Archive for the ‘Lathe’ Category

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.

NewswireToday – /newswire/ – Warrenville, IL, United States, 02/11/2008 – Ellison Technologies is a provider of advanced machining solutions to North American metal-cutting manufacturers and their global affiliates.
	By contributing with technological solutions that strengthen their customers’ ability to compete locally and globally, Ellison Technologies is committed to the survival and progress of American Manufacturing. The company announced today that it will become the exclusive distributor for Kitako in Northern and Central Illinois. Ellison Technologies has been serving Illinois manufacturers since 1981, and the most recent addition to the product offering solidifies its place as the top choice for machine tool distributors in this market. Whether the solution involves a stand alone machine, multi-process equipment, or an integrated manufacturing system with robotic automation, Ellison’s goal remains the same; to optimize throughput and quality at the lowest per-part manufacturing cost. Kitako Corporation, based in Hiroshima, Japan, produces high production CNC lathes. Kitako four-spindle vertical and horizontal CNC lathes allow for machining on two spindles while parts are loaded and unloaded on the other two spindles. All four spindles are on a large carrier that indexes in less than 2 seconds. This virtually eliminates part loading time. Manufacturers can triple their production by using high speed, bi-directional indexing for productivity without sacrificing flexibility. This partnership brings Illinois manufacturers the superior machining capabilities of Kitako and the very strong application engineering, service and automation capabilities of Ellison Technologies.

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.

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.

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

For the complete machining of small parts, in batches of 50 to 5,000-off, a high performance, competitively priced universal lathe has a Y-axis and a sub-spindle

Emco in Austria said about its Maxxturn 25 high-performance universal lathe that it is the first time that such a compact machine has been equipped with a Y-axis and a sub-spindle. Emco said that the machine suits the complete machining of small parts. batch sizes range between 50 and 5000-off.

Emco added that the Maxxturn 25 is particularly interesting for smaller suppliers or subcontracting firms, who need to machine at a highly competitive price.

Introduced at EMO 2007, the MAXXURN 25 can be used for many applications ranging from the production of hydraulic components to parts for timepieces and jewelry.

It performs complete machining of bar stock parts of up to 25mm diameter and chuck parts up to 85mm diameter.

Most manufacturers, said Emco, employ this machine segment for machining bar stock parts starting with a diameter of 45mm.

Emco claims that the Maxxturn 25 is the first 25mm bar capacity lathe to allow complete machining.

The machine is offered at what Emco claims to be an ‘unbeatable price-performance ratio’.

The Maxxturn 25 has a compact counter- or sub-spindle, which can take over position-orientated workpieces for the prcise machining the reverse side.

Emco said that this feature eliminates a second clamping step, reduces doen-time and so increases productivity.

Additional technical features are as follows.

* The Maxxturn 25 can be configured either with tailstock or counter spindle or alternatively with or without Y-axis.

* The turret with hydraulic lock offers space for up to twelve VDI16 tool holders.

* With a total of 36 switch positions, the number of cutting edges may be increased up to 42.

* The driven tools and the c-axis are already included in the standard model.

* Like in all bigger models of the same range, the Y-axis of the Maxxturn 25 is fully integrated in the body of the machine, ensuring maximum stability as well as utmost precision of all parts manufactured.

* The extremely wide distances between the guides make for stable turning and even offer the user additional possibilities for complete machining.

* In the course of modular assembly customers can choose between a Siemens control interface (including the popular ShopTurn dialogue interface) or a FANUC control interface (featuring the equally popular Manual-Guide-i interface).

Technical details/Concept of the machine are as follows.

* Machine base – the machine has a 60 deg inclined bed.

The extremely rigid and compact cast-iron design provides the basis for this robust and precise lathe.

Heavy duty reinforcing ribs provide additional rigidity in zones that are subject to intense stress.

All guides are crafted as preloaded cross-roller guideways.

They are screwed onto bearing surfaces that have been precisely ground, with additional wedges that brace them against a plane of reference which is also ground.

Covers along the guides as well as additional telescope covers made of stainless steel increase operational safety and durability.

* Main spindle – the high driving power of the spindle combined with optimal torque curve ensures economic efficiency in cutting steel, as well as high-speed cutting of aluminum.

The main spindle which is pivoted with a sizeable precision bearing allows for a wide range of speeds with extremely good running truth.

A nearly symmetrical headstock with a large cooling surface ensures optimal thermostability.

* Tailstock – on the Maxxturn 25 with tailstock, the tailstock is set up on the linear roller slide and can be positioned automatically within a range of 360mm.

The rolling centre with MK3 shaft is directly integrated into the tailstock and can be removed using a pressure wedge.

* Counter spindle – on the Maxxturn 25 S, which is equipped with a counter spindle, the counter spindle headstock is placed on a separate linear roller slide and can be positioned within a range of 360mm.

A stroke-monitored parts ejector, flushed with coolant, ensures safe removal of the finished parts.

* Tool turret – a 12-position VDI16 disc turret has 36 indexed positions and servo technology.

A servo motor powers the driven tools and the swivel movement, respectively.

The machine operator may adjust the slewing speed at any time, using a feed-override switch.

The turret switches with direction logic.

This means that it always takes the shortest way when swiveling to the next tool.

Tool holders complying with VDI 69 880 allow easy tool insertion with repeatable accuracy without time-consuming adjustments.

* C-axis/main spindle (model-specific) – the C-axis is part of the machine’s standard equipment.

The spindle can be positioned with a resolution of 0.001 deg.

A directly attached rotary encoder, which is no-contact and without a belt drive ensures the precision of the c-axis as well as precise contour milling.

In addition, the main spindle can be clipped into the right position for drilling and milling operations using a spindle brake.

* Y-axis (model-specific) – the Y-axis is integrated in the standard build of the machine and is positioned at an angle of 45 deg in relation to the X-axis.

Extremely short protruding lengths are the basis for solid lathing and drilling operations as well as for milling without receiving imprecise contours.

* Feed drive – highly dynamic three-phase drives in all linear axes with preloaded circulating ball spindles provide high feed forces and positioning with repeatable accuracy.

* Measure system – incremental measure systems in the feed motor are integrated in all linear axes.

Positioning variation according to VDI3441 in X/Y/Z: 0.0035/0.003/0.004mm.

* Clamping unit – he clamping unit is a hydraulic clamping system with a bar capacity of up to 25mm diameter including chuck stroke monitor.

Either a pull-back or push-back collet chuck may be attached to the main spindle as well as a three-jaw power-operated lathe chuck.

The counter spindle provides space for a pull-back or push-back collet chuck.

* Lubrication – the Maxxturn 25 uses an automatic centralized lubrication system with lubricant-saving impulse lubrication due to its integrated pressure and quantity monitoring.

* coolant system – a central coolant supply through the VDI interface at the turret and through the tool holder ensures optimal cooling and lubrication during the machining process.

An additional coolant pipe is installed to clean the clamping devices and the work area.

* hydraulic system – the hydraulic system is a high-pressure compact hydraulic system with a pump and a fine filter in the head pipe, with which the chucking pressure can be more finely adjusted, a precondition for clamping sensitive work-pieces in the main and the counter spindle.

Thanks to its compact construction it only has a small footprint.

* Housing – the machine housing is completely closed.

Its door is monitored with safety switches to prevent operator injury and features a sizeable viewing window made of laminated safety glass.

* Finished parts pick-up unit (optional) – the pneumatically operated pick-up unit removes finished parts from the main or the counter spindle.

Thus, the parts are gently put into a finished parts container outside the work area.

Maximum length of finished parts is 120mm; maximum diameter is 25.5 mm and maximum weight is 0.5kg.

• HK Technologies: contact details and other news

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

UK – At EMO 2007, the Japanese machine tool manufacturer, Okuma, introduced a new way of turning tapered bores and outside diameters using its horizontal machining centers, which are available in the UK through NCMT.

Called turn-cutting, the patented technique is in contrast to the established process of revolving a component on the rotary table of a 4- or 5-axis machining center and feeding in a static turning tool mounted in the spindle to machine the OD. The bore would be impossible to turn to any reasonable accuracy, as a long right-angle head would be needed.

Instead, the turn-cut function in the Okuma OSP-P200M control allows a single-point turning tool in the spindle of one of the manufacturer’s horizontal machining centers to turn a static component, even on a 3-axis machine. It is achieved by taking advantage of linear feed rates up to 60 m/min to circular-interpolate the X and Y axes rapidly while feeding forward in Z.

The clever part, which forms the core of the patent, is the ability of the control to continuously orientate the tool in the spindle by rotating it at precisely the same speed as, and in synchrony with, the circular X/Y path. The tool therefore cuts at the correct rake angle at every point throughout the 360-degrees to ensure efficient and precise metal removal.

Cylindrical bores and ODs are easily achieved by keeping the X/Y travels constant, while tapers and other profiles can be turned by varying the amplitude of circular interpolation.

The benefit of turning on a machining center is that components can be finished in a single clamping, avoiding a subsequent set-up on a lathe and the consequent handling costs, increased floor-to-floor time and tolerance build-up. If parts are heavy and / or have eccentric bores or ODs, rotating them for conventional turning becomes difficult, requires expensive lathes and can lead to further inaccuracies.

At EMO, the machining center demonstrating the turn-cutting technique was an Okuma MA-600HB, which can machine workpieces weighing up to 1.2 tonnes within a nominal one metre cube. Turn-cutting accuracy is to within microns and it is this degree of precision that is crucial; some machine manufacturers might be able to approximate the procedure, but only for open-tolerance work.

As with all the latest Okuma machine tools, the MA-600HB features the manufacturer’s Thermo Friendly Concept. Symmetrical design and electronic compensation from sensors around the machine structure and spindle hold dimensional drift to below 10 microns, even if the ambient temperature changes by up to 8 degrees Centigrade. Repeatability is ± 1.5 microns.

While turn-cutting is applicable to any component, the company singles out large, multi-port valves as particularly suitable for being machined in this way. Not only can the bores and flange ODs be conveniently turned, but it is also possible to single-point cut an accurate scroll pattern on the flange faces for improved sealability.

SOURCE: Okuma