CNC Machines Sales Tools Repair Information

Variable speed die grinder has spindle lock

2007-03-07T04:31:00.001-08:00

A new variable speed 2in (50mm) die grinder that greatly simplifies the procedure required to change accessories. Having a spindle lock only one wrench is needed on the collet.

A new variable speed 2in (50mm) die grinder that greatly simplifies the procedure required to change accessories has been introduced by Metabo. While other tools require two wrenches to change accessories, the GE700 has a spindle lock, so only one wrench is needed on the collet. The new grinder is extremely flexible, featuring an extended spindle ideal for operation in confined areas and Metabo's Vario-Constamatic (VC) full-wave electronic speed control.

The VC speed control allows users to vary speed to accommodate a variety of accessories, including flap wheels, carbide burs, abrasive cut-off wheels, and mounted points.

This makes the tool useful for grinding and cutting a wide range of materials, from hard to soft, including plastic.

The GE700 has a hardened and ground 1/4in collet for accurate balance of fitted attachments, and auto-stop carbon brushes that increase brush life while preventing motor damage that can be caused by worn brushes.

The power switch is ergonomically located on the top of the tool, making it easy to operate for both right- and left-handed users.

Production grinder has 3-axis loader as standard

2007-03-07T04:30:00.001-08:00

Offered with a 3-axis NC gantry loader as standard an angle-approach, cylindrical grinder has a 320mm swing and 125mm maximum centre distance for grinding small, high precision parts.

New from the grinding machine division of Toyoda will be theGW3A-12, an angle-approach, cylindrical grinder with a 320mmswing and 125 mm maximum centre distance. Available also with astraight approach wheel, the machine is Ideal for grindingrelatively small components such as fuel injector and electronicparts. The machine is the first Toyoda grinder to be offered witha 3-axis NC gantry loader as standard equipment, allowing longperiods of unattended running.

Further integration with otherproduction cells is achieved using pallets or conveyors.

Idealfor use with alumoxide wheels, or with CBN as will bedemonstrated at MACH 2002, the machine has a compact footprintmeasuring only 950mm wide without the loader.

It is also thefirst Toyoda grinder to be fitted with a Fanuc control - the 21iCNC - rather than the manufacturer's own.

This providecontrol of six axes, three for the machine and three for theloader.

A notable feature on this and all other Toyoda grindersis the STAT hydrostatic / hydrodynamic wheel spindle bearing.Absence of metal-to-metal contact and good vibration dampingcharacteristics assure high accuracy and long service life.Grinding speed is 45 m/s, although 60 or 80 m/s is available forCBN.

Other specifications include 219mm wheelhead infeed and20m/min rapid traverse rate; 32 - 1,000 rpm workhead spindlespeed; and 25mm tailstock quill stroke.

A single point, diamondwheel dresser is standard with the machine.

On show also will bethe Toyoda GU4x100 CNC, a universal grinder featuring automaticindexing of the wheelhead under computer control for deployingeither the internal grinding spindle or one of two externalgrinding wheels for straight- and angle-approach.

Poweredindexing of the wheelhead is in five degree or one degreeincrements using a Hirth coupling and hydraulic clamping toensure precise location.

A full B axis is a further option.Available in two versions with 1000mm or 1500mm between centres,the machine has maximum internal and external grinding diametersof 300 mm and 120 mm respectively, 320 mm swing over the tableand a wheel surface speed of 30m/s (optionally 45m/s).

Electronic control ups angle grinder productivity

2007-03-07T04:29:00.000-08:00

An angle grinder, which maintains a constant speed while operating during both maximum load and no-load conditions, allows the user to achieve significantly greater productivity while grinding.

The WE14-150 Plus angle grinder, which maintains a constant speed while operating during both maximum load and no-load conditions, has been introduced by Metabo. The tool features Metabo's Vario-Constamatic (VC) full-wave electronic speed control, allowing the operator to achieve significantly greater productivity while grinding. The WE14-150 offers thermal overload protection to reduce motor burn out when used in heavy-duty applications.

A light signal flashes to give warning of impending overload to the operator if the temperature of the windings should approach the maximum permissible value.

The grinder includes several standard features for easy operation, including Metabo's unique 'Quick' system that enables the operator to change grinding wheels without the use of tools, significantly reducing downtime.

Metabo also offers a tool-less wheel guard adjustment that allows the operator to make adjustments rapidly and safely.

The WE14-150 incorporates Metabo's Marathon motor with epoxy resin powder-coated field coils, which make the motor extremely resistant to destructive grinding dust and help prevent overheating.

The grinder also includes a two-position side handle for additional comfort and control during operation, as well as Metabo's exclusive S-automatic safety clutch to prevent injury from kickback in the event of a wheel jam.

A winding protection grid deflects harmful airborne debris away from armature windings, increasing motor life by up to five times.

Precision dosing ups CBN/diamond wheel life

2007-03-07T04:27:00.000-08:00

Using a biomedical engineering micro-dosing technique, CBN and diamond coated honing tool lives can be increased up to 10 to 20 times, while grinding performance can be quadrupled.

Using a biomedical engineering micro-dosing technique, CBN anddiamond coated honing tool lives can be increased up to 10 to 20times, while grinding performance can be increased up to fourtimes. It is no surprise that the tool grinding time and costs -and quality of finish - is directly dependable on the quality ofthe grinding wheel. Distribution of CBN or diamond grains on awheel surface is random - which influences grindingcharacteristics.

Dr Gregor Burkhard of the Institute of MachineTools and Manufacturing, the Swiss Federal Institute ofTechnology, Zurich, has developed a precise grain-placing methodbased on medical practices.

The result is significant shorteningof tool grinding time and grinding wheel life.

Dr Burkhardpresented his results at the Fritz Studer Grinding Symposium,held in Thun, Switzerland, earlier in 2002.

With random spacingof CBN or diamond grains, the spaces in between the grains canclog, resulting in 'burning' of the tool or workpiecesurfaces, said Dr Burkhard.

Usually CBN and diamond coatedgrinding wheels consist of a steel or aluminium wheel body thecircumferential work surface of which is electroplated withnickel or nickel alloy to secure the abrasive grains.

Usually,the surface is coated with an adhesive, and the wheel rolled in alayer of abrasive grains.

The adhesive holds them in place duringthe electroplating process.

'The grains are randomlyarranged,' said Dr Burkhard, 'which means that thedistance between the individual grains - which serves totransport cooling lubricant into, and chips out of, the machiningzone, is also random.

This represents a major disadvantage ofsuch tools, as individual spaces can easily become clogged duringmachining, which then eventually leads to abrasive burning on thetool and, therefore, to spoilage.' Another point made by DrBurkhard was that with existing grinding wheel electro-platingmethods, the abrasive grains are only 'mechanicallyclamped' in place and grain projection is only 40 - 50% ofthe mean grain diameter.

With the new grain dispensing method, itis possible to determine the size and location of the vacantspaces.

Then, if an active brazing alloy bond is used, grainprojection can amount to 80-100% of the mean grain diameter.'This permits good supply of the cooling lubricant into, andgood removal of the chips from, the machining zone, ' saidDr Burkhard, 'thus enabling higher metal removal rates andcutting times.' Dr Burkhard's team has adapted the useof micro-dosing from biomedical engineering processes.

Normallyused for precision pipetting purposes, micro-dosing producesuniform drops with a maximum diameter of about 40 microns at anemission frequency of up to 2000Hz.

Such a dosing head consistsof a glass capillary tube connected to a reservoir via a feedpipe.

It forms a jet with its mid-section enclosed by apiezoactor.

The piezoactor contracts when a voltage pulse isapplied, so causing a drop to be emitted.

A heater is alsoincluded to set the optimum viscosity of the fluid.

So DrBurkhard's team built a prototype device to sequentiallydose the work surface of a grinding wheel body with liquidadhesive drops in specific patterns and distribution.

The wheelis then rolled through a thin layer of abrasive grains, the sizeof the drop determining whether a single, or clusters of, a CBNor diamond grain are picked up.

Brazing paste is then applied tothe wheel work surface.

In practice, the prototype'micro-dosed' structures were applied to mandrel-typehoning tools (or honing sleeves) to hone the interrupted bore ofa hardened gear wheel to the finished size of 12F7 diameter.Before, the process was carried out in three stages usingelectroplated honing sleeves with settings of 0.04, 0.04 and acalibrating pass of 0.01mm (on diameter).

The mean service lifeof the electroplated tools was 5000 strokes at the 0.04mmsetting.

In tests, with setting at 0.08mm on diameter, life ofthe electroplated honing sleeve was 1000 bores.

The micro-dosedand brazed honing sleeve lasted for 6000 bores.

Yet themicro-dosed tools had not yet been fully optimised in terms ofgrain size and grain spacing! Further development resulted in themicro-dosed honing sleeves producing a service life of 10 to 20times greater than the traditional electro-plated honing sleeves.Development went on to produce internal grinding CBN and diamondcoated pinwheels and a disc-type grinding wheel.

In tests withthe latter, a wheel of 300mm diameter and 20mm wide was used intests in hardened tool steel in a Maegerle surface grinder,producing a related time/machining volume of Qw = 20mm3/mms at acutting speed of Vc = 40m/s.

'This is four times the valuefor conventional tools,' said Dr Burkhard.

Bear in mind thatthe increased metal removal rate was achieved without optimisingcoolant to suit the new wheel.

Modular platform concept is the user's advantage

2007-03-07T04:22:00.000-08:00

In many industrial fields, including the automobile industry, product platforms have been used successfully for several years, it has now been applied to cylindrical grinders.

The modular platform concept is to the customer's advantageIn many industrial fields, including the automobile industry,product platforms have been used successfully for several years.A standardisation of systems, sub-assemblies and components, evenover different makes and models, are of central importance, themain target being a reduction of engineering time and costs.Although the above cannot be directly applied to machine tolls,the following explanations should show that similarities existand a platform concept also provides considerable advantages withregard to the universal and external cylindrical grindingmachines of Studer. The Studer product range is characterised bya large variety of machine types and versions with the intentionof satisfying the different requirements of a large number ofinternational customers. Due to this multitude of types andvariations, there are additional expenses for engineering,production and logistics.

In this field, a modular platformconcept, combined with a consequent 'same partstrategy', provides economical and technical advantages forthe manufacturer as well as for the customer.

All the newdevelopments of recent years in the field of universal andcylindrical external grinding machines are based on two basicplatform types with standardised sub-assemblies, components andinterfaces.

The product platforms for the respective machinetypes derive from this: Platform basis A for the machines S21,S31 and eco, Platform basis B for machines S32 and S41 Furtherproduct platforms can be built from the above, and realised withminimal technical risks.

Characteristics of the basic types ofplatforms A and B - common characteristics * Machine bed inGranitan S103 with 3-point support.

* Circulating balls screwswith directly coupled servo motors.

* Linear measuring systems.

* Well dimensioned slides.

* Coolanttray.

* Protected guideways.

Varying characteristics: Platformtype A: * Distance between centres max: 1000mm.*Centre height max: 175mm.

* workpiece weight, max: 120kg.

*Guideways, X and Z axis: linear roller ways.

* Distance betweenthe guideways: 200 mm.

* Workpiece table: 140 mm for centreheight 175mm and 200mm for centre height 225mm.

Platform type B:* Distance between centres, max: 1600mm.

* Centre heightmax: 225mm.

* Workpiece weight max: 180kg.

* Guideways: X axis:Pre-loaded hydrostatic guideways and Z axis, linear rollerbearings.

* Distance between the guideways: 250mm.

* Workpiecetable: 140mm.

Platform concept combined with modularsub-assemblies - the combination of product platforms and modularsub-assemblies, such as wheelheads, workheads, tailstocks, etc,form the basis for a versatile and clear product structure.However, the possibilities of combining are limited by physicaland economical restrictions.

These are due to the machine sizes,the drive power of the wheelhead and the type of machine, i e,universal or cylindrical external grinding machine.

Product andstrategic marketing considerations are further criteria which caninfluence and restrict the combination possibilities.

The basicversions of wheelheads are firmly allocated to the differentproduct platforms.

We distinguish between wheelheads withintegrated B axis for the universal cylindrical grinding machinesand the fixed or limited swivelling wheelheads for thecylindrical external grinding machines.

The layout of grindingwheels can be adapted to the customer's requirements withinthe possibilities of the respective modular concept.

For furtherinformation with regard to the grinding wheel layout, pleaserefer to the respective documents.

Depending on the main use, theproduct platforms can be equipped with workheads for universal orchuck applications.

One of the main differences, apart from theadmissible load, is the tool clamping interface.

For automaticprocessing, for instance of highly accurate components in largeseries for the Diesel injection industry, special workheads canbe installed.

On all the product platforms there is the samebasic tailstock type.

This unit is conceived for the differentcentre heights and table loads.

For automatic processing, specialversions are available.

Summary - the modular platform conceptfor the universal and external cylindrical grinding machines ofStuder brings various advantages: * Reduced engineering time andcosts for realising similar machine types or versions.

* Savingsfor the manufacturer and the customer by using compatible systemsand components.

* Versatile product structures by combining theproduct platforms with modular sub-assemblies and standardisedinterfaces.

* High reliability of the products thanks to ampleexperience gained with the product platforms under differentworking conditions.

* High and stable quality thanks toproduction in series and standardised quality checks.

*Accessories can be used for different product platforms.

*Identical service and maintenance thanks to similar systems andcomponents.

* Short-term availability of spare parts.

*Simplified retrofitting of functions and sub-assemblies..

Facing and internal grinding made in one set-up

2007-03-07T04:21:00.001-08:00

Facing and internal grinding machine can concentrate and combine serveral operations - including profile grinding - into one set-up under CNC.

Danobat offers maximum flexibility in internal and face grinding with the new Overbeck IG 400 CNC internal and face grinding machine. Increase productivity and efficiency of the processes, reduce the space in the plant and guarantee the finishing of parts are the results of the new Overbeck IG 400 in the demanding internal grinding sector. * Danobat: Overbeck IG 400 - the IG 400 offers the possibility of concentrating and combining several operations coordinated by numerical control.

This model performs form grinding, and also has up to four workstations combining internal and face grinders and measuring devices.

The main advantage offered by the IG400 is the capacity to carry out all the part internal and face grinding operations in one clamping, regardless of the size of the batch.

The software designed for this machine allows for easily carrying out simple cycles by means of the introduction of basic parameters or more complex combinations that enable a greater degree of automation of the process.

Surface grinders have more CNC flexibility

2007-03-07T04:07:00.000-08:00

More flexibility in programming with variable graphics simulation for grinding and wheel dressing feature the latest Chevalier CNC surface grinding machines.

Expansion of the Chevalier range of CNC surface grinding machines, represented in the UK by C Dugard of Hove, UK, brings new levels of programming flexibility with variable graphics simulation for grinding and wheel dressing where the speed of review sequences can be varied by the operator. The Smart II - Series of multi-function, 3-axis machines has been developed for surface, form, step, slicing and profile grinding parts as diverse as turbine blades, punches, graphite electrodes and ceramics and production batch work such as automotive cam followers and valve stems. With the new control and software, the machines can also be programmed to produce different slots with varying depths and pitches on the same part.

In addition, with the inclusion of a CNC rotary table giving speeds up to 33 rev/min, the machines can be used to create cylindrical grinding cycles as well.

Key to the flexibility of the Smart-II Series is the simple graphics-based conversational control that incorporates a wide range of macros for grinding and wheel dressing including compensation with full grinding and wheel dressing simulation.

The simulation cycles utilise the electronic handwheels for manual axis movements to provide the facility whereby forward or reverse display of the program paths can be viewed.

The faster the handwheels are rotated in either direction, governs the speed of the execution of the simulation cycle.

There are four automatic graphic modes for dressing: table type with single point diamond or diamond roller, overhead diamond roller or full profile dressing.

Further advantages of the Chevalier system is the automatic wheel compensation that can even be executed in profile dressing mode, while pre-set dressing cycles can be initiated at anytime during the grinding cycle.

Once the dressing cycle is complete, additional finish or 'patch' passes can be made without having to repeat the complete cycle.

The new machine range spans the Smart II-818, 1224 and 1640 providing table sizes of 200mm by 460mm, 300mm by 600mm and 400mm by 1000mm and table loadings up to 670kg.

The maximum distance from table surface to spindle centre 406mm on the smallest machine, 630mm on the 1224 and 630mm on the larger machine.

Grinding wheel sizes are 203mm by 12.7mm by 31.75mm, 355mm by 50mm by 127mm and 355mm by 50mm by 127mm.

The machine is built on a single T-shaped base casting giving maximum rigidity with hardened and ground double 'Vee' ways and Turcite-B coated longitudinal and crossfeed guideways between base, saddle and table.

There is a range of options for the spindle specification from 1.5kW to 11.25kW depending on the machine size with further options for oil or air cooling.

Additional options include: linear scales, automatic wheel balancing, single disc dresser and a paper filter coolant system.

Production cylindrical grinders are fast, precise

2007-02-27T22:37:00.002-08:00

The highly productive S-series of cnc cylindrical internal and external grinding machines offer a wide range of options, fast setting-up and high precision.

Grinding Technology for Tool Production The highly productiveS31cnc cylindrical internal and external grinding machine has awheelhead with two external grinding wheels for rough and finishgrinding left/left. Range of applications includes any type ofcylindrical internal and external machining for automaticproduction of individual components and series. The modularmachine structures, the modern control and programming technique,as well as the grinding technologies, guarantee a highproductivity and excellent machining quality.

The S31cnc isavailable with a distance between centres of 650/1000mm and acentre height of 175mm.

The machine has now been completed withan additional wheelhead version.

This allows the installation oftwo motor spindles.

Consequently, two diagonally installedgrinding wheels, with diameters up to 500mm, can be used.

Thanksto the independently programmable drives, these wheels can beadapted optimally for the respective grinding task, guaranteeinga large speed and perfor- mance range.

The B-axis swivelsautomatically with a resolution of 0.0001deg so that even thesmallest taper angles can be processed with cylindrical grindingwheels to extreme accuracy.

The Studer S32cnc is a fast, accurateand reliable external, cylindrical CNC grinding machine.

TheS32cnc has chameleon-like properties.

Thanks to the large varietyof extensions and versions, a large number of applications can becarried out on this machine according to customers requirements.This is possible thanks to X-axis versions at 0deg or 30deg, andthe possibility of positioning the grinding wheel on the left orthe right side.

Thanks to the versatile machine concept, thismachine permits a selection of the most suitable grinding method,according to individual customer requirements.

This means thatthe machine can master simple and complex tasks in a very highquality.

In the standard version, with the grinding wheel on theright side and a distance between centres of 400mm, this machineis perfectly suited for grinding small and average-sizedworkpieces.

In conjunction with the diamond roll dressingattachment, the S32cnc becomes a highly productive machine.

Ofcourse, thanks to the proven Studer concept it can be automatedeasily.

The use of our C axis turns the S32cnc into a high-powerplunge grinder.

In this context, the hydrostatic guideways of theX axis play an important role as they allow extremely rapid axestraversing with a minimum of axis lag.

Due to the new materialsthat are emerging in the market, the machining process has to beadapted to the situation.

The S32cnc can also master this problemas it can be equipped for high-speed grinding.

With a cuttingspeed of more than 125m/sec, even materials difficult to machine,such as zirconium ceramics or tungsten carbide, can be processedeconomically.

The Studer S40cnc is a highly productive universalinternal and external cylindrical grinding machine.

Its range ofapplications includes any type of external and internalcylindrical grinding task for the automatic production of one-offand series production.

The modular machine structures, the moderncontrol and the programming technique as well as the most recentgrinding technology guarantee a high productivity and machiningquality.

The S40cnc is available with distances between centresof 1000 or 1600mm and centre heights between 125 and 225mm.Wheelheads and workheads for practically any type of use areavailable.

The B-axes is oriented automatically with a resolutionof 0.0001deg so that even the smallest taper angle can be groundto the utmost accuracy with, straight grinding wheels.

We showthe universality of the machine on a complex chuck element.Grinding of forms and threads is always one element of completemachining.

The position and speed-controlled C-axis renders thesegrinding procedures possible.

A measuring system installed on themotor axis of the workhead or on the work spindle providesmaximum form accuracy of the form during the grinding process.Acceleration and grinding forces are easily absorbed by thedynamic rigidity of the axes drives.

With regard to threadgrinding parallel to the axes, the grinding wheel is notswivelled to the pitch angle of the thread, but it remains in thevertical position so that its angle of rotation remains parallelto the Z-axis.

Consequently, while grinding the thread there willbe a distortion of the profile which is compensated by the Studersoftware StuderThreadCNC to a negligible deviation.

Bycalculating the profile distortion and the automatic generationor optimised dressing programmes, thread grinding becomes nearlyas simple as plunge grinding or traverse grinding.

The StuderS60cnc is designed for the grinding of tool holders with theuniversal and production external cylindrical grinding machine.Progress can be obtained by force.

One is tempted to say thiswhen watching the Studer S60cnc in operation.

In order to fulfilthe increasing requirements of the tools, the quality of the toolholding fixtures has to be improved continuously.

The very bestquality of the workpiece is obtained if it can be processed inone single clamping and in one machining pass.

The Studer S60cncpermits complete grinding of tool holders up to the dimensionISO50.

By complete grinding we mean: the V-groove, the externaldiameter, the taper and, if required, the shoulder of the taperin one plunge cut.

Work is carried out by means of a profiledgrinding wheel.

The S60cnc with its elements entirely laid-outfor the production, for instance the grinding wheel width of upto 160mm and the grinding wheel diameter of 750mm, is perfectlysuitable for this type of application and therefore providesexcellent grinding results.

With this procedure, a tool holderISO 50, for instance, is manufactured to quality class AT-3 injust less than 90 seconds.

For this machine, the quality classAT-1 is no problem any longer.

In fact, it is a standardmachining task in a second clamping combined with in-processgauging.

Programmable surface grinders reduce lead times

2007-02-27T22:37:00.001-08:00

The installation of two programmable surface grinders has allowed toolmaker Tarpey-Harris to reduce lead times by up to 25% and optimise grinding times for dies, moulds and precise parts.

The installation of two Okamoto ACC 450 DXA surface grindingmachines by 600 Centre of Shepshed, Loughborough has allowed theBelper-based toolmaker Tarpey-Harris to reduce lead times by upto 25 per cent, have one operator to look after both machines formost of the day and optimise grinding times for a wide range ofdies, moulds and precision parts. In addition, the company hasfound the Okamoto machines very easy to operate and to make itspurchase justification more significant, the final machinespecification worked out 20 per cent less than comparable surfacegrinders on the UK market. Established in 1969 as precisionengineers and toolmakers specialising in tooling for theinvestment casting industry, Tarpey-Harris is now part of theFairbrook Group.

The 32-strong Derbyshire company producesextrusion dies, injection mould tools, rubber mould tools and waxpattern dies that are mainly used for plastics window elementsand profiles as well as cladding for buildings.

The wax andrubber tooling it produces is primarily used in the manufactureof seals for hatches, doors and other openings for the aerospaceindustry.

However, the company also manufactures injection mouldtooling for a range of medical products and provides a componentmachining subcontract service for an array of different industrysectors.

With over 80 per cent of its machining work involvingtool production, grinding is therefore a key process.

So when thecompany decided to replace a couple of ageing manual surfacegrinders it looked around for the most suitable machine on themarket in terms of performance, accuracy, ease of use andespecially set-up and cost effectiveness.

As works director TonyHarris explained: 'After seeing an Okamoto 450 DXA in actionat a 600 Centre customer, we decided that this machine was idealfor our needs, combining precision with affordability.

Sinceinstallation the repeatability, ease of operation and minimalmanning requirements of the machines has transformed ourbusiness.

I look out of my office window and they are runningthroughout the day with hardly anybody ever near them.' Some90 per cent of the company's surface grinding work is nowchannelled through the Okamotos for processing a wide range ofdie parts, bolsters, die blocks, top plates, ceramic core diesplus a range of blank strips for components which aresubsequently profiled by wire-cut EDM.

Work can range fromgrinding the ends of 3 mm by 5 mm probes right up to quite largebolster elements, measuring 350 mm by 400 mm.

Although the tableof the Okamoto ACC 450 DXA is hydraulically actuated, the machineincludes a fully automatic grinding cycle controlled viamicroprocessor with digital readout (DRO) in two axes.

'Thisprovides us with maximum flexibility in terms of just how themachines can be operated,' maintains Tony Harris.

Each ofthe Okamoto grinding cycles tend to be split between variousmodes of operation for which a quarter accounts for manual andsemi-automatic cycles but fully automatic operation is nowapplied to half the work flow passing though the machine.Depending on the mix of work, one man can look after the twomachines for most of the time and in a typical working day, theoperator is only present at the machine for as little as 12 percent of the time which includes wheel dressing, outlines TonyHarris.

He maintains: 'This means we get 16 hours worth ofproduction from the two machines each day with an operator inputof around two hours.' However, he says: 'The biggestsingle saving has been the ability to measure components directlyon the machine using its integral, two-axis DRO.

Here thecontribution to productivity is much higher because parts do nothave to be removed from the table to perform key measuring tasksand we reckon this reduces our lead times by some 20 per cent.While the Okamoto's automatic operation, using auto downfeedand crossfeed has proved of major benefit to the company, thisfeature was not high on the list of priorities when the machinewas initially selected.

As Tony Harris recalled: 'Comingfrom purely 'hands on' manual machines, we were not toofussed about automatic cycles.

However, now that we have such aneasy to use facility, we are making more and more use of autocycling on specific types of work because it is dramaticallyincreasing the flexibility of labour.

Combined with quick set-uproutines, the Okamoto machines have proved to be a really soundinvestment and their repeatability is first class.' Equippedwith 450mm by 150mm magnetic chucks, the Okamoto machines areused on a wide range of tooling work - much of it involvinghardened steel elements.

Typical metal removal rates on hardeneddie blocks, for example, is about 0.5mm and tolerances as tightas two microns are regularly achieved.

Maintains Tony Harris:'Surface finish is another important consideration,particularly on mould type work, and the machines regularlyproduce finishes to 0.05 micron Ra.' The installation of thetwo Okamoto machines has made a big impact on surface grindingefficiency, accuracy, productivity and cost-effectiveness.

And asTony Harris concluded: 'When we need additional surfacegrinding capacity we will undoubtedly go back to the 600 Centre,because these two machines have transformed the way we wereworking.

Die grinder offers more torque and variable speed

2007-02-27T22:36:00.002-08:00

A new versatile, variable speed 3in die grinder offers a torque three times higher than similar units, making it ideal for grinding internal surfaces in polishing and finishing applications.

A new versatile, variable speed 3in die grinder that offers a torque three times higher (27 inch lb.) than similar units, making it ideal for grinding internal surfaces in polishing and finishing applications, has been introduced by Metabo. The new GE900 Plus is geared to run at a lower rpm range than similar grinders, which increases the number and type of usable accessories for sanding, polishing or buffing, such as flap wheels and non-woven abrasive finishing wheels. The new grinder is designed for ease-of-use, featuring a side handle for increased user control and a spindle lock-one wrench feature that enables users to change accessories using only one wrench instead of two.

The switch is ergonomically located on the top of the tool, making it easy to operate with either the right or left hand.

Metabo's Vario-Constamatic (VC) full-wave electronic speed control allows users to vary speed to accommodate a variety of accessories, making the GE900 Plus useful for grinding and cutting a wide range of materials, from hard to soft, including plastic.

The GE900 Plus has a hardened and ground 1/4in collet for accurate balance of fitted attachments, and auto-stop carbon brushes that increase brush life while preventing motor damage that can be caused by worn brushes.

The grinder has a no-load speed of 2,500 - 6,000 rpm and is rated at 7.5 amps, 900 watts.

A collet wrench, spindle wrench, the 1/4in collet, and the side handle are all offered as standard with the GE900 Plus.

Cylindrical grinder ready for next generation

2007-02-27T22:36:00.001-08:00

Increased machine rigidity, longer X-axis travels and higher speeds and the capability of taking larger wheelheads, feature a new versatile cylindrical grinder.

Increased machine rigidity, longer X-axis travels and higherspeeds and the capability of taking larger wheelheads, feature anew versatile cylindrical grinder. Future models will includehard turning operations. The concept and dimensions of the S41cnccylindrical grinder are comparable with the proven S40cnc, butfeatures some recently developed elements and modifications readyfor a new generation of wheelheads and further peripheralelements.

The S41cnc is the first machine which comes with thenew Studer design concept.

* Increased machine bed rigidity,optimised for workpieces of up to 180kg (396lb).

* Pre-Loadedhydrostatic guideways in the X-axis (feed motion).

To thecustomer's advantage is the optimal dynamic behaviour forform grinding, taper grinding and interpolation grinding,combined with increased rigidity.

* Longer in X-axis travel, now300mm (11.8in).

* Increased axis speed in X, now 15m/min(590in/min).

* Larger distance between the guideways of theZ-axis, providing more rigidity against the feed forces whenplunge grinding.

* Massive layout of the longitudinal guideway.Increased longitudinal table stability.

* Longer longitudinalslide to make sure that dressing attachments and similarequipment can be mounted.

* Longer in Z-axis travel, now 1200mm(47in).

* Increased axis speed in Z, now 15m/min (590in/min).

*The absolute length measuring systems of the axes X and Z makereferencing at machine start unnecessary.

* Larger swivel radiusof the B axis: I e a larger wheel-head can be installed.

* Newmaintenance and service-friendly enclosure concept.

* Better workarea accessibility when loading from the top (i e portal loader).* Energy supply on the Z-axis prepared for additional options.

*New control FANUC 16i or 160i.

With the control 160i, thismachine is now entirely compatible with Windows applications andwith both control types connections to networks via Ethernetinterfaces are possible.

* Generally, actuators and sensors areconnected by means of ASi-Bus.

This simplifies retrofits.

Futureapplications and procedures - further developments will follow,especially with regard to wheelhead layouts.

A glance towards thefuture of the S41cnc reveals the following: * Dual motor spindlewheelhead with up to four grinding wheels 500mm (20in) diameter.* Integration hard turning operations, either with a single tool(only one turning operation, e g internal profile turning of anHSK taper shoulder) or by means of an indexing tool holder.

*Y-axis to grind longitudinal grooves.

* A-axis applications togrind threads with slanted pitch angles.

The S41cnc has beendemonstrated hard turning and grinding a HSK63 tool holder.

External cylindrical grinder offers more scope

2007-02-27T22:33:00.000-08:00

A cylindrical, external grinding machine offers much wider scope with regard to accuracy, quality and concept, and at an extremely competitive price.

The cylindrical, external grinding machine eco650 offers muchwider scope with regard to accuracy, quality and concept, and atan extremely competitive price. The machine is many times provenin job shops in the field of tool making. There is also therevolutionary eco1000 for machining long and shaft-likeworkpieces to the well-known Studer quality.

Also this machine issold at a price which is outstanding in its category.

The mostimportant features in brief * Distance between the centres: 1000mm/40in.

* Centres height 175 mm/6.9in.

* Machine bed in StuderGranitan S103 with 3-point support.

* Vee and flat guideways withthe patented knob-type coating in Studer Granitan S200.

* Rotarymeasuring system for the axes X and Z with a revolution of0,0001mm/0,000,004in (a linear measuring system is available as aretrofit kit).

* grinding wheel layout on the right hand side,orientable to 0 degree and to 30 degrees for straight and plungegrinding.

* Rigid, roller bearing grinding spindle with a drivepower of 7.5kW/10HP.

* Grinding wheel diameter up to 500mm/ 20in.* Roller bearing workhead for grinding between fixed or rotarycentres, with tool retention taper MT5.

* tailstock with quilldiameter 50mm/1.97in and retention taper MT3.

* Orientablelongitudinal table, tilt up to 8.5 degrees for grinding highlyaccurate tapers.

* CNC control FANUC 21i.

* Programming with theStuder prictogramming software.

* Compact layout and attractivedesign.

* Excellent view onto the working process and optimalaccess.

* Additional equipment in the shape of retrofit kits isavailable.

Such devices can be installed by the customer and nospecial knowledge or training is required.

S31leanCNC withdistance between centres of 1000 mm/40 - this machine conceptcannot be compared to anything else with regard to universal usein the field of complete machining.

With the S31leanCNC1000 allyour requirements and wishes can be fulfilled.

Maximumflexibility thanks to the proven turret-type wheelhead withexternal grinding wheels on the left and on the right side togrind diameters and shoulders as well as internal operations oncomplex workpieces, in a single clamping.

Interactive hand wheelmode - this operator-friendly element which plays an importantrole in the successful history of the S30leanPRO is now alsoavailable on the S31leanCNC.

The most important features are, inbrief: * Distance between centres: 1000mm/40in.

* Centre height175mm/6.9in.

* Machine bed in Studer Granitan S103 with 3-pointsupport.

* Vee and flat guideways in the patented knob-typecoating in Studer Granitan S200.

* Rotary measuring to aresolution of 0,0001mm/0,000,004in on the axes X and Z.

*Universal, orientable wheelhead, manual positioning 2,5deg andoptional automatic positioning in1deg.

* Motor grinding spindlewith infinitely adjustable speed control and a drive power of7,5kW/10HP.

* Grinding wheel diameters up to 500mm/20in, rightand left side.

* Workhead with roller bearing for grindingbetween stationary or rotary centres with tool taper ISO50.

*Tailstock with quill diameter 50mm/1.97in.

and tool taper MTK3.

*CNC control FANUC 2li.

* Programming by means of the Studerpictogramming software.

* Hand wheels to influence the grindingprocess manually through the axes X and Z, by means of the StuderInteract software.

Internal grinders machine flexibly within microns

2007-02-23T04:32:00.001-08:00

Safety critical machining of fuel injection components in large series, or universal machining of small series, always within tolerances of a few microns: these are the jobs for internal grinders.

Safety critical machining of fuel injection components in largeseries, or universal machining of small series, always withintolerances of a few microns: these are the jobs for Studerinternal grinding machines, which are built in differentversions. On the S145cnc with up to four spindles, for instance,complex components in small and average series can be groundeconomically. Featuring a centre height of 175mm a maximumgrinding length of 200mm and a substantial table load, themachine is suitable for a wide range of applications.

Grindingspindles according to requirements of 24000 rev/min to 120000rev/min installed on the indexing turret head allow high-accuracymachining of bores up to diameters of 200mm and the manufactureof smallest bores of less than 3mm in diameter.

This is the idealmachine for the production of small and average series as well asfor mould making applications.

For internal production grinding,the S140cnc is available.

Based on its modular concept, thismachine is suitable for a large number of production tasks.

Thestandard version is equipped with hydrostatic guide-ways; thisbasic version of the Studer S140cnc provides the ideal basis forhigh accuracy machining.

Simple machining tasks with one grindingspindle can be achieved by means of the S140 modular kit, as wellas complex elements including simultaneous external and internalmachining.

Reductions of cycle times of up to 40% can beobtained.

Specially adapted machining modules, such as internaland external grinding spindles, workheads and different dressingattachments, can be installed on the standardised machine tableaccording to requirements.

The machine tables with hydrostaticguide systems, in conjunction with the optional, alsohydrostatically- operated drive spindle guarantee a smooth motionand perfect surface quality of the workpiece.

Up to threeinternal grinding spindles with ceramic bearing systems andspeeds above 100,000 rev/min installed on a slide allow machiningof extremely small bores to the narrowest tolerances.

Roughingand fine machining can be carried out without time-consumingindexing of a revolver.

Simultaneously to internal roughgrinding, finish grinding of external diameters or surfaces canalso be done.

The installation of a handling system withintegrated gauging and palletising units converts the S140cncinto an unmanned machining centre.

In three shifts and seven daysa week, elements for diesel injection systems, for instance, inhighest quality, can be machined.

Hard materials ground and sliced accurately

2007-02-23T04:31:00.004-08:00

Ceramic? Silicon? Quartz? Glass? Tungsten? - whatever the hard or brittle material, slicing and surface grinding and vertical profile grinding machines perform consistently and accurately.

Chevalier (distributed in the UK by Dugard Machine Tools) offerthe essential hi-tech grinding machines for high-precision andefficient performance across a large range of industrialapplications. Ceramic? Silicon?

Quartz?

Glass?

Tungsten?.whatever the hard or brittle material, the Chevalier range ofslicing and surface grinding machines and vertical profilegrinding machines are designed to perform consistently andaccurately.

For example, take the FSG-H818CNC or the B818CNCmachines.

Both are high efficiency, high precision multipurposegrinders particularly suited to intricate profiles and moldcomponents such as those required in for aerospace, automotive,electronic, medical and defence applications.

Both provideexcellent rigidity and precise positioning with full Fanuc OMautomation - and both offer outstanding versatility for all typesof grinding (multilevel surfaces, punch, slice, plunge, pitch,side-wheel, profile, form, index and creepfeed).

Or there are theFSG-2040TC and 2060TC column type, high precision three-axissurface grinders.

These programmable machines provide rough orfine grinding for mass production.

The precisely balanced spindlemotors are air cooled to ensure accuracy and the wheelhead isfinely positioned to ensure downfeed repeatability to within0.002mm.

For two-axis, submicron surface grinding Chevalierprovide the ULTRA-H612CNC or the ULTRA-B612CNC.

Both of thesemachines provide mirror sufacing (surface roughness) to within0.25mm; a positioning accuracy to within 0.5mm and a grindingaccuracy to within 1mm.

The extra long guideway design of thespindle seats on these machines provides high rigidity and helpsto overcome the cutting resistance.

An optional linear scalesystem can be mounted on the column to compensate for pitch errorand to ensure accuracy.

For a smaller, multifunction surfacegrinder, Chevalier offer the SMART-H818 which is designed to meetthe needs of novice and experienced CNC operators alike byproviding the simplicity of a manual grinder and thesophistication of a CNC machine.

Without requiring complexprogramming codes, the SMART-H818 can still be programmed inG-code format or can download from a CAD/CAM system.

The tablespeeds vary from 0.02 - 25m/min.

Meeting the financial needs ofthe industry today - 'Cost is the major issue intoday's industry,' says Eric Dugard, Managing Directorof C Dugard.

'Our customers need accuracy, reliability,performance and high productivity - but at the right price.

Toenable them to achieve this we offer a range of innovative andpractical rental schemes and finance packages to help them spreadtheir investment over a period of time.

We also provide fullinstallation, support and maintenance packages - plus extendedwarranties - so that our customers can choose the option thatsuits them.

Flexibility is the key word in order to meet the everevolving needs of our customers.' 'As ourcustomers' requirements become more and more sophisticated,Dugard offers them the very latest in technology (both in themachines themselves and in the control systems) to help them stayat the forefront of today's industry.

At the same time, wemaintain our fundamental policy of providing affordable qualityplus performance.' CD-ROM catalogue - Eric Dugard adds,'Many of our customers have been requesting our new CD-ROMcatalogue of products.

This is a recent innovation for Dugard andit was particularly well received at the recent MACH 2002 show.While our website already provides up-to-date details on ourproduct ranges, services and financial packages, many customersprefer to use our CD-ROM in order to browse through our ranges(off-line) at their leisure.

This is just another way in whichDugard continue to make it as easy as possible for our customersto access the information they need.'

Manual grind and cut large jobs safely

2007-02-23T04:31:00.003-08:00

Two large angle 7in or 9in wheel grinders designed for cutting and grinding applications incorporate a two-step power switch at the rear of the tool, allowing users to tackle large jobs safely.

Two new large angle grinders designed for both cutting and grinding applications have been introduced by Metabo. Featuring a 7in or 9in wheel, the W23-180 and W23-230 grinders incorporate a two-step power switch at the rear of the tool, allowing users to tackle large jobs safely. Users must have the first button depressed to engage the power switch, preventing accidental turn-on during operation.

The tools feature a flexible rear handle that rotates 90deg for comfort during cutting operation.

A 3-position side handle for left- or right-handed operation allows users to turn the tool 90deg to cut vertically, while still having a firm grasp on the grinder.

The grinders incorporate Metabo's Marathon motor with epoxy resin powder-coated field coils, which make the motor extremely resistant to destructive grinding dust and help prevent overheating.

Also included in each grinder is a winding protection grid that deflects harmful airborne debris away from armature winding, increasing motor life by up to five times.

The grinders feature an easy-to-use wheel guard that requires no tools to adjust, and auto-stop carbon brushes for longer service life.

The W23-180 is rated at 2,300 watts, has a torque value of 124in.lb, operates at 8,500 rpm using a 15.0A motor, and weighs 13.3lb.

The W23-230 is rated at 2,100W, has a torque of 150in lb, operates at a no-load speed of 6,600 rpm using a 15.0A motor, and weighs 13.6lb.

Programmable bearings raise grinding accuracy

2007-02-23T04:31:00.001-08:00

Hydrostatic bearings in surface grinding machines have programmable variable pressure to achieve flatness and straightness levels within 0.5 micron/m machine table stroke.

The latest 'groundbreaking' development in adding programmable variable pressure to hydrostatic bearing technology by Okamoto of Japan, the world's largest manufacturer of grinding machines, enables some four times greater levels of rigidity to be obtained over conventional surface grinding machines that use hydrostatic bearings. As a result, flatness and straightness levels within 0.5 micron can now be held per metre stroke of the machine table in the latest UPG-84NC Ultra Planarization surface grinder while supporting table loads up to 700kg. Now available from the 600 Centre of Shepshed near Loughborough, the UPG-84NC is the most compact of the latest UPG machine range of 13 machines which can be specified having table lengths up to 4000mm and all are capable of generating the same degree of flatness.

The technology was originally developed by Okamoto's special purpose application engineering team to create a new order of 'mother' machine capability with minimum inertia and vibration when the table reverses.

The idea was to create new orders of flatness and straightness for production grinding its own surface grinding machine tables, beds and bearing guide rails.

The latest UPG range is ideal for grinding tasks such as dies, master granite surface plates, metrology equipment, LCD and semiconductor production.

All the machines in the range have been completely re-designed using totally enclosed stainless steel guarding giving easy access to the grinding area.

The programmable Okamoto 'non-contact' hydrostatic slide system reduces the oil supply to the bearing by one-third of a conventional hydrostatic system and improves the strength of the guideway structure of the machine giving improved table loading performance.

As a result, it achieves a consistent level of accuracy throughout the grinding plane giving a longitudinal straightness of 0.5 micron/1000mm and 0.4 micron/800mm on the cross axis.

In addition, it is possible to establish a minimum 10Nm input increment and work within a resolution of 2Nm in both axes.

Traditional hydrostatic slideways vary the thickness of the oil film layer formed on the surface of the guideway according to the load on the table.

Maintains Okamoto, by controlling this oil film layer grinding accuracy can be improved by some 400%.

Also, by avoiding high levels of hydrostatic oil pressure combined with traditional temperature control techniques, this significantly reduces running costs of the machine.

Automatic compensation is applied to the Okamoto slideway bearings that have six faces all under variable hydrostatic control through the Okamoto developed software in the Fanuc 31i Model A control system.

The hydrostatic oil, hydraulic oil for the table longitudinal axis drive and the coolant fluid are all temperature controlled on the UPG to within +/-0.1 deg C and an ultra-accurate hydrostatic spindle is also part of the standard machine specification.

A recent Okamoto grinding demonstration on a larger UPG 408 NC machine, able to accept a table load of 5.5 tonnes, illustrated how a coating roller die some 2000mm long could be ground to a flatness of 0.15 microns.

Normally a die of this type, which is used to apply glue to postage stamps, is ground, lapped by hand and polished to achieve a flatness of 0.3 micron.

The UPG-84NC has a table size of 850mm by 400mm and an electro-permanent magnetic chuck size of 800mm by 400mm by 100mm.

Grinding wheel size is 305mm by 38mm by 127mm driven by a 5.5kW motor and distance between wheel and table surface is between 50mm and 550mm.

The X-axis longitudinal table speed is variable between 0.3 and 25m/min, vertical and cross-feed rate is between 1 and 790mm/min.

The Fanuc 31i-MA control provides two-axis simultaneous movement in Z and Y and interpolation in the X-axis.

Options include automatic dynamic balancing of the grinding wheel, linear glass scale feedback for the vertical axis, gap elimination and a table longitudinal axis crowning.

Plated CBN wheels up output on rigid machines

2007-02-23T04:27:00.000-08:00

Why higher production rates using plated CBN abrasive grinding wheels cannot be achieved may be the spindles are not fast enough and the machine requires fast set-ups and high rigidity.

Enterprises that are willing to pay up to ten times more for CBN grinding wheels expect a large payback in terms of faster material removal, or more parts per wheel, or better form consistency, and usually all three. However, although it might seem easy to add a high speed spindle to an existing machine to take a CBN wheel, the user might then find that his parts have surface finish problems caused by the machine vibrations and chatter, which can occur at these high speeds. This is not usually a problem with the abrasives; rather it is with the machines onto which the CBN wheels are applied.

Fitting new high technology wheels onto old or existing machines is almost certain to result in the wheels not achieving their production potential, leading to disappointment for the user.

The most obvious reason why higher production rates cannot be achieved on conventional machine tools is that the spindles simply don't go that fast; but there is also another reason: the machine must be designed for fast set-ups and with the accuracy and stiffness that anticipates such elevated process speeds.

The same problems do not apply to machines designed specifically to employ the latest plated CRB wheels.

Holroyd's Edgetek range is a good example: the machines are produced with high power/high speed spindles that optimise the use of plated CBN wheels at surface speeds of up to 9000m/min.

This enables them to achieve high depths of cut and optimised metal removal rates far exceeding those of more conventional machines, such as CNC lathes, milling and machining centres and grinders.

In addition, the Holroyd Edgetek machines are manufactured with a polymer granite base, which has been shown to have strong damping properties.

These have been proven in dynamic response tests carried out by AMTRI.

Developed to satisfy the need for extreme rigidity and enhanced vibration damping, the polymer base typically weighs 3 tonnes and has no resonant frequency.

As a result, it enables higher precision machining to be achieved.

Combining this stiffness and damping capability with the Edgetek's ultra high speed machining capabilities and plated CBN wheels, is drastically reducing cycle times in many crucial industry sectors.

In one example, the cycle times for producing automotive parts manufactured from sintered metals were reduced from 70s per component to just 22s.

At the same time, the Edgetek's plated CBN technology is cutting consumable parts costs, achieving a reduction from US$1 to just 3.3 cents per component.

This is the result of the Edgetek machine producing a much larger number of components between tool changes: 15,000 as opposed to the 50 achieved with conventional milling and turning machines.

In another UK application, a single 5-axis Edgetek machine is slashing process times with single lift and set-up.

The Edgetek is replacing seven conventional milling and grinding machines, providing a reduction in the throughput time for a complex finished part from 8h to just 12min.

'This application epitomises lean manufacturing technology,' said Holroyd sales director, Neil English.

'It provides the opportunity to begin with a hardened blank, and then produce a part complete in a single set-up, using plated CBN wheels.

It is not the cost that is driving the trend toward plated CBN but the productivity,' said English.

'Smaller production runs and more set-ups, means that many companies no longer have the luxury to amortize the cost of bonded wheels, and the long non-productive set-up times associated with them, over extended production runs.

Plated technology fills the need for high metal removal rates with short set-up times and eliminates the need for dressing.

The plated CBN form wheels we use on our Edgetek machines have several advantages over bonded conventional or superabrasive wheels: they have higher material removal rate capabilities, and are freer cutting, which reduces thermal metallurgical damage to the work's surface.

Equipped with steel cores they are also safer, providing safety at high operating speeds in excess of 20,000 sfm.' He said: 'In addition, plated wheels offer the highest levels of consistency: they grind virtually the same profile, from the first cut to the last, across hundreds or thousands of workpieces.

As a result, the times associated with set ups, wheel changing, and wheel dressing are significantly reduced or eliminated.

Also greatly reduced is the average wheel cost.

This is because the wheels can be stripped of worn CBN and re-plated several times.' * Unequalled levels of precision and productivity across almost all part types - the flexibility of the Holroyd Edgetek design, and the huge variety of machine types and multi-axis configurations available, enables the machines to provide unparalleled levels of precision and productivity in the manufacture of almost any type of parts - gears and sprockets, rotors and impellers, medical instruments, hand tools, air foils and nozzle guides, airframe actuation components, ducting supports, mechanical seals - and many, many, more.

The machines serve a broad spectrum of industry types, including power generation, automotive, aerospace, medicals, tools and general engineering.

They can be tailored to suit specific applications and supplied as complete turnkey solutions as part of a manufacturing cell.

A worldwide service network provides support for the machines, and they also benefit from manufacturer- developed preventative maintenance plans.

Superabrasive grinding reduces cycle times by 80%

2007-02-14T23:21:00.001-08:00

Superabrasive machining and turning systems deliver massive reductions in product cycle times - in some cases by over 80% - and equally impressive tool cost savings.

Holroyd's new Edgetek range of superabrasive machining andturning systems is providing European industry with a uniqueopportunity to improve competitiveness by delivering massivereductions in product cycle times - in some cases by over 80% -and equally impressive tool cost savings. Designed for use onwide range of standard and ultra hard and exotic materials,including ceramics, nickel, tool steel, Waspalloy, Inconel,Hastelloy, powdered metals and Stellite, the Edgetek machinesdeliver improved quality and part consistency as well as offeringsimplified set-up to optimise manufacturing time. The launch ofthe Edgetek machines further strengthens Holroyd's positionas the world leader in the manufacture of machines and turnkeymanufacturing cells to produce worm and helical gears and helicalscrew rotors.

Manufactured in the UK, at Holroyd's factoryin Rochdale, the multi-axis, CNC controlled machines deployproven high efficiency deep grinding (HEDG) techniques, usingCubic Boron Nitride (CBN) wheels at surface speeds of up to9000m/min.

This enables them to achieve high depths of cut andoptimised metal removal rates far exceeding those of moreconventional machines, such as CNC lathes, milling and machiningcentres and grinders.

In addition to improving product cycletimes, the 'low heat' HEDG system also produces astronger finished component that, when compared to those producedby other techniques such as creep feed grinding, is less likelyto be deformed.

Fundamental to the Edgetek machines superiorlevels of performance and precision, is a unique granite polymerbase and column.

Developed to satisfy the need for extremerigidity and enhanced vibration damping, the polymer basetypically weighs 3 tonnes and has no resonant frequency.

As aresult, it enables higher precision machining to be achieved.Like other unique components in the design, the base reflects themanufacturer's determination to develop a machine range thathas been engineered specifically for high performancesuperabrasive machining.

Holroyd Sales Director, Paul Hannah,explains: 'Unlike other manufacturers, Holroyd is notoffering a range of existing machines that have been adapted.Rather, we are providing a comprehensive product range that hasbeen designed from scratch, incorporating new and sophisticatedtechnology which has been developed specifically withsuperabrasive machining in mind.' 'Every aspect ofHolroyd's Edgetek range has been engineered to provideunsurpassed performance coupled with a level of versatility thatis sure to appeal to the widest possible range of manufacturingoperations.

The massive productivity gains and cost savingsexperienced by those who have made the switch to superabrasivemachining speak for themselves and prove that the technologicaldevelopments pioneered by our machines represent a highlysignificant breakthrough for the future of machining.' Theflexibility of the Holroyd Edgetek design, and the huge varietyof machine types and multi-axis configurations available, enablesthe machines to provide unparalleled levels of precision andproductivity in the manufacture of almost any type of parts -gears and sprockets, rotors and impellers, medical instruments,hand tools, air foils and nozzle guides, airframe actuationcomponents, ducting supports, mechanical seals - and many, many,more.

The machines serve a broad spectrum of industry types,including power generation, automotive, aerospace, medicals,tools and general engineering.

In all of these industries thesimplified set-up of the Holroyd machines ensures that muchproduction time is saved.

At the same time, tooling costs aremuch reduced as the CBN wheels do not suffer from excessivelevels of wear as a result of being subjected to the interruptedcuts experienced on conventional machines, due to their set-uplimitations.

Further emphasising the case for CBN wheels is theremarkable accuracy and metal removal rates that can be achievedby Holroyd Edgetek machines on a wide range of ultra hard andexotic materials and carbon-rich metals.

The large depths of cutthat can be achieved, and the accompanying lower temperature ofHEDG techniques are particularly relevant to aerospacemanufacturing processes, promoting dramatically improvedproductivity, less surface deformation, improved accuracy andbetter surface finish.

Superabrasive technology using CBNgrinding wheels is also a highly successful method of machiningcomponents made from powdered metals popular with automotivemanufacturers.

Although valued for their homogeneous andstress-free composition, materials which have undergone thesintering process are notoriously difficult to machine and aretotally unsuitable for conventional turning.

A combination ofHigh Efficiency Deep Grinding techniques and CBN grinding wheelshas proved extremely successful for the accurate and efficientmachining of powdered metals and has earned Holroyd'sEdgetek superabrasive machining centres growing support amongmanufacturers of components such as gears and sprockets.Providing an ideal complement to the Edgetek machinesmanufacturing flexibility - while at the same time improvingproduction rates, is a unique, Holroyd-designed, 3-dimensionalscanning and measurement system.

Powerful in operation, thesoftware based system measures 500 separate points and comparesthem against the perfect profile while the component is still inthe machine.

Any deviations are corrected automatically beforecompletion of the machine cycle.

If the deviation is greater thana set norm, however, then the system program alerts the operatorto the fact that the wheel may need re-dressing.

Holroyd ismanufacturing Edgetek machines in all types and configurations,3, 4 or 5 axes.

The machines offer state-of-the-art controlfeatures such as Fanuc CNC controls, automated parts handling,customised workholding, cooling systems, programming and processdevelopment and CBN wheel development.

The machines can betailored to suit specific applications and supplied as completeturnkey solutions as part of a manufacturing cell.

They aresupported by a worldwide service network and benefit frommanufacturer developed preventative maintenance plans..

Grinding cycle programs now easier to set up

2007-02-14T23:20:00.003-08:00

A CNC grinding machine builder has now included cycle programming in its control system, permitting very easy programming for grinding any type of workpiece by the aid of pictogramming.

Experience, market observation and feedback from our customershas encouraged us to develop the existing and proven StuderNCbasic package further. The package includes cycle programming,permitting very easy programming for grinding any type ofworkpiece by the aid of pictogramming. The new version has nowbecome a real desktop platform of grinding technology.

From thisdesktop, all data related to grinding are available forpractically any component.

The new version V5.x of StuderNC alsofeatures the calculation of grinding process data.

This includesmachining data as well as time and cost calculation.

All theother software packages, StProfil, StForm, StPunch and StThreadare related to functions and can be called up as perrequirements.

Philosophy - in our engineering work we made greatefforts to create advantages for our customers.

Our aim was,comparable to StPunch (Software for grinding non-round punches),to integrate the grinding technology in order to guaranteereproducibility, to ensure constant high quality and to reducegrinding times as much as possible.

Data storage should beworkpiece-related and logically clear and straightforward for theuser.

The idea was to preserve the customer's know-how andto call up the respective data later in order to adapt it to thenew machining task.

The process of component machining has beenmade transparent in every detail in order to make use of all theoptimising potential.

This is definitely the only method forincreasing the efficiency continuously: preserving the provenknow-how and to make it accessible to any other user a laterdate.

,Look and feel' This means: the appearance andoperation correspond as much as possible to the commercialWindows applications as they are known in conjunction withMicrosoft products.

High operator ergonomics was one of our maingoals.

The integrated grinding technology improves the efficiencyof the machine considerably.

Experience based on practical workin the range of fine machining by cylindrical grinding haveproved that rather often the operators of grinding machines workwith values resulting from their experience, which isastonishingly far away from the optimum.

So-called machiningtasks which can be defined by our customer's or by our ownspecialists help to produce components in a constantly goodquality and time independently from the operator who carries outthe job.

A machining task defines the behaviour of a certaingrinding tool in a specific material.

By doing so, the coolant,the rigidity of the component, the machinability of the materialand many other factors can be taken into consideration.

Byincreasing the quality of the optimisation of machining tasks,the optimising times can be reduced considerably for new, similarworkpieces.

For the production of individual parts and series,one will always be able to operate with former, highly optimiseddata for the same combination of tool and material.

This willreduce the running-in times to a level corresponding to that ofsame components which are machined repeatedly.

By indicating theexact time of each individual process, those for dressing andtraversing as well as the auxiliary times such as longitudinalpositioning by means of a length positioning, one should obtaininformation about the productivity.

The calculation should giveaccurate information for the quotation.

In addition, thecalculation of costs can go much further than that based merelyon the grinding time for a component.

For instance, toolingexpenses have to be taken into account.

This is extremelyimportant for job planning and for quotations.

* Dressing: Roughdressing cycles to profile, respectively reprofiling grindingwheels - for profiling, new rough dressing cycles are now atdisposal.

Roughing means - similarly as for milling or turning -creating an optimal assignment of cuts in order to remove as muchmaterial as possible in the shortest possible time.

By doing so,the set-up times are reduced to a fraction compared to those ofthe conventional method.

* The advantages - by using StuderNC andthe respective options for profiling and dressing the grindingwheels as well as for thread grinding and grinding non-roundsections of components, the customers gain an extremelysignificant increase of functionality for their universalcylindrical grinding machine.

In the simplest case this meansthat set-up, programming and grind-ing times will be reducedconsiderably.

In other cases, it may even be possible to avoidthe use of special machines, such as thread and cam grindingmachines.

Partially, the same also applies to special clampingfeatures such as eccentric chucks.

From this point of view, theinvestment will certainly be written off in a very short time.

*Range of applications - the range of application of StuderNC isalso intended for the real grinding Professional.

The system iscompletely open and allows changes in every section.

However,this product is useful even for the inexperienced user who,thanks to this application, can operate with littlegrinding-specific know-how.

Also standard Macro's defined inadvance by Studer cover a wide range of components.

In addition,this software is also useful for the job planning, namely forestablishing quotations and process data for the properproduction.

No backing pad eases portable grinding work

2007-02-14T23:20:00.001-08:00

Eliminating the backing pad and tapered flange nut from portable grinding wheel securement results in a lighter unit to ease operator control and comfort and reduce fatigue.

Metabo Corporation, a leading international manufacturer of professional grade portable electric power tools and abrasives for various industrial, construction and welding applications, has introduced the Type 29 Z-Plus grinding wheel that eliminates the need for a backing pad and tapered flange nut. The Type 29 Z-Plus weighs less than half of a typical 4-1/2in grinding wheel. This significantly increases the operator's control and comfort while decreasing fatigue, particularly with small grinders used in tight spaces and at odd angles.

The wheel's slightly concave profile also lessens the grinder's angle of attack, reducing operator fatigue.

The Type 29 Z-Plus, with its aluminum oxide abrasive, is well suited for blending and surface weld removal on steel, stainless steel and aluminum.

The wheel, a refinement of Metabo's Type 29 grinding wheel, can also be used to grind other non-ferrous metals, as well as most plastics and resin or fiberglass-based structural materials.

The Type 29 Z-Plus is available in 4-1/2in or 7in diameter, with a 7/8in arbor or 5/8in-11 hub.

Superabrasives machine superalloys productively

2007-02-14T23:19:00.001-08:00

A research project using superabrasive machines has achieved a significant breakthrough in machining superalloys - in terms of reduced cycle times and better surface finish and accuracy.

A research project undertaken by a team at CranfieldUniversity's School Of Industrial and Manufacturing Sciencehas employed Holroyd's superabrasive Edgetek machines toachieve significant breakthroughs when machining Nickel basedsuperalloys; materials which are notoriously difficult to work.The breakthroughs, in terms of reduced cycle times, bettersurface finish and improved accuracy, have been achieved usingthe latest high efficiency deep grinding (HEDG) techniques. Theyare likely to have a profound influence on the way thatsuperalloys are machined in the future within the aerospaceindustry. The Cranfield team, led by Professor David Stephenson,carried out lengthy 'Burn Threshold Studies' on Inconel718 - a superalloy commonly employed for gas turbine components,using Holroyd's 'Edgetek' Superabrasive Machiningprocess.

Manufactured at Holroyd's UK factory in Rochdale,the multi-axis, CNC controlled Edgetek machines deploy provenhigh efficiency deep grinding (HEDG) techniques, using CubicBoron Nitride (CBN) wheels at surface speeds of up to 200m/s.This enables them to achieve high depths of cut and optimisedmetal removal rates far exceeding those of more conventionalmachines, such as CNC lathes, milling and machining centres andgrinders.

An Edgetek machine (a five-axis unit) was specified forthe Cranfield research project due to its ability to machineNickel-based superalloys such as inconel 718, which are extremelydifficult to work.

The ability of these alloys to retain much oftheir strength at elevated temperatures means that wear rate onconventional tooling is rapid, even when cutting at low speeds.In addition, problems such as workpiece burn and poor surfaceintegrity are common, due to the alloys low thermal conductivity.Over the last 30 years developments in creep feed grindingtechniques have addressed some of these problems, notably inachieving higher rates of metal removal, but economic pressuresto reduce manufacturing costs further, and to improveproductivity, still remain.

As a direct result of thesepressures, a growing interest in HEDG (high efficiency deepgrinding) has developed, which can be considered as a combinationof creep feed grinding and high speed grinding, using high wheelspeeds often in excess of 200m/s.

A main area of research hasbeen to attempt to prove a commonly held HEDG theory that veryhigh stock removal rates are associated with low work-piecetemperatures.

Key to this, were the grinding trials carried outat Cranfield University.

The trials were undertaken on blocks ofInconel 718 measuring 40 x 40 x 40mm, using a 'downgrinding' mode and grinding parameters were varied over thefollowing range: depth of cut: 0,05 - 1,5mm, work speed: 0,05 -55mm/s and wheel speed: 50-150m/s.

For each test a series of 15mmwide cuts was taken and resultant forces were measured using athree-axis dynamometer.

Although the results of the trials arenaturally very detailed, the general trend shows a reduction inspecific grinding energy as specific stock removal ratesincrease.

Commenting upon this, Professor Stephenson said:'The thermal modelling results correlate well withexperimental observations of grinding burn.

Modelling indicatesthe potential benefits associated with HEDG, using high workspeeds and large depth of cut to minimise the finished surfacetemperature.

Thermal modelling also highlighted the significantcontribution that CBN abrasives can make to heat removal.'These results, highlighting the large depths of cut andaccompanying lower temperature work-piece characteristic of HEDG,have significant practical relevance in terms of aerospacemanufacturing processes, in that the two promote dramaticallyimproved productivity, less surface deformation, improvedaccuracy and better surface finish.

'We are delighted, butnot surprised by these results,' said Holroyd SalesDirector, Paul Hannah.

'The massive productivity gains andcost savings experienced by those who have made the switch toEdgetek superabrasive machining speak for themselves and provethat the technological developments pioneered by our machinesrepresent a highly significant breakthrough for the future ofmachining.' In addition to its key role in the BurnThreshold Studies, Holroyd's Edgetek machine is also centralto another Cranfield project, 'Ultraflex', which isrunning simultaneously.

'Ultraflex' is a European /automotive industry-funded project, for the development ofinnovative manufacturing technologies for reducing processchains.

Its specific objectives are to develop and to demonstratethe following two processes: * Cost-effective and highproductivity machining process of high-alloy steel beforehardening operation and hardening process.

* Ultra-precision andenvironmentally friendly machining process of high-alloy steelafter hardening operation.

The Edgetek machine is playing a keyrole in developing these processes and in achieving the twoperformance targets for the project: (1) working towards opticalquality, machined surface finish levels of Ra 0.0micron and (2)the ability to rough finish a high alloy steel CVT gearshaft inless than 2 minutes.

The groundbreaking research carried out byCranfield University on both Burn Threshold Studies and projectUltraflex and the positive results obtained, proves conclusivelythe effectiveness of Superabrasive machining on difficult to workmaterials, not only within its 'traditional' sector ofhigh volume production associated with milling machineaccuracies, but also on very close tolerance work with highlevels of surface finish.

However, despite these results, neitherCranfield University nor Holroyd are resting upon their laurels.Holroyd is conducting ongoing technical developments at itsfactory in Rochdale which complement the innovative researchcarried out by Cranfield University, developing further thepotential that exists in this rapidly growing area of machinetool technology.

Stressing the latter point, Holroyd's PaulHannah said: 'Feedback from customers and the results ofdetailed research into superabrasive machining both support theview that this exciting technological breakthrough has massiveimplications for the future of a wide range of machiningoperations.

The dramatic reduction in cycle times and toolingcosts which result from a switch to Holroyd's Edgetek'superabrasive machine tools contribute to significantimprovements in overall productivity for every company usingthem.'.

Cylindrical grinder does one-off and small batches

2007-02-14T23:17:00.000-08:00

Cylindrical grinder provides a highly flexible, single-cycle universal solution to the finishing of one-off parts or small batch runs.

Developed to provide a highly flexible, single-cycle universalsolution to the cylindrical grinding of one-off parts or smallbatch runs, the latest Danobat G-41 cylindrical grinding machineis able to accommodate external, internal diameters, faces andtapers. Now marketed through 600 Centre of Shepshed nearLoughborough, the Danobat G-41 Universal 'U' machinecan also be specified as a lower cost 90 (degree) approachconventional cylindrical grinder designated 'S'. Themachine has been developed in order to maximise the potential ofcubic boron nitride (CBN) wheel technology through high orders ofdesign rigidity.

This means high performance, accuracy andrepeatability have been developed into the machine.

When thesefeatures are combined with Danobat's DanOp, DanBop andDanCad software modules, flexibility and operationalfunctionality provide a high performance grinding package forcomponents up to 348 mm diameter by 1,000 mm long.

Built on astabilised pearlitic cast iron base with integrated 'doublebody' table, the machine is compact, stable and very rigid.Table swivel is +9 degree to -2 degree.

The servo driven table isable to swivel between +45 degree and -15 degree and the workheadwill accept components weighing up to 125kg between centres withstepless programmable speed range between 30 and 1,000 revs/min.The indexing universal wheelhead has zero, 30 degree, 90 degreeand 180 degree working positions and the ability to carryexternal, face grinding or internal grinding spindles.

Theuniversal wheelhead has a 7.5kW drive, 45m/sec wheel speed and500mm by 80mm by 203mm external grinding wheel and a facegrinding wheel.

It also has the ability to carry one of a rangeof four internal grinding spindles having up to 30,000 revs/minspeed and the capacity to grind bores up to 160mm diameter.

Withthe option of a 90 degree approach wheelhead, this has a 5.5kW,45m/sec grinding speed and wheel size of 400mm by 63mm by 127mm.Based on Fanuc 210i control system, software development was seenas important to the Danobat specification.

This has resulted inthe DanBop machine control software being classified to be assimple to operate as a manual machine and this is achieved bysimply selecting the type of work required.

It can incorporatefully or semi-automatic cycles and accommodate dressing,measurement and changes to grinding parameters.

The DanOpsoftware module accommodates machine functions with soft keyprogramming for set-up, wheel management, work cycling andproduction management.

DanCad incorporates graphic support directfrom CAD systems to enable programming based on componentgeometry and is able to optimise tasks such as wheel profilecreation and dressing.

Options include gauging, gap eliminationand crash detection devices, steady rests and a range offiltration and coolant systems.

Dynamic balancing, workholdingand a portable handwheel unit are available to help in machineoperation..

Compact sander tackles curved surfaces

2007-02-08T22:24:00.003-08:00

A compact portable sander allows for better control when sanding over curves and convex surfaces, and its small pad size enables the easy sanding of concave surfaces a well.

Metabo Corporation, a leading international manufacturer of professional grade portable electric power tools and abrasives for industrial, construction and welding applications, has introduced a new 3-1/8in random orbital disc sander that provides increased additional flexibility for use in all types of sanding applications. The SXE400's Variospeed full-wave electronic speed control makes the sander suitable for several types of applications, including woodworking, automotive bodywork, fine metalworking, and polishing. Weighing only 3.3 lb., the SXE400 is easily maneuverable and its low 4-1/8in profile makes the sander compact enough to get into confined spaces difficult to reach with larger sanders.

Dust extraction is conducted through the sanding pad itself, so there is no bulky shroud to obscure the work surface.

The small 3-1/8in sanding disc diameter enables even pressure to be exerted over the entire sanding surface, resulting in clean sanding on narrow surfaces such as door and window frames.

- The small size of the SXE400 allows for better control when sanding over curves, making the sander well suited for convex surfaces, and its small pad size enables the easy sanding of concave surfaces a well.

The SXE400's Power Control System, featuring an integrated backing pad brake, helps eliminate sanding scratches, which significantly reduces the time needed to smooth sanded surfaces, resulting in increased productivity.

The SXE400 provides 5,000 to 10,000 orbits per minute with a 2.0A motor and features an orbit size of 1/8in.

Triple dust-sealed bearings help increase the life of the sander.

Standard equipment includes a hexagon key for changing the backing pad and 5 cling-fit sanding discs.

An optional carrying case as well as a variety of sanding discs for different applications are also available.

Best swiss grinding features offered competitively

2007-02-08T22:24:00.001-08:00

Best described as a distillation of the classic features of previous Swiss-built grinders this universal type comes with a wide range of hardware and software options at competitive prices.

Best described as a distillation of the classic features ofseveral previous Kellenberger models, the Swiss designed andbuilt Kel-Viva has an R type wheelhead for straight approachexternal grinding, and UR versions with a high resolution B-axisas standard for the multi-wheel universal internal / externalmachines.

Normal Kellenberger features such as true hydrostaticslideways and 0.0001mm resolution on diameter are included alongwith a complete range of hardware and software options to producethe highest quality ground parts with round cylindrical profiles,non-round parts using C-axis workhead option and even groundthreads.

The above Hardinge produced machines are pricedcompetitively and reflect the forward looking corporateobjectives of expansion through geographic markets and products.

Machine tool package satisfied need for precision

2007-02-08T22:23:00.002-08:00

It was the need to maintain high levels of flatness and parallelism within a few microns for its in-house press tooling that led Datum to buy a machine tool package including precision grinders.

It was the need to maintain high levels of flatness andparallelism within a few microns for its in-house developedUniCut press tooling that led Hampshire based Datum PrecisionTooling to the purchase of a machine package including twoOkamoto surface grinders, a Bridgeport Series 1 turret mill and aHarrison Model 390 centre lathe from 600 Centre of Shepshed nearLoughborough. Since the installation of the two grindingmachines, which also coincided with the purchase of a wire EDMand five-axis vertical machining centre, the company has beenable to diversify from being a very successful printed circuitboard tooling and press tool manufacturer into the automotive,medical, telecoms and plastic injection mould tooling business.And, due to the capacity of the larger Okamoto 105 DX-V is nowable to provide a sub contract grinding service to localindustry. Datum Precision was set up in 1990 and now employs 24people in two 7,000 (square feet) factory units in Finchdean justoutside Waterlooville, with sales of over GBP 850,000.

With anown product in UniCut, which is a new concept for producinghighly accurate shaped holes and profiles in acetates, polyester,polycarbonate, plastics, paper and flexible circuit boardmaterials, the business is building.

It is now supplying toolingfor producing the likes of mobile phone lenses, automotivedashboard instruments, panels and fascias, labels, gaskets andapplications where overlays are required.

In order that theshaped parts can be punched using the UniCut press tool design,the relevant materials are fed in strip format which is mountedon a backing strip which allows the components to be simplypeeled off at the point of assembly.

However, the critical natureof maintaining the depth of cut of the tool so the resulting edgeis clean, the razor sharp tool is not blunted and the backingmaterial is not pierced, is where the investment in newproduction machining was key to Datum.

Says Sales and MarketingManager Gary Gibbs: 'We are now supplying most UK and agrowing export market with UniCut tooling for producing productssuch as telephone lenses, labels and fascias and have recentlybroken into the Far East with a major producer which means thetooling concept is proving to be a real winner.' The UniCutpunch tool concept can produce up to nine components at a time.It can be supplied as a bolster with a tool cassette whichenables different profile shapes to be quickly and easily changedover or as a compound pierce and blank tool in order tocombination punch holes and the profile of the part in the samepressing cycle.

When the tool is produced from design to finalpass-off it is championed by one of Datum's six highlyskilled toolmakers.

Each toolmaker will operate any of thecompany's machines, to produce the relevant parts, thenassemble the finished tool, perform the try-out and finallysign-off the project.

Because of the accuracy required from thepress tool, the machining datums initiated by grinding the platesflat and parallel is critical to all the following operations andthe ultimate tool performance.

The larger of the two Okamotos,the ACC 105 DX profile and surface grinder has a table size of1050mm by 500mm and a load capacity of 700kg, while the smallerACC 450 DXA profile grinding machine has a 410mm by 150mm table.Each machine was chosen due to simplicity of setting and thecapability to be set up on a task in automatic cycle and left torun unattended allowing the tool maker to get on with somethingelse.

Maintains Technical Director, Robin Lovett: 'This madethe machine purchases excellent value for money and gave us acapability we never had before.

Also, because of the accuracy wecan obtain, this ensures that when following milling operationsare performed the tool blade can be maintained to a consistentsharp edge around the profile and we can therefore preciselycontrol the quality of cut the tool makes and ensure a longservice life.'

Automatic wheel balancers hold grinding precision

2007-02-08T22:23:00.001-08:00

Automatic wheel balancers enable CNC valve seat grinders to maintain dimensional tolerances of under 5 microns, while producing up to 15 components a minute, 24 hours a day.

Designing and manufacturing special purpose CNC machines capableof maintaining dimensional tolerances of better than 5 microns,while producing up to 15 components a minute, 24 hours a day, isundeniably a tough task. But when these same machines are likelyto be installed in plants located anywhere from Argentina orIndia to China or South Africa, then the need for precision mustalso go hand-in-hand with reliability, durability and excellentproduct support. The same is just as true for any 3rd partyequipment incorporated in the design.

That's certainly theview taken by Earlsdon Technology; which is why the specialistmachine tool builder has specified automatic wheel balancingtechnology from Schmitt Europe for its latest generation ofpurpose-designed valve seat grinding machines.

Custom-engineeredequipment and automation solutions for high speed or massproduction applications are at the heart of EarlsdonTechnology's business.

The Coventry-based company isparticularly strong in the fields of high volume engine componentmanufacture, high performance fastener production and automatedcentreless grinding machinery.

Not surprisingly, its customersinclude many familiar names in the aerospace sector, as well asautomotive component suppliers such as TRW, Federal Mogul andEaton.

'As a relatively small, but experienced player, wehave focused our activities on niche market requirements,'says Managing Director Simon West.

'Our latest VSG-X1grinders are a typical example, being designed specifically forengine valve production.

The machines incorporate fully automaticcomponent loading and unloading and will achieve cycle times ofless than 5 seconds on components up to 160mm long and 50mm headdiameter.' 'Maximum manufacturing tolerances willnormally be less than 20 microns on seat-to-face length, 15microns TIR (total indicated run out) on seat run out, 3 micronson seat roundness and less than 0.25 microns on surfacefinish,' he adds.

Precise control - meeting these sorts ofrequirements calls for precise control of the grinding process.

Akey element in this is ensuring the dynamic balance of thegrinding wheel itself.

It is not only central to maintainingdimensional accuracy and surface finish, but also contributes toother benefits, such as extended component runs between dressingcycles, increased wheel and dresser life, minimised vibration andreduced spindle bearing wear.

These in turn, result in greaterproductivity and lower machine maintenance costs.

'Ineffect, the wheel balancing equipment plays a crucial role in theperformance of the whole machine,' continues West.'That's why we went to significant lengths to assessthe capabilities of a number of suppliers' products beforespecifying any equipment for our new valve grinder models.'During our evaluation, we were impressed by the range ofgrinding wheel balancing solutions offered by Schmitt.

Detaileddiscussions with the company led to a series of trials, and thesubsequent adoption of their SBS dynamic balancers.'Comprising a sensor, spindle mounting adapter, balance head andelectronic control unit, the SBS system provides continuousmonitoring of the grinding process; eliminating the need forpre-balanced wheels and greatly reducing set-up times.

Theequipment uses the principle of mass compensation to correctimbalance.

SBS balance heads incorporate two eccentric weights,each of which is driven independently by electric motors througha precision gear train.

In operation, vibration or imbalancedetected by the sensor is relayed to the controller at the heartof the system.

The unit processes the signal and sends commandsto the balance head to advance each weight in the correctdirection to reduce the amplitude of the input.

When the minimumvibration level is achieved, the balance cycle is complete.

Thesystem continuously monitors the machine to provide a fullyautomatic system that maintains balance even if the wheel isstopped and re-started.

Balance accuracy - SBS equipmenttypically achieves balance accuracy of 0.1 micron peak-to-peakvibration displacement, which compares to 5 microns for normalunbalanced grinding operations and a figure of around 3 micronsusing statically balanced wheels.

'Not only did the Schmittsolution provide the high balance accuracy we were looking for,but the system's components are small and neat, enablingthem to be mounted more easily in restricted accessapplications,' says West.

'The SBS control unit isequally compact and proved easier than many of its competitors tointerface with the machine control system we had designed for thenew machines.

'A further important factor in our decisionwas that, as part of a large international organisation, SchmittEurope could provide us with first class, world-widesupport.' 'Indeed, we have already taken advantage ofthis facility,' he adds.

'Through the response ofSchmitt's US-based engineers, we have quickly resolved arecent problem at one of our customers' manufacturing plantsin Mexico, where 20 of our machines are installed.' So whatare the prospects for the future?

'Part of our reputationrides on the balancing equipment's performance,' notesWest.

'Since partnering with Schmitt, we have developed aclose relationship, where both companies work together to addressany issues that arise.

'Not surprisingly, we intend tocontinue incorporating Schmitt balancing and process controltechnology on our machines; and not just on valve seat grinders,but on other equipment - such as special purpose grinderswe've developed to produce critical components for aninnovative new medical device.' About Schmitt Europe - basedat the University of Warwick Science Park, Schmitt Europe offersbalancing and vibration control solutions that harness precisionas the key to manufacturing productivity.

The company'swheel-mounted, in-spindle, ring or hydro type automatic grindingwheel balancing systems dramatically improve surface finish andwheel life, while its acoustic emission monitoring equipmentprovides precise monitoring and control of grinding and wheeldressing operations.

Schmitt also offers high accuracy, verticalor horizontal axis component balancing machines, as well asnumerous laser measuring, alignment and surface textureinspection systems..

Plated CBN wheels up output on rigid machines

2007-02-08T22:19:00.000-08:00

5in angle grinder has electronic speed control

2007-01-30T22:53:00.001-08:00

A variable-speed 5in angle grinder/cut-off machine features automatic electronic speed stabilization and is ideal for applications requiring quick stock removal and/or efficient cutting.

Metabo Corporation, a leading international manufacturer of professional grade portable electric power tools and abrasives for industrial, construction and welding applications, has introduced the WE14-125 Plus 5in Angle Grinder, a variable-speed grinder/cut-off machine featuring automatic electronic speed stabilization. The WE14-125 is ideal for applications requiring quick stock removal and/or efficient cutting. The new WE14-125 Plus is powered by the Metabo Marathon 12.0 amp motor, with special winding protection that prevents damage from dust for longer motor life.

Disc speed is variable from 7000 to 10,500 rpm (no-load).

Electronic speed stabilization maintains disc speed under load, for efficient material removal.

When equipped with the Metabo 'Slicer' abrasive wheel, the new WE14-125 easily cuts through a range of building and construction materials.

The angle grinder/cut-off machine features the Metabo 'Quick' wheel change system, enabling rapid tool-less changes for increased productivity.

The wheel guard can also be adjusted without tools, allowing operators to quickly shift from grinding to cutting.

The WE14-125 is equipped with the Metabo S automatic safety clutch, which prevents sudden reverse torque in the event of jams or snags, as well as with e

Modular cylindrical grinders eliminate compromise

2007-01-30T22:52:00.000-08:00

Suitable to grind one-off or series produced parts, these cylindrical grinding machines' modular design allows customisation without having to make any compromises.

Both S21 and S31 machines are suitable for one-off components aswell as small or large series production operations. And becausethe modular design system leaves all options open, the S21 andS31 can easily be adapted to individual requirements - withoutany compromise. Another element of the Studer concept: economicalhigh-level series production and expandability according to thecustomer's needs.

The S21, a compact universal cylindricalgrinding machine, is designed for small workpieces.

Distancebetween centres 400mm (15.7in), centre height 125mm (4.92in).With a distance between centres of 650mm or 1000mm (26 or 40in),the S31 is the solution for medium-sized workpieces.

A versatileCNC universal cylindrical grinding machine that isn't scaredof big jobs, either.

Programming and operation of the machines isalso consistently designed to ensure economy, precision andefficiency.

The Studer Pictogramming software is easy to use,with complete standardised hardware and software modulesavailable for every conceivable special job.

It's definitelyworth taking a closer look at the performance data andpossibilities of the two new Studer machines.

Precision engineers keep grinding in-house

2007-01-25T04:53:00.001-08:00

JJ Hardy and Sons, has widened its range of services and raised productivity with the purchase of a Jones and Shipman 'TechMaster' 634X 600 x 300mm table capacity surface grinder.

North-east precision engineers JJ Hardy and Sons, has widened itsrange of services and raised productivity with the purchase of aJones and Shipman 'TechMaster' 634X 600 x 300mm tablecapacity surface grinder. The microprocessor controlledTechMaster, which was selected and specified by Hardy'sManaging Director Andrew Pailor, was commissioned and productivewithin a month of the initial sales enquiry. 'It was an easyfinancial decision to choose the TechMaster,' says MrPailor, 'As it gives us the opportunity to keep control ofgrinding operations in-house and to seek new business horizonswith the added flexibility this excellent machine gives us.'Jones and Shipman's worldwide reputation of excellence inprecision surface grinding attracted Mr Pailor when he wasinvestigating the feasibility of adding grinding operations tohis company's capabilities.

With considerable experience inquality CNC milling, Hardy's saw a growth opportunity forsupplying precision-ground components.

American Axle andManufacturing, which has several plants in the UK and who isalready an established customer, was identified as a possibleclient for ground parts.

Regional Sales Manager Paul Chickinvited Mr.Pailor to Jones and Shipman's LeicesterHeadquarters to identify his exact needs.

The new 600 x 300mmTechMaster 634X (part of a four model range with table capacitiesfrom 500 x 200mm to 1000 x 500mm) was recommended anddemonstrated.

Andrew was very impressed as it perfectly matchedhis requirements for quality, price range, health and safetyconsiderations and expected volume of work.

Working closely withGeoff Walker of Jones and Shipman's technical department, aninitial batch of samples was produced and submitted toHardy's for inspection.

The results were excellent and theorder for the TechMaster 634X was subsequently placed.Established in 1856 in Hartlepool, JJ Hardy and Sons enjoys alongevity and reputation that few companies can claim to have.The company started manufacturing as brass founders andengineers.

Andrew Pailor is the third generation of his family torun the company successfully.

'I strongly believe ininvesting in new technology,' says Mr Pailor, whosegrandfather bought the company from the founding Hardy family in1937.

They have been in the present premises since 1967 andachieved ISO9002 accreditation back in 1990.

'We are aforward looking company and in five years we will be celebratingour 150th anniversary.

We believe in investing in training sohave a good modern apprenticeship scheme, employ thirty peopleand operate around the clock,' continued Mr Pailor.'The new machine gives us a good rate per hour and weoperate five days and nights per week,' states Mr Pailor.'It allows us to get the most out of our skilled people whocan produce top quality components with no wastage.' Withits simplified Man machine interface (MMI) and microprocessortechnology, the Techmaster assists the operator to achieve thehigh levels of productivity, together with the precision and easeof use that the company is looking for.

The firm's customerbase currently includes many of the UK's leading railwaycompanies and provides precision services for a wide range ofindustry sectors including commercial and off-highway vehicles,chemical, oil and food processing, power generation and sub-seaapplications.

JJ Hardy and Sons now enjoys an excellent workingrelationship with Jones Shipman and can see the possibility ofinvesting in other 'J and S' grinding machines asmarkets develop.

'To sum up the whole commissioningprocess,' continued Mr Pailor, 'I am very impressedwith the facilities, personnel and technical support provided byJones and Shipman International.

They worked with us quickly andefficiently right from my initial enquiry to provide the idealsolution for our production needs at a price that we couldafford.' Managing Director Andrew Pailor also confirmed,'With the Jones and Shipman TechMaster 634X we are providingour customers with the right product first time, everytime.'2

Universal cylindrical grinder has teach-in CNC

2007-01-25T04:49:00.000-08:00

The Cetos BUA 25A universal cylindrical grinding machine with teach-in CNC system boasts an unrivalled price-to-performance specification that will appeal to both toolmaking and production.

Manufactured in the Czech Republic by Cetos, the new BUA 25Auniversal cylindrical grinding machine with teach-in CNC systemnow available from Ward CNC of Sheffield boasts an unrivalledprice-to-performance specification that will appeal to bothtoolrooms and companies involved in either one-off or volumeproduction. With a swing diameter of 500mm and a distance betweencentres of 1500mm, the Cetos BUA 25A can accommodate workpiecesof 500kg. Workhead swivel and speeds are 90 degrees and 18 to 560revs/min, and wheelhead swivel is quoted as + 40 degrees to -15degrees.

Able to utilise 500mm diameter grinding wheels, wheelspeed is 1,695/1,960 revs/min and peripheral wheel speed is45m/sec.

Table feed rate is 0.05m/min to 5m/min.

The K51 teach-inCNC is a high-performance control system that allows grinding tobe performed under manual control or automatically, while alsoaccommodating longitudinal grinding with auto infeed at tablereversal points, wheel dressing and intermediate wheel dressing.In manual mode, wheelhead infeed length and rate control is via acontrol knob, which can be used to increase the step ten-fold.For manual longitudinal grinding, automatic infeed can beadjusted at the reversal points.

In volume mode, programs can becreated automatically during the grinding of the first workpieceby teach-in methods, with no special programming knowledge beingrequired.

Programming can also be by direct entry of cycleparameters.

As standard, up to 10 teach-in programs can be stored(ie five plunge-cut and five longitudinal grinding programs) andprogram changes can be easily accommodated for further work sinceeach change is automatically remembered.

The BUA 25A is one of anumber of Cetos grinders available from Ward CNC.

These alsoinclude other universal CNC cylindrical grinders as well asinternal/external, single/two-wheelhead cylindrical plunge andcrankshaft-type machines.

Teach-in cylindrical grinder appeals universally

2007-01-21T22:47:00.001-08:00

An unrivalled price-to-performance specification that will appeal to both toolrooms and companies involved in one-off or volume production is claimed for a Czech teach-in cylindrical grinder.

Manufactured in the Czech Republic by Cetos, the BUA 25Auniversal cylindrical grinding machine with teach-in CNC systembeing shown at MACH 2002 by Ward CNC boasts an unrivalledprice-to-performance specification that will appeal to bothtoolrooms and companies involved in one-off or volume production.With a swing diameter of 500mm and a distance between centres of1500mm, the Cetos BUA 25A can accommodate workpieces of 500kg.Workhead swivel and speeds are 90 deg and 18 to 560 revs/min,respectively, and wheelhead swivel is quoted as + 40 deg to -15deg. Able to utilise 500mm diameter grinding wheels, wheel speedis 1,695/1,960 revs/min and peripheral wheel speed is 45m/sec.Table feed rate is 0.05m/min to 5m/min. The K51 teach-in CNC is ahigh-performance control system that allows grinding to beperformed under manual control or automatically, while alsoaccommodating longitudinal grinding with auto infeed at tablereversal points, wheel dressing and intermediate wheel dressing.In manual mode, wheelhead infeed length and rate control is via acontrol knob, which can be used to increase the step ten-fold.For manual longitudinal grinding, automatic infeed can beadjusted at the reversal points.

In volume mode, programs can becreated automatically during the grinding of the first workpieceby teach-in methods, with no special programming knowledge beingrequired.

Programming can also be by direct entry of cycleparameters.

As standard, up to 10 teach-in programs can be stored(ie five plunge-cut and five longitudinal grinding programs) andprogram changes can be easily accommodated for further work sinceeach change is automatically remembered.

The BUA 25A is one of anumber of Cetos grinders available from Ward CNC - which includesinternal/external, single/two-wheelhead cylindrical plunge andcrankshaft-type machines - as well Hankook two-axis turningmachines, Union horizontal live spindle machining centres,Soraluce travelling column and travelling table milling machinesand bed mills, Toshulin vertical boring, turning and millingmachines, as well as Kia CNC lathes, turning centres, andvertical and horizontal machining centres - representatives ofwhich will also be on show at MACH 2002 - NEC, Birmingham: April29-May 3 Hall: 4.

Stand: 4660.

Cylindrical grinder produces boring bars

2007-01-21T22:46:00.001-08:00

A Cetos universal cylindrical grinder is being used by Forth Tool and Valve as a key machine in the manufacture of the company's market-leading tooling systems.

A Cetos universal cylindrical grinder is being used by Forth Tooland Valve as a key machine in the manufacture of thecompany's market-leading tooling systems. Supplied by WardCNC of Sheffield, the Cetos BU 25A grinder is being used in theproduction of a range of standard and special-purpose controlledboring bars and facing heads - products for which the Scottishcompany is world renowned. With a swing diameter of 500mm and adistance between centres of 1500mm, the Cetos BU 25A wasinstalled to replace an ageing grinder in the ITS Division, saysgeneral manager, Campbell MacPherson.

'We looked at othercomparable machines,' he comments, 'but chose the Cetosbecause it offered the most economical price-capability package.The fact that it was also available ex-stock from Ward CNC was amajor plus, since we wanted to install it as soon aspossible.' The BU 25A is one of a number of Cetos grindersavailable from Ward CNC.

These also include other universal CNCcylindrical grinders as well as internal/external,single/two-wheelhead cylindrical plunge and crankshaft-typemachines.

Workhead swivel and speeds are 90 degrees and 18 to 560revs/min, and wheelhead swivel is quoted as + 40 degrees to -15degrees.

Able to utilise 500 mm diameter grinding wheels, wheelspeed is 1,695/1,960 revs/min and peripheral wheel speed is45m/sec.

Table feed rate is 0.05m/min to 5 m/min.

The BU 25Afeatures the K51 teach-in CNC - a high-performance control thatallows grinding to be performed under manual control orautomatically, while also accommodating longitudinal grindingwith auto infeed at table reversal points, wheel dressing andintermediate wheel dressing.

Vertical workhead simplifies handling on grinder

2007-01-21T22:45:00.000-08:00

Placing the production grinder's workhead in the vertical position simplifies component handling on the compact Taiyo Koki IGV 3NT Multi-Process vertical production cylindrical grinding Machine.

Placing the production grinder's workhead in the verticalposition simplifies component handling and makes the set-up andcentring of the workpiece easier on the compact Taiyo Koki IGV3NT Multi-Process Vertical Grinding Machine. In one chucking, theIGV 3NT will perform internal, external and face grinding on aworkpiece in one set-up and to very close tolerances down to 1micron. A grinding spindle turret carries internal and externalgrinding spindles, which the CNC system indexes very quicklybetween external and internal grinding operations.

Taiyo Koki haspaid close attention to the rigidity and ruggedness of the IGV3NT, says Pollard Mori Seiki, which is introducing the machine tothe UK market.

Designed for production grinding of components upto 200mm diameter by 150mm long and a maximum swing of 300mmdiameter, the machine very quickly executes internal, externaland face grinding cycles using a fast indexing grinding spindleturret.

The machine can bring into play a high speed, internalgrinding spindle with a programmable speed range of 9,000-75,000rev/min, using pinwheels 11.5-95mm diameter.

A second grindingspindle is for external grinding and facing, using a programmablewheel speed range of 2,400-3,700 rev/min and a wheel of 355mmdiameter by 65mm face width.

Drive power is 3.7kW.

The 2.2kWworkhead, located on a substantial X-Z worktable on the bed ofthe machine is at a comfortable operator reach height and has aprogrammable speed range of 40-800 rev/min.

A precision,pneumatic 250mm chuck is fitted.

The workhead has a load capacityof 100kg.

The worktable traverses are 460mm for X-axis and 400mmfor the Z-axis.

Traverse rates in both axes are steplesslyvariable, 0-16m/min.

Grinding feed rate is 0 - 16m/min.

Fitted asstandard items are a rotary diamond cup wheel dressingattachment.

Wheel dressing is carried out using a 50mm diamondcup wheel at up to 10,000 rev/min.

Taiyo Koki has designed theIGV 3NT with a massive box structure to ensure rigidity andvibration damping during grinding.

The grinding spindles areoil-cooled and oil-air lubrication is fitted as standard.Optional extras include in-process and post-process work probing,and automatic load/unload equipment.

Ergonomics have alsoreceived special attention; the vertical workhead is easilyaccessible, at a comfortable working height.

The operator caneasily load and unload parts very quickly, when compared withworkhandling on a conventional horizontal spindle productiongrinder.

Automatic workloading, accessing the work area throughthe left-hand side of the machine, is much simplified whencompared with loading a traditional horizontal machine.

The CNCis Fanuc 18i-T with full automatic programming, operator promptsand graphic displays of the grinding process sequences chosen.Programming is in increments down to 0.0001mm, Included arelinear and circular interpolation, oscillation, traverse,multi-cut, plunge-cut and taper grinding features as well aswheel dressing routines.

Summing up, Taiyo Koki has designed avery compact, rugged, production grinder capable of combininggrinding processes and offering a very comfortable operatorworking environment..

Universal cylindrical grinder has teach-in CNC

2007-01-13T23:03:00.001-08:00

Precision engineers keep grinding in-house

2007-01-13T23:03:00.000-08:00

Linear surface grinders up production eight-fold

2007-01-12T23:02:00.001-08:00

Targeted at the carbide industry for grinding components such as punch forms, the latest Okamoto UPZ 315Li high speed CNC surface grinding machines have up to 100m/min feed rate.

Targeted at the carbide industry for grinding components such aspunch forms, the latest Okamoto UPZ 315Li high speed CNC surfacegrinding machines with up to 100m/min feed rate are able toproduce punch type components up to eight times faster thantraditional optical profile grinding methods. Available from 600Centre in Shepshed, the UPZ uses linear motor drives for thetable with linear glass scales to provide precise closed-looppositioning. With the new 4.2kW drive system, the grinding feedrate is totally programmable up to 100m/min through the Fanuc18iMB system.

Central to the machine design is the placement ofthe dual linear drive system which is set on the vertical planeeach side of a tennon section that runs the length of theunderside of the table.

This configuration overcomes any forcesthat could be created by the linear drive and thus eliminates anytendency for table lift or pull-down during the grinding process.This action would not only reduce the maintenance of grindingsize and the holding of geometric tolerances, but would also leadto bearing surface wear on the table.

The table design alsoeliminates effects of thermal growth generated from the hightable speed and any heat generated by the high power drivesystem.

The main wheel head has a 3.7kW AC motor and maximumwheel size of 200mm with a surface speed of 6,000m/min.

Thewheelhead assembly is attached to the main bed casting andreaches the floor which improves rigidity.

The wheel to tabledimension is 400 mm, longitudinal table travel is 280mm and crosstravel is 170mm.

The magnetic chuck size is 175mm by 105mm.

Themachine control software is able to accommodate the grinding of aseries of 'family' parts of various sizes using a gridreference style tabulation of the magnetic chuck surface inconjunction with program positional and size data.

By using atouch trigger probe, higher levels of datum position for formgrinding can be made in order to accommodate high accuracyrequirements.

CNC centreless grinder is easy to set up

2007-01-12T23:01:00.001-08:00

In partnership with Douglas Curtis, Kellenberger is entering the CNC-centreless grinding machine market with the Kel-Curtis machine.

In partnership with Douglas Curtis, Kellenberger is entering theCNC-centreless grinding machine market. The Kel-Curtis machine isa joint development based on the design of the compactKellenberger Kel-Vision cylindrical grinding machine withstationary table and X- and Z-axes underneath the wheelhead. Thespecific technology know-how of centreless grinding originatesfrom Douglas Curtis.

Main features include: * Space requirementsvery limited due to compact design.

* Ergonomic design of themachine allowing excellent access to the grinding and dressingareas.

* Quick and easy automatic set up of the machinepermitting economical grinding of single parts and small batchesof components.

* High-precision swivelling wheelhead for straightand angle-approach grinding operation.

* Grinding of shouldersand faces on right-hand and left-hand sides in one operation.

*Dressing concept permitting multiple dressing cycles for thegrinding wheel with 6 optional dressing tools at the contactpoint of grinding wheel/component.

* In-process measurement ofthe component.

CNC centreless grinding versatility improved

2007-01-11T23:00:00.000-08:00

Approximately 5 years ago the concept for a new centreless grinding machine was conceived with a number of objectives, to increase the reliability, consistency of the process and speed setting up.

Approximately 5 years ago the concept for a new centrelessgrinding machine was conceived with these objectives. * To reducethe known problem areas associated with centreless grinding suchas taper on parts after dressing, difficult and slow wheelchange, slow changeovers, and only through and straight approachgrinding. * To enable centreless grinding on components notnormally associated with this method of grinding.

* To reduce thenumber of cnc controlled servo slides and make more universal.

*To dress both grinding and control wheels from the front toreduce the tapers after dressing.

Douglas Curtis were successfulin applying for a Smart award, a government funded grant to helpwith the development costs in new projects, and designed andbuilt the prototype on our existing between centre grindingmachine base and enclosure.

This was extensively tested and anumber of limitations with the existing machine base becomeapparent.

It was restricted in z axis travel (400mm) limitingdressing variations, fitting automatic loading was difficult dueto the position of electrical cabinet and when heavy cuts weretaken vibrations occurred due to poor damping of machine slides.On a visit to an EMO exhibition in 1998, a visit to theKellenberger stand was made.

The sales director of Kellenbergerworked in the past with our sales director for a centrelessgrinding company, and general talk about the grinding businessand of our development of a new concept centreless grindingmachine were discussed and the problems we had incurred.

furthermeetings between ourselves took place and it was decided to usethe Kellenberger Kel-Vision machine base, slides and B axis ifrequired and enclosure.

This would give us the increased strokewe required (650mm) and also the base was vee and flat cast ironbed ways oil lubricated which would give very good damping.

Kellenberger made a number of small modifications to the standardmachine base and slideways and modifications were made to ourwheelhead and control wheel assembly to suit the new machine.

Douglas Curtis fits their own design wheelhead and control wheelassemblies, fit all the electric's including Siemens 840DCNC control and digital servo motors, design and integrate partshandling equipment and write all the machine software.

To datetwo machines have been sold and a machine has been exhibited atthe EMO show on the Hardinge/Kellenberger stand.

The joint veturewe hope will be benificial to both companies, Douglas Curtis area small company with little sales overseas except through to ourU.K customers and are not known outside the u.k.

Kellenberger onthe other hand are vey well established in external grindingworldwide with a large sales network.

Dress with CBN on tool grinders

2007-01-11T22:59:00.000-08:00

Until now, CNC dressing with a diamond dressing roll has only been possible with CBN wheels and has rarely been used on tool grinders, but Schuette now offers a solution.

Until now, CNC dressing with a diamond dressing roll has onlybeen possible with CBN wheels and has rarely been used on toolgrinders, not least because it demands an inordinate designeffort to accommodate an appropriate, speed- controlled dressingattachment on a 5-axis grinder. It is here that Schutte exploitsthe opportunities provided by the well proven, digital,synchronous AC motor's use as a universal rotary axis(A-axis). This multi-functional machine module performs well, notonly as - a high-precision dividing attachment for helix grindingoperations, - a fast rotating work spindle for high-performancecylindrical grinding operations, but also as - a dressingattachment that carries the diamond dressing roll and whose speedcan be set to the appropriate technologically most advantageousvalue.

These optimal conditions allow not only for the CNCdressing of CBN wheels, but also of diamond wheels on the SchutteWU 305.

A collision-free, integrated laser measuring system cangauge the grinding wheel geometry with great dynamic.

This hascreated the conditions that lead to constantly maintainedworkpiece quality in batch production, by applying optimaltechnological grinding conditions.

Modular grinding platform custom-configured

2007-01-10T01:28:00.000-08:00

Horizontal HG CNC machine platform is designed for external cylindrical, out-of-round, face and internal grinding.

Horizontal HG machine platform is designed for externalcylindrical, out-of-round, face and internal grinding. The designallows for a great number of machine variants to be configuredexactly in accordance with individual machining requirements:from the external grinding of one-offs and the productiongrinding of large batches of small or large, long or shortshaft-type components (know-how Karstens) to the internal andexternal grinding of high-precision chucked components (know-howReinecker) and the grinding of cams, camshafts and crankshafts(know-how Kopp). Even very different manufacturing problems aresolved by using largely identical basic machines, with all theobvious advantages for the user: standardised operation,programming and maintenance, resulting in a shorter learningcurve and reduced maintenance costs.

Planning the deployment oflabour becomes easier, owing to increased flexibility, makingmultiple-machine operation possible.

Based on this machineplatform for grinding lengths of up to 3,000 mm and grindingwheel diameters of up to 762mm EMAG showed at EMO 2001 the size3, the Karstens HG 310A for the external cylindrical grinding ofmedium size shaft components.

The quality standards for groundcomponents in particular, increase day by day.

At the same timeprocess integrity has become the main criterion in serialproduction grinding; values of Cpk 1.67 / Cmk 2.0 are a reality.Other important objectives of production planning are short,flexible production sequences.

Short retooling times must beachieved, to ensure that component manufacturing costs do notrise despite a steadily increasing workpiece diversity and theshrinking of batch sizes.

In addition to that, different batchsizes require different automation concepts.

The deciding factorwhere machining results are concerned, is the correct grindingtool.

The requirements of the various abrasives used on modernmachine tools have to be met.

The same applies to cutting fluids,as they too have a fundamental influence on machining results.Machine manufacturers (and often users too) have paid littleattention to them in the past; but they must be given dueconsideration in any new machine design.

The new horizontal HGgrinding machine platform of EMAG's grinding machine grouptakes account of all the demands required by modern externalcylindrical grinding machines.

The basic assemblies, such asspindles, measuring devices and drives are manufactured in largenumbers within the Group and assembled into working entities ofmodular design.

This also includes various work headstocks,grinding units, tailstocks, measuring devices, dressingattachments for CBN and corundum grinding wheels, and interfacesfor loading and unloading equipments.

The thermostable machinebase - also of static and dynamic rigidity - carries the slides.The sturdy compound table design reduces the footprint and saveson expensive production floor space.

It also makes the changeoverof grinding wheels easier.

NC tailstocks and flexible driversensure that a variety of workpieces can be quickly accommodated.The machining area allows generous axis movements.

The energysupply circuits are maintenance friendly.

Hydrostatic guidewaysin all linear axes allow for smallest infeeds, with optimalcontinuity of movement.

They are stick-slip free and welldampened and lead to contour integrity and an exceptional surfacefinish.

The machine is prepared to accept cutting oils as well asemulsions and allows high pressure and high volume deliveries,which facilitate CBN technology.

The demand for operator comfortand ease of servicing is fulfilled by the standardised controlsystem.

The EMAG on/off-line operating and programming systemtakes care of the varied demands made on the different machiningrequirements of this modular grinding machine platform.

Allprocess-specific functions, including loading, gauging, etc., canbe called up with standardised commands and are dialogue-based, avery operator-friendly feature.

Other demands from productioncompanies have also been taken into account.

Energy supply linesare located outside the machining area.

This preventscontamination and downtimes, makes for an uncluttered machiningarea and eases servicing.

The machine envelope is separate fromthe machine base, so that outside influences can have no adverseeffect on machining results.

The various grinding lengths and thedifferent sizes of work headstocks, tailstocks and back restsallows for the machining of a large variety of workpieces frommany branches of industry, from 200g to 700kg in weight, with atailor-made machine, using the most appropriate grinding method:gear shafts, differential gear shafts, camshafts, motor shafts,pump pinions, steering pinions, slide valves, steering gearboxes,turbine wheels, compressor wheels, axles and work spindles,components for textile machinery, for wind generators and otherhigh-precision equipment.

Kopp also will use this grindingmachine platform and offer in the near future the HG 310N typefor the machining of cams, polygon profiles, camshafts andcrankshafts.

Add other operations onto grinding centres

2007-01-10T01:27:00.001-08:00

The Kopp SK 25 is an innovative 5-axis high-performance grinding centre for multi-functional complete machining.

The Kopp SK 25 is an innovative 5-axis high-performance grindingcentre for multi-functional complete machining Kopp has been partof the EMAG grinding group - Reinecker Karstens Kopp - sinceAugust 2000. Within this group, Kopp is the specialist ingrinding and milling machines for the out-of-round machining ofhigh-precision workpieces, as used by many branches in theautomotive and mechanical engineering industries: cams, polygons,operating cams for printing presses and textile and packagingmachines, injection pump housings, housings for power-steeringpumps, tripods for drive elements, camshafts and crankshafts. AtEMO 2001 the Emag grinding group showed its Kopp SK 25 5-axisGrinding Center in its presently realisable top version, formulti-functional, 5-sided complete machining.

With thisproduction tool Kopp belongs to the trendsetters in combining andintegrating different processes thus reducing the processsequence succession - with all the advantages for the user:higher machining quality, faster throughput, as there are nointerim storage periods between several individual machines,shorter retooling times, lower capital outlay and reducedcomponent manufacturing costs.

The Kopp SK 25 is primarily usedwhere complex, high-precision workpieces have to be completemachined from 5 sides in one set-up, necessitating severaldifferent machining processes: internal and external machining ofround and prismatic workpieces of up to 500mm diameter or 500mmside dimension, employing internal and external cylindricalgrinding, out-of-round grinding, surface grinding, slot grinding,polishing, drilling, and milling operations.

The workpiecesinclude chuck casings, housings for thread rolling heads andcomponents with free-form or functional multi-plane surfaces.

The3 linear and 2 rotary axes can be used independently or ininterpolation.

To fulfil the demands for tight tolerances themachine is exeptionally sturdy and thermo-stable in design.

Theguideway layout and the use of precision linear guideways ensurethe necessary high dynamic of the axes.

Various automationmodules for tool and workpiece changes are available to create atailor-made production tool.

As is customary on machiningcenters, the 16-station tool changer allows for individual toolsto be changed; but in addition to that, or in lieu of it,complete machining units can also be changed at a chip-to-chiptime of just 20 minutes.

This permits the use of grinding unitswith high-frequency or belt-driven spindles, planetary grindingattachments for the grinding of slots or grooved cams, and alsoof milling units.

The simple exchange of individual tools orcomplete machining units also makes it possible to use the mostfavourable grinding material for each application: CBN, diamond,ceramics or PCD.

Workpiece loading/unloading is also designed tosuit individual customer requirements: manual or automatic, bypallet changer or gantry loader.

When it becomes necessary togauge the machining allowance or carry out an in-process gaugingoperation on the machined component, the appropriate measuringprobe is transferred from the tool changer.

An acoustic touchrecognition device is employed to avoid unproductive'air-grinding'.

The capability of the Kopp SK 25 wasdemonstrated at EMO 2001 with the complete machining of ahigh-precision component for a hydraulic power chuck: externalcylindrical grinding of the O/D, grinding of the front and rearend faces, three-dimensional grinding of the innner and outerguideways for the chuck jaws.Press Release Communiqu‚ dePresseInformationen fr die Presse1 / 1.

Surface grinder produces sub-micron finishes

2007-01-09T01:26:00.001-08:00

Introduced by Chevalier at EMO is the Ultra-H612/B612CNC Submicron profile grinder capable of producing 'mirror' surface finishes on highly accurately ground workpieces.

Introduced by Chevalier at EMO is the Ultra-H612/B612CNCSubmicron profile grinder capable of producing 'mirror'surface finishes on highly accurately ground workpieces. Themachine was demonstrated producing microfinishes to 0.25 micronRmax. Positioning accuracy is 0.5 micron and grinding accuracy,1micron.

Movements are programmable in increments of 0.0001mm.Table size is 305mm by 152mm, maximum distance from table tospindle centreline is 355mm and wheel spindle is rated at 1.5kWand 1000-4500 rev/min, or optionally, to 7000 rev/min.

Standardgrinding wheel size is 203mm diametre by 12.7mm wide.

Profile grinder is has conversational CNC

2007-01-09T01:26:00.000-08:00

Chevalier introduced its Smart-H1224 Conversational CNC Profile Grinder which is designed for the machining of profiles such as thread rolling dies orfir tree root profiles. 'comb' sect.

Chevalier introduced its Smart-H1224 Conversational CNC ProfileGrinder which is designed for the machining of profiles such asthread rolling dies, turbine blade fir tree root profiles,'comb' sections and so on. Chevalier builds two sizes.The Smart H/B1224 has a 500mm by 300mm table, 620mm Distance fromtable surface to wheel spindle centreline is 620mm and range ofgrinding wheel spindle speeds is up to1750rev/min. Three spindlehead ratings can be specified: 3.7, 7.5 or 11.25kW.

Standardgrinding wheel size is 355mm diameter by 50mm wide.

The smallerSmart-H/B818 has a table size of 460mm by 200mm and distance fromtable surface to wheel spindle centre line of 510mm.

Grindingwheel speeds are up to 3450rev/min and spindle power is 1.5kW.Wheel size is 203mm diameter by 12.7mm wide.

Grinding beats milling for aircraft engine parts

2007-01-08T01:25:00.000-08:00

Major reductions in capital investment, set-up times, production costs and lead times have resulted at Rolls-Royce group factories as a result of viper grinding on Makino M-Cs.

Major reductions in capital investment, set-up times, productioncosts and lead times have resulted at Rolls-Royce group factoriesin Glasgow, Derby and Bristol as a result of viper grinding onMakino machining centres. Required process capability oftypically Cpk 1.3 is being achieved easily on components rangingfrom turbine blades to compressor casings. During a recent openhouse at NCMT's Coventry technical centre, productionengineers from Rolls-Royce as well as other OEMs andsubcontractors were shown demonstrations of so-called'viper' grinding of inconel on a Makino A99-CDmachining centre.

The technique was developed in collaborationwith grinding wheel manufacturer, Tyrolit, for producing aircraftengine parts.

The first operation on an Inconel test piece duringthe open house showed a 15mm wide aluminium oxide wheel roughgrinding an 8mm deep slot in six seconds, using continuousdressing of the wheel.

The same operation would take 3 minutesusing a carbide end mill on the same machine.

Operation 2involved using a similar wheel, this time 30mm wide, to produce a25mm wide flat on the flange into which the previously mentionedslot had been ground.

Stock removal depth was 8mm, as evidencedby the disappearance of the slot, and the process took just 12seconds.

It would have taken a face mill much longer to do thesame job.

If the expense of a diamond continuous dressing wheeland arbour cannot be justified for a particular application,Makino can equip the machine with an hydraulic, 3000 rpm,table-mounted diamond dresser, as was demonstrated at the openhouse.

One factor behind the success of viper grinding is the useof very high pressure, high flow rate, refrigerated coolantdirected at the machining area - 70 bar through an NC nozzledirected continuously just above the point of grinding and 100bar through the spindle.

To withstand these pressures as well asthe copious generation of grinding dust, the Makino A99 isconstructed with a double skin and has its slideways protected byspecial guards.

The application takes advantage of themachine's rigid structure, efficient swarf and coolantcontainment and management, and advanced spindle technology witha wide speed range of 50 to 12,000 rpm, all consistent with highmetal removal rates.

Both internal and external grinding may beundertaken.

Owing to the difficulty associated with milling ofInconel, conventional creep feed grinding has traditionally beenused wherever practicable.

The rationale behind finding analternative stems from the significantly higher capital cost ofgrinders compared with that of a machining centre.

Otherfinancial considerations are the high price of standard,large-diameter profile grinding wheels and the greater levels ofoperator attendance associated with conventional grinding ascompared with a machining centre.

In particular, a grinder maytake up to a day to set up for a new component whereas a Makinomachining centre can be reconfigured in one to two hours, andoften considerably faster.

Another relevant factor is that asingle, large wheel has to incorporate the forms of all thefeatures to be ground on a component, so whilst only a small partof the periphery may be grinding the component at any particulartime, continuous dressing of the whole wheel peripheryunnecessarily wastes this expensive consumable.

Herein lies thekey benefit of translating the process onto a machining centre.Small grinding wheels, each with the profile of a specificfeature on the component, are held in the tool magazine.

They arechanged automatically in the same way as, for example, a millingcutter, and dressing is restricted to the profile that is in use.For complete machining of components, milling cutters, drills andother tools may be stored in the magazine as well and called upautomatically within the cycle.

It is also possible to carry outstatic tool work such as broaching.

In the viper grindingprocess, vitrified, aluminium oxide wheels are employed in creepfeed grinding mode.

They have been found to machinelong-chipping, sticky, nickel-based alloys faster than cubicboron nitride.

Additionally, the porosity of aluminium oxide isbeneficial in retaining coolant and assisting in its delivery tothe point of cutting.

The open grain carries the coolant throughthe point of cutting, providing both lubrication and cooling andavoiding the problem of push-off caused by the wheel floatingover the component if the jet is aimed directly at the point ofmachining.

Accurate control over the coolant is achieved bymounting a 2-axis programmable coolant nozzle around the spindlenose, one axis (U) providing rotation, which allows bothhorizontal and vertical grinding, and the other (V) allowingradial positioning of the nozzles to take account of grindingwheel wear.

Automatic nozzle changing is effected from a cabinetmounted on the rotary table (B) axis, behind the rotaryhorizontal A-axis on which the workpiece is fixtured.

Pick-up spindle bearing track grinder developed

2007-01-08T01:24:00.000-08:00

Meccanodora will be showing at EM0 a bearing track grinding machine concept, which also allows for future developments in hard turning and mill-turning.

Meccanodora will be showing at EM0 a bearing track grindingmachine concept, which also allows for future developments inhard turning and mill-turning. The Futura turns the workpieceupside-down for the combined machining of the spherical innerdiameter and six ball tracks of an automotive constant velocityjoint outer race. In doing sop, it offers the followingadvantages: * The machine grinds the outer/inner diameters andtracks in one clamping, so improves final quality.

* Theslide-mounted workhead picks up and deposits workpieces from andonto a conveyor.

* The workpiece is automatically indexed forball tracks machining.

* The workpiece is continuously rotatedfor the machining of the spherical inner diameter.

* Machineslides are completely isolated from the working area, so thatguideways, motors, lubrication, hydraulic and pneumatic unitsnever come into contact with chips or coolant.

The machine isdesigned to operate with: * superabrasives or CBN wheels; *toolholders suitable for hard-turning using CBN tooling and *high frequency spindles for hard-milling using CBN tooling.

Brochure details superabrasive machining

2007-01-07T01:24:00.000-08:00

Jones and Shipman has issued an informative new brochure about the superabrasive machine tools developed by Edgetek.

Jones and Shipman has issued an informative new brochure aboutthe superabrasive machine tools developed by Edgetek. Based inConnecticut, US, Edgetek builds superabrasive slant bed andconventional turning systems and machining systems in a widechoice of capacities. The process is used by aerospace,automotive and medical instrumentation industries.

Edgetek is amember of the Renold Precision technologies group.

It includesgrinding machine builder Jones and Shipman International andleaders in rotor, gear and thread milling and grinding machinetechnology, Holroyd.

Chinese grinder manufacturer sets up in Europe

2007-01-07T01:23:00.000-08:00

Wuxi is the largest manufacturer of grinders in China, having designed and produced a range of machines for over 50 years, and has now set up Wuxi Machine Tools (Europe).

With the recent formation of Wuxi Machine Tools (Europe) inHertfordshire, there's now a major new player in the CNCgrinding machine tool market. While new to the UK and continentalEurope, Wuxi (pronounced 'whooshy') is the largestmanufacturer of grinders in China and has been designing andproducing a range of machines for over 50 years. Wuxi KaiyuanMachine Tools Group Co Ltd (its full title) is one ofChina's leading state-owned companies and it has ambitiousplans to become a global supplier of precision grinding machines.And the first step in expanding into Europe is the establishmentof the European operation in Berkhamsted -- a joint venturebetween Wuxi and a team of UK investors.

Wuxi produces around2500 machine tools a year from its factory in the Jiangsuprovince and has in excess of 60% of the Chinese market.

Theproduct range is wide covering: cylindrical, internal, centrelessand bearing track grinders as well as special honing machines.ISO9001 part 1 accredited, the company's CNC grinders arenow approved by some of the world's leading bearingproducers and it also offers a complete line capability for theproduction of most precision components.

The company employs over500 qualified engineers, is well supported by modern westernsoftware (on the CAD, CAM and production control fronts), has apolicy of recruiting university graduates and invests heavily inR and D.

Wuxi Machine Tools (Europe) has been set-up to handletechnical sales, distribution and support for CNC grinders inthis country and continental Europe.

Heading up the UK operationis managing director John Hire -- a former manufacturing directorof SKF and recently managing director of machine tool spindleremanufacturing specialists MTSR.

With a wealth of experience inprecision grinding technology, Mr Hire is impressed by both thequality and price performance ratio of Wuxi machines.

'Ithas taken us two years to set up this new venture and we had tosatisfy ourselves that quality levels were first class.

Alongwith our own investigations, the certification of quality by someof the world's leading bearing manufacturers, who hadevaluated various Wuxi grinders, helped to convince us this was amajor investment opportunity.

We also placed great store on thecompany's on-going commitment to research and development,training, design and manufacturing techniques.' Wuxiproduces smaller, more flexible and economically priced grinderswhich, for large scale users, will allow complete grinding linesto be set up for a lower investment as well as being more quicklyreconfigured for different products.

While for smalleroperations, these machines meet the demands of lower batchproduction in terms of quick set-up and changeover and all-roundflexibility.

As far as costs are concerned, Wuxi grinders can beup to 30% cheaper than comparable models while offering the sameperformance, and up to 70% cheaper than top-of-the-range machinesalbeit with a lower performance ratio.

Quality, accuracy andrepeatability standards are specified to a high order.

Such aprice tag also means that new Wuxi machines can also competedirectly with rebuilt and upgraded CNC machines in terms of basiccost.

While the use of western control systems (from the likes ofSiemens and Omron) and hydraulic components (from Vickers) onEuropean machines will help to ensure fast and efficientservicing and support.

All grinders produced for Europe conformto CE marking and can have full certification, if required.

Whilenot well known outside of China, Wuxi has supplied some grindinglines to the USA, Sweden and India.

However, with its newEuropean operation, the Chinese company is determined make itspresence felt on a truly global scale.

And to further thisobjective, Wuxi Machine Tools (Europe) will be setting up anetwork of selected distribution agents across Europe, withGermany and Italy probably being the first two targets.

Chinesemachine tools have something of an image problem in the west asthey have yet to fully establish their credentials on the qualityand reliability fronts and build-up significant export sales.However, China is determined to establish itself as a leadingmanufacturer in a number of key areas including machine tools,bearings and automotive components.

And the establishment ofWuxi's European operation in Berkhamsted shows just howserious this well-established machine tool builder is aboutsucceeding in world markets.

Universal cylindrical CNC grinder cuts set-ups

2007-01-06T22:58:00.001-08:00

The Japanese machine tool builder, Okuma, has introduced a new, universal cylindrical CNC grinder for chucking or between-centres working on components up to 300 mm diameter, 650 mm long.

The Japanese machine tool builder, Okuma, has introduced a new,universal cylindrical CNC grinder for chucking or between-centresworking on components up to 300 mm diameter, 650 mm long.Designated GU-34T, the machine is available in the UK throughsole agent, NCMT. The combination of an internal grinding spindlewith straight-approach and angle-approach external grindingwheels allows the most complex components to be produced in oneset-up. As a result, floor-to-floor times are reduced andaccuracy is improved by not having to refixture the part onanother grinder.

The diamond dresser is able to dress both ID andOD grinding wheels and has automatic withdrawal to preventinterference during production.

Swivelling of the internalgrinding spindle into the working position is automatic and thetailstock may be conveniently slid out of the way, rather thanhaving to remove it entirely from the work table.

Internal tapergrinding is achieved by swivelling the headstock by up to 90degrees, with fine adjustment up to 17 degrees being made usingthe table swivel.

Changeover between straight- and angle-approachexternal grinding is effected manually by swivelling thewheelhead through 30 degrees and reclamping, a process madevirtually effortless by a pneumatic head support.

The mountingnut needs only to be loosened, not removed, when changing thewheel.

Two design features are of particular note.

Themaintenance-free wheel spindle has a non-cylindrical, plainbearing which runs in an oil reservoir, ensuring rotationalaccuracy of 0.01 æm.

Contributing further to top accuracymachining is the wide 'V-flat' guideway structure forthe saddle.

Other principal machine specification includes IDgrinding in the diameter range 10 - 120 mm; maximum workpieceweight between centres of 50 kg; grinding at up to 2,700 m/min;and rapid traverse in both the X and Z axes of 20 m/min.

Controlis by Okuma's own OSP-U10G CNC which incorporates asstandard the company's MacMan system, offering a wide rangeof data transfer facilities.

Programs, component and toolingdrawings and parts orders can be made available on-line whileprogress data can be collected fully- or semi-automatically foranalysis off-line.

Rebuilder manufactures new CNC grinders too

2007-01-06T22:58:00.000-08:00

In addition to its machine rebuilding and retrofitting services, IMTS also designs and manufactures a range of new grinding machines including CNC cylindrical grinders.

Established 20 years ago, Industrial Machine Tool Services (IMTS)in Rochester, Kent offers a wide range of specialised grindingservices. This includes: complete machine rebuilds, partialrebuilds, CNC retrofitting, on-site service (for both manual andCNC grinders) and the supply of spare parts. In addition,however, IMTS also designs and manufactures a range of newgrinding machines which include the Rochester series of CNCcylindrical grinders.

One such new model, a Rochester 850 CNCcylindrical grinder, has helped a leading bearing manufacturer toimprove productivity on a range of inner bearing rings requiredin small batches -- generally around 20 off.

Using a magneticface plate (with varying gripping force), this three axis CNCmachine grinds the OD of the bearing rings which are supported bytwo curved brass shoes.

Both the 500mm diameter grinding wheeland the 250mm diameter bearings run in the same direction (likecentreless grinding) so that the parts are forced down into thesupport shoes as they are ground.

Compared with manual methods,CNC grinding provides more consistent results and has cut cycletimes by 60% and set-up times by 70%.

This customised Rochester850 grinder has a centre height of 150mm, 850mm between centresand an NUM 1040 CNC system with special software (for dovetailwheel dressing, angle approach grinding and gothic arch-typeprofiles) written by IMTS.

A menu-driven display simplifieson-machine programming routines.

The straight-approach machinehas a CNC radial dresser and two diamond dressers mounted on thetailstock and can grind at peripheral wheels speeds of up to45m/sec.

These bearing rings are finished ground to 1 micron onthe profile, 0.4 micron for roundness and with surface finishlevels of 0.8 micron Ra\.

Cross-hatching applied to flat or spherical parts

2007-01-05T22:57:00.003-08:00

A two station cross-hatch-pattern-finishing machine can be used for flat and spherical surfaces with high accuracy.

A two station cross-hatch-pattern-finishing machine can be usedfor flat and spherical surfaces with high accuracy. Part feedingis via NC-axis. The machine has a rapid feed as well as a finefeed with spark-out operation.

Therefore extreme high parallismand surface flatness, such as required for pump parts withstepped surfaces and uneven cross sections, can be produced.

Themachine can be operated semi automatically or automatically.

Anoptional attachment is a gauging device.

The machine can beeasily operated and has a low change-over time.

Therefore only alow budget for tools is required.

The machine offers an universalapplication, including the automotive, hydraulic components in,injection pumps, electronics industries and others.

Theelectrical cabinet contains the control, which isfreely-programmable.

The control panel contains a CRT for faultdiagnostics, operator guidance and process visualisation.

Themachine accepts components up to 400 mm diameter.

Working dia.

Is30 - 300 mm and workpiece height is 1 - 185 mm, or larger onrequest.

Grinding wheels and nozzles changed automatically

2007-01-05T22:57:00.001-08:00

Developed to achieve the most cost-effective grinding, the latest Schutte WU 305 five-axis universal tool and production grinding machine is equipped with an automatic wheel changer.

Developed to achieve the most cost-effective grinding of cuttingtools and components, the latest Schutte WU 305 five-axisuniversal tool and production grinding machine is equipped withan automatic wheel changing system and magazine able to hold fourdifferent wheel and arbor assemblies. As part of the wheel changeprocedure, coolant nozzles are also automatically exchanged inorder to ensure delivery is optimised for each size and shape ofgrinding wheel. Available from Traub Heckert UK, the grindingperformance of the WU 305 is maximised through the use of directdrive digital AC motors to grinding spindle, universal rotaryaxis and C-axis positioning.

The compact, high-performancegrinding spindle has a 15 kW power rating giving up to 12,000revs/min while the three linear axes have maximum feed rates of24 m/min.

The closed-loop universal workhead rotary axis ispowered by a 4.7 kW motor capable of 2,500 revs/min and iscapable of high accuracy positioning within 0.0002deg via theC-axis.

It will accommodate components up to 250 mm diameter by570 mm between centres.

The WU 305 is capable of cylindricalgrinding, helical grinding and grinding features such as the fullradius on ballnose cutters, step drills and shell end mills aswell as special tool forms.

In addition, production cylindricalgrinding and heavy duty plunge grinding can be carried out due tothe inherent rigidity of the machine.

On machine inspection canbe carried out via an integral 3D Renishaw probe mounted on thegrinding head.

The probe, for instance, is able to determineunclamped length, diameter, helix lead and indexing position ofthe spiral flute on the circumference of cutting tools such asend mills and feeds the data direct to the Siemens control fromwhich the automatic grinding cycle is initiated.

The machine iscompact having a footprint of just 1718 mm x 1840 mm with axistravels of 400 mm by 250 mm by 250 mm.

The machine is designedwith the grinding wheelhead set at 30deg to the vertical with thecentre of the wheel close to the centre of the workheadrotational C-axis to maximise rigidity.

And, because thelongitudinal guideway is inclined at 30deg, coolant effectivelywashes away grinding debris into the coolant tank filter systemand makes the rotary axis more convenient for manual loading.

Anoptional automatic workpiece loader that is integral in themachine is available for parts between 4 mm and 32 mm diameterand weighing up to 1.2 kg.

The pallet system is mounted on thelongitudinal axis of the machine with the workpieces positionedvertically.

The table and head axes are used to position thepick-up for transferring the workpiece from the pallet to theworkhead.

During grinding, the loading arm is parked in a safetyzone over the wheelhead of the machine.

The WU 305 uses theSinumerik 840D control system with Windows-based 'openarchitecture' special Schutte grinding software that is easyto use allowing programs to be entered or edited on the machinewith full graphics support.

There is a wide choice of menu-driventool-specific programs with operator prompts to simplify andspeed up programming for milling cutters, drills, step drills andstep tools as well as profile knives and cutting tools used inwoodworking and plastics machining.

Hard turn and grind gears in one set-up

2007-01-04T22:56:00.000-08:00

The Uranos M Flexible Multi-functional Machining Centre is the first product following the merger of the Schleifring Group's automation orientated companies, Schaudt Mikrosa BWF.

The Uranos M Flexible Multi-functional Machining Centre is thefirst product following the merger of the SchleifringGroup's automation orientated companies, Schaudt Mikrosa BWFGmbH. Shown at the AMB machine tool exhibition in Stuttgart lastyear, the Uranos M is of pick-up spindle design. It wasdemonstrated hard turning and internal and external grinding anautomotive timing gear.

Cycle time was around 60s.

Operations onthe timing gear included rough turn the bore and fillets,finish-turn faces, finish grind the bore and then externallygrind corners.

The pick-up spindle processes components throughthree workstations which can be configured for turning, internaland external grinding (using an ID grinding wheel up to 400mmdiameter) or, grinding OD and ID and superfinishing.

Machinedesign features a cast mineral concrete bed, hydrostaticguideways, use of linear motors on the X axis and stable grindingwheel dressing using high frequency dressing spindle and diamondform roll.

Working range is 280mm swing diameter by 100mmworkpiece width.

Main spindle operates at 0 - 3000 rev/min anddelivers torque up to 300Nm.

X axis stroke (main spindlepositioning axis) is 1500mm at up to 60m/min and positioning iswithin a resolution of 0.0001mm.

Z axis stroke is 250mm at30m/min and 0.0001mm resolution.

CNC is Siemens Sinumerik 840D.The Uranos M machines are designed for placing together in closegroups in confined spaces.

Universal grinder a major step for Toyoda

2007-01-04T22:55:00.000-08:00

Toyoda has announced the GU4x100, the first universal grinder ever built by the Japanese manufacturer.

Toyoda has announced the GU4x100, the first universal grinderever built by the Japanese manufacturer. Indexing of thewheelhead is effected manually in five degree increments using aHirth coupling and hydraulic clamping to ensure precise location.Either of two external grinding wheels for straight- orangle-approach may be deployed, or alternatively an internalgrinding spindle. The machine's introduction heralds furtheruniversal models, according to Mick Webster, European OperationsDirector, as well as the introduction of powered wheelheadrotation under CNC.

Toyoda is known worldwide for externalcylindrical grinders and in the UK has around 20 per cent of themarket (MTTA figures).

The company does not produce internalgrinders, so the appearance of this new model, available in twoversions with 1,000 mm or 1,500 mm between centres, representsthe first time that Toyoda has offered equipment for producingcomponents requiring internal as well as OD grinding.

Thespecification includes maximum internal and external grindingdiameters of 300 mm and 120 mm respectively, 320 mm swing overthe table and a wheel surface speed of 30 m/s (optionally 45m/s).

A second innovation is an upgraded version of the GL5Pstraight-approach cylindrical grinder capable of peripheral wheelspeeds of up to 120 m/s, 50 per cent more than the previousmaximum.

The increased rev/min enables the high speed productionof parts using cubic boron nitride (CBN) abrasive wheels.

Cycletimes are typically 20 per cent less than when using conventionalaluminium oxide wheels.

Toyoda has the hard turning market in itssights with the introduction of this machine.

More and more,lathe suppliers are claiming that hardened metals may be turnedat high production rates and with the added flexibility ofsingle-point turning.

To emphasise the grinder'ssuperiority, Toyoda points out that the GL5P can producecomponents in hardened steel by traversing the wheel across thediameters and shoulders, rather than by plunge grinding.Angle-approach grinding with a CBN wheel, a combination which isvery unusual, is also possible with the GL5A variant of thismachine as was demonstrated at MACH 1998.

Both 'A' and'P' versions are offered in two bed lengths havingbetween-centres capacities of 320 mm or 630 mm.

Well-priced hydraulic table surface grinder

2007-01-03T22:54:00.000-08:00

A new competitively priced hydraulically operated table surface grinding machine developed by Okamoto, the world's largest grinding machine manufacturer, incorporates AC servo control.

A new competitively priced hydraulically operated table surface grinding machine developed by Okamoto, the world's largest grinding machine manufacturer, incorporates AC servo control to provide a very simple to operate automatic vertical down-feed operation of the wheelhead to a high precision datum. Targeted to meet toolroom grinding requirements and small batch surface grinding, the Okamoto ACC-450 DXA machine is now available from 600 Centre of Shepshed, Loughborough. It has been priced very competitively due to the economy of scale production build capability of the Japanese company.

The machine includes a fully automatic grinding cycle through the Okamoto microprocessor based control with digital readout in two axes.

A coarse and fine downfeed selection are available at one, or both table reversals with automatic cross-saddle reversal.

The ACC-450 DXA weighs some 1.25 tonnes and is built on a heavily ribbed Meehanite casting.

Rigidity is high to accommodate heavy roughing and precise finishing cycles with a twin-vee saddle and table construction.

Magnetic chuck size is 450 mm by 150 mm with longitudinal travel of 530 mm.

Cross travel is 175 mm and the air gap between the 205 mm by 25 mm by 31.75 mm wheel and table is 310 mm.

The Wheel spindle has a 1.5 kW direct drive giving 2.850 revs/min.

Automatic downfeed is between 0.0001 and 0.03 mm with a cross-feed per revolution of 5 mm.

Continuous cross-feed rate is specified as between 0.16 to 0.4 m/min and intermittent cross-feed between 0 and 1.5 mm.

Options include, PG OPTI-DRESS or overhead straight dresser.

Conventional lathe has digital drives

2007-01-03T22:32:00.000-08:00

The world innovation - the NEF 320 K - a conventional lathe with navigator system rounds off successful NEF product line.

The world innovation - the NEF 320 K - a conventional lathe with navigator system rounds off successful NEF product line. TWIN 500, CTV 200/250, TWIN 32, GM 35-8, or SPRINT 42 - behind all of these names are hitech innovations from the Gildemeister concern in the field of turning, each and every one of which has set new standards. But if you really want to be serious in claiming the attribute of full liner, then you shouldn't restrict your attention alone to the high-end segment.

What small production plant and the workshop and training fields especially need are flexible lathes for single indexing and job lot production.

These companies have always been the traditional clients of Gildemeister, and now they are given a very special innovation in the form of the new NEF K line, in other words a 'conventional' lathe that optimises both the data processing and its operation alike with electromagnetic IF gears, digital drives, pretensioned (and so zero backlash) ball spindles, electronic handwheels, and - last, but not least - the control panel with touch screen display.

Armed with a 750 mm centre distance and 320 mm swing, users can now profit from the latest equipment as soon as they enter the realm of lathe technology.

In brief, the advantages are as follows: a constant cutting speed optimises cutting conditions; the orientated spindle mount in place of the chuck key reduces tooling times; new drive concept for the finest of surfaces; continuously adjustable rpm and feed rates optimise cutting conditions; optimised cutting performance and tool life; chip breaks and surface quality optimised during cutting; production safety and the greatest ease of operation; greatest ease of use and an extraordinary price performance ratio.

Ease of use is a direct result of a special Siemens compact controller whose touch screen control panel lets you easily enter values for rpm, feed, and thread pitch and which provides functions for travelling to the stop measure, radiusing, and automatic taper turning.

So operators no longer need to set stops for the lathe saddle or radial facing slide, never again need to switch between change gears, never again need to set the levers for rpm, feed, and threads, and never again need to adjust taper turning attachments.

The NEF K line lets you do all this at the touch screen control panel in self-explanatory input masks and parameter dialogs.

So no matter whether for jigs and fixtures, tools, or moulds, whether for prototypes or models, whether for servicing or in training shops - the product lines NEF and NEF K from Gildemeisterhave redefined the field of universal lathes for single indexing and job lot production.

Specifications for the NEF 320 K include a swing of 320mm; distance between centres of 750mm; main drive of 7kW; 7 maximum spindle speed of 3,550 rev/min; tailstock sleeve diameter of 70mm and sleeve spindle nose MK 5.

Flat bed electronic lathes have extensive memories

2007-01-02T22:32:00.001-08:00

Top seller in the Pinacho electronic lathe range is the Mustang, which is now available from Traub Heckert UK of Brackley.

Top seller in the Pinacho electronic lathe range is the Mustang, which is now available from Traub Heckert UK of Brackley. The Spanish machine tool builder ships some 300 lathes each month and has appointed Traub Heckert to capitalise on its turning application engineering expertise, sales and service support in the UK. The Mustang is available in two capacities in the standard 200 and 225 versions which reflects centre height over the flat bed.

Between centre distance options are 1,000mm and 1,500mm on both machines while a heavier duty C400 version can be specified with 2,000mm and 5,000mm between centres.

Swing over the 400-450 HB hardened and ground bed is 400mm and 450mm respectively.

While main spindle power is 7.5kW, the machines have an automatic change between low and high range at 700 revs/min.

The highest spindle speed is 3,000 revs/min and X and Z axis rapid traverse rates are 10m/min.

Central to the Pinacho machine concept is the latest Fagor 8055TC control with high capacity memory.

The control also provides a constant cutting speed where the automatic range change is initiated with the two speed gearbox.

The high resolution graphics screen provides a choice of visualisation zones and zoom with high level solid and trajectory graphical simulation of turning and profiling cycles.

Through electronic handwheels, manual operation is ergonomic and simple and the operating resolution of the handwheels can be changed at will.

Macro or canned routines of most frequently used turning cycles can be called from memory and used in conjunction with the positioning handwheel while a profile editor automatically creates the finished program.

For subsequent part production, a full CNC operation can be performed direct from memory.

Part of the Traub Heckert specification is the inclusion of a 'ready to run' package with chuck and quick-change tooling system.

With this tooling system operators will be able to achieve higher productivity and more accurate and consistent tool exchanges.

Alternatively, the Mustang can be purchased with an eight-station VDI 30 tooling automatic turret.

Manual/CNC lathe reduces product cycle times

2007-01-02T22:31:00.000-08:00

The installation of a Harrison Alpha Plus 550S manual/CNC lathe has led to a dramatic reduction in product cycle times for Stoke-based sub-contractor, Alton Precision Engineering.

The installation of a Harrison Alpha Plus 550S manual/CNC lathe, supplied by Derek Robinson Machine Tools of Leicester, has led to a dramatic reduction in product cycle times for Stoke-based sub-contractor, Alton Precision Engineering. The Harrison's state-of-the-art Alpha System software is playing a crucial part in the lathe's remarkable productivity and has won the unreserved approval of its operators. Alton Precision Engineering required an affordable, versatile and user-friendly high-performance lathe for turning a wide range of components with diameters of 100-400mm, in carbon and stainless steel, super-duplex and brass.

Precision-made parts manufactured by Alton include hydraulic pistons and cylinders, grinding wheel centres and components for use in machinery supplied to the bakery and pottery industries.

Already familiar with products from 600 Lathes' highly acclaimed product range, the Alpha Plus 550S was chosen by Alton for its combination of performance and versatility, which together have contributed to a reduction in product cycle times of between 15% and 20%.

The Alpha Plus 550S supplied to Alton features a 2m bed, 550mm swing, and a spindle speed of up to 1800 rpm, and is used particularly for one-off and small batch production.

Company Director, John Salt, explained, 'We looked at a number of different lathes but only the Alpha offered the combination of accuracy, ease-of-use and flexibility required by the wide range of precision applications undertaken at Alton.

The fact that we've been impressed by the performance and reliability of other machine tools from 600 Lathes only added to the Alpha's appeal'.

Crucially, the Alpha's all-round ability has also enabled Alton to win a long-running contract to supply a precision-made hydraulic component whose internal shape could not have been produced cost effectively using a traditional centre lathe.

John Salt explained, 'The sheer versatility of the Alpha provides us with scope for taking on new business while helping to streamline our existing operations and maximize the company's overall productivity'.

A key factor in the Alpha's success at Alton is its innovative software control system, developed by Harrison to provide highly flexible yet remarkably user-friendly programming and operation, ideal for the fulfillment of one-off orders, prototypes and both small and large batches.

Two fundamental aspects of this system are the lathe's AlphaLink CAD/CAM system and AlphaSystem semi-automatic, autocycling and electronic handwheel (manual) modes of operation.

These systems are accessed through a twin keypad configuration, providing the operator with the choice of ISO CNC operation from the right-hand keypad and AlphaLink and AlphaSystem interactive operation from the left-hand keypad.

The right-hand ISO keypad has full CNC facilities, utilising canned cycles G70 to G76, tool nose radius and wear offsets, tool path graphics, inch/metric conversion and background editing.

Programs can be entered and/or edited directly at the machine.

The left-hand keypad generates on-screen programmed sequential operations in simple question/answer page format for parallel turning, chamfer, radius, taper and multi-start threads.

Another powerful 'user-friendly' feature of the Alpha Plus 550S is that graphical representation and CNC control is through the super compact GE Fanuc 21i-T controller, featuring a grey-scale TFT (thin film transistor) flat screen.

The 21i-T has a powerful memory, providing instantaneous response to program commands through ultra high-speed serial communications (single optic fibre).

Troubleshooting and data input/output are accommodated with a PCMCIA modem slot.

The Alpha's accuracy is another important factor in its overall appeal and has enabled Alton to manufacture components within tolerances ofñ 0.01mm.

John Salt explained, 'The Alpha has obviously been engineered for highly accurate machining, delivering a level of repeatability which guarantees the consistent quality of every component we produce.

The Alpha's combination of build quality and state-of-the-art control means we can manufacture identical batches of components to tight tolerances, over and over again, irrespective of which machinist operates the lathe'.

Summing up the wide-ranging appeal of the Alpha Plus 550S at Alton, John Salt commented, 'The Alpha's combination of ease-of-use, accuracy and remarkable versatility belies its competitive price and accounts for its enormous contribution to our productivity and manufacturing capacity.

Not only has the Alpha Plus 550S enabled us to speed-up our production cycle times without compromising the quality of our products, the lathe's all-round ability has opened up a number of opportunities for us to win additional business and increase our profitability'.

Easy-to-use manual/CNC lathe launched in Chicago

2007-01-01T22:31:00.000-08:00

Unrivalled ease-of-use features the latest manual/CNC lathe, thanks to its specially developed Fanuc/Harrison control and full-size colour touch-screen. It makes its debut at IMTS.

High capability and exceptional value for money will be the key underlying themes of 600 Group's considerable presence at the forthcoming IMTS show in Chicago. As well as tried and tested products from the Group's celebrated ranges, the show will also provide a backdrop for the launch of a number of exciting new machine tool innovations. 600 Group's major involvement in the show signals its confidence that a gradual recovery in the US machine tool market is now within sight.

Central to 600 Group's IMTS activity will be world's first showing of the new Alpha U 2 manual/CNC lathe from Harrison, offering unrivalled ease-of-use thanks to its specially developed Fanuc/Harrison control and full-size colour touch-screen.

Colchester's driven-tooling equipped Storm 120M and 220M, the US version of its highly successful Tornado turning centre, will also be on show, as will Colchester's Combi K state-of-the-art CNC/manual lathe.

Continuing the theme of high capability will be Pratt Burnerd America's much-publicised Programmable Power Chuck, whose ability to be program-controlled and fully integrated with the parent machine's own control earned it the coveted title of Best workholding equipment at the International machine tool industry Awards in April.

In response to market demand for ever-lower equipment costs, Colchester will unveil the latest incarnation of the world's most famous lathe, the Colchester Triumph centre lathe, complete with infinitely variable spindle speed and now available at the unprecedented and highly competitive price of $20,000.

IMTS will also see the US launch of Richmond Machine Tools' range of high-specification vertical machining centres, as well as Electrox' highly acclaimed Cobra Marker laser marking system and representation from Crawford Collets.

From its own stand at the show, 600 Group company Clausing Industrial will exhibit its extensive range of turning, milling, sa wing and sheet metal products from Group brands Kalamazoo and Metal Muncher.

600 Group Chief Executive, Tony Sweeten, explained, '600 Group's intensive IMTS campaign will focus on a powerful combination of great value machines and those which offer high levels of capability and performance.

The fact that the Group will be so well represented at the show reflects our unswerving faith in this important machine tool market and our long-standing belief that a dynamic and large-scale approach befits a machine tool force of 600 Group's global stature'.

Demand for centre lathes brings prices down

2007-01-01T22:30:00.000-08:00

A dramatic turnaround in the demand for conventional lathes has enabled a lathe builder to reduce the price of selected models in its centre lathe range by up to 40 per cent.

A dramatic turnaround in the demand for conventional lathes which has improved the benefits associated with economies of scale has enabled Colchester Lathe to reduce the price of selected models in its centre lathe range by up to 40 per cent. The new pricing structure is in response to Colchester Lathes' distributors reporting a world-wide resurgence of training schools and workshops who are preferring to buy known brands such as Colchester. This follows bad experiences such as long-term reliability, poor spares and service support and disastrous residual values that are a growing problem associated with the newer breed of low-cost centre lathe suppliers.

The effect of the market shift in Colchester's favour is qualified by a recent surge in demand where some GBP 750,000 worth of centre lathes have been ordered from seven different countries in the Far East, America and Southern Ireland.

According to Sales Director, Mike Dawes: 'Sales of our traditional centre lathes have experienced a dramatic turnaround.

This has motivated us to rationalise machines in the range and certain key component parts while maintaining or improving quality of build.

With orders rising, we have been able to instigate value engineering and more competitive sourcing which also capitalises on the efficient production methods that are well-proven on our two and three-axis Tornado CNC lathe range.' Over the last five years or so, Colchester Lathe has grown its market share with its CNC range of slant bed Tornado and the Combi combination lathe.

Says Mike Dawes: 'Now with the new economies of scale, we have justified a total re-focus on our conventional machines which has resulted in a massive 40 per cent reduction in price on selected models.' When this is added to the world respected name of Colchester, built-up from over a century of centre lathe manufacture and being Europe's biggest lathe builder, distributors have already responded with a growing order book.

Quality centre lathe price cut by 40%

2006-12-31T22:30:00.000-08:00

The latest 'special edition' variable speed centre lathe is now available from just GBP 12,750 - representing a massive price reduction of 40 per cent from the previous model.

The latest 'special edition' Triumph VS2500 variable speed centre lathe is now available from Colchester Sales from just GBP 12,750 a massive price reduction of 40 per cent from the previous model. Based on a world-wide resurgence in the conventional manual machine market for Colchester Lathe and extensive value engineering, the new Triumph has a 7.5kW motor with triple range, variable speed drive giving 14 to 2,500 revs/min. It has a 400 mm swing over the 1250mm long hardened and ground bed and has been regarded internationally as the 'best-known' model of centre lathe.

The machine weighs in at a hefty 1,610kg in standard trim which demonstrates the inherent rigidity of the basic machine design and potential for high accuracy turning tasks.

The price reduction is a result of a swing to traditional centre lathe manufacturers such as Colchester Lathe due to problems of long-term reliability, poor spares and service support and disastrous residual values associated with low cost suppliers over the last five years or so.

This has enabled Colchester Lathe to respond to rising demand especially in workshop, education and training schools and instigate value engineering and competitive sourcing to maintain the level of quality associated with the brand name and make it more affordable.

Electronic lathe frees up CNC production machines

2006-12-31T22:29:00.000-08:00

The installation of an 'electronic' lathe has saved up to a third in machining times over previous methods for copper welding arms and released CNC machines for higher volume work.

The installation of a Pinacho Mustang 200 'electronic' lathe by StarragHeckert UK of Brackley has saved up to a third in machining times over previous methods for copper welding arms at Welding Electrode Store of Redruth, Cornwall. Says Andrew Hosking, managing director: 'We carefully evaluated the market for the most suitable machine before purchasing the Pinacho and concluded that it represented excellent value for money over the competition. The added benefit of the flexibility of the Mustang 200 is that it releases our other CNC machines for higher volume work.' The decision to purchase was also aided by the ability and reputation of StarragHeckert UK as a lathe specialist with the resource to provide training and full service backup.

Installed in August 2001, the electronic Pinacho is now used exclusively for the production of welding arm components which were previously machined on more expensive CNC machines or manual centre lathes using skilled operators.

It is in daily use producing batches of between one and 10 components that vary in diameter from 12 mm to 50 mm and are up to 500mm long.

Tolerances are generally within + 0.05mm.

The copper welding arms are widely used by the automotive industry for fitment to industrial robots engaged in car body welding and are ordered directly by the vehicle manufacturers from the Redruth company.

Welding Electrode Store, which is a 30 employee company with some 10 CNC and 15 manual machines on the shopfloor, produces resistance welding equipment and consumables for most of the major automotive companies in the UK.

The Pinacho Mustang 200 has a swing over the bed of 400mm, a 7.5kW drive giving up to 3,000 revs/min with constant cutting speed and electronic handwheels for X and Z axes.

Ideal for single parts or small batch runs, the operator is fully supported by high level graphics with a choice of different visualisation zones as well as zoom and a large capacity memory allows program storage for repeat machining tasks.

Value engineering exercise reduces lathe costs

2006-12-30T03:30:00.001-08:00

A resurgence in international demand for manual centre lathes combined with avalue engineering exercise have brought down their costs significantly.

Following the resurgence in international demand for its manual centre lathe range and the resulting value engineering exercise carried out by Colchester Lathe design and production engineering team, the Colchester Sales operation is now able to offer the newly developed variable speed Master and Triumph VS centre lathes at GBP 11,950 and GBP 12,750 respectively. Providing outstanding value for money, both machines feature an AC inverter 7.5kW electronic spindle drive giving constant power, through three infinitely variable ranges. There is also a constant surface speed option which gives improved surface finish capability and shortened facing-off cycles.

Each machine uses a heavy duty construction with a wide bed and triangular webs to provide high torsional stiffness and stability.

Slideways are coated with 'Moglice' PTFE low friction linings for longer life and reduced 'stick-slip'.

The Master has a 350mm swing and 650mm between centres capacity with 17 to 3,250 revs/min speed range and No 4 taper tailstock.

Meanwhile, the larger Triumph has a 400mm swing with 1250mm between centres.

Its speed range is between 14 and 2,500 revs/min with a No 5 tailstock taper.

Turn a key to select simple turning or CNC

2006-12-30T03:29:00.001-08:00

Equally at home in the school workshop, technical college or factory, toolroom standard, flat bed range of lathes have the production capabilities and flexibility of a CNC machine.

British lathe builder Harrison has produced a new world-beating lathe, which is equally at home in the school workshop, technical college or manufacturing environment. Benefiting from an even larger swing-over-bed, as well as new production enhancements and manufacturing refinements, the new Alpha 1350S is the foundation model for Harrison's landmark S1000 range of two-axis manual/CNC lathes. Extremely easy-to-use, the Alpha S1000 series is a toolroom-standard, flat bed range of lathes with the production capabilities and flexibility of a CNC machine.

The power and sophistication of the Alpha 1350S brings, at modest cost, easy to assimilate yet extremely advanced programming and machining functions to teaching lathes.

On the other hand, it is just at home in the manufacturing workplace, providing a sophisticated, extremely productive and flexible turning platform from a modest cost base.

The Alpha 1350S incorporates the most advanced and easy-to-use CNC/manual lathe control in the world, the Alpha 1000 series control.

Specially developed for Harrison's revolutionary Alpha lathes, the new Alpha 1000 control features a 260mm (10.4 in) wide touch panel, alphanumeric keypad and a system selection key to provide effortless switching between powerful, but simple-to-use turning options.

This allows technology students to progress, with ease, from simple manual turning concepts right through to sophisticated CNC programming and machining.

A major feature of the control is its Manual Guide System, a welcome addition to the comprehensive range of operating modes already available on the Alpha range.

The Manual Guide System is a touchscreen accessible cutting program enabling the full generation of simple cutting profiles and complex automatic programs directly at the machine.

A teach facility is available, allowing hand wheel initiated moves to be recorded as a program and rerun automatically after completion of the first component, while all programs generated can be stored to memory for later use or saved to the supplied AlphaLink software.

Additionally, all programs generated in the comprehensive 'Cycle Cutting' mode may be converted to a full CNC program if required.

The Manual Guide System complements the industry proven AlphaSystem which has gained wide popularity through its flexibility and ease-of-use.

The AlphaSystem provides a semi-automatic machining capability for stops, taper turning and automatic thread cutting; and an offline CAD/CAM machining facility.

The Alpha 1350S completes a comprehensive and extremely popular Alpha S1000 range, which also includes the 1400S (400mm swing), 1460S (460mm swing) and 1550S (550 swing), and complements the established Alpha U and Alpha T ranges of lathes

Electronic lathes are effective on small batches

2006-12-29T03:31:00.000-08:00

Precision machinist says that electronic manual lathes are more cost-effective on small batch work and prototype production than either the company's CNC lathes or traditional centre lathes.

Precision machinist says that electronic manual lathes are more cost-effective on small batch work and prototype production than either the company's CNC lathes or traditional centre lathes. Three Harrison Alpha T (Touchscreen) electronic lathes, supplied and commissioned by RK International of Erith, Kent have increased manufacturing flexibility for sub-contractor Norman Precision of Thrupp, Gloucestershire by filling a production 'gap' between full CNC and manual turning operations. The three lathes, an Alpha 330T (330mm swing over bed), Alpha 460T (460mm swing) and Alpha 550T (550mm swing), have proved to be far more cost-effective on small batch work and prototype production than either the company's CNC lathes or traditional centre lathes.

The Alphas also provide 'toolroom' support for the CNC operation.

Specialists in high precision CNC machining with customers in the oil, medical and automotive industries, Norman Precision took delivery of its first Alpha, the 460T, in December 2001.

The acquisition proved so successful that it was followed up in August 2002 with the purchase of the Alpha 550T and Alpha 330T.

Managing Director Kevin Norman comments: 'Business has grown tremendously over the last few years and although we never particularly wanted to get involved in small batch and prototype machining, it is something that was necessary due to customer requirements.

Also our own CNC department requires considerable support by way of the manufacture of fixtures.' While many sub-contractors have experienced a downturn in business, Norman Precision's policy of aggressive marketing coupled to an ambitious investment in new machinery has seen the company virtually double its turnover in the last year alone.

The recessionary trend in the manufacturing sector has also had a knock-on, but rather unexpected effect on the company.

As the downturn has taken hold, many of Norman Precision's larger manufacturing customers have cut costs by contracting their supply network while at the same time expecting more value from those suppliers retained.

While this has had dire financial consequences for some sub-contractors, Norman Precision's outstanding ability to produce precision-engineered products at very cost-efficient prices has helped it to actually increase business from some sectors.

The ability to survive in such a competitive marketplace is one thing, to prosper in such trading conditions is quite another and reflects well on the skill and dedication of both staff and management of the company - fully justifying Managing Director Kevin Norman's ambitious decision to invest over 25 per cent of annual turnover in new machinery in a single year.

The three Alphas have taken up a proportion of this investment, though the bulk was spent on acquiring machining centres and CNC spark erosion equipment, and these acquisition costs have had to be fully justified in terms of improved productivity and competitiveness for the company.

Certainly the three Alpha T lathes with their modest acquisition costs, extremely easy-to-use features and productivity benefits from 'day-one' have justified their presence in Kevin Norman's mind: 'I have been keenly aware of the benefits of the Alpha T and its predecessors for some time and although our work is primarily CNC machining I could see a niche for such machines in our operation.

Threading, tapers and large radii are much quicker and easier on the Alpha than on conventional lathes, and it's also a lot more cost effective for small batch work than CNC.' The Alpha T offers the user the benefits of both manual operation, semi-automatic and fully automated cycles, as well as a comprehensive offline CAD/CAM system.

To add to its versatility Harrison has recently embodied automatic 'thread chasing' and 'Acme' threading cycles to the Alpha T repertoire, enhancing the lathe's productivity and boosting Harrison claims that the machine is the logical successor to the manual centre lathe and the natural choice for any manual lathe user wishing to upgrade its production machinery.

Electronic lathe transforms jobbing shop

2006-12-29T03:30:00.000-08:00

The productivity and flexibility of a newly acquired electronic lathe has transformed a small agricultural jobbing shop into a busy sub-contract operation serving a wide range of industries.

Ray Barnes Engineering of Kendal has been transformed from a small agricultural jobbing shop into a busy sub-contract operation serving a wide range of industries - thanks to the productivity and flexibility of a newly acquired Harrison Alpha 400T electronic lathe, and the ambition and determination of company owner Graham Barnes. Delivered and commissioned in July 2002 by distributor BL Gilbert of Barrow-in-Furness, the Alpha was productive on its very first day. Since then, the productivity and profitability of the Alpha has allowed the company to bid for, and win, a wide variety of machining contracts - from sophisticated 'one-offs' up to batches of 3500.

Graham Barnes recently took over the company on the retirement of his father.

Up until then, the company had been a very small operation chiefly serving the agricultural community as a small jobbing shop for over 20 years.

Barnes already knew that work from this sector - the company_s biggest earner - was in decline, in part due to the lasting effects of the foot and mouth epidemic.

Although there was some local industry in Lancaster and Kendal, chiefly the paper industry, machine fabricators and laundry equipment manufacturers, Ray Barnes Engineering was hardly equipped to make inroads in these markets - particularly for complex machining work or medium-to-large batches.

The company's production facilities comprised three elderly manual centre lathes all of which were labour intensive.

The decline in business was further compounded by a skills shortage in the Lakeland area, so the company found it difficult even to recruit to increase capacity.

Graham Barnes was left with a stark choice - do nothing and risk eventually going out of business, or invest and re-equip while chasing new business from different sectors.

Choosing the latter course of action, his first step was to consult trusted local machine tool distributor BL Gilbert and ask their advice on which machine they thought would best fit the production profile of the company.

Managing Director, Richard Gilbert's view was that the Harrison Alpha T electronic lathe was the most cost-effective option for increasing productivity and thus capacity for Ray Barnes Engineering.

Graham Barnes comments: 'I considered both the Harrison Alpha and a foreign import, however the British machine looked much more ruggedly built for the large percentage of axle machining we carry out - and if anything did go wrong with it, Harrison wasn't that far away.' Gilberts arranged to demonstrate the Alpha T at a local sub-contractor in Carlisle and then took Mr Barnes through to the Harrison factory in West Yorkshire.

There, an applications engineer programmed the Alpha from an axle drawing supplied by Graham Barnes.

Set-up took 15 minutes - a fraction of the time Barnes would have taken on one of his manual lathes and enough to convince him that the Alpha would be a considerable asset to the company.

The Alpha had an immediate effect on productivity, the company owner quickly assimilating the Alpha's CAD/CAM system and creating a complex machining routine on the very first day.

As he says: 'It's pointless to buy a machine and use it to only half its capacity.' General turning is proving to be 30-50 per cent quicker than conventional centre lathes and that has helped increase turnover considerably.

Word has also spread within the local engineering community about the company's expertise.

It has already received orders from OEMs and larger sub-contractors, aware that the Alpha is fully capable of carrying out large batch, sub-contract work to the necessary standards.

One typical job is the machining of a one metre, 200kg, fine tolerance shaft that would occupy a skilled operator for a full day using a traditional centre lathe.

With the Alpha however, the lathe is set up and left to run while the operator attends to other work.

Also there is no requirement for form tools, as radii and complex forms can be executed as simple semi or fully automated operations.

Graham Barnes sums up the Alpha T very simply: 'I can't understand why anybody would buy an ordinary centre lathe with a machine like this on the market.'

Easy-to-use conversational CNC suits small batches

2006-12-28T01:57:00.001-08:00

Easy-to-use conversational programming routines on a manual/CNC lathe have made a significant difference when applied to the small batch work, says a precision machining company.

If one event in its 52-year history could be said to encapsulate Ilford Engineering's tradition of engineering excellence, it would be the 1995 Le Mans 24 hour endurance race. The winning car featured engine, brake and body components produced by the company, and the achievement is still regarded as a defining moment in terms of the precision and reliability of this Basildon, Essex sub-contractor's output. Indeed, the round-the-clock demand for its engineering expertise is such that the 65-employee company continues to operate a night shift.

Ministry of Defence approved since 1973, Ilford Engineering's reputation has ensured its involvement with a diversity of projects, from 'supercars' and body scanners to Challenger tanks, where Ilford components have been used in a computerised suspension system.

'The advantage we have is that we operate in niche markets,' says Chris Greenhalgh, Ilford's Production Manager, 'which means a high percentage of repeat orders and a lot of scheduled work that could entail making the same part for, say, five years.' Even so, batch quantities tend to be small, with prototype and development work benefiting from a 'one-stop-shop' combination of precision machining, fabrication and assembly.

It's also an environment where, with motor sport customers in particular demanding both precision and fast response, CNC milling and turning machines supplied by XYZ Machine Tools have found their niche, their 'prompted' conversational programming proving to be an especially useful attribute.

The latest acquisition is a 7.5 HP/5.6kW Proturn VL 355 manual/CNC lathe that has replaced a manual centre lathe.

Machinist John Knight describes the new machine, which has a 360mm swing over bed and a 52mm spindle bore, as 'fast and accurate, holding [tolerance] limits well'.

And he says the easy-to-use conversational programming routines of the Prototrak VL control have made a significant difference when applied to the small batch work, usually up to 20-off, earmarked for the new machine.

When programming the Prototrak VL CNC, the operator simply inputs the geometry that is required before then filling in the prompts.

And, having defined the part geometry and stock dimensions, the tool path, including all roughing passes and the speeds and feeds, is then generated.

Constant surface speed is an integral feature of the Prototrak VL's software, as is spreadsheet editing which caters for extensive changes to large programs.

At Ilford Engineering, the time taken to program from drawing to finished component can be as little as ten minutes, which in a fast-moving business is a considerable benefit.

Typical of the type of work being tackled on the Proturn is a batch of one-metre long, zinc plated steel tubes and complementary white nylon collars destined for a sister company, Miltra Engineering, specialising in training and multiple munitions sets (TAMMS).

Once machining is completed, the three sizes of tube are telescoped together and incorporated into replica munitions.

Civilians and military personnel around the world depend on these inert devices, which are entirely free from explosive or incendiary materials, when being trained in recognition, awareness and disposal procedures.

Currently engaged in updating its BS EN ISO 9002-1994 accreditation and aerospace approvals, Ilford Engineering attaches considerable importance to innovation, experience, up-to-date technology and, above all, quality workmanship.

Which is why the company's customer list includes such 'blue chip' names as British Aerospace, Thales and Lotus Cars.

'It's about getting quality parts out of the door and keeping the customer happy,' says Chris Greenhalgh, 'but in these days of the 'cost down' culture, you have always got to be asking 'why are we doing it this way?' and 'how can we do it better?' You can't wait for a customer to answer these questions, because by then the work could be on its way to someone else.'

Electronic lathe first time user produces in hours

2006-12-28T01:56:00.000-08:00

Within a matter of hours an operator with no CNC experience was able to program and produce parts using icon-based commands, virtual tool display and graphic support on an electronic centre lathe.

When managing director Andrew Dobson, went looking for a computer driven centre lathe at MACH 2000, he also knew that his company SG Equipment would need further machines over the next 12 months. In the event, it was the effect on the business of the performance and ease of use of the first Colchester Combi K2 installed that led him to speed up the purchase programme and install three machines within six months. The key to this accelerated rate of introduction was the speed of operator conversion as Andrew Dobson recalls: 'The first operator to use the Combi was Alan Corless, a very experienced centre lathe operator, who had no previous CNC experience.

Within a matter of hours he was able to program and produce production components using the icon-based commands, virtual tool display and graphic support and has since progressed to develop very good CNC skills.' He then recounts how they moved another operator from an existing Colchester Electronic centre lathe: 'He was well up to speed within half a day,' said Andrew Dobson.

While it was the apparent ease of use that won the initial order for Colchester, today Andrew Dobson freely admits he was surprised at how well it was translated into practice on the shopfloor.

SG Equipment is a subsidiary of the Hyde Group plc.

It specialises in design, development, refurbishment and manufacture of ground support equipment for civil and military aircraft.

This embraces a wide range of activities covering production of locking pins for weapons systems, fabricated staging for external maintenance and sophisticated electronic and hydraulic test equipment.

Whilst much of the equipment is highly sophisticated, batch quantities are normally quite small averaging around 15 parts with single component requirements being quite common.

There is also the occasional need for batches up to 500.

As Andrew Dobson outlines, with the type of work the company produces, a production type CNC lathe would probably be counter-productive.

However, he acknowledged the benefit from batch-to-batch consistency and repeatability offered by CNC turning.

'We produce components such as dynamic seals out of stainless steel with dimensions tied to 0.012mm and a high standard of finish.

Our original Colchester Electronic lathe provided part of the solution with its ability to repeat cycles but it had insufficient capacity for our largest components and was far less sophisticated then the Combi K2,' he says.

The type of turned parts machined by SG Equipment generally range from 8mm to 60mm diameter, however, the company has one regular job which requires a 23/4 inch Acme thread to be cut on a 1320mm long shaft produced from a 180mm diameter bar.

This part is well within the 400mm swing capacity of the Combi.

Material specifications cover anything from EN3A to S154, which is an high tensile aerospace quality stainless steel and here, the 11 kW spindle with its gearless drive with a six to 2,500 revs/min speed range, is ideal.

As Andrew Dobson maintains, the company is reducing its past dependence on form tools 'This means we have a lot of quite complicated component shapes to produce which can now be single point turned and easily programmed through the software and graphics with detail scaling of features.

Also, as we have to carry out more reverse engineering tasks we now have the ability to adapt or modify a CNC program quickly which is extremely useful.

The combination of specialist Colchester windows-based software and Fanuc 210i-TA control on the Combi K2 provides us with those facilities and much more besides.

For instance the constant surface speed machining is particularly valuable as it guarantees that we achieve a consistently high standard of finish and overcomes possible problems such as not being able to tolerate rips or tears when machining threads and we need to comply with aerospace standards.

From its machining experience, SG Equipment are very complementary over the accuracy capability of the Combi machines and in particular the repeatability and reaction to respond to minor size adjustment.

And, according to Andrew Dobson: 'Colchester support is extremely good; if we have a programming query we get an answer on the 'phone, while if we have a need for something like a steady, it arrives next day.' The operators have found that when setting up, the ergonomic aspects of the machine's design have proven to be a key benefit.

Alan Corless commented: 'Everything on the machine falls easily to hand and the shallow 30 (degrees) slant of the bed definitely makes it easier to load and unload the machine and work on the far side of a job.

The guarding also gives an excellent view of what's happening and you can use the on-screen graphics simulation to monitor internal machining and areas which are flooded with coolant.' All three of SG Equipment's Combi K2s are identically equipped as chucking machines with the eight station electric turret option.

Six tools are common to almost every component produced while two are variable to accommodate specific requirements, such as different thread forms.

This commonality of set-up provides the company with a lot of flexibility, while ability to save programs to a flash memory card has allowed the building up of a CNC program archive for future repeat operations.

From a productivity standpoint Andrew Dobson feels the machines have demonstrated at least a 25 per cent improvement over a centre lathe though this is in direct proportion to the demands of the job and the size of the batch.

A prime example is the turning of the 23/4 inch Acme thread where production of a single part on a manual centre lathe used to take 16 hours.

The Combi K2 is able to complete the task in around 9 hours.

As Andrew Dobson concluded: 'We're extremely pleased with the performance of these machines, to the extent that we would have no hesitation in adding a fourth as and when our production requirements justify.

The outstanding thing about the Combi is definitely the control interface.

It has good simulation facilities that give the setter/operators the confidence needed to push along and in the early days quickly develop their programming skills.'

Manual/CNC flatbed lathe benefits from touchscreen

2006-12-27T01:56:00.000-08:00

Believed to have one of the most advanced control systems on the market yet, a two-axis, flatbed lathe is designed to operate across a wide spectrum of manual/CNC working parameters.

British lathe builder Harrison showcases three examples from its world-beating 'Alpha' ranges of CNC/manual and electronic lathes at MACH 2004, as well as a lathe from its classic, variable speed 'V' Series. Incorporating one of the most advanced control systems on the market yet is Harrison's Alpha 1550S - a two-axis, flatbed lathe designed to operate across a wide spectrum of manual/CNC working parameters. An Alpha 1550S x 2m (550mm swing over bed capacity by 2000mm distance between centres capacity) will be demonstrated at MACH 2004.

The lathe uses the Harrison/Fanuc Alpha 1000 Series control, which features a 260mm (10.4 in) wide colour touch panel, alphanumeric keypad and system selection key to provide effortless switching between powerful, but simple-to-use turning options.

This allows non CNC-trained operators to progress with ease from simple manual turning right through to sophisticated CNC programming and machining.

A major feature of the control is its Manual Guide System, a new addition to the comprehensive range of operating modes already available on the Alpha range.

The Manual Guide System is a touchscreen accessible cutting program enabling the full generation of simple cutting profiles and complex automatic programs directly at the machine.

The Manual Guide System complements the industry proven AlphaSystem which has gained wide popularity through its flexibility and ease-of-use.

The AlphaSystem provides a semi-automatic machining capability for stops, taper turning and automatic thread cutting, as well as an offline CAD/CAM programming facility.

Alongside the Alpha 1550S is an example from Harrison's Alpha 'U' range - the 1330U (330mm swing over bed capacity).

The foundation model for the range, the Alpha 1330U is a sophisticated, highly versatile, slant-bed manual/CNC lathe contained within a compact machine envelope.

The Alpha 1330U incorporates the state-of-the-art Alpha 1000 Series control.

The Alpha 'U' is engineered with a high performance composite base assembly, which is matched to a 30-degree box section slant-bed to form a single, rigid unit.

This configuration offers outstanding thermal, kinematic and dynamic damping characteristics that relate directly to the quality of component surface finish and accuracy of cut.

Complementing the Alpha 'S' and 'U' is an example from the Alpha 'T' range of electronic lathes - a 400T.

Harrison's Alpha 400T has been developed to offer super quick drawing to component times without the complication or cost of a full CNC system.

With a machine swing over bed capacity of 400mm and 1250mm distance between centres, the Alpha 400T is ideal for any lathe user looking for a competitively priced replacement for the traditional centre lathe.

Harrison's variable-speed 'V' Series centre lathes remain ever popular and Harrison has an example of the range in the MACH line-up.

The V390 (390mm swing over bed capacity) offers customers maximum cost saving in a top specification lathe, with infinitely variable, digital display, spindle speeds up to 3250 rpm and constant surface speed [CSS] with DRO for optimum cutting performance.

Three gear ranges are incorporated for maximum metal removal rates, as well as a powerful 7.5kW (10hp) spindle motor with AC inverter drive and 33:1 constant power range.

The V390 design provides excellent rigidity and swarf clearance.

For the medium-to-heavy production environments the V390 - with heavy-duty bed and cast iron base - is ideal for both heavy metal removal and precision finishing.

Manual/CNC lathes satisfy safety critical criteria

2006-12-27T01:55:00.000-08:00

Nickel-titanium material is expensive and machining by turning is regarded as very difficult, but innovative lathe control helped to optimise machining conditions to get good results.

The impressive signage adorning Goldring Industries' Trafalgar Works in Cable Street, Wolverhampton, serves a dual purpose. It is first and foremost a highly visible symbol of what in less than 15 years has become an extremely successful engineering business. But it also bears witness to Ivor Dring's determination to overcome redundancy, a circumstance that for some has been known to signal the closing of one door and the slamming shut of the next.

However, for Goldring Industries' founder and managing director, the decision to start his own sub-contracting company, while not without its setbacks, opened the door to a new way of life.

'I initially envisaged running a small machine shop with, say, five or six employees,' he says, 'but there is now a team of more than 30 people and we are still recruiting.

Our 45,000ft2 premises are owned rather than leased, and we provide a one-stop-shop for fabrication, casting, machining, assembly, test and painting.' Ivor Dring's previous experience with NEI's nuclear engineering division, latterly as operations manager, has proved invaluable, enabling Goldring Industries to become a main contractor to the Ministry of Defence and to include on its customer list some of the biggest names in British industry.

'We are an ISO 9002 - 2002 accredited company and we are very good at complying with procedures while still being able to produce work quickly,' he says.

This explains why Goldring Industries is now producing safety critical components for one of the UK's largest generators of electricity.

Machined on one or other of two recently installed XYZ Proturn 425 VL manual/CNC lathes to a diametric tolerance of +/-0.0005 inch, these nickel-titanium alloy components play a key role in avoiding unscheduled shutdowns of expensive generating plant.

However, the machining process is complicated not so much by the varying sizes required within any given batch of components or the tight tolerance, but by the nature of the material.

It belongs to the group of metallic materials known as Shape Memory Alloys, which possess properties of particular relevance to this application.

Although a relatively wide range of alloys are known to exhibit the shape memory effect, only those that can recover substantial amounts of strain or that generate significant force upon changing shape are of commercial interest.

It is the latter quality that is crucial because the component is frozen in liquid nitrogen - extending its length by some 40 per cent and reducing its external diameter accordingly - before being placed in position.

It then returns to its original size as the temperature rises above the transition temperature necessary to trigger the shape memory effect.

The end result is an extremely tight fit, with the component held securely in place.

The nickel-titanium material specified is expensive and machining by turning is regarded as very difficult, while heat treatment after machining, which ensures the necessary changes in the material's structure, must be undertaken in a vacuum furnace to prevent unacceptable oxidation of the alloy.

Prior to heat treatment, the components must be free from grease and other contaminants, particularly chlorides, and must not be handled directly, which demands great care throughout the manufacturing process.

The two XYZ Proturn 425 VL manual/CNC lathes equipped with the innovative Prototrak VL control have shown themselves to be ideally suited to their role in this demanding process.

Although dimensional accuracy and surface finish are the critical criteria, ease of programming and the ability to run through the entire sequence of turning the outer diameter, including the two locating 'nibs', and machining an internal bore before committing to computer control have proved invaluable.

This takes account of the high cost of the material and the numerous variations in the sizes of components specified within each batch.

It says much for Goldring Industries' enhanced turning capability that, having succeeded in obtaining the order, the company's first batch of 42 components was the subject last November of a complimentary letter from its new customer.

'It is gratifying,' he wrote, 'to be able to say that this is the first batch of these components I have ordered [from any supplier] that has had no rejects.

Manual/CNC lathe is better and quicker

2006-12-26T01:47:00.002-08:00

Since acquiring a manual/CNC lathe, a leading motor factory is producing turned parts 'better and quicker' allowing new parts - and 'one-offs' - to be produced to high quality standards.
A leading motor factory based in the south of England, which successfully expanded its business into fabricating and machining parts for vehicle operators and other industries, is producing turned parts 'better and quicker' since acquiring its Harrison Alpha 1550S manual/CNC lathe. Aghabridge , of Rochester, Kent, which supplies vehicle parts to hauliers, vehicle repairers throughout the Kent, Surrey, Sussex and London region, uses the Alpha 1550S, with its 554mm swing over bed, to produce a wide range of components, from hydraulic rams to flywheels. Director of Aghabridge, Ceri McGregor-Davies, says the company opted for the advantages of a proven and successful British-built lathe from Harrison's main distributor RK International Machine Tools, of Erith, Kent, after experiencing difficulties with reliability and parts supply for an existing non-British machine.
McGregor-Davies says: 'The Alpha 1550S has been extremely reliable, and it is doing the job much better and quicker than our previous lathe'.
'Because it is able to be used as a totally CNC machine, the operator can set it up to carry out a turning operation and then move to another job'.
'It has made our business significantly more efficient in that way'.
'We are a very flexible company, which is why we are successful in attracting a lot of business from a wide range of customers who require repairs or replacement parts, including large haulage companies, owner-drivers, fork lift and crane companies and even individuals needing parts for private cars'.
'Many are now realizing that new parts can be produced to a very high quality, including one-offs.' David Smith, Harrison's Sales Director, says: 'The Alpha 1550S is one of Harrison's class-leading S1000 range, which combines the virtues of a high quality conventional toolroom lathe, namely ease-of-operation, build quality, strength and reliability and supreme cutting performance with the production flexibility and capabilities of a full ISO (CNC) machine'.
'Our many customers, like Aghabridge, have already discovered the improvements that the Alpha 1550S brings to their business in terms of improved turning performance and finish quality, efficiency, manufacturing capacity and speed of producing single or multiple turned parts'.

Combination lathe turns ACME threaded SS shafts

2006-12-26T01:47:00.001-08:00

Flat bed combination manual/CNC lathe offered with a special macro written to produce an ACME thread form won a contract against another supplier that planned to thread whirl a shaft.
A couple of years ago when the Californians were having terrible problems with their power generation systems, it was a small Yorkshire three-man subcontract machinist that was called upon to produce within 2.1/2 weeks special oil wiper rings and remake segmented metal seals some one metre in diameter. The company, A A Lampkin Engineering is owned and run by three members of Britain's most famous family name in motorcycle scrambling and trials riding, and is located up a little lane in Silsden, just outside Keighley. At the time of the Californian crisis, the company had only manual machines but bucketfulls of machinist skills gained through supplying some 30 customers with parts such as clutch, carburettor and general parts for scrambling bikes, and at the other end of the spectrum, large components for power generation and valve industries.
Quite often stainless steel shafts up to 2m long, heavy electrical brush gear and seals up to 4m diameter were machined.
The Lampkin business trio of David, Alan and Stephen are well known in their sector for the supply and machining materials most engineers have never heard of.
These include centrifugal spun nickel brass and bronzes where spinning is used to rid the material of imperfections.
Cast nickel brasses and very tough stainless steels can also be a common find on the workshop floor.
The material for some components can cost up to GBP 2,000 for each part even before they are loaded to the machine tools.
The company had already installed a vertical machining centre and had considered a CNC lathe but the decision was forced when they got the chance of a contract to produce 20 special 50mm stainless steel shafts 1.5m long.
At that point they decided to call up local lathe builder, Colchester Lathe at Heckmondwike, to see if it could supply a machine.
Ex trials rider and director David Lampkin takes up the tale.
We told them: 'We have some threads to produce.' 'What type,' they asked?
'ACME,' was our reply.
To which they responded: 'Oh?' We added: 'The threads are about 600mm long on a 1500mm shaft and left-hand' 'Oh,' was the reply again.
Then we told them: 'They are two-start, 4 tpi (threads/inch) and the line went quiet'.
''But,' he maintains, 'Colchester came up with the goods in the form of its new MultiTurn 2000 flat bed combination lathe and offered a special macro written to produce the ACME thread form which won us the contract against another supplier that planned to thread whirl the shaft.' Colchester's solution was to use a special parting tool insert set at a compound angle to rough out the thread form then repeat the cut on each flank before going through the whole process for each individual start of thread'.
''What amazed us, bearing in mind the toughness of the material, was the level of finish we achieved on each thread.
We also had to produce a nut to check the machined thread on each shaft and again we could not believe how perfect they were across the whole batch of 20 parts.
Once one part was programmed at the machine control and produced, it was then a simple matter of repeat cycle direct from memory in CNC mode.
The MultiTurn 2000 has a 400 mm swing over the bed, 585mm x 165mm in the gap bed and 1250mm between centres.
It has a 250 mm chuck and an eight-station 30 VDI electric turret.
A 8.4 inch colour TFT flat screen and keyboard is carried on the saddle with electronic handwheels and the machine can be used in manual or CNC mode.
Programming can be by teach repeat using the electronic handwheel, through macros or ISO, DNC or CADCAM at the Fanuc Oi-TB control.
Toolpath verification is included on the flat screen.
The family business of A A Lampkin Engineering was set up in 1946 by David's grandfather, his father Arthur and his uncle Alan.
It was Arthur who was often followed on Saturday afternoon black and white TV for his very successful exploits in scrambling - and Alan, another top-class rider, who still works in the business with David and the other director Stephen.
The factory is a true Aladdin's cave of machine fixturing and tooling set in several workshops that lead warren-like from one to another.
However, the work produced demonstrates high traditional toolroom skills of milling, turning and extremely high levels of creativity to engineer a solution, which is obvious in the continued success of the business.
As David Lampkin maintains, prior to the MultiTurn he had never touched a CNC lathe; his turning skills were traditional centre, capstan and turret lathe based: 'When the MultiTurn was first installed I looked at it and wondered how to work it'.
'Now you can not get me away from it,' he says and he even runs the machining centre and MultiTurn together in automatic cycle, walking between each machine loading, unloading and checking parts.
Primarily they use the control system macros with manual data input in at the Fanuc Oi-TB control to set up the first piece'.
''The fact we can use the graphic simulation is an important comfort factor and we can easily slow down into creep feed or zoom in whenever we are not sure'.
'This is most important if you have a stick of specially imported material from Sweden costing over GBP 1,000 in the chuck,' he says.
With such a high level of background manual machining skills, David Lampkin confirms the machine will operate the way each of them want to work and 'we can do it in our own time'.
To produce the first part he reckons it takes about three-quarters of the time it would take on a manual machine.
However, with the six-station automatic turret there is no contest for repeat cycles, the consistency of size and finish and, of course, the time taken.
Because of the success of the two-start threaded shaft, the Lampkins have taken more business from the same customer and describes a bronze shaft with a 6 tpi Whitworth thread where they were concerned over the surface area of the thread form'.
''We decided to break the thread into four passes with a 0.1mm final skim to take out any spring in the shaft'.
'This really proved to us the level of repeatability we can achieve and the blending on the final pass was absolutely perfect,' he maintains.
He follows on to re-live the recent turning of a large vee-belt timing pulley with a trapezoidal groove'.
''When you lift it out of the machine and look at the surface finish in the groove and across the turned face, achieved because of the constant speed capability in the control, you could never equal this on a manual machine,' he says.
Then he comments with a smile: 'You look at the part and feel really proud of what you have just achieved - but then, all three of us love engineering and making things'.

Combination lathe chosen for advanced research

2006-12-25T01:46:00.000-08:00

Bristol University needed a large machine to be used manually but also had the software programs to turn more complex shapes, for which a 'half-NC' or 'combination' lathe was selected.
Bristol University has opted for the advanced touchscreen technology of Harrison's Alpha T range of electronic lathes to support the work of its Engineering Faculty, including major new research facilities, which will 'enable world-class UK scientists to remain at the leading edge of research'. An Alpha 460T has been supplied to the refurbished central manufacturing workshop within the faculty; this incorporates the recently-opened Bristol Laboratory for Advanced Dynamics Engineering (BLADE), described as Europe's most advanced multidisciplinary dynamics engineering research facility. Ivan Laver, the Central Workshop Manager, said: 'The workshop is a manufacturing facility for project work, research work, one-offs and specialist requirements for a wide range of engineering studies carried out across the Engineering Faculty'.
'Active suspension, vibration control, materials tests, dynamics engineering, aeronautics and even earthquake research are just some of the projects and areas'.
'There are around 300 undergraduates in each year, who carry out projects, mainly in their third and fourth years, and we also manufacture parts required for these projects'.
'Some projects are carried out in partnership with businesses outside the university so they have to meet standards required by the industry concerned'.
'We needed a large machine that had the capability to be used manually but also had the software programs to be able to turn more complex shapes'.
'The Alpha 460T was recommended to us and we found it was competitively-priced and fulfilled our technical requirements.' Workshop Technician Chris Hunt, who is one of a team of experienced operators, said the Alpha 460T electronic lathe had proved that it was highly capable of producing high-precision turned items, using computerised programs: 'To begin with we mainly used the software on the lathe, but recently we have done a lot more off-line programming and this has enabled us to make even more advanced and complex items.' David Smith, Harrison Lathes' sales director, said: 'The education sector is an important and expanding area for our business'.
'The Engineering Faculty at Bristol University is one of the foremost research and training centres for graduate engineers in Europe and we are very proud that an Alpha lathe was selected to meet the highly demanding requirements of a facility at the very cutting edge of science in this country.' The Harrison Alpha 460T electronic lathe was supplied to Bristol University by Harrison's main UK regional distributor, R K International Machine Tools of Erith, Kent.

Manual/CNC lathes satisfy safety critical criteria

2006-12-25T01:45:00.000-08:00

Nickel-titanium material is expensive and machining by turning is regarded as very difficult, but innovative lathe control helped to optimise machining conditions to get good results.
The impressive signage adorning Goldring Industries' Trafalgar Works in Cable Street, Wolverhampton, serves a dual purpose. It is first and foremost a highly visible symbol of what in less than 15 years has become an extremely successful engineering business. But it also bears witness to Ivor Dring's determination to overcome redundancy, a circumstance that for some has been known to signal the closing of one door and the slamming shut of the next.
However, for Goldring Industries' founder and managing director, the decision to start his own sub-contracting company, while not without its setbacks, opened the door to a new way of life.
'I initially envisaged running a small machine shop with, say, five or six employees,' he says, 'but there is now a team of more than 30 people and we are still recruiting.
Our 45,000ft2 premises are owned rather than leased, and we provide a one-stop-shop for fabrication, casting, machining, assembly, test and painting.' Ivor Dring's previous experience with NEI's nuclear engineering division, latterly as operations manager, has proved invaluable, enabling Goldring Industries to become a main contractor to the Ministry of Defence and to include on its customer list some of the biggest names in British industry.
'We are an ISO 9002 - 2002 accredited company and we are very good at complying with procedures while still being able to produce work quickly,' he says.
This explains why Goldring Industries is now producing safety critical components for one of the UK's largest generators of electricity.
Machined on one or other of two recently installed XYZ Proturn 425 VL manual/CNC lathes to a diametric tolerance of +/-0.0005 inch, these nickel-titanium alloy components play a key role in avoiding unscheduled shutdowns of expensive generating plant.
However, the machining process is complicated not so much by the varying sizes required within any given batch of components or the tight tolerance, but by the nature of the material.
It belongs to the group of metallic materials known as Shape Memory Alloys, which possess properties of particular relevance to this application.
Although a relatively wide range of alloys are known to exhibit the shape memory effect, only those that can recover substantial amounts of strain or that generate significant force upon changing shape are of commercial interest.
It is the latter quality that is crucial because the component is frozen in liquid nitrogen - extending its length by some 40 per cent and reducing its external diameter accordingly - before being placed in position.
It then returns to its original size as the temperature rises above the transition temperature necessary to trigger the shape memory effect.
The end result is an extremely tight fit, with the component held securely in place.
The nickel-titanium material specified is expensive and machining by turning is regarded as very difficult, while heat treatment after machining, which ensures the necessary changes in the material's structure, must be undertaken in a vacuum furnace to prevent unacceptable oxidation of the alloy.
Prior to heat treatment, the components must be free from grease and other contaminants, particularly chlorides, and must not be handled directly, which demands great care throughout the manufacturing process.
The two XYZ Proturn 425 VL manual/CNC lathes equipped with the innovative Prototrak VL control have shown themselves to be ideally suited to their role in this demanding process.
Although dimensional accuracy and surface finish are the critical criteria, ease of programming and the ability to run through the entire sequence of turning the outer diameter, including the two locating 'nibs', and machining an internal bore before committing to computer control have proved invaluable.
This takes account of the high cost of the material and the numerous variations in the sizes of components specified within each batch.
It says much for Goldring Industries' enhanced turning capability that, having succeeded in obtaining the order, the company's first batch of 42 components was the subject last November of a complimentary letter from its new customer.
'It is gratifying,' he wrote, 'to be able to say that this is the first batch of these components I have ordered [from any supplier] that has had no rejects.

Manual/CNC lathe is better and quicker

2006-12-24T01:44:00.000-08:00

Combination lathe turns ACME threaded SS shafts

2006-12-24T01:43:00.000-08:00

College adds six more manual lathes

2006-12-23T03:34:00.001-08:00

Manual turning is the building block for lathe operators and six new manual machines will helps them to understand the turning process and acquire the basic skills.

Coleg Menai in Bangor, one of the largest Further Education colleges in North Wales, has significantly extended its engineering teaching facilities by acquiring six new Harrison V350 high-speed lathes to add to its six Harrison M300 centre lathes and an Alpha 1330S manual/CNC lathe. The latest machines, which were supplied to the college's Faculty of Technology by Harrison's main regional distributor, [DATAMACH] were grant-funded through ELWa (the National Council for Education and Training for Wales) as part of a GBP 1.5 million technical upgrade programme at the college. Colin Parry, a lecturer in the faculty, introduces groups of local school pupils (14-16s) and an annual intake of around 35 post-16 year old full time college students on a one-year performing Engineering Operations course to basic engineering skills like manual turning.

He explained: 'Most engineering and metalworking workshops have disappeared from schools and so now when the apprentices start out on their courses they have no hands-on experience.' Parry said: 'It is particularly good for the 14-16s to be able to come to the college - it gives them an insight into some of the skills involved and they also receive a qualification at the end of the course.' 'Manual turning is the building block for lathe operators and we believe that operating the manual machine helps them to understand the turning process and acquire the basic skills.

The M300 centre lathe is the ideal first training machine and the new V350 machines give us considerably more flexibility.

These lathes are bigger and have a constant surface speed facility which is very useful in a training context.

When we had the opportunity for funding for these extra lathes, we definitely wanted to buy British.' Parry added:'We have had foreign-made lathes in the past and had problems with maintenance issues.

The Harrison M300 lathes we got last year are very reliable and popular with the students and lecturers, and Harrison has a good brand name.' Apprentices who attend the college's one-year full-time course advance onto a three-year day-release scheme, supported by their employers, and during this time have a further opportunity to progress to using the Alpha 1330S manual/CNC lathe.

The college's facility, incorporating a state-of-the-art computer aided design (CAD) suite to which the Alpha 1330S is networked, represents the ideal way for local companies who are upgrading their own workshops with CNC lathes to train their young engineers: 'With the requirements of the local economy and investment by local engineering-based companies developing all the time, it is vital for us to keep pace with the technology and what is happening out in the market place'.

'Local companies send their staff here to receive training on this type of machine'.

'They realise that this modern technology represents the future for their industry,' said Parry.

Harrison Lathes' sales director, David Smith, said :'I am delighted the students and staff at the Faculty of Technology at Coleg Menai have found this ongoing partnership with Harrison so useful in training the engineers of tomorrow'.

'I am confident that the latest six V350 lathes they have acquired will enable the students to maximise their skills and prepare them well with the turning skills they will require in their careers and everyone at Harrison wishes them well.'

Budget priced manual machine tools make debut

2006-12-23T03:33:00.001-08:00

Manual machine tools remain popular in training organisations and maintenance departments, for which a range of budget priced turret mills, lathes and grinding machines is available.

Manual machine tools remain a popular choice for training organisations and maintenance departments but price is always a constraining factor. With this in mind XYZ Machine Tools has added the budget priced e series of turret mills, lathes and grinding machines to its product portfolio. Sourced from China, prices start at GBP 4500 for the eMILL 2000 and the smallest of the three models of eTURN, and GBP 9000 for the eGRIND 1020.

Despite their ultra low price tags, these machines are of solid ribbed cast iron construction and are fitted with European-sourced bearings and electrical components.

All have full CE approval and will be backed by a UK company that has become synonymous with quality, reliability and value for money.

Standard on the 3 hp eMILL 2000 is a dual speed range 60-4200 rev/min spindle, powerfeed to the 1270mm by 254mm table and two-axis digital readout.

Options include a 5000 rev/min inverter driven spindle, power feed to the cross slide and three- or four-axis DRO.

The three models in the eTURN range - 1430, 2060 and 2680 - offer spindle speed ranges from 45-1800 rev/min to 26-2000 rev/min, a swing over the bed from 356mm to 660mm and a between centres distance from 750mm to 2000mm.

In similar vein the eGRIND 1020 is the ultimate 'economy' grinding machine, providing a maximum grinding length of 500mm and a maximum grinding width of 250mm.

Maximum spindle speed courtesy of a 2 hp spindle motor is 3000 rev/min for a standard 180mm diameter wheel, and standard equipment includes a 250mm by 500mm electromagnetic chuck, dust extraction and flood coolant.

Manual/CNC straight bed lathe learnt in a day

2006-12-22T02:37:00.000-08:00

A manual/CNC straight bed lathe is a low cost, 'entry level' machine has a control system that can be mastered within a day, even by users with no previous CNC experience.

The new 400 mm swing over bed, 54mm spindle bore XYZ ProTURN SLX 1630 manual/CNC straight bed lathe is XYZ Machine Tools' answer to requests for a low cost, entry level ProTURN. This new machine, which has a distance between centres of 760mm, retains features such as solid castings for the main elements, oversize 'vee and flat' bedways that provide a large bearing surface, heavy duty tailstock and high quality gears and bearings in the headstock, while introducing the ProtoTRAK SLX control. This latest version of the innovative ProtoTRAK control has been designed to provide entry level CNC technology that can be mastered within a day, even by users with no previous CNC experience.

It's unique 'traking' feature allows the operator to physically wind through the tool path, ensuring collision-free operation and boosting user confidence.

Other features include constant surface speed, colour graphics and Windows XP operating system.

The XYZ ProTURN 1630's 5.5kW spindle motor provides a variable speed range of 150-2500 rev/min, and standard equipment includes a 200mm diameter three-jaw chuck, four-way square toolpost, joystick control for rapid movement, electro-magnetic spindle brake, and interlocked chuck and swarf guards.

Optional equipment includes DXF file converter, RS232 interface, USB thumb drive flash memory, Dickson quick change toolpost and six holders, steadies and collet closers.

Heavy duty combination lathe has latest CNC

2006-12-22T02:36:00.000-08:00

A heavy duty flat bed 'combination' lathe - with 800mm swing and 170mm bore - has Fanuc 210i-TA control with its single screen program creation software and six methods of programming.

Colchester Lathe's heavyweight Combi 6000 flat bed combination lathe, with a massive 800mm swing over the bed and a 170mm large bore that is ideal for oil and gas industry type applications, has bed length options of 2000; 3000 and 4000mm between centres and will be under power on the Colchestersales (UK) stand at MACH 2006 featuring its optional eight-station VDI 50 disc turret. While having a muscular specification, it is the Fanuc 210i-TA control with its single screen program creation software and six methods of programming that really set this flat bed combination machine apart from the competition. It has the flexibility for cost-effectively producing single cycle turning operations using the intuitive menu selection and extensive 960 tool library memory with simple to use macros giving step by step operation sequences.

However, most important is its ability to re-enact programmed cycles in automatic mode for batch production.

Having some 26kW of power available at the spindle with a low and high range providing speeds between 10 and 1,500 rev/min according to specification, it is the control system that enables the versatility of the machine to be fully explored according to the skill level available or type of machining required.

For instance, the Fanuc 210i-TA control can act as a simple digital readout in conjunction with electronic handwheels, be used in a teach and repeat mode or the operator can make full use of the on-screen icon-based command CADCAM capability and virtual tool and solid modelling programs.

In addition, the system will accept off-line created program download via DNC.

With each method, the control will automatically convert the input data into G-code format which means editing at the machine is very simple using copy and paste similar to a PC editor.

Once created, programs can be transferred or used with any Fanuc compatible machines.

Programs can be stored on the hard drive in the control and once prepared can be subjected to 'fast-check' simulation cycles involving the tool tip shape depicting the relevant toolpath.

The Combi 6000 has a swing in the gap bed of 870mm, ideal for face plate work and has a cross slide travel of 400mm.

The quill diameter of the power operated tailstock is 120mm with 210mm travel and there is a choice of toolposts from Multifix (size C) or Parat size 3 or 4.

As an aid to batch machining, the machine can be specified with a choice of two types of VDI 50 automatic indexing turret, an eight-station disc or four-station head unit.

Both are fully programmable.

There is also a range of stationary or travelling steadies, face plates up to 790mm diameter and three jaw self-centring 400mm or 535mm chucks or four jaw independent chucks of either, 460mm or 610mm diameter.

Budget-priced lathes and millers introduced

2006-12-21T21:24:00.000-08:00

A budget priced series of turret millers and lathes, with prices starting at GBP 4950 for a milling machine are fitted with European bearings and electrical components, and all have CE approval.
Manual machine tools remain a popular choice for training organisations and maintenance departments but price is always a constraining factor. With this in mind XYZ Machine Tools has added the budget priced e series of turret mills and lathes to its product portfolio. Sourced from China, prices start at GBP 4950 for the eMILL 2000 and the smallest of the three models of eTURN.
Despite their ultra low price tags, these machines are of solid ribbed cast iron construction and are fitted with European-sourced bearings and electrical components.
All have full CE approval and are backed by a UK company that has become synonymous with quality, reliability and value for money.
Standard on the 3HP eMILL 2000 is a dual speed range 60-4200 rev/min spindle, power feed to the 1270mm by 254mm table and two-axis digital readout.
Options include a 5000 rev/min inverter driven spindle, power feed to the cross slide and 3- or 4-axis digital readout.
The three models in the eTURN range - 1430, 2060 and 2680 - offer spindle speed ranges from 45-1800 rev/min to 26-2000 rev/min, a swing over the bed from 356mm to 660mm and a between centres distance from 750mm to 2000mm.

Manual/CNC lathe expands turning capacity

2006-12-21T02:35:00.000-08:00

Subcontract machinist said his customers knew he had acquired a manual/CNC (combination) lathe because he could make several parts in the time needed previously to machine one.

Chris Evans has been running Buckwood Engineering on his own for the past 20 years, and that is just the way he likes it. 'After 15 years in the family business, which employed 350 people, I decided I could do without the aggravation and set up on my own. I like being hands-on and will machine anything that comes my way.

I am never going to be a millionaire but I enjoy what I do.' Half of Buckwood Engineering's 1000ft2 premises at Markyate, Hertfordshire, is leased to another one-man engineering business, while the remainder is home to manual machines and, more recently, two manual/CNC machines supplied by Burlescombe, Devon-based XYZ Machine Tools.

Evans said: 'I bought an XYZ Edge 1500 manual/CNC turret mill as a replacement for an old manual turret mill and thought it would be my last machine tool purchase.

It proved to be an unbelievably good machine and I found myself taking a third of the time to complete a job, even though I had no previous CNC experience.

I did not even go for training because it is so easy to use.' Despite this success Evans continued to rely on a manual lathe until he realised that he was losing out on turning work from existing customers and decided to do something about the situation.

One month later, in January 2005, he took delivery of a new XYZ ProTURN VL 355 lathe equipped with ProtoTRAK CNC.

'My customers know I have the ProTURN because I can now make several parts in the time needed previously to machine one.

This allows me to quote lower prices while still earning enough to pay for the machine and to put money in my pocket.' According to Evans, he opted for the 5.75kW, 360mm swing over bed XYZ ProTURN VL 355 because it matched the capacity of his DRO-equipped manual lathe while offering a choice of manual machining or, courtesy of the ProtoTRAK VL control, partial or full CNC control.

This flexibility is ideal for a small business like Buckwood Engineering that is called upon to machine a wide range of work pieces in varying batch sizes.

'There is not a turning job I can not do on the ProTURN because it is so simple to program, usually taking two to three minutes, and the program can be stored and recalled if I get a repeat order.

Although a one-off takes around a quarter of the time needed on a manual machine, a production batch probably takes 10 to 20% of the time, with a guarantee that every part will be identical.

I have just completed a 120-off job in a cycle time per part of six minutes compared with about an hour on the manual lathe, and within those six minutes I completed a second operation milling and drilling cycle on the ProtoTRAK mill.' Although adamant that the ProTURN lathe, definitely, is his final machine tool purchase, Evans says the move to CNC has made a very real difference to his life.

High value offered in manual and CNC lathes

2006-12-20T21:26:00.000-08:00

Manual and CNC lathes include three 'value-for-money' models of heavy duty, geared head manual lathes with 400mm, 500mm and 560mm swing-over-bed dimensions respectively.
MACH 2006 sees the world launch of a completely new range of 'value' manual and CNC lathes from 600 Group - the Clausing CV-Series. Three of these affordable, versatile lathes will be shown to MACH visitors on Clausing's stand (Hall 4, Stand 4578), with new and existing UK-based distributors having the first opportunity in Europe to offer the new machines to their customers. Based in Michigan, USA, Clausing Industrial , is a world-leading machine tool manufacturer and importer, which has been part of 600 Group - the UK's largest machine tool company - for over 20 years.
Clausing's latest CV-Series lathes are products resulting from a 600DMTG project which is a collaboration between 600 Group, its specialist subsidiary 600 Lathes, Clausing and 600 Group's manufacturing partner Dalian Machine Tool Group (DMTG), based in China.
All the new export-quality lathes are being built to 600 Group's performance specification and every machine will pass through 600 Group's own pre-delivery quality inspection process at the factory in China.
The Clausing CV-Series machines will be available in the UK market within four to six weeks after MACH 2006, and will be launched in the USA later this year.
Clausing CV-Series Heavy Duty Geared Head Lathes The new Clausing CV-Series will consist of three value-for-money models of heavy duty, geared head manual lathes with 400mm (16in), 500mm (20in) and 560mm (22in) swing-over-bed dimensions respectively.
Machines will be available in the UK with a choice of distances between centres, namely 1m (1000mm/40in) 1.5m (1500mm/60in) and 2m (2000mm/80in).
All versions feature large spindle bores 105mm (4.13in across the range), high-precision Gamet tapered roller bearings, hardened and ground heavy duty head stock gears and the flexibility of 16 spindle speeds, ranging from 26-1700 rev/min.
Further standard technical features of Clausing CV-Series manual lathes are as follows.
* Spindle bearings, gears and shafts lubricated by a forced lubrication system.* Easy-to-read index plate for fast selection of the correct feed or thread.* Extra-wide bedways 395mm (15.5in) for maximum accuracy and minimal wear.* Chuck guard, saddle-mounted chip guard, full splash guard and leadscrew cover.* Clutch drive, reverse leadscrew with spindle turning for faster thread cutting.* Clutches operated by levers on apron and headstock for forward/reverse.* Wide range of standard and optional accessories Options include quick-change tool-post and digital read-out.
Clausing CNC CV-Series Lathes Engineered for CNC performance, wedded to maximum affordability and versatility to handle a wide variety of turning applications, the new Clausing CNC CV-Series machines being unveiled at MACH 2006 are available in four models with 350mm (14in), 400mm (16in), 500mm (20in) or 560mm (22in) swing-over-bed.
As with the manual Clausing CV models, the two larger CNC machines offer customers a choice of three distances between centres, namely 1m (1000mm/40in), 1.5m (1500mm/60in) and 2m (2000mm/in).
The new series is equipped with the advanced FANUC Oi-TC Mate control system, offering great value and reliability, to simplify operation and maximize productivity.
All Clausing CNC CV-Series lathes benefit from heavy duty, flat-bed construction, a wide range of variable spindle speeds with automatic speed range change for more efficient parts turning and horizontal four-position electrical toolpost, among a host of advanced, standard features.
Ideal for first-time CNC buyers and workshops wanting to increase output - as well as operators such as education and training facilities requiring a low-cost lathe with CNC facilities normally only found on higher priced machines, the brand new Clausing CV-Series is especially suited to producing highly accurate one-offs and low-to-medium production runs.
Stephen Le Beau, product strategy and marketing director of 600 Group, said: 'These exciting new Clausing CV lathes have been developed with the expertise of three leaders in the world machine tool industry - 600 Group, Clausing and DMTG - which means customers can order with total confidence.
They represent a fantastic opportunity to acquire the latest quality-built, advanced design lathes at a highly attractive and affordable price.' The launch of the Clausing CV-Series at MACH 2006 means that lathes featuring 600 Group's long-established know-how, reliability and technical excellence are now within the reach of many more tool-rooms and workshops than ever before.
They offer true value for money.
Clausing CV-Series lathes making their world debut at MACH 2006 will be the CV-1640 and CV-2280 manual lathes and the CV-2060 CNC The Clausing stand at MACH will be staffed by Clausing Industrial , and 600 Group personnel from 600 Machinery International who will be pleased to meet potential new distributors for the Clausing CV-Series lathes, and details of product pricing, full specifications and availability will be supplied.

Toolroom CNC lathe is powerful, flexible, simple

2006-12-20T21:25:00.000-08:00

Toolroom Lathe has a proprietary conversational operating system that makes cutting parts and creating part programs nearly effortless, and operation ranges from manual to CNC.
With a functional range from manual turning to full CNC, the Haas TL-1 Toolroom Lathe features a proprietary conversational operating system that makes cutting parts and creating part programs nearly effortless. The operator chooses an operation, touches off the X and Z surfaces, and is then prompted to enter basic dimension information. Default values for feed per revolution, spindle speed and depth of cut are automatically entered by the control, but may be changed by the operator.
Once all necessary information is entered, a push of the Cycle Start button performs the desired operation.
A Recorder function allows information to be saved for future retrieval.
The TL-1 operates in four modes.
In all modes, the Haas control provides extremely accurate digital read-out (DRO) of position, displayed to 0.0005in when using the manual handwheels or to 0.0001in when using the electronic jog handle.
Electronic soft stops may be set to limit the travel of the lathe.
In manual mode, the X and Z axes are moved via standard handwheels.
In semi-automatic mode, the TL-1 performs simultaneous linear interpolation for both axes using a single handwheel.
ID/OD chamfers and tapers, for example, are easily cut in semi-automatic mode.
In automatic mode, built-in machining cycles (both single- and multi-pass) are available for rough and finish profiling, chamfering, grooving, parting off, threading, drilling and tapping.
In full CNC, the TL-1 is programmed using standard G code, and all axis motion is regulated by the Haas control via a G-code program.
Operations that would be difficult or impossible on a manual machine, such as radii, tapers, profiles, grooving, ID and OD threading, and rigid tapping, are all possible on the TL-1 - without knowledge of G-code programming.
Help menus are available directly on-screen, and a dry-run graphics feature allows operators to check their work before running a part.
MACH 2006 witnessed several new machines from Haas Automation, the largest CNC machine tool manufacturer in the world.
Haas demonstrated machines and metal cutting technology for aerospace, automotive, medical, mould and die and general machining industries.
More than 25 CNC technology products were on show demonstrate vertical and horizontal machining and turning applications.

Manual/CNC lathe has large 104mm spindle bore

2006-12-19T21:23:00.000-08:00

A manual/CNC lathe has a large 104mm spindle bore, which combined with a 560mm swing over bed and a choice of 1000mm, 1750mm or 3000mm between centres, gives maximum flexibility.
The vital statistic of the new XYZ ProTURN SLX 555 manual/CNC lathe is its large 104mm spindle bore. This, combined with a 560 mm swing over bed and a choice of 1000mm, 1750mm or 3000mm between centres, guarantees maximum flexibility, whether machining one-off components or in small batch production mode. However, it is not just the physical dimensions and structural integrity of the ProTURN SLX 555 that prompts XYZ Machine Tools to describe its new lathe as ideal for such applications.
With just a few hours training even someone with little or no CNC experience will be confident of producing complex parts, because the unique 'traking' feature of the ProtoTRAK SLX control ensures that the operator is always in control.
This feature allows the operator to physically wind the hand wheel and so to move the machine through the program at a speed proportional to the speed at which the hand wheel is moving.
Stop or reverse the hand wheel and the machine will do the same.
This allows the operator to check the programmed toolpath before switching to computer control, thereby avoiding collisions and boosting operator confidence.
Standard machine equipment includes a 300mm diameter three-jaw chuck, Dickson quick change toolpost with six holders, air-assist 'floating' tailstock, interlocked chuck and swarf guards, and joystick control for rapid movement.
The ProtoTRAK SLX control contributes constant surface speed, tool tip radius compensation and a host of other features.
Together it adds up to a productivity package that is many times faster than a manual lathe and often faster than a turning centre on low volume and one-off production.

Manual/CNC lathe can also perform milling

2006-12-19T02:34:00.000-08:00

The latest generation of advanced customised controls and conversational programming systems feature on the first Harrison manual/CNC lathe to have a milling facility.

The new Alpha X Series lathes from British lathe manufacturer T S Harrison, which was premiered at EMO 2005, features the latest generation of advanced customised controls and programming systems developed by Harrison design engineers in partnership with the industry-leading automation technology specialist, GE Fanuc. The Alpha X Series, comprising the XT, XS and top-of-the-range, 3-axis XM - the first Harrison lathe produced with milling capability - takes the Harrison range into a new era of performance, with significant enhancements in the crucial parameters of turning speeds, power and reliability. All new Alpha X Series lathes incorporate Fanuc's latest conversational programming software facility and offer the fastest, easiest set-up of any lathes in the market.

* Controls and control features - the 'entry-level' Alpha XT models (comprising the 1350XT, 1400XT, 1460XT and 1550XT) are all equipped with the GE Fanuc Oi Mate TC control.

This is loaded with the new Fanuc Turn Mate i conversational system.

The new controls for Harrison Alpha XT lathes feature: * 7.2in LCD mono operator touchscreens.

* ISO standard CNC.

* Full Fanuc CNC keyboards.

* One-click-one-micron feel handwheels.

* Sliding operator console for maximum convenience during loading and set-up.

* Rapid traverse joystick.

The Turn Mate i system on the XT models enables up to 40 separate operations to be stored in the software, allowing multiple options for profiling, grooving, facing, threading, drilling and tapping, radii and chamfers, boring, tapering and simple stops.

For the first time on the Alpha T range of machines it allows full contour programming at the control.

Another 'first' for the Alpha XT range, compared with the previous Alpha T models, is the ability to switch the control to full ISO functionality (CNC).

This empowers more experienced operators to run programmes previously used on other machines and/or to generate programs in the CNC format.

This is also the first time that any Alpha T model has been available with an eight-station bi-directional turret which increases its automation capability.

As with all previous Alpha machines, Harrison's Alphalink CAD/CAM software is supplied to customers free of charge.

The Windows-compatible system allows simple generation of standard ISO (CNC) programs and the use of previously-generated DXF files.

David Smith, Harrison's sales director, explained that the customized control system for the Alpha XT models has been extensively developed to provide a 'total system solution' for optimum integration of all key systems: servos, spindle, drives, control, operator panel and electrical components.

'Like all versions of the X Series, the Alpha XT lathes are perfectly suited to producing 'one-offs' and small-batch turned parts.

No other lathes on the market today, including full CNC machines, can compete with the X Series for speed of production when it comes to these small volume turning applications,' he said.

The new Harrison Alpha XS line-up (comprising the 1350XS, 1400XS, 1460XS, 1550XS, and 1800XS), was similarly developed between Harrison and GE Fanuc.

The Alpha XS lathes have the GE Fanuc 21i TB control, loaded with custom-written Alpha mode programming software, which is unique to Harrison Alpha lathes, and the Fanuc Manual Guide i conversational programming system.

The key specifications are: * Ultra high-speed GE Fanuc 21i TB CNC control.

* 10.4in colour operator touchscreen.

* Two software systems (Alpha system + GE Fanuc Manual Guide i).

* Industry standard ISO programming.

* High-speed fibre optic data transfer.

* PCMCIA (flash card) and RS232 communication ports.

* Twin MPG handwheels.

* Rapid traverse joystick.

'The Alpha system software is well-recognised as the easiest control in the world to both learn and operate by a manual-lathe trained operator.

Its functions start with electronic stops, which directly mimic the familiar manual stops, and progress to automatic machining of complex forms.

At no time does the operator require any knowledge of CNC programming,' explained Smith.

'Manual Guide i is an easy-to-use, intuitive programming system designed to assist the less experienced operator to gain full advantage of the features of even the most complex of machining functions.

It is important to note this has been customised by Harrison to make the Manual Guide i fitted to these XS machines absolutely unique to the Alpha products and faster to programme than any other similar lathe.' The customised control system fitted to all Alpha XS lathes are designed to allow operators to utilize the machines to their full potential and capability with minimal training.

The Manual Guide i system offers a full range of easy, conversational cycles for direct 'at the machine' component set up.

Following programming the cycles may be simulated using 3D solid model graphics.

The new Alpha 1550XM lathe is identical in operation to the XS range, but has the additional functionality of a C axis and driven tool capability.

These machines utilise a standard headstock and newly-developed servo-driven worm and wheel drive.

Engagement of the drive to establish C-axis control is achieved via an electrically-driven actuator.

The tool-mounting options offered with the Alpha 1550XM are a Duplomatic 8-station turret (4 driven tool positions) or a Sandvik Capto driven tool-post allowing manual change of standard, Capto or driven tool holders.

Precision CNC toolroom lathe works manually too

2006-12-18T21:23:00.001-08:00

A compact precision toolroom lathe has full CNC, but can also be operated manually - the machine's distance between centers is 18in, cross-slide travel is 8in and spindle speed is 0-3000 rev/min.
As technology advances toward miniaturization, machines and machine components get smaller and more efficient. Many shops are purchasing smaller-size lathes to produce these parts. Haas Automation's new compact HHLV-1 precision toolroom lathe is a perfect choice for producing high-quality small- to medium-sized parts without the expense of purchasing a larger machine.
The new HHLV-1 is a hybrid precision toolroom lathe that has a full CNC control, but can also be operated manually.
The distance between centers is 18in, and the cross-slide travel is 8in.
The machine has a part swing of 14in over the guide rail, with 6in over the cross slide.
For versatility, spindle speeds are infinitely variable from 0-3,000 rev/min, and the 5C collet nose accepts a variety of workholding options.
The HHLV-1 has a compact 77' x 32.5in footprint that occupies very little floor space, and the machine is slim enough to fit through a standard 36in doorway.
Haas Automation designed the HHLV-1 to be easy to use and efficient.
A No 3 Morse-taper tailstock and 10-gallon coolant tank are standard equipment.
The heavy steel base includes a utility cabinet with a built-in tooling rack, utility shelf and plenty of room for storage.
The cabinet also allows easy access to the coolant tank.
Options for the HHLV-1 include 4in and 5in 3-jaw chucks, a cam-lock tool post for 1/2in tooling, a steady rest and an 8-station automatic tool turret.
The famous Haas CNC control makes the HHLV-1 easy to program and operate, even for beginners.
Its bright, color LCD display and thoughtful keyboard layout make it a pleasure to use.
The machine comes standard with the Haas Intuitive Programming System, a conversational operating system that guides the operator through basic CNC operations - from initial set up to pressing the Cycle Start button.
You don't have to know G-code to cut make parts, and that makes it one of the most user-friendly CNC controls in the industry.
In manual mode, the standard handwheels and precise digital readout ensure high accuracy and ease of operation.
Manual machinists will be making parts almost immediately.
The tough HHLV-1 is a small, high-precision CNC lathe that incorporates the design philosophy and high quality that make Haas the largest machine-tool manufacturer in North America.
And because it's built in the USA by Haas, it's backed by the worldwide Haas Factory Outlet network of support and service.
* Haas Automation at IMTS 2006, Chicago, USA, September 6-13, South Hall, Booth A8000.

Instrument makers' lathe has sensitive feed

2006-12-18T21:22:00.001-08:00

A compact clock, watch and instrument makers' lathe accepts the 8mm horological collets in headstock and tailstock spindles and has a saddle lever feed for sensitive or rapid traverse.
A compact clock, watch and instrument makers lathe accepting the 8mm horological collets in both headstock and tailstock spindles. Constructed from cast iron and steel, individually built and issued with an Engineers Test Certificate, the 90 CW is mounted on a cast aluminium base with integral thyristor speed control and is a portable unit. * Lathe bed - a one piece massive iron casting of cantilever form ground on all faces.
The bed has a central tee slot providing a positive and accurate location for the tailstock, incorporating a gap permitting the accommodation of large diameter clock wheels, total swing is 120mm (4.7in), the bed is in dovetail form.
* Saddle and slides - the cast iron saddle can be rapidly or sensitively traversed via the saddle lever feed (a leadscrew can be fitted if preferred).
A long tee slotted steel crosslide permits the mounting of accessories such as the Jacot (RG59) unit or Roller (RG53) filing rest, for example.
The crosslide has an etched angular scale 45-0-45 deg and carries the swivelling topslide to permit taper turning.
A quick change height adjustable tool holder is fitted.
All slides are fitted with full length adjustable gib strips.
Handwheels are steel and incorporate laser etched, re-set to zero calibration dials, clearly marked and graduated in 0.025mm increments.
* Tailstock - the tailstock is cast iron, bored and honed to accommodate the hardened ground steel barrel.
The barrel accepts the 8mm horological collet, which is secured in the conventional manner with a draw-in bar.
The barrel is lever fed to facilitate high sensitivity drilling.
Locking handles are fitted to both body and barrel.
The tailstock may be off-set for the turning of long and shallow tapers

Turning can be manual, electronic or CNC

2006-12-17T21:21:00.000-08:00

Combination' or 'half-NC' lathes combine conventional turning, electronic cycle turning and full CNC turning in one machine and the user needs no CNC training to use electronic turning cycles.
Centre lathe turning has progressed at an impressive rate since the conception of electronics, driving axis and spindles, and computer driven programming. The Ajax Evolution range of machines, combines all the virtues of conventional turning, electronic cycle turning and full CNC turning all in one machine. The Ajax Evolution machines can be used as a manual lathe by using the electronic handwheels and axis joy stick, the control is used as a simple DRO measuring system.
For the 'one-offs' and small batch production the Ajax Evolution can be programmed, using the flexible electronic turning cycles, its quick, its convenient and you do not have to be CNC trained to use the electronic cycles.
You can produce tapers, radii, grooving, multi point profiles and screwcutting by answering simple questions direct from the Fanuc screen.
These electronic cycles can then be linked together to give a complete electronic programme.
For complicated shapes and batch production, full ISO programming on the Fanuc Oi Turn Mate control is possible.
The Ajax Evolution machines include fully enclosed guarding, meeting CE regulations, automatic four-way indexing toolpost, automatic speed range change and new Fanuc touch screen control and monitor on sliding pendant.
Machine programs can be up and downloaded through the RS232 port or saved directly to the PMCIA card.
The range starts at 165mm centre height to 325mm centre height, with bed lengths varying from 750mm to 5000mm, spindle speeds vary for sizes of machines but all have CSS fitted as standard.
Axis and spindle drives are all Fanuc to give reliability and longevity of service.
* Prices - for example - Evolution 200 x 1000mm BC is GBP 23,500.00 + carriage + VAT and Evolution 260 x 1500mm BC is GBP 28,650.00 + carriage + VAT.

Operations software boosts manual/CNC lathe usage

2006-12-17T21:20:00.000-08:00

'Operations Link' software offers operators of manual/CNC 'combination' lathes further important advantages in time-saving, automatic linking of operating cycles and workshop efficiency.
British lathe specialist T S Harrison has significantly enhanced its successful Alpha XT Manual/CNC lathe range with the introduction of 'Operations Link' software, which now offers operators further important advantages in time-saving, automatic linking of operating cycles and workshop efficiency. Technical designers at Harrison, part of the internationally-renowned 600 Group machine tools company based at Heckmondwike, West Yorkshire, have worked closely with the market-leading control systems provider, G E Fanuc, to develop this new software. 'Operations Link' will be incorporated on all newly-supplied Alpha XT machines.
It is also being offered to existing Harrison XT customers free of charge as an easily-installed update.
The four-version Alpha XT range (XT 1350, XT 1400, XT 1460 and XT 1550), is equipped with Fanuc's latest Oi TC Mate control which enables no fewer than 40 advanced, individual machining cycles to be programmed and stored, using the system's Fanuc TurnMate i conversational shop floor programming.
Now, thanks to the launch of 'Operations Link' these cycles can be linked together to create a fully-automatic and continuous machining sequence from start to end, without the need for the lathe operator to tend the machine or switch between cycles.
Philip Stockdale, technical support engineer at T S Harrison, said: 'The early versions of the Alpha XT required the operator to complete each operation and then move from one cycle to the next.
For example you might want to create cycles for a facing operation, followed by a rough and finish turning cycle, and then a threading cycle.' He said: 'Fanuc and Harrison engineers have created the ability to link together these separate operations to produce a complete program, which operates the whole sequence completely automatically with just one press of a button which makes it more like a CNC machine.' The second major benefit of 'Operations Link' is that multi-cycle programs can be transferred via a memory card and stored on a PC for future use - or, crucially, for off-line programming/simulation of complex parts and safety-checking prior to machining.
Furthermore, up to five of these complete programs can be stored on the Alpha XT's Oi Mate control itself, for maximum operating flexibility.
Stockdale explained: 'For small to medium numbers of turned components, the new software speeds up the all-important 'floor-to-floor' time, especially when the Alpha XT lathes are used with the multi-station tool turret.
For these types of turning operations, the quicker and easier it is to complete the machining, the better and more cost-effective it becomes for the toolroom.' He added: 'There are also important benefits in programming time, because large numbers of complete turning programs can be stored.
Operators can create a directory of complete programs on their PCs, which can be downloaded onto the lathe again and again.' As well as Fanuc TurnMate i conversational programming, the advanced Alpha XT lathe range features the ability to switch to full ISO (CNC) functionality.
All Alpha XT customers also receive Harrison's 'Alphalink' CAD/CAM software which is a fully Windows-compatible system for flexible off-line programming.

Laser beam direction system ordered

2006-12-16T02:30:00.000-08:00

A leading North American turbine engine builder has ordered a six axis 790 BeamDirector system, equipped with a CP3500 CO2 laser provided by Convergent Lasers, from Prima North America.

Prima North America, announced that its Laserdyne Systems Division, a world leader in multi-axis laser machining systems, has received an order for a six axis 790 BeamDirector system from a leading North American turbine engine builder. This system is equipped with a CP3500 CO2 laser provided by Convergent Lasers, also a division of Prima North America. Dr Paolo Cigna, president of Prima North America, announced the order and said, 'The sale included the customer trading in a Laserdyne system'.

'This represents the launch of our new 'Technology Trade-up' programme for valued customers who have made a long-term commitment to Laserdyne's unique laser system technology for providing exacting laser-based manufacturing solutions for difficult aerospace applications'.

' By trading in a 1991 780 BeamDirector Nd:YAG laser system, which served the customer well for nearly 14 years, the company transitions to Laserdyne's newest system design, the 790 BeamDirector,' reported Cigna'.

''For the last two years Laserdyne has offered complete mechanical rebuilds and controller upgrades for customers' 780 systems'.

'In fact, this customer has another 780 BeamDirector system scheduled for remanufacture'.

'The choice between remanufacturing and acquiring a new 790 is partly economics and partly application driven'.

'Our new programme expands the options for our customers'.

'The 780 will be brought back to Laserdyne and will also be remanufactured'.

' The demand for remanufactured 780 systems is high,' Cigna stated'.

''After remanufacturing and retrofitting the system with a new laser and controller, the system will most likely be again used for laser hole drilling'.

'There are many laser applications such as drill on the fly hole drilling where the 780 BeamDirector is a proven and productive system.' The 790 BeamDirector with the Convergent Lasers CO2 laser has the flexibility to perform cutting as well as welding operations.

Laserdyne Systems has been providing equipment to turbine engine manufacturers for over twenty years.

Laserdyne laser systems are used worldwide for laser processing a wide variety of turbine engine parts.

Most of these parts are produced from difficult to machine higher temperature materials such as inconel and super cobalt.

With the newest Laserdyne laser systems, these parts are produced accurately and with greater productivity than in the past.

With over 340 multi-axis laser systems in use worldwide, Laserdyne products have become the technology standard for the aerospace industry and are used in turbine engine manufacturing facilities across North America, Europe and Asia.

Digital platform enhances laser machining

2006-12-16T02:28:00.000-08:00

Digital automation platform with a 32-axis motion engine features pulse synchronised output, with error mapped systems for enhanced accuracy laser machining.

Aerotech's A3200 Digital Automation Platform is a powerful, software only machine control system combining a high-performance, 32 axis motion engine with decentralised drives interfaced via Firewire and other machine control function modules such as HMI and soft PLC, for a completely integrated solution. Widely used in semiconductor, data storage, laser processing, automotive, and machine tool industries, the A3200 includes a wide range of advanced motion control commands aimed at increasing and improving the finished quality and throughput performance of demanding production and test applications. Along with an extended range of advanced commands for motion including electronic gearbox, cam profiling, high speed registration/position capture and velocity profiling, Aerotech have developed a number of commands targeted to augment application specific performance in combination with its wide range of mechanical positioning systems.

An example of such enhanced performance is that of Position Synchronised Output or PSO.

Widely used for high performance laser machining applications, PSO allows the precise, 'on-the-fly' synchronisation of the laser's pulse, power level and firing pattern with the exact position of a multi-axis positioning system typically moving the work piece undergoing laser feature generation.

PSO will acquire and analyse the position of all axes of motion on the A3200 using real time encoder feedback and will process a two or three axis vector position to provide an output for laser firing control which is exactly synchronised to the 2D or 3D contoured position.

For extremely high accuracy requirements, PSO can be combined with positioning systems that have been interferometer calibrated and error mapped using Aerotech's HALAR option, where micron level linear errors are analysed and the resulting calibration information is included as a look-up table in the A3200 motion controllers' parameter file.

The combination of PSO and HALAR is unique to Aerotech and allows the real time encoder information to be read then error corrected before the vector position is processed, resulting in laser pulse synchronisation that achieves an unsurpassed level of accuracy.

Aerotech's PSO provides a versatile and easy method of interfacing laser firing with high throughput positioning systems and has been broken down into a number of simple commands and parameters to allow for output modes including fixed pulse, analogue, PWM, ramping and bit pixel mapping.

Other PSO commands cover encoder position tracking input set-up, definition of distance and firing trigger, pulse sequence and pulse on/off characteristics as well as a command to define a window for absolute or incremental position window firing.

There is also provision for an array to be used to define bitmapped firing, used to fire the laser at only specific axis locations.

Interfacing with lasers that allow external control, including CO2, YAG and Excimer lasers is easily achieved.

Tracking latency varies depending upon the drive product used in conjunction with the A3200; the best performance is achieved with the Aerotech Nservo digital drive with 140 nsec for a single axis and 220 nsec for dual and triple axis tracking.

In addition to laser firing applications PSO has been successfully applied to non-destructive testing applications where its ability to provide a fixed pulse spacing along complex contours has been found ideal for ultrasonic, eddy current and X Ray inspection systems.

Aerotech's A3200 Digital Automation Platform is a software based machine control system for IEEE-1394 (Firewire equipped PCs combining synchronised motion control for up to 32 servo axes with fully integrated modules for HMI, machine vision and soft PLC functions.

Programming and software development tools allow the Automation 3200 to be programmed in native RS274 G-code and a software development kit may be used to program with ActiveX based components as well as other languages including C, C++, VisualBasic and Labview.

The high speed Firewire interface delivers fully deterministic position and velocity motion updates to all axes with no system degradation as the number of axes increase.

A range of compatible digital servo drives with high performance, 20kHz position, velocity and current loop update rate can be supplied in stand alone or rack mounted configuration.

All drives come complete with local I/O and an optional 10/100 BaseT Ethernet interface which may be used add third party I/O and PLCs if required.

Choices of PWM or Linear power stages are available with sinusoidal commutation and onboard encoder multiplication.

The A3200 also includes extensive system commissioning tools for servo tuning and system analysis.

A range of stepper drives for open loop control systems is also available.

When compared to traditional PCI card solutions, which usually include numerous breakout modules requiring complex wiring and interfacing, the reduced cost benefit of the A3200 in terms of its simplified wiring, fewer components and Firewire based plug and play interfacing, offers OEMs and System Integrators a complete machine control solution with lower startup and lifecycle costs.

Aerotech design and manufacture a wide range of mechanical position systems and associated control and drive products for laser machining applications.

These include the new VasculatheTM, single machine platform for the production of cardiovascular stents.

All Aerotech systems are supplied complete with motor power and encoder cables, all performance and calibration related documents and a CD with complete interconnection drawings to help integrators with their own system documentation.

In addition, all motor parameter set-up data for the software configuration file is included; with full technical support and product training always on hand, system commissioning is straightforward requiring little more than connecting cables and applying power before programming application software.

Laser machines include high speed milling

2006-12-15T02:28:00.003-08:00

Among a range of 2D and 3D laser cutting, welding and drilling machines being introduced to the UK is a machine that combines laser cutting and high speed milling in one unit.

The Lasertec-Series for precision 2D and 3D cutting, welding and drilling combines the respective talents of DMG and Sauer to create a range of machines that are both flexible and highly dynamic. As well as dedicated machines for drilling and filigree cutting, the product programme includes laser cutting and high speed milling on a single combination machine. The user can also choose the best laser source to suit the application, Nd: YAG or CO2 and the optimum power from 15W to 1kW.

Designed for high precision cutting and drilling of sheet metal between 0.1mm and 3mm thick, the Lasertec 80 Series is characterised by its accuracy of 10 micron, high positioning speeds up to 120m/min and acceleration of up to 2G.

The massive, vibration-damping machine bed with 3-point support, linear drives and solid X-Y compound table enhance the performance of this machine.

Working area is 800 x 500 x 700mm.

Control of all machine functions is provided by the Siemens 840D powerline, accessed via the DMG ControlPanel with 17in TFT screen.

The overall footprint of the machine is just 3 x 3.5m and to facilitate servicing, a walk-on panel is provided for fast access to the laser.

The modular concept of this machine with 3, 4 and even 5 CNC axes makes the Lasertec 80 ideal for fine 2D and 3D cutting and for a broad spectrum of laser drilling and welding applications.

This flexibility allows it to be configured for specific needs in the automotive, electronic and aerospace industries.

Typical applications for the Lasertec 80 FineCutting model include the production of electronic circuits, surgical instruments, prototype car parts and hydraulic valves.

Its dedicated counterpart for drilling, Lasertec 80 PowerDrill is best suited to hypodermic needle, micro tool, oil filter and turbine blade manufacture.

Five-axis laser performs engraving, marking

2006-12-15T02:28:00.001-08:00

Five-axis control has allowed for better positioning of deep mold cores and cavities, laser engraving with optimum tool orientation, and precise repeatability.

In response to the growing complexity of part design, Precision Laser Technology (PLT) provides 5-axis laser technology for both engraving and micro-machining applications. In today's domestic market, many mold makers are being called upon by their customers to provide complex surface machining. PLT is stepping in to offer precision laser services as a solution to multi-axis surface etching and micro-machining.

'In addition to offering a cost-efficient service, the true driver was the ability to provide our customers with a solution to expand their mold design and construction capabilities,' adds Ron Natale Jr, PLT Co-Owner.

'As a service partner, our objective is to increase our customers' capacity.' 5-axis control has allowed for better positioning of deep mold cores and cavities, engraving with optimum tool orientation, and precise repeatability.

Ideal for extreme contour surfaces, the 5-Axis technology has reduced the number of required set-ups yielding higher savings to customers.

Affordable machine laser cuts, engraves precisely

2006-12-14T02:27:00.000-08:00

Laser cutting/engraving machine offers power, precision and flexibility, yet is as simple to set up as a printer and is affordable for industrial and educational users.

The new Legend 36EXT laser cutting/engraving machine is setting new standards in accuracy, performance and throughput according to Unimatic Engineers of London. Yet it is as simple to set up as a printer and offered at a price that is affordable for both industrial and educational users. The Legend 36EXT offers high energy optics that enhance the natural characteristics of its CO2 laser beam, software that precisely coordinates the firing of the laser with the position of the work piece carriage and a large work area.

Combined with the precision and repeatability of linear encoders and a vacuum table with an integrated vector grid that permits cutting of materials from paper to wood without the risk of under-side burning of the work piece, these features ensure users can achieve high levels of throughput worked to the tightest of tolerances (1200 DPI).

Unimatic's 'Radiance' high energy optics system has been developed to shape and refine the laser beam to create the best possible beam profile for engraving and cutting applications to ensure both high accuracy and maximum productivity on work pieces up to 355mm thick.

Indeed, to handle the higher volume of gases resulting for the increased throughput, Unimatic has installed a twin exhaust facility.

'HyperDrive', Unimatic's own motion control software, provides the total harmonisation between laser beam firing and work piece positioning.

This facilitates process operation whilst ensuring quality of output.

With its work area of 914 x 609mm, the Legend 36 EXT can handle the largest of engraving/cutting work jobs.

It also permits multiple task working; either straight forward step and repeat jobs or quantities of one-offs.

Other features include 'NeverWear' stainless steel bearings, advanced B-stile Kevlar precision drive belts and high speed, continuous loop DC servomotor system.

Cylindrical laser machining gets motion platform

2006-12-14T02:24:00.000-08:00

Direct-drive, brushless linear and rotary motion platform that includes automated workpiece handing and tooling platforms is intended for cylindrical laser machining applications.

Aerotech's LaserTurn combines high performance, direct-drive brushless linear and rotary positioning stages with automated workpiece handling and provision for customised tooling - for a completely integrated motion solution for high-throughput cylindrical laser machining applications. The new LaserTurn series is the result of Aerotech's dedicated research and extensive experience to provide improved productivity, industry-specific motion sub-systems, for high-throughput manufacture and test applications. The LaserTurn series features direct-drive brushless linear and rotary stages with non contact encoders for high speed, zero backlash performance with micron level precision and repeatability.

The integrated linear and rotary design allows a low machine centre of gravity that reduces the potential for dynamic pitch error under rapid acceleration and reversal conditions - offering a vast performance improvement over separate linear and rotary stages.

Other benefits include superior productivity, higher rigidity, smoother motion with faster settling times, and consistently improved high quality of the laser machined part.

Available in two sizes for workpiece diameters up to 30 mm with a choice of 200mm or 300mm linear travel, the smaller LaserTurn 2 has an ER16 collet supporting tube and bars from 0.5mm to 10mm diameter.

The LaserTurn 5 has a larger width footprint and is available with options of an ER25 or ER40 collet for 0.5 to 16mm and 16mm to 30mm workpiece diameters respectively.

In addition the larger model may be fitted with a three-jaw gripper.

All workpiece handling may be pneumatically automated and includes a clear aperture for product feed through.

The linear stage includes a hard top design with side seals for full protection and the complete assembly is fully protected against laser machining debris.

As well as motor power and encoder wiring, pneumatics and customer specific cabling is routed through an e-chain cable management system with interfacing connectors provided.

This greatly simplifies machine design and commissioning time and ensures high reliability and a long maintenance-free life.

For custom fixtures such as workpiece alignment supports and automated material advance, the LaserTurn's front facing end-plate provides a tooling platform with a matrix of M6 holes on a 25mm square pattern.

As this tooling interface is an integral part of the linear stage, a common reference is guaranteed for maximum system stiffness.

An optional rear tooling platform may also be specified and customised mounting patterns or additional fixtures may be provided upon request.

With a choice of linear encoders, overall accuracy of +/-5 micron is achievable, alternatively a 'Halar' calibrated option provides for +/-1 micron accuracy over the full travel range.

Positional repeatability is within +/-0.5 micron and straightness and flatness is within a total deviation of +/-1 micron.

Maximum linear speeds are up to 2m/s.

For both models, rotary stage accuracy is +/-15 arc-sec with repeatability at +/-3 arc-sec for the smaller LaserTurn 2 and +/-6 arc-sec for the LaserTurn 5.

Axial and radial runout and wobble specifications correspond with the overall high precision of these assemblies and rated speeds for the smaller and larger models are 2000 rev/min and 600 rev/min respectively.

Complementing the performance capability of LaserTurn laser machining systems, Aerotech's A3200 Digital Automation Platform is a powerful PC based, software-only, machine control system combining a high-performance, 1 to 32 axis motion engine with decentralised digital servo drives interfaced via a high-speed Firewire network.

The A3200 has integrated machine control function modules such as HMI, Vision, soft PLC and a 10/100 Base-T Ethernet interface for third party I/O and PLCs.

It includes a wide range of advanced motion and machine control commands aimed at increasing and improving the finished quality and throughput performance for demanding applications.

An example is the acclaimed Position Synchronised Output or PSO command that maintains precise, 'on-the-fly' synchronisation of the laser's pulse, power level and firing pattern with the exact position of the multi-axis positioning system typically moving the work piece undergoing laser feature generation.

Aerotech are able to meet and often exceed a customers' performance requirements by providing engineered systems with fully tested and calibrated mechanical stages and associated control and drive equipment.

This reduces the overall cost of ownership when compared to individual design, purchase and assembly of motion control components.

Typical systems include all motor power and encoder cables plus performance and calibration related documents to help integrators with their own system documentation.

All motor parameter set-up data for system configuration is included, making commissioning straightforward.

These features are standard for every Aerotech product and with full product training and comprehensive on-line technical support, the true cost of ownership is extremely competitive.

Laser machining done to micron scale resolution

2006-12-13T02:26:00.001-08:00

Ultrafast laser micromachining system is the first of its kind in the UK and provides ultimate flexibility in laser processing as it can machine virtually any material with micron scale resolution.

Ultrafast Laser System For Micro and Nanotechnology Oxford Lasers announce the supply of key enabling technology to create the most advanced micro technology and nanotechnology manufacturing centre in the UK. An Oxford Lasers Ultrafast Laser Micromachining System will be employed in the MicroBridge Project at the Manufacturing Engineering Centre (MEC) in Cardiff, UK. The PicoLase 1000 system from Oxford Lasers features a state-of-the-art picosecond laser system with 532nm and 355nm harmonics and 12 axis motion control system.

It is the first of its kind in the UK and provides the ultimate flexibility in laser processing as it can machine virtually any material with micron scale resolution.

Special features of the system include dual beamline, automated trepanning systems and special micro-milling routines for ablating complex structures.

The system will be used for product miniaturisation and for developing future manufacturing platforms for the next generation of microsystems-based products.

The project will provide a vital resource for improving the effectiveness of UK industry by generating a critical mass of facilities and expertise that will underpin the development of microtechnologies beyond the ones that rely on conventional IC tools and materials The PicoLase 1000 is an enabling technology within the MicroBridge project at MEC which is part funded by the UK's DTI under the Micro and NanoTechnology Initiative with matched funding from the other industrial partners including Oxford Lasers and other funding from the Welsh Development Agency.

MicroBridge is a GBP 7 million, 5 year project to provide Facilities for Micro-Machining and Micro Fabrication of Non-Silicon Components.

This project extends the existing micro-manufacture facilities at the MEC and creates a much-enhanced 'bridging' capability for micro-machining and micro-fabrications in a range of materials not currently available in the UK.

In particular, the aim is to use picosecond laser ablation and focused ion-beam machining to bridge the existing 'machining gap' between classical precision micro-machining and the lithographic/direct write semiconductor patterning technologies.

The new facility will be commissioned in 2006 and will be one of nine open access facilities within the UK to promote the use of micro and nanotechnology and to provide specialist training alongside these unique facilities.

Oxford Lasers are a partner in the MicroBridge project and will be working closely with MEC through the 5 year project to develop and support picosecond laser-based microprocessing.

Laser to drill wide range of components

2006-12-13T02:26:00.000-08:00

Laser system delivered to EBTEC has the capability to drill a wide range and size of parts and products range from sheet metal combustors to nozzle guide vanes.

Prima North America has announced that Laserdyne Systems, the world leader in precision multi-axis laser machining systems, delivered a Laserdyne 790XL BeamDirector Nd:YAG drilling system to EBTEC Corporation, Agawam, Massachusetts. Dr Paolo Cigna, president and CEO of PRIMA North America, announced the shipment saying the delivery was made to EBTEC to expand their capacity for laser drilling with the latest system technology. 'We are pleased to have the opportunity to provide this system to EBTEC, a pioneer in high energy beam processing.' stated Dr Cigna.

'EBTEC has over 40 years of experience providing parts for the aerospace, medical, defense, power generation and commercial industries.

We are grateful for their positive evaluation of our system technology and the Convergent P50L laser, another product of Prima North America.

Laserdyne products are in use in aerospace and turbine engine manufacturing sites around the world.' stated Dr Cigna.

EBTEC Corporation is owned by Aquasium Technology, Cambridge, England, and has been a supplier of electron beam welding and laser processing services to North American industry since 1963.

As an early user of these processes it has developed an expertise in the supply of difficult to weld and drill components.

According to John Leveille, president of EBTEC Corporation, the Laserdyne 790XL system was purchased as the first new laser system outlined in an equipment phase replacement plan.

The 790XL was chosen over other systems primarily for overall processing versatility.

The 790XL system is a 6-axis system with a 2m x 1m x 1m (40in x 40in x 40in) work envelope with a 25in diameter high accuracy rotary table and Laserdyne's latest software features including Optical Focus Control (OFC) and BreakThrough Detection.

OFC complements the 790 BeamDirector's patented Automatic Focus Control (AFC) and BreakThrough Detection has been shown to not only produce parts with a shorter cycle time but with a better flow consistency.

This will enhance EBTEC's capability to provide precision drilling of cooling holes in thermal barrier coated turbine engine components.

An additional feature of the EBTEC system is the ability to drill parts programmed for Laserdyne's new 450 systems on the 790 as a result of the Part Surface Coordinate, or PSC, programming feature of the Laserdyne control.

Laserdyne products have become the technology standard for the aerospace industry and are used in turbine engine manufacturing facilities across North America, Europe and Asia.

Single integrated platform developed for laser use

2006-12-12T02:25:00.000-08:00

A laser galvo head control has been added to a software based motion and machine control platform to produce a single integrated development platform for laser applications.

Aerotech's PC based A3200 software machine control system combines 1 to 32 axes of Firewire distributed motion control with HMI, PLC and vision control modules and is now available with the Nmark galvo control package for vector and graphics based laser marking applications. OEMs and machine builders of laser marking systems are able to significantly reduce application development time and cost by controlling industry standard XY2-100 protocol galvo scanning heads and additional axes of servo based linear and rotary motion with other machine control functions within a single, integrated programming environment. Two versions of Nmark are available - the Nmark VCT (vector) suits vector laser marking applications where lines, arcs and circles define the marking path, and the Nmark GRC (graphic) is available for raster-scan based marking.

Both versions are supported with a comprehensive range of programming commands and parameters that are used in conjunction with the A3200 Digital Automation Platforms' powerful software to achieve complete control of multi-axis laser machining applications including marking 'on-the-fly' for continuous web processes and Z-focus height control for 3D processing.

All Nmark galvo motion and functional parameters can be controlled in synchronisation with motion and machine control commands directly from within the Automation 3200 program space, providing a single integrated program development environment for the complete application.

Galvo based laser marking provides a fast and convenient means of coding and identification, and is used extensively in the aerospace, automotive, industrial, and medical industries.

Galvo's can also be applied to other medium accuracy marking and machining applications such as micro-hole drilling and decorative work on a range of thin metal and non-metal substrates.

Aerotech's Nmark products use the industry standard XY2-100 serial protocol to communicate with galvo scanning heads from a wide range of manufacturers.

Aimed at laser marking, cutting, welding, sealing and ablation applications, the Nmark VCT is programmed from the A3200 in the industry standard RS-274 G-code language with Aerotech's own AeroBASIC command extensions for laser and I/O control.

As all major CAD/CAM suppliers support RS-274 output, a direct conversion path from CAD to galvo motion is available.

The Nmark VCT is used in conjunction with a PCI interface board and via a Windows DLL, is able to access all commands, status and diagnostic information from the galvo head in real time.

The Nmark GRC is targeted at applications such as barcoding, engraving, serialisation, and character scribing.

Laser marking projects are created using a simple Windows tool that is used to import and manipulate bitmaps, graphics and barcode images and store the resulting marking profile in a project file.

Straightforward AeroBASIC commands within the A3200 are used to download the file at run time and additional commands are available to manipulate the properties of objects such as text strings or barcode values during the marking process for serialisation applications.

Commands are also available to scale, rotate and change the orientation of the object.

Aerotech's A3200 Digital Automation Platform is a powerful PC based, software-only machine control system combining a high-performance, 1 to 32 axis motion engine with decentralised drives interfaced via Firewire with other machine control function modules such as HMI, Vision and soft PLC.

A 10/100 Base-T Ethernet interface is also available to add third party I/O and PLCs for a completely integrated solution.

Typically used with Aerotech's extensive range of high performance direct-drive, linear and rotary positioning stages and digital servo drives, the A3200 based motion and machine control system includes a wide range of advanced motion and machine control commands aimed at increasing and improving the finished quality and throughput performance for demanding applications.

Laser engraves deeply from 3D CAD models

2006-12-12T02:22:00.000-08:00

Laser engraver performs deep engraving direct from 3D CAD models on workpieces up to 500mm3, including cutting complete tool cavities, adding fine detail, textures, logos or producing electrodes.

To accommodate the first ever UK exhibition for the FOBA Laser Engraving machine Kaye-Dee have had to move to the larger C52 stand Hall 3 at the forthcoming PDM show. Centrepiece will be the G5 Laser Engraver demonstrating its capability of deep engraving direct from 3D CAD models. You can engrave work pieces up to 500mm3 and applications include cutting complete tool cavities, adding fine detail, textures, logos or producing electrodes in copper or graphite.

Kaye-Dee invites you to come and see how you can totally transform your mould and tool manufacture with this equipment.

In addition to the G5 there will also be a second FOBA laser showing you its expertise of marking a wide range of materials using fibre laser technology.

As the market leaders in the pad printing industry we will also be displaying the exceptional Teca-Print pad printing machines.

On show will be the TP printer series designed with the operator in mind, equipped with sealed ink pot system and extended pad stroke to allow mouldings to be printed in either a fixed jig position or whilst being indexed on a production line.

Also on show will be the TPX 100 Open Ink Well System with touch screen control panel, easy learn logic and an extremely user friendly programming menu.

Next to this state of the art machine will be a working 30 year old TC70 unit highlighting the quality and value for money you get from this precision Swiss manufactured equipment.

To ensure you get the best print on your product we can also advise on pad and screen printing inks from the extensive Ruco ink range.

This includes the new T40 ink with excellent opacity and no harmful cyclohexanone or hydrocarbonates.

Another addition to our collection of marking equipment and on show is the new range of Hot Foil machines.

With an extensive model range manufactured to the height of British excellence, automation and a wide range of accessories, foils and dies Kaye-Dee can accommodate your every hot foil requirement.

We look forward to you visiting our stand so we can help make your marking requirements simple, reliable, cost effective and most importantly allow you to achieve the ultimate marking perfection! Written invitations will follow for your personal attention shortly.