The editors of Cutting Tool Engineering visited IMTS 2014 with a mission to find and report on new, innovative technology. The following products are some of what we found.
Apps make it easier to run good parts faster
Okuma America Corp. offers its new App Store at www.myokuma.com. Applications created by Okuma developers, distributor developers and members of Partners in THINC are available for CNC functionalities that reportedly increase productivity and streamline machine tool processes. Okuma's THINC-OSP CNC makes it possible to use apps, because the control is built using a Windows-based open-architecture platform that allows users to easily install PC applications, according to the company. Most apps are available free of charge. One app, for example, monitors the machine alarm status and automatically sends an email, text or phone message to the user when alarm condition is activated. Users also have the ability to create and share apps they develop themselves or in conjunction with their distributors.
Solid-carbide drill with radial-margin land design
Walter USA LLC introduced the Walter DC170 solid-carbide, internally cooled drill for drilling ISO-P and ISO-K materials. It has a land design that orients the margins radially and a copper-color finish (DPP coating). The design of the lands improves the drill's performance, based on their shallow cooling grooves at the drill end, according to the company. The coolant flow encompasses the entire drill point, cooling both the drill and the workpiece interface, and inhibiting chip packing. The new drill's design features also adds more material behind the cutting edge, improving stability. The alignment of the new lands-design results in smoother drill operation, reducing vibration to a minimum, which also enhances hole quality, according to Walter. Which is initially offering the DC170 in sizes of 16 and 20 times diameter.
Wire EDM is targeted for aerospace work
GF Machining Solutions' CUT 200 Dedicated wire EDM has a built-in tilt/rotary table for cutting complex aerospace components, such as turbine discs, using B-axis rotation and a +/-20° A-axis tilt. The machine also incorporates on-machine, in-process inspection, which encompasses a measuring probe and supporting software. The latest generation of the company's spark generators allows the machine to vaporize at up to 38 sq. in./hr. (400 mm2/min.) and produce tapers up to 30° in the Z-axis height. This is achieved while imparting fine surface finishes and eliminating recast layers and microcracks—critical requirements for aerospace parts. To significantly reduce noncutting times, the wire EDM offers fast axis speeds and quick wire threading, according to the company. In addition to the aerospace industry, other suitable markets for the machine include mold and die, medical and contract manufacturing.
Horizontal machining center accurately cuts challenging materials
Methods Machine Tools Inc. offers the YASDA YBM 7Ti 5-axis HMC for machining heat-resistant materials, such as titanium and Inconel. According to the company, the machine has a unique rotary table design that offers four times the rigidity compared to other tables. Positioning accuracy on the X, Y and Z axes is +/-0.005 (0.0002") and is ±1 second (measured in degrees) on the rotary and tilting A/B-axis. The machine has a 25-ton, H-shaped steel base for enhanced rigidity, absorbing cutting forces and minimizing vibration. Hardened, ground and lapped guide ways enable rapid feeds up to 48 m/min. (157.5 sfm), yielding high accuracy throughout every full stroke. To maximize performance levels, all linear axes are hand-scraped, and the mating faces of the guide ways are about double the width of conventional designs. The HMC comes with a 10,000-rpm, 50-taper direct-drive spindle and a 240-tool capacity automatic toolchanger.
Miniature clamping nut is slip-proof
Rego-Fix Tool Corp. has introduced the Hi-Q/ERMX miniature clamping nut for applications on Swiss-style automatic machine tools. The nut has an antislip locking design engineered to prevent the locking wrench from slipping off the nut during assembly and disassembly of ER collets. The nuts can replace any brand of older-style miniature nuts and are available in ER 16 and 20 sizes in standard and through-coolant versions. Frontal milled slots on the OD of the nut mate with corresponding features of the wrench to prevent slippage when tightening and loosening a nut. The nuts have a special surface treatment for increased clamping force and a coating that prevents corrosion. Benefits include enhanced operator safety and prevention of damage to other tools, according to the company.
Grinding machine has two rotary hydrostatic turrets
The Landis Twin Turret grinding machine from Five Landis Corp. features two rotary hydrostatic turrets with integral servomotors and X-axis hydrostatic ways with linear motor infeed. The grinder can handle workpieces with a swing up to 180mm (7.1") and lengths up to 400mm (15.7") using CBN wheels up to 350mm (13.8") in diameter and 40mm (1.6") wide at wheel speeds up to 120 m/sec. (393.7 sfm). It can perform eccentric and concentric multiple-axis contouring in various traverse configurations with optical levels of precision, according to the company. The design eliminates mechanical backlash through the use of linear and radial servomotors for all motions, and achieves high system stiffness and damping with hydrostatic spindle bearings. The grinder has a 1,125mm (44.3") load and access height. This enhances ergonomics and makes it easy to integrate with standard industrial robots for parts loading and unloading, eliminating the need for special automation or a gantry system in many applications.
Blow-off gun cleans without compressed air
Specialized Safety Products' Jet-Kleen personal safety blow-off gun delivers a high volume of air at the relatively low pressure of 3.0 psi (207 mBar) to remove residue such as dust, fiber and water from people, surfaces, components or work environments. Available in portable and wall-mounted models, the blow-off gun requires virtually no maintenance and consumes less energy than high-pressure air compressors, according to the company. All models feature a flexible, heat-resistant hose for easy control in all work environments and a foam-insulated interior to ensure noise levels do not exceed 78 dB.
Virtual reality enhances remote monitoring
Indiana Technology and Manufacturing Cos. has made use of wearable monitoring systems to enhance its remote monitoring capabilities. The Oculus Rift virtual reality headset, currently in development, allows stereoscopic 3D vision and real-time head motion, allowing users to view all parts of a 3D model, while the Leap Motion gesture-control sensor can enable operators to interact with the model in real time. To illustrate the capabilities, ITAMCO allowed attendees at IMTS to drive a virtual forklift around a simulated warehouse course via the Oculus Rift, awarding a Leap Motion controller to the fastest time and shirts to all finishers. In addition to the Oculus Rift, ITAMCO Technology Manager Joel Neidig said the company recently began utilizing Google Glass for remote monitoring as well.
Industrial vending system maximizes storage space
The new TX750 vending system from AutoCrib Inc. utilizes a rolling dual tambour-style door that can open to any specified size to dispense standard and other maintenance, repair and operations items without repackaging them. Using a patented rectangular-bin shelf system, the TX750 offers 30 percent more storage capacity than its predecessors and allows each storage bin to be customized from 2" to 60" in ½" increments (50.8mm to 1,524mm in 12.7mm increments) to fit the item being dispensed, virtually eliminating vertical bin “height” waste associated with fixed-door machines. The computer can also be connected to the company's new AutoLocker FX, a modular locker system with "smart" charging capabilities and management control for a company's tools and technology assets.
Dual-stage coolant reduces resource use
Quaker Chemical's new two-phase 2PAQ fluid system can be used as both a cleaner and to top off sump tanks. The emulsion is formulated in different solution ratios of the alkaline and oil phases, mixed with water, depending on the nature of the operation; operations requiring higher levels of lubrication use the oil phase at a higher ratio, while cleaning operations use a higher ratio of the alkaline phase. When the cleaner becomes saturated, it is added to the coolant tank to aid with volume control. According to Product Manager Laurent Ilievski, the system can reduce waste generation by up to 90 percent. Water consumption is minimized, capital investments in wastewater treatment equipment are reduced or eliminated, and energy and wastewater treatment costs are reduced because significantly lower quantities need to be treated.
Modular conveyors reduce cost of automation
Wes-Tech Automation Services' Tech-Trak conveyors are single-strand, power-and-free palletized conveyers available in a variety of preset modules. This modularity allows for the design of any configuration required to accommodate any process while making efficient use of space requirements, according to the company. If multirail conveyers are necessary, other brands' conveyors can be accommodated and integrated into the system design. Each module uses a single part number for ease of ordering, and the modular nature of the system reduces cost and delivery time.
Related Glossary Terms
- automatic toolchanger
automatic toolchanger
Mechanism typically included in a machining center that, on the appropriate command, removes one cutting tool from the spindle nose and replaces it with another. The changer restores the used tool to the magazine and selects and withdraws the next desired tool from the storage magazine. The changer is controlled by a set of prerecorded/predetermined instructions associated with the part(s) to be produced.
- backlash
backlash
Reaction in dynamic motion systems where potential energy that was created while the object was in motion is released when the object stops. Release of this potential energy or inertia causes the device to quickly snap backward relative to the last direction of motion. Backlash can cause a system’s final resting position to be different from what was intended and from where the control system intended to stop the device.
- computer numerical control ( CNC)
computer numerical control ( CNC)
Microprocessor-based controller dedicated to a machine tool that permits the creation or modification of parts. Programmed numerical control activates the machine’s servos and spindle drives and controls the various machining operations. See DNC, direct numerical control; NC, numerical control.
- coolant
coolant
Fluid that reduces temperature buildup at the tool/workpiece interface during machining. Normally takes the form of a liquid such as soluble or chemical mixtures (semisynthetic, synthetic) but can be pressurized air or other gas. Because of water’s ability to absorb great quantities of heat, it is widely used as a coolant and vehicle for various cutting compounds, with the water-to-compound ratio varying with the machining task. See cutting fluid; semisynthetic cutting fluid; soluble-oil cutting fluid; synthetic cutting fluid.
- cubic boron nitride ( CBN)
cubic boron nitride ( CBN)
Crystal manufactured from boron nitride under high pressure and temperature. Used to cut hard-to-machine ferrous and nickel-base materials up to 70 HRC. Second hardest material after diamond. See superabrasive tools.
- electrical-discharge machining ( EDM)
electrical-discharge machining ( EDM)
Process that vaporizes conductive materials by controlled application of pulsed electrical current that flows between a workpiece and electrode (tool) in a dielectric fluid. Permits machining shapes to tight accuracies without the internal stresses conventional machining often generates. Useful in diemaking.
- emulsion
emulsion
Suspension of one liquid in another, such as oil in water.
- grinding
grinding
Machining operation in which material is removed from the workpiece by a powered abrasive wheel, stone, belt, paste, sheet, compound, slurry, etc. Takes various forms: surface grinding (creates flat and/or squared surfaces); cylindrical grinding (for external cylindrical and tapered shapes, fillets, undercuts, etc.); centerless grinding; chamfering; thread and form grinding; tool and cutter grinding; offhand grinding; lapping and polishing (grinding with extremely fine grits to create ultrasmooth surfaces); honing; and disc grinding.
- grinding machine
grinding machine
Powers a grinding wheel or other abrasive tool for the purpose of removing metal and finishing workpieces to close tolerances. Provides smooth, square, parallel and accurate workpiece surfaces. When ultrasmooth surfaces and finishes on the order of microns are required, lapping and honing machines (precision grinders that run abrasives with extremely fine, uniform grits) are used. In its “finishing” role, the grinder is perhaps the most widely used machine tool. Various styles are available: bench and pedestal grinders for sharpening lathe bits and drills; surface grinders for producing square, parallel, smooth and accurate parts; cylindrical and centerless grinders; center-hole grinders; form grinders; facemill and endmill grinders; gear-cutting grinders; jig grinders; abrasive belt (backstand, swing-frame, belt-roll) grinders; tool and cutter grinders for sharpening and resharpening cutting tools; carbide grinders; hand-held die grinders; and abrasive cutoff saws.
- in-process gaging ( in-process inspection)
in-process gaging ( in-process inspection)
Quality-control approach that monitors work in progress, rather than inspecting parts after the run has been completed. May be done manually on a spot-check basis but often involves automatic sensors that provide 100 percent inspection.
- land
land
Part of the tool body that remains after the flutes are cut.
- linear motor
linear motor
Functionally the same as a rotary motor in a machine tool, a linear motor can be thought of as a standard permanent-magnet, rotary-style motor slit axially to the center and then peeled back and laid flat. The major advantage of using a linear motor to drive the axis motion is that it eliminates the inefficiency and mechanical variance caused by the ballscrew assembly system used in most CNC machines.
- machining center
machining center
CNC machine tool capable of drilling, reaming, tapping, milling and boring. Normally comes with an automatic toolchanger. See automatic toolchanger.
- outer diameter ( OD)
outer diameter ( OD)
Dimension that defines the exterior diameter of a cylindrical or round part. See ID, inner diameter.
- stiffness
stiffness
1. Ability of a material or part to resist elastic deflection. 2. The rate of stress with respect to strain; the greater the stress required to produce a given strain, the stiffer the material is said to be. See dynamic stiffness; static stiffness.
- threading
threading
Process of both external (e.g., thread milling) and internal (e.g., tapping, thread milling) cutting, turning and rolling of threads into particular material. Standardized specifications are available to determine the desired results of the threading process. Numerous thread-series designations are written for specific applications. Threading often is performed on a lathe. Specifications such as thread height are critical in determining the strength of the threads. The material used is taken into consideration in determining the expected results of any particular application for that threaded piece. In external threading, a calculated depth is required as well as a particular angle to the cut. To perform internal threading, the exact diameter to bore the hole is critical before threading. The threads are distinguished from one another by the amount of tolerance and/or allowance that is specified. See turning.
- toolchanger
toolchanger
Carriage or drum attached to a machining center that holds tools until needed; when a tool is needed, the toolchanger inserts the tool into the machine spindle. See automatic toolchanger.
- wire EDM
wire EDM
Process similar to ram electrical-discharge machining except a small-diameter copper or brass wire is used as a traveling electrode. Usually used in conjunction with a CNC and only works when a part is to be cut completely through. A common analogy is wire electrical-discharge machining is like an ultraprecise, electrical, contour-sawing operation.
INDUSTRY NEWS
