August 2008 Edition

IMTS 2008 Hall A

Hall A is located in the South Building and houses Metal Cutting:

Machining centers · turning centers · assembly automation · milling machines and centers · boring machines · drilling machines · transfer machines · screw machines · broaching machines · skiving/trepanning/roller burnishing machines · gun drilling machines · planer/mills · boring mills · multiple spindle drills and automatics · drill/mill/bore heads and slides · thread rolling · jig boring/milling machines and knurling machines · VTLs · bar feeds · automation systems · assembly machines · end finishers · machining cells · chuckers · CNC lathes · Flexible Manufacturing Systems (FMS)

ID/OD grinding machine

Kellenberger designed its ID/OD grinding machine, the Kel-Vita, with numerous wheelhead configurations, low friction linear rails, and a newly-developed CNC control.

The Kel-Vita offers eight different grinding wheelhead types, providing flexibility for the customer to design a specific machine configuration. UR and URS wheelheads feature a unique swiveling design with two external (and one internal) grinding wheels. They are capable of performing multiple processes, including external diameters, opposed faces, bores, tapers, polygons, tapered non-rounds and thread grinding — all in a single chucking.

Other wheelhead configurations are offered: OD only (R) and OD and face (RS). Grinding wheels up to 500mm OD can be used.

Kellenberger Inc., Booth A-8032

Gang tool lathe

SNK’s Prodigy GT-27 gang tool lathe features C-axis spindle as standard, a polymer base and precision components for accurate small parts turning. The nature of the design of the gang tool lathe, where the absence of a turret eliminates tool changes, lends itself to shorter cycle times, as well as higher precision. The Prodigy GT-27’s spindle speeds reach up to 6,000rpm.

The Prodigy GT-27 lathe uses three axes of motion that can be commanded in absolute or incremental modes. Its C-axis spindle allows for indexing and positioning as well as more advanced functions including interpolation and polar coordinate milling.

SNK America, Inc., Booth A-8432

Steady rests

LNS America has developed new steady rest configurations for a variety of applications that allow precise machining of exceptionally long workpieces used in oil drilling and large truck drive shafts.

These systems can also be used in any application in which the length and stiffness of a workpiece makes it difficult to machine without distortion or deflection.

In addition to a broad assortment of quality steady rest components, LNS devotes applications experience, 3D design capabilities, and nationwide service and support to every steady rest project. 

LNS America Inc., Booth A-8755

In-line twin spindle lathe

The twin spindle/twin tailstock ANW-3500S from Fuji is suited for shaft turning applications. It handles heavier workloads, larger machine envelopes, and higher machine powers and torques than previous models. Applications for the 3500S include drive pinions, CVTs, CVJs, and outer races.

The dual spindles operate at 20/25 hp each. An A2-6 spindle nose comes standard; an A2-8 spindle nose is available as an option. The lathe features MT.4 tailstock, a quill stroke of 130mm and a work size of 120mm × 250mm.

Fuji Machine, Booth A-8721

High-speed horizontal machining center

Enshu’s JE80S, a high-speed horizontal machining center, features a 300-tool matrix-style tool magazine and an 18-pallet flexible manufacturing system (FMS). The JE890S adds 31.5" X, Y and Z travels atop of 500mm pallets within a smaller machine footprint. The standard dual-contact 40-taper spindle ramps up to 15,000rpm in 1.9 seconds and develops 24.8hp at 1,061rpm. Achieving rapid traverse rates of 3,543ipm at 1G acceleration, the JE80S can become a suitable tool for increasing production.

The FMS is capable of storing both machine pallets and storage baskets interchangeably. It is designed with a unitized steel frame and comes standard with two levels of pallets.

Enshu Corp., Booth A-8717

Flexible/rotary center

Hydromat has developed a new machining center, the ICON 6-250, which combines flexible machining principles with rotary transfer production philosophy. The ICON features four cutting stations and can produce five-sided machining with four-axis interpolation. Each machining unit is equipped with its own 10-tool changer for specific applications.

A six-position pallet changing table quickly transports the 300mm workholding pallets to the index drives at each cutting position, or to two other stations. The ICON’s loading station is designed for manual or robotic production configurations, and an idle station has been incorporated for reclamping or gauging processes. 

Hydromat Inc., Booth A-8435

Bar feeder keeps pace

Iemca, a manufacturer of automatic bar feeders for single-spindle and multi-spindle lathes, is showcasing its Elite 112 bar feeder. It is able to feed bars of 0.8-12.7mm, even on lathes with high rotation and headstock acceleration speeds, without limiting performance.

The Elite 112 features a hydrodynamic guide channel system, which enables quick changeover and reduced noise and vibrations. Its design allows the guide diameter to be changed by switching the front guide sections. The bar pusher is contained in a tube fixed to the upper wall of the rear guide. 

Iemca, Booth A-8274

Vertical machine center

Designed for precision machining of mold and die parts, MAG Fadal’s VMC 4525 combines a 53.5 x 25" table with 15,000rpm air/oil spindle and Infimatic Freedom NC200 control with a CAD/CAM software package for mold and die.

The high-speed spindle enables fast axis feeds and fine finishes, while air/oil injection yields extended duty cycles. Its C-frame architecture provides vibration damping to deliver heavy cuts with tolerances to ±4 µm (0.00016"). XYZ travels of 1,143x635x609mm (45x25x 24") allow processing flexibility handling large mold workpieces or enabling simultaneous machining of matching die halves.

MAG Fadal, Booth A-8218

Laser drilling machine

Mitsui Seiki’s VLD-300 is a small, vertical, Nd:YAG laser drilling machine for 12" cube parts (300mm x 300mm x 300mm in X-, Y-, Z-axes). This machine was developed by aerospace engine component manufacturers who expressed a need for high-speed and accurate laser-drilling machines.

The VLD-300 offers positioning accuracy and repeatability in X-, Y-, Z-axes of 0.00004" (0.001mm). It is designed to also work with CO2, diode pump, and fiber lasers for different aerospace and other industry applications, such as certain electronics, medical, and automotive parts. 

Mitsui Seiki, Booth A-8767

Horizontal machining center

The G350 horizontal machining center from GROB Systems Inc. features multi-tasking capabilities of up to five axes productivity. It incorporates a slide-mounted spindle module that results in a precise and stable Z-axis for extra tool rigidity. The GROB design locates the spindle module and table to one side of the machine’s centerline, providing front and side access for part loading and tooling inspection.

With the control on the side, the G350 provides clear sightlines to review programming inputs and tool paths. Its lateral layout also creates a stand-alone machine having a small footprint for space-saving efficiency or ergonomic integration into cells and systems.

GROB Systems, Inc., Booth A-8163

Small flat tape layer

MAG Cincinnati’s Small Flat Tape Layer (SFTL) for automated composites fabrication, the latest in its Charger series, enables a transition from metal to composite structures and from hand lay-up to automated tape lay-up.

The SFTL, with its bed-type configuration, features a simplified but versatile tape head and integral vacuum lay-up table. It is offered in two models and can produce laminates up to 47" wide on the standard width machine and up to 100" wide on the wide version platform.

Either model can be configured with additional bed and vacuum table modules to increase the maximum laminate length in 1m increments. 

MAG Cincinnati, Booth A-8218

New five-axis machines

Hurco’s SR five-axis machines are designed to tackle complex, multi-sided parts with a B-axis swivel head and a C-axis rotary table design. The machines include a special version of WinMax control software to help streamline setup and simplify programming for complex parts.

Among the features are a B-axis with table removed, which means access to four axes; heavier digital servo drives; larger ball screws; and larger linear rails to help increase accuracy and surface finish.

X-, Y-, and Z- axis travel, inches (mm), is 42 x 24 x 24 (1,067 x 610 x 610). The peak spindle motor delivers 48hp. Number of tools standard is 40 CAT 40. 

Hurco Companies Inc.

Traveling column machining center

The SHW UniSpeed 5 traveling column machining center from Bohle Machine Tools can complete parts in a single setup with five-sided machining. The UniSpeed is designed for precision applications in aerospace, petroleum, mold-making, and subcontracting.

With a work envelope of 63x63x47" (X, Y, Z), speed, and five-sided machining and turning capabilities, the UniSpeed 5 offers versatility with its ability to reduce in-process times. The UniSpeed features an SHW universal spindle head for high-speed machining, offering five-sided machining with 64,800 programmable spindle orientations.

Bohle Machine Tools, Booth A-8462

Horizontal boring mill

The FT 3500 HBM, from MAG Giddings & Lewis combines a range of part capacities with design flexibility. Customers can configure an HBM specifically to their needs for maximizing productivity. Two available platforms (FT and ram-style FTR) can be fitted with choice of travels, headstocks, spindle diameters and spindle power, controls, coolant systems, workholding, and tool magazines.

The FT 3500 features 10m (32.8ft) of X travel and 3.6m (11.8ft) of Y travel, but standardized modules allow HBMs to be configured with travels from 4 to 16m (13.1 x 52.5ft) and Y axis headstock travel to 5m (16.4ft).

MAG Giddings & Lewis, Booth A-8218

Turning center

Equipped with two spindles and three turrets, Miyano’s ABX Super Turning Centers are capable of processing complex parts in a single setup.

The ABX-51TH3 has two upper turrets on the left and right side, both with Y-axis controls. A lower turret, capable of working on both the left and right spindles, makes a total of 36 tools (with all tool stations able to utilize live tools) available to perform complex front and back operations simultaneously.

Miyano Machinery, Booth A-8717

Swiss-type turn-mill

The C100 series of production turn-mill centers from Index Corp. has three 14-position tool turrets and identical main and counterspindles, designed for production of medium complexity parts turned from bar stock of 30 to 42mm diameter. The machine occupies a small floor space, and is targeted toward fixed headstock work often run on Swiss-type machines.

Index Corp., Booth A-8253

Five-axis HMC

Makino’s MAG1 is the latest in the MAG series of five-axis horizontal machining centers designed to handle quick, high precision aluminum production of parts up to 1,500mm.

The MAG1’s construction features a three-point support system that eliminates leveling maintenance and reduces the cost of installation, and a 60-position automatic tool changer (up to 120 available), allowing continuous, uninterrupted machining.

The MAG1 also features Super Geometric Intelligence v.4 (SGI.4) control technology to allow for high feed machining without losing accuracy, and monitoring software for users to keep constant watch on bearing temperature and vibration during cutting.

Makino Inc., Booth A-8301

Turning centers

Hardinge Inc. is expanding its line of turning centers with the GS 200 MSY and GS 250 MSY Performance multitasking turning centers. The GS-Series expands levels of functionality to address complex parts resulting in increased throughput and reduced cycle time in a single setup.

The multi-axis machines include dual wound spindle motors featuring 30hp (22kW) on the main spindle and 20hp (15kW) on the sub spindle, 10hp (7.5kW) live tooling with C-axis, Y-axis, and spindle orient as standard equipment for complex multitasking operations.

Both the main and sub spindles feature wraparound high torque motors designed for optimum thermal stability. 

Hardinge Inc., Booth A-8032

High-productivity horizontal

Haas Automation’s newest horizontal machining center, the EC-550, represents the latest expansion of the company’s line of high-productivity HMCs. The EC-550 features a 30" x 34" x 32" work envelope, 50-taper geared-head spindle, dual pallet changer with 550mm pallets, 50-pocket side-mount tool changer and a built-in 1-degree pallet indexer.

The EC-550’s standard geared head couples the motor directly to the spindle through a Haas-built, high-precision gearbox.

Each of the EC-550’s pallets handles a 2,205lb load, and the servo-driven pallet-changer swaps pallets quickly. For long-cycle production with minimal downtime, the EC-550 is equipped with a large-volume coolant tank and a high-capacity belt conveyor for chip removal. 

Haas Automation, Booth A-8000

32mm Swiss-turning machine

Tsugami’s newest Swiss-turn, the SS32 model, is designed for shorter cycle times and premium performance, offering new Swiss capabilities. The machine’s standard main spindle configuration includes seven turning tools, five cross rotary tools, and five ID tools.

The standard sub-spindle setup includes three ID stations and three face drills and can include up to two cross rotary drills. Thread whirling, polygon turning, and angular face drilling operations are possible with an adjustable face tool attachment.

The Tsugami SS-32 can handle cross and face milling, drilling, and tapping, as well as angular drilling, thread whirling and polygon turning.

Rem Sales/Tsugami, Booth A-8701

Boxway horizontal machining center

Kitamura’s Mycenter-HX1000i horizontal machining center is designed to produce close tolerance parts from the tough materials. An induction-hardened solid boxway design, combined with the rigidity of high-grade Meehanite casting, offers the stiffness needed for high precision, hard milling of larger parts.

Guideways are equipped with high precision twin ballscrews and twin servo motors that provide the capability of running speeds of 1,417"/min. With a net weight of 126,104lb and linear scale feedback on all axes as a standard feature, the Mycenter-HX1000i has accuracies of ±0.000079”, full stroke, and repeatability of ±0.000039". 

Kitamura Machinery, Booth A-8054

Taper VMC

Methods Machine Tools Inc.’s new F Series RoboDrill offers fast drilling and tapping, high-speed milling, precision boring, and high-speed deburring. The RoboDrill is capable of rigid tapping to 8,000rpm, peck tapping for blind holes, and high-speed reverse tapping.

Speed and versatility make the RoboDrill suited for offloading larger, slower machines as well as for performing secondary operations, regardless of production volumes. The RoboDrill can be equipped with a pallet-changer system or a high-speed six-axis robot. With a PC-2 Pallet Changer system, the RoboDrill offers the changeover flexibility of a stand-alone machine plus the productivity of a pallet shuttle.

Methods Machine Tools Inc., Booth A-8517

Four-spindle CNC lathe

Kitako has added a new generation, four-spindle CNC lathe to its line, the HS4200i with ultra high-speed automated gantry loader. Available from SB Machine Tools, the CNC lathe offers X-axis gantry loading feed rates of 6,700ipm. The four-spindle operation and gantry loading capability accomplish unattended operation with no idle time for part loading/unloading. Carrier indexing time is 1.5 seconds, and 0.3 seconds for turret indexing per station.

Operating much like a pallet changer on a machining center, parts are transitioned in and out of the machining zone in as little as 0.8 seconds each. The HS4200i’s maximum spindle speed is 4,500rpm (5,000rpm optional). Each slide features a high-speed eight-station drum turret. Chuck sizes are 8".

Kitako, Booth A-8276

Three-milling HPM

GF AgieCharmilles’ Mikron HPM 600 HD high performance machining center offers three-axis milling, high spindle speeds up to 20,000rpm and high chip removal rates.

Built with a one-piece polymer granite base to provide high performance, the machine performs high precision cutting of materials such as alloyed steels and aluminum. The integration of a pallet changer allows repetitive machining without interruption in multi-shift operations for efficiency.

GF AgieCharmilles, Booth A-8343

HMC for large parts

MAG Hüller Hille’s new NBH 5+ Speed horizontal machining center combines a center work envelope with a 15,000rpm motorized spindle, 90m/min (295ft/min) linear feeds, and 80 rpm B-axis.

The machine will handle large aluminum parts or tombstones in automotive, electronic, and general industrial applications. Through-spindle coolant at 40bar, a 134-tool magazine, and an integrated spiral chip conveyor can provide flexible processing capability and high-volume metal removal capacity.

MAG Hüller Hille, Booth A-8218

HMC features 60-tool storage magazine

Mazak’s Horizontal Center Nexus 8800-II features several design innovations. These include a roller gear cam mechanism for the C-axis, a different design for the slideway covers, a new tool-change mechanism, and an increased tool capacity.

The unit has a 60-tool storage magazine, and a 10,000rpm, 50hp integrated spindle which generates up to 1218Nm of torque. The spindle can be upgraded to either an 8000rpm/50hp or a 16,000rpm/50hp unit. The machine has a 110.4 ton base and column, rigid in construction and designed to accommodate the torque levels.

A standby mode in the 8800-II automatically stops various components when the machine is unused for a period of time.

Mazak Corp., Booth A-8101

Bridge-style design five-axis machine with rotary table

The Bridgeport XR 600 5AX features a rigid bridge-style design and 45mm fixed pre-tensioned double-nut cooled ballscrews on all linear axes. The 600mm (23.62") diameter integrated dual-axis rotary table with 150-degree tilt and 5-arc second accuracy gives the machine flexibility and high precision machining capability. The 48-tool carousel-type automatic tool changer (ATC) features random access, bidirectional indexing, and 4.9-second chip-to-chip change time.

The 33.5-hp (25kW) 15,000-rpm Weiss directly-coupled spindle option offers high metal removal rates and the ability to run at high spindle speeds for long periods of time due to the unique grease replenishment system. This highly stiff and thermally-stable spindle design can eliminate belts and gearboxes.

Bridgeport/Hardinge, Booth A-8032

VMC for aerospace

Developed for the aerospace industry, the Mighty USA Viper Pro-4210TS is a three-spindle, full-range cutting, bridge-type vertical machining center.

The VMC is capable of cutting three identical aerospace structural parts simultaneously to save cycle time, operation overhead, and increase productivity. Cutting materials ranging from aluminum and tool steel to titanium and Inconel can be handled.

Tripling production can be completed in each single operation, saving floor space with only one machine needed instead of three.

Mighty USA, Booth A-8058

Gantry-design machining center

Hermle has introduced the B 300 machining center, which utilizes patented gantry design for fast, precise movement, a trunnion table mounted on precision bearings for optimum performance in multi-axis work, and a mineral casting base offering low thermal conductivity and vibration dampening properties.

The B 300 is available in both three- and five-axis configurations. The three-axis version features a rigid clamping table measuring 1,000x560mm with a load capacity of 1500kg. The five-axis version utilizes an NC controlled swiveling rotary table, 280mm in diameter with the maximum load of 250 kg. A variety of clamping plates are available as options.

Hermle Machine Co., Booth A-8265

MN/CNC lathe

Toolmex Machinery, specializing in rugged long-bed Manual Plus CNC lathes, has launched its newest MN/CNC lathes.

The TRI-V bedway design on Toolmex TUR is a feature for difficult turning and boring applications, while extending the lathe’s life and protecting it against instability and wear. All Toolmex TUR-MN/CNC 22"-25"-28"-32"-37"-43" swing lathes now feature this bedway design.

Toolmex Machinery, Booth A-8535