Combining concepts of CoroMill 390 and CoroTurn 107, CoroPlex(TM) MT is applied rotating as effective tool for milling applications, or indexed in number of optional positions for stationary turning using 2 different inserts. Multi-tasking machining tool is designed for use of all insert positions possible without support of any extra software. It is also usable on older machines working with software capacity limited to conventional standard cycles.
********************
By introducing the multifunctional CoroPlex(TM) MT Sandvik Coromant establishes a new standard that is of outmost user benefit for operations performed with the latest of machine tool technologies.
CoroPlex MT is a combination of two winning concepts in one - CoroMill 390 and CoroTurn 107. It is either applied rotating as an effective tool for milling applications - or indexed in a number of optional positions for stationary turning using two different CoroTurn 107 inserts.
Sandvik Coromant[acute accent]s multifunctional tool CoroPlex MT is designed for practically unrestricted use of all the insert positions possible without support of any extra software Although CoroPlex MT is dedicated for Multi-Task machining it is easy to use the tool in somewhat older machines working with the software capacity limited to conventional standard cycles.
CoroPlex(TM) MT is an innovative multifunctional tool for finishing the workpieces in a single set-up with reduced downtime on the machine.
It also completes together with CoroPlex TT twin tools, with two inserts in one holder giving the possibility to change operations momentarily, and CoroPlex SL mini-turret, with four turning tools in one, the dedicated tooling Sandvik Coromant provides Multi-Task machining.
Saturday, December 16, 2006
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.
Friday, December 15, 2006
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.
********************
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 aircraftCurrently, 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.
Thursday, December 14, 2006
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 answersfitness 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.
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.
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.
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.
Wednesday, December 13, 2006
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.
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.
********************
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
********************
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
Tuesday, December 12, 2006
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).
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).
Monday, December 11, 2006
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.
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.
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.
Sunday, December 10, 2006
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.
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.
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.
Saturday, December 09, 2006
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.
********************
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.
********************
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.
********************
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.
********************
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.
Friday, December 08, 2006
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:
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.
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.
Subscribe to:
Posts (Atom)
