Even for a simple application – such as milling a 90° shoulder of low alloy steel, 10mm height and 10mm width – tools selected by ITA delivered more productivity compared to manual tool selection done by industry experts.

Users can enter only a few mandatory fields – two to six – for quick results, or complete more detailed fields specifying machine parameters, tool diameters, tool type, grade, etc. The application provides the three best tooling options, but can display up to 25 tool recommendations per application search. Results include tool details, insert details, cutting conditions, power, metal removal rate, and cutting time. Each search has a printable recommendation report valuable to the user.

Iscar Metals
Arlington, TX
iscarmetals.com

Taper-Removal Cutting Head, Large- Format Waterjet Cutting
The 80X JetMachining Center is a highly accurate, large-format machine equipped with a Tilt-A-Jet taper-removal cutting head and the latest advance in direct drive technology.The 80X JetMachining Center is ideal for large-scale precision machining of larger or multiple parts, and is equipped with Intelli-TRAX traction drive, which not only ensures higher accuracy but also enables expansion of the cutting envelope in increments of about 6ft. The drive is fully enclosed inside coated steel covers, making the 80X a robust and reliable system that is well suited to harsh environments while requiring little maintenance. The Intelli-TRAX traction drive enables faster traverse speeds, which can greatly reduce the throughput times when machining multiple and nested parts.

The 80X JetMachining Center features an X-Y cutting travel of 165" x 80" (4,191mm x 2,032mm), and comes standard with the OMAX Intelli-MAX Software Suite, which runs on the Windows 7 Ultimate operating system. The system can calculate the precision of a toolpath at more than 2,000 points per inch, allowing for complete control over the motion of an abrasivejet, and enabling precise, rapid machining.

Omax Corp.
Kent, WA
omax.com

Solid Carbide Tread Mills
An expanded line of solid carbide thread mills from the THREADS-ALL Solid Carbide Thread Mills Program is now available. The thread mills require minimal tooling and quickly adapt to a wide range of threading requirements, delivering thread quality and extended tool life. Requiring only eight standard tool sizes, #10, 1/4, 5/16, 3/8, 7/16, 1/2, 5/8, and 3/4, it is now possible to quickly, economically produce 100+ commonly produced screw thread designations including UNC, UNF, STI UNC, STI UNF, UNEF, UNS, UNJC, UNJF, M, and MJ. In addition, THREADS-ALL tools provide total control over pitch diameter limits including 2B, 3B, 3BG, and all oversize variants.

The THREADS-ALL program is designed for difficult-to-cut materials, up to 58Rc, including stainless steels, titanium, and Inconel.

THREADS-ALL tools will meet the most demanding quality standards. Designed through an in-depth analysis of thread dimensions and tolerances, together with an advanced profile geometry correction in the finish grind, the Emuge thread mill range deliver true-to-gage threads.

The THREADS-ALL Solid Carbide Thread Mills Program also includes miniature tools for dependable, easy machining of difficult materials. Miniature size thread mills provide a reliable threading solution and are available in 10 sizes ranging from 0 to STI 8.

Emuge Corp.
W. Boylston, MA
emuge.com

Load on One Side, Perform Heavy Cutting on the Other
The VC430 vertical machining center features a 25hp motor that generates up to 12,000rpm at the spindle and 123.6ft/lb of torque. With a stationary table, workpieces may be loaded on one side while parts are machined on the other. Each VC430 has a compact footprint of 116.5" x 93.3", while the pallet measures 28.0" x 18.7" with a 660 lb load capacity. Table indexing time, including clamp and unclamp, is 5 seconds.

The spindle is mounted directly to the Fanuc spindle motor for rapid acceleration/deceleration and reduced vibration during high-speed operation.  ISO #40 tools are housed in a 40-station, double-arm magazine with 1.3 second tool-to-tool times. The ATC’s bi-directional magazine automatically selects the shortest path to minimize out-of-cut times. The dual-contact Big Plus tool mounting system provides direct contact between the machine spindle face and toolholder flange face. The greater rigidity results in precision and longer tool life.

The VC430 is constructed with a one-piece Meehanite casting that is heavily ribbed to withstand the heat and forces associated with heavy cutting conditions. Linear motion guideways and high speed servomotors enable high rapid-axis movements, with traverses of 1,574ipm along the X and Y axes, and 1,259ipm along the Z.

Doosan Infracore
Pine Brook, NJ
infracoremt.com

Highly Accurate Absolute Position Measurement
The MLW series of long stroke linear position sensors, for highly accurately absolute position measurement of displacements up to 1.2m, are available in ranges of 300mm (11.8") to 1,200mm (39.4"). The sensor can be mounted externally or embedded into the cylinder or actuator body.

Utilizing magnetostrictive technology, the MLW sensors operate by transmitting a current pulse through its tube, which is reflected by a moveable permanent magnet. The sensor measures the time of flight to determine the position of the magnet on the tube. The time-based position measurement is translated into an output signal.

Powered by 24VDC, the MLW series of long stroke linear position sensors have less than ±0.25% linearity and ±0.01% repeatability over the full scale with outputs that include analog voltage, current, and SSI. As these magnetostrictive transducers provide absolute output, no data is lost should power be interrupted.

As the sensor probe is sealed up to 5,000psi, the MLW sensors can be packaged within hydraulic cylinders as a closed loop feedback device. With an optional float kit for the magnet, the MLW sensors can be used to sense the level of liquid inside of a tank.

Macro Sensors
Pennsauken, NJ
astsensors.com

Abrasive Belt Machining Saves Time on Grinding Applications
The Mini-Dynafile II is a lightweight air-powered abrasive belt machine for grinding, blending, and deburring in normally inaccessible areas.

Running at 25,000rpm, the Mini-Dynafile II utilizes 1/8" to 1/2" wide x 12" long abrasive belts. The tool accepts coated and abrasive impregnated non-woven nylon belts. The multi-positioning grinding head pivots 180°, ideal for grinding into hard-to-reach areas. The lightweight, composite housing reduces vibration and is thermal insulated to prevent cold air transmission to the operator’s hands. The air motor is also adjustable to the most comfortable throttle lever position. Eight different contact arms are also available for a wide variety of distinct applications.  The tool is excellent for finishing and deburring within narrow openings, and for blending stainless steel and grinding right angle welds.

A Mini-Dynafile II Versatility Kit is also offered, and includes the tool, contact arms, various abrasive belts, and a threaded collet for easy conversion to a Die Grinder.

Dynabrade Inc.
Clarence, NY
dynabrade.com

Lighter Duty Drag Conveyor
The lighter-duty version of PRAB’s proven drag conveyor technology has been redesign in a low-profile format to be easily integrated under certain types of CNC machining centers for removal of chips at the source.

PRAB’s lighter-duty drag conveyor is a very economic replacement alternative to factory-installed 1.5" pitch steel belt conveyors, which can often require frequent maintenance due to premature wear. The specially designed drag conveyor also features a grated end plate to allow metalworking fluid transferred from chips to exit the conveyor and collect in a liquid-tight trough. 

In addition to added reliability due to less moving parts, PRAB’s drag conveyor offers zero carryover to improve productivity.

PRAB
Kalamazoo, MI
prab.com

Truing, Dressing on Diamond, CBN Single, Multiple Wheel Packs
The FC-250EX and FC-700EX Automatic Diamond and CBN Wheel Truing and Dressing Machines are designed for truing and dressing of flats, angles, and radii on diamond and CBN single wheels and multiple wheel packs. They feature PLC-controlled, automatic dressing cycles with servo-driven dressing wheel infeed, power swing, and oscillation. The machines can be fully enclosed for operator safety and dust control.

Use of the Models FC-250EX and FC-700EX allow for increased efficiency and accuracy by profiling, modifying profiles, and truing wheels off-line of the production grinding machinery. The machines are simple to operate; quick, accurate, and cost effective; and feature wheel diameter capacities up to 28" (700mm).

The heavy-duty one piece cast iron base provides extra rigidity and minimizes vibration. Standard features include ExVision, a computer-driven vision system with a software program specifically designed for the FC-250EX and FC-700EX and their various applications; an automatic power zoom; and a 2-axis DRO for measurement.

Rush Machinery Inc.
Rushville, NY
rushmachinery.com

Multi-tasking Production Center Offers Main, Counter Spindles
The Hyperturn 45 is a high-performance, multi-task production turning/milling center with main and counter spindles, two tool systems, stable Y-axis, water-cooled spindle motors, dynamic digital drives, a thermo-symmetrical machine construction, and compact dimensions makes the HT 45 a high-capability production machine.

In addition to the two spindles, two turret tool systems with a total of up to 24 driven tools and a VDI25 rapid change system, as well as several automation options, the HT 45 includes a Y axis with a 70mm travel in the upper slide system and a Z2 axis in the lower slide system. A 45mm (standard 32mm) through-hole counter spindle is available for longer parts.

Very flexible, the machine can be applied in a wide range of sectors: from general mechanical engineering, job shops, and the aerospace industry.

The main and counter spindles are equipped with integrated water-cooled spindle motors with high drive power of 15kW, a maximum speed of 7,000rpm, and an even higher torque of 100Nm. The counter spindle’s nose is also larger: With A2-5, the counter spindle can be used to remove bar stock parts with a diameter of up to 45mm. Maximum turning diameter is 300mm.

With the Siemens control and drive system, the Sinumerik 840D-sl, programming the machine is quick and easy.

Emco Maier Corp.
Columbus, OH
emcomaier-usa.com