Machine tool basics: Part 2

This second installment of our series looks at key machine-tool elements and addresses the tool, the toolholder, and machine control.

The cutting action in a machine tool when milling and drilling involves the spindle, toolholder, and tools.

Spindle Design

Spindles, which secure the tool and its holder, are key in determining machine tool accuracy. In early machine tools, the spindles were simple bearing-- mounted shafts driven by a constant-speed electric motor, achieving different speeds through belts and gears. Operators changed spindle speed by shifting gears or moving belts to and from various pulleys.

As drive motors achieved higher torque and were designed to operate at variable speeds, belt and gear-driven systems began to wane in popularity, but both are still used. Stronger, longer-wearing, quieter belt and gear-- drive designs have been developed. Variable-speed direct drive, or integral-- motor spindles have replaced geared spindles for high-speed applications. At the same time, spindles with planetary gear systems, much like a car's automatic transmission, are now used to provide a wide torque output.This second installment of our series looks at key machine-tool elements and addresses the tool, the toolholder, and machine control.

The cutting action in a machine tool when milling and drilling involves the spindle, toolholder, and tools.

Spindle Design

Spindles, which secure the tool and its holder, are key in determining machine tool accuracy. In early machine tools, the spindles were simple bearing-- mounted shafts driven by a constant-speed electric motor, achieving different speeds through belts and gears. Operators changed spindle speed by shifting gears or moving belts to and from various pulleys.

As drive motors achieved higher torque and were designed to operate at variable speeds, belt and gear-driven systems began to wane in popularity, but both are still used. Stronger, longer-wearing, quieter belt and gear-- drive designs have been developed. Variable-speed direct drive, or integral-- motor spindles have replaced geared spindles for high-speed applications. At the same time, spindles with planetary gear systems, much like a car's automatic transmission, are now used to provide a wide torque output.

Pistorius Machine Co - Brief Article

Pistorius Machine Co'.s model EMN-14 double miter cut-off saw is extremely versatile. Saw blades will cut nearly any material, including up to 6-inch-wide ornate mouldings, with only one cycle of the saw heads. Each cut is a finished cut suitable for assembly. Built to last with extra-heavy-duty-cast-iron and steel construction, this machine is virtually maintenance free, eliminating costly down-time. Pneumatic or manual models available

Drilling/Trimming Routers machine aircraft materials

HyperMach(TM) System is available as 5-axis head plate mill that delivers 460 cu-in./min metal removal rate for aggressive cutting of large aluminum structures. Twin independent, 5-axis head, dual work zone version offers same cutting capability with large capacity automatic tool changers. Users can load/unload parts in one work zone while machining 2 parts simultaneously in second work zone. Both have internal vacuum system to accommodate dry or near-dry machining.

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Ultra high-precision technology will dramatically improve machining of new

materials used in today's aircraft

Hebron, Kentucky, December 20, 2005 - Cincinnati Machine announced today that it has expanded its HyperMach(TM) Series of High Rail Linear Motor Profilers by adding a Drilling and Trimming Router platform. This new machine will serve to meet today's demand for extreme accuracy in high-speed processing of composites. The design is also well-suited for a variety of other new materials, metallic & non-metallic honeycomb and aluminum as well as structures utilizing a combination of these materials.

As the use of new, high-strength/light-weight materials has migrated from military to commercial aircraft, improved drilling and trimming capabilities are required to meet higher volume assembly rates, according to Cincinnati Machine engineers. Less sophisticated routers designed for wood or plastic materials can no longer provide the accuracy or throughput required for determinate assembly processes used to produce today's commercial and military aircraft

Currently, Cincinnati Machine offers two HyperMach platforms. A single 5-Axis head plate mill delivers a 460 cubic in./min. metal removal rate for aggressive cutting of large aluminum structures. The Twin Independent 5-Axis Head, Dual Work Zone Machining System offers the same powerful cutting capability with the added flexibility of large capacity automatic toolchangers. This configuration provides extremely high spindle

utilization facilitated by the ability to load/unload parts in one work zone while machining two parts simultaneously in the second work zone.

The new Router platform incorporates proven Hyper Mach machine modules that include expandable X-Axis travel available in rack & pinion or linear motor direct drive configurations, standard linear direct drive Y-Axis, and vertical ram and A/C spindle head. Additionally, the HyperMach Router is equipped with a fully integrated internal chip and dust vacuum system to accommodate dry or near-dry machining.

The new router will be offered with multi-function options to maximize flexibility in meeting a wide variety of processing approaches. The first HyperMach Drill and Trim Router will be available for delivery in late 2006. Complete information on the HyperMach Drilling & Trimming Router platform can be obtained by contacting Cincinnati Machine toll-free at 1-800-934-0735, or by visiting the company's web site at www.cincinnatilamb.com

News Source:

Ms. Jami Leininger

Cincinnati Lamb

Tel: (859) 534-4839

About Cincinnati Machine (www.CincinnatiLamb.com): Cincinnati Machine, as part of Cincinnati Lamb, designs, builds and integrates high-volume and flexible machining systems as well as stand-alone production equipment for global aerospace, automotive, heavy equipment and general machining markets. The company offers technology-driven solutions that include composites processing equipment, profilers, routers, and

five-axis CNC machining centers; horizontal and vertical machining centers and turning centers; and automated assembly and test machines and systems. Additionally, the company provides the manufacturing industry's most comprehensive package of service and support through its PLUS program.

Cincinnati Lamb is a MAG Industrial Automation Systems business unit; both are headquartered in Warren, Michigan. Other operating locations include: Machesney Park, IL; Hebron, KY; Windsor, Canada; Mildenhall, England; Solihull, England; Birmingham, England; Remscheid, Germany; and Asian operations in China and Korea.

Smarten up your cardio: which machine blasts the most calories? How hard do you need to exercise? We've got the answers, plus three workouts to help y

You know that cardio workouts are crucial for a healthy heart and lungs and that they burn calories and fat, lower stress and boost energy. But what are the factors that make for the best possible sweat session? Is one machine better than another? How hard should you push yourself? Do you need to do more cardio, or less?

With so much confusion, it's no wonder a lot of us simply climb on our favorite machine (or the one we loathe the least), press the same old buttons and sink into a comfortable routine, inevitably undercutting our results. To the rescue: this exclusive Smart Cardio plan, designed to help you get the most from your workouts.

Created by certified trainer Keli Roberts, group fitness manager at Equinox in Pasadena, Calif., and a competitive cyclist, these mega-effective programs each focus on a specific goal. We'll show you which type of aerobic training is best for losing weight, boosting endurance and staying motivated. If you still have questions about all things cardio, turn the page for enlightening answers

fitness experts weigh in on seven common conundrums.

q How much cardio do I really need?

a It depends on your goals, says Glenn Gaesser, Ph.D., an exercise physiologist at the University of Virginia in Charlottesville. For weight loss, at least 200 minutes of moderate-intensity cardio a week may be optimal, he says. In one recent study published in the Journal of the American Medical Association, obese women on calorie-controlled diets who exercised at least 200 minutes each week lost nearly 14 percent of their total body weight, while those who accumulated fewer than 150 minutes of exercise reduced their weight by less than 5 percent. "When it comes to shedding weight, total calories expended is most important, and this is a product of duration and intensity," Gaesser adds. "Since longer duration can usually be tolerated better than higher intensity, duration should be emphasized."

To boost cardiovascular fitness, on the other hand, you'll need to elevate your heart rate, working at higher intensities and, therefore, taking more time off between difficult workouts; 25-45 minutes of moderate- to high-intensity cardio four to five times a week should do the trick.

q Are long, slow, steady workouts better for burning fat?

a No. It is true that lower-intensity aerobic workouts burn a slightly higher percentage of calories from fat (versus carbohydrate), while burning lots of carbs during higher-intensity exercise usually leads to more fat being burned after exercise. However, when it comes to shedding body fat, it doesn't matter what form the calories are stored in or how quickly or slowly you burn them, Gaesser says. The only thing that counts is the total number of calories burned. Steady-state workouts take longer than higher-intensity workouts to get you to the same total, although you may be able to exercise longer at a lower intensity. "Ultimately, it doesn't matter whether you burn your calories long and slow or short and quick," says Cedric X. Bryant, Ph.D., chief exercise physiologist for the American Council on Exercise in San Diego.

q Is there one cardio machine that's most effective for burning calories?

a Only if you work at a higher intensity or stay on a particular machine for more time. The harder and longer you work, the more calories you'll burn, regardless of the type of workout. That said, you may be apt to exert more effort, and thus burn more calories, on certain pieces of equipment. According to a landmark 1996 study, machines such as the treadmill and stair climber raised heart rate more than machines such as the cross-country skier, rowing ergometer and stationary bike. These results could be related to familiarity with the activity demanded by the machine (i.e., for most people, walking, running and climbing stairs are more familiar than skiing and rowing). However, using the same machine day after day just because it could burn a few more calories may not be the smartest idea. "If your program has variety, you're less likely to become bored," Bryant says. "It also helps to prevent overuse injuries and can keep your body from adapting, so you may even see an increase in caloric expenditure." As Roberts says, "Once you've adapted, you stop improving. If you're not making progress, it's definitely time to change."

q How do I know which preprogrammed cardio workout to choose?

a It's really a matter of personal preference, Bryant says. Such preset workouts are essentially a marketing tool developed by equipment manufacturers. Interval workouts that include recurring changes in intensity may be slightly better from a calorie-burning standpoint, he notes. But for the most part, it boils down to how hard you work, which you can control by pushing a button to change the level or resistance, or by speeding up your pace.

Coated tools can provide double output with same tool - machine tooled tools - column

Coated Tools Can Provide Double Output With Same Tool

The F. P. Schmidt Manufacturing Company makes accurately machined parts in high volume, directly from coiled wire stock, on automatic and semi-automatic machines of its own design and construction. These machines knurl, thread-roll, mill, swage, press and cut a variety of materials such as brass, aluminum, carbon steel, 52100 roller bearing steel, and types 303 and 416 stainless steel. Schmidt's products usually form part of everyday consumer items, such as appliances, toys, hand and power tools, plumbing and electrical supplies, office equipment and automobiles.

Each part the company manufactures has its own precision form tool profiled in the shape of the cut, and is made of either T5 or M4 tool steel. Because coated tools are claimed to exhibit high-surface hardness, resist corrosion, and have low coefficients of friction, F. P. Schmidt began researching and sampling various coatings, hoping to reduce their production costs. Based on their findings, they selected Titankote-C, manufactured by Richter Precision, Inc., 1021 Commercial Ave., East Petersburg, PA. This coating is a physical vapor deposition (PVD) titanium nitride (TiN) coating at thickness of 0.0001-inch on each side of the tool.

PVD coatings, such as Titankote-C, are produced in a vacuum chamber at low temperatures as low as 650[degrees] F. In the vacuum chamber, TiN ions are transported by physical means, although they may be "directed" by polarizing the tool surface. The force of the TiN ions bonds the coating to the metal surface Although tools can be coated before or after sharpening, Schmidt decided to coat their tools before sharpening. In practice, and coating covers the side of the tool that wears most, while the front rake remains uncoated. These particular tools have between a 15-degree to 25-degree rake angle, depending on the material and the finish the customer requires.

F.P. Schmidt found that coating not only improves their own form tools, but those in a secondary operation, such as milling cutters, as well. One product operation requires milling the punches for paper punches. These steel punches are cut to form and shape on automtic machines. A V-shaped groove is milled in the one end that is to punch the paper. The punch is then heat treated. Finally, the finished cutting edge is ground in a centerless grinding operation.

The company says that after coating their tools, they notice an increase in tool life. Tools that previously turned out 200,000 workpieces now turned out 500,000 to 600,000 workpieces. In addition, this increase in the number of workpieces includes a variety of materials ranging from aluminum and brass right up to 52100 roller bearing and 303 and 416 stainless steels.

The company feels that utilizing a coated tool coating is relatively inexpensive when compared to the cost of a new tool, even if there is only a marginal increase in tool life. If a coated tool lasts longer than an actual second tool, then any use of the tool after that is all savings. Increased production per minute and better finish, at a lower cost, are the reasons F. P. Schmidt has been coating their tools for four years.

Coated tools can provide double output with same tool - machine tooled tools - column

Coated Tools Can Provide Double Output With Same Tool

The F. P. Schmidt Manufacturing Company makes accurately machined parts in high volume, directly from coiled wire stock, on automatic and semi-automatic machines of its own design and construction. These machines knurl, thread-roll, mill, swage, press and cut a variety of materials such as brass, aluminum, carbon steel, 52100 roller bearing steel, and types 303 and 416 stainless steel. Schmidt's products usually form part of everyday consumer items, such as appliances, toys, hand and power tools, plumbing and electrical supplies, office equipment and automobiles.

Each part the company manufactures has its own precision form tool profiled in the shape of the cut, and is made of either T5 or M4 tool steel. Because coated tools are claimed to exhibit high-surface hardness, resist corrosion, and have low coefficients of friction, F. P. Schmidt began researching and sampling various coatings, hoping to reduce their production costs. Based on their findings, they selected Titankote-C, manufactured by Richter Precision, Inc., 1021 Commercial Ave., East Petersburg, PA. This coating is a physical vapor deposition (PVD) titanium nitride (TiN) coating at thickness of 0.0001-inch on each side of the tool.

PVD coatings, such as Titankote-C, are produced in a vacuum chamber at low temperatures as low as 650[degrees] F. In the vacuum chamber, TiN ions are transported by physical means, although they may be "directed" by polarizing the tool surface. The force of the TiN ions bonds the coating to the metal surface Although tools can be coated before or after sharpening, Schmidt decided to coat their tools before sharpening. In practice, and coating covers the side of the tool that wears most, while the front rake remains uncoated. These particular tools have between a 15-degree to 25-degree rake angle, depending on the material and the finish the customer requires.

F.P. Schmidt found that coating not only improves their own form tools, but those in a secondary operation, such as milling cutters, as well. One product operation requires milling the punches for paper punches. These steel punches are cut to form and shape on automtic machines. A V-shaped groove is milled in the one end that is to punch the paper. The punch is then heat treated. Finally, the finished cutting edge is ground in a centerless grinding operation.

The company says that after coating their tools, they notice an increase in tool life. Tools that previously turned out 200,000 workpieces now turned out 500,000 to 600,000 workpieces. In addition, this increase in the number of workpieces includes a variety of materials ranging from aluminum and brass right up to 52100 roller bearing and 303 and 416 stainless steels.

The company feels that utilizing a coated tool coating is relatively inexpensive when compared to the cost of a new tool, even if there is only a marginal increase in tool life. If a coated tool lasts longer than an actual second tool, then any use of the tool after that is all savings. Increased production per minute and better finish, at a lower cost, are the reasons F. P. Schmidt has been coating their tools for four years.

New machine guarding policy

The Mine Safety and Health Administration (MSHA) has come out with revised guidelines on how mining operations may safely and lawfully guard machinery and equipment. In MSHA's "Guide to Equipment Guarding," revised 2004, MSHA has done several things that are hoped will provide more flexibility to mine operators.

Possibly the most significant thing about this guide is that it recognizes for the first time the lawfulness of what has been called "area guarding." If properly constructed, implemented and maintained, guards that cover multiple pinch points will be accepted by MSHA as lawful compliance. The guide provides details on what would be necessary to protect multiple pinch points with a single guard It must be remembered that policy is just that. It is not law. Unlike a regulation, which is law because it is developed according to procedures prescribed by Congress, policy may be adopted by an agency without the safeguards of mandatory procedures for rulemaking.

For MSHA to make rules that have the force of law, it must follow all the procedures prescribed by Congress in the Mine Act. These procedures allow the public and all regulated parties ("stakeholders") to: 1) have an opportunity to be informed in advance, by public notice (in the Federal Register), of what rules and standards are being proposed; 2) have an opportunity to comment on those rules and have their comments considered; and 3) have an opportunity to immediately challenge final rules in court after they are finalized by the agency.

In making policy, on the other hand, there is rarely even a semblance of such safeguards. Usually, MSHA simply announces how it thinks a regulation should be followed. However, in the case of the new guarding policy, MSHA worked closely with the National Stone, Sand and Gravel Association to respond to the many issues the association had brought to its attention.

In rulemaking, the agency tries to achieve a rule that is clear and says exactly what the agency believes should be required. Many rules turn out to be less than completely clear and that is when the agency tries to explain what it thinks is required under the rule. That is where policy comes in. It explains what the agency says the regulation means and how the agency thinks the requirements can and should be met.

Plungers for Fast, Effective Machining of Cavities - machine tools from Iscar Ltd - Brief Article

ISCAR presents its new milling concept for plunging with high material removal rates. This system incorporates a combination of drilling and milling operations into a single tool. When plunging, the tools are subjected mainly to axial forces -- with minimal radial forces compared to those involved in conventional side machining of cavities. Machining in the axial direction results in increased stability, higher feeds and longer tool life.

This new tool provides efficient metal removal rates in a variety of applications, including the machining of deep cavities, high shoulders, slots, and straight or sloped walls.

Three types of cutters available: one is for plunging into solid material--similar to a drill--in the axial direction only. The second is for plunging but, as a trepanning tool, with a central hole to improve performance. The third is based on HELIQUAD inserts for side plunging with a limited frontal width and for finishing with side cutting.

I/O Modules help simplify machine design

SQIO line is comprised of SynqNet Interface Device offering up to 256 digital I/O and 16 analog I/O, plus analog and digital add-on boards. Total of 32 SynqNet Interface Devices can be installed on SynqNet network. Diagnostic capabilities allow for firmware/configuration file upgrade on nodes from any remote host computer. All programming is under single API, and is supported by library of I/O configuration software, including MotionConsole, MotionScope, and VM3.

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SQIO delivers flexible bulk I/O solutions for SynqNet networks.

Nurnberg Germany, SPS/IPC/Drives Fair - 23 November 2004 - Motion Engineering, Inc. (MEI) today announced the launch of a new family of modular SynqNet I/O products compatible with any SynqNet network. SQIO product line is comprised of a SynqNet Interface Device (SQID) and flexible analog and digital 'add-on' boards that provides machine builders a modular and cost effective high-count I/O solution. In addition, SQIO can be easily integrated to work with existing machine I/O and is also offered as part of a SynqNet developer kit solution for custom OEM solutions.

"Our goal was to produce a robust SynqNet I/O product that could fulfill a high-count I/O solution for OEMs, and provide a platform that could easily be modified to accommodate existing I/O," said Ross McMillan, SQIO Product Manager. "The fact that machine builders can now implement performance motion and I/O solutions on a single network make this a very attractive solution for further simplifying machine design." MEI's SQIO products work across any SynqNet network and with any SynqNet motion control platform. The SynqNet I/O product family provides up to 256 digital inputs and outputs and 16 analog inputs and outputs per SynqNet Interface Device (SQID). A total of 32 SQIDs can be installed on a SynqNet network. Diagnostic capabilities of SynqNet allow for firmware / configuration file upgrade on nodes from any remote host computer. Breakout boards on the I/O modules allow for convenient prototyping. All programming is under a single API, and is supported by MEI's extensive library of I/O configuration software, including MotionConsole, MotionScope, and VM

SQIO products are available for immediate order and 6-8 week delivery.

Founded in 1987- and now part of the Danaher Motion Group-Motion Engineering Inc. designs, manufactures, markets and sells performance network motion control solutions to high value capital equipment builders in the semiconductor, electronic assembly, robotics and medical markets. MEI's SynqNet[R] motion platforms combined with advanced tools and engineering services allow OEMs to build better machines, faster. Danaher Motion is a leading global manufacturer of motion control products that improve the efficie

Faster machining

The approach is to have a series of LTCs (four- and six-spindle configurations are available) setup in a line. Each of the machines is tooled to perform a limited number of operations, unlike the typical case in a machining center-based line (parallel processing), wherein a single machine typically performs all of the operations required to finish a part. So what happens in an LTC system is that the part, which is fixtured to a pallet (which provides the opportunity for five-axis machining through part positioning), undergoes metal removal in a series of machines that can provide "toolchange" in 0.8 seconds, which means positioning another of tooled spindles to the work, not changing discrete tools from toolchanger to spindle. This is a serial processing approach.

Benz admits that in addition to being quick, this approach is somewhat more expensive if there is a simple comparison made of, say, machining center to LTC. But he notes, "Price isn't everything," and goes on to point out that what needs to be taken into account is "the total cost of ownership."

In other words, if it is possible to produce parts much more quickly--in one time study on an aluminum steering knuckle, the job required 143 seconds with machining centers and could be done in 45 seconds with three LTC six-spindle machines integrated with a rotary part transfer device--then the investment may be well spent, Benz adds, "Our machines are used where labor costs are high." Which means that they're used in places where the machinery and equipment need to be exceedingly productive.

On The Web - automated machine tools using Internet - Brief Article

On occasion, we here at OTW notice "things" that help define an online trend for our industry. These examples are often companies or products that come along and suggest the Web's potential for metalworking.

Well, nothing has caught our online attention more effectively than the potential of "Web-enabled Machine Tools." And activities at two companies suggest that progress in this area is far from comatose.

eMation is a "new" company that espouses Device Relationship Management (DRM). More than just another acronym, the DRM applications are said to transform machine tool data--temperature, fluid levels, tool condition, spindle performance, part run schedule, or any machine condition--into "business intelligence." Simply put, this system defines progress toward applications that allow for more efficient monitoring, maintenance, repair and management.

e-manufacturing Networks, Inc. (www.e-manufacturing.com) has been around for a while. It has been spreading the "Machine Is A Node On The Network" gospel for some time. But this Canada-based company has recently introduced a new line of after-market products that Internet-enable the machine tool through its control. Now, we aren't saying these companies are preferable to others; many OEMs, distributors and suppliers are pursuing their own, noble Internet-enabling efforts. But the efforts of these and other developers suggest strong Internet technology advancements for our industry.

Job Shop Site Of The Month

Metro Mold & Design, Inc., is a full service, nearly 50-person mold shop just north of Minneapolis. Its Web site www.metromold.com) is organized into easily navigable sections, all describing the company's capabilities to support precision injection mold making. Included are sections on Design, Programming, High Speed Machining, EDM and more. Metro has also done a fine job with its "File Area" (for uploading or downloading files) and its "Request for Info" utility. (Check out the nifty selection scheme for getting more specific information).

Automatic Messaging From The Machine Tool - Brief Article

Users of CNC Professional, the company's PC-based CNC machine tool controller software for Windows, are said to now have an added benefit. A machine tool will automatically call the user's cell phone or pager and send a detailed text message on the status of the machine.

The messages from the machine tool can be any ASCII text message, alphanumeric message or tone signals. The messages can be initiated and/or triggered by almost any event. Perhaps an error occurred, M code, end of program, completion notice, number of parts made, laser power, low voltage, loss of motor control or any certain user interaction. Users can arrange for their machine tools to send messages at regular time intervals so that they can receive machine updates. A complete list of national and international SMS (short message service) service providers for all major cell phone and pager carriers is included.

Large Halogen Machine Lights feature dual lens design

Equipped with double glass lenses, HGW series is comprised of 18 and 32 in. arm models for broad work areas and head only model (HGWK) for compact work areas. Having inner and outer glass lens enclosed in one machine light protects lamp from breakage and causes outer lens to remain cooler. Viewing area stays clear of coolant and other fluids, maintaining consistent illumination of application at hand. Series comes with 12 V, 55 W lamp, or 24 V, 60 W halogen lamp.
Wheeling, IL-Waldmann Lighting Company's Large Halogen Machine Lighting series now features double glass lenses included with all luminaires. Having both an inner and outer glass lens enclosed in one machine light protects the lamp (bulb) from breakage, and causes the outer lens to remain cooler since there is a thermal barrier between the two lenses. This barrier helps to prevent coolant and other chemicals from baking onto the outside lens, and heat generated from the halogen lamp (bulb) is absorbed by the inner glass lens only. Operator safety is also improved because the viewing area stays clear of coolant and other fluids that may be prevalent, and the light consistently illuminates the application-at-hand. See our cooler halogen HGW and our entire line of machine tool lighting solutions at the Westec Trade Show in Los Angeles, California, on March 27-30.

This new standard double lens is available on Waldmann's 18-inch and 32-inch arm HGW for broad working areas. A "head only" (HGWK) double lens model is offered for compact work areas where space is limited. Other features of the HGW double lens series include either a 12V 55-watt lamp, or a 24V 60-watt halogen lamp with polished reflector that provides high intensity light and an estimated lamp life of over 3500 hours. An ergonomically designed handle and heat shield attached to the head provides safe and easy positioning. The light also includes a 4-hole pattern mounting base. All 120V versions include a remote transformer in a waterproof case for plug-in to a 120V power supply.

All HGW Halogen Machine Lights are ideal for heavy coolant environments and provide IP-65 waterproof protection. The lights are used for CNC machinery, conventional mills, lathes, and other metalworking machinery and machine tools. The lights are also ideal for packaging machinery and food processing equipment where coolant, oil, and other fluids are present. The "head-only" models are ideal for grinders, machining centers, CNC lathes, screw machines, turning centers, and packaging and processing machinery where space is limited.

Faster machining

When Winfried Benz, managing director, LiCON[MT] (Laupheim, Germany; Ann Arbor, MI; www.licon.com), relates the types of systems and machines that the company has provided to companies (Volkswagen is a big customer) for a variety of parts, ferrous and nonferrous alike, it becomes clear that there is a focus on high uptime, especially as he's talking about equipment that typically runs in the range of 100,000 to two million parts per year. When you get to those kinds of volumes, then whatever time the spindles aren't removing metal is time wasted. So they have developed a machining module called the "Linear Tool Changer" (LTC) that reduces toolchange time to less than one second. That's right: less than one second.

This isn't predicated just on a mechanism but, rather on a rethinking of what is actually occurring in conventional high(er) volume applications. That is, LiCON[MT] engineers have calculated that in the typical production machining operation, the cutting cycle time for a given tool is on the order of three seconds. What's more, they've determined that overall, there are fewer than 20 tools used to machine a given part. So instead of the approach that is often used by machine builders, which is to provide a means where tools can be swapped in and out of the spindle in, say, three seconds, what they've done is essentially eliminate the automatic tool change--which is, perhaps, more astonishing than the one-second time. In this case, "toolchange" means using another tool. And the other tool is fitted to the spindle head that is part of the LTC.

Essentially, each head, which has four to six CNC spindles, is powered all the time by a 15-kW motor (standard). Spindle speeds (standard) of up to 10,000 rpm can be achieved on the four-spindle version; 15,000 rpm on the six-spindle. Distances between each of the spindle centers is 160 mm. Maximum tool diameter is 125 mm. The axis travels are 400 X 400 X 630 mm for the four-spindle version; 600 X 600 X 800 for the six-spindle style; the positioning accuracy and repeatability are 0.01 mm and 0.005 mm, respectively. Rapid traverse can be performed at 60 m/min. The approach is to have a series of LTCs (four- and six-spindle configurations are available) setup in a line. Each of the machines is tooled to perform a limited number of operations, unlike the typical case in a machining center-based line (parallel processing), wherein a single machine typically performs all of the operations required to finish a part. So what happens in an LTC system is that the part, which is fixtured to a pallet (which provides the opportunity for five-axis machining through part positioning), undergoes metal removal in a series of machines that can provide "toolchange" in 0.8 seconds, which means positioning another of tooled spindles to the work, not changing discrete tools from toolchanger to spindle. This is a serial processing approach.

Benz admits that in addition to being quick, this approach is somewhat more expensive if there is a simple comparison made of, say, machining center to LTC. But he notes, "Price isn't everything," and goes on to point out that what needs to be taken into account is "the total cost of ownership."

In other words, if it is possible to produce parts much more quickly--in one time study on an aluminum steering knuckle, the job required 143 seconds with machining centers and could be done in 45 seconds with three LTC six-spindle machines integrated with a rotary part transfer device--then the investment may be well spent, Benz adds, "Our machines are used where labor costs are high." Which means that they're used in places where the machinery and equipment need to be exceedingly productive.

Magazine has revolving disk to reduce tool change time

Toyoda Machinery's Matrix tool magazine is a large capacity, stationary tool storage rack that accommodates as many as 500 tools. It allows Toyoda HMCs to be tooled for more part numbers and keeps backup tools on hand while virtually eliminating time-consuming trips to the toolroom.

The magazine has several features designed to maximize ease of use, including PC-based software, tool identification and monitoring, and OP Supporter software. Its compact design houses an array of tools in a relatively small footprint, says the company. The magazine accommodates tools as long as 21.6", with 9.84" diameter and weighing 59.4 lbs. Features include a revolving disk to reduce tool change time and PC-based software that displays a layout of the entire magazine.

Software aids development of machine vision applications

Optimized for use on smart cameras and other systems using TI's TMS320C6400 DSPs, InstantVision Integrated Software Environment v2.2 utilizes C++ programming language running on TI's Code Composer Studio. Multitarget Tracking Library tracks multiple objects moving at high speeds with pinpoint accuracy, even in cluttered environments. Other libraries include complex classification methods as well as optimized processing of images and video stream.

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Budapest, Hungary and Berkeley, CA - February 2, 2006 - AnaLogic Computers and Eutecus, Inc. are pleased to announce the release of the InstantVision Integrated Software Environment (ISE) 2.2 for the development of a wide range of machine vision applications. InstantVision ISE makes available all of AnaLogic/Eutecus' award-winning software tools in a comprehensive and easy-to-use package. New features in version 2.2 include improved performance, enhanced interfaces, and better support for rapid application development using Microsoft's .NET platform.

Dr. Csaba Rekeczky, CTO of Eutecus says, "InstantVision enables commercial users to rapidly and cost-effectively develop machine vision, security/surveillance, and other vision applications using the powerful Cellular Visual Technology (CVT) that Eutecus and AnaLogic developed to closely mimic human vision InstantVision ISE's image processing libraries include speed-enhanced versions of the standard vision tools offered by other vision software providers, as well as groundbreaking advanced tools unavailable elsewhere.

Most unique is the Multitarget Tracking Library (MTT Lib), developed in part with funding from several U.S. government agencies. The MTT Lib tracks multiple objects moving at very high speeds with pinpoint accuracy, even in cluttered environments containing a great deal of other visual activity.

The other libraries include complex classification methods (FC Lib) as well as optimized processing of images and video streams (SI Lib and SIF Lib). They run seamlessly with each other and with the MTT Lib to significantly reduce the cost of developing machine vision applications.

Dr. Gusztav Bartfai, CEO of AnaLogic Computers, states, "AnaLogic's multitarget tracking capabilities in concert with the advanced features of the other libraries enable us to enter markets that have not yet embraced advanced vision technology. We have identified applications for our software in science and medicine, the entertainment industry, and traffic management, to name a few examples.

"With the release of InstantVision, AnaLogic and Eutecus have reaffirmed their commitment to solving the most difficult image processing problems, while at the same time raising the bar for speed and accuracy for the industry as a whole."

Optimized for use on Eutecus/AnaLogic's Bi-i family of smart cameras and other systems using Texas Instruments' leading TMS320C6400 series of DSPs, InstantVision takes advantage of the versatile C++ programming language running on Texas Instruments Code Composer Studio. For quick profiling and less complicated tasks, AnaLogic provides an easy-to-learn proprietary programming tool. The InstantVision libraries can also be ported to a wide variety of other platforms and vision systems.

Injection Molding Tool enables zero defect production

Como Injection can optimize, monitor, and document up to 8 channels of cavity pressure or 4 channels of cavity pressure and 4 channels of machine signals. Available with optional touch screen for curve visualization, compact device is machine-mounted and compatible with coaxial and single-wire Kistler sensors. It can also be used to separate non-conforming parts to questionable parts bin. Collected data can be stored to server and accessed remotely via Internet.

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Amherst, NY (May 15, 2006) - Kistler Instrument will introduce at NPE 2006 a new system for zero defect production in the injection molding industry. This device will optimize, monitor, and document up to 8 channels of cavity pressure, or 4 channels of cavity pressure and 4 channels of machine signals (typically voltage signals). This new product is available with in a compact device that is machine mounted and with an optional touch screen for curve visualization.

The new Kistler unit is compatible with coaxial and single wire Kistler sensors. New cabling concept is offered with the Como Injection that offers one cable that combines up to 8 cavity pressure signals. The new cable offering allows for quicker set up time and protects users from confusing plug connections during machine and mold setups. Como Injection can be also used to separate non-conforming parts to be separated to questionable parts bin. Parts are continuously monitored and diverted if parts are not produced to optimum standards.

The data collected from the Como Injection system can be stored for use in production analysis and quality assurance, via an Ethernet connection to a server. Data can be accessed remotely from any location via the Internet.

Kistler is a global supplier of precision instrumentation for the Plastics market as well as the Research and Development, Industrial, Aerospace, Engine, and Bio-Mechanical marketplace.

Protecting machine tool spindle bearings

The most critical components of a machine tool spindle are its bearings. Bearings support the shaft and provide accurate. smooth rotation. Foreign particles and fluids damage bearings, and ultimately shorten spindle life.

Seals placed between the shaft and stationary parts protect the spindle bearings. There are many seal designs, but none are perfect for every application. The main challenge is interfacing with a shaft that can spin, while still providing a good seal. Other factors, such as size constraints, temperature, humidity, environmental air pressure fluctuations, chemical exposure, and particle geometry, influence seal selection.

Historically, machine tool spindles employ rubbing-type lip seals for slower applications, and labyrinth-type gap seals for high-speed applications. In instances where environments are extreme, air purge is added to the labyrinth seals to continuously purge contaminants from the sealing area. In the mid1990s, safety concerns prompted machine tool builders to more completely shroud the working area of machine tools. This change, in conjunction with dramatically increased coolant flow rates and pressures, creates a situation where traditional seals are inadequate. Bearing contamination occurs within a relatively short time.

In 1996, Setco constructed a test apparatus that would enable the replication of in-service seal failures. A further objective was to build a foundation on which seal performance could be assessed. Among the features were:

MINIMIZING TOOL BREAKAGE COST

It's possible to minimize unexpected tool failure by adhering to best practices, error proofing, and other automation strategies

When a tool breaks during a machining operation, the part being processed is often destroyed, and sometimes the machine is damaged. Aerospace parts are often complex shapes, manufactured from exotic materials that require prolonged machining cycle times. Therefore, a scrapped part is a significant loss in raw materials and value-added machining.

Because single-piece lot sizes are not uncommon in the aerospace industry, the loss of a single part is a real hit to production yield. An aircraft part failure can have catastrophic results, consequently compliance controls and risk mitigation makes reworking damaged parts more complicated than in other industries. The loss of a part or a machine due to tool breakage can have a significant impact on profitability and customer satisfaction.

Many of the specialized machine tools used in the industry perform mission-critical machining. Due to the cost and the long lead times for these machines, they are most likely bottleneck assets, and a crash can have a significant impact on production capacityThere are many reasons for tool breakage during machining, and there is not one solution that can ensure 100% detection or protection. Purpose-built tool-breakage recovery cycles can also save parts and lost production. Given the cost of the machines, material, and value-added work-in-progress that are characteristic of the aerospace tdindustry, several levels of preventive and detection strategies are justified to protect the company's investment.

The value of the parts and types of materials machined in the aerospace industry demands that the highest quality tooling be used for most applications. But even the best tools will fail if the processing parameters in the part program are wrong for the particular tooling or application, or if the operator makes a mistake during setup or adjustment.

Aerospace parts are machined from forgings, castings, bars, and sheet stock, and from materials with generally poor machinability. Variations in material composition, surface conditions, and depths and widths of cut make it very difficult to specify optimum cutting parameters throughout the part program, and for every part produced.

Engine parts are manufactured from heat-resistant superalloys (HRSA), such as Inconel, Hastelloy, and Waspaloy. Titanium is also used for many aircraft parts. The machinability of these alloys is generally poor because of the very nature of the material structure that is required for the application. Cast or forged components typically have a rough, uneven surface.

High cutting forces and high temperatures are generated when these tough materials are processed. Carbide in the structures of HRSA materials is abrasive, and a tendency for work-surface hardening can cause tool notching. Other tool failure modes such as cratering, thermal cracking, chipping, edge buildup, and deformation can occur, as well as a machine crash, if the feeds, speeds, and depths of cut are not specified correctly for the application.

So the very nature of aerospace part machining is likely to cause uneven tool wear and high stresses, which are prescriptions for premature tool failure. These problems can be avoided, however, by optimizing process parameters.

Even if the process parameters are perfect, tool-setup tasks and tool-wear offset adjustments are error-prone. Measurement, calculation, and data entry mistakes are common causes for tool breakage and machine damage.

Given the high machinery and work-in-process values typical in aerospace manufacturing, it makes sense to implement several levels of safeguards to protect these investments. Some potential solutions are well documented, such as sonic or vibration monitoring, and the use of inspection and tool-setting probes to error-proof the tool setup and adjustment processes. Data collection and Failure Mode and Effects Analysis (FMEA) techniques can provide valuable insight into the root causes of tooling failures and related machine crashes. This analysis can help select the most effective strategies for a particular business operation.

Who's afraid to cut to zero? Most U.S. mold shops still leave extra stock on the cores and cavities of the molds they machine. This practice is unnece

To go from milling machine to mold press to perfect molded part with the first shot is the dream of many mold shops.

"There's no reason a mold shop can't achieve that goal," says Keith Kauzlarich, vice president of Single Source Technologies (SST) in Auburn Hills, Michigan. "The process to machine molds that need no benching or spotting exists today. Most mold shops in the United States simply haven't embraced the technology that this process requires," he says.

A high percentage of mold shops habitually leave at least 0.001 to 0.003 inch of extra material on cavities and cores. This practice ensures the shop that there is sufficient stock to allow for hand grinding, polishing and other adjustments without exceeding the dimensional tolerances on the mold. It also allows for a safety factor to compensate for the margin of error in parts of the customary moldmaking technology, To go from milling machine to mold press to perfect molded part with the first shot is the dream of many mold shops.

"There's no reason a mold shop can't achieve that goal," says Keith Kauzlarich, vice president of Single Source Technologies (SST) in Auburn Hills, Michigan. "The process to machine molds that need no benching or spotting exists today. Most mold shops in the United States simply haven't embraced the technology that this process requires," he says.

A high percentage of mold shops habitually leave at least 0.001 to 0.003 inch of extra material on cavities and cores. This practice ensures the shop that there is sufficient stock to allow for hand grinding, polishing and other adjustments without exceeding the dimensional tolerances on the mold. It also allows for a safety factor to compensate for the margin of error in parts of the customary moldmaking technology,

Research Notes

At the Machining Research Centre of the School of Engineering Systems and Design at London South Bank University (London, England, UK), researchers are is running a project designated Machining of Hardened Aerospace Steel (Super CMV) and Nimonic C-263 Alloys with Cubic Boron Nitride (CBN) Tools. The production of aerospace parts with conventional tools such as coated carbides usually involves cutting-hardening-grinding practices. Replacing these tools with CBN leads to improvements in part fatigue strength and productivity, and reduced energy consumption. This project evaluates CBN tools when machining at cutting conditions two to four-times higher than those achieved with coated carbide. Detailed study of the interaction at the tool-chip and tool-workpiece interfaces, as well as tool-failure modes, will help researchers understand mechanisms responsible for wear and failure modes from the work material and cutting-tool standpoints. A speedfeed chart will be established for each tool-workpiece combination. project called A Parallel Kinematics High-Speed Machine Tool has resulted in the development of a high-speed three-axis machine tool based on a novel parallel kinematics XY table (PKXYT). It offers low inertia, dynamically matched axes, trivial kinematics, and high accuracy, according to researchers at the Center for Machine Tool Systems Research (CMTSR) of the Department of Mechanical Industrial Engineering at the University of Illinois at UrbanaChampaign. They are now developing planning and control strategies to maximize performance objectives while operating within the feasible region of the hardware. The machine's capabilities are being evaluated in applications such as machining graphite electrodes, biomédical implants, and aerospace components.

For more information go to: www.mie.uiuc.edu/content/asp/researc h/research_projects/manufacturing_sy stems_1. asp.

Sandia National Laboratory (Sandia, NM) has quite a number of manufacturing research programs underway. One such project is called Advanced Machine Processes for Micro fabrication. It's a three-year R&D project that seeks to fabricate subminiature parts with non-planar surfaces from materials such as steels, plastics, and ceramics. Focused ion beams and ion accelerators are being used to make micron-sized features and tools in various metals.

For more information, go to mfgshop. sandia.gov/1400_ext__RDPro jects.htm.

At the NSF Engineering Research Center for Reconfigurable Manufacturing Systems of the University of Michigan (Ann Arbor, MI), a project conducted under the name Testbed/Machining Systems is underway. Its goal is to demonstrate the technology base of reconfigurable systems that are upgradeable, changeable, and quickly diagnosable. Some objectives include strategically planning for industrial collaboration and technology transfer, and evaluating new machine tools, sensors, controls, design methods for systems and machines, manufacturing network software, and other enabling technologies.

VMC Design Turned Upside Down - YCI Supermax breaks from convention with new machine tool design - Brief Article

Is there room for improvement in the fundamental design of a vertical machining center? At least one machine tool builder thinks the answer is yes. For its larger-travel VMCs, YCI Supermax (Santa Fe Springs, California) has broken from design convention to place the Y axis on top of the X axis. Improved precision is the reason for the change.

A conventional VMC has X atop Y. This means that support for the work remains near the middle of the machine no matter where the work is located in X. As the work moves toward extreme positions in X, overhang increases. Some machine tool builders address this problem with non-integral supports located on either side of the base. By contrast, placing the X axis on the bottom of the machine results in a one-piece base providing consistent support along the machine's travel.

There are tradeoffs. According to company executive vice president Bryan Chen, the design's one-piece, T-shaped base results in a machine that is more expensive both to manufacture and to ship. However, for large, heavy jobs, the improved precision may justify the added cost. The one-piece design not only counters overhang, it also improves leveling accuracy.

It may also improve floorspace requirements. The footprint for one of these machines is 20 to 30 percent smaller than the footprint for comparable machines with the same travels, YCI says. This design is available for machines featuring X-axis travels of 59 or 82 inches.

Release the potential of your machine tool: probing can improve OEE in many different ways throughout the machining cycle

Probing has long been used for setup. With an inspection probe in its spindle, the machining center can touch a workpiece to quickly establish its location. Many manufacturers understand this, and many shops use the probe in this way. However, most of those shops fail to realize the many additional ways that on-machine probing can improve process efficiency. By using the probe strategically, a manufacturer can make 100% good parts--right the first time--in the lowest possible production time. The probe can even make it possible to do away with off line inspection as a regular part of production. Given all that the probe can do, calling it an "automation tool" is not enough. A probe is actually many automation tools in one The most effective machining processes use probing for different purposes throughout the cycle. Manufacturers that use probing only at the start, to locate parts and set tools, miss out on much of what probing can accomplish. Adaptive process control and part verification are where probing can deliver the greatest gains.

Here is how probing improves efficiency and accuracy at many stages throughout the machining cycle:

* Setup. Used to locate the part automatically and establish a work coordinate system, probing cuts setup time, increases spindle availability, lowers fixture costs and eliminates non-productive machining passes. On complex parts, 45 minutes of fixture alignment can be replaced by 45 seconds of probing, which is performed automatically by the CNC.

* Fail-Safe Operation. Through probing macro cycles, a CNC can quickly check for changes to work coordinates, tool dimensions or part dimensions, and input the revised values automatically. This eliminates costly errors resulting from incorrect manual calculations or miskeyed information.

* Part Identification. Probing can determine that the correct part has been loaded before the CNC calls up the program. This procedure protects the machine against wrecks that might result from an accidental mismatch between the program and the loaded part.

* Tool Setting. A tool setting probe is an economical solution for on-machine verification of tool geometry and tool condition. The tool setting probe can automatically set length and diameter and identify broken tools, performing these functions while the tool is in motion.

* In-Process Control. Probing can be used to monitor the size and position of machined features during the cutting process. The information can be used to automatically apply cutter compensation or adjust the work coordinates. Correcting the program in-process in this way can eliminate scrap, reprogramming or rework

Versatile Tools Speed Turning

Established in 1999 by Josef and Susan Kaltenegger, their two sons Hans and Jeff, and son-in-law Nico Morowat, Kaltech Mfg. (Delta, British Columbia) specializes in whiteiron machining and other tough, quick-turnaround jobs for local pulpand-paper industries and other applications.

One of the shop's most difficult jobs involves threading of large bolts used to secure heavy cables on hydroelectric dams. The operation requires removal of a lot of material to produce the 460 × 14-mm trapezoidal threads.

For turning, the shop was searching for a tool that could handle roughing of the entire workpiece, then finishing the thread root. "We were ordering an insert from Sweden, and it just wasn't convenient or cost-effective," operations manager Hans Kaltenegger recalls. "We didn't think there were any inserts in North America that could do the job."

Then a tooling rep introduced Kaltech to the A4 groove and turn tooling system from Kennametal Inc. (Latrobe, PA). Designed for high productivity on machines with limited tool positions, the system is rigid enough to provide stable cutting even with high machining pressures and relatively long overhangs. Secure clamping and bottom-V seating of the insert enable higher feed rates and depths-of-cuAlthough the A4 system was engineered for turn, face, profile, OD and ID groove, bore, and cutoff applications, Kaltech uses it in 95% of its production of large external square threads. Used for primary roughing, the system cuts finishing time by removing the bulk of the material before finish passes are made with a threading insert. "The tooling enables our machinists to precut the coarse thread on very large bolts," Hans Kaltenegger says.

According to Kaltenegger, Kaltech was able to push the tool to accommodate a thread feed rate of 50 ipm (1.3 m/min) at 88 rpm. Machinists are now threading eight pieces per A4 edge, helping to reduce production time by 70%.

"The bolts are machined from large amounts of material, and we often have a lot of overhang, which usually causes chatter," Kaltene

Versatile Tools Speed Turning

Established in 1999 by Josef and Susan Kaltenegger, their two sons Hans and Jeff, and son-in-law Nico Morowat, Kaltech Mfg. (Delta, British Columbia) specializes in whiteiron machining and other tough, quick-turnaround jobs for local pulpand-paper industries and other applications.

One of the shop's most difficult jobs involves threading of large bolts used to secure heavy cables on hydroelectric dams. The operation requires removal of a lot of material to produce the 460 × 14-mm trapezoidal threads.

For turning, the shop was searching for a tool that could handle roughing of the entire workpiece, then finishing the thread root. "We were ordering an insert from Sweden, and it just wasn't convenient or cost-effective," operations manager Hans Kaltenegger recalls. "We didn't think there were any inserts in North America that could do the job."

Then a tooling rep introduced Kaltech to the A4 groove and turn tooling system from Kennametal Inc. (Latrobe, PA). Designed for high productivity on machines with limited tool positions, the system is rigid enough to provide stable cutting even with high machining pressures and relatively long overhangs. Secure clamping and bottom-V seating of the insert enable higher feed rates and depths-of-cuAlthough the A4 system was engineered for turn, face, profile, OD and ID groove, bore, and cutoff applications, Kaltech uses it in 95% of its production of large external square threads. Used for primary roughing, the system cuts finishing time by removing the bulk of the material before finish passes are made with a threading insert. "The tooling enables our machinists to precut the coarse thread on very large bolts," Hans Kaltenegger says.

According to Kaltenegger, Kaltech was able to push the tool to accommodate a thread feed rate of 50 ipm (1.3 m/min) at 88 rpm. Machinists are now threading eight pieces per A4 edge, helping to reduce production time by 70%.

"The bolts are machined from large amounts of material, and we often have a lot of overhang, which usually causes chatter," Kaltene

Plugged in: to maintain a warm connection with customers, you need to master the use of cold information technology tools

Everyone knows that it is much easier to keep an existing customer than it is to gain a new one. Thus, an emerging trend among many pro dealers is to focus on developing customer relationship management programs. In this quest to strengthen customer relationships, many people believe the most important step is establishing deeper personal contact. An important key to building long-term business relationships is your company's ability to implement sound database management strategies behind the scenes.

Amazingly, many salespeople and sales managers today still are not utilizing computer programs to better manage basic information about their clients. This resistance reminds me of a legendary cartoon that depicts a salesperson at the back of a tepee waiting to meet the chief of a warring tribe who is in the midst of a battle being fought with bows and arrows. While the salesperson waited for an appointment to sell the chief a machine gun, the chief exclaimed, "I don't have time to see a salesperson. I am in the middle of a war!" Similarly, an organization that manages information about its customers without the use of modern technology is fighting a machine gun war with bows and arrows.

There are numerous database software programs on the market--such as ACT!, Goldmine, and Microsoft Outlook--that provide simple methods to manage vast amounts of complex information. All of these programs extend far beyond the mere management of names, addresses, and phone numbers. For example, they allow a salesperson to track appointments, conversations, correspondence, and more. They provide simple methods to send newsletters, merge mail, and track secondary information about clients. The use of a structured database system results in stronger long-term relationships with customers. Use caution, however, as some programs generate complex management reports, which can pose implementation problems if your information technology (IT) department is eager to help you implement every available software feature. These problems can occur when your database methods are lumped into the general category of IT. A sales manager's simple request to the IT department for a database software solution can spoke out into a number of issues such as order entry, linking customer data with back-end systems, inventory management, information feedback to the sales force, and more. In the end, a simple IT request to log names and phone numbers turns into a multi-department initiative that threatens to cost tens of thousands of dollars! When this potential information overload arises, the key ingredient to a program's success--buy-in from the sales team--often is destroyed.

Many companies that I have worked with enthusiastically embrace the idea of a new software strategy to retain important customer information. However, managers quickly become distressed when they discover the difficulties of overcoming sales resistance. Moreover, they fail to realize that their approach is creating the very resistance they want to avoid.

Salespeople are rugged individualists. Rather than accepting the use of a modern technology as a personal productivity tool, some salespeople view a database software initiative as a way for the boss to keep an eye on them, a concept that smacks of George Orwell's "Big Brother" in the novel 1984. In addition, many salespeople are technically challenged and, thus, are resistant to investing in and learning new computer software.

Great sales managers have learned that in order to successfully lead they must continually focus on the needs of their employees. When it comes time to implement a new database strategy (or any initiative for that matter) they recognize that salespeople should be treated like customers and be sold on the "What's in it for me?" idea. Of course not every salesperson will happily embrace your new ideas. even after you explain the benefits, and at some point, coercive measures may be required to successfully implement a new software strategy. Still, it is easier to gain voluntary acceptance than enforced obedience, and the value of information that an organization can obtain will be much better when salespeople are happily on board with the program. Therefore, sales managers should focus on the following keys to improve database implementation within their organizations:

1. Treat salespeople like customers. It is important to show them the value they receive by implementing a data-management process. Salespeople already know that when they quit or get fired, they can walk away with a lot of valuable information about your organization and its customers and that a database program helps companies keep that information in house. Therefore, be open and honest about the value that successful database management creates in their careers. Remind them that the information they obtain will help them personally in the form of increased compensation and stronger personal business relationships. Salespeople often are critical of customer relationship management campaigns, in part because they are the ones that must gather the information that enables the organization to strengthen business relationships. Until your salespeople see the personal value in retaining important information, your database management program will be challenged. Sell them on the idea that the management of customer and prospect information will help build their careers.

ArchiCAD 9: 3D for architects: building modeler delivers drawings with easy to use modeling tools

ArchiCAD 9 arrived with what at first I thought were minor improvements. But they add up to quite a lot, especially for 3D work, visualization, and working on a laptop with a cramped screen (figure 1). The latter situation may occur often now that ArchiCAD supports terminal server technology that makes it possible to work over the Internet from a remote location.

[FIGURE 1 OMITTED]

This new release also benefits from improvements in DWG compatibility and an improved library search system that enables symbols to be found by name (figure 2). About 2,600 symbols are included in the libraries that ship with the software All of this is particularly important to ArchiCAD's market of architects, builders, planners and facilities managers (there's a special ArchiCAD version for FM). Among major, full-featured (and, need we say, expensive) CAD packages, only ArchiCAD and Nemetschek's Allplan are specifically aimed at the builder market. Bentley and Autodesk add an architectural interface to their products. ArchiCAD can't match Allplan for structural design calculations, although it does feature a built-in truss designer and column designer. ArchiCAD provides a lot more power than the typical architectural design software package, but is still easy, nimble and intuitive to use.

As with v8.1, ArchiCAD runs on Macintosh and Windows 2000/XP machines. Graphisoft's minimum memory requirement for both platforms is 512MB. I found v9 usable on a Windows XP machine, but slow and crash-prone on an OS X Macintosh G4. I suggest that you spring for a gigabyte of memory for either platform. The new version is faster than v8.1, and I suspect it's faster than v7 (I benchmarked the older version on a slower machine, so I'm not absolutely sure). Crash recovery is better now--all the project files seem to survive.

Moving to 3D

I've been an ArchiCAD fan for well over a decade, since the days when it was Macintosh-only. Because I started early on with slower machines, I still tend to draw in 2D plan or elevation, knowing that a 3D object is being created at the same time (figure 4).

[FIGURE 4 OMITTED]

I've started to adapt, editing directly in 3D and then defining objects in greater detail later, as necessary. Younger architects usually draw in 3D from the start. ArchiCAD works well both ways, but this version makes 3D easier to use. This is not a true modeling package ranking with products such as form*Z. With it users can draw creatively, although this means that the model may look fine but won't give accurate results with programs that handle, for example, energy and weight analyses. But ArchiCAD is getting closer to that capability, and in the meantime, separate model-checking packages are available. Until the CAD vendors get this right, the structural and construction folks will continue to redo the model.

Look and Feel

Keeping its commitment to cross-platform compatibility between the Macintosh and Windows forced Graphisoft to make some compromises over the years in regard to look-and-feel. As the interface has evolved and software functionality has increased, the interface has tended toward telescoping palettes, multiple toolboxes, context-sensitive palettes that pop up with the windows they refer to and all the other tricks software designers use to keep as many command icons as possible close at hand while still leaving screen space for the drawing.

This version is the best yet. It clears up some of the icon clutter (mainly with more context-sensitive palettes that show all options for an element, no matter what tool is being used) while keeping everything handy. Suddenly, the screen looks 10-20% larger. There's a setting that provides up to 50% more space, but running that way forced me to open too many toolboxes on my own. A Classic setting puts an extra line of old favorites back on the screen. Of course, users can customize the interface any way they want.

Although I've become quite comfortable with ArchiCAD over the years, the new interface didn't cause much uncertainty. This is an upgrade that will require an absolute minimum of user reorientation and training, with good productivity benefits.

Under one roof - Bulletin Board - Detroit Precision Tool Co. and Hommelwerke form Detroit Precision Hommel - Brief Article

Detroit Precision Tool Company (Rochester Hills, Michigan) and Hommelwerke (Germany) have formed a global partnership called Detroit Precision Hommel, which will be headquartered in Rochester Hills. The new partnership is said to combine the strengths of the two companies in the measuring field. It is said to put under one roof all the metrology technology a manufacturer requires to assure the quality of its production, from surface finish and form measuring instruments to automated gaging and assembly systems, plus high level metrology services.

Slow Growth for Machine Tools

Machine tool users are more financially sound, but business is not growing rapidly. According to a report from Agie Charmilles Corp. (Lincolnshire, IL), our economy is clearly reacting to high interest rates and oil prices. Tooling appears to be holding up better than production. If the recent weakening of the US dollar continues and the Federal Reserve does not attempt to strengthen the dollar with higher interest rates, it's likely that long-term manufacturing growth will continue.

The Charmilles Machining Business Activity Index was down moderately at 62 from 67 in May. The improvement in business activity was strongest in the Captive Production sector and was uniformly strong in all regions. For more information try

Twin-column surface grinding machine—Matrix Machine Tools, booth B-6948

The company's twin column surface grinding machine is a three-axis CNC machine that uses a Siemens 810D control. The machine is said to provide submicron accuracies at a production machine cost. It can be used as a surface, creepfeed or in high speed grinding applications. The machine has a cast iron base and columns, and weighs 10,000 kg. It is completely enclosed and includes fume extraction capability. While ballscrews on all three axes are standard, linear motors are available as an option. The machine is offered with a standard horizontal spindle or optional vertical spindle

Cutting tool support for the automotive industry

The Leitz Metalworking Technology (LMT) Group has established an Automotive Support Center (ASC) for the North American automotive industry in Auburn Hills, Michigan. The ASC serves as a technology source for cutting tool development, installation, presetting, refurbishment and management.

The center is designed to support customers in production or new-tool-runoff phases. Its facility includes presetting equipment and various machine tools and grinders for tests and demonstration purposes. The ASC training center has direct access to other LMT companies and the Engineering Center located in Oberkochen, Germany, via an internal broadband computer network.

"The two most important trends we are currently observing in the automotive industry are globalization and localization," notes Dieter Brucklacher, executive chairman of the company. "Globalization is compelling businesses to build networks--not only internally, but also externally--and to form partnerships. Localization, on the other hand, means that businesses have to be in a position to support their local partners." The ASC was developed to address both of these needs.

The ASC offers a regrinding unit for tool refurbishment and modifications. Also, a separate production and service unit has been setup at Onsrud, the North American LMT production company. Onsrud is now producing solid carbide tools for the automotive industry, in addition to tooling for composite materials and hobs

Locking pins feature five types of handles—Jergens, booth E-2021 - Machine Tool Components and Accessories - Brief Article

The Kwik-Lok family of locking pins is available in five handle styles: T, L, button, recessed button and ring. Standard sizes range from 3/16" to 1" outside pin diameters in 1/2" to 6" grip lengths. Metric sizes are available from 5 mm to 25 mm outside diameters in 10 mm to 100 mm grip lengths.

All are made of 17-4 pH stainless steel or carbon steel. Special configurations are available in 2 weeks or less via a special flexible manufacturing process, says the company.

Standard sizes are available from stock. According to the company, the pins can be used on diverse applications wherever a quick release capability is desired. When their buttons are depressed, the balls at the end of the grip shaft retract, permitting insertion or remova

Integrated tool management solution—DLoG

WinTool is a software solution developed to address costs associated with tool logistics and planning, including indirect costs arising from factors such as chaotic tool storage and purchasing conditions, errors in presetting or the use of mediocre cutting data. The software integrates all CAM tool data, as well as presetting gage storage, ERP-system and production data management into a central database. This eliminates "paper traffic" and isolated data tables in different departments, enabling simple tool communication and reduced errors.

Using the software, companies can develop a tool library with complete information about tool components, assemblies and lists, as well as information on 2D/3D geometries, technologies, CNC operations, stock, suppliers and manufacturers. In addition, the company says the software is in sync with industry norms and the latest developments of common CAD/CAM systems, which can help alleviate interface costs caused by integrating with third-party solutions.

To optimize manufacturing for a new NC program, the software accesses detailed tool data--including cutting data from previous jobs--directly out of the CAM system. It then compiles a list of the finished NC program and verifies the availability of all used components. Finally, the program generates 3D tool solids In the shop, operators must calculate a "tool net list" before presetting the job for a machine. Depending on the work, the tool list can be in any format. For example, formats could include a parts list with bar codes for gathering components, a setup sheet for production or a measured tool drawing for presetting. The company says this can increase efficiency by ruling out possible mistakes early in the process and reduce machine downtime caused by tooling issues. In addition, companies will have access to information about quality, operation time and lifetime for future jobs. They also and will be able to analyze and optimize tool usage and waste.

Manufacturers also can use this solution to quantify tool needs directly out of the NC program. In addition, a central "shopping cart" replaces purchase order request forms in all departments, which can simplify coordination. Operators can transmit evaluated demand directly to the ERP system and integrate tool dispensers from suppliers with the software. This is said to allow reduction of tool variety and stock level in the shop and help eliminate administrative overhead.

Conceptual design of machine tool interfaces for high-speed machining

High-speed machining is a promising technology to drastically increase productivity and product quality. However, conventional machine tool design often cannot meet stringent requirements needed to overcome various problems brought about by high-speed rotations. One particularly critical issue is how to hold an exchangeable tool rigidly during high-speed rotations. For this purpose, several new standards of tool interfaces between the toolholder and the spindle nose have been proposed. However, it has become increasingly difficult to choose among various competing interface standards or even different variations within a common standard. This issue is further complicated because many machine tool builders also offer various proprietary modifications to the common standards. Furthermore, there is also a need to develop new tool interfaces or modifications if existing standards are not satisfactory. The objective of this paper is to provide a systematic approach that can assist in the conceptual design of machine tool interfaces for high-- speed machining. This conceptual design methodology can also be used to select appropriate interface designs from various competing alternatives that exist today. Two embodiment concepts for high-speed end milling are developed as a case study based on the proposed conceptual design methodology. It is shown that the proposed design methodology can assist systematic design decision making and sound reasoning of the design choice.Machine tools such as machining centers have spindles that consist of the arbor, the toolholder, and the tool, with interfaces and separation points in between (Ronde 1991). Toolholding is essential for machining processes to establish precise relative positions between tools and workpieces (Agapiou, Rivin, Xie 1995; Aronson 1994a, 1994b). As machining speed and precision requirements become higher, the need to hold tools rigidly at high speeds and under high loads continues to grow in importance. Tool interfaces are pairs of mating geometries that are standardized to permit exchangeability. This paper deals with the interface between the toolholder and the spindle nose. In general, the interface includes three major couplings: the mating surfaces of (1) the toolholder and the arbor, (2) the toolholder and the tool, and (3) the gripping chuck and connections to the toolholder, which are used for tool ejection and optional transmission of cutting fluid. Figure 1 illustrates the location of the interface of interest and the related components.

7/24 Taper Shank

Conical shanks without keys were the earliest shapes of tool interfaces. The basic principle is a conical toolholder that is drawn into an equally shaped hollow cone with a constant force that is usually generated by spring or hydraulic pressure. The conical surface centers the tool, determines its axial position, takes all external forces and bending moments, and transmits torque. To transmit torque, it is important that friction between interface surfaces is sufficient during operation.

One radius-to-length ratio of the cone was chosen as 7/24, which became a standard both nationally (ANSI B5.18-1960, ANSI B5.18-1972) and internationally (ISO 7388). For automated tool change, a circular groove with a V-shaped cross section was added, which is known as a V-flange tool shank (ANSI B5.50-1978). The 7/24 steep angle taper is the most common interface type for machine tools with large inventories in industry (Beier 1994, Wang and Horng 1994, Weck and Schubert 1994).

Various gripping mechanisms are available for the 7/24 toolholder. Most often, a retention knob is added at the tail of the taper, where it can be clamped by levers from the outside and drawn axially into the spindle nose. Another common option is a threaded bolt built in as part of the spindle that can be activated to screw or unscrew the toolholder (Effenberger 1987).

Many problems, however, are associated with 7/24 toolholder interfaces. One problem is that tool-- holders from different companies are not always exchangeable because this toolholder standard leaves too many aspects unspecified (Eckle 1986), and many companies have developed their own proprietary modifications.

Another problem with the 7/24 steep angle taper is its comparatively lower radial stiffness for the same nose diameter (Scheer 1986). The standard 7/24 taper is defined to guarantee a clearance between the end face of the spindle and the tool-- holder flange. The lack of end surface contact can result in lower radial stiffness. This problem can be explained by a stiffness cone concept as shown in Figure 2. An imaginary cone can be drawn, with the cone base defined by the most outward contact points. The length of the stiffness cone provides a comparison for permissible external radial loads without exceeding a given deflection. The angle of the imaginary stiffness cone can be chosen arbitrarily but must be held constant for comparison of alternatives. As shown in Figure 2, for two conical shanks of the same diameter, the one with a flange (Figure 2b) has a longer stiffness cone and thus suggests a higher radial stiffness than the one without (Figure 2a). Of course, proper end-surface contact with the flange is assumed for this comparison. However, it is not a trivial issue to achieve proper end-surface contact. The precision requirement for the relative positioning between the taper and the end surface is very high. This issue is critical and must be addressed.

Speed increasers improve machine productivity - Modern Equipment Review - Brief Article - Product Announcement

The company announces the availability of a new series of high speed spindle increasers that is said to offer greater rigidity and accuracy. The Big-Sheppard GTGhigh speed spindle increasers make it possible, even on low speed machines, to run cutting tools at higher speeds in order to obtain optimum tool performance and a reduction in machine time usage. Further, since the cutting resistance of the tool tip decreases as the cutting speed increases, the possibility of tool breakage is greatly reduced. In addition, by lowering the operating speed of the machine, heat generation and hearing wear will be minimized, thereby prolonging the life of the expensive machine spindle.

The increasers are equipped with hardened and ground steel gears that minimize noise and vibration. Super precision high thrust angular hearings along with rigid and large diameter spindles permit high speed and feed carbide operations.

Models for machining centers feature a coolant jacket and multi-directional coolant nozzles that efficiently direct the coolant to the tool cutting edge while simultaneously cooling the body. The compact design with adjustable locating pin assemblies and 360-degree adjustable orientation rings assure smooth operation in the automatic toolchangers of machining centers. Models for conventional machines use a stop bar to prevent rotation and are available with NMTB tapers as well as straight shankshe increasers are available in four different ranges. The Model GTG6 has a collet capacity of 3/8" and will increase speeds up to 20,000 rpm with a 6 to 1 increasing ratio. The Model GTG5 has a collet capacity of 3/8" and will increase speeds up to 20,000 rpm with a 5 to 1 increasing ratio. The Model GTG4 has a collet capacity of 5/8" and will increase speeds up to 15,000 rpm with a 4 to 1 increasing ratio. All of these models are equipped with the company's precision New Baby chuck collet system that offers high accuracy. The heavy duty Model NXG3 has a collet capacity of 1 1/4" and will increase speeds up to 8,000 rpm with a 3 to 1 increasing ratio

CNC Vertical Hobbing Machine optimizes dry machining

Based on single-piece frame cast from polymer composite material, Genesis(TM) 130H can be installed and re-located with no special lifting equipment. Direct-drive spindle motors eliminate need for mechanical adjustments, while cam-driven double gripper loader enables part load/unload times of 2 sec. Work area is isolated from machine frame to minimize thermal expansion from contact with hot chips. Stainless steel cutting chamber with steep inclination ensures that chips fall clear of work area.

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Rochester, New York, February 16, 2006-- Gleason's new Genesis(TM) 130H CNC Vertical Hobbing Machine features a revolutionary new design that optimizes dry machining, significantly reduces floor space requirements and greatly improves cycle times.

The 130H Hobber is the first in a new family of gear production equipment from Gleason called Genesis(TM). All of the Genesis machines share a common platform: a single-piece frame cast from an advanced polymer composite material, which can be made faster, more accurately and with inherently more rigidity than conventional cast-iron assemblies. This common platform design also ensures a small, compact machine footprint and enables the user to install and re-locate the machine with no special lifting equipment or special foundations While the 130H Hobber can accommodate wet cutting processes, it is particularly well-suited for dry machining. The work area is completely isolated from the machine frame to minimize thermal expansion from contact with hot chips, and a stainless steel cutting chamber with steep inclination ensures that chips fall completely clear of the work area.

The 130H Hobber is equipped with an innovative new mechanical cam-driven double gripper loader fully integrated into the machine. As a result, costly non-productive time can be cut to a minimum, with part load/unload times as short as two seconds.

Unlike conventional hobbing machines, the Genesis 130H utilizes a new, patent-pending hob drive system to eliminate complicated mechanical and hydraulic clamping systems. Instead a simple "D-Drive" system enables the spindle to transmit more torque, with less runout, and at the same time accommodate the use of larger diameter hobs for greater performance and longer tool life.

The 130H also features direct-drive spindle motors, which further reduces setup and machining times by eliminating the need for mechanical adjustments and change gears. Higher acceleration/deceleration rates and increased torque, combined with faster axis motions reduce non-cutting time between cycles and increase overall productivity during machining.

Other significant features include:

o An Easy Access Service Module that consolidates hydraulics, lubrication and pneumatics into one location.

o Optional on-board chamfering and deburring capability.

o Availability of the latest SIEMENS or FANUC controls and the latest Gleason software running in a true Windows[R] environment.

o The chip conveyor may be located from either the side or rear of the machine to meet any cell/system arrangement.

Gleason Corporation is a world leader in the development, manufacture and sale of gear production machinery and related equipment. The Company's products are used by customers in automotive, truck, aircraft, agriculture, construction, power tool and marine industries and by a diverse set of customers serving various industrial equipment markets. Gleason has manufacturing operations in Rochester, New York; Rockford, Illinois; Dayton, Ohio; Plymouth, England; Munich and Ludwigsburg, Germany; Bangalore; India, Studen, Switzerland; and Harbin, China and has sales and service offices throughout the North and South America, Europe and in the Asia-Pacific region

Today's bar essentials: as the art of the cocktail becomes more sophisticated, the bar tool box gets an update

You can make a drink, or you can craft an experience," says Tony Abou-Ganim, the prominent beverage consultant also known as The Modern Mixologist. "But to craft an experience, you need the proper tools."

While professional chefs have "tool" kits--good knives, favorite tongs, brushes, and more, says Abou-Ganim, "a lot of bartenders are used to using whatever tools are available to them at the bar." To remedy that, Abou-Ganim recently began marketing his TAG Bar Tools line to provide today's bartenders with a tool kit similar in quality to those of top chefs.

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"But times are changing," adds Ryan Magarian, professional mixologist behind Liquid Kitchen beverage consulting in Seattle. "Chains are beginning to understand that the bar should be an intrinsic part of the concept's overall culinary experience." And as the culture for cocktail excellence grows, beverage professionals are becoming much more savvy and choosy about the tools they use to enhance both the beverage and bar experience.

So, what's the well dressed bar wearing? "First and foremost, a good quality Boston shaker," says Kathy Casey of Kathy Casey Food Studios in Seattle. Boston shakers, which consist of a pint glass and tin, have advantages over the three-piece, solid metal shakers with the built-in strainers and jigger tops, according to Casey. "The three-piece shakers tend to stick and when you do get them apart, it's abrupt and you spill," she says Adam Seger, noted bar chef and general manager of Nacional 27, in Chicago, agrees. "I like a really heavy-duty glass pint and tin, and I actually like a pint that's marked with ounces."

BUY QUALITY

Magarian gets even more specific. "The best tin I've found is the Vollrath 30-ounce. It forms a tight seal, but pops apart from any standard pint easily every time." Magarian adds that shakers that stick and spill can ruin a bartender's confidence--he or she might avoid using them as a result. Abou-Ganim agrees, "Do not spend $1.99 on a tin; it's like a chef buying knives at the discount store."

Next up, muddlers. Until recently, muddlers hadn't changed much in 20 years--they were still dyed, lacquered, too short, too narrow and made of soft wood, writes Dave Nepove on his web site, www.mistermojito.com. "Varnish and dyes are no-no's," says Abou-Ganim, whose TAG line includes a hardwood muddler. "After a while they chip, and where do you think those little flakes go?"

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Nepove's line of Mr. Mojito muddlers also addresses those issues head-on. "We use the hard plastic version of Mr. Mojito at the Cheesecake Factory," says Matt Raftree, beverage and bakery operations manager for the 100-plus-unit Calabasas Hills, Calif.-based chain. "Other muddlers were always too short; if you tried to muddle in the tin you'd cut your hand. We made our bartenders very happy when we brought in the new muddlers."

The Mr. Mojito muddler is 10-inches long and bat shaped; the Mr. Mojito Master muddler is 12 inches with a wide bottom on one end that tapers to a narrower diameter on the other end. Both ends can be used for muddling fruit, herbs and more.

The plastic versions are dishwasher safe. Magarian likes them because they will never pick up flavors of the items being muddled; others prefer the hardwood versions, citing the notion that muddlers can become "seasoned."

Another muddler gaining fans among top mixologists, including cocktailian Gary Regan, is the Pug!, a fat-bottomed muddler with a tapered handle handcrafted by woodworker Chris Gallagher of Cornwall-on-Hudson, N.Y. Word-of-mouth raves are driving sales, and Gallagher may soon take orders via the web.

STANDARD STRAINERS

After all that shaking, stirring and muddling, you need to separate the potables from particulates. The standard strainer is the Hawthorne, with two or four prongs and a wire spring around the edge. It fits into the tin or pint to strain the beverage. Less common, but coming on, is the Julep strainer, a perforated, spoon-shaped strainer that is held over the serving glass to strain larger bits of fruit, herbs, pulp, rind and such.

"The general rule is: If a drink calls for a spirit with juice, milk or cream, shake it with the ice and strain it with a Hawthorne because you are looking for the froth; you want some texture," explains Abou-Ganim. "If the drink calls only for the base spirit and flavoring ingredients--a Negroni or Manhattan--use a long-handled bar spoon to stir it with ice and pour it smoothly into the serving glass, using a Julep strainer. This results in a clear, elegant cocktail."

The latest addition to the strainer family is a kitchen sieve or fine mesh skimmer--the kind chefs use to clarify bouillon, for example. "We started using three-inch diameter mini strainers for our fresh strawberry-infused drinks," says Cheesecake Factory's Raftree. "They're very fine and really strain out all the particles and seeds

Turning Center has tool setter with4-position touch sensor

Offered in 3 models with 6.5 or 8.25 in. chuck, Lynx 220 OD Turning Center is powered by 20 hp motor and features 30[degrees] slant bed with single-piece, strategically ribbed design and fine-grain Meehanite composition that dampens vibration and helps dissipate heat. Spindle accelerates to 6,000 rpm in 2.3 sec, and rapid traverses for X and Z axes are 1,181 and 1,417, respectively. Heavy-duty, 12-station turret is non-stop and bi-directional with 0.15 sec station index time.

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West Caldwell, NJ - The new Lynx 220 packs speed and power in an economical O.D. turning center.

Three models are available: the 220A with a 6.5" chuck, the 220C with an 8.25" chuck and a 220LC with an 8.25" chuck and elongated bed. All are powered by a 20 Hp motor that provides the muscle to power through heavy cuts in tough metals.

A 30[degrees] slant bed maintains a minimal and constant distance from tool tip to guideway, and assures maximum rigidity and eliminates of deformation under heavy loads. This design also allows excellent chip flow and operator access for loading and unloading material, replacing chucks and tools, and repositioning the optional tailstock. The one-piece bed is strategically ribbed. Its fine-grain Meehanite composition dampens vibration and helps dissipate heat. The spindle accelerates to its peak 6,000 rpm (Lynx 220A) in a quick 2.3 seconds. The large contact surface of the cylindrical roller bearings provides high rigidity for heavy loads and mirror finishes. All bearings are permanently lubricated, precision class P4.

The 12 station, heavy-duty turret is non-stop and bi-directional, with a quick 0.15 sec. station index time. Its heavy-duty design, with a large 8.27" diameter curvic coupling, provides high rigidity, long boring bar overhang ratios, and extended tool life. Rapid traverses are 1,181 ipm on the X axis, and 1,417 ipm on the Z. An integral tool setter minimizes the need for manual skim cuts. Its four-position touch sensor allows tool setting in any direction. Offsets are entered automatically in the controller, eliminating errors that can arise from manual data entry.

Automatic forced lubrication is provided to all guideways, ball screws and the tailstock quill. Non-clogging piston distributors minimize way lube consumption. The 1/2 gallon lubricant reservoir lasts up to 100 hours. Sensors activate a low-level alarm, and monitor pressure to detect open or broken lube lines.

Coolant is delivered through the turret from a 30 gallon tank by a 1.2 Hp multistage centrifugal pump. The 65 psi of pressure flushes chips from drilled holes, often eliminating the need for time-consuming peck and drill cycles. The coolant tank and chip pan are separate from the machine bed, preventing heat transfer to the machine casting. A waylube separation system removes tramp oils from the coolant reservoir, and deposits it in a separate external tank

Machining center—Hurco Machine Tool Products, booth A-8117 - Machining Centers, Mills and Drills - advertisement

The VMI is a true 6,000-lbs machining center built around a solid, cast iron frame and UltiMax controls. With travels of 26" x 14" x 18" in a small footprint, the center is said to be useful in almost any shop for primary or secondary operations. Its standard, 8,000-rpm spindle, 750-ipm rapids and 16-station swing arm ATC are said to provide fast throughput, improving shop profitability.

This product also features a new version of company's control. The new control has a 14", color LCD touch screen, an ergonomic console and the full capability of PC-based UltiMax software and hardware. Its many NC and conversational programming features allow the operator to expedite job turnaround time, according to the company. The machining center also offers a range of accessories and options including a fourth axis table and a 10,000-rpm spindle

DACA Machine & Tool Co. Receives Boeing Silver Supplier Certification

DACA Machine & Toot Co., Inc., Dutzow, Missouri, recently was named a Silver Level Certified Supplier by Boeing at a ceremony held at the company's facility on June 28th.

Representatives from Boeing and Missouri Enterprise joined the family and friends of DACA staff for the event.

DACA, which offers CNC machining & turning, welding, sheet metal fabrication and waterjet cutting, was recognized for its quality, delivery, affordability and customer satisfaction excellence.

The award is part of Boeing's Preferred Supplier Program. The "Silver" status requires a quality rating above 99% and a delivery rating of at least 95%.

This award rates DACA in the top 2% of the aircraft manufacturer's worldwide supplier base.

"You've joined a rather elite group of suppliers," noted Daryl Yochum, Boeing's director of product operations in St. Louis. "Boeing works with more that 13,000 different suppliers and only two percent have ever achieved silver certification."DACA President Phil Pecaut accepted the award along with Perry Pecaut, vicepresident, Art Pecaut, QC manager.

Phil and his wife, Norma, purchased the firm in 1975.

Today the company's 40 employees operate in a 3 1,000-sq.ft. facility in Dutzow, four miles north of Washington, Missouri or 50 miles west of St. Louis.

DACA's equipment includes: 10 CNC machining centers (including two 5-axis); a multi-head waterjet cutting system; three CNC turning centers (featuring Swiss type & twin spindle "Y" axis capability); and a full line of CNC sheet metal equipment including a shear, turret punch, brake presses, sheet leveler and automatic deburring equipment.

Five-axis tool cutter and grinding machine—J. Schneeberger, booth B-7053 - Grinding/Abrasive Machining Equipment - advertisement - Brief Article

The Corvus GDS with new wheelhead design features a double-ended direct drive wheel spindle for up to six wheels and is vertically mounted on the rigid, box-type column. The company's fixed-table bed-type design is said to allow for a wide range of options, such as a fast A axis for cylindrical grinding, dressing devices, wheel sticking, tool supports and optical profile checking.

For large tools, the machine is available in 17", 26", 44", 67" and 118" X-axis configurations, as well as 13-, 20- and 34-hp spindles. Automatic loading options include two or four pallet loading robots for large production runs, carousel loaders for heavy tools mounted in IS050 toolholders or low-cost internal loading solutions. It is also available with a special sixth axis on the spindle head for grinding flat, helical and cylindrical broaches, as well as standard shop tools.