Able to control up to 5 axes and a spindle, Advantage 400 includes 32 digital inputs, 2 analog inputs, 16 digital outputs, and variety of programming features. Product also includes ability to send torque or step and direction command formats. Dual-processor control utilizes dedicated DSP based CPU to service motion control tasks, and Pentium-based PC is at heart of user interface. Unit comes with 8.4 in. color LCD and can include Ethernet and USB utilities.
Chatsworth, Ca. - Delta Tau Data Systems, Inc. has released the Advantage 400 CNC control system. Created for the machine tool builder and retrofitter who require a powerful, feature packed control, which sets up quickly and whose price does not limit performance, capability, or flexibility.
The Advantage 400 will control 5 axes, a spindle, includes 32 digital inputs, 2 analog inputs, 16 digital outputs, and all the programming features customers would expect from a high-performance control package, all in a standard configuration and at a very reasonable price. The Advantage 400 includes the ability to send torque or step and direction command formats.
The Advantage 400 is a dual-processor control utilizing a dedicated DSP based CPU to service the motion control tasks. A Pentium based PC is the heart of the user interface. The DSP motion control CPU ensures the machine is accurate at any speed. The Pentium based interface allows Delta Tau to include utilities such as Ethernet and USB at no additional cost to the user. The control comes standard with an 8.4" color LCD.
The Advantage 400 is a perfect example of how intelligent design and technology is bridging the gap between software and hardware and bringing unprecedented levels of performance and value to the shop floor.
About Delta Tau Data Systems
Delta Tau Data Systems is the global leader in high-performance machine control products. By developing and manufacturing a full range of motion control products, software, and accessories, Delta Tau delivers motion control solutions that solve the simplest to the most complex positioning applications. Products are marketed through a worldwide distribution network and application engineers are located globally to provide timely customer support.
Friday, September 15, 2006
Vertical turning debut boosts productivity in aerospace application - Better Production Spotlight: Turning - Thomson Machine and Tool installs Webster
Thomson Machine & Tool (Somerset, England) required a large-capacity turning center for machining aerospace components with diameters of up to 2,000mm, in a range of materials including titanium and nimonic alloys. Although this operation had previously been performed using a traditional horizontal lathe, the nature of the application suggested that a switch to vertical turning would provide advantages leading to significant improvements in productivity.
"After considering a number of options, we decided that a vertical turning center offered the right combination of capacity, rigidity and versatility for this application," explains Thomson Machine & Tool's managing director, Allan Thomson. "We chose a Webster & Bennett (Coventry, England) machine because of the company's expertise in vertical turning, coupled with the unrivalled reputation for performance and build quality enjoyed by its products."
Webster & Bennett supplied Thomson Machine & Tool with a two-axis vertical turning center with 72-inch table and 8-inch square ram, suited to machining large cylindrical components thanks to a maximum height under the cross rail of 57.5 inches, a ram stroke of 48 inches and maximum swing of 84 inches. The machine incorporates a range of features designed to maximize productivity while maintaining the quality of the components being machined.
With a maximum load capacity of 11,363 kg, large and heavy components can be supported on the machine's table and held in place using Webster & Bennett's four-jaw independent chuck, a setup that eliminates inaccuracies associated with the effect of gravity on horizontally clamped components. This inherent advantage of vertical turning, complemented by the inclusion of a Timken table bearing and ballscrews on the X and Z axis, has enabled Thomson Machine & Tool to achieve levels of machining accuracy and consistency that they could not match using horizontal lathes. Operators at the company have also noticed a significant improvement in the surface finish of components manufactured on the Webster & Bennett machine.
"Every aspect of the vertical turning center's design and construction contributes to its overall rigidity, resulting in a superior machining performance, which is reflected in the quality of the components we produce," says Mr. Thomson.
The machine's 18-station automatic tool changer enables multiple machining operations to be performed in a single setup. This is crucial in the manufacture of large and awkward components at Thomson Machine & Tool, and this benefit has contributed to a typical reduction in product cycle times of 20 percent. Another significant benefit of this versatility is the scope for product diversification it has provided. "The machine's ability to perform a wide range of machining operations quickly and efficiently has helped us to reduce throughput times while increasing our scope for diversification into new products and markets," Mr. Thomson explains.
Optimum metal removal is assured by the machine's wide speed range of 5-167 rpm, provided by a two-speed gearbox and 37.5 kw main drive motor, specified by the customer in order to provide the low-speed, high-torque machining required for the successful production of aero engine components. CNC controlled servodrives add to the machine's operational speed and ease of use and contribute to the consistency of its machining accuracy.
Another factor in the vertical turning center's overall appeal has been its trouble-free integration into manufacturing operations at Thomson, made possible by a combination of the machine's easy-to-learn Fanuc l8Ti CNC control system and integral swarf conveyor with coolant system. Mr. Thomson also drew attention to the high level of technical support provided by Webster & Bennett, which enabled the installation of the machine with minimal disruption to Thomson Machine & Tool's manufacturing operations.
Full working area guarding and ease of use have also played a part in the machine's popularity among operators at Thomson Machine & Tool, Mr. Thomson explains. "Those operating the machine have been amazed by the ease with which it can perform a number of high precision machining operations quickly, safely and with a minimal amount of setup, helping to streamline this particular manufacturing process in a way that traditional horizontal turning couldn't match."
"Making the switch to vertical turning with a Webster & Bennett has proved a major success for this demanding application, providing significant improvements in productivity and component quality, while simultaneously creating considerable scope for us to enter into new markets."
"After considering a number of options, we decided that a vertical turning center offered the right combination of capacity, rigidity and versatility for this application," explains Thomson Machine & Tool's managing director, Allan Thomson. "We chose a Webster & Bennett (Coventry, England) machine because of the company's expertise in vertical turning, coupled with the unrivalled reputation for performance and build quality enjoyed by its products."
Webster & Bennett supplied Thomson Machine & Tool with a two-axis vertical turning center with 72-inch table and 8-inch square ram, suited to machining large cylindrical components thanks to a maximum height under the cross rail of 57.5 inches, a ram stroke of 48 inches and maximum swing of 84 inches. The machine incorporates a range of features designed to maximize productivity while maintaining the quality of the components being machined.
With a maximum load capacity of 11,363 kg, large and heavy components can be supported on the machine's table and held in place using Webster & Bennett's four-jaw independent chuck, a setup that eliminates inaccuracies associated with the effect of gravity on horizontally clamped components. This inherent advantage of vertical turning, complemented by the inclusion of a Timken table bearing and ballscrews on the X and Z axis, has enabled Thomson Machine & Tool to achieve levels of machining accuracy and consistency that they could not match using horizontal lathes. Operators at the company have also noticed a significant improvement in the surface finish of components manufactured on the Webster & Bennett machine.
"Every aspect of the vertical turning center's design and construction contributes to its overall rigidity, resulting in a superior machining performance, which is reflected in the quality of the components we produce," says Mr. Thomson.
The machine's 18-station automatic tool changer enables multiple machining operations to be performed in a single setup. This is crucial in the manufacture of large and awkward components at Thomson Machine & Tool, and this benefit has contributed to a typical reduction in product cycle times of 20 percent. Another significant benefit of this versatility is the scope for product diversification it has provided. "The machine's ability to perform a wide range of machining operations quickly and efficiently has helped us to reduce throughput times while increasing our scope for diversification into new products and markets," Mr. Thomson explains.
Optimum metal removal is assured by the machine's wide speed range of 5-167 rpm, provided by a two-speed gearbox and 37.5 kw main drive motor, specified by the customer in order to provide the low-speed, high-torque machining required for the successful production of aero engine components. CNC controlled servodrives add to the machine's operational speed and ease of use and contribute to the consistency of its machining accuracy.
Another factor in the vertical turning center's overall appeal has been its trouble-free integration into manufacturing operations at Thomson, made possible by a combination of the machine's easy-to-learn Fanuc l8Ti CNC control system and integral swarf conveyor with coolant system. Mr. Thomson also drew attention to the high level of technical support provided by Webster & Bennett, which enabled the installation of the machine with minimal disruption to Thomson Machine & Tool's manufacturing operations.
Full working area guarding and ease of use have also played a part in the machine's popularity among operators at Thomson Machine & Tool, Mr. Thomson explains. "Those operating the machine have been amazed by the ease with which it can perform a number of high precision machining operations quickly, safely and with a minimal amount of setup, helping to streamline this particular manufacturing process in a way that traditional horizontal turning couldn't match."
"Making the switch to vertical turning with a Webster & Bennett has proved a major success for this demanding application, providing significant improvements in productivity and component quality, while simultaneously creating considerable scope for us to enter into new markets."
Spain's big splash - Scanning the Horizon - Spanish machine tool industry and BIEMH 2002 - Industry Overview
In the worldwide arena of manufacturing, Spain isn't widely known as a top contender. But the numbers from Gardner Publications' 2002 World Machine Tool Output & Consumption Survey tell a different story. Spain's population is less than one-seventh that of the United States, but Spanish machine tool builders annually produce a number of machine tools equal to nearly one-third the total volume produced by American builders. Furthermore, at the same time that production has declined in the United States, the Spanish machine tool industry has experienced gradual but continuous growth since 1995. For example, in 2001, Spain's machine tool production increased more than 6 percent from the previous year.
The heartland of this dynamic industry is the beautiful and rugged Basque section of northern Spain near the Atlantic coast and the French border. As the commercial center of the industrious Bizkaia region, Bilbao is the host city for one of Europe's largest machine tool shows, the biennial BIEMH. In the past, Bilbao was known primarily as a gritty center of heavy industry. But after undergoing an impressive renaissance, this city of 400,000 residents has emerged as a place of alluring charm.
When the 22nd BIEMH exhibition opened at Bilbao's International Trade Fair on March 11, the Spanish machine tool industry had some important accomplishments to celebrate. For example, Spanish builders currently manufacture more than 2,000 different machine models. Many of these products feature innovative technology that was developed in Spain.
The rapid improvement of Spanish technology in recent years is primarily the result of strong investment in research and development. On the average, Spanish machine tool builders allocate 5 percent of their annual turnover to R&D. For the country's largest builders, this investment may represent 10 percent or more. The success of this industry has been greatly facilitated by inter-company alliances in the areas of process development, marketing, distribution and supply chain management. Many of these cooperative efforts have been coordinated through the Machine Tool Manufacturers' Association of Spain (AFM) and its sister organization, the Export Trade Association of Spanish Manufacturers of Accessories, Component Parts and Tools for Machine Tools (AMT).
Strong investment and effective cooperation enable Spanish machine tool manufacturers to compete aggressively in global markets. Spain's principal machine tool builders offer products for high speed milling, turning, grinding and EDM that incorporate advanced capabilities. As a reflection of the growing reputation of Spanish technology, Germany was the largest customer in 2001 for Spanish machine tools, purchasing more than 18 percent of all the country's exports.
The defining characteristic of the most prominent Spanish machine tools is flexibility in meeting specific user requirements. Thus, many of the large machining centers exhibited at BIEMH 2002 are designed to suit the production systems of important automotive and aerospace clients. At the same time, however, Spanish builders offer a wide range of conventional and CNC machine tools that are suitable for typical job shop applications.
Spanish-American Market
While Spain's largest machine tool builders have established solid marketing networks in the United States, economic conditions during the past 12 months have created a slump in the market for Spanish exports. Because the United States currently accounts for less than 8 percent of Spain's total export trade, however, this doesn't represent a serious problem by itself. Because the appetites of American consumers continue to drive manufacturing activity around the globe, however, many Spanish builders are experiencing the impact of a softer American economy on their customers in Europe and Asia. As a result, AFM predicts that the steady growth its members have enjoyed since 1995 may be interrupted when the final figures for 2002 are recorded.
In this vein, AMT president Ramon Cenar-ruzabeitia recently discussed some of the difficulties that his member companies face in penetrating the American market. AMT recently attempted to put together a consortium of firms to market products in the United States. The combination of a weak machine tool industry, firmly entrenched competitors and unresolved inventory/delivery issues, however, have frustrated this effort. Unlike Spain's larger machine tool builders, the relatively small firms of AMT are still searching for an effective strategy to tap the American market.
Show Highlights
BIEMH 2002 featured the sixth edition of Spain's National Machine Tool Design competition. This year, the award was shared by Kondia Urbano Conde S.A. (Elgoibar, Spain)--in recognition of its P60-V2 high speed precision machining center-and ONA Electroerosion S.A. (Durango, Spain and Dayton, Ohio)--for overall product design strategy. Kondia manufactures a complete line of conventional, CNC-operated and high speed milling machines. ONA is the world's oldest manufacturer of EDM equipment and also the leading EDM builder in the European Union. ONA ram- and wire-EDM machines feature advanced spark-control and automatic programming technologies.
The heartland of this dynamic industry is the beautiful and rugged Basque section of northern Spain near the Atlantic coast and the French border. As the commercial center of the industrious Bizkaia region, Bilbao is the host city for one of Europe's largest machine tool shows, the biennial BIEMH. In the past, Bilbao was known primarily as a gritty center of heavy industry. But after undergoing an impressive renaissance, this city of 400,000 residents has emerged as a place of alluring charm.
When the 22nd BIEMH exhibition opened at Bilbao's International Trade Fair on March 11, the Spanish machine tool industry had some important accomplishments to celebrate. For example, Spanish builders currently manufacture more than 2,000 different machine models. Many of these products feature innovative technology that was developed in Spain.
The rapid improvement of Spanish technology in recent years is primarily the result of strong investment in research and development. On the average, Spanish machine tool builders allocate 5 percent of their annual turnover to R&D. For the country's largest builders, this investment may represent 10 percent or more. The success of this industry has been greatly facilitated by inter-company alliances in the areas of process development, marketing, distribution and supply chain management. Many of these cooperative efforts have been coordinated through the Machine Tool Manufacturers' Association of Spain (AFM) and its sister organization, the Export Trade Association of Spanish Manufacturers of Accessories, Component Parts and Tools for Machine Tools (AMT).
Strong investment and effective cooperation enable Spanish machine tool manufacturers to compete aggressively in global markets. Spain's principal machine tool builders offer products for high speed milling, turning, grinding and EDM that incorporate advanced capabilities. As a reflection of the growing reputation of Spanish technology, Germany was the largest customer in 2001 for Spanish machine tools, purchasing more than 18 percent of all the country's exports.
The defining characteristic of the most prominent Spanish machine tools is flexibility in meeting specific user requirements. Thus, many of the large machining centers exhibited at BIEMH 2002 are designed to suit the production systems of important automotive and aerospace clients. At the same time, however, Spanish builders offer a wide range of conventional and CNC machine tools that are suitable for typical job shop applications.
Spanish-American Market
While Spain's largest machine tool builders have established solid marketing networks in the United States, economic conditions during the past 12 months have created a slump in the market for Spanish exports. Because the United States currently accounts for less than 8 percent of Spain's total export trade, however, this doesn't represent a serious problem by itself. Because the appetites of American consumers continue to drive manufacturing activity around the globe, however, many Spanish builders are experiencing the impact of a softer American economy on their customers in Europe and Asia. As a result, AFM predicts that the steady growth its members have enjoyed since 1995 may be interrupted when the final figures for 2002 are recorded.
In this vein, AMT president Ramon Cenar-ruzabeitia recently discussed some of the difficulties that his member companies face in penetrating the American market. AMT recently attempted to put together a consortium of firms to market products in the United States. The combination of a weak machine tool industry, firmly entrenched competitors and unresolved inventory/delivery issues, however, have frustrated this effort. Unlike Spain's larger machine tool builders, the relatively small firms of AMT are still searching for an effective strategy to tap the American market.
Show Highlights
BIEMH 2002 featured the sixth edition of Spain's National Machine Tool Design competition. This year, the award was shared by Kondia Urbano Conde S.A. (Elgoibar, Spain)--in recognition of its P60-V2 high speed precision machining center-and ONA Electroerosion S.A. (Durango, Spain and Dayton, Ohio)--for overall product design strategy. Kondia manufactures a complete line of conventional, CNC-operated and high speed milling machines. ONA is the world's oldest manufacturer of EDM equipment and also the leading EDM builder in the European Union. ONA ram- and wire-EDM machines feature advanced spark-control and automatic programming technologies.
2004 machine tool consumption
According to AMT--The Association For Manufacturing Technology and the American Machine Tool Distributors' Association (AMTDA), June U.S. machine tool consumption totaled $236.93 million. This total, as reported by companies participating in the USMTC program, was up 19.5 percent from May and up 0.9 percent from the total of $234.79 million reported for June 2003. With a first-half total of $1,249.68 million, 2004 is up 31.9 percent compared with 2003.
U.S. machine tool consumption is also reported on a regional basis for five geographical breakdowns: Northeast, Southern, Midwestern, Central and Western. For more information on these regions, as well as other USMTC data
U.S. machine tool consumption is also reported on a regional basis for five geographical breakdowns: Northeast, Southern, Midwestern, Central and Western. For more information on these regions, as well as other USMTC data
Thursday, September 14, 2006
Spain steps it up: the country is now home to the world's fourth largest machine tool show. That fact, combined with Spain's long metalworking history
This year's Spanish machine tool show was big in many respects. Known as BIEMH, the 2004 edition of this biennial show was its largest in terms of number of attendees and exhibitors. In fact, BIEMH now ranks as the world's fourth largest machine tool show, behind EMO, IMTS and BI-MU.
Show organizers and Spain's association of machine tool manufacturers, known as AFM, have made strides to generate greater interest from the international metalworking community. It seems this effort has paid off, because this year's show drew visitors from 54 countries and featured 1,894 exhibitors from 34 countries. Of course, these numbers would not have been attainable were it not for a new, larger exhibition center. The show's new home is the Bilbao Exhibition Center (BEC), which offers 60,000 square meters of exhibition space (41 percent more than the previous venue) and a layout that features six column-free exhibition halls.
Show organizers and Spain's association of machine tool manufacturers, known as AFM, have made strides to generate greater interest from the international metalworking community. It seems this effort has paid off, because this year's show drew visitors from 54 countries and featured 1,894 exhibitors from 34 countries. Of course, these numbers would not have been attainable were it not for a new, larger exhibition center. The show's new home is the Bilbao Exhibition Center (BEC), which offers 60,000 square meters of exhibition space (41 percent more than the previous venue) and a layout that features six column-free exhibition halls.
US machine tool sales soar in June - Materials Outlook - Brief Article
U.S. machine tool consumption totaled an estimated $244.6 million in June, up a whopping 67.1 percent from a revised $146.4 million the previous month but just 3.3 percent higher than $236.8 million in June 2002, according to a joint report by the American Machine Tool Distributors' Association (AMTDA), Rockville, Md., and the Association for Manufacturing Technology (AMT), McLean, Va. Noting the first monthly year-on-year increase since November 2000, AMT president Albert W. Moore said that "a single instance does not constitute a trend, but a trend must have a starting point." Machine tool consumption in the first half totaled $952.9 million, down 17.9 percent from $1.2 billion in the same period last year.
CAM software for probing: software for creating probing routines off-line promises to make machine tool probing easier to use. As a few examples show,
Shops and plants that are thinking of investing to realize a more automated process may be overlooking an automation tool that already waits in the machining center.
Through the use of a machining center's spindle-mounted probe, a shop can save time and effort in a variety of ways. Prior to machining, probing can be used to automatically confirm that the correct part has been loaded to match the program. Probing can also locate that part, wherever it sits on the table, so time-consuming setup might be eliminated. During machining, probing can check the semi-finished part to see how much of a finishing pass is needed. And after machining is done, probing can be used to perform certain inspections right at the machine tool, before the part is unclamped and taken away.
In fact, because probing can improve efficiency in so many different ways, it is probably sate to say that the probe is underused in almost every shop that owns one.
The shops themselves are not entirely to blame for this. Part of the reason probing is underused is the awkwardness that often comes with adding probing to the process. Shops generate milling and drilling tool paths with ease, using any of a variety of CAM systems. But probing calls for macros that are often either added to the NC code through manual editing, or else entered right at the CNC.
Some recently introduced software tools attempt to address this shortcoming. The systems described in the following pages make it more practical to program probing operations off-line. They could all be thought of as "CAM for probing," in that they generate machine-independent probing routines that can be postprocessed for individual machining centers. However, the three examples of probing software included here also represent three different ways of thinking about the way that probing is used.
One of the systems recognizes the probe-equipped machine tool as a metrology device. This system allows programs to be shared seamlessly between CMM and machine tool, and it allows the same analysis that is applied to CMM data to be applied to data captured with a machine tool probe.
Another system emphasizes the role of probing in specialized machining challenges, seeking to coordinate probing with the machining moves in cases where an important part of the job is unpredictable.
A third approach, and the first one described below, is intended simply to make probing in general a more natural part of the typical machining process. By operating as a plug-in within the CAM software that is used for tool paths, this utility expands the reach of the shop's primary CAM system to include probing moves.
Probing As A Plug-In
Productivity+, pronounced "productivity plus," is a CAM software plug-in from Renishaw (Hoffman Estates, Illinois), the maker of probes and probe accessories. Currently, the plug-in is available with GibbsCAM software from Gibbs & Associates (Moorpark, California).
The point of this plug-in is to allow the CAM software that uses it to call upon the probe as easily as it might call up any cutting tool in its library. That means probing no longer has to be a separate programming consideration apart from the tool paths. In addition to the convenience this provides, improved confidence is another benefit. Like the tool paths, the probing moves can be verified using the CAM software's own verification capability.
This utility supports probing for part setup, identification and inspection. It can also be used with the stationary tool setting probe to automate tool length and diameter measurements.
There is another version of the utility that is not a plug-in. Productivity+ Active Editor is a stand-alone software product. For existing CAM systems that do not include functionality for probing, this software lets the programmer import and modify NC programs, so the programmer can add probing moves as a follow-up step.
Probing The Unknown
PS-Fixture from Delcam (Windsor, Ontario) is part of the company's Power Solution family of integrated CAD/CAM products. That same family includes PowerMill software for generating NC part programs, and also PowerInspect software, which is capable of equipping these programs with probing routines. The focus of PS-Fixture lies between these modules. Its purpose has to do with putting probing to work in ways that overcome unknown variables in the machining of certain complex parts.
Exactly what variables are addressed can vary, depending on the application and the shop. For an ordinary part program, three things can be treated as known. They are: the precise position of the workpiece, the precise shape of the stock before machining and the precise shape that the machining program is supposed to create. When any one of these three aspects of the job cannot be known, PS-Fixture can potentially fill in the gaps.
Here are examples:
* Unknown work position. Plenty of production applications use dedicated, customized fixturing to lock a part in place precisely where the NC program expects to find it. But as the part size gets bigger, setting up the work that precisely becomes more difficult to do. Shifting and rotating a large workpiece can be time-consuming, not to mention fraught with error. It would be easier just to move the program instead--and that is what PS-Fixture attempts to do. After probing a complex workpiece in numerous locations, the software can use best-fit calculations in conjunction with a CAD model to determine the part's location and orientation in space. The software then sends a variety of offsets to the CNC that both shift and rotate the program's coordinate axes so that the program aligns with the part.
Wednesday, September 13, 2006
Mittler Brothers Machine & Tool Moves into Larger Facility & Adds New Equipment
Mittler Brothers Machine & Tool has recently moved to a new facility in Wright City, Missouri Oust west of St. Louis) and installed new CNC equipment and expanded its capabilities.
The 25-year-old firm produces, tools, dies and special machines as well as offering custom CNC machining and fabrication. The company also produces its own lines of products for the racing industry.
The Mittler brothers (Mike and Paul) started their business with the two of them as the only employees in a 2,500-sq.-ft. facility. They eventually grew into 30,500sq.-ft. of space across three adjacent buildings in Foristell, Missouri.
The current and planned growth of the company led the brothers to move to a 3year-old facility with 50,400-sq.-ft. in neighboring Wright City.
"The opportunity to consolidate our operations under one roof with room for expansion is tremendous," stated Mike Mittler.
Since the facility had been designed for manufacturing it has been a great fit for us," commented Paul
Mittler. "We haven't found anything that we would change in the layout or design."
With the larger space and growing business, the company quickly started adding new equipment. Two major pieces of CNC equipment have been added since the move took place.
One is an Okuma MA-40H horizontal machining center with a 10-pallet Fastems automatic loader. It features a 100-tool changer, a 40-taper 15,000-rpm spindle, and a table capacity of 24" x 28" up to 880 pounds.
Another new piece is a Haas SL20 CNC lathe with a magazine-style barfeeder. It features a 5hp motor with 3,000-rpm; a full C-axis on the spindle; a capacity of 24" between centers and live tooling.
"This equipment, with all the advanced technology, will allow us to improve our efficiency and expand our 'lights out' production," stated Mike Mittler.
Other new capabilities at the company include wet painting and shot blasting. Both booths were already in the facility. "The booths will enable us to improve our turnaround time and finish quality," noted Paul Mittler.
Mittler Brothers works with steel, tool steel, aluminum, stainless steel, brass, bronze, titanium and other exotic metals.
It serves such industries as automotive, medical, heavy transportation and automation.
Other equipment at the company includes: four CNC vertical machining centers; a 4-axis horizontal machining center; four CNC turning centers; an Okuma lathe with a Westech gantry loader (for unattended operation) and a CNC high definition plasma cutter.
CAD is used on all software and Virtual Gibbs CAM software is used for programming.
The 25-year-old firm produces, tools, dies and special machines as well as offering custom CNC machining and fabrication. The company also produces its own lines of products for the racing industry.
The Mittler brothers (Mike and Paul) started their business with the two of them as the only employees in a 2,500-sq.-ft. facility. They eventually grew into 30,500sq.-ft. of space across three adjacent buildings in Foristell, Missouri.
The current and planned growth of the company led the brothers to move to a 3year-old facility with 50,400-sq.-ft. in neighboring Wright City.
"The opportunity to consolidate our operations under one roof with room for expansion is tremendous," stated Mike Mittler.
Since the facility had been designed for manufacturing it has been a great fit for us," commented Paul
Mittler. "We haven't found anything that we would change in the layout or design."
With the larger space and growing business, the company quickly started adding new equipment. Two major pieces of CNC equipment have been added since the move took place.
One is an Okuma MA-40H horizontal machining center with a 10-pallet Fastems automatic loader. It features a 100-tool changer, a 40-taper 15,000-rpm spindle, and a table capacity of 24" x 28" up to 880 pounds.
Another new piece is a Haas SL20 CNC lathe with a magazine-style barfeeder. It features a 5hp motor with 3,000-rpm; a full C-axis on the spindle; a capacity of 24" between centers and live tooling.
"This equipment, with all the advanced technology, will allow us to improve our efficiency and expand our 'lights out' production," stated Mike Mittler.
Other new capabilities at the company include wet painting and shot blasting. Both booths were already in the facility. "The booths will enable us to improve our turnaround time and finish quality," noted Paul Mittler.
Mittler Brothers works with steel, tool steel, aluminum, stainless steel, brass, bronze, titanium and other exotic metals.
It serves such industries as automotive, medical, heavy transportation and automation.
Other equipment at the company includes: four CNC vertical machining centers; a 4-axis horizontal machining center; four CNC turning centers; an Okuma lathe with a Westech gantry loader (for unattended operation) and a CNC high definition plasma cutter.
CAD is used on all software and Virtual Gibbs CAM software is used for programming.
Machine Tool Consumption Up 38.4%
In August, US machine tool consumption amounted to $225.52 million, according to AMT-The Association For Manufacturing Technology (McLean, VA), and the American Machine Tool Distributors' Association (AMTDA, Rockville, MD). This number, reported by companies that participate in the US Machine Tool Consumption program, was up 6.4% from July and up 54.2% from the total of $146.27 million reported for August 2003. With a year-to-date total of $1778.59 million, 2004 is up 38.4% compared with 2003.
Jointly compiled by the two trade associations, the USMTC report provides regional and national consumption data on domestic and imported machine tools and related equipment. Machine tool consumption in the US is also reported on a regional basis for five geographic breakdowns.
August machine tool consumption in the Northeast Region totaled $31.39 million, up 5.0% when compared to July's $29.89 million, and 20.6% ahead of August 2003. At $259.45 million, year-to-date machine tool consumption has increased 48.0%.
In the Southern Region, machine tool consumption in August was $32.62 million, 17.6% less than July's $39.59 million, but up 34.8% when compared to last August. Year-to-date, the total consumption of $270.92 million is a 5.4% drop when compared to the same time last year.
At $80.96 million, the August machine tool consumption in the Midwestern Region was 1.6% higher than July's $79.72 million, and 58.9% higher than the total for August 2003. With a year-to-date total of $710.59 million in consumption, the year 2004 is running 46.5% ahead of 2003 at the same time.
Central Region machine tool consumption in August, at $44.06 million, was 20.8% ahead of July's $36.49 million, and up 67.3% from the August 2003 report. Totaling $309.22 million, year-to-date 2004 machine-tool consumption was 47.3% higher than the comparable figure for 2003.
In the Western region, August machine tool consumption reached $36.48 million, up 39.1% compared to the $26.22 million total for July, and 94.4% higher than the August 2003 total. At $228.40 million, year-to-date 2004 is an impressive 77.9% ahead of the same period in 2003.
Jointly compiled by the two trade associations, the USMTC report provides regional and national consumption data on domestic and imported machine tools and related equipment. Machine tool consumption in the US is also reported on a regional basis for five geographic breakdowns.
August machine tool consumption in the Northeast Region totaled $31.39 million, up 5.0% when compared to July's $29.89 million, and 20.6% ahead of August 2003. At $259.45 million, year-to-date machine tool consumption has increased 48.0%.
In the Southern Region, machine tool consumption in August was $32.62 million, 17.6% less than July's $39.59 million, but up 34.8% when compared to last August. Year-to-date, the total consumption of $270.92 million is a 5.4% drop when compared to the same time last year.
At $80.96 million, the August machine tool consumption in the Midwestern Region was 1.6% higher than July's $79.72 million, and 58.9% higher than the total for August 2003. With a year-to-date total of $710.59 million in consumption, the year 2004 is running 46.5% ahead of 2003 at the same time.
Central Region machine tool consumption in August, at $44.06 million, was 20.8% ahead of July's $36.49 million, and up 67.3% from the August 2003 report. Totaling $309.22 million, year-to-date 2004 machine-tool consumption was 47.3% higher than the comparable figure for 2003.
In the Western region, August machine tool consumption reached $36.48 million, up 39.1% compared to the $26.22 million total for July, and 94.4% higher than the August 2003 total. At $228.40 million, year-to-date 2004 is an impressive 77.9% ahead of the same period in 2003.
Monday, September 11, 2006
Ceramic balls—Saint Gobain Advanced Ceramics, booth D-427 - Machine Tool Components and Accessories
According to the manufacturer, Cerbec ceramic balls for bearing applications last longer and provide better performance than steel bearings because of their inherently lower thermal expansion; smoother surface; increased hardness and stiffness; lighter weight; and corrosion/electricalresistant properties. These attributes recommend the use of these ceramic balls for bearings, linear guideways and machine tool spindles.
Autonomous robot cell—Motoman, booth B-6000 - Machine Tool Components and Accessories
In the A.R.C., autonomous robotic cell, one Motoman robot positions parts for one or more additional process robots, eliminating the need for complex part fixtures and positionsers. According to the company, multiple-station processing allows parts to be completed within one workcell, and speeds throughput by eliminating transfer time.
Also on display will be the inverted-mount U50 robot from a servo-controlled overhead rail that is said to save floor space and improve access to two lathes durng tool changes, and the UP20 robot wall-mounted from a servo gallows to provide the extended reach needed to tend three boring and tapping machine tools.
Also on display will be the inverted-mount U50 robot from a servo-controlled overhead rail that is said to save floor space and improve access to two lathes durng tool changes, and the UP20 robot wall-mounted from a servo gallows to provide the extended reach needed to tend three boring and tapping machine tools.
Fully hydrostatic tool grinding machine—Rollomatic, booth B-6838 - Grinding/Abrasive Machining Equipment
The GrindSmart 6000XL is a fully hydrostatic grinding machine. Hydrostatic functions allow friction-free linear and rotary movements for all six axes, including grinding spindle, to enhance the accuracy, speed, rigidity and perpetual repeatability of the machine in production, according to the company.
The machine is a fully automated, CNC super-precision grinding center with six hydrostatic machine axis and three axis for the integrated robot load/unload station. It is designed for the complete manufacture of small-to large-diameter carbide and HSS cutting tools in one clamping with a range of 0.1 mm (0.008") to 32.0 mm (1.250") in diameter.
Also on display will be the GrindSmart 620XS universal tool grinding machine for production grinding of rotary cutting tools in the size range of 0.2 to 16 mm (0.008" to 0.625").
The machine is a fully automated, CNC super-precision grinding center with six hydrostatic machine axis and three axis for the integrated robot load/unload station. It is designed for the complete manufacture of small-to large-diameter carbide and HSS cutting tools in one clamping with a range of 0.1 mm (0.008") to 32.0 mm (1.250") in diameter.
Also on display will be the GrindSmart 620XS universal tool grinding machine for production grinding of rotary cutting tools in the size range of 0.2 to 16 mm (0.008" to 0.625").
Saturday, September 09, 2006
Balanceable toolholder system—Rego-Fix Tool, booth E-2623 - Machine Tool Components and Accessories - Brief Article
The new Hi-Q ring system can be added to any standard holder that has the necessary mounting surface. According to the company, its new balancing ring system will help manufacturers and machine shops meet these balancing requirements. For smooth operation at higher speeds, holders must be balanced to meet the specifications set by machine and tooling manufacturers.
Most holders currently being manufactured by the company will accept the new rings. While the design of the new holders has changed, the end user will get the same high quality with added features as holders purchased in the past, the company says.
The company will also be displaying a new tabletop balancing machine that allows users to balance the Hi-Q balancing ring system using the angular method, or to balance existing holders by material subtraction, material addition or fixed position.
Most holders currently being manufactured by the company will accept the new rings. While the design of the new holders has changed, the end user will get the same high quality with added features as holders purchased in the past, the company says.
The company will also be displaying a new tabletop balancing machine that allows users to balance the Hi-Q balancing ring system using the angular method, or to balance existing holders by material subtraction, material addition or fixed position.
Machine tool economics
The 2004-2005 Economic Handbook of the Machine Tool Industry is now available from AMT--The Association for Manufacturing Technology. This annual guide offers the latest information about the domestic and international machine tool industries, as well as their respective economies. It was compiled from hundreds of domestic and foreign sources, and both product- and company-specific machine tool data are included. Information about capital equipment purchases is outlined for several major consuming industries. The domestic data cover areas such as employment, machine tool shipments, machine tools in use, and the financial condition of the industry. The handbook also provides a range of international facts for almost two dozen foreign countries, typically including production, imports and exports by type of machine tool. The handbook is free to AMT members, or $295 plus $5 postage and handling for non-members.
Machine Tool Sales Hit Four-Year High
Manufacturing industry optimism continued to pay dividends for equipment builders as sales of US machine tools in September reached the highest level in four years. With September sales totaling $389.20 million, machine tool builders saw an increase in sales of 74.6% over $222.86 million reported for September 2003, according to the latest figures of the US Machine Tool Consumption (USMTC) report released by the American Machine Tool Distributors' Association (AMTDA, Rockville, MD) and AMT-The Association For Manufacturing Technology (McLean, VA).
The latest report showed sales rose 89.8% in September compared to August sales of $205.01 million, and the 2004 year-to-date total of $2146.95 million rose 42.2% versus 2003 sales of $1509.41 million through September. The figures are based on the totals of actual data reported by companies participating in the USMTC program.
"Manufacturing in the US continues to show signs of a strong comeback," according to AMTDA President Ralph J. Nappi. "Machine tool orders in September hit their highest level in four years with all regions of the country showing growth."
Regional sales showed strong overall gains paced by robust improvements in the West Region, which totaled September sales of $56.07 million, an increase of 72.1% over $32.59 million in August sales and a 196.1% leap over the September 2003 total of $18.94 million. The West Region's year-to-date total of $279.39 million rose 89.6% over September 2003 sales of $147.33 million.
In the Midwest, September sales of $162.77 million rose 156.5% over the prior month's $63.47 million in sales and increased 46.6% compared with sales of $111.03 million during September 2003. With a year-to-date total of $853.66 million, the Midwest region is 43.2% ahead of $595.99 in sales through September 2003.
With September sales of $72.47 million, the Central Region machine tool consumption increased 50.6% compared to $48.13 million in August and sales were up 115.4% over September 2003 sales of $33.64 million. With a year-to-date total of $386.50 million, the Central Region sales are up 58.7% compared to the YTD 2003 sales of $243.58 million.
Northeast Region sales of $55.03 million rose 102.3% compared to August's $27.21 million and 98.0% compared to $27.79 million last September. At $312.64 million, year-to-date machine tool consumption in the Northeast ran 52.7% higher than $204.71 million through September 2003.
In the South Region, September machine tool consumpdon totaled $42.85 million, 27.5% higher than the $33.62 million in August and 36.2% higher than $31.46 million for September a year ago. The year-to-date South Region total of $314.77 million fell 1.0% compared to $317.80 million through September 2003.
The latest report showed sales rose 89.8% in September compared to August sales of $205.01 million, and the 2004 year-to-date total of $2146.95 million rose 42.2% versus 2003 sales of $1509.41 million through September. The figures are based on the totals of actual data reported by companies participating in the USMTC program.
"Manufacturing in the US continues to show signs of a strong comeback," according to AMTDA President Ralph J. Nappi. "Machine tool orders in September hit their highest level in four years with all regions of the country showing growth."
Regional sales showed strong overall gains paced by robust improvements in the West Region, which totaled September sales of $56.07 million, an increase of 72.1% over $32.59 million in August sales and a 196.1% leap over the September 2003 total of $18.94 million. The West Region's year-to-date total of $279.39 million rose 89.6% over September 2003 sales of $147.33 million.
In the Midwest, September sales of $162.77 million rose 156.5% over the prior month's $63.47 million in sales and increased 46.6% compared with sales of $111.03 million during September 2003. With a year-to-date total of $853.66 million, the Midwest region is 43.2% ahead of $595.99 in sales through September 2003.
With September sales of $72.47 million, the Central Region machine tool consumption increased 50.6% compared to $48.13 million in August and sales were up 115.4% over September 2003 sales of $33.64 million. With a year-to-date total of $386.50 million, the Central Region sales are up 58.7% compared to the YTD 2003 sales of $243.58 million.
Northeast Region sales of $55.03 million rose 102.3% compared to August's $27.21 million and 98.0% compared to $27.79 million last September. At $312.64 million, year-to-date machine tool consumption in the Northeast ran 52.7% higher than $204.71 million through September 2003.
In the South Region, September machine tool consumpdon totaled $42.85 million, 27.5% higher than the $33.62 million in August and 36.2% higher than $31.46 million for September a year ago. The year-to-date South Region total of $314.77 million fell 1.0% compared to $317.80 million through September 2003.
Friday, September 01, 2006
Getting to submicron accuracy: as machine tool builders introduce models designed for submicron accuracies and subminiature workpieces, a variety of d
In nature, scientists are sometimes able to distinguish one species from another only by examining DNA, the unique genetic code in every living cell. In these cases, external appearances do not offer reliable clues. This is much the case with a new breed of vertical machining centers designed for submicron accuracy. These machines do not look strikingly different from other precision machine tools. Yet the submicron model has hidden features and subtle attributes that prove it to be a very different creature, one that has evolved to function in an environment where microns and nanometers (millionths and billionths of a meter) are critical.
Some of the ways in which these machines are likely to deviate from normal expectations for a VMC can be observed in the Hyper2J from Makino (U.S. headquarters in Mason, Ohio). Comparable models from other builders may represent further radical departures from the norm, but looking at this machine helps us understand the design factors that tend to define the "nature of the beast." The chief factors are vibration, heat, rigidity and control unit capability.
* The four-point leveling mounts underneath the Hyper2J rest on a base made of metrology-grade granite that is 250 mm (almost 10 inches) thick. This granite "foundation" isolates the machine structure from vibration in the floor. Granite has 1/10 to 1/20 the thermal conductivity of cast iron, so it resists the effects of ambient temperature changes.
* The spindle is designed to reduce vibration and counter thermal growth. It has a direct tool clamping system that does not require a toolholder or collet. A mechanism inside the spindle uses hydraulic pressure to collapse around the tool shank, much the way the individual hydraulic toolholder would. According to the designers, this feature minimizes rotational vibration inevitably introduced by imperfections in a separate toolholder. Minimizing vibration is a priority because super small cutting tools (end mills with a diameter of 0.03 mm are typical) are susceptible to breakage when subjected to minute vibrations.
* The internal temperature of the spindle is maintained by automatically cooling the lubricant that circulates through it. The work light inside the machine uses LEDs because they are much cooler than other types of lights.
Spindle speeds range from 3,000 to 40,000 rpm (a 170,000-rpm spindle is available.)
* There are no linear motors. Makino has opted for ballscrews and slideways for axis drives, citing the company's ability to achieve the necessary straightness and smoothness in its production techniques. Maximum feed rates and rapid traverse rates are 12 m/min. (472 ipm).
* The machine has provisions for measuring the position of the tool tip to less than 1 micron. An "ultra-low pressure" contact-type measuring device determines tool length. A proximity-style non-contact spindle positioning device allows the position of the tool tip to be corrected in all three (X, Y and Z) axes. After a tool change, the level of machining surfaces will be higher or lower by less than 1 micron. To detect broken tool tips, an electrical current is transmitted through the cutting tool. If the tool breaks, the disrupted circuit triggers an alarm.
Interestingly, Makino says it has the most experience determining appropriate speeds and feeds for a 0.03-mm diameter carbide end mill. Machine settings for other tools are established on an application-by-application basis.
* The axis position feedback system uses a 0.5-nanometer scale to reliably track axis motion commands programmable in steps as small as 10 nanometers. Makino's stated positioning accuracy for this machine is [+ or -]0.3 micron, with a repeatability accuracy of [+ or -]0.2 micron.
* The control unit, which combines Fanuc hardware for CNC processing with a Windows CE graphical user interface, supports nanometer interpolation and millisecond block processing time. A proprietary "Super Geometry Intelligence" servo control system provides smooth machined surfaces. This kind of smoothing feature grows in importance as cutting tools and programmed steps become so small that workpiece features and tool marks approach the same size range.
Makinng Submicron Machining Practical Makino stresses that the Hyper2J is an attempt to make submicron machining in three axes practical for shops intent on moving to this level of accuracy. The company says that the machine is intended for the real world, not the laboratory. The Hyper2J does require a temperature-controlled room. Another version, the Hyper2, incorporates a thermal chamber for controlling its own temperature in ordinary shop environments to achieve submicron accuracy.
Some of the ways in which these machines are likely to deviate from normal expectations for a VMC can be observed in the Hyper2J from Makino (U.S. headquarters in Mason, Ohio). Comparable models from other builders may represent further radical departures from the norm, but looking at this machine helps us understand the design factors that tend to define the "nature of the beast." The chief factors are vibration, heat, rigidity and control unit capability.
* The four-point leveling mounts underneath the Hyper2J rest on a base made of metrology-grade granite that is 250 mm (almost 10 inches) thick. This granite "foundation" isolates the machine structure from vibration in the floor. Granite has 1/10 to 1/20 the thermal conductivity of cast iron, so it resists the effects of ambient temperature changes.
* The spindle is designed to reduce vibration and counter thermal growth. It has a direct tool clamping system that does not require a toolholder or collet. A mechanism inside the spindle uses hydraulic pressure to collapse around the tool shank, much the way the individual hydraulic toolholder would. According to the designers, this feature minimizes rotational vibration inevitably introduced by imperfections in a separate toolholder. Minimizing vibration is a priority because super small cutting tools (end mills with a diameter of 0.03 mm are typical) are susceptible to breakage when subjected to minute vibrations.
* The internal temperature of the spindle is maintained by automatically cooling the lubricant that circulates through it. The work light inside the machine uses LEDs because they are much cooler than other types of lights.
Spindle speeds range from 3,000 to 40,000 rpm (a 170,000-rpm spindle is available.)
* There are no linear motors. Makino has opted for ballscrews and slideways for axis drives, citing the company's ability to achieve the necessary straightness and smoothness in its production techniques. Maximum feed rates and rapid traverse rates are 12 m/min. (472 ipm).
* The machine has provisions for measuring the position of the tool tip to less than 1 micron. An "ultra-low pressure" contact-type measuring device determines tool length. A proximity-style non-contact spindle positioning device allows the position of the tool tip to be corrected in all three (X, Y and Z) axes. After a tool change, the level of machining surfaces will be higher or lower by less than 1 micron. To detect broken tool tips, an electrical current is transmitted through the cutting tool. If the tool breaks, the disrupted circuit triggers an alarm.
Interestingly, Makino says it has the most experience determining appropriate speeds and feeds for a 0.03-mm diameter carbide end mill. Machine settings for other tools are established on an application-by-application basis.
* The axis position feedback system uses a 0.5-nanometer scale to reliably track axis motion commands programmable in steps as small as 10 nanometers. Makino's stated positioning accuracy for this machine is [+ or -]0.3 micron, with a repeatability accuracy of [+ or -]0.2 micron.
* The control unit, which combines Fanuc hardware for CNC processing with a Windows CE graphical user interface, supports nanometer interpolation and millisecond block processing time. A proprietary "Super Geometry Intelligence" servo control system provides smooth machined surfaces. This kind of smoothing feature grows in importance as cutting tools and programmed steps become so small that workpiece features and tool marks approach the same size range.
Makinng Submicron Machining Practical Makino stresses that the Hyper2J is an attempt to make submicron machining in three axes practical for shops intent on moving to this level of accuracy. The company says that the machine is intended for the real world, not the laboratory. The Hyper2J does require a temperature-controlled room. Another version, the Hyper2, incorporates a thermal chamber for controlling its own temperature in ordinary shop environments to achieve submicron accuracy.
Enhancing machine tool productivity
In addition to quickly responding to customer demands, job shops can also reduce programming, tooling and production times with ShopMill version 6.4, says manufacturer Siemens.
Featuring step-by-step, onscreen programming, the software includes 3D views with simulation, including real-time simulation: an engraving cycle; an enhanced tooling list with angle head cutter definition, tap definition and Pace mill geometry; and enhanced workpiece measurements in manual mode.
Users are provided with a 3D view of the part to be cut while in simulation or real-time mode. As a result, possible machining errors can be detected relatively early, says the company.
The new engraving cycle offers the capability of engraving complex text on a radius. This single-button feature can be useful when engraving serial numbers, company names, and dates and times on cut parts.
Additionally, the software can be used in conjunction with the Sinumerik 810D or 840D while running Windows XP.
Featuring step-by-step, onscreen programming, the software includes 3D views with simulation, including real-time simulation: an engraving cycle; an enhanced tooling list with angle head cutter definition, tap definition and Pace mill geometry; and enhanced workpiece measurements in manual mode.
Users are provided with a 3D view of the part to be cut while in simulation or real-time mode. As a result, possible machining errors can be detected relatively early, says the company.
The new engraving cycle offers the capability of engraving complex text on a radius. This single-button feature can be useful when engraving serial numbers, company names, and dates and times on cut parts.
Additionally, the software can be used in conjunction with the Sinumerik 810D or 840D while running Windows XP.
Fast and flexible - EMO, machine tool show
This year's EMO - he premier European machine tool show - saw that continent's builders once again focused on innovative, but practical, product development.
When EMO was last held in Hannover, Germany, four years ago, the show was in a word, depressing. The mighty German machine tool industry, as well as the rest of Europe, was mired in the worst slump in a generation. And the news from this normally technologically elite exhibition had more to do with corporate realignments and cost reduction than with anything else, as so many European companies were moving into a survival mode reminiscent of the American machine tool industry of the mid 1980s.
This time around, however, the story was very different. While the general European economy is still in recession, conditions are far better for the machine tool builders. For one thing, the builders as a group are on stronger financial footing, having cut much of the fat out of their organizations and having established more viable business alignments - we'd call them mergers and acquisitions - where individual companies were in serious trouble going it alone. And equally important, European manufacturing in general is stepping up its investment again, cognizant of the need to cut costs through the development of more efficient production processes.
This situation, thankfully, has many European machine tool builders returning to more aggressive product development strategies of their own. While, like usual, many builders are pursuing a range of approaches to solving the manufacturing puzzle, there were some strong themes that played consistently throughout the halls of EMO. Most apparent were the notions of achieving greater speed and flexibility. By speed, we mean machines that move faster both in and out of the cut. And by flexibility, we mean machines that set up faster or otherwise move more deftly from one workpiece to the next. Here are some of the ways those ideas were on display at EMO.
Simply Fast
Perhaps the most striking presence at EMO is how commonplace high speed machining has become. Most of the leading European machining center builders had high speed models on display, and not just machines with fast spindles, but with significant other machine features that support accurate contouring at high feed rates as well.
High speed spindle makers are looking both to push the speed-and-power combination higher and to make their designs more dependable. Urged on largely by the aerospace industry, some builders are actively pursuing the technological goal of building a 100/100 (100,000 rpm/100 kW) spindle. But more are focused on addressing some lingering practical concerns in the 20,000 to 40,000 rpm range, which is growing common. Once such concern is service life. Currently a good life for a high speed spindle is 3,000 to 6,000 hours. That translates to just about two years.
High speed spindle failure is generally not catastrophic, says Siegfried Weiss, president of the German high speed spindle builder Weiss GmbH (Dyna Drive, Inc., Mentor, Ohio). "We've found that spindles are subjected to numerous little wrecks that over time that add up to a failure." According to Bill Popoli, president of the U.S. arm of Swiss spindle maker Ibag (Milford, Connecticut), there is a need for shops to understand that high speed spindles are not as "tough" as spindles found on standard machine tools. Still, it is a goal for Ibag and other spindle builders to get average service life up to five years.
As for control capabilities, it seems like the whole industry has upgraded to high speed CNCs capable of executing extraordinarily accurate cutter paths at very high feed rates - an enabling technology that has machining centers cutting everything from hardened tool steels (as hard as 62 Rc) to cast iron and aluminum auto and aerospace parts. For die/ mold machining, the newest capability now in the spotlight is curve interpolation, which a number of machine tool builders were touting - mainly those with Siemens and GE Fanuc controls. This feature allows complex curves such as non-uniform rational B-splines (NURBS) to be imported directly into the CNC rather than having to approximate those curves with point-to-point moves as is done in conventional contouring. The CNC interpolator then references the true curve math to contour more accurately, smoothly and, by most accounts, much faster too.
However, not everyone believes that curve interpolation is yet the total answer for high performance contouring. German control builder Heidenhain, Schaumburg, Illinois, for instance, thinks that curve interpolation makes sense only where data points in a conventional part program are clustered too close together to maintain a desirable feed rate. The far larger issue, they contend, is to apply look-ahead capabilities for the sake of real time "jerk control" - that is, to soften abrupt moments of axis acceleration and deceleration in order to create a smoother execution of conventional point-to-point contouring cuts. And that is a feature the builder was emphasizing, though they have introduced a curve interpolator as well.
When EMO was last held in Hannover, Germany, four years ago, the show was in a word, depressing. The mighty German machine tool industry, as well as the rest of Europe, was mired in the worst slump in a generation. And the news from this normally technologically elite exhibition had more to do with corporate realignments and cost reduction than with anything else, as so many European companies were moving into a survival mode reminiscent of the American machine tool industry of the mid 1980s.
This time around, however, the story was very different. While the general European economy is still in recession, conditions are far better for the machine tool builders. For one thing, the builders as a group are on stronger financial footing, having cut much of the fat out of their organizations and having established more viable business alignments - we'd call them mergers and acquisitions - where individual companies were in serious trouble going it alone. And equally important, European manufacturing in general is stepping up its investment again, cognizant of the need to cut costs through the development of more efficient production processes.
This situation, thankfully, has many European machine tool builders returning to more aggressive product development strategies of their own. While, like usual, many builders are pursuing a range of approaches to solving the manufacturing puzzle, there were some strong themes that played consistently throughout the halls of EMO. Most apparent were the notions of achieving greater speed and flexibility. By speed, we mean machines that move faster both in and out of the cut. And by flexibility, we mean machines that set up faster or otherwise move more deftly from one workpiece to the next. Here are some of the ways those ideas were on display at EMO.
Simply Fast
Perhaps the most striking presence at EMO is how commonplace high speed machining has become. Most of the leading European machining center builders had high speed models on display, and not just machines with fast spindles, but with significant other machine features that support accurate contouring at high feed rates as well.
High speed spindle makers are looking both to push the speed-and-power combination higher and to make their designs more dependable. Urged on largely by the aerospace industry, some builders are actively pursuing the technological goal of building a 100/100 (100,000 rpm/100 kW) spindle. But more are focused on addressing some lingering practical concerns in the 20,000 to 40,000 rpm range, which is growing common. Once such concern is service life. Currently a good life for a high speed spindle is 3,000 to 6,000 hours. That translates to just about two years.
High speed spindle failure is generally not catastrophic, says Siegfried Weiss, president of the German high speed spindle builder Weiss GmbH (Dyna Drive, Inc., Mentor, Ohio). "We've found that spindles are subjected to numerous little wrecks that over time that add up to a failure." According to Bill Popoli, president of the U.S. arm of Swiss spindle maker Ibag (Milford, Connecticut), there is a need for shops to understand that high speed spindles are not as "tough" as spindles found on standard machine tools. Still, it is a goal for Ibag and other spindle builders to get average service life up to five years.
As for control capabilities, it seems like the whole industry has upgraded to high speed CNCs capable of executing extraordinarily accurate cutter paths at very high feed rates - an enabling technology that has machining centers cutting everything from hardened tool steels (as hard as 62 Rc) to cast iron and aluminum auto and aerospace parts. For die/ mold machining, the newest capability now in the spotlight is curve interpolation, which a number of machine tool builders were touting - mainly those with Siemens and GE Fanuc controls. This feature allows complex curves such as non-uniform rational B-splines (NURBS) to be imported directly into the CNC rather than having to approximate those curves with point-to-point moves as is done in conventional contouring. The CNC interpolator then references the true curve math to contour more accurately, smoothly and, by most accounts, much faster too.
However, not everyone believes that curve interpolation is yet the total answer for high performance contouring. German control builder Heidenhain, Schaumburg, Illinois, for instance, thinks that curve interpolation makes sense only where data points in a conventional part program are clustered too close together to maintain a desirable feed rate. The far larger issue, they contend, is to apply look-ahead capabilities for the sake of real time "jerk control" - that is, to soften abrupt moments of axis acceleration and deceleration in order to create a smoother execution of conventional point-to-point contouring cuts. And that is a feature the builder was emphasizing, though they have introduced a curve interpolator as well.
KMG Tool & Machine Co. adds more CNC equipment
KMG Tool & Machine Co., Wichita, Kansas, has recently added more CNC equipment.
The 22-year-old firm, which specializes in tooling, precision machining, welding and fabrication, is adding the equipment to handle larger-sized jobs.
Two pieces of equipment were recently installed. The first is a Mazak AN 60/120 3-axis vertical machining center with a 124"X, 58"Y and 23"Z.
The other piece is a Mazak SV-25 4-axis vertical machining center, which features an 80-tool changer.
"This equipment was needed to handle the larger parts and will also help us expand our customer base," stated KMG Tool & Machine's Mike Coffey.
Other equipment in the company's 24,000-sq.-ft. facility includes: a Flow waterjet (6.5' x 24'); a Mazak CNC lathe, four CNC mills; numerous vertical and horizontal mills; grinding equipment; and an 8,000-sq.-ft welding shop (AWS certified) with aluminum-Heli-Arc, steel-MIG, Tig and Arc welding.
KMG works with CATIA version 4 and 5 CAD software and SMARTCAM software with full 3D surfacing, 411 axis and 5th axis indexing.The company also has a QC lab with a CMM (48" x 78") and meets the requirements for DI-9000A, MIL-I-45208A and is a delegated source inspector.
"Our employees have an average of 25 years experience building quality tooling and production parts," stated KMG's Ken Coffey.
He noted that KMG has built long-term relationships with several suppliers and can provide such services as: heat treating; plating; broaching; precision grinding; sandblasting and painting.
The 22-year-old firm, which specializes in tooling, precision machining, welding and fabrication, is adding the equipment to handle larger-sized jobs.
Two pieces of equipment were recently installed. The first is a Mazak AN 60/120 3-axis vertical machining center with a 124"X, 58"Y and 23"Z.
The other piece is a Mazak SV-25 4-axis vertical machining center, which features an 80-tool changer.
"This equipment was needed to handle the larger parts and will also help us expand our customer base," stated KMG Tool & Machine's Mike Coffey.
Other equipment in the company's 24,000-sq.-ft. facility includes: a Flow waterjet (6.5' x 24'); a Mazak CNC lathe, four CNC mills; numerous vertical and horizontal mills; grinding equipment; and an 8,000-sq.-ft welding shop (AWS certified) with aluminum-Heli-Arc, steel-MIG, Tig and Arc welding.
KMG works with CATIA version 4 and 5 CAD software and SMARTCAM software with full 3D surfacing, 411 axis and 5th axis indexing.The company also has a QC lab with a CMM (48" x 78") and meets the requirements for DI-9000A, MIL-I-45208A and is a delegated source inspector.
"Our employees have an average of 25 years experience building quality tooling and production parts," stated KMG's Ken Coffey.
He noted that KMG has built long-term relationships with several suppliers and can provide such services as: heat treating; plating; broaching; precision grinding; sandblasting and painting.
Wednesday, August 30, 2006
Millions of components machined to millionths - Street Smarts - machine tool tolerances
"Inch worm, inch worm. Measuring the marigolds. Seems to me you'd stop and see how beautiful they are."
Let me tell you something about inch worms. We couldn't live without them.
In 1958 a U.S. Air Force contract was let to MIT and Giddings & Lewis Machine Tool to retrofit a standard boring mill for completely automatic operation. The result was the first numerically controlled machine tool, at least in North America. Kearney & Trecker came up with the automatic tool changer and it was off to the races. The advent of PLCs and microprocessors accelerated the manufacturing revolution.
I used to argue with my father that this was clearly the greatest advance in manufacturing in the second half of the 1900s. As he was chief of metrology for the U.S. Army Signal Corps in the early 1970s, his perspective was a little different. He insisted the coordinate measuring machine (CMM) and laser alignment were more important because they provided the foundation for accuracy and interchangeability on a repeatable basis. It really made plants interchangeable as well as parts.
A story told to me many years ago said that it was Henry Ford who brought back the first set of Johansson gauge blocks from Europe to the U.S. to put a sound metrology backbone into his flourishing enterprise. Jo blocks became standard throughout industry but they had limitations. They were ground to an accuracy of 1/100,000th of an inch. The accuracy of anything aligned with Jo blocks would thus be somewhat less than that. And the farther away you got from the master blocks, the looser the assured accuracy would be.
All this came to mind recently as I was visiting the Indianapolis diesel engine plant of International Truck and Engine and later the Sharonville transmission plant of Ford Motor Co. These are the respective homes of the new 6.0 L Power Stroke Diesel and the new R5 TorqShift automatic transmission. The Sharonville plant has recently received the highest score for quality among all Ford powertrain plants.
It is remarkable that both the engines and the transmissions have parts that are machined to the micron level, one millionth of an inch. That means that such parts are actually 10 times more accurate than yesterday's Jo blocks. Just think about that.
The superior shifting characteristics and durability of the new R5 are grounded in the ability to machine to the micron level. The new Siemens G-2 fuel injectors could not approach the level of performance required without micron level accuracy.
It's one thing to achieve micron level accuracy with a couple of parts, but now we're doing it with millions of parts and while it isn't exactly SOP at this point, it is not unusual either. When necessary, it is an advanced weapon available in today's arsenal of mass production manufacturing technology.
Not so long ago, injector parts were often sorted into undersize and oversize classes after machining was complete and then selectively assembled with other components that were broken down the same way Well, that just doesn't cut it anymore. And tell me that isn't an extremely expensive proposition.
Imagine producing over 8000 injectors per day in Carolina and getting them to Indianapolis JIT for tomorrow's 6.0 L production. You sure want to keep selective assembly to a minimum. High precision machining does have an economic payoff. Can you image the havoc that could be wrought by a bad batch of injectors?
There is an extreme need for consistency in order to meet performance and emission standards now and even more so in the future. When we are getting into pilot injection and rate shaping, playing with post injection, when we are peeling a second like an onion, when we need a very precise amount of fuel delivered with an exact atomization pattern, our dependence on micron level accuracy in parts production will only become greater.
It is only with the more accurate metrology base that we have been able to field the new generation of powertrain components and systems. And this is the base on which future progress depends. In short, only the inch worms can help us build a better marigold.
Subscribe to:
Posts (Atom)
