December 2010 Product Spotlight
BIG Kaiser has introduced a new, high-precision hydraulic chuck for clamping straight shank tools with diameters ¼" to 1¼” and 6mm to 32mm. They are ideal for tools such as drills, reamers, ball mills, end mills and other tools used in processes that require extreme accuracy and a fine surface finish.
“Our customers in the automotive, aerospace and medical fields will love this tool holder for its precision and stability,” says Jack Burley, BIG Kaiser vice president of sales and engineering. “What’s more, cutting tools can be easily clamped and unclamped with just one wrench.”
The hydraulic chucks are pre-balanced to within 15 gr.mm for vibration-free machining at speeds of up to 20,000 RPM. Precision and rigidity are improved due to an integral sleeve construction, dual-oil pressure points and a short projection length. They feature runout accuracy guaranteed to less than .00012” (3 microns) at 4xD and repeatability less than .00006” (1.5 microns)—shown to improve the surface finish of workpieces and extend tool life. They are available for BIG-PLUS® (CAT and BT), HSK and CAPTO® interfaces.
Want more information? Click
below.
Big Kaiser
Sunnen's new SV-400 Series vertical CNC honing system combines a wide choice of tooling options, large work envelope, and up to 1524 mm (60") stroke for bore sizing of small and medium-sized gas/diesel engine blocks, oil/gas components, hydraulic/pneumatic parts, compressors, bearing sleeves, gear hobs and similar small or large multi-bore parts. A work envelope of 915 mm x 1015 mm (36" x 40") and weight capacity up to 90 kg (2000 lb) provide versatility for processing a wide range parts.
An optional tool-guide assembly and variety of bore-diameter gaging systems combine with a servo-controlled X-axis travel of 1143 mm (45") to allow automated honing of multi-bore blocks with high precision. Straightness sensing capability provides a display of the bore profile during the cycle. Combined with a patented, servo stroking system, it allows the SV-400 to auto-dwell in any part of the bore to correct straightness automatically in the shortest cycle time. The SV-400 can be used to hone parts with inside diameters from 19-200 mm (0.75-8.00"), or diesel liners up to 150 mm (6") depending on the tool options selected.
Designed from the ground up for automated processing of mid to high part volumes, the SV-400 Series features full-height access doors and enclosure preconfigured for use with robotic part loading systems, while the CNC control includes a built-in automation interface. A 20-amp power supply and multiple E-stop contacts add versatility and allow convenient automation control. Setup is simplified with a multi-axis hand wheel for fine-tuning vertical stroke, tool feed, column position (SV-410 only) and optional cradle position. Automatic tool feed can be selected for constant load or constant rate.
The PC-based, color touch-screen control features multi-language capability, pull-down menus, unlimited capacity for job setups, and programmable custom tools. In addition to optional in-process air gaging, a variety of optional post-process air-gage systems can integrate with the control for SPC data collection, as well as automatic compensation of size, taper and straightness. The control allows easy programming of multiple bore positions.
Want more information? Click
below.
Sunnen
Synergies from different areas of application play an important role in the development of tools and cutting material. This is demonstrated by the new ISO insert with NMT geometry from Walter. The geometry, which was originally designed for titanium material in aerospace technology, is also excellent for forged and cold-formed steel components that are predominantly used in the automotive industry.
The chip fracture behavior of forged and cold-formed components is as problematic as it is for titanium alloys. The tendency to produce coiled swarf is particularly pronounced for materials such as Cf53, C10 and St37. In addition, material removal for forged parts is often only 1.0 to 2.0 mm, which again impedes chip breakage. In order to break the chip reliably and enhance process reliability, optimized cutting edge geometries are necessary. With its NMT ISO insert geometry Walter has introduced one such solution to the market for turning titanium material. This geometry is also suitable for steel formed parts, such as those typically produced in large quantities in the automotive industry and other similar sectors. Examples include ball joint pivots, gear parts, converter housings for automatic transmissions and drive shafts. Walter combines the original titanium geometry with a cutting tool material for ISO-P materials in accordance with the component target group. The Tiger•tec® WPP10, WPP20 and WPP30 grades are available for selection. These three grades (very hard WPP10, universal WPP20 and very tough WPP30) provide the user with sufficient leeway for individual process adaptation. The product range currently comprises the following basic shapes: CNMG, DNMG, TNMG and WNMG.
The NMT geometry is particularly impressive due to several features. The main feature is the curved cutting edge, whose purpose is to reduce the cutting forces and to prevent variations of the workpiece surface when profiling (e.g. ball joints). Close behind is a closed series of dome-shaped bumps which provide an obstacle for the swarf and deflect it, while simultaneously providing a constriction on the overall cutting depth. The cutting edge has been drawn up slightly around the corner radius to enable positive geometry conditions at this point. This new optimized cutting edge design results in a feed range of 0.12 to 0.40 mm per rotation and a main cutting depth of 0.6 to 3.0 mm. Conventional material removal for hot and cold-formed parts lies in precisely this range.
Want more information? Click
below.
Walter
The new VHX-1000 Digital Microscope from KEYENCE represents the fusion of high-performance digital microscopy with precision measurement. Quick, accurate measurement and observation for the most challenging applications are rapidly becoming standard requirements for an observation system. The integration of advanced technology into a powerful, all-in-one unit launches microscopy into the next generation. The new VHX-1000 Series features the world's first, real-time, 16-bit imaging resolution that makes subtle color differences visible, and optimizes areas that are too dark or too bright to see. The brightness range has been increased from the previous 256 levels to 65,536 levels. Likewise, the 3CCD color clarity has increased from 16 million to over 2.8 trillion colors.
Advanced sensor technology and microscopy/optical design and application expertise, has resulted in a revolutionary technology known as the DOUBLE'R automatic lens/zoom recognition system. The VHX recognizes, in real time, which lens is mounted to the camera, as well as the current magnification. Calibration adjustment is automatic with magnification changes.
The VHX-1000’s extraordinarily large depth-of-field is at least 20 times greater than conventional microscopes. Combined with an Accurate DFD (Depth from Defocus) function, the new VHX generates fully-focused images of virtually any sample. The compact 3CCD Camera includes a pixel-shift actuator, achieving sharp, ultra-high resolution images of up to 54 million pixels. A flicker-free progressive scan method and new graphics engine allows texture expression and color reproduction similar to observation with the naked eye. A wide selection of high-resolution, leading-edge RZ zoom lenses, with up to 5000x magnification, provides superior image quality with excellent chromatic aberration correction.
Targets can be freely observed with the camera/lens unit used either handheld or mounted in a multi-angle viewing stand that enables angular observation without changing the target position. Through simple mouse operations, the VHX-1000 performs real-time, on-screen measurement of the distance, radius, angle and area of the target. For larger targets that need to be observed or measured, the unit has the added capability of real-time stitching of 2D and 3D images up to 10,000 X 10,000 pixels thereby increasing the viewing area up to 50 times.
Want more information? Click
below.
Keyence
Angle encoders provide reliable position and speed control through use on rotational axes such as on rotary tables, tilting axes and direct drives, and are often the encoders of choice when angle measurement in accuracy of a few angular seconds is required. Now, HEIDENHAIN introduces a new phase of these absolute angle encoders offering numerous advantages for today’s machine tools.
Called the RCN 2000, RCN 5000 and RCN 8000 Series, these new angle encoders from HEIDENHAIN are characterized by their simple mounting and high accuracy. Some new benefits include greater mounting tolerances, optimized new scanning, evaluation electronics with diagnostic functions, plug-in cables with quick disconnect at the encoder, and a variety of hollow shaft diameters.
The greater mounting tolerances now possible because of these angle encoders are due to the better axial and radial deflection behavior, as well as the torsional rigidity, of the newly developed stator couplings. Together with a new sealing design on the encoders, relatively larger mounting tolerances are now possible without restricting the operational functions and accuracy.
Also thanks to the use of an innovative single-field scanning principle with a special optical filtering, this series of HEIDENHAIN angle encoders produces scanning signals of very high quality. The resulting position errors within one signal period are typically smaller by a factor of three to four compared to previous angle encoders. The scanning principle also contributes to a significant reduction in sensitivity to contamination. With the new scanning and evaluation electronics, it has become possible to dramatically reduce the influence of the rotational speed on the generation of position values. This ensures that, even at high speeds, the scanning signals have high signal quality and continue to interpolate well.
In contrast to previous units, these new HEIDENHAIN angle encoders feature a flange socket to which an adapter cable is attached. In instances where a normal screw-on connection is not practical, HEIDENHAIN offers a special quick disconnect system (push-pull solution) where the adapter cable is simply snapped on and off.
Want more information? Click
below.
Heidenhain
OMAX Corporation has released Intelli-ETCH, a new software tool that allows the company’s abrasive waterjet machining centers to create 3D patterns in a wide array of materials. Available free of charge to all OMAX customers, the patent-pending Intelli-ETCH package was added to version 15.0 of OMAX’s Intelli-MAX® software.
With Intelli-ETCH, operators create or import a grayscale version of the image or CAD file of the feature they wish to machine. The software then enables completion of the 3D etching by translating the brightness values of individual pixels into a function of Y-axis traverse speed. Unique and proprietary algorithms are integrated to control acceleration, deceleration, turning and cornering.
“At OMAX, we are constantly looking for ways to increase the value that customers receive from our machines,” says Carl Olsen, senior software engineer at OMAX. “With Intelli-ETCH, we identified an opportunity to capitalize on the strength of our software and the speed of our machines to introduce an entirely new functionality. As with all of our software innovations, Intelli-ETCH is free to all OMAX owners, allowing customers to get even more out of the machines they’re already using.”
Intelli-ETCH is ideal for applications that require low precision, but high visual aesthetics, such as artistic components or etching of words or logos. As a software-based solution, Intelli-ETCH does not require any special accessories or tools, allowing cutting and etching of parts to take place in a single setup.
Want more information? Click
below.
OMAX
CNC Software's release of Mastercam X5 introduces significant new capabilities, including new dynamic milling techniques, multi-axis machining, Smart Hybrid Finishing, and much more.
Dynamic milling constantly adjusts the toolpath to ensure the most efficient cut possible and allows use of the entire tool flute length, often eliminating the need for multiple depth cuts. New dynamic milling techniques include Dynamic Rest Mill and Dynamic Contour. Dynamic Rest Mill behaves in a manner similar to the current toolpath, only it uses dynamic milling motion instead of core mill or area mill motion for the rest operations. Dynamic Contour uses an intelligent, efficient high speed contouring strategy to remove material along walls. It supports multi-passes and can optionally include finishing passes.
Mastercam’s multi-axis suite has new machining techniques and a new, easy, workflow-oriented interface. Mastercam lets you choose the basic type of work you’re doing using clear illustrations, and then gives you a clear, step-by-step process for defining how you’ll cut the part. Mastercam’s multi-axis machining also includes a new highly specialized interface for smooth, gouge-free engine head porting.
Mastercam’s new 3D surface high speed OptiRough toolpath is a new technique designed to remove large amounts of material quickly using its successful dynamic milling motion. Large, aggressive cuts are followed by fast, smaller up-cuts, safely delivering a fully roughed part faster than ever.
Hybrid finishing intelligently blends two efficient cutting techniques in a single toolpath. This new toolpath evaluates the model shape and smoothly switches between Constant Z cutting and Constant Scallop machining. The result is a dramatically finer finish with less work.
Want more information? Click
below.
Mastercam
MultiCam Inc. now offers plasma operators an option for drilling and tapping large holes in steel plate. The new Max40 drill and tap spindle mounts next to a high-performance Hypertherm torch on MultiCam’s heavy-duty 6000 Series bridge and rail plasma system.
The Max40 spindle can drill holes up to 1.125” in diameter and has an optional 8-position tool changer for automatic tapping as well. The system also has an optional Z-axis probe to accurately determine the Z-axis plane on warped or inconsistent sheet. This option allows the system to drill and tap blind holes very accurately. Coolant is applied through the center of the cutting head, allowing operators to extend the life of the tooling and improve the amount and location of lubricant applied. The 6000 Series Plasma and the optional Max40 drill and tap spindle provide plasma operators an opportunity to expand their cutting capabilities.
Want more information? Click
below.
Multicam
Seco Tools has announced its new comprehensive line of Jabro routers specifically developed for the machining of composite materials, which are increasingly found in aerospace, automotive and medical applications. The new family features five different solid carbide styles with cylindrical shank diameters that range from 3.0 to 20.0mm depending upon the style.
“We are excited to enter this new area of material application,” said Seco Jabro product manager Bill Bogue. “Our efforts in R&D have created a high-performing choice of solutions that addresses the problems inherent in composite machining to help shops improve both the quality and productivity of their operations.”
Each of the routers features a DURA high performance CVD diamond coating, which is thicker than traditional CVD coatings. The DURA coating provides an outstanding thermal and abrasive barrier to effectively manufacture composite materials.
The JC840 Left-Right Helix Router handles slotting operations in carbon- and/or glass-fiber composites. The JC850 Light Helix Ballnose Router is for 3D copy milling of components such as landing gear and is suitable for carbon fiber PEEK type materials. The JC860 Honeycomb Router perform slotting/side milling of honeycomb materials with carbon and/or glass top layers and paper and or/aluminum honeycomb. The JC870 Diamond Cut Router acts as a trouble shooter in slotting applications in various layered carbon and/or glass fiber materials. And, the JC880 Light Helix Router is for maximum material removal in slotting and side milling of carbon fiber and PEEK-type materials.
Want more information? Click
below.
Seco