On the radar

Honing system for precision, small-bore parts

The small-diameter HTE honing system produces precise bore geometry and surface finish while eliminating problems from bad tool-to-part alignment and excessive feed rates. The tube hone’s one-piece base maintains excellent tool/part alignment, and the feed system protects against tool overloading. A Windows-based touch-screen control stores tool-specific force limits and run settings.

Three fixturing options are available: a manual chuck, a pneumatic chuck, and a V-type chain vise for parts with ODs up to 6" (150mm). A travelling steady rest comes standard. An optional guide pot automatically guides the honing tool straight into the bore. Standard, non-CE guarding includes easily removable covers for each end of the honed part, while optional CE guarding includes a light curtain and wire mesh enclosure.

FYI
HTE specs

• Max. part length: 60" (1,524mm)
• ID range: 0.16" to 0.75" (4mm to 19mm)
• Spindle speed: 5rpm to 2,100rpm
• Stroke motors: 1-98ft/min. and 1-30m/min.

Material applications

• Inconel
• 410 stainless steel
• Zirconium
• Titanium

Sunnen Prodcuts Co.
www.sunnen.com
IMTS 2014 booth #N-7400

 

External laser scanner

The Probe Laser 20.8 (HP-L-20.8), a new generation external laser scanner for use with the ROMER Absolute Arm, replaces the CMS108 and offers improved performance on complex surfaces and workpieces made of challenging, shiny materials.

The portable coordinate measuring system with certified scanning system accuracy has an adjustable scanning width, a line length of up to 230mm, and a scan rate of up to 150,000 points per second. It is the first laser scanner for the ROMER Absolute Arm tcertified to ISO 10360-8.

Fully integrated with the ROMER Absolute Arm, the HP-L-20.8 does not require additional cables or external controllers. It automatically adapts to the surface color or reflectivity of materials such as machined, cast, stamped, or forged metals, plastics, and carbon fiber.

Hexagon Metrology
www.hexagonmetrology.us
IMTS 2014 booth #E-5202

 

Tool lifecycle management software

Software manufacturer TDM Systems will showcase its tool lifecycle management (TLM) solutions at IMTS 2014, demonstrating its TDM 4.7 software package in its booth, Walter’s booth (W-1700), and Parlec’s booth (W-2300). As production becomes more digital and networked, the software aims to cover a wide variety of process steps in tool-based machining, from data and inventory management to provision of simulation-ready 3D data. TLM advantages range from defining the tools, to using them in planning, to ensuring a seamless use in production, according to the company.

TDM Systems
www.tdmsystems.com
IMTS 2014 booth #E-3264

 

Extra-large pitch tool line

The Mega Line is a new range of solutions for heavy-duty applications with extra-large pitches. Formerly only available as special items, Mega Line tools are now available as standard items in a wide range of profiles.

Encompassing a pitch range of 10mm to 24mm, the tools feature an insert design with a new geometry. These tools provide increased levels of stability and support during machining owing to the tailored support of the toolholder to each insert profile. In addition, the line boasts a clamping system with an indented insert edge that is designed to withstand increased cutting forces during machining and prevent insert rotation.

Offered in VKX tough, submicron grade, the inserts are available in size IC 5/8" MG with one cutting edge for improved machining of large pitches. Standard inserts are available for the following profiles: ISO, round (DIN 20400), trapez, ACME, stub ACME, American Buttress (ABUT), Metric Buttress (Säge), and specials.

Vargus Ltd.
www.vargususa.com
IMTS 2014 booth #W-2245

 

New vises to be introduced

Kurt Manufacturing will introduce its expanded lineup of advanced workholding products at IMTS 2014.

Cobra is a 5-axis dovetail vise designed for aggressive 5-axis machining. It provides up to 4,000 lb of precision force without distorting workpieces. A 0.5" movable jaw stroke allows precise raw stock clamping with less material preparation for fast positioning in the vise jaw. It is 2" wide and handles part widths from 1.375" to 1.800".

Chameleon is designed for tool room, knee mill applications, and use on smaller CNC machining tables. With up to 5,000 lb of precision clamping force, the Chameleon provides more clamping options than previous standard vises. It is 3.5" wide with a 4" jaw opening and mounts easily upright and on both sides. The Chameleon features predrilled sine holes for use with a receiver vise to achieve 30°, 45°, and 60° angle settings.

Sidewinder SDW35 is 3.5" wide and designed for mounting to the back of 6" and 8" single station vises. It has an increased 4" wide jaw opening, with up to 5,000 lb of clamping force, and provides vertical workholding for second operation machining in the same setup. This redesigned vise, like its predecessor, reduces setup time for second operation vertical machining when integrated with existing machine tools and vises. Both models have robust 80,000psi ductile iron bodies.

VersatileLock features a one-piece body and stationary jaw design. It provides 0.0005" part clamping repeatability. The VersatileLock is now available in four 8" vise models that have a 10" jaw opening. The 3800 vises are replacing Kurt’s PT series:

• Manual standard
• Manual reverse
• Hydraulic standard
• Hydraulic reverse

Kurt Mfg. Co.
www.kurtworkholding.com
IMTS 2014 booth #W-2423

 

High-precision 5-axis machining center

YASDA H40i 5-axis high-precision machining center’s rigid structure includes roller-type guideways with a retainer on the X-Y-Z axes for high-speed operations and high acceleration. A Z-axis ball screw positioned center of the guideways enables an accurate fast feed. The center’s bed is a ribbed cast iron unit with good vibration damping characteristics. Three-point mounting maintains static accuracy.

The H40i is equipped with direct drive (DD) motors in the rotary axis for simultaneous high-speed 5-axis machining with A- and B-axis rotational speeds of 100rpm and 75rpm, respectively. A high-performance spindle provies optimal power and torque for machining a wide range of metal alloys. The spindle is guaranteed under normal use for up to 20,000 hours, and it minimizes thermal distortion for optimal tool performance and high surface finishes.

Specifications

• X-axis travel: 875mm
• Y-axis travel: 740mm
• Z-axis travel: 685mm
• B-axis travel: 230° (-185° to 45°)
• Table working surface: 400mm x 400mm
• Table loading capacity: 200kg (200Nm)
• Spindle max. speed: 20,000rpm
• Direct drive motor:
  • A-axis: 100rpm/min.
  • B-axis 75rpm/min.

Methods Machine Tools Inc.
www.methodsmachine.com
IMTS 2014 booth #S-9119

 

Large through-bore turning center

Rigid, accurate, and thermally stable, the ST-55 is a heavy-duty, large-bore turning center with twin-chuck capability, high-torque spindle, and 12.5" (318mm) diameter through-bore. It has a maximum cutting capacity of 25.5" x 80" (648mm x 2,032mm), with swings of 35.5" (876mm) over the front apron, and 25.5" (648mm) over the cross slide. The ST-55 comes equipped with a large, hydraulically clamped 12-station bolt-on style tool turret that accepts 7.25" (184mm) split boring bar holders, as well as standard BOT toolholders. A heavy sheet-metal enclosure provides complete protection from chips and coolant during machining, while a pair of wide sliding doors provides unobstructed access to the front chuck and main work area, both from the front and the top, allowing easy overhead loading.

The rear chuck area is also fully enclosed during machining, but a wide sliding door and swinging end panel provide access from the front and top, simplifying chuck installation and adjustment.

ST-55 standard equipment

• Rigid tapping
• Color remote jog handle
• 15" color LCD monitor
• Built in USB connectivity
• High-productivity options
• Belt-type chip conveyor
• High-torque live tooling with C-axis
• High-pressure coolant system

Haas Automation Inc.
www.haascnc.com
IMTS 2014 booth #S-8119

 

Robotic bin-picking automation

IMTS visitors can watch a smart part-handling solution that can remove randomly placed items from a container and place them accurately in a machine production line – using 3D image recognition software, a robot, and a sophisticated handling strategy.

Specially developed grippers with additional axes enable collision-free access and the removal of items from the container, and subsequently allow for precise positioning of the item into a fixture or pallet.

The custom bin-picking solution, designed for components weighing between 1kg and 50kg, delivers the potential for productivity and efficiency increases in a range of parts-producing industries with the cycle times and high availability rates manufacturers require.

The advantages of this scalable automation process include increased productivity, improved machine utilization rates, reduction of the need for additional machines to achieve desired plant production volumes, and more consistent production quality. The beginning of a production line is the key point where picking from the bin is necessary.

The 3D laser scanner precisely recognizes the components for picking. Outside light of any type in the production building has no effect on the ability to pick a part.

Liebherr Automation Systems
www.liebherr-us.com
IMTS 2014, booth #N-6930

 

Advanced technology in cutting tools

The new Walter Blaxx F5055 slitting cutter incorporates similar technology to the Walter Cut SX grooving systems that is based on self-gripping, form-locking indexable inserts. The SX parting and grooving system features coolant supply through the tool.

Two new standard solid carbide deep-hole drills will be introduced at IMTS 2014. The Walter Titex X.treme D40 and the X.treme D50 drills provide 40xD and 50xD drilling depths, respectively. XD technology, which stands for extremely deep, enables holes to be drilled in one operation without pecking in steel, cast iron, or non-ferrous metals.

New Tiger.tec Silver high-performance cutting material, with new positive rake 7° and 11° geometries for cast-iron machining, will also be on hand. New geometries include a classic flat top with a stepped plateau and a strong geometry for maximum process reliability, even for interrupted cuts.

Walter will also be highlighting other technologies, such as counterboring and precision boring tools, through-hole taps, cutting fluids, and coolants.

Walter USA LLC
www.walter-tools.com/us
IMTS 2014 booth #W-1700

 

VERICUT integration with NOVO

CGTech has integrated its software with Kennametal’s NOVO application. As a result, users can directly download a Kennametal tool assembly and use it within VERICUT software in fewer steps compared to manual configuration. CGTech will demonstrate this new capability at IMTS 2014 using the latest version of VERICUT, version 7.3.

VERICUT simulation applications

• Drilling and trimming
• Parallel kinematic hexapods
• Waterjet
• Riveting
• Robots
• Mill/turn

CGTECH
www.cgtech.com
IMTS 2014 booth #E-3346

 

Big bore turning center

Based on Hi-Tech 550, 700, and 850 horizontal turning machines, the Hi-Tech BB & BB+ turning centers’ spindle torque permits productive cutting in tough material up to 36" in diameter and more than 216" in length. A 4-speed automatic transmission system allows low-speed, high-torque turning and high-speed machining. Ultra-precision recuperative cylindrical roller bearings and multiple thrust angular bearings have been incorporated to enable hard turning of tough alloys. The spindle can be geared down for extra torque. Integrated bed frames of fine-grain meehanite castings minimize heat distortion. Thermal displacement control prevents deteriorated machining tolerances, and lubrication is constantly applied to the spindle bearing, prolonging machine life and precision. Each turning center is controlled by the Fanuc 0i control with Manual Guide i.

At-A-Glance

• Max. cutting diameter: 36” (fits large air chucks at front and back of spindles)
• Spindle holes: 7.08" to 14.57" in diameter
  • HT-550BB: 7.08" through-spindle hole
  • HT-700BB: 7.08"
  • HT-700BB+: 11.61"
  • HT-850BB+: 14.57"
• Spindle noses: ASA A2-15 to A2-20
• Long bed spindle versions available from 84" to 216"

Hwacheon Machinery America
www.hwacheon.com
IMTS 2014 booth #S-8129

 

Extended-range contouring head

Upsized features can be turned on Giddings & Lewis boring mills with the introduction of a larger-range integrated contouring head that handles up to 980mm ID (38.6") and 780mm (30.7") OD. Rated at 56kW (75hp), the integrated head has a standard Kennametal KM80 or Sandvik Coromant Capto C8 interface to reduce tooling costs. It loads tools via the machine’s automatic tool changer for faster processing without operator involvement. The head accommodates tools up to 600mm long and weighing up to 18kg. It can produce features with repeatability of ±0.005mm and accuracy of ±0.015mm. In addition, the live boring spindle can use 50-taper tools up to 750mm long, and an auto-coupler provides the interface for feedout tools, such as programmable boring bars.

The contouring spindle’s U-axis slide stroke of 440mm provides the ability to produce small- or large-diameter features in a single setup on a boring mill, without head changing or manual intervention, allowing complex features to be machined with greatly reduced cycle time and labor. The contouring head can produce features such as valve seats, seal faces, O-ring grooves, straight/tapered threads, chamfers, and external profiles.

A touch probe can be used in the boring spindle or on an auxiliary arm for in-process or post-process measurement of part features machined by either spindle. Standard services, such as coolant supply with high pressure (40 bar / 580psi), are plumbed through the contouring head to eliminate manual intervention and ensure maximum tool life.

Fives
www.fivesgroup.com
IMTS 2014 booth #N-7018

 

High-production, precision turning automatic lathe

Developed for high production precision turning, the 42mm Traub TNK42 Fixed Headstock Automatic produces turned parts up to 250mm in length and geometrically complex workpieces in large and medium volumes.

The TNK42 offers high production rates with a 5.5m2 footprint without the bar loader. It has two tool turrets, a main spindle with C-axis and 42mm bar capacity (7,000rpm, maximum 29kW and 65Nm), and a swivel counter spindle with C-axis for extensive rear end machining.

A vertical design permits unobstructed chip flow and good ergonomics for setup operations. The stable, vertical cast machine bed is mounted on a heavy cast iron machine base, providing excellent damping properties for high-precision cutting.

Specifications

Upper tool turret

• 10 stations with slide travels of 140mm and 300mm in the Z-axis
• Turret indexing via NC-rotary axis with a direct measuring system
• Upper tool carrier equippable with up to 20 tools

Lower tool turret

• 9 stations with functions identical to upper turret
• Lower cross-slide serves as a swivel counter- spindle for rear-end machining
• 7,000rpm (max. 12kW and 22.5Nm) counter spindle with 42mm spindle clearance

INDEX Corp.
www.indextraub.com
IMTS 2014 booth #S-8136

 

Range of CNC machine tools

FEMCO’s IMTS 2014 booth will feature the HL-55/2000, a dynamic, heavy-duty boxway CNC lathe that will be integrated to a Fanuc robot emulating a production wheel turning cell. In addition, the HL-35DMSY multi-axis CNC lathe equipped with a sub-spindle, Y-axis, C-axis, and a 23-station, live tool dual-disk turret will demonstrate its ability to machine complex parts efficiently and accurately. In addition, FEMCO will demonstrate the HL-25DM CNC lathe that allows for quick setups and fast tool change times. Finally, the BMC110R2 boring mill, featuring a fourth axis rotary table and a 60-station automatic tool changer, will demonstrate its multi-sided machining capabilities.

FEMCO Inc.
www.femcousa.com
IMTS 2014 booth #S-8021

 

Minimum quantity lubrication system

The Quantum minimum quantity lubrication (MQL) system, when integrated with CNC machines and other automated equipment, uses discrete inputs or serial communication, which allows users to program controlled amounts of lubricant for automated machining processes. The system features one to 12 outputs that can be independently configured as either MQL or air blow-off outputs. Air controls for MQL outputs can be controlled manually or automatically, and the air blow-off outputs assist in removing chips from the machining area. Built around positive-displacement pumps, the Quantum provides accurate and consistent lubricant output.

Unist Inc.
www.unist.com
IMTS 2014 booth #N-7088

 

Cloud-enabled CAM

New cloud capabilities of ESPRIT Cloud-Enabled CAM software enable programmers to select tools based on part features in minutes, without flipping through catalogues to find tooling. Using the ESPRIT MachiningCloud Connection, programmers can access complete and up-to-date tooling product data, which eliminates the need for manual tool creation. ESPRIT also includes time-saving upgrades in the areas of tooling automation, simulation, and shop-floor collaboration. With improved features for editing and numbering tools, the software simplifies tool management and cuts programming time.

An interactive website including video is available at http://bit.ly/1thPynO.

DP Technology Corp.
www.dptechnology.com
IMTS 2014 booth #E-3210

 

150W horizontal boring machine

Premiering at IMTS 2014, the KB-150W horizontal boring machine meets an assortment of requirements.

The KB-150-W Series is a T-type boring machine for streamlined, multi-face machining of large-sized work pieces. The combination of linear guiding and hydrostatic systems provides high dynamics, improving machining capability, while the highly rigid structure and boring spindle design ensures long-term machine precision.

This machine offers high performance, high feed forces of the cross axis and quill spindle, resulting in high stock removal capacity. Its heavy-duty design and high dynamics provide optimum power and cutting speed capacity. With all main machine elements made of cast iron, the rigid, robust, and stable design provides for high precision. The machine has been developed using the finite elements method and tested for maximum rigidity to reduce vibration problems to a minimum. It has a user-friendly machine configuration which allows the operator to be next to the working area, enabling easy part setting and measuring operations. In addition, a full enclosure is available.

The rigid quill spindle is mounted on large-angular-contact ball bearings, lubricated with an air-oil system. The quill’s maximum thermal stability is due to a complete cooling system of the bearing, gearbox, and spindle motor systems, This, combined with a high-power transmission, guarantees high stock removal capacity as well as high feed force.

The rotary table rotates by high-precision bearing and low-friction surfaces for smaller load capacities and hydrostatic bearings for larger load capacities. These rotation systems ensure no surface wear, meaning it is optimal for highly demanding and accurate processing. Table rotation is via a dual-drive system using a large external crown gear with helical gearing and zero-backlash precision gearbox. The hydraulic clamping system allows for maximum tangential clamping force up to 140,000Nm (103,244 lb-ft).

Specifications
In addition to the EM80, BLM Group will also address options for tube processing, including laser tube cutting, tube and wire benders, tube end formers, and cold saws.

SORALUCE America Inc.
www.soraluce-america.com
IMTS 2014 booth #S-8692

 

5-axis machining and automation

The smallest machine in the line of G-series universal machining centers, the G-350 requires less floor space than other machines with the same work zone. The machine’s spindle design accommodates very long tools (365mm or 14.3") with no interference. The maximum part is a 600mm cylinder (diameter: 23.6") and 500mm in height (diameter: 19.7").

The mid-size G-550T features a turning option for parts up to 900mm in cylinder (diameter: 35.4"). The high-speed table rotates at 800rpm while compensating for uneven loads. Maximum part height is 730mm, and longest tool is 500mm (19.6"). Both models feature a table with 225° of rotation in the A-axis and continuous 360° in B-axis. It is possible to completely invert the table for upside-down machining while chips free-fall from the part.

GROB Systems
www.grobgroup.com
IMTS 2014 booth #S-9490