July 2008 Edition

IMTS COUNTDOWN

Counting Down to IMTS – Part II

This is the second of a three-part preview of the International Manufacturing Technology Show, 2008. In this, and the next issue – August – MAN will highlight the products and events taking place in Chicago from September 8 to 13.

The 27th International Manufacturing Technology Show in McCormick Place, Chicago, is scheduled to feature more than 1,500 companies exhibiting their products and will occupy 1.2 million ft² of exhibit space. Show officials state they expect more than 91,000 buyers and sellers from 119 countries to tread the aisles from Sept. 8 through 13. Show hours will be from 9 a.m. to 5 p.m. in McCormick Place Lakeside, and from 10 a.m. to 6 p.m. in the North, South, and West buildings.

Show representatives said they expect exhibitors to fill nine pavilions, each with its own theme.

Each pavilion has a different aspect of the metalworking industry as its focus:

• Abrasive Machining/Sawing/Finishing – North Building, Hall B
• Controls and CAD/CAM – East Building, Hall D
• EDM – East Building, Hall D
• Gear Generation – North Building, Hall B
• Machine Components/Cleaning/Environmental – East Building, Hall D
• Metal Cutting – South Building, Hall A
• Metal Forming and Fabricating/Lasers – North Building, Hall B
• Quality Assurance – East Building, Hall D
• Tooling and Workholding Systems – West Building, Hall F

The June issue described the focus of the first five exhibit halls. This issue will detail the offerings in the remaining pavilions.

Metal Cutting – South Building, Hall A

The Metal Cutting pavilion will have as its focus machining centers; turning centers; assembly automation; milling machines and centers; boring machines; drilling machines; transfer machines; screw machines; broaching machines; skiving, trepanning, and roller burnishing machines; gun drilling machines; planers and mills; boring mills; multiple spindle drills and automatics; drills, mills, bore heads, and slides; thread rolling; jig boring, milling machines, and knurling machines; VTLs; bar feeds; automation systems; assembly machines; end finishers; machining cells; chuckers; CNC lathes; and flexible manufacturing systems.

Metal Forming and Fabricating / Lasers – North Building, Hall B

Laser technology, along with the machinery for forming and fabricating, are in Hall B, covering straight side presses; straightening presses; OBI and hydraulic presses; water jet machining systems; CNC turret punch presses; tube and pipe benders; press brakes; roll formers; assembly automation; welding and robotics welding equipment; cold forming and rolling technology; iron workers; headers; spinning machines; wire bending and forming equipment; forming and fabricating systems; foundry and casting equipment; investment casting equipment; flame and plasma cutting; friction welding; stress relief equipment; coil and strip handling equipment; plate benders; robotic systems; die handling equipment; press room equipment and software; press safety equipment; thread rolling equipment; marking equipment; laser cutting systems; marking; scribing; drilling; cladding; trimming; engraving; laser welding systems; heat treating; and laser measuring equipment.

Quality Assurance – East Building, Hall D

Measurement equipment and quality assurance products are featured in Hall D, and include precision measuring machines; laser measurement machines; coordinate measuring machines; precision gaging; automated gaging; in-process gaging; tool condition monitoring equipment; measurement software; quality, control, testing, and measuring equipment; comparators; metrology; and vision systems.

Tooling and Workholding Systems –
West Building, Hall F

Hall F focuses on tooling and workholding systems such as boring bars; coolants; oils; cutting fluids; ceramics and composite cutting tools; tool coatings; drills; chucks; tools; milling cutters; form cutters; cutting tools; tooling systems; end mills; fixturing systems; gun drilling tools; cutting tool measurement and checking systems; hobs; tool inserts; jigs; key seating tools’ ball nose end mills; lapping tools; magnetic chucks and plates; collets; NC tables; spindle adaptors; plates; quick change dies; reaming tools; screw thread inserts; tool storage equipment; deep hole and trepanning cutting tools; jigs and fixtures; tooling columns; universal fixturing; vises; and workholding systems.

Along with specific categories of the metalworking industry on display, individual manufactures will be showing their products. Here is the second of three previews of what will be at the show.

Touch-screen Controlled Deburring

Custom-designed rotary indexing systems are for high volume, multiple-surface finishing in machining system applications. The systems combine an indexing turntable with motor stations, fixturing options, and on-board tooling options. Each system is designed for a customer’s parts and application requirements. The unit is designed to deburr and clean gears used in motorcycle transmissions. The rotary indexing system’s cells has programmable feeds, speeds, automatic brush-wear compensation, and tooling change alarm signals. These functions are controlled by a touch-screen interface.

Abtex Corp., Booth B-7112

Tombstone Territory

Tombstones can be built to user specifications with edge locating, hardened and ground wear pads, center locating or just mounting holes. In addition, they can be designed with plain faces, with or without special machining, hole patterns, precision bushings and threaded inserts, or with precision T-slots. Triag’s modular design allows clamping of small parts in high density by attaching the clamp modules to rails. This rail-based system provides both high part density in a limited working area and quick-change setups. Dedicated manual fixtures offer improved operator safety; improved tolerances resulting from the use of a single fixture as opposed to multiple fixtures; and reduced workpiece handling, which in turn can result in increased part production. All can be accommodated using a compact clamping system with integrated trunion. This fixture allows continuous three-sided machining and eliminates substantial handling and machine downtime.

Advanced Machine & Engineering Co., Booths B-7136, F-2320

Soft Material VMC

The M10 Power is designed for machining non-ferrous materials, such as aluminum and plastics. It offers up to 40,000 rpm with a 3 kW high-frequency spindle. The toolchanger holds 11 small mills and drills with diameters ranging from 0.002" to 0.375" for applications in aerospace, medical, and electronics. The X, Y, Z work envelope is 40"×28.5"×9.25". The VMC includes rigid steel construction with a solid granite table or concrete polymer table for low-vibration motion. It has a functional access design with a storage compartment. The chip disposal system can be adjusted to accommodate different production volumes. Intelligent sensors monitor operating states of the mechanics and the PC-based control system can compensate for tolerance variations. The software is Windows based and menu-driven.

Datron Dynamics, Inc., Booth-6564

Long-range X-axis Horizontal Boring Mill

The FT 3500 floor-type horizontal boring mill demonstrates modular design flexibility. It features 32.8' of X travel and 11.8' of Y travel, but standardized modules allow HBMs to be configured with travels from 13.1'×52.5' and Y-axis headstock travel to 16.4'. It is suitable for oilfield, construction, mining, and job shop work. Two platforms – FT and ram-style FTR – can be fitted with a choice of travels, headstocks, spindle diameters and spindle power, controls, coolant systems, workholding, and tool magazines. Traveling-column design provides a wide range of X-axis travel for processing of large and long workpieces, or multiple batch parts, with 787 ipm rapid traverse rates. Special-geared AC digital drives maintain high torque and stiffness at high traverse speeds and feed rates. Standard Y-axis vertical headstock travel starts at 6.6'. The FT and FTR Series floor-type models offer choices in spindle reach from 31.5" to 49.2". Both feature live spindles providing a programmable axis for drilling and tapping as well as adding reach for boring operations.

MAG Giddings & Lewis, Booth A-8218

Quick-change Chucks

The Quick-Pitch Diaphragm PLD – Pitch Line Diaphragm – Chucks feature quick-change, top jaw tooling sets. These chucks use the company’s radius diaphragm chuck technology, and are targeted at gear manufacturing, grinding, and hard-part processing where low- to medium-volume runs are the norm. They provide 60-second changeouts. The system incorporates the use of fixed-length, interchangeable wedge pins that locate and lock on the gear’s pitch diameter, work with pieces with any number of teeth, and can compensate for varying teeth spacing and pitch values. The chucks can be used on applications with sun, ring, pinion, and output gears with spur and helical gear tooth forms. Four chuck units, featuring three 3-jaw versions with pitch diameter capacities of 25mm to 100mm, 100mm to 170mm, 170mm to 245mm, plus a 6-jaw unit with 245mm to 350mm gear pitch diameter range.

N.A. Woodworth, an ITW Workholding company, Booth F-2486

Five-axis Flexibility in a Horizontal Machining Center

The G350 horizontal machining center features a design that provides for 5-axis productivity and flexibility. It incorporates a slide-mounted spindle module – located to one side of the machine’s centerline – establishing 0.00039" positional tolerance and 0.00019" positional variation. The design provides front and side access for part loading. This system’s working range is 23.6" in the X-axis, 25.8" in the Y-axis, and 26.6" in the Z-axis. Speeds for the X-axis is 2,559 ipm, the Y is 1,417 ipm, and the Z-axis is 3,543 ipm. Standard spindle speed is up to 12,000 rpm. Four control options – Fanuc, Siemens, Bosch Rexroth, and Heidenhain – are available. It includes a 40-pocket tool disc magazine – rack-type magazine for 140/221 tools – to accommodate HSK 63, CAT 40, BT 40, or Big Plus 40 style tools.

GROB Systems, Inc., Booth A-8163

Contour Surfaces in One Setup

The ZX Boring, Facing, and Contouring Systems machine surface contours in one setup, or with a minimum number of tool changes. The tools are designed to run on horizontal boring machines with a CNC inner programmable quill. Users report reduced setup time, higher machining rates, and productivity increases of 500 percent or greater. The machine sizes, finishes, and work-hardens cylindrical diameters in seconds. The company will also exhibit a design for its Flipcut Back-Spotfacing and Chamfering Tools.

Cogsdill Tool Products, Inc., Booth F-2270

Interferometry Using White Light

Using white light interferometry in a compact design, the MarSurf WS 1 offers vertical resolution of 0.1nm and provides 3D measurement in a few seconds. Using MarSurf XT 20 topographical evaluation software, MarSurf WS 1 can be configured to work both in the lab and on the shop floor. The white light optical sensor provides rapid, high-precision recording of surface topography on a range of materials. Along with a CCD camera, the system collects height information through the field of view of the camera. Both the test surface area and a reference surface built into the objective lens are imaged simultaneously by the camera. During measurement, the Mirau objective is moved in small steps in the Z direction, using a piezo positioner. The resultant interferograms are recorded as image stacks and converted into height data.

Mahr Federal, Booth D-4324

Software Enhancements

The Advanced 3D with HSM enhancement for GibbsCAM SolidSurfacer will be demonstrated at the show. The enhancement introduces a range of 3-axis milling functionality with support for high-speed machining. Enhancements include support for 3D material only; support for more advanced tool shapes – tapered tools; new types of finishing processes, e.g., surface step-over cut and steep and shallow combination; improved toolpath quality; options to provide a toolpath that better supports high speed machining; improved use of boundaries; enhanced entry and exit control; ability to directly machine faceted bodies, including imported STL files, and automatic core and cavity detection for inside-out or outside-in determination; operation splitting for tool wear and for optimal length out of holder; multi-threaded for multi-CPU machines and to support batch toolpath generation; and automatic filleting of a surface to avoid sharp concave corners.

Gibbs and Associates, Booth D-3037

Gauges Get Thin

The M3 Star manual snap gauges combine high technology with high quality in only a 10mm thickness. The gauges are available in mechanical, electronic, and wireless Bluetooth versions, with dedicated or adjustable V-part reference. The design lets the M3 Star snap gauge engage narrow diameters between shoulders on crankshafts and is suitable for measuring short external diameters close to shoulders on transmission and main shafts. Other products displayed include the Merlin Mobile, a wrist-band mounted electronic gauge computer and products in the Mida probing line, including WRS world radio transmission probing system; OGP70 optical, high precision spindle probe; Optical Twin Probe interface unit; Laser 75P programmable, non-contact tool setting system; and a line of Mida Arms for tool setting and breakage detection on lathes.

Marposs Corp., Booth D-4514

Honing with a 30" Stroke

The SV-310 vertical CNC honing system combines multi-spindle machine configurations with tooling choices and a 30" stroke for bore sizing of small and medium-sized gas and diesel engine blocks, large gears, air compressors, and similar small or large multi-bore parts. A work envelope of 40"×70" and weight capacity up to 2,000 lb provide for processing a range of parts. The SV-310 can be used to hone parts with inside diameters from 0.75" to 8". A 20-amp power supply and multiple E-stop contacts allow automation control. The SV-310 is built on a malleable iron base for rigidity and vibration damping. The machine’s servo-controlled, straight-line stroke motion is driven by a ballscrew at rates of one to 160 strokes per minute, while a 7.5 hp spindle provides torque for metal removal with tools outfitted with metal-bond cubic boron nitride and diamond abrasives or standard aluminum oxide and silicon carbide stones. It has lubed-for-life horizontal and vertical axes guide ways.

Sunnen Products Co., Booth B-7200

Workholding Options

A full line of workholding components includes material handling devices, precision mechanical and magnetic workholding, demagnetizers, custom sine tables, custom rail milling systems, and more.

SAV North America, Booth-2345

Loaded and Locked

VForce with SideLok direct-insert clamping design has diameters from 3" to 10". Incorporating three carbide grades and three expanded top-form geometries, the machining applications for VForce include a range of materials and is suitable for cast iron. The SideLok technology uses a single screw with no extraneous parts, allows for quick release of the insert to minimize insert indexing time, is easier to use than screw-down or wedge-type systems, and permits the use of a stronger, solid insert design. VForce features a hexagonal shape providing up to 12 distinct cutting edges. The insert cavity and locking screw are precision aligned and angled relative to each other in order to apply force in two directions as the screw is tightened. The insert is both pushed against the pocket-side walls and pulled down securely to the pocket bottom. The resulting wedge-like condition retains the insert but by applying constant lateral resistance on the threads, also prevents the lock screw from loosening.

Valenite, LLC, Booth F-2979

Hex Chuck Makes North American Debut

The TOPlus hexagonal mineral cast chuck and other workholding technologies will be on display, including the North American debut of the B-Top3 chuck, the HYDROK hydraulically-actuated stationary chuck, the MANDO T212 segmented mandrel, and the automatic zero-positioning Centrex Interface Centering System. The manufacturer states the TOPlus hexagonal chuck offers 25 percent more holding power, central lubrication, improved dampening characteristics, and a clamping head that is fitted free of joints and solidly to the chuck surfaces. It does not allow any radial displacement between the clamping head and chuck body, resulting in a seal against contamination.

Hainbuch America Corp., Booth F-2973

Smarter CAM Software

CAMWorks is a CNC programming solution for producing molded parts from solid models. Demonstrations of the software as well as DFMPro, eDrawings Publishers, and GeomCaliper will take place. CAMWorks incorporates Knowledge-based Machining technology to automate the generation of toolpaths based on a user-defined database. Automatic feature recognition defines machinable features. Programmers can set up the database to represent standard processes for typically recognizable features. CAMWorks recognizes these features and generates an operation plan. The strong integration between solid modeling and toolpath generation provides associativity between CAD and CAM functions. The application identifies and recalculates toolpaths based on changes to the part model. Modules for 2- to 5-axis milling, turning, and wire EDM are available.

Geometric Technologies, Inc., Booth D-3110

A Bridge too Cool

The RB-200F Series 5-axis bridge type machining center offers machining of multiple angles and 3D contours. The machine series spindles – 30/25 kW, 40 to 10,000 rpm; or 55/50 kW, 150 to 15,000 rpm – has the power to machine monolithic aerospace parts. The combination of its ISO 50 taper spindle and a 394 ipm cutting feedrate enables high-speed cutting. The 5-axis control of the RB-F Series offers precision multi-angle milling and drilling, contour milling, and flat machining. The table size of the RB-200F is 79"×157", with a load capacity of more than 33,000 lb. X-, Y-, Z-, W-travels are 167"×114"×23.6"×33.5". Spindle head rotation – B – is ±95° and spindle head rotation – C – is ±360°, continuous rotation optional. Features include a 40 tool ATC, through-the-tool coolant, chip conveyors, splash guards, a Fanuc 30i CNC system, and more.

SNK America, Booth A-8432

VMCs in a Series

The GX 1300 and GX 1600 Performance vertical machining centers offer mold and die manufacturers, as well as precision engineers in the automotive, aerospace, medical, and general engineering sectors, optimum capability and functionality for machining large components. They are rigid machines, featuring a stiff and thermally-stable spindle, a rigid C-frame fixed column design, and fixed pre-tensioned double-nut ballscrews on all axes. The heavy-duty linear guide and truck configuration provides added stiffness, damping, and surface contact area. The machines are configured with two guideways and six guide trucks on the X- and Z-axes; two guideways and four guide trucks on the Y-axis. The 30-tool side-mount/swing-arm automatic tool changer features random access, bidirectional indexing, and 4.5-second chip-to-chip change time.

Bridgeport, a member of The Hardinge Group, Booth A-8032

Steel and Cast Iron Cutting Tool

The TP1500 is an addition to the DurAtomic line. It meets the mechanical and physical demands required for turning steels at high cutting speeds without sacrificing the toughness needed for reliability. In conjunction with the MR6 chipbreaker, the maker states it has longer tool life, increased productivity, and lower costs than competitive grades. It was developed using the DurAtomic process, where the crystalline structure is manipulated at the atomic level to produce a durable coating. While targeted for steel machining, the coating and substrate properties also make the cutting tool a choice for a wide range of cast iron applications, especially those involving ductile and compacted graphite iron.

Seco Tools Inc., Booth F-2247

Expanded Sized HMC

The FH1250SX is the company’s largest horizontal machining center, featuring a column and high-torque spindle designed to handle rapid cutting without compromising rigidity. It is designed to provide the cutting power of a box way machine with more than 50 percent higher rapid feed rates than a typical box way design. Also on display will be the 550SX HMC, featuring technological advancements that include a compact tool matrix. This model has double the driving force in the Y-axis than previously, with a ballscrew and motor on each side of the spindle. The compact matrix is a stationary tool storage rack that holds up to 280 tools – 40 taper – or 184 tools – 50 taper. The matrix lets HMCs be tooled up for more part numbers with the added benefit of fast tool-to-tool times.

Toyoda Machinery, Booth A-8131

EDM Graphite Electrode Cutter

The TrodeMaster is a modified Fanuc RoboDrill high-speed vertical machining center for cutting graphite EDM electrodes. With full enclosures and a Torrit dust collection system, it is geared toward both small job shops and large in-house EDM facilities. It uses a 30-taper tooling and offers 3D contouring capabilities. With feedrates to 2,125 ipm, accelerations to 1.5g or more, a 24,000 rpm Big Plus spindle, and 0.9-second tool changes, it shortens the machining of electrodes. It comes with AI Contour Control II with 1000 block “look-ahead,” Jerk Control, and a 0.4 ms block processing speed. Spindle HRV control and thermal compensation ensure accuracy and circularity to 0.00011" TIR.

Methods Machine Tools, Inc., Booths A-8517, D-4114

Toughened-up Inserts

The AC410K grade consists of two types of coating layers – the Super FF Alumina layer and the Super FF TiCN layer – both of which provide peeling resistance and overall insert stability. Its ultra-thick, inner Super FF Alumina layer provides thermal resistance, while the outer Super FF TiCN layer offers chipping resistance. The grade combines these coatings with a hard carbide substrate, resulting in wear resistance in continuous-to-light interrupted-machining of gray and ductile cast iron. Consisting of a wider application range, the AC410K is capable of covering medium- to high-speed machining applications. This grade is available in positive insert styles for light-to-medium cutting applications and negative insert styles for light-to-rough cutting applications.

Sumitomo Electric Carbide, Inc., Booth F-2668

Fast Marking

The DMwriter is an indent marking tool for CNC milling machines. Using compressed air through the spindle, or from a secondary air supply to actuate carbide stylus, it can mark as fast as 120 ipm. Alpha-numeric characters and logos can be generated using standard engraving software to create the marking layout. With a 5/8" shank, the marking tool is designed to fit standard toolholders and eliminates the need for secondary marking operations. It is capable of marking parts up to 62R_C, with the depth of the marks dependent upon the air pressure used. The low-stress indent marking performed with this tool does not remove any material from the part.

Dapra Marking Systems, Booths B-6256, F-2651

Flexible Swiss Turning

The SS32 model Swiss-style turning machine has a flexible modular tooling arrangement and driven tools on both the main and subspindles, to machine complex components in a single setup. Its modularity is a contribution to Swiss technology, as is its work zone space. Its fast and easy-to-change tools meet user needs. The machine’s standard main spindle configuration includes seven turning tools, five cross-rotary tools, and five ID tools. The standard subspindle setup includes three ID stations and three face drills, and can include up to two cross-rotary drills. Thread whirling, polygon turning, and angular face drilling operations are possible with an adjustable face tool attachment. Key specifications include 12.6" of Z-1 stroke and 8,000 rpm main and subspindles.

Tsugami, Rem Sales, a division of Morris Group, Inc., Booth A-8701