With the Tendo E compact from Schunks, it is no longer required to use different holder technologies for milling, drilling, and reaming. 

For the first time ever, hydraulic expansion toolholders can safely transfer torques of up to 520nm (384 ft/lbs) at a 20mm clamping diameter and are perfectly suited for high volume cutting.

With excellent vibration damping, and precise run out accuracy of less than 0.003mm (0.0001”) at 2,5 x D, the Tendo E compact protects the machine spindle and the cutting tool from damage. The attractively-priced hydraulic expansion toolholder works well across the application range from rough milling to finish operations such as reaming and fine milling.

In roughing operations, the Tendo E compact has recduced tool costs up to 40%. Tools can be quickly changed with an Allen key, making this hydraulic expansion toolholder an excellent alternative for operations where the toolholder quantities do not justify peripheral equipment purchases.

Common spindle connections are available, including interfaces HSK-A63, SK40, BT40, CAT40, and CAT50.

The slim design of Schunk's Tribos-SVL toolholder extensions allows precise and smooth machining of workpiece areas that are difficult to access. In spite of the slim design, the extension is robust and permits a run-out accuracy of less than 0.003mm.

The Tribos-SVL can be combined with a  variety of toolholders, such as our Tendo hydraulic expansion toolholders, Celsio heat shrink toolholders, with collet toolholders, and of course with Tribos toolholders.

The Tribos extensions in connection with our Tendo hydraulic expansion toolholders or the Tribos-R polygonal toolholders complement each other in an ideal manner. Both systems have a vibration damping effect on the overall system.

The Tribos SVL has a wide range of clamping diameters. They are available from 0.3mm to 20mm, or 1/8” to 3/4”.
 

With manufacturers constantly improving the performance and reliability of their mechanical designs, they want subcontractors that can supply finished parts that reflect the accuracy demanded by the new sophistication found in these designs. In business since 1978, New World Machining Inc. manufactures products for primarily the semiconductor and medical industries. In addition to meeting machining needs, the company also provides such processes as lay patterns andother finishes. In 1944, the company moved to its 30,000ft² facility and its 50 employees work two 9-hour shifts.

New World requires precision machining capabilities by machines that are extremely rigid as well as accurate. That is why New World selected Mighty Comet VMCs for the bulk of its CNC machining center operations. New World manufactures very intricate parts that are machined, plated or hard anodized, and then machined again to very exacting tolerances- part tolerances are in the +/-0.005" to 0.0005" range.

Small runs and prototypes are key to New World's operation, but the company is equipped to handle large production runs as well. Quality control plays and important role, as a zero defect plan is used and deliveries are to JIT requirements. This entails source inspectors coming to the plant to check on quality. To ensure consistency throughout the operation, i.e. between machining and quality control, the entire facility is air conditioned.

PRECISION ENGINEERING
Precision machining starts with engineering supplying precision data. All customer drawings and CAD files are thoroughly reviewed before machining operations start. Whenever necessary, drawings are red lined and reviewed wiht the customers beforehand. In some cases design engineers are not thoroughly experienced with the unique techniques necessary to machine difficult designs. For example, to machine a pocket without a radius in the corners, it may be necessary to have holes (reverse radius) in the corners. Geovision is used for CAM programming, and a drawing is sent out with each job traveler so the machinist has a clear picture of the job being machined. Bar coding is also used to keep tabs of jobs running through the shop.

MACHINING OPERATIONS
Machining operations consist of CNC turning centers, CNC machining centers, manual mills, engine lathe and grinding machines. The largest area is the CNC machining center with Mighty Comet VMCs being the predominant machine tool. Leading the way are four VMC-1000's, followed by two VMC-1100s and one each of the VMC-1500 and VMC-520. One VMC-1000 is equipped with a 12:, full 4th axis rotary table. In addition to the Mitsubishi Meldas controller, all Mighty VMCs are equipped with high speed rigid tapping.

Because precision machining requires both skill and technical expertise, VMCs that rated high in machine geometry and construction were required. The machine had to be able to withstand the dynamic loads during cutting. Although the entire shop are is air conditioned, the VMCs selected had to be able to compensate for thermal effects. For example, the Mighty's have the ballscrews located in the exact center of each axis, thus heat and lost motion is effectively eliminated. In addition, a cartridge-type spindle is used for heat dissipation, and the spindle cooler effectively maintains the temperature of the cooling lubricant.

While controlling the thermal effects was an important factor in selecting VMCs for the company, other factors were equally important. To achieve precision machining, an accurate, stiff and stable spindle was equally important. The Comet uses a cartridge-type spindle that is made of chromium-molybdenum alloy steel that is supposed by very precise angular contact ball bearings. The spindle more than met the need for stability necessary for precision machining.
The rigid tapping feature reduces tapping time by as much as 50% over conventional tapping. A direct synchronous sensor is built into the spidle motor. The digital control achieves a perfectly synchronous rotation of the spindle and Z axis servo motor. Costly, floating-type tap holders are not required and depth control is greatly enhanced.

QUALITY CONTROL
Because of New World's pride in its precision machining capabilities and demands placed on it by the medical and electronics industries, the company emphasizes a high degree of quality in all facets of its operation. The quality program starts with the personnel. Not only are all new employees in structed on company quality techniques, but they receive ongoing training in TQM and SPC.

An important part of the operation is the use of its CMMs for checking finished machined parts. New World has two Mitutoyo coordinate measurement machines utilizing Geo Pak software. An automatic Renishaw probe allows even more precisse measurements. In addition, all machine operators are involved with in-process inspection, especially on first-article parts. Along with the production of quality machined parts, New World performs sub-assembly operations for its customers.

CNC MANUFACTURING
One of the keys to New World's operation is to keep the VMCs running production parts. The advantage of using Mighty Comets is twofold: part quality ad reproducibility. Becasue of their reliability, maintainability, and ease of programming with their Mitsubishi controllers, New World's Comets are producing parts with exceptional accuracy. Quality parts coupled with JIT delivery schedules allows New World to offer an unbeatable combination as a supplier of precision machined parts.

By: Rodney Guilbert, Operations Manager

Siemens demonstrates its recent collaboration with KUKA Robotics, where a KUKA robot articulates parts, simulating the operation on a CNC machine tool. Key to this development is the machine builder’s ability to integrate mxAutomation from KUKA directly through the Siemens Sinumerik CNC platform, thereby allowing the operator of the machine to run both the machine tool and robot from the single control panel. 

The motion sequence of the robot is entirely engineered within the Sinumerik 840D sl CNC, then transferred by the 840D sl’s PLC function to the mxAutomation interpreter on the KR C4. All program changes to a 6-axis robot can be input on a second channel of the CNC and fully operated. This scenario provides the ability to not only run a machine tool’s automation sequence more efficiently, but also make more changes on-the-fly to minimize machine downtime, with no special knowledge of robot programming language. During the operation of the machine tool, all changes made can be visualized directly on the CNC screen, further minimizing operator actions. 

Siemens is the first CNC supplier to show this capability for single-screen operation of the machine tool and robotic materials handling on the CNC.

In operation, the KRC4 integrator and mxAutomation convert the robot language into the same commands used for multi-axis machine tool functions. A single Profinet cable runs between the robot and the CNC.  According to KUKA’s Andreas Schuhbauer, key technology manager for machine tool automation (Augsburg, Germany), “mxAutomation allows the machine tool builder a single I/O language for integrating robotics on the CNC, while the end user operator can run both the machine tool and the robot from a single screen on the control.”  

mxAutomation for Sinumerik CNC was a joint development between KUKA and Siemens. KUKA created plug-in function modules for the Siemens Step 7 PLC engineering software and provided its robot knowledge to Siemens for creation of the second channel logic on the CNC, Andreas Schuhbauer further notes. 

All safety functions and test functions for load /unload, brake test, gripper, robot communication, and safe operation of the robot are provided through the Siemens Profinet and Profisafe platforms. 

Future developments for mxAutomation are planned, including a wider application range for robots in the CNC machine tool environment.