August 2008 Edition

IMTS 2008 Hall F

Hall F is located in the West Building and houses Tooling & Workholding Systems

Boring bars · coolants · oils · cutting fluids · ceramics and composite cutting tools · tool coatings · drills · chucks · tools · milling cutters · form cutters · cutting tools · tooling systems · endmills · fixturing systems · gun drilling tools · cutting tool measurement/checking systems · hobs · tool inserts · jigs · key seating tools · ball nose end mills · lapping tools · magnetic chucks and plates · collets · NC tables · spindle adaptors · plates · quick change dies · reaming tools · screw thread inserts · tool storage equipment · deep hole/trepanning cutting tools · jigs and fixtures · tooling columns · universal fixturing · vises · workholding systems

 

 

Part-loading systems

For workplaces wishing to automate their CNC lathes and vertical machining centers, Midaco Corp. offers a series of robotic part-loading and unloading systems that help maximize machine throughput.

Midaco’s series are available with a variety of different robot brands, each of which can load and unload one or two machines. The systems are mounted on linear guides, so shops can move them out of the way when not in use to facilitate conventional operation of the machine tool.

Midaco Corp. Booth F-2217,

Mineral oil-free oils

The Cut-Max V500 series of neat cutting oils are biodegradable, vegetable-based metalworking oils and are free of mineral oil and chlorinated additives. The cutting oils resist oxidation and provide high natural lubricity to extend the life of cutting tools.

Their low viscosity helps maintain fluid longer and reduces dragout on swarf. They also have higher flash points than traditional cutting oils and produce less mist and fumes, reducing the risk of fire and improving worker safety. Cut-Max V500 products can be utilized for applications requiring a higher level of tooling performance or for applications where leaks and losses occur in the manufacturing environment.

Houghton International, Booth F-2317

Hexagonal chuck

Hainbuch has increased by 25 percent its TOPlus hexagonal chuck, while improving central lub rication and dampening characteristics. The TOPlus features a clamping head that is fitted free of joints and solidly to the chuck surfaces. The does not allow any radial displacement between the clamping head and chuck body, which results providing a seal against contamination.

Hainbuch, Booth F-2973

Carbide micro end drills

Emuge has released a line of solid carbide micro end mills for micro machining metals. The mills have geometrically optimized cutting edges combined with slim, concave and tapered necks to provide flexible, high-performance milling for materials from hardened steel to graphite.

The tools have cutting diameters of 0.2 to 2mm, with effective cutting length-to-diameter ratios of 2.2:1, 5:1 and 10:1.

The tools can be used to mill injection moulds, extrusion dies, and electrodes. They can also be used for high-precision surface structuring of macroscopic components and micro-mechanical parts production.

Emuge, Booth F-2667

Chuck jaw master plates

New master plates from Carr Lane are ideal for machining large thin-walled parts. Made in three sections that mount on a chuck similarly to top jaws, the plates accept a wide variety of machinable jaw segments.

The plates are available for chucks from 10 to 60" diameter, in standard height and extra high. Made of aluminum alloy, the plates’ mounting pattern is machined to the chuck’s specifications when the customer specifies make and size of chuck when ordering.

Carr Lane Manufacturing Co., Booth F-2431

Probe system

The Digi Probe System from Knaebel allows the connection of Knaebel probes to the user’s computer. Probe and digital electronics are one linearized unit and the module case can be mounted without tools. The electronics can withstand physical gaging demands, offering flexibility, speed and resolution at maximum measuring accuracy.

The Digi Probe System allows 1 to 512 connections and the possibility to connect the modules by USB, RS232, Ethernet, Wireless LAN, or Profibus to any user’s PC.

Euro-Tech Corp. Booth F-2310

Collet blocks

Hardinge collet blocks can be used horizontally or vertically on mill tables, flat or angled fixture plates, tombstones, or rotary trunnions. Sizes are available from the 1C micro medical machining industry up to the 35J mid-range automotive and aerospace industries. Modular collets blocks are compact with a low profile for increased axis travel and for maximum layout of the workspace. A collet can provide certain advantages over a jaw chuck, vise, and other clamping methods.

Collets ordered with serrations can add additional gripping power to prevent push-back and radial slipping. Extended-nose collets can provide additional tool clearance. Some collet blocks accept expanding collets to grip a part at the internal diameter.

Hardinge Inc., Booth A-8032

Coolant system

The Jet-Stream Thru Coolant System, a high-pressure control for coolant volume and pressure from Dorian Tool, is useful for both turning and threading applications. The coolant stream, when aimed at a close range of an insert, lubricates the cutting edge, thus reducing the coefficient of friction and preventing the chips from adhering to the insert.

The physical combination of high velocity and high pressure forces the hot chips away, allowing the insert to operate at more consistent lower temperatures.

Dorian Tool, Booth F-2501

Wear resistance

Using its DurAtomic coated grade process, Seco Tools Inc. offers the TP1500, which is designed for the mechanical and physical demands that come with turning steels at high cutting speeds. The DurAtomic process results in the ability to produce a coating with edge toughness in combination with wear-resistance.

While targeted specifically for steel machining, the coating and substrate properties allow the TP1500 to be used for a range of cast iron applications, including those involving ductile and compacted graphite iron. TP1500 is offered in different insert geometries to cover turning applications from finishing to heavy roughing, where productivity and long tool life are of special importance.

Seco Tools Inc., Booth F-2247

Parts accumulator

The Royal Rota-Rack parts accumulator from Royal Products is a stand-alone workpiece collection device designed to allow unattended turning work. The device indexes each time a finished part exits the machine, safely collecting, and protecting finished workpieces.

The Royal Rota-Rack offers the ability to run a second or third shifts with existing equipment and no additional employees, while the first-shift employees are freed up to handle more productive tasks.

The Royal Rota-Rack consists of a welded steel turntable, solid-state PLC control, and optional integrated conveyor. All contact surfaces are covered with a high-lubricity UHMW plastic for optimum workpiece protection.

 Royal Products, Booth F-2124

Machine-ready blanks

TCI Precision Metals’ machine-ready blanks offer the chance to reduce the cost of labor, designed to achieve lower part costs and greater efficiency.

The blanks maintain dimensional tolerances ± .0005" and squareness, flatness and parallelism tolerances of ± .0002". They are processed with double-disc grinding, blanchard grinding, duplex milling and sub-operations such as flattening, deburring, and surface improvement.

Blanks are available in aluminum, titanium, tool steel, stainless, high temperature and nickel alloys, spring steel, and other materials.

TCI Precision Metals, Booth F-2107

Collet/boring systems

The CBER Boring System, from Criterion Machine Works, converts precision ER collet holders into precision boring systems. The CBER system fits into ER20, ER25, ER32, and ER40 collet holders and uses CB style insert holders and bar holders.

The system is capable of boring holes as small as .035" in diameter to as large as 1.700" in diameter. All of the CBER sizes have a standard .001" on diameter directing reading adjustment dial. The ER32 and ER40 sizes are also available with a 0.000050" on diameter micro adjusting dial. All sizes will be available in a standard and short length.

Criterion Machine Works, Booth F-2147

Grinding chucks

SAV North America, the recently established subsidiary of Spann Automations Normteiletechnik (SAV) GmbH of Nuremberg, Germany, is launching several new workholding lines in the United States, Canada, and Mexico. The first of these is a series of fine pole transverse electromagnetic chucks for surface, or reciprocating, grinding applications.

The pole orientation of these chucks is 90° to the grinding forces. This orientation provides strong holding power than similar designs on the market. An increased number of magnetic circuits result in improved performance over other chucks in this class. The number of circuits is relational to the size of the chuck.

The SAV surface grinder chucks can offer consistent, uniform holding conditions over the entire work area. The nominal holding force is 145lb/in2 (100N/cm2). Their low profile design can increase machine capacity. This design is also available in permanent and electro-permanent variations. Standard sizes are available from stock in the Connecticut facility. SAV engineers can also design and build custom sizes for special applications.

SAV North America, Booth F-2345

High-pressure vise

The new Allmatic Titan 125 high-pressure vise combines almost all the functions of Allmatic NC and T-REX. It has a GGG 60 base with hardened and ground guideways to help provide a high level of accuracy and wear resistance.

The large side openings allow chips and cooling lubricant to escape. Threaded holes on both sides allow for the attachment of workpiece stops, and precise aligning slots in the base help ensure smooth handling. Other benefits include short set-up times, without an external power supply, and the capability to change workpieces in seconds.

At the heart of the Titan 125 is an enclosed, maintenance-free, high-pressure spindle, equipped with a wear-resistant mechanical power intensifier. Variable jaw and gripper clamping systems are other features. Pivot jaws rotate 360 degrees to compensate for non-parallel clamping surfaces and are threaded for supports. Their rear is serrated, and they are equipped with the quick change system.

Dapra Corp., Booth F-2651

Clamping system

The Unilock Clamping System from BIG Kaiser Precision Tooling Inc. can help reduce set-up time and part-processing time. Unilock’s clamping concept provides a system to position and clamp workpieces for efficient part loading. The clamping mechanism utilizes spring pressure to drive wedges against a tapered wedge lock (clamping knob). Air pressure is used to compress the springs, releasing the wedge lock.

Unilock can be used on workpieces of any size or weight. For small part machining, the system eliminates the need for repeated clamping and unclamping. For large work, a crane can be used to position a heavy workpiece into an exact position in minutes.

The system can be used in any configuration and in almost any process. Multiple receiver sizes are provided so the system size can be matched to the process.

BIG Kaiser Precision Tooling, Booth F-2114

Magnetic chucks

MagVISE EEPM (electro-permanent) chucks are used for normal and heavy-duty drilling, milling, and boring operations on medium- or large-sized workpieces. Rough and uneven stock can be held. A sliding pole extension supports uneven workpieces. A minimum of four alternate poles contact is necessary for optimum magnetic holding power. Minimum thickness of job is 3/4".

EEPM magnetic workholding chucks reduce setup time while maintaining uniform electro-permanent holding power over the entire workpiece. Since workpiece distortion does not occur, tool chatter can be minimized and surface finish and tool life can be improved.

No electricity is needed to keep the EEPM chuck connected. The magnet keeps on holding tight even during a complete power loss.

Earth-Chain Inc., Booth F-2591

Hydraulic toolholders

Schunk Inc. introduces new features to its hydraulic toolholders, modifying its bestseller TENDO to be able to clamp different types of cutting tools with cylindrical shanks directly in the toolholder without using intermediate sleeves. Torque transmission capacity has also been increased by up to 15 percent.

A steel sleeve surrounded by hydraulic fluid performs the clamping of the cutting tool. When initializing the clamping process, an internal piston forces the hydraulic fluid into a cavity surrounding the steel sleeve. The high pressure uniformly forces the sleeve around any cutting tool shank.

Cutting tools with different shanks are held with great concentricity of less than 0.002mm. The clamping pressure displaces oil or grease into the TENDO groove in the clamping bore. Clamping areas remain dry and high-torque transmission is guaranteed at all spindle speeds. The hydraulic system also absorbs vibrations inherent in the cutting or grinding processes. The results are high TIR accuracy and repeatability of less than 3 microns (0.00012"), tool life is extended up to four times, and greatly improved surface quality of machined parts.

The toolholders are suitable for high-speed and fine milling, heavy-duty milling, wood machining, high-speed machining, internal grinding, boring, and chamfering, precision reaming, and precision tool grinding. All TENDO toolholders are completely closed systems that operate free of dirt, coolants, lubricants, and chips to ensure low maintenance and high operating lifetime. As an option, TENDO toolholders are available with a radial length adjustment allowing micro-precise adjustment to guarantee higher process performance.

Schunk Inc., Booth F-2020

Rotary table

The Tsudakoma RTV-202 is a direct drive, ultra-high-speed, super-precision rotary table. The RTV-202 features a top speed of 150rpm and indexing accuracy of ±5arc sec. A Fanuc servo motor powers the gearless RTV-202 generating zero backlash.

Koma Precision Inc. is the exclusive North American importer of Tsudakoma rotary tables, Alberti angle heads and live tools, JauchSchmider EDM rotary tables, Koma Z⁺ angle heads and live tools, and Romai specialty tooling.

Koma Precision Inc., Booth F-2277

New insert grades

Featuring a Super ZX multi-layered coating, the new grades AC510U and AC520U from Sumitomo are a tool for roughing, finishing, and medium cut machining of super alloy materials.

The Super ZX Coating consists of ultra-thin layers of TiAlN and AlCrN, alternately stacked up to 1,000 layers. The AC510U grade is efficient in finish turning of exotic materials, while the AC520U grade is geared toward roughing and medium cut machining applications.

The grades are available in both molded and ground insert types. Ground tolerance inserts provide improved accuracy, significantly reducing the amount of parts scrapped.

Sumitomo Electric Carbide Inc., Booth F-2668

Automatic positioning system

OML, S.p.A. has launched its Automatic Positioning System (APS), a universal connection between the machine tool, the clamping device and/or the workpiece that allows accurate positioning and clamping in a single operation. APS can reduce setup times by up to 90 percent, and offers a high level of flexibility.

The APS System consists of clamping pins and clamping modules. Clamping pins can be attached directly to the workpiece, or to an auxiliary workholding device such as a vice or special plate. Clamping modules can be attached to fixture plates, tombstones, or rotary tables. Both positioning and clamping are done in one operation with repeatability accuracy of <0.005mm (0.0002").

OML, Booth F-2040

Face driver

LMC Workholding introduces the new Neidlein FBS MK5 face driver. The FBS MK5 features a fixed center for high-quality turning and a near-zero runout designed specifically for hard turning or grinding operations. The FBS MK5 turns a workpiece from end to end in one operation and eliminates drive dogs.

Neidlein face drivers allow the entire OD of a workpiece to be machined in a single operation, which can provide increased productivity, quality, and cost efficiency while eliminating changeovers. Mechanical face drivers are designed to be virtually maintenance-free and can allow for heavy and interrupted cuts, turn small and large parts, and increase flexibility in turning applications for faster cycle times.

LMC Workholding, Booth F-2955

TiCN-coated tap

Vega Tool Corporation’s XTF Forming Tap is a high-performance TiCN-coated tap geared toward high-speed tapping of stainless and carbon steels.

XTF Forming Taps produce threads by displacing material to create the thread form. According to the company, since there are no cutting chips, higher speeds can be achieved compared to conventional cutting taps. XTF Forming Tap’s crests are rounded off to promote smooth plastic flow and prevent cracks and burrs in the root of the internal thread.

XTF Forming Taps feature a high Cobalt HSS substrate designed to improve the taps’ hardness and heat-resistance.

Vega Tool Corp., Booth F-2984

Five-axis clamping

A Kurt Workholding response to five-axis machining operations is a new five-axis clamping system. It allows continuous five-axis cutting motion of complex pockets, sculptured and contoured surfaces, and intricate 3-D features with repeatable high-precision accuracy.

Called the Kurt VB 5X100 Schenke 5.1 Clamping System, this system provides a clamping force up to 8,992lb (40kN) for obstruction-free, high-speed machining in all five axes. The system is adjustable to handle any desired clamping width and it is limited only by the size of the machine table. The system’s two clamping jaws, one stationary and one moveable, can be positioned at any desired distance from each other.

The system eliminates jaw deflection and/or part misalignment during machining operations. By locating the tension spindle directly under the workpiece, the jaws do not flare out under tension and the machine table does not distort. The system handles blank workpieces, machined workpieces, and round and irregularly shaped workpieces with repeatable accuracy.

Specifications of the VB include a clamping width from 0.0787 to 9.291" (2 to 236mm) that can be extended with optional spindle screws, a clamping depth of 0.315" (8mm), height above the machine table of 6.889" (175mm) with extended height options to 7.874" (200mm) and 8.858" (225mm). The system is designed to mount on standard T-slot tables, location grid machine tables, or custom fixtures.

Kurt Manufacturing Co., Booth F-2565

Production vises

Jergens Inc. has launched a new series of hydraulic-powered production vises. The vises combine an innovative compact design with jaw changeovers taking less than a minute to provide significant flexibility to workholding. Internal hydraulics provide up to 4,700lb clamping capacity.

Three base styles are available. The Ball Lock Mounting System style features an interlocking “jigsaw” pattern, which permits multiple vises to closely nest together, maximizing workpiece density on a fixture while simultaneously allowing changeover of entire vises in a minute. The universal base style mounts directly to machine tables. The narrow base style is designed for stand-alone fixture plate mounting while providing high-density capability.

The vises have many other advanced features to help speed production — all jaws are fully machinable and reversible, providing more flexibility for each jaw set; steel rails are hardened and ground for accuracy and repeatability; a flow-through base lets chips and fluids escape; and a fully sealed lead screw assembly reduces maintenance.

Jergens Inc., Booth F-2540

Adapters accept collects

Preci-Flex system adapters are available for standard mill/drill operations, end milling, tapping, and shell mills. Collet chucks can be adapted to reduce overhang and tool interference. The basic adapters accept standard collets in ER 25, ER 32, or ER 40 pocket configuration.

These adapters fit into this pocket of the basic holder in an axial or radial configuration for fixed and live tools. Reduced setup times and short setup cycle can be attained. Repeatability of this system is in the low microns.

Exsys Tool Inc., Booth F-2407

Live tool square drives

SMW Autoblok’s live tools feature gears with a square drive for uniform torque, minimized backlash and reduced tool noise. The special sealed, precision, dual-spindle bearings allow for even flow of grease between bearings, resulting in reduced heat and extended bearing life. Additionally, all live tools are completely sealed to resist outside contamination and coolant intrusion.

Available in straight, right angle, offset and adjustable angle styles, the live tools are equipped with either an ER collet or face mill output spindle. Coolant-through the tool ranging to 1,000 psi is available on most styles, and special-application live tools are available upon request.

SMW Autoblok, Booth F-2040

Heavy duty swing clamps

Fixtureworks has launched a new series of Imao swing clamps that provide approximately five times the clamping force of Imao’s standard swing clamp configurations. The heavy duty series of clamps is suited for fixture, jig, and workholding devices of all designs and highly repetitive applications or for use with conventional work piece requirements.

Within the clamp series are two size ranges — the first provides up to 786lb. of clamping force while the larger size offers pressures to 1,348lbs. Though increasing the holding strengths significantly, each clamp body diameter is only 10mm larger than its standard size counterpart.

The clamp arm lengths are 42 and 48mm, respectively, and are complete with a tapped hole on the clamping arm for provides knife edge, slot, uniforce, toe, low profile, and expansion clamp designs.

 Fixtureworks, Booth F-2610