March 2008 Edition
WESTEC 2008
WESTEC 2008 Preview
The WESTEC show returns to the West Coast for the Society of Manufacturing Engineers' annual display in Los Angeles
An estimated 600 exhibitors will be on the Los Angeles Convention Center floor, March 31 to April 3, showing the latest technologies in machine tools, metalworking, and advanced manufacturing at the WESTEC 2008 Exposition & Conference. New at the show will be Back-to-Basics workshops, and demonstrations of basic machining and milling, to create career pathways in manufacturing to provide qualified manufacturing professionals.
Back will be the Comparative Process Technology Forum. A comparison of the benefits of technologies such as grinding versus machining; waterjet versus laser, EDM, wet machining, or MQL; and manufacturing comparisons.
Free to all attendees will be sessions focusing on business solutions. The Business Management Strategies — Solutions for Small & Medium Sized Businesses, cover a range of topics, from financing to lean principles.
Optomize NC Programs
VERICUT 6.2 lets manufacturing engineers develop, analyze, inspect, and document the CNC programming and machining process. The application eliminates manually proving-out NC programs. It reduces scrap loss and rework. The program also optimizes NC programs in order to both save time and produce higher quality surface finish. The software simulates all types of CNC machine tools, including those from leading manufacturers such as Mazak, Makino, Matsuura, Hermle, DMG, DIXI, Mori Seiki and Chiron. It runs standalone, but can also be integrated with leading CAM systems such as Catia V5, Unigraphics, Pro/E, MasterCAM, EdgeCAM, and GibbsCAM. CGTech, Booth 2628
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Waterjet Cutting at 87,000 psi
The Integrated Flying Bridge and WMC2 waterjet machines incorporate 87,000 psi waterjet cutting. HyperPressure technology enables faster, more cost-effective cutting, lower part cost, and higher production. Compared to 60,000 psi operations, it offers cutting speeds up to 50 percent faster, with up to 30 percent lower part cost, and from 30 to 50 percent less abrasive use. Flow International Corp., Booth 3350
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Digital Readout and Scale
The ND 500 mid-level digital read-out system is coupled with an LS linear scale. It comes in two- or three-axis versions, with an LCD screen, and offers many standard functions for both milling and turning applications. Also on display at the company's booth will be the TS 444 battery-free probe, with its built-in air turbine generator and capacitors that use the same burst of air that cleans the part to charge the probe. The TS 740 probe, with a ≤1µm accuracy, and repeatability of ≤0.25µm, also will be on display. Heidenhain Corp.,Booth 2612
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Metal-cutting Bandsaw with Dual Columns
The Model DC-310NC II, a dual column metal cutting bandsaw, will be introduced at the show. It has a 1-1/4" blade and a 5 hp AC inverter band drive system with variable speeds from 50 fpm to 400 fpm for cutting materials up to 12" diameter rounds and 12"×12" rectangles. The saw has a floating style index assembly with automatic multiple-indexing slues right or left on a roller-style bed to accommodate crooked stock. Linear ways support the dual column saw head. It offers a split-style front vise assembly with full-stroke cylinders that hold the workpiece on both sides of the blade. A work-height sensor detects material height for rapid head approach and minimized upward travel of the head. DoALL Sawing Products North America, Booth 4344
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Waterjet and Pneumatic Drill Combo
The High Rail Gantry waterjet has an iP60-50 ultra-high pressure intensifier pump and a self-feeding pneumatic drill, capable of producing complex parts out of almost any material. It features an overhead design for full access to the work envelope, and raises critical components out of the process environment. It uses high-volume, low-pressure air around the ball screws and linear motion guides and bearings, which increases durability by preventing contamination from entering these areas. The waterjet has a ±0.005" accuracy of motion over the entire work envelope, ±0.001" linear positional accuracy over 12" travel per axis, and ±0.001" repeatability bi-directional. It is available in 2' increments. Custom sizes are available. Jet Edge, Inc., Booth 4112
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"Smarter" Machine in a Smaller Footprint
The Hyper Quadrex 150 MSY is a new generation of the Multi-Tasking Integrex i-150 Machining Center featuring a smaller footprint and more intelligent functions than previous models, and designed for multi-tasking of cylindrical and prismatic parts completed from bar stock. It is designed for high-volume, done-in-one production of turned and machined workpieces from bar stock up to 2.56" in diameter. It features two horizontally opposed spindles for turning and C-axis control, plus two full-function tool turrets with milling capability. Each turret offers a complement of 12 VDI-type tools, including 7.5 hp, 6,000 rpm live spindles for milling, drilling, and tapping operations. Mazak Corp., Booth 2900
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Portable Mag Drill Goes to 2" Deep
Two holemaking products will be featured, along with a range of portable equipment and series of annular cutters designed for on-site fabrications or for work in machine shops where workpieces are large, heavy, or too awkward for processing in stationary machines. The Model HMD904S Swivel Base Portable Magnetic Drill features a drill body/magnetic base coupling that provides dual axes of motion-pivoting 1-1/8" side-to-side motion and sliding 1-3/8" for front-to-back travel after magnet engagement. The HMD904S weighs 30.5 lb and provides drilling capacity to 1-1/2" diameter and 2" depth. Also shown will be the carbide-tipped Holcutter Sheet Metal Cutters available in diameter sizes from 11/16" through 3". Hougen Manufacturing, Booth 2720
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Hydraulic Clamps Grip up to 5,000 lb
Hydraulically-activated clamps are available either in top or bottom flange styles, with either single- or double-acting actions. Either style can be manifold-mounted, utilizing #2 SAE ports, or can be plumbed conventionally through two #4 SAE ports. Three sizes are available, with clamping capacities from 1,100 lb to 5,000 lb. The clamps' piston rotates 90° to the right in its standard configuration, but may be ordered with either a 90° left rotation or no rotation. The clamps can be used via a through hole bottom mount or top plate mount. Non-threaded bodies simplify mounting. Jergens, Inc., Booth 4001
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Quick Covers
Machine protection and coolant management products, including steel way covers, bellows, wiper systems, roll-ups and apron covers, as well as chip conveyor systems, will be offered to viewers at the show. The manufacturer has eight North American service centers, and is able to provide same-day turnaround of repair diagnoses and cost estimates on damaged steel covers. The company provides repair and refurbishment services for both its own and other way covers. The firm's line of chip conveyors includes the Chip Disc Filter and the Cast Iron CDF, designed to catch cast iron fines. Hennig, Inc., Booth 5628
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Software Release Debuts
GibbsCAM 2008 will be previewed at the show. This release introduces capabilities across the entire product family, along with a range of 3-axis milling functionality with support for high speed machining. Some of the enhancements in the release include virtually unlimited undo/rollback capability; multiple viewport display capability; toolpath tool traversal visualization; hidden line toolpath display; pre-select highlighting; expanded display color management; and advanced 3D, high-speed machining for SolidSurfacer. Gibbs and Associates, Booth 3268
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Horizontal Milling Machine Capabilities Expanded
The EC-630PP HMC expands the production capability of the company's EC Series of horizontal machining centers. The addition of an integrated, six-station pallet pool to the HMC brings lights-out machining capability to small- and medium-sized manufacturers and production shops. Designed for high-volume production and unattended operation, the EC-630PP features a 40"×33"×35" work envelope, a 50-taper geared-head spindle, a six-station pallet pool with 630mm pallets, and a 1° pallet indexer. The unit is equipped with a 72-pocket side-mount tool changer, a large-volume coolant tank, and a high-capacity belt conveyor for chip removal. Haas Automation, Booth 3200
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Bio-based Cutting Fluid is a Renewable Resource
The PC Series cutting fluid is a combination of vegetable and polar cutting technology lubrication delivered directly to the tool/work piece interface. In addition to lubricating the tool, polar cutting technology lubricates the work piece/chip discharge zone. The PC Series is bio-based, renewable vegetable oil for use on alloy steels, titanium, and other exotic materials. The lubricant features very high flash point technology. Hangsterfer's Laboratories, Booth 3849
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Hole Control With the Operator
The SV-1015 series vertical CNC honing system with integrated air gaging system, when matched with diamond-plated CGT Krossgrinding tools or MMT TurboHone multi-stone mandrel, can control hole size to accuracies of 0.25µm without operator intervention, working in a size range of 0.120" to 2.56" in diameter. The machine provides closed-loop control of tool size, along with downloadable SPC data, for automated, high-Cpk production of small engines, hydraulic valves/bodies, fuel injectors, gears, compressor parts, turbocharger housings, and gun barrels, in medium and high volumes. Sunnen Products Co., Booth 2916
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When Darkness Falls
The Digital Elite Series auto-darkening welding helmets offer one helmet for welding, cutting, and grinding. Building on the features of the Elite series helmet, the Digital Elite series switches between four modes: welding, cutting, grinding and X-Mode, while retaining the preferences for shade, sensitivity, and delay. The X-Mode eliminates interference from sunlight and out-of-position welding angles, such as those found in pipe welding or in obstructed or hidden-cavity welds. Miller Electric Mfg. Co., Booth 4161
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Workholding System for Small Parts
The QwikStack is designed to use large workholding systems for high-density, small workpieces by interfacing directly with Chick System 5 1550 QwikLoks and MultiLoks. This also creates a pallet-changing system that allows for seamless transition between jobs, since the unit is removed in seconds. The QwikStack can be mounted to a VMC's T-slotted table using toe clamps. Up to ten 2" QwikLoks can be mounted horizontally, creating 20 small-part clamping stations, or six QwikLoks can be mounted vertically to add even more versatility to the QwikStack. Chick Workholding Solutions, Inc., Booth 4423
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How High? This Will Tell
The Digimar 817 CLM Height Measuring Instrument offers three ways to initiate measurement. In addition to keypad initiation, a Quick Mode feature starts the measurement cycle by pushing the carriage in the direction of the object to be measured. Also, two Speed Keys on the base let the operator move the measuring carriage to the desired position and start a measurement. Combined with a Teach-In Mode, these features can reduce inspection time for a mini series consisting of only a few test pieces. Mahr Federal, Booth 2416
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No-turret Gang Tool Lathe
The Prodigy GT-27 gang tool lathe features a standard C-axis spindle, 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 short cycle times, with spindle speeds reaching up to 6,000 rpm. It uses three axes of motion that can be commanded in absolute or incremental modes. The C-axis spindle allows for indexing and positioning as well as interpolation and polar coordinate milling. SNK, Booth 3544
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Wee Inserts
The MiniGROOVE ‘N TURN is a line of inserts for customers that need to both groove and turn using narrow insert widths in small bores. The offset insert design allows grooving or turning up to a shoulder. The toolholders' clamping geometry and built-in stop prevent slippage and rotation during axial or radial cuts and allows the user to groove, turn, and profile. Toolholders start with minimum bores of 0.325" and are available in sizes of 1/4", 3/8", 1/2", and 5/8" in steel, heavy metal, and carbide with straight and 90° insert presentations. The same insert can be used for internal grooving, face grooving, profiling, or boring. Inserts are available in groove width sizes of 0.004" to 0.125" in 0.001" increments with either sharp corners or corner radius. Inserts are available in two sub-micron grain carbide grades: DM-2 for steel and interrupted cutting, and DM-5 for aluminum and other non-ferrous alloys. Kaiser Tool Co., Inc., Booth 3557
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6-axis VMC
The JobShop Cell is an integrated production cell combining a RoboDrill Vertical Machining Center with a FANUC 6-axis robot for automated loading/unloading. It can handle almost any part that will fit in its 6" vise or chuck. It comes with inbound and outbound conveyors and guarding. The heart of the cell, the automotive-duty-rated FANUC RoboDrill VMC, offers a 14-tool — or optional 21-tool — tool changer. It also offers torque to 56 ft-lb, rigid tapping to 5,000 rpm with 8,000 rpm optional, accelerations in X-, Y-, and Z-axes to 1.5 g, rapid traverses to 2,125 ipm, feed rates to 1,181 ipm, high-speed reverse tapping, thread milling, 1,000 registerable programs, and 54 work offsets. Methods Machine Tools, Booth 3032
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Parts Programming Combination
Mastercam will be featuring several items at the trade show. Feature-based Machining evaluates parts and program pockets, contours, bosses, and drilling routines with minimal user input. Mastercam for SolidWorks is an integrated CAM system that runs in SolidWorks. SolidWorks users can now program their parts directly within SolidWorks using Mastercam's toolpaths and machining strategies. The latest release of the CAM package, X2MR2 will be demonstrated, features include Peel Milling toolpath which moves the tool in and "peels" away material, layer by layer; an Operations Manager pane that floats to a different area of the graphics window or to a separate screen when working with dual monitors; the Create Boundary function, which expands toolpath boundary creation, restricting the toolpaths to specific areas; common edge nesting optimization support; and other features. CNC Software Inc., Booth 3258
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5-axis Machining in Less Space
The VMX42SR is designed with a swivel head and horizontal rotary table to meet the demands of 5-axis machining without taking up as much floor space as other systems. In addition to a small footprint, it includes a version of WinMax control software designed to simplify setup and programming of complex, multi-sided parts. The VMX42SR delivers part accuracy with digital drives, larger ball screws, larger linear rails, and heavier servo drives with the following specifications: X-, Y-, and Z-axes travels of 42"×24"×24"; maximum weight on table of 1,100 lb; maximum spindle speed is 12,000 rpm; spindle motor peak of 48 hp; max spindle motor torque of 87 ft-lb at 2,900 rpm; number of tools standard — 40 CAT 40; positioning of ±0.0002"; repeatability of ±0.0001"; and a machine weight of 16,640 lb. Hurco Companies Inc., Booth 2500
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Turning, Drilling, and Milling All in One Lathe
The TNW-3500R automated lathe provides turning, drilling, and milling operations in one machine. It features twin spindles, a gantry robot, and slant bed. A live tool turret performs secondary operations with a tool motor rated at 3/5 hp. It features a gantry loader with a 22 lb capacity and dual 10 tool turrets. Its A2-6 spindle turns with a 15/20 hp spindle motor and operates at a maximum of 4,200 rpm. A work stocker of 12 stations, chip conveyor, and a set of turret holders are included. It comes with a Fanuc 310i-A CNC Control. The recommended gantry robot work size of the TNW3500R is 7.5"×4". Fuji Machine America Corp., Booth 2950
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Step-by-step Serves Speed
Updated ShopMill and ShopTurn software packages let job shops achieve higher productivity and greater speed according to the maker. By featuring step-by-step, on-screen programming, shops can respond to customer demands by reducing programming, tooling, and production times. The SINUMERIK 802D solution line CNC is an operator panel-based control system that combines the numerical control, the programmable logic controller, and the human machine interface in a single unit. It has the capability of 5-axis machining — two of which may be spindles — and is a solution for the low- and medium-range milling and turning machine markets. Siemens Energy and Automation, Inc., Booth 3639
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EDM with 3D Analysis
The Mitsubishi FA10 Advance wire EDM features a M700 Series control. The Windows-based system with a 15" LCD touch screen display provides a menu configuration for navigtion. The machine pioneers a 3D adaptive EDM control, which can analyze 3D data and recognize shape characteristics, eliminating transition lines in stepped workpiece areas. MC Machinery Systems, Booth 3532
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Upgraded for Performance
The GX 1000 Performance vertical machining center is based on the Bridgeport P3-Series VMC platform with performance upgrades to meet the increased demands of the metalworking community. It features a stiff and thermally-stable spindle, a rigid C-frame fixed column design, and fixed pre-tensioned double-nut ballscrews on all axes. The heavy-duty linear guide and truck configuration provides added stiffness, damping, and surface contact area. The machine is configured with three guideways and five guide trucks on the X- and Y-axes, and two guideways and six guide trucks on the Z-axis. The 24-tool side-mount/swing-arm automatic tool changer features random access, bidirectional indexing, and 2.5-second tool-to-tool change time. Bridgeport, a member of the Hardinge Group, Booth 3316
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Spindle Goes to Infinity and Beyond
The "Plug and Go" HFK 95 S40 high-speed spindle is designed for easy setup in most vertical or horizontal machining centers. The spindle is rated at 4 hp peak power, 2.6 hp continuous duty, providing speeds up to 42,000 rpm, infinitely variable. Also on display will be 20mm and 22mm diameter high-speed — up to 100,000 rpm — milling and drilling spindles. Also displayed will be Witte vacuum workholding chucks, pumps, and accessories. IBAG North America, Booth 2140
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Worm Reduces Friction
The 5AX-200II CNC Rotary Table's carbide worm system uses a carbide worm screw and ion nitrided worm wheel, rather than a conventional bronze or bronze alloy actuation mechanism. The result is a reduction in friction and wear by up to eight times, according to the manufacturer. This reduces backlash when compared to the standard bronze worm gears. The worm screw consists of a less brittle V-grade form of carbide, while the worm gear is ion nitrided to a depth of 0.1mm and an external surface hardness of 68 RC. These properties, as well as a steel way hardened up to 60 RC, enhance system rigidity and longevity. Allowing for the machining of five sides of a workpiece, the 5AX-200II has application for medical and aerospace 5-axis work. It features a drop trunion and clamping torque of 588/490Nm. The faceplate maximum work load is 176 lb. Lyndex-Nikken Inc., Booth 2616
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Thread Mills Deal With Difficult Materials
A series of Miniature Solid Carbide Thread Mills are designed for machining of difficult materials such as stainless steels, titanium, K-monel, hastelloy, and Inconel. The line is suitable for applications including those in the medical, aerospace, defense, and computer industries. The thread mills are available in both one-flute and three-flute versions, with the latter designed for high-volume output. The miniature thread mills function with externally-supplied coolant and eliminate the need for thread-cutting oil, so parts and coolant reservoirs are not contaminated. Overall length of the thread mill is 1-5/8" with a shank diameter of 1/8". The line includes thread sizes of #0-80, #2-56, #4-40, #5-40, #6-32, and #8-32, and cutting diameters from 0.045" to 0.124". Thread length ranges from 0.125" to 0.328". Emuge Corp., Booth 4233
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VMC Features 20 hp Spindle
The Johnford SV-48H vertical machining center has 48"×28"×25" travels along the X-, Y-, and Z-axes; a 20 hp spindle with a two-speed gearbox; four square box ways on the Y-axis; stable cutting on the large, fully supported table with zero overhang; and rapids of 944 ipm. It is engineered for heavy cutting applications. The machine features four square Y-axis box ways and a large fully supported table with zero overhang. It has Mating Turcite-B coated surfaces, a 3.35" spindle shaft employing five bearings. Absolute Machine, Inc., Booth 3250
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No G-code Experience Needed with Probing System
The Mida Wireless Intuitive Probing System is for use with Haas Automation CNC machining centers. The probing system kit, which is available as a factory-installed option, includes a spindle probe and a wireless contact tool-setter to set tool length and diameter. The control includes step-by-step instructions to guide the operator through the probing process. No G-code programming experience is necessary. Once information has been entered, the cycle start button executes the probing. The probing cycle can be saved in memory and recalled when needed. Available probing cycles include calibration cycles for touch probes, bore and boss measurements, web and pocket measurements, single surface measurements, inner and outer corner measurements, and tool length measurement for center cutting tools and tools with insert cutters. Marposs Corp., Booth 2519
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Technologies Combined in Touch Probe
The RMP600 touch probe combines two technologies: strain-gage sensing, and frequency-hopping spread-spectrum radio transmission. The design allows part-checking precision on 5-axis machining, contours, deep cavities, and undercuts, where obstacles or part features can block transmission by optical line-of-sight probes. The probe's construction, design, solid-state electronics, and interference-free signal transmission works on radio-noisy plant floors with competing wireless Wi-Fi communications. Using RENGAGE strain gage technology allows sub-micron 3D probe performance on contoured surfaces, even with long styli. The probe delivers uni-directional repeatable of 0.25µm with a 50mm long stylus and 0.35µm with a 100mm stylus. It is recommended for styli up to 200mm. Renishaw, Booth 4016
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Mini Cutter Reduces Deburring
The C-Cutter Mini's compact design reduces the cutting diameter to the lowest limit, helping achieve ultra-high spindle speeds and feeds. The high-feed chamfer mill delivers multi-functional cutting, including chamfering, back chamfering and face milling. Its high speed back chamfering capability reduces hand deburring, and face milling is possible with a 45° chamfering type with 0.394" square insert. The C-Cutter Mini is available in single insert and four-insert designs. The single insert design uses a 0.197" square insert with four cutting edges for smaller 45° chamfers and a slightly larger insert for 30° and 60° chamfers. BIG Kaiser Precision Tooling Inc., Booth 2632
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Enhancements Grace CAM Software Release
CAMWorks 2008 delivers a set of more than 50 performance enhancements, user interface improvements, and strategies to meet machining requirements. These include improved speed and toolpath reliability for multi-axis operation, improved simulation speed and quality, and user interface options for display and navigation. Toolpath strategies and controls have been implemented for 2- to 5-axis milling, turning, and wire EDM to improve quality and decrease machining time. Enhancements in 3-axis milling include: Z-Level combination toolpath option for constant step strategy on shallower slope areas and additional control over pencil milling. Geometric Technologies, Inc., Booth S-3574
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Magazine Bar Feeder Deals With Different Diameters
The Genius 120 magazine bar feeder will be operating on a Star SR20 CNC automatic lathe at the trade show. The unit's hydrodynamic guide channel system lets the guide diameter be changed by changing the front guide sections. The bar pusher is contained in a tube fixed to the upper wall of the rear guide. The internal diameter of the tube varies depending on the bar pusher it contains, while its external diameter remains unchanged. This eliminates the need to replace the bar feeder's rear guide sections when changing guide diameters. IEMCA, a division of Bucci Industries USA, Booth 3500
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Rotary Union Spins at 24,000 rpm
Workholding and tool clamping products from Jakob Antriebstechnik will be on display, including the Power Clamping Nut and the Hydro-mechanical Spring Clamping System. The OTT-Jakob GDR rotary union has a maximum spindle speed of 24,000 rpm and a maximum coolant pressure of 80 bar. Also on display will be a small rotary union that has a maximum spindle speed of 75,000 rpm and 80 bar coolant pressure. It features a hybrid bearing, balanced design for high-speed rotation, a closed sealing surface, and minimum volume lubrication, externally mixed. Advanced Machine & Engineering Co., Booth 5630
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