February 2011 Product Spotlight
EXAIR’s new Long Super Ion Air Knives neutralize static electricity while blowing away dust and particulates from printed surfaces, paper, plastics and three dimensional shapes up to 96” (2438mm) across. The wide laminar airstream full of static eliminating ions is effective at high speeds and provides superior cleaning up to 20 feet away. Poor print quality, dust attraction, tearing, jamming, and related equipment downtime can be eliminated.
The Long Super Ion Air Knife is highly efficient, using only a minimal amount of compressed air at 5 PSIG to entrain high volumes of surrounding room air. An electrically powered static control bar fills the uniform sheet of air with a high concentration of positive and negative ions. The laminar airstream increases the surface exposure to the ions, making it effective for high speed processes and over long distances. Force can be adjusted from a "blast" to a "breeze". The shockless design is UL Component Recognized to US and Canadian safety standards. There are no moving parts to wear out.
Long Super Ion Air Knives are available in 60" (1524mm), 72" (1829mm), 84" (2134mm) and 96" (2438mm) lengths that are fully assembled. A factory installed plumbing kit is also available that makes it easy to connect Long Super Ion Air Knives to any plant’s compressed air system and obtain the best performance.
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EXAIR
Celeritive Technologies, Inc., an independent, third-party developer of innovative high-speed machining technologies that increase machine shop productivity, has announced the release of version 3.5.2 of its VoluMill™ toolpath software. VoluMill, the industry standard for 2- and 3-axis high-performance rough milling toolpath engines, has undergone a major re-engineering and is now 30 percent faster on complex parts than previous versions.
“The primary focus of version 3.5 was on reducing overall path length and machine cycle times,” said Joe McChesney, VoluMill product manager. “Although customers have consistently reported cycle time reductions of 70 percent or more with older versions of VoluMill, we realized that there was still room for improvement, particularly when repositioning the tool between cuts.”
Testing of VoluMill 3.5 has shown reductions in overall toolpath length by up to a third over version 3.0, and reductions in retracts to the rapid plane by up to 90%. Much of this improvement is due to Freeway Linking™, a new technique that lifts the tool slightly off the floor of the part and detours it at high speed around obstacles along a smooth path. In addition, VoluMill 3.5 introduces major improvements in toolpath sorting that minimize the length of linking moves between cutting passes.
Other enhancements include avoidance of fixtures or other obstacles, improved cutting around islands, and better use of multiprocessor computers, including dramatic reductions in processing time for the new generation of quad-core processors. In addition, VoluMill Universal™, a stand-alone version of VoluMill that can be used with any CAD/CAM system, now features toolpath verification and other new features that make part programming even easier.
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VoluMill
The new versatile KEYENCE high-speed LJ-G Series 2D laser sensors accurately measure the surface profile of targets in the X and Z directions. Considered the fastest in its class with a high-speed sampling of 3.8 ms and high-accuracy of ±0.1% F.S. in the Z-Axis, the LJ-G can perform 8-point measurements, making 100% inspections possible. No PC processing is required.
Five sensor-head types ranging from 15 mm to 200 mm can handle tight specifications for many applications in a wide range of industries. The all-in-one controller allows easy setup on screen or using the LJ-G Navigator software (optional). Also available is the capability to connect two sensor heads to one controller. Designed for intuitive operation and user-friendly setup, programming and troubleshooting are simple.
The LJ-G achieves a high-speed of 3.8 ms with the Quatro link system that enables accurate measurements on fast production lines or moving targets. Equipped with the E3-CMOS image sensor that provides stability, the LJ-G can measure virtually any targets ranging from black rubber (weak reflection) to metals (strong reflection). In addition, a 2D Ernostar lens is used to provide the optical system with optimal accuracy.
Measurements of width, profile and distance can be accomplished using 28 modes at 8 different points simultaneously: peak height, bottom height, average height, gap, width/position, section area, angle/intersection, profile comparison. A wide area coverage enables fast measurement without moving the sensor or the target. IP67 rating ensures that the LJ-G will operate safely in a water spray environment.
A multifunctional controller satisfies any need. It provides dual independent analog and discrete outputs, RS-232 port, Ethernet port, a 2-sensor head capability. A high-capacity internal memory can potentially store up to 160 programs, 1034 profiles or 65,000 data points. Simple setting, data storage and analysis can be performed with the optional LJ-Navigator software.
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Keyence
Stama America, Itasca, Illinois has introduced its MC 726/MT-2C mill/turn, twin spindle machining centers for the automotive, fluid power, tooling, medical and other industries, where parts needs to be milled and turned in production operations. This new machining center is the latest iteration of the popular TANDEM concept mill/turn centers, introduced by Stama in 2007.
Two independent spindles are onboard, each on a traveling column assembly and each supporting an independent swivel table, one of which acts with a bar feeder mechanism. Workpieces are introduced to the turning spindle, then transitioned by a conveyorized gripper assembly to the milling indexer and fed to the milling spindle, before finally exiting the work area.
Complete six-sided machining is possible between the two cutting operations, all on one machine with approximately twice the speed of a conventional m/t center in 30% less footprint. Since the first part is being milled simultaneously to the next part being turned, the overall production operation is greatly enhanced, nearly doubling in many applications.
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Stama America
The ELECT XL™ all-electric 12-axis tube bending machine from BLM GROUP USA (Wixom, MI) brings new levels of productivity, flexibility and accuracy to the bending of large diameter (up to 150 mm/6 in.) tube, making it the ideal choice for many demanding automotive, machinery, motorcycle, hydraulic, railway and shipyard applications.
Flexibility and productivity are both enhanced by the fact that the ELECT XL is a multi-stack bender capable of holding up to 8 tool sets permitting rapid processing of complex parts and faster changeover, benefits not generally associated with the bending of large diameter tubes. The machine can be converted into right-hand or left-hand configurations, and features both fixed or variable radius bending.
Changeover times are further reduced because all critical machine settings, such as clamping, pressure die, mandrel, etc., are automatically established by ELECT XL’s innovative VGP3D software and managed by the CNC control. The fact that there is no longer any need for time-consuming manual adjustments during set up, results in less scrap.
ELECT XL’s advanced all-electric design is central to its accuracy, efficiency and cost effectiveness. Electric drivers allow the production of very tight radii and of complex shapes with guaranteed repeatability. In addition, maintenance costs and downtime can be significantly reduced, thanks in part to the elimination of all hydraulic devices such as fittings, tubes, cylinders and valves. Importantly, the full-digital connections of the motors allow users to obtain diagnostic information about each machine component, helping ensure optimal machine performance and minimal downtime. The machine is also economical to operate, with power consumption reduced up to 80% compared to electro-hydraulic machines, and it is environmentally friendly since oil spills and costly oil disposal become things of the past.
Another key to ELECT XL’s superior performance is VGP3D, its easy to use, yet advanced 3D graphical programming software. By simply inputting the component’s bend coordinates the software can quickly provide real-time simulation of the bending operation and automatically correct for possible collision points. By automatically selecting optimum machine parameters for the cycle, thus decreasing setup and cycle times, VGP3D maximizes productivity, in some cases by as much as 200%, while simultaneously enhancing quality and minimizing operator involvement. The software system also permits off-line programming for high degrees of automation and production planning.
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BLM GROUP
BIG Kaiser has introduced the new, large diameter Kaiser 318 Series—a complete tooling system supporting a variety of aluminum and steel components optimized for twin cutter rough boring, precision finish boring, and precision OD turning operations.
The new series features a standard boring range of Ø7.87"-13.39" for ISO40/HSK-A63 tapers, and Ø7.87"-24.41" for ISO50/HSK-A100 and larger tapers. Special components allow the system to extend up to Ø118". The mounting flanges feature Kaiser’s new CKN modular connection with a 3-screw interface, developed for high torque transmission with light weight tools.
The system supports spindle speeds of up to 6,600 SFM thanks to safe and secure “pinned to fit” light weight aluminum mounting components. The high strength aluminum components are hard coated to protect against wear and corrosion, and all assemblies deliver high pressure coolant through the tools to cutting edges.
“The 318 series features aluminum extension slides that allow for diameter and length setting adjustments without a tool presetter,” says Jack Burley, BIG Kaiser vice president of sales and engineering. “The simplicity of this system virtually eliminates operator error during assembly and promotes safety during operation.”
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Big Kaiser
ZPS America has designed the Swiss CNC by combining traditional mechanical knowledge with the most up-to-date developments. The ZPS Swiss series covers the range from 3 to 32 mm bar diameter. The rigid, European-built machine is designed for continuous or series production of precision turned parts. Solid base casting ensures maximum rigidity and stability.
The Swiss style turning centers provide outstanding accuracy and quality surface finish conditions for precision parts. The machines are equipped with the GE Fanuc 160i control systems and drives that are capable of handling up to 12 controlled axes.
The specially developed programming software, Swiss Plus, simplifies the programming so the programmer takes in consideration only the X- and Z-axes during programming just as on typical two-axis CNC lathes.
Swiss Plus operates with Windows and offers user-friendly programming specially adapted for simultaneous operations. Each machining operation is individually programmed in ISO code with graphic interface and tool library. Swiss Plus generates the part program by taking into consideration the machine kinematics and machine requirements. The Swiss Plus, integrated in the Fanuc 18i controls, or programmed off line, ensures the full benefit from ZPS Swiss’ performance.
It's possible to machine a part with up to 4 tools cutting simultaneously. The sliding headstock provides up to 250 mm stroke that enables part machining in succession at one collet clamping as well as the machining of long parts with small diameter.
There are 23 tool stations and 14 stations can be driven, so the machine can finish the most complex parts that are otherwise machined in several operations. The use of two identical spindles increases machining capacity in rear slide operations and enables evacuation of long parts (more than 250 mm) through the subspindle.
Three live spindles may be fitted on the rear tool rack for cross drilling and tapping as well as milling with the Y-axis. Multiple live spindles also enable high-speed drilling, polygon turning or thread and slot-milling. Two axial and three transversal live spindles may be fitted on the rear machining unit in order to work via the subspindle.
To accomplish nearly any operation the machines can be provided with a wide range of optional equipment, including NC drive of the pick-up spindle, bar stock feeding and clamping, attachments for high-speed drilling, reaming, tapping and broaching, and multi-spindle drilling heads on the frontal slides.
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ZPS