Archive for the ‘Lathe’ Category

Machining refers to the industrial process of cutting and fabricating metals and other materials into predetermined shapes and sizes. Machining process is controlled with the help of computer numeric control (CNC) software that guides the cutting equipment along the lines and arcs of a computer aided design (CAD) drawing.

A machining process may involve the use of different techniques depending on the number of parts being manufactured and the type of material. Machining techniques may include manual machining, which is used for cutting metal sheets in simple shapes such as circular, square, and rectangular. This process is however being replaced by automatic machining systems and processes that can cut any type of shape out of metal sheets needed for different purposes.

Chemical etching machining technique is mainly used for producing typical precision parts. The machining system offers a great flexibility for producing precision parts with unusual configuration as well as metals with tight tolerance within .0005′. Besides this, chemical etching machining is capable of producing small holes and bars that are not possible with other machining techniques. Another common process is Wire Electrical-Discharge Machining (EDM) in which the metal is separated from a conductive work piece by means of electrical erosion. During this process, the wire never touches the conductive work piece and leaves a path on the work piece, which is slightly larger than the wire.

Another technique known as the metal stamping machining phenomenon, which is also referred to as progressive die stamping or long run metal stamping, is extensively used in production of precision parts with thickness from .002′ to .135′. The technique is mainly used for processing typical low price parts that are formed into three dimensions.

Apart from these, some modern techniques are also in use such as abrasive water jet and laser machining that are more accurate and environment friendly as compared to conventional machining techniques.

Originally posted 2007-09-30 09:18:07. Republished by Blog Post Promoter

Originally posted 2008-02-12 00:43:38. Republished by Blog Post Promoter

Precision machining is a process that is used to produce a large number of both large as well as small objects that we make use of in our daily lives. Each intricate and detailed piece that makes up an object needs the touch of a machinist’s skills. Similarly, a machine or tool that is worn down will require the action of machine tool calibration quite frequently. There are also other facilities provided by precision machining apart from calibration. These would be detailed welding or grooving carried out by a precision machinist. Ranging from aircraft aluminum alloy production right till devices for surgically drilling of bones precision machining caters to almost every industry and technology. Put simply, if an object is made of parts, it would have needed precision machining.

While the majority of precision machining companies usually work with one form of CAD/CAM programs or another, they still do often work with sketches that are hand drawn. Although the hand sketches are usually made use of only in the initial phases of a design. Precision machining can be used on a variety of materials that include graphite, bronze, steel, plastics and glass to name just a few. Based on the project size and the materials that are to be used, different kinds of precision machining tools are put to use. Precision machining is indispensable to numerous industries and various kinds of technologies. Without precision machining we would be unable to manufacture a number of detailed and intricate parts of various objects. The detail and accuracy it brings into the manufacturing procedure is what renders precision machining as so indispensable. There is a long list of machining companies that specialize in precision machining and you can use the Internet to locate them and avail their services. Precision machining is an integral part of mechanical and manufacturing industries.

Originally posted 2007-09-28 01:46:30. Republished by Blog Post Promoter

As every one knows, chips are formed during the machining of workpieces. The side of the chip in contact with the cutting tool is normally shiny, flat and smooth while the other side, which is the free workpiece surface, is jagged due to shear.

It is important to study the formation of chips during the machining process as the former affects the surface finish, cutting forces, temperature, tool life and dimensional tolerance. Understanding the chip formation during the machining process for the specific materials will allow us to determine the machining speeds, feed rates and depth of cuts for efficient machining and increased tool life in the specific actual machining operation. During the machining process, three basic types of chips are formed. They are discontinuous chips, continuous chips, and continuous chips with built-up edge.

Discontinuous chip formation normally occurs during machining of brittle work material. This type of chips also occus in machining operation with small rake angles on cutting tools, coarse machining feeds, low cutting speeds. Discontinuous chip formation results in poor workpiece surface finish.

During continuous chip formation, a continuous "ribbon" of metal flows up the chip-tool zone. This is considered to be the ideal condition for efficient cutting action.

Continuous chip with built-up edge formation is basically the same process as continuous chip formation, except that as the metal flows up the chip-tool zone, small particles of the metal begin to adhere or weld themselves to the edge of the cutting tool. As the particles continue to weld to the tool, it affects the cutting action of the tool.

This type of chip formation is common in machining of softer non-ferrous metals and low carbon steels. Common problems are the built-up edges breaking off and being embedded in the workpiece during machining, decrease in tool-life and final poor surface finish of the workpiece.

Studies on the built-up edges have shown that the chip material is welded, deformed and then deposited onto the rake face of the tool layer by layer. It is thus possible to observe the presence of built-up edges by studying the back face of the chip during the machining process. This is normally used in micro or ultra precision machining operation.

To reduce built-up edges, improve the lubrication conditions, use sharp tools and better surface finish tool and also apply ultrasonic vibration during the machining process.

About the Author

Author Ken Yap is a director of Suwa Precision Engineering Pte Ltd in Singapore and represents precision metal stamping, swiss screw machining, miniature precision balls and printed circuit boards manufacturers from Suwa, Japan.

Originally posted 2007-10-04 15:33:07. Republished by Blog Post Promoter

CNC multi-spindle automatic lathes have been regarded by many machine shops as too expensive.

Now, Index in Germany said that the cost of such machines is constantly reducing. It is now possible to buy a six-spindle CNC automatic (multi) for around twice the cost of a high-end sliding-head lathe, said Richard Kingsbury, managing director of the UK agent for Index turning machines, Geo Kingsbury Machine Tools.

The machine in question is the Index MS22C CNC six-spindle automatic intoroduced at EMO 2007 for milling and turning parts up to 22mm diameter.

While it is true that CNC multi-spindle automatics are not cheap machines, the price in real terms has been coming down steadily over the years.

The MS22C brings the technology within reach of a much wider section of manufacturing industry.

Kingsbury said: ‘The CNC multi-spindle range is proving so popular that Index will increase production in 2008 to 200 units across all sizes of multi.

Of these, 80 will be in the 22mm category.

Four fifths of them are destined for Germany, France, Switzerland and Italy’.

Kingsbury commented that British manufacturers have been falling behind in adopting the technology, but that he has high hopes for an increased level of order conversions in 2008, due to the introduction of the competitively priced MS22C.

OEMs and subcontractors alike are beginning to see the productivity advantages, having noted the big advances in capability of the machines.

Kingsbury said that he is particularly encouraged by the fact that, once a customer has been ‘won over’, not one has stopped at a single multi; they have all gone on to buy a second, third, fourth and even a fifth machine.

He continued, ‘A few years ago, people cottoned to the fact that modern CNC sliding-headstock lathes could make a lot of money.

Many firms invested, mostly in multiple machines and some subcontractors have as many as 25 or more.

But where is the competitive edge now that so many firms use them?

I suggest that if component length-to-diameter is 4:1 or less, the next big thing in British turned parts manufacture will be the CNC multi, with its extensive prismatic machining and endworking capabilities, coupled with the flexibility to run batch sizes of just a few thousand’.

Kingsbury added that competitive pricing has placed these machines in the ‘mainstream’ of manufacturing, and programming and operation have been ‘demystified’ to the point where operation is almost as simple as running a single-spindle CNC lathe.

* About the Index MS22C multi-spindle automatic – the six-spindle mill-turning centre has been added to the lower end of the Index range, which until now comprised machines with maximum bar capacities of 32, 42 and 52mm.

According to configuration, the MS22C can have up to 62 CNC axes, including 12 compound slides with X and Z travels of 62 and 85mm.

Each spindle is configured with a full C-axis and a number of Y-axis slides can be added.

Simultaneous back-working is achieved using one or two scara robot arms carrying synchronous pick-up spindle(s) that present the parted-off components to six separate tools, four of which can be driven.

As the MS22C’s tool carriers/slides are arranged in a V shape, two CNC slides can work on one spindle simultaneously.

This is in contrast to the configuration of multi’s from other manufacturers.

Each of the 12 slides can perform internal or external turning, or boring, or driven tool work.

Workshops are therefore not locked in to running one kind of tool in one position, because there is no set order as to where to run which tool.

Only the toolholder determines the type of machining.

This flexibility of tool layout plays a key role in optimising machining times, according to Index.

Although the machine can be extended to the full 62 axes, this is rare in practice.

The standard configuration would be with a single NC system capable of controlling 31 programmable axes, more than adequate for the vast majority of small turned parts, said Kingsbury.

It is a specification that offers all the benefits of phenomenal production rates without the restrictions in flexibility that are normally associated with multis.

* feed rates and cutting speeds optimised at each spindle – in common with other Index CNC multis, the MS22C has the ability to optimise feed rates and cutting speeds at each 14kW/10,000 rev/min spindle, avoiding compromised machining conditions and so maximising productivity as well as tool life.

The MS22C is therefore ideal for economical production of components in materials such as high temperature alloys that previously could not easily be machined on a multi.

Control is by the INDEX C200-4D, a derivative of the Siemens 840D CNC, which is easy to program on the shop floor and automatically performs collision checking including for the pick-up spindle(s).

Comprehensive diagnostics for the machine and control are included, and it is possible to specify tool monitoring and a teleservice connection to an Index engineer for troubleshooting.

Originally posted 2008-01-10 20:32:23. Republished by Blog Post Promoter

Builder of medium to heavy duty CNC milling/boring machines, Unisign, reported more than double the number of enquiries from EMO 2007, when compared with th 2006 show

Builder of medium to heavy duty CNC milling/boring machines, Unisign in The Netherlands, reported The EMO 2007 had exceeded all of its expectations and that not only was the quality of enquiries better than earlier years but more than double the amount of new enquiries was received on its EMO stand.

Unisign told manufacturingtalk.com that visitors wanted new technologies.

Of special interest to visitors was the Unipent UNIPENT 4000 5-axis portal machining centre.

The new Uniport 4000 CNC portal machining centre drew much interest because of its multi-tasking features.

Unisign has again shown that with the Unipent 4000 and Uniport 4000 it has two machines ithat will take a top position in their market segments.

Unisign also exhibited its Uniport 6000 portal machining centre in gantry configuration and its smaller Univers 4000.

The very successful Unicom 6000 was too large to exhibit but drew a large amount of enquiries.

Unisign said it is very confident about a successful future and is establishing an ever growing prominent position in the market of vertical CNC machining centres.

• Unisign: contact details and other news

Originally posted 2007-11-11 17:35:07. Republished by Blog Post Promoter

Affordable CNCs and DROs will be demonstrated at MACH 2008 performing milling, machining centre and turning applications and show that price does not compromise performance

Anilam will be demonstrating the easy-to-use yet powerful functionality of its extensive range of CNC systems for milling, machining centre and turning applications (Series 3000, 4000, 5000 and 6000) alongside its equally impressive Wizard 411 and Wizard 1000 digital read-outs (DRO). And it will show how price does not compromise performance.

The 2-/3-axis milling Anilam Series 3000M will sit side-by-side with the 3-/4-/5-axis 5000M Series and the multi-axis 6000 Series, as well as the 2-/3-axis 4200T turning system.

The aim, said Anilam, is to highlight their unbeatable cost-to-performance ratios.

Visitors to the stand will be able to learn that Anilam CNCs feature a minimum of 8 Mbytes of RAM (up to 64 Mbytes) and networking capability that boasts auto-sensing at 100Mbit/s for data transmission.

The result is that users can gain improvements of up to 50% in program verification, and performance improvements of 15% in the processing of 8,000-block programs featuring 0.003in step-over increments.

* probing functionality – probing functionality for all industry-standard probes is standard on the 6000 Series (optional on the 3000 and 5000 Series) and, as is usual with all Anilam control functions, probe cycles are easy to use through a graphical/conversational screen.

After a cycle is selected, the appropriate variables are input via simple question and answer routines.

Tool measurement cycles include the following.

* Tool probe calibration.

* Tool length and diameter offset preset.

* Manual tool length and diameter measurement (for special tools).

* Tool breakage, length and diameter wear detection.

Workpiece measurement cycles cover the following functions.

* Edge find – single surface measure/edge.

* Corner out/in – outside/inside part corner find.

* In/out boss – inside/outside hole or boss find.

* In/out web – inside/outside web or slot find.

* Probe move – protected positioning.

* Skew comp – skew error compensation or angle find.

The multi-axis 6000 Series CNC is increasingly gaining approval by original equipment manufacturers and importers of vertical machining centres.

The control combines Anilam’s conversational Machinist’s Language programming routines with G Code programming to create a CNC that has an unrivalled level of functionality and user-friendliness within a single system.

It is supplied as a complete OEM package with a range of nine axis motors rated from 3Nm to 20.5Nm and ten spindle motors covering the power range 4.5kW to 22kW.

These suit the high traverse speeds of up to 30m/min and the up to 10,000 rev/min spindle speeds common on such machines.

The CNC has a powerful 586 DX4 133 PC processor and 16Mbytes of RAM, plus a 12in TFT screen.

It has enhanced mould and die capability (scaling, mirror image, modal corner rounding/chamfering, for example), said Anilam to manufacturingtalk.com, as well as a host of canned cycles including mould rotation and draft angle.

It also features a cam programming mode for interactive programming using icons (moves shown as they are being programmed), menu-driven tooling, tool compensation and interference checking, as well as built-in post-processor.

Simulation graphic functions embrace rapid, feed and compensated moves (colour differentiated) isometric views, auto part fit, window zoom and static tool display, for instance.

Canned cycles include the following.

* Irregular pockets – a simple routine of prompts produces clearances of irregular shapes.

* Geometry – the geometry calculator, for determining points, lines and circles, automatically forms the program foundation.

* Bolt hole pattern and drill cycles are created by simple question and answer routines.

The 6000 Series CNC also features Anilam’s Integral Programmable Intelligence, so there is no need for a separate PLC unit and, compared to older CNC systems accompanied by a separate bank of drives, these are now housed in one compact module.

* Turning – for lathes, the 4200T turning control’s functionality includes create, delete/undelete, list, copy, rename and print, and the system also features constant surface speed as standard, to help guarantee consistent surface finish and extended tool life.

Also, the control can run in several operational modes – including teach mode achieved via single or dual handwheel operation with dual axis interpolation.

* Milling – the Anilam 3300 MK 3-axis milling CNC on show also features the Machinist’s Language coupled with a wide range of standard cycles such as peck drilling, bolt-hole patterns, pocket milling and face milling; advanced cycles including ellipse, spiral, helical, tapping, irregular pocket milling and profile milling, as well as special cycles that include counter boring.

* Borering machines – the stand at MACH 2008 will also highlight how the Anilam Commando CNC has for almost 30 years been synonymous with transforming the performance of manual borers, and in its latest guise harnesses the ease-of-use capabilities of Machinist’s Language in a Series 3000 CNC system.

In its new format driven by 8.1 Gbyte Intel hard drive, Commando complements its ability to automate machine positioning with the offer of on-screen editing and help graphics as well as DXF and G-code conversion to further save operator time and increase machine productivity.

* DROs – of the two Wizard DROs being shown, the 1-/2-/3-axis Anilam 411 (which complements the 4-axis Wizard 1000) is an ‘entry-level’ DRO.

It has powerful functionality, substantial technical service back-up and three-year warranty reassurances that belie its low-cost price tag making it incomparable with any other product available in the global low-cost DRO marketplace, said Anilam.

In addition to standard functionality embracing tool offsets, sub datums, linear patterns (row, frame, array), PCD calculations (full and partial) and vectoring, the ultra-reliable all diecast-constructed Wizard 411 sets itself apart from other systems courtesy of LCD screen (the only DRO available using this technology) plus sealed membrane keypad and powerful canned functions for incline, arc, rectangular frame and rectangular pocket routines.

Complemented by ENC 125 precision glass scales that boast a resolution of five microns and an accuracy rating of 10 micron/m, the Wizard 411’s ease of set-up and use is also signified by the fact that the system will be shopped with a two-page quick reference set-up guide rather than a handbook.

* Anilam at MACH 2008, NEC, Birmingham, UK, April 21- 25, Hall 5, Stand 5011.

Originally posted 2008-02-12 16:41:16. Republished by Blog Post Promoter

High-pressure, hydraulically balanced, coolant pumps for machine tools reduce maintenance costs because there are no packings, cups, or seals, said the manufacturer

High-pressure MP-B series coolant pumps use a Hydra-Cell diaphragm pump. This patented, hydraulically balanced design reduces maintenance costs because there are no packings, cups, or seals. This rugged, fixed or variable volume pump is built to handle the abrasive particles found in machine tool coolant that can wear out conventional centrifugal, screw, or piston pumps.

* Lathes and milling machines – In lathe and milling machine applications, this pump effectively removes chips from even deep and blind holes and reduces ‘cyclic cooling’ in milling applications, said Monster Swiss to manufacturingtalk.com.

Cyclic cooling occurs when steam is produced and creates a boundary layer, which interferes with coolant effectively reaching the tool/workpiece interface.

In grinding, the MP-B’s high-pressure (1,000 lb/in2) keeps the wheels free of swarf build-up and optimally cooled, again by breaking the boundary layer created by the wheels high speed, and giving the successful result of increased wheel life and metal removal rates.

* Positive displacement – the MP-B’s positive displacement design allows users to adjust the flow rate by changing the speed of the pump shaft.

This is a helpful feature when using tools with different coolant flow requirements.

The unit is portable on sturdy locking castors, so that operators can easily move it when necessary, even with the 50-gallon reservoir filled.

MP-B pumps have electrical components manufactured by Sprecher + Schuh, a Swiss company, and are certified to the highest standards including UL, CSA, and CE.

All of the machine components, including twin filters, are housed conveniently and neatly inside the cabinet assembly.

Vertical Machining CNC Center Cuts Tough Products

Rugged vertical machining centre with an 18kW high-torque spindle and through-tool coolant delivery enables a UK subcontractor to efficiently cut SS and Duplex, as well as other tough alloys

The purchase of a new Hurco VMX64 vertical machining centre (VMC) has enabled Pharma Tooling to more than double its maximum component size capacity. The VMC has a rotary turntable and high-pressure coolant delivery through its BT40 spindle. Said owner and managing director, of Pharma Tooling, Phil Vines: ‘My plan is to grow the business and to do that, we have to be able to take on anything that comes through the door, 24 hours a day’.machine bigger components within the Hurco’s working envelope of over 1600 x 850 x 750mm, and we also have the flexibility to produce smaller parts by setting up two or even three together on the table, using the 4th axis if required.’ Vines said that the 18 kW high-torque spindle and availability of through-tool coolant meant that Pharma Tooling can efficiently cut stainless steels (SS) including Duplex, as well as other tough alloys.

Most of the work put on the VMX64 so far has been either prototypes or small batches of one- and two-off.

Some dimensional tolerances, especially for medical and aerospace applications, are tight at +/-0.05mm, a level of accuracy that Renishaw component and tool probing helps to maintain.

All jobs for the Hurco are programmed on the shop floor.

The ease and speed with which this is carried out using the proprietary Ultimax twin-screen control system was one of the principal reasons for Vines selecting this machine tool manufacturer.

With small batch work, fast turnaround is of the essence to ensure profitability.

A 24h lead time from order to delivery is not unusual, particularly for pharmaceutical components.

Vines was already familiar with the benefits of Hurco machines and their Ultimax CNC system from his work at previous companies.

The VMX64 is the first machining centre that he has acquired since he bought the Cheltenham subcontract firm from administration in 2003.

There are eight existing vertical and horizontal machining centres on site, all 4-axis models, which are programmed off-line, batch size on these smaller machines being typically 50-off.

The capacity list also includes four CNC lathes and a new Robofil 300 wire EDM machine that was installed in 2007 at about the same time as the Hurco.

* About Pharma Tooling – based in Cheltenham, UK, around one third of Pharma Tooling’s business is pharmaceutical-related.

Blister pack tooling is regular work, which involves machining a 1.6m long, aluminium bedway that joins the forming and sealing sections in the production line.

The bedway is now machined in ‘one hit’ on the Hurco VMX64, rather than in two clampings as previously.

Aerospace work accounts for another third of turnover and is currently a particular focus for Pharma Tooling, which was granted AS9001 approval during 2007.

The company is a member of the West of England Aerospace Forum and follows cGMP (current good manufacturing practice) guidelines throughout all stages of design and manufacture.

The SBAC (Society of British Aerospace Companies) has recently trained the subcontractor’s 16 staff in lean manufacturing and capacity planning.

The company is aiming to become a signatory to SC21, which is designed to accelerate the competitiveness of the aerospace and defence industry by raising the performance of its supply chains.

Latest universal turning and mill/turning machines offer up to 25% performance improvement, when compared with the last generation, while work area visibility has been improved

Gildemeister said that its ‘fifth generation’ CTX Series of CNC universal turning and mill-turn machines offer up to a 25% improvement in performance. Also an ultra-modern enclosure design provides up to 40% improved visibility of the working area. Also, Gildemeister’s DMG ERGOline control system introduces new levels of functionality and presentation.

DMG of Luton, UK, said that the ‘new look’ CTX Series is modular across the range, allowing users to choose capacity, specification and performance from the Gildemeister’s use of three basic platforms.

The platforms are designated Alpha, Beta and Gamma.

These platforms are divided into 10 different models.

Then there is a further 24 variations of equipment available to add to the specification.

As a result of the design and development criteria for CTX, as the size and requirements generally increase so does the performance.

Here, a prime example is torque available at the main spindle which ranges from 127Nm on the Alpha 300 to 2,400Nm on the top of the range Gamma 2000.

Chuck diameters are available from 160mm to 630mm, barfeed capacities from 51mm to 102mm and turning lengths between 300mm and 2000mm.

There is also a range of built-in spindles available having up to 113kW of power, turret, Y-axis cross feeds and tailstock options, driven tools and secondary spindles plus a range of integrated tool magazines.

Also, Gildemeister has incorporated the already well-proven, high speed 60m/min linear motor drive systems as an option and made available high accuracy linear scale positioning.

* Y-axis – at the top of the range, the ‘TC’ variants of Beta and Gamma machines incorporate a Y-axis crossfeed as standard to the heavy duty B-axis milling and turning head with full interpolation and 5-axis simultaneous positioning.

There is also capacity for up to 36 tools in the magazine and both main and secondary spindles have identical machining power with up to 770Nm of torque available.

With the new ‘branded’ enclosures, distinctive in matt white and high gloss black finish, these enhance the large safety glass viewing panel, said DMG (UK) to manufacturingtalk.com.

The viewing panel is some 40% larger within the access door to not only create an identity, but also add new levels of practicality to the range.

Also as part of the futuristic design, a highly practical DMG Lightline indicator of the machine’s operational status spans the side door area across the entire height of the machine.

This is further emphasised by the 19in ultra-clear DMG ERGOline control with its brushed chrome surfaces that can be ergonomically set for the most appropriate operational positioning.

• DMG (UK): contact details and other news