August 2008 Edition

IMTS COUNTDOWN

2008 IMTS Show Promises to be Bigger and Better than Ever

Chicago will be the place for the biggest machining trade show in the U.S. It promises more floor space, exhibitors, and attendees than any previous show.

The 27th International Manufacturing Technology Show is set for September 8 through 13 at McCormick Place Chicago. More than 1,200 exhibiting companies will occupy 1.2 million ft² of the convention center. This guide provides floorplans for the different exhibit halls, descriptions of the technologies shown in each hall, and a look at some of the products that will be on display.

IMTS exhibits are organized in pavilions that address specific industries, technologies, and solutions:

• Abrasive Machining, Sawing, Finishing
• Controls & CAD/CAM
• EDM
• Gear Generation
• Machine Components, Cleaning, Environmental
• Metal Cutting
• Metal Forming & Fabricating, Lasers
• Quality Assurance
• Tooling and Workholding Systems.

Along with the exhibitors, there will be manufacturing and business forums such as "Where Technology and Business Connect," which brings together experts from the industry.

The Emerging Technology Center – ETC – exhibits technology research and development efforts by university and research laboratories, displaying science-based manufacturing and innovative processes, including MTConnect, a communication protocol standard for passing data between devices, equipment, and higher level applications.

The Innovation Center at the show showcases thought-provoking presentations by industry experts in a theater-style venue during the six days of the show. The Innovation Center/Theme Day lineup includes

• Automotive Day, Monday, September 8
• Quality Day, Tuesday, September 9
• Aerospace/Aeronautics Day, Wednesday, September 10
• Power Generation/Green Day, Thursday, September 11
• Medical Day, Friday, September 12
• Job Shop Day, Saturday, September 13

A complete list of Innovation Center programs and the daily schedules is available at www.imts.com .

Company Says Inserts Adhere to its 3P Philosophy

The 3P Sumo Line of tools and inserts is based on the company’s concept of Premium Productivity Products – 3P – for better Productivity, Profitability, and Performance. The highlight of the 3P product introduction is Sumo Tec, which features a series of tungsten carbide grades to meet the contemporary machining challenges of the metal cutting industry. The series of carbide grades are designed for metal cutting performance in drilling, milling, turning, and grooving applications. Complementing SUMO TEC, the company developed a series of tools and inserts branded Sumo Lines.

Iscar Metals, Booth F-2010

CNC System Handles Up to 31 Axes

The new Sinumerik 840D solution line is CNC technology that, according to the manufacturer, increases performance and user productivity. The 840D sl is a universal and flexible CNC system featuring the Sinamics S120 drives that can be used for up to 31 axes. It is a distributed, scalable, open, and inter-connecting system offering a wide range of specialized functions for milling, drilling, turning, grinding, and handling technologies. The 840D offers users features that increase productivity on the manufacturing floor in high-speed and five-axis aerospace machining.

Siemens Energy & Automation, Booth D-4208

“Sharp” Drill Bit Maintenance

The CNC XPS-16 automatic CNC drill sharpener sharpens conical, four facet, standard split point and radius split points 90° to 150° with one touch. It stores dozens of special drill point geometries in memory, and sharpens HSS, cobalt, and carbide 2 flute twist drills with diameters from 1/8" to 5/8". It automatically sizes, aligns, and sharpens in one setup. Standard accessories include a 180 grit CBN wheel, a 220 grit diamond wheel, a 180 grit hone brush, and a 115V vacuum. Optional accessories include a 260 grit diamond wheel, a 320 grit diamond wheel, a 120 grit hone brush, and a machine cover.

Darex, Booth B-7102 and Booth F-2236

Drawing a Blank

Demonstrations of how purchasing machine-ready blanks allows dramatic reductions in the cost of labor, leading to lower overall part costs and greater operational efficiency, will take place at the show. According to the company, machine-ready blanks allow production to start immediately, with blanks loading into the machine without prep operations such as sawing, grinding, flattening, or squaring. The company offers machine-ready blanks that arrive with tolerances guaranteed as close as ±0.0005" dimensionally and ±0.0002" flatness, squareness, and parallelism. The blanks are processed using double-disc grinding, blanchard grinding, duplex milling, and sub operations, such as flattening, deburring, and surface improvement. Materials available include aluminum, tool steel, stainless, controlled-expansion alloys, brass, ceramics, copper, spring steel, titanium, ductile iron, plastics, carbon steels and tubes, and high-temperature and nickel alloys.

TCI Precision Metals, Booth F-2107

Rotary Table Has Patented “Worm”

The 5AX-200II CNC Rotary Table has a patented carbide worm system that uses a carbide worm screw and ion nitrided worm wheel, rather than a conventional bronze or bronze alloy actuation mechanism. The result is an eight-times reduction in friction and wear, according to the company. The worm screw consists of a less brittle V-grade form of carbide, while the worm gear is ion nitrided to a depth of 0.1mm and an external surface hardness of 68 R_C. The table allows for the machining of five sides of a workpiece, and is suitable for medical and aerospace 5-axis work. It features a drop trunion and clamping torque of 588/490Nm. The maximum work load is 176 lb.

Lyndex-Nikken, Booth F-2221

VMCs Offer Spindle Speeds from 6,000 to 20,000 rpm

The traveling X-axis VMCs feature spindle choices of 6,000 to 20,000 rpm, plus high torque of up to 453 ft-lb. Engineered with X-axis travel in the spindle and a supported table in the Y-axis, the line supports production or one-off work in materials from aluminum to titanium. The heavyweight, compact machine features a vibration-damping cast-iron platform engineered with an electrical cabinet inside the column structure. With maximum X-Y-Z travels of 51.2", 29.5", and 27.6", it can handle parts up to 3,870 lb. The line includes four models combining a Z-axis of 700mm, X-axis of 900mm or 1,300mm, and Y-axis of 600mm or 750mm. Spindle choices include 22 kW, 40 taper belt-driven – 10,000 rpm; 37 kW, 50 taper belt-driven – 6,000 rpm; or 28 kW, HSK63A motorized – 20,000 rpm. Tool changer capacity for the 40-taper and HSK spindles is 30 pockets; 24 pockets for the 50 taper spindle. Dual-arm tool changers maximize in-cut time with tool-to-tool time of 2.5 sec.

MAG Cincinnati, Booth A-8218

VMC with Large Work Cubes in Small Footprints

The VM Series of machining centers have large work cubes and small footprints. The models added to the VM Series include more Y-axis travel, a longer table, and a faster spindle. In addition to the general purpose VM10, VM20, and VM30, the VM Series includes two specialty machines, the VM1P and the VM1G. The VM1P is a production machine with fast rapids, fast tool changes, and the ability to tap up to 4,000 rpm. The VM1G is designed to machine graphite with positive air flow to remove the dust, a tight enclosure, and a standard 20,000 rpm spindle.

Hurco Companies, Booth A-8117

Boring Head Displays Adjustments

A boring head with an optoelectronic adjustment measuring system and digital display with 0.0001" accuracy in the diameter range 0.118" to 4.882" will be on display. It has maintenance-free automatic balance compensation and flexible Screw Fit connections for all spindle adaptations. The modular design offers a large diameter range for precision digital boring. The basic head can hold multiple tools, such as solid carbide boring bars which cover the working range 0.079" to 0.394" and various indexable insert boring bars for ranges from 0.394" to 2.677". For larger diameters, there are two bridges made from aluminium. The inner coolant supply throughout the tool is consistent both with boring bars and bridges. The MQL technology requirements were considered when designing the coolant channels. The diameter range above 0.394" has only two indexable insert sizes needed, and these are three-edge ANSI W-type inserts. Balance allows speeds up to 16,000 rpm, reducing machining times.

Walter USA Inc., Booth F-2257

Turnkey High-speed Drill Units

The SSM4 and SSM5 drill units are designed with a modified configuration which uses two servo motors, which are synchronized for through-hole applications. The units are capable of high-speed drilling and tapping to produce class 3 thread production in a single pass. They feature infinite control of feed rates and rpms allowing program control of the dual servos with a ball screw movement for rigid tapping. The turnkey units come with Mitsubishi servo motors as standard equipment; other manufacturer’s servo motors and controls are available upon request. The touch screen control monitor features conversational software and active diagnostics. The drill units are available with feed motors ranging from 2.8 ft-lb of torque at 3,000 rpm to 15.85 ft-lb at 2,000 rpm, and spindle motors rated from 15.86 ft-lb at 2,000 rpm to 36.95 ft-lb at 2,000 rpm.

Sugino Corp., Booth F-2137

No Outriggers with this Boring Mill

The Johnford BMC-110 is a 50-taper horizontal boring mill. The 55,000 lb machine has a Meehanite cast iron structure and features a moving column for the Z-axis and a moving table for the X-axis only. This design allows rigidity, accuracy, and support of the table over X-axis travel. The moving column design eliminates the need for outriggers or outboard supportive ways to support high table loads. The X-axis is supported by the base with no overhang of the table. It has precision ground and induction hardened box ways in the X-, Y-, and Z-axes. All mating surfaces are coated with Turcite-B and hand scraped for fit. The ways are force lubricated via a pressurized automatic oil lubrication system. Positioning is carried out by 2.5"-diameter, pre-tensioned ballscrews and servo motors. Heidenhain linear scales in all linear axes are standard. The 4.33" quill is made from chrome-moly steel alloy. The spindle and sleeve are nitride hardened and then ground and lapped for precision performance. The 35 hp main motor has a two-speed gear drive. The spindle delivers a maximum speed of 3,000 rpm and the spindle and headstock are oil-cooled.

Absolute Machine Tools, Inc., Booth A-8252

Twin-spindle Automated Lathe

The TNW-3500R automated lathe provides turning, drilling, and milling operations in one machine. Now available in the U.S., the lathe has twin spindles, a gantry robot, and slant bed. A live tool turret performs secondary operations; live tool motor power is 3/5 hp. The gantry loader has a 22 lb capacity and dual 10-tool turrets. The unit’s A2-6 spindle turns with a 15/20 hp spindle motor and operates at a maximum of 4,200 rpm. A 12-station work stocker, chip conveyor, and a set of turret holders are standard. It includes a Fanuc 310i-A CNC Control.

Fuji Machine America Corp., Booth A-8721

CNC Simulation

Vericut 6.2 CNC machine simulation and optimization software features enhancements that increase the ability of manufacturing engineers to develop, analyze, inspect, and document the CNC programming and machining process, according to the manufacturer. It is CNC machine simulation, verification, and optimization software that lets users eliminate manually proving-out NC programs. The program also optimizes NC programs, and simulates all types of CNC machine tools, including those from leading manufacturers such as Mazak, Makino, Matsuura, Hermle, DMG, DIXI, Mori Seiki, and Chiron. The software runs standalone, but can also be integrated with leading CAM systems such as Catia V5, Unigraphics, Pro/E, MasterCAM, EdgeCAM, and GibbsCAM. The “NC Program Preview” offers an option to process an NC program without simulating material being removed. This “quick check” uses much less memory. When in preview mode, the software displays a tool trace of the NC program over the design model. The Preview checks for collisions, gouges, minimum excess, and instances where axis limits are exceeded.

CGTech, Booth D-3035

Waterjet Sports 87,000 psi

The HyperPressure 87,000 psi waterjet cutting technology benefits, according to the company, include cutting speeds that are 20 to 50 percent faster than 60,000 psi; 20 to 30 percent lower part cost than 60,000 psi; and lower abrasive consumption, with 30 to 50 percent less abrasive used than 60,000 psi. HyperPressure 87,000 psi is available on the company’s Integrated Flying Bridge and WMC2 waterjet machines. Also at the show, FlowConnex will be introduced, the next generation of interconnectivity of the company’s waterjet operation. Conforming to MTConnect connectivity standards, FlowConnex provides waterjet machining and production status with a dashboard that displays information on machine operation and machine productivity. FlowConnex also provides for e-mail alerts to signal waterjet operators and management of waterjet machine and pump conditions that could shut it down.

Flow International, Booth B-6200

Direct Drive Spindles on HMCs

The EC-550 HMC horizontal machining center represents the latest expansion of the company’s line of high-productivity HMCs. It is a 30"×34"×32" work envelope, 50-taper geared-head spindle, dual-pallet changer with 550mm pallets, 50-pocket side-mount tool changer, and a built-in 1° pallet indexer. Its standard geared head couples the motor to the spindle through a gearbox. This system offers thermal stability. The two-speed gearbox provides 450 ft-lb of torque for heavy material removal, and speeds to 6,000 rpm for finish cuts. For high-speed work, an optional 10,000 rpm inline direct-drive spindle is available. Driven by a 45 hp vector dual-drive system, this spindle yields 170 ft-lb of torque at 1,400 rpm, and a peak power rating of 60 hp at 7,000 rpm. Each center handles a 2,205 lb load and a separate, protected load station lets the operator load and unload parts or change fixtures on one pallet, while parts are being machined on the other – keeping spindle run-time at a maximum.

Haas Automation, Booth A-8000

Full 50 “horses” Powers HMC

The Niigata HN80D Horizontal Machining Center machines medium to large parts in a wide range of materials. It features traverse rates of 1,181 ipm and feed rates of 592 ipm on heavy-duty box ways. Full 50 hp cuts are achieved through a two-range geared headstock. With three rotating components, power is transmitted to the cutting tool. Large-diameter ball screws, coupled direct to AC digital servo motors, provide high-thrust drilling. The HMC features a large spindle diameter and a single piece, snout-type head design for heavy milling capability. Other features include heavy-duty box ways with hand-scraped mating members and triangular rib structure construction. The bed-type design provides support for entire X-axis travel. The Y-axis double guide system offers stability. The unit also has a spindle chiller unit. This unit removes excess heat from the spindle and bearing housing. Oil temperature is controlled by a sensor in the machine base that adjusts the lubricating oil temperature relative to the machine’s thermal characteristics. The spindle bearings are lubricated using an oil injection system. Other design features include an automatic rotary-type pallet changer, a Fanuc CNC control, a variety of built-in diagnostic features, accessible service points, and more.

SNK America, Inc., Booth A-8432

Magnetic Workholders with Attractive Grip

A product line will be on display that includes material handling devices, precision mechanical and magnetic workholding, demagnetizers, custom sine tables, and custom rail milling systems.

SAV North America, Booth F-2345

One Thousand Layers of Coating

Featuring a Super ZX multi-layered coating, the new grades AC510U and AC520U are designed for roughing, finishing, and medium-cut machining of super alloy materials. The coating consists of ultra-thin layers of TiAlN and AlCrN, alternately stacked up to 1,000 layers. According to the maker, the AC510U grade is efficient in finish-turning of exotic materials, while the AC520U grade is designed for roughing and medium cut machining applications. The grades are available in both molded and ground insert types.

Sumitomo Electric Carbide, Inc., Booth F-2668

Diamonds are a Dressing’s Best Friend

The Model FC-250W Diamond and CBN Wheel Truing and Dressing Machine will be shown at the exhibition. The Model FC-250W is designed for truing and dressing of flats, angles, and radii on diamonds. According to the manufacturer, the FC-250W increases efficiency and accuracy by profiling, modifying profiles, and truing wheels properly – offline of the production grinding machinery. Its heavy, one-piece cast iron base provides rigidity and minimizes vibration. Standard features include ExVision, a computer-driven vision system with a software program specifically designed for the FC-250W and its various applications; an automatic power zoom; and, a 2-axis DRO for measurement.

Rush Machinery Inc., Booth B-7221

Laser Drill Designed with Aviation in Mind

The VLD-300 is a small, vertical, Nd:YAG laser drilling machine for 12" cube parts – 300mm × 300mm × 300mm, in X-, Y-, Z-axes. This machine was developed in collaboration with aerospace engine component manufacturers, who expressed a need for a higher-speed and more accurate laser-drilling machine than what was available. It’s common for some workpieces, primarily jet engine high temperature alloy parts, to require about 3,000 small diameter cooling airflow holes – each at a different angle – to be drilled in a non-contact manner. Laser is often the best option for speed and to minimize material stress. Inconel, Waspalloy, Hastalloy, and nickel-based titanium alloys are the typical materials. The laser drill offers positioning accuracy of 0.00004" and repeatability in X-, Y-, Z-axes. Axis positioning accuracy is ±6 arc seconds; repeatability ±3 arc seconds. C-axis accuracy is ±4 arc seconds; repeatability ±2 arc seconds. X-, Y-, Z-axes cutting feed rate is 0.004" to approximately 787", X-, Y-, Z-axes acceleration rate is 1.5g.

Mitsui Seiki (USA) Inc., Booth A-8767

Infrared Probe Sans Battery

The TS 444 battery-free infrared probe, the TS 740 probe, and the UTI 192 interface box, which allows for probe integration to non-TNC controls, will be on display.

Heidenhain Corp., Booth D-4419

CAD/CAM Software: the Next Generation

The next generation of Mastercam CAD/CAM software – Mastercam X3 – will be unveiled and demonstrate its Feature Based Machining – FBM – the Mastercam in SolidWorks product. FBM will detect solid machining features for the chosen FBM operation type, based on selection criteria; machine pockets using 2D roughing, rest mill, and finish operations; automatically support closed, open, nested, and through-pockets and set-the-right-toolpath options; optionally create a separate finish toolpath for floors and walls; identify when external machining is required and enable users to activate or deactivate it; identify when facing is required; create drilled, tapped, counterbore, and countersink holes; perform deep drilling, spot drilling, pre-drilling, tool selection, and tool creation if needed; provide advanced controls to drill blind, through, co-axial, and split holes; and select the appropriate tools for all operations. Mastercam in SolidWorks is fully integrated CAM that runs in SolidWorks.

CNC Software, Booth D-3027

Gear Tester

The GMX 400, a Class 1 universal gear tester provides analysis for a range of gear and gear tool applications on gears with ODs up to 15.75". The GMX 400 incorporates a 4-axis Power PC controller with automatic tailstock and a high-accuracy 3D scanning probe head for use in both universal and specialized gear manufacturing processes. Equipped for both stand-alone shop floor or gear lab applications, the tester provides automatic inspection of straight and helical cylindrical gears; spiral and hypoid bevel gears; crown gears; cylindrical worm shafts; conical cylindrical gears; segment gears; shaving cutters and hobs; pinion-shaped cutters; beveloid gears; synchronous gears; 3D geometry; and form and positional measurements, diameters, and distances.

Mahr Federal, Booth D-4324

Nanoscanner Measures Up

The Hommel nanoscan can measure surfaces with a stroke of 24mm with a resolution of 0.68nm for the entire measuring range. It features integrated software and hardware that lets users capture micro- and macro-structures of parts with narrow tolerances in short cycle times. It is designed for producers of high-precision parts and assemblies where contour and roughness features are critical, such as fuel injection, transmission parts, pumps, and valves for automotive, aerospace, and medical applications. Due to the high resolution of the interferometer, structures of the workpiece surface can be recorded ranging from the submicrometer range to 24mm or 48mm – depending on the probe arm length. Measurement tasks can be set up and performed on the operator panel while CNC-controlled axes allow automatic measurement runs in short cycles. The measuring accuracy is based on a mechanical precision-designed and built column and traverse unit. The horizontal and vertical axes are equipped with high-resolution, digital scales providing a resolution of 10nm. A minimal guidance error of 0.3µ over the traverse of 200mm in the horizontal axis supports the measuring head travel. Column – vertical – travel is 550mm with repetitive positioning accuracy of less than 10µ.

Hommel-Etamic America Corp., Booth D-4535

Portable CMM Scanner

The naviSCAN is a portable system for scanning and probing in the object coordinate system without the use of targets or post-process patch stitching. It is designed for inspection and reverse engineering of large components on the shop floor, even under harsh conditions. The system is a combination of a Duo portable CMM for navigation and a stereoSCAN white-light-scanning system. While the Duo system sets up a large working volume, the stereoSCAN scans areas up to 1m² per shot within this volume. The Duo aligns all shots without any user interaction.

Metronor, Booth D-4636

Compact Heads at the Right Angle

Two new angle heads include the ONBS and the Compact Angle Head. Angle heads combine vertical, horizontal, and angular operations on one machine, eliminating multiple setups. The ONBS Angle Head offers a coolant-through-the-tool design. ONBS is available as standard in BIG-PLUS CAT40 and CAT50 tapers. The Compact Angle Head is smaller, designed for lighter duty work, and lower priced than original angle heads. The Compact Angle Head has a maximum 1/2" capacity and is available in BIG-PLUS CAT40 tapers.

BIG Kaiser Precision Tooling Inc., Booth F-2114

Magnetic Lifts Hoist more than Three Tons

Working together, EZ-Lift material handling magnets and MagVISE magnetic workholding systems reduce setup and part changeover times by 50 percent or more compared to traditional material handling and workholding methods, including clamps and vises, according to the manufacturer. The EPM electro-permanent magnetic chucks, and ECB permanent magnetic vises are for workholding. Both solutions provide tons of holding power, and can be customized to suit application with induction blocks, subplates, and work stops as needed. EZ-Lift material handling magnets have a built-in safety factor of 3.5 times capacity, and are rated to lift up to 6,600 lb. They come in six sizes.

Earth-Chain Inc., Booth F-2591

Tooling and Accessories for Swiss Work

Specialized high-precision tooling and accessories designed for users of Swiss-type machines and the broad range of small parts manufacturing equipment will be on display, including Utilis Swiss made inserts providing repeatability of less than 0.0004" for turning work 1" diameter and below, and the Thread Whirling system featuring 12 cutters for higher bone screw production rates. Other special tools include a range of micro-sized solid-carbide slitting saws, floating reamers, holders, and micro reamers, compact straddle knurling tools, and axial feed knurl dies ideal for small parts. In addition, high-speed spindles for Citizen Machines, magnetic finishing and deburring units, quick change collet holders and Premium Swiss cutting oils, as well as Specialty Swiss-type tooling application solutions.

Genevieve Swiss Industries, Inc., Booth F-2423

Cableless Probe Detects Broken Tools and Settings

The cable-free Twin Probe System combines part setup and measurement with tool setting and broken tool detection. The system uses the same optical receiver to process signals from a spindle-mounted OMP40-2 inspection probe and OTS tool setting probe. Optical signal transmission enables fast system integration and a cable-free machine environment. The system lets users achieve greater automation of part processing and enable more productive use of operator time and skills, according to the maker. Cable-free operation eliminates restrictions on table movement. The cableless tool setter is suited to machines with twin pallets or rotary tables. The OMP40-2 is an upgrade to the OMP40 touch probe. Its compact design makes it suitable for small machining centers and the growing range of high-speed machines fitted with small HSK and other small taper spindles. User programmable parameters offer simple optimization for specific machine applications. Its Trigger-Logic programming method lets users program probe options. This avoids the need to access internal probe components, eliminating the risk of damage from coolant or debris ingress.

Renishaw plc, Booth No. D-4511

Bar Feeder Works in Limited Space

The Elite 112 bar feeder will operate on a Star CNC lathe. It can feed bars of 0.8mm to 12.7mm on lathes with high rotation and headstock acceleration speeds without limiting performance. It has a minimum inertia – -40 percent – mechanical synchronization system to follow headstocks, even those actuated by linear motors, regardless of bar diameter. The bar feeder is engineered with closed, calibrated, round section channels. No special adjustments are necessary when switching jobs. The Smart 320 is designed for sliding headstock lathes. It accommodates small-diameter bars – 3mm to 23mm – and offers automatic remnant recovery and bar-headstock synchronization. The compact Prodigy bar feeder was designed for use in limited floor space.

IEMCA, a division of Bucci Industries, Booth A-8274

Three-turret Turn Mills

The C100 series of production turn-mill centers are designed for production of medium-complexity parts turned from bar stock from 30mm to 42mm in diameter. The three-turret machines fit into a small floor space, and are targeted to handle fixed headstock work often run on Swiss-type machines. It has 42 quick-change tools, fixed and driven; high horsepower and torque, but with the rpm typical of Swiss-style machines. The turn-mill center has a 30mm bar capacity and comes with 9,000 rpm spindles. A 42mm bar capacity is available with 7,000 rpm spindles. Both versions can run parts to 200mm in length. The drives are 20/29 kW and 25/29 kW – 100 percent / 40 percent – for the 30mm and 42mm version respectively. Motorized main and counter spindles are identical and liquid-cooled. Up to three tools can be at work simultaneously with both Y-axis and backworking at the same time. The counterspindle with linear-motor driven Z-axis can be synchronized with travel of turret three. Counterspindle pick-up from the spindle is accomplished in 1.5 seconds.

INDEX Corp., Booth A-8253

A Traveling Column Machining Center

The SHW UniSpeed 5 traveling column machining center is designed for precision applications in the aerospace, petroleum, mold-making, subcontracting, and other fields. It has a work envelope of 63"×63"×47" – X, Y, Z and five-sided machining and turning capabilities. The machine features the SHW universal spindle head, with 64,800 programmable spindle orientations. It features a milling spindle with 35 hp drive, spindle speeds up to 6,000 rpm or, if equipped with a high frequency spindle, up to 30,000 rpm. The traverse rate is 98 fpm with 2g acceleration. The X-axis travel of the machine column is 78". The turning table diameter is 63" with a table load capacity up to 13,200 lb. Table speed for turning operations is up to 250 rpm. The automatic toolchanging system includes up to 90 tools for fully automatic production.

Bohle Machine Tools, Booth A-8462

No Pilot Hole Drill

The Revolution drill is engineered to drill without need of a pilot hole by using an over-center cutting geometry for the indexable carbide inserts and the single, adjustable cartridge. This cartridge – removable for fast replacement – allows the diameter to be adjusted up to 5.1mm, permitting a hole-size range of 1.875" to 4.0". Also slated for demonstration is the GEN3SYS High Penetration Drilling System with increased range of 12mm to 32mm, with 3x, 5x, and 7x drill depth–to-diameter ratios. It is available with straight and helically fluted holders. The system is engineered to provide improved chip formation, increased penetration rates, and a longer tool life. It is coated with the AM200 coating.

Allied Machine & Engineering Corp., Booth, F-2030

Factory-aligned Precision Grinders

The VSS Series 2 Single Stroke machines are factory aligned for precision centering of the spindles and tooling plate to produce better bore geometries. Alignment accuracy exceeds DIN 8635 requirements for vertical honing machines. The machines incorporate up to six spindles to progressively size and finish part bores with tools of preset diameter and grit size. The machines are designed for precision sizing of bores 0.149" to 2" diameter in stamped parts, hydraulic valve bodies, gears and sprockets, parking pawls, rocker arms, turbocharger housings, and similar parts. Appropriate materials include cast iron, powdered metals, ceramic, glass graphite, and other free-cutting materials. The machines use a belt-drive spindle cartridge with a 28.5" stroke and 2" to 250 ipm stroking speed for flexibility with a variety of parts and tooling combinations. The servo-powered stroke system provides crash protection and is hand-wheel-controlled for quick setting of vertical position. The menu-driven PLC Control with human-machine interface lets the column feed and spindle speed be varied throughout the cycle. The VSS Series 2 is available in three models: the 84 – eight-station, four-spindle, the 86 – eight-station, six-spindle, and the 64 – six-station, four-spindle, to meet various mid- to high-production needs.

Sunnen Products Co., Booth B-7200

Extended Lengths for Deep Pockets

Extended length versions of the T90cn-0.5 through T90cn-3.5 right angle heads are available. These tools are suited for machining deep pockets and bores. Alberti extended length tools are constructed with the same chromium plated, high tensile strength GS 600 spheroidal cast iron bodies and Abec 7 angular contact bearings as the standard length tools. The extended reach angle heads are to be stocked with CAT40, CAT50, and HSK shanks.

Koma Precision Inc., Booth F-2277

Keeping Threads Honest

The CHT Thread Inspection System is designed for the in-process inspection of large diameter parts featuring an extended range of measurement capability. Available for any UN, UNJ, Buttress, Metric, or Acme thread greater than 3". All existing pitch diameter or functional size rolls are interchangeable on the systems. Also being demonstrated at the show will be the ThreadSpecs 2.0, a fully-integrated thread engineering software program designed to simplify the calculation of critical thread elements and characteristics for UN, UNJ, Buttress, Acme, Metric, Metric J, and Whitworth thread forms.

The Johnson Gage Co., Booth D-4509

Predicting Future Chip Forms

Deform-3D is used by cutting tool and other manufacturers to analyze the influence of tool design, cutting parameters, and tool wear on machining performance. It is a finite-element based system that can predict chip form, cutting forces, temperatures, tool wear, workpiece surface integrity, and other parameters based on cutting tool geometry, feed, speed, depth of cut, and coolant. It can model turning, milling, drilling, tapping, broaching, and most other single and multi-point cutting processes. Its material library contains more than 50 materials, including common grades of steel, titanium, aluminum, and superalloys.

Scientific Forming Technologies Corp., Booth D-3303

Tapping Into High-speed Threading

The XTF Forming Tap is a TiCN coated tap for high-speed tapping of stainless and carbon steels. The taps produce threads by displacing material to create the thread form. Since there are no cutting chips, higher speeds can be achieved compared to conventional cutting taps, according to the manufacturer. The taps’ crests are rounded off to promote smooth plastic flow and prevent cracks and burrs in the root of the internal thread. They feature a high cobalt HSS substrate for hardness and heat-resistance. The TiCN coating further enhances these properties. The taps are available in inch sizes from 0 to 80 to 1/2 to 20, and in metric sizes from M2 × 0.4 to M12 × 1.75.

Vega Tool Corp., Booth F-2984

Two-armed Robot

Slim and agile, with human-like flexibility of movement, the dual-arm SDA10 robot is slimmer, stronger and has significantly faster acceleration than the previous DIA10 model. With a shorter link distance between the P-point and flange, the SDA10 provides flexible tool motion and a higher load carrying capacity. Its arms are set forward to maximize work envelope. This design makes the robot suited for assembly, part transfer, machine tending, packaging, and other handling tasks that could only be done by people. It features 15 axes of motion – seven axes per arm, plus a single axis for base rotation. Internally routed cables and hoses reduce interference and maintenance, and make programming easier. Its actuator-based design means that the motor, encoder, reducer, and brake for each robot axis are combined in one package that is smaller than a traditional AC servo motor drive. Advantages include a slim arm profile, lightweight robot body, and high wrist moment and inertia ratings. The robot features a 22.1 lb payload per arm, a 77.6" horizontal reach, and a 56.7" vertical reach per arm, with a repeatability of 0.004". Both robot arms can work together on one task to double the payload or handle heavy, unwieldy parts, trays, or pallets. The two manipulators can perform independent operations at the same time. A dual-arm robot can hold a part with one arm while performing operations on the part with the other arm, and can also transfer a part from one of its arms to the other with no need to set the part down. The robot is controlled by the NX100 robot controller that features PC architecture, Windows CE programming pendant, and INFORM III programming language.

Motoman Inc., Booth B-6400

Easy Drill Length Adjustment

SDM Tool Holders feature one-touch drill length adjustment without the need for tools. Drill projection length can be adjusted by hand-rotating the knurled guide ring on the outside of the SDM Toolholder. Axial adjustment range varies from about 0.394" to 0.984", depending on the size of the given tool holder. The tool holders use the FDC Collet System, which provides run-out accuracy to be within 0.0002" at 4xD, for AA Class collets. FDC Collets are available from stock in sizes ranging from 0.020" to 0.866". The collets can accommodate coolant pressure as high as 1,000 psi either through the drill or alongside the drill. To prevent cutting tools with tangs from rotating within the toolholder, the tool holders include a preset screw. They are available from stock in CAT, BT, and HSK styles.

NT Tool, Booth F-2160