Bundling With Machine Tools - Brief Article

The company has partnered with Servo Products Company for the bundling of SFP Express programming software with Servo's SAM, IMPACT and SERVO II machine tool product lines. With this software bundled with its machine tools, Servo's customers will have access to powerful shopfloor programming functionality at their machine tools, allowing them to realize greater efficiencies that significantly reduce cycle times and scrap.

SFP Express is an entry-level CNC programming and graphical editing system specialized for the shopfloor environment. The graphical user interface, specifically timed for the machinist, enables users to start making parts the same day they install the system. It includes features such as optimized geometry creation, graphical process verification and built-in training with step-through wizards to speed program creation and eliminate programming errors. Servo Products says SFP Express is a natural extension of its new Windows NT based CNC software

Cylinder head porting on a turn/mill machine

CNC milling is the machining that an automotive cylinder head is likely to require. Turning is not a capability you would look for in a machine tool meant to run such a part.

Indeed, when Mazak (Florence, Kentucky) first started to work on a better machining process for the benefit of a maker of high-performance heads, the machine tool company's first attempt involved a five-axis machining center. But Robin Cave, national applications engineer for Mazak, says that a more capable and efficient process has now been developed for an Integrex machine.

"Integrex" is the company's brand name for a family of CNC turn/mill machines. The term is traditionally associated with multitasking lathes.

However, the machine tool proving effective at cylinder head porting is no lathe, says Mr. Cave. It's an "e"-series Integrex, and this distinction is significant. Earlier machines in the family have the slanting structure of a lathe, with the wedge-shaped work zone causing Y-axis travel to get progressively more limited toward the bottom of the machine. The e-series design gives the machine's milling spindle the freedom to move like a machining center can move, with a box-shaped work zone permitting the same full field of travel at the machine's top or bottom. The unit is still a turn/mill machine, but while the traditional Integrex might be thought of as a lathe effective for milling, the e-series version is essentially a machining center effective for turning.

The machine permits full five-axis milling. While B-axis motion comes from the tilting of the e-series machine's spindle head, C-axis motion comes from the rotation of the horizontal spindle used for turning. The maker of cylinder heads does no turning on this machine, but instead uses this turning spindle exclusively in the five-axis mode. This direct-driven rotation does not involve a worm gear, unlike a previous process in which the company used indexers on vertical machining centersThe milling cutter is a long-reach lollipop tool capable of cutting from various engagement angles along the inside of a complex channel. Mazak is working with cutting tool supplier Kennametal (Latrobe, Pennsylvania) to develop a diamond-coated version of this tool. The higher spindle speeds on the newer machine (relative to the previous process) will make it possible to use this tool productively. Comparison testing between coated and uncoated tooling in this application shows a clear improvement in finish. With a coated tool incorporated into the process, says Mr. Cave, it may be possible to perform this porting solely through CNC machining, without a subsequent need for finishing by hand

Tool measurement system works inside grinder

Users can rapidly measure the shape, profile and outer diameter of a cutting tool while it is clamped in the grinding machine, then compare measurements to ideal tool geometry with ANCA's iView system. The benefit is that discrepancies can then be addressed immediately, without the need to remove the tool and measure off-machine. Measured data can be fed back into the grinding cycle for automatic compensation.

A cost-effective solution for high-precision tool measurements, the system includes software that works seamlessly with its machine operating software and a camera that mounts easily inside the tool and cutter grinder in less than 1 minute, the company says. It may be stored outside the machine when not in use. A single system can serve up to four grinding machines and has a standard magnification of 300:1. The accuracy of the system is 2 microns.

The system's software generates the ideal shape for standard tool geometries and protracts it over the actual tool image. It can import DXF overlay files for complex profiles. A high-visibility image of the ground tool as taken by the system's camera is compared to the ideal (as designed) overlay shape. Tolerance bandwidth can be specified and graphically displayed over the tool image. Automatic generation of tangent to the profile simplifies the measurement processSemiautomatic measurement mode means the tool overlay is automatically positioned over the corresponding point on the ground tool. The operator acknowledges the measured point, and the machine advances to the next predetermined point. A 0.005-mm grid or auto shadowgraph can be superimposed over the tool for measurement. Images can be stored in graphical file formats so they can be shared via e-mail. Measurement protocol can also be automatically generated and printed. The system can measure three-point angle; it also offers three-point radium measurement and two-point distance measurement.

Cylinder head porting on a turn/mill machine

CNC milling is the machining that an automotive cylinder head is likely to require. Turning is not a capability you would look for in a machine tool meant to run such a part.

Indeed, when Mazak (Florence, Kentucky) first started to work on a better machining process for the benefit of a maker of high-performance heads, the machine tool company's first attempt involved a five-axis machining center. But Robin Cave, national applications engineer for Mazak, says that a more capable and efficient process has now been developed for an Integrex machine.

"Integrex" is the company's brand name for a family of CNC turn/mill machines. The term is traditionally associated with multitasking lathes.

However, the machine tool proving effective at cylinder head porting is no lathe, says Mr. Cave. It's an "e"-series Integrex, and this distinction is significant. Earlier machines in the family have the slanting structure of a lathe, with the wedge-shaped work zone causing Y-axis travel to get progressively more limited toward the bottom of the machine. The e-series design gives the machine's milling spindle the freedom to move like a machining center can move, with a box-shaped work zone permitting the same full field of travel at the machine's top or bottom. The unit is still a turn/mill machine, but while the traditional Integrex might be thought of as a lathe effective for milling, the e-series version is essentially a machining center effective for turning.

The machine permits full five-axis milling. While B-axis motion comes from the tilting of the e-series machine's spindle head, C-axis motion comes from the rotation of the horizontal spindle used for turning. The maker of cylinder heads does no turning on this machine, but instead uses this turning spindle exclusively in the five-axis mode. This direct-driven rotation does not involve a worm gear, unlike a previous process in which the company used indexers on vertical machining centersThe milling cutter is a long-reach lollipop tool capable of cutting from various engagement angles along the inside of a complex channel. Mazak is working with cutting tool supplier Kennametal (Latrobe, Pennsylvania) to develop a diamond-coated version of this tool. The higher spindle speeds on the newer machine (relative to the previous process) will make it possible to use this tool productively. Comparison testing between coated and uncoated tooling in this application shows a clear improvement in finish. With a coated tool incorporated into the process, says Mr. Cave, it may be possible to perform this porting solely through CNC machining, without a subsequent need for finishing by hand

Machine Vision Software supports 3rd party cameras

Providing optical character recognition as well as security and data collection for achieving CFR Part 11 compliance, iNspect Vision Appliance software features 1D barcode and 2D matrix reader tools, including support for QR code. It is also equipped with iLabel product for verifying placement and quality of labels on packaged goods. Software offers machine vision solution for range of industries, from precision metrology to pharmaceutical packaging.

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STUTTGART, GERMANY (November 8, 2005) - ipd, a DALSA Coreco Group, today announced the release of Version 1.4 of the company's easy-to-use Vision Appliance software, iNspect. Packed with new capabilities, such as Optical Character Recognition (OCR), and advanced user controls, such as security and data collection for achieving CFR Part 11 compliance, iNspect offers an attractive machine vision solution to a broad range of industries, from precision metrology to pharmaceutical packaging.

"The evolution of our Vision Appliance software is very exciting. We are continually adding new features and capabilities without compromising the user interface that customers have come to appreciate," said Steve Geraghty, Director of ipd. "Version 1.4 demonstrates our commitment to bring simplified machine vision technology to ALL users. With iNspect now supporting 3rd party hardware platforms, such as IEEE 1394 cameras, users have an easy-to-use inspection tool with widespread applicability and a choice of hardware deployment options In addition to OCR, security and data collection tools, iNspect includes new and improved versions of its 1D barcode and 2D matrix reader tools, including support for QR code, along with many other features and enhancements. Furthermore, the iNspect software package now includes ipd's iLabel product, which was designed specifically for the Packaging Industry and is used for verifying the placement and quality of labels on packaged goods.

The iNspect product is offered as a standalone software package for use with 3rd party cameras, or combined with ipd's line of Vision Appliance hardware products. Pricing starts at $1,495.

More information about ipd and its product offerings-including Vision Appliances, NetSight II(TM) Vision Systems and Sherlock(TM) inspection software-can be found on the company

About ipd

ipd's mission is simple: to provide robust, intelligent and easy-to-use machine vision solutions to improve quality throughout the manufacturing process. Headquartered in Billerica, MA, ipd manufactures hardware and software machine vision products for end users, OEMs and systems integrators worldwide. ipd offers three product lines that simplify machine vision tasks: iNspect based vision appliances, Sherlock inspection software and the NetSight II family of pre-integrated machine vision systems. ipd is a group within DALSA Coreco (St. Laurent, Canada), a leader in the design and development of hardware and software for high-performance computer vision applications

A winner's view of the machine tool industry

Determination and technical ingenuity enabled Haas Automation to find a respected place in US manufacturing. In this exclusive article, the company's founder, Gene Haas, responds to questions from Manufacturing Engineering on the business

and technology of machine tools.

Manufacturing Engineering: What future do you see for North American manufacturers of machine tools? Gene Haas: If you look far into the future, you'll become very depressed over the situation facing American machine tool builders. Over the past 30 years, imports have gained a larger share of the market in the US every year. Currently they control around two-thirds. This is a very scary truth.

But automation can level the playing field. We've become successful by using our own product to reduce our production costs. As a result, we are not as sensitive to the high cost of labor as companies that use less automation. We've demonstrated that it's possible to build an entire machine in the US and be very successful.

We find it disappointing that so many US builders have trouble competing with imports. Some say they only import the iron and add the high-tech controls to it. Some say they only import the control and add the machine iron. But we-and a small number of other companies-have demonstrated that it's still possible to do it all. Unless this attitude spreads throughout manufacturing, the US machine tool builder may disappear.

ME: How much more consolidation do you expect to see in the machine tool industry in the US, Japan, and Europe?

Haas: The US machine tool industry is consolidating because small builders are having trouble surviving and the larger builders are trying to buy market share. This trend will continue as long as the US builders' market share is falling.

It's also true that consolidation is occurring across international boundaries. In the near future, it may be difficult to determine what country a builder is from, just as it's difficult today to tell where your car was built.

Because supply continues to be higher than demand, there will continue to be consolidation in the machine tool industry on all continents. Sustained over-supply is creating price pressures, and many machine tool builders are not profitable today. Even Southeast Asia isn't immune to this phenomenon. Consolidation is usually associated with shrinking. To survive, machine tool companies must become global and increase market share, so they can have the volume they need to make them price-competitive.

ME: Given the number of low-wage manufacturers in the world, how much manufacturing work will continue to be done in high-wage countries like the US?

Haas: The fact that machine builders in the US are in decline is probably closely related to the fact that manufacturing in general is leaving this country. It's a simple fact that it appears to be cheaper today to make most things outside of the US. The problem with this perception is that it's short-sighted.

We can only keep a great deal of manufacturing in this country by getting much smarter about the way we manufacture. As I said before, automation is the key to reducing manufacturing costs and thus keeping manufacturing here. Low wages affect areas where a great deal of labor is required. Replacing labor with automation wherever it's possible to do so reduces overall cost through labor savings, more consistent production, and better quality.

People in the United States must remember what wealth is and where it comes from. Wealth does not come from cooking hamburgers. Wealth does not come from cleaning one another's windows. Wealth consists primarily of "things." If we continue to import "things" we will, by definition, become less wealthy. At the same time, the nations who do manufacture things will become more valuable to our economy.

ME: How will the Internet change the way your company does business?

Haas: The Internet has already changed our business. We have online quote generation today, along with full product line and options information. We also use the Internet for service support. Software updates and automatic parameter checking can be done over the Internet. We fully expect this trend to continue and to involve sales, support, and service more and more. The Internet will become the universal information source. It will give our customers access to the information they need to make purchasing decisions.

ME: How will the role of your distributors change as more and more business is done via the Internet?

Haas: The role of our distributors is already changing. We have spent the last couple of years developing a common approach to the operations of our dealers. They already use the Internet for sales, service, and training. Ultimately, the distributors will become service organizations-not information sources. Because of the Internet, distributors will provide more technical support to their customers and less sales/information type support.

Machine tool basics--Part 1

This article series is not a comprehensive explanation of manufacturing equipment, but a once-over-lightly discussion of how the major chipmaking machine tools, and supporting elements function. We hope they will help two groups of people: The first consists of recent manufacturing engineering graduates who might need more information about the tools of their trade. The second group are those who have worked in nonmanufacturing fields, but are transferred to a position of responsibility in manufacturing, and find themselves challenged when it comes to knowledge of industry basics.

Turning, drilling, and milling are the three basic manufacturing techniques that use a tool to remove metal. Recently there has been a move to multitasking machine tools in which a single machine performs all three functions, plus grinding in some cases. These multifunction machines can work on a variety of parts and carry out more operations in a single setup. Despite this blurring of distinctions among machine tools the basic operations are still unchangedThis process uses the relative motion between a rotating, multiedge cutter and a workpiece to generate both flat and curved surfaces. During rotation, each tooth of the cutter alternately enters and leaves the cut, removing small amounts of material (chips). Called interrupted cutting, it results in more mechanical shock to the part and tool than occurs with continuous cutting, which is characteristic of turning.

Milling is done by a variety of machines. Simple stand-alone machines perform a minimal number of functions and are chiefly used in job shops. Machining centers have a wider variety of tools and sometimes have additional live spindles for drilling, turning, and even grinding. Milling functions can also be a major part of transfer lines. In these high-volume applications milling is often simple and repetitive.

The capabilities of a milling machine or machining center are measured by motor horsepower, maximum spindle speed, spindle taper size (which determines the size of the toolholder and tool), worktable size, and the amount of cutting tool travel.

Much toolmaking, prototype machining, and low-volume milling machining is done on small, lightweight, vertical spindle ram-type machines called knee mills. They are rarely used for production work.

This design includes a knee-and-column support for the machine table, hence the name, "knee mill." Base and column are one piece and the knee travels vertically on the column. The knee supports the saddle and table. The saddle moves in-and-out from the column, and the table moves side-to-side.

The ram atop the column supports the head and provides horizontal motion in-and-out from the column, parallel to the saddle movement.

At the front of the ram is the milling head, with motor, toolhead, speed-and-feed controls, quill, and spindle. The nonrotating quill holds the rotating spindle and allows the spindle to be fed on its own axis. Tilting the spindle axis allows milling or drilling at an angle to the table. Cutting tools are held in drill chucks or in collets, that are, in turn, held in the spindle, or mounted directly in the spindle.

On manual mills, the operator sets the machine parameters for each cut, positions the tool for the start of the cut, directs all of the machine's motions manually, and changes the settings and tools after each operation.

The two main types of machining centers are the vertical spindle machining center (VMC) and the horizontal spindle machining center (HMC). A third, less-- common type is the universal machine, which is capable of both vertical and horizontal spindle orientations.

Verticals may be preferred over HMCs when working primarily on a single work face. When a rotary table or indexer is added to the VMC machine table, more than one side of a workpiece or a multiple-part setup can be machined without operator intervention. Rotary devices either index the part to present a new work surface to the spindle, or they rotate it slowly, under full CNC control, while it's machined.

There are the three linear axes:

X defines side-to-side table motion,

Y defines in-and-out table motion,

Z defines head movement up and down the column,

B and C may be added as rotary axes, usually as a rotating spindle or mounting table.

T-slots in the machine table are still the primary means of holding work and workholding devices to a machining center table.

Because an HMC's spindle is orientated horizontally, it may be preferred for heavy, boxy parts. Chips fall out of the way better on a horizontal machine, and more workholding and automation options may be possible than on a vertical machine.

The HMC table typically rotates to expose four sides of the workpiece, or fixture, to the tools.

Tombstones, commonly used on HMCs, come in a wide variety of configurations to hold multiple parts. The part program is written to machine all parts on the tombstone before shuttling it out of the machine.

Machine Tools are available with VDI-driven units

Mazak Quick Turn Nexus, Super Quick Turn, and Multiplex-series machine tools are offered with self-contained VDI-driven units that enable multiple part processes such as milling, drilling, and turning on same part in one setup. Available with KM interface or ER collet style, units feature sealed spindle bearings, recessed spindle configuration, and through-coolant capabilities up to 1,500 psi. Tool setups can be pre-staged offline.

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(LATROBE, PA) - Self-contained VDI-driven units from Kennametal for Mazak Quick Turn Nexus, Super Quick Turn, and Multiplex-series machine tools enable multiple part processes such as milling, drilling, and turning on the same part in a single setup. Available with either the Kennametal KM interface or standard ER collet style, setups can be accomplished accurately and efficiently. Since the units make offsets known quantities, tool setups can even be pre-staged offline for greater productivity gains. As Product Manager Curtis Rellick succinctly puts it, "Less setup time, more spindle time."

Individual driven units are designed to work specifically with each model variation of the Mazak machine tools for maximum equipment capability. The units feature high-precision gears and sealed spindle bearings for smooth operation, and a recessed spindle configuration that reduces spindle stress and increases bearing life. High-quality seals and O-rings enhance protection against external contamination. Through-coolant capabilities of up to 1500 psi are available.The driven units increase rigidity by design, enabling higher spindle speeds and feeds and longer tool life. Product life averages of three years before repair or rebuilding are required, compared to nine to 12 months for other drive spindles. One customer described the advantages of a driven unit running a four-tooth, 1.57-in. face mill rough-cutting cast stainless steel at 600 SFM at a depth of 0.07 inches taking a full 1-inch width of cut. "Our maintenance personnel were frequently rebuilding competitive units due to bad gear backlash and blown spindles from the heavy interrupted cut," he says. "Despite the pounding the Kennametal unit takes, we have experienced better tool life, increased surface finishes, and no downtime with broken spindles/gears. That translates into productivity and dollars that go right to the bottom line."

Machine tool consumption up 6% - Brief Article

CHICAGO -- U.S. machine tool consumption totaled $182.66 million in March, up 6 percent from a revised $172.32 million the previous month but down 42.2 percent from $315.8 million in March 2001, according to a joint report by the American Machine Tool Distributors' Association, Rockville, Md., and the Association for Manufacturing Technologies (AMT), McLean, Va. "The poor start to the 2002 machine tool market illustrates that the general economic recovery has not filtered down to manufacturing," said Don F. Carlson, AMT president. "While economic recoveries usually start without a pickup in investments in manufacturing, they never last without sustained manufacturing output." Machine tool consumption in the first quarter totaled $513.62 million, down 35.2 percent fromlast year

Versatile Machine Tools

Okuma America Corporation is the US-based affiliate of Okuma Corporation, a world leader in the development of computer numeric controls (CNC) and machining technology, founded in 1898 in Nagoya, Japan.

Okuma is known for its technology leadership and world-class manufacturing, product quality, and dedication to customer service. Okuma products are used in the automotive industry, aerospace and defense, construction and farm equipment, energy, medical, mold and die, and fluidpower industries.

Machines include vertical and horizontal machining centers, lathes, double column machining centers, grinders, and wheel machines that offer users high throughput, high accuracy, and reliable solutions to production machining operations.

Using Mechatronics, our full-circle approach to equipment design, we build machines that have the exact balance of power, speed and size to meet most any application-machines that can hold tight tolerances, perform more sophisticated cuts, and create precision-crafted parts time and again.Okuma has entered into a partnership agreement with the National hot Rod Association and has been named Official Machine Tool Sponsor of the NHRA. This partnership is part of Okuma's High Performance Motorsports Industry program.

With Okuma as your machining partner you are free to imagine a more productive, cost-effective solution, knowing we can work together to make it happen.Okuma has entered into a partnership agreement with the National hot Rod Association and has been named Official Machine Tool Sponsor of the NHRA. This partnership is part of Okuma's High Performance Motorsports Industry program.

With Okuma as your machining partner you are free to imagine a more productive, cost-effective solution, knowing we can work together to make it happen.

Cutting Tool Supplier's Involvement Helps Security Systems Manufacturer Optimize Machining

Pelco (Clovis, California), the world's leading manufacturer of video security systems, is one firm that appreciates the value of involving key suppliers early on. When developing its important new stainless steel product, Pelco called in cutting tool supplier Seco-Carboloy.

The need for greater surveillance around ships, defense installations, power plants and other locations within the marine environment recently led Pelco to begin offering an explosion-proof pan-and-tilt video security system for marine applications. "Our product engineers had a conceptual idea of how to introduce the stainless steel product," explains Lolo Garza, machine shop manager at Pelco.

Daryl Serna, Seco-Carboloy Senior Technical Specialist says, "We came to the conclusion that machining the component from one large 316L stainless steel billet would be the most cost-efficient way to go."

Seco-Carboloy employed its perfoMAX indexable drills with T300D coated inserts, and boring bars using grade TP400 for finishing. The result was a reduction in total cycle time (from previous method) per module from twelve minutes to just three

Ergonomic Tool cuts, crimps, and strips wire in one step

Designed for auto repair, PWCS9 features construction cold forged from alloy steel and heat-treated. Tool provides functionality for wire stripping, bolt cutting, and terminal crimping. It strips stranded wire from AWG 20-10 and solid wire from AWG 16-8. In addition to bi-molded, soft-grip handles, tool features narrow pliers tip, lock that maintains closed position during transport or storage, and internal spring that maintains open position during use.

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FUNCTIONAL DESIGN COMBINES ERGONOMICS AND VERSATILITY

KENOSHA, Wis., November 28, 2005 - In response to technicians' demands for a high-quality wire stripper/cutter/crimper that would better meet their needs for auto repair, Snap-on has introduced the PWCS9 wire stripper.

The PWCS9 is specifically designed to work on auto wiring and is cold forged from special alloy steel and heat-treated to offer technicians a tool of superior durability and lasting performance. An improvement from the traditional stamped units, the PWCS9's manufacturing process also helps maintain consistency from tool to tool, providing the same performance for every user. This wire stripper also helps technicians complete several tasks while using only one tool - wire stripping, bolt cutting and terminal crimping. These features allow the tool to strip stranded wire from AWG20 to 10, solid wire from AWG16 to 8, crimp insulated and non-insulated terminals, shear wires, and cut both no. 6 and no. 8 machine screws. The wire stripper also features:

- A narrow pliers tip for grabbing or pulling wire

- A lock to keep the tool in the closed position during transport or when it's in storage

- A patented internal spring that will keep the tool in the open, ready-to-use position when technicians need it handy

- Bi-molded, soft-grip handles that provide technicians greater comfort and decrease fatigue incurred from use

Customers can find out more about the Snap-on[R] PWCS9 wire stripper/cutter/crimper by contacting their local Snap-on representative, visiting www.snapon.com or calling toll free 877-SNAPON-2 (877-762-7662).

Snap-on Tools Company, LLC is a subsidiary of Snap-on Incorporated, a leading global developer, manufacturer and marketer of tool and equipment solutions for professional tool users. Product lines include hand and power tools, diagnostics and shop equipment, tool storage products, diagnostics software and other solutions for the transportation service, industrial, government, education, agricultural, and other commercial applications, including construction and electrical. Products are sold through its franchised dealer van, company-direct sales and distributor channels, as well as over the Internet at snapon.com. Founded in 1920, Snap-on is a $2 billion-plus, S&P 500 company headquartered in Kenosha, Wis., and employs approximately 11,400 people worldwide

Produce good surface finishes without tool breakage

Useful for die mold operations that require accuracy, short cycle times and good surface finishes, Makino's V-series vertical machining centers feature a 30,000-rpm spindle and compact footprint.

Machine rigidity and low vibration that result from the core-cooled spindle technology are said to make the machine particularly suited for high speed milling of deep ribs. Therefore, users can penetrate the part without tool breakage. In addition, benchwork on dies and molds can be virtually eliminated because of the quality of surface finishes, says the company.

Custom Tool Division

Back in 1919 when Matthew Ford introduced the first high-performance steel rotary file in Davenport, he understood the true value of a tool should be measured by its ability to increase productivity through superior craftsmanship, performance, and tool life. Today, M.A. Ford Manufacturing Company continues this tradition by taking advantage of advanced machine tool technology and materials to make the most innovative, high-quality cutting tools available in today's marketplace.

By partnering with select machine tool users, the Custom Tool Division will develop and supply customengineered carbide tools of unmatched quality, which meet or exceed productivity, delivery, and utilized cost expectations. Custom tools are proven to increase speeds and feeds, and save setup and handling time, which leads to faster run times, more efficient manufacturing, and more importantly, increased profits.

M.A. Ford's Custom Tool Division offers application development, design and manufacturing expertise in high-performance drills, G-drills, step drill reamers, subland drills, subland drill reamers, coolant-thru specials, step reamers, coolant-thru reamers, custom end mills, and custom form tools.

Milling on a grinding machine: a grinding machine is not a machining center, but it can sometimes take on milling and drilling to make the overall pro

However, certain profile grinding machines have developed in the direction of this type of multitasking, even when combining operations was not necessarily the goal. The MFP-TC grinding machine pictured, from Magerle (represented in the United States by United Grinding Technologies, Miamisburg, Ohio), provides an example. To support an increasing role for creep-feed grinding (a higher-metal-removal rate process than grinding just for finish), this machine features a powerful spindle and stiff hydrostatic ways. Further, because wheel types such as conventional abrasive, plated CBN and vitrified CBN all excel in different applications, the machine has been equipped with the capability to store different wheels and automatically switch between them.

This latter feature relies on proven technology. Specifically, it relies on a toolchange arm like that of a machining center, along with toolholders (or wheelholders in this case) that use the HSK interface of a machining center's toolholders. Taken together, this machine's tool changing, spindle power and rigidity produce the equivalent of a highly capable machining center. Precise heavy milling can be performed on this machine, and milling and drilling tools can be stored in the tool magazine alongside the grinding wheels.

Minimal Milling

Chris Stine is a vice president of United Grinding Technologies. He says performing chip-making operations such as milling and drilling on a grinding machine is best suited to certain types of parts. It also requires a particular mindset about production.

For a part to benefit from milling or drilling on a grinder, the cycle should consist of mostly grinding. The MFP-TC machine cited above remains a grinder first and foremost, offering precision beyond what might be associated with even a higher-end machining center, he says. As a result, the machine can't compete economically against a machining center if traditional metalcutting makes up most of the work.

However, many ground parts do feature a small but critical amount of this metalcutting. Even on a grinding machine equipped with multiple wheels and capable of high metal removal rates, there are plenty of features that simply cannot be ground. Holes, pockets and slots that don't run completely through the workpiece are examples. When the part has one or more features such as these, performing these cuts on the grinder can save considerable cost by eliminating the need to set up on multiple machines. This is particularly true for parts such as airfoils, in which the location of machined features may be defined with respect to ground surfaces that have complex geometries.

Another argument for consolidating operations relates to the part's size. Large parts magnify the savings in floor space that might result from combining grinding and machining center operations into one machine. Labor savings might also be more significant. The bigger the part, the better it is to set it up in just one place.

For particularly large parts, Mr. Stine says that the range of potential operations expands to include turning. A rotary table that can turn at 70 rpm can deliver 1,500 sfm of cutting speed to a turning tool that cuts at a diameter of 7 feet. This is exactly the solution that GE Gas Turbines (Greenville, South Carolina) adopted for machining large turbine wheels. Parts that used to be machined on a grinder, a vertical lathe and a boring mill now receive all of this machining on one Magerle machine tool. The change saves about 6 hours of setup time and 2 days of queue time, according to engineers at the plant. Overall, there has been a 30 percent cycle time reduction.

Shop Floor Inspection Machine measures compressor blades

Non-contact, automated Lightscan measures compressor blade airfoils for comparison with CAD data (with 160,000-point 3D point cloud) to obtain immediate go/no go sentencing. In addition to measuring sensor and associated application software, blade gauging inspection solution uses white light technology and has typ inspection cycle of 20 sec. With accuracy exceeding 0.0005 in., machine can be programmed to inspect new parts in as little as 4 hr.

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The new Lightscan non-contact blade gauging inspection from GE Inspection Technologies is a complete, automated, shopfloor solution for quickly and accurately measuring compressor blade airfoils for comparison with CAD data to obtain immediate go/no go sentencing. The new system offers significant cost-saving and time-saving advantages over conventional hard gage inspection and is the first system of its type to feature both measuring sensor and associated application software, providing a total turn-key inspection solution.

Using state-of-the-art white light technology, the operator-friendly, Lightscan has a typical inspection cycle of just 20 seconds, compared with the 60 to 90 seconds required by competitive equipment. It is accurate to greater than 0.0005", which is comparable with more cumbersome CMM equipment, and it can be programmed to inspect new parts in just four hours. Compare that to the 16-18 weeks required to manufacture of new hard gauges. As a result, Lightscan provides significant benefits in terms of production output and reduced tooling costs over hard gage inspection and provides significant improvements in manufacturing flexibility over mechanical and laser CMM systems and other white light systems

In operation, Lightscan uses LCD technology to project and move software-generated light patterns over the part to be inspected. The reflected pattern is detected by two CCD cameras, using the latest firewire technology. The modulated fringe is then analyzed by the software to create a point cloud, featuring 80,000 measuring points. The part is then turned very precisely rotated and the procedure repeated, so that a total 3-D point cloud of 160,000 measuring points is produced for comparison with the CAD-generated master part model. From this comparison, a surface deviation map is generated and a series of software gauges are used to determine standard gauge outputs such as contour, bow, warp, platform and thickness. These results are then displayed on the system's monitor so that the operator can make a simple go/no go sentencing decision. This entire process is completed in 20 seconds.

The application specific software features advance data filtering to ensure the rapid presentation of the highly accurate results, which can be printed as a report or saved to a data file in standard formats. This data can then be further analyzed to help in the improvement of upstream processes, such as enhanced tool design.

Lightscan is capable of handling blades with a wide range of surface finish. There is no need to tumble components or to apply a white coating, as is the case with competitive products and the system will even handle "benched" parts, which feature a mix of surface finishes.

About GE Inspection Technologies

GE Inspection Technologies is a global leader in technology-driven inspection solutions that deliver customer productivity, quality and safety. The company designs, manufactures and services radiographic, ultrasonic, eddy current and metrology equipment to inspect and test materials without deforming or damaging them. Its products are used in a wide range of industries, including Aerospace, Power Generation, Oil & Gas and Automotive. The company has 11 application centres around the globe and offers a range of services including repair,

Release delivers new high speed tool paths—Mastercam/CNC, Inc., booth 427

Mastercam X's latest maintenance release, MR1, includes various new capabilities, such as added high speed machining tool paths, holder definition, the release of Mastercam X and more.

Seven high speed surface machining (HST) tool paths--two roughing and five finishing paths--have been incorporated into the release, including an interface for toolpath creation. These added types are tailored to high speed machining while offering smooth cutting motion and smooth entry/exits, says Mastercam/CNC Software. The high speed tool paths include core roughing, area clearance, waterline, scallop, horizontal area, raster and an enhanced pencil tool path.

Using the release, operators can define a holder (or select one from a library) and gouge-check the holder during toolpath generation. The holder definition can be used to detect possible toolpath gouges.

This release is now available to all maintenance customers. SP2, a service pack release, is also available to those who do not participate in the maintenance program