Honing system for sizing complex bores
The SSH-1680 honing system is designed for multiple-land and tandem bores, heavy/odd shaped parts, keyed or splined bores, blind bores, and thin-wall parts. The hone features zero shutoff for automatic cycle control and consistent bore size, finish, and geometry with minimal operator attention. Rough-and-finish honing capability eliminates preliminary reaming, boring, and grinding operations to help lower per-part costs. An adjustable spindle allows the operator to eliminate mandrel runout, making it easier to achieve precision bore geometry. Multiple land and tandem bores are bridged with long stones, maintaining alignment and consistent size without camber or washout.
The hone cuts a wide variety of materials and handles part lengths up to 9.84" (250mm) with bore diameters from 0.12" to 2.36" (3mm to 60mm). Diameters 1.57" (40mm) and smaller are said to be a sweet spot for this machine, when compared to ID grinders.
A rigid cast iron machine base provides strength for handling heavy parts and isolates moving components to eliminate vibration problems. The machine’s robust design enables rapid stroking for shorter cycle times. Incrementally adjustable stroke rate (80spm to 310spm) and spindle speed (250rpm to 2,500rpm) deliver fast stock removal rates. The spindle and stroker are both powered by variable frequency drives, eliminating drive belt changes and allowing dial-adjustment of speeds via the swiveling control panel.
The unit accepts standard Sunnen tooling, including K, P20, and P28 mandrels. A universal honing fixture is standard, with a variety of workholding options available to securely fixture odd shapes and thin walled parts without distortion.
All electrical components are housed in an interlocked, side-mounted enclosure.
Standard equipment includes a universal honing fixture, parts tray, spindle runout indicator, side splash guards, and detachable 25gallon (96L) coolant cart mounted on casters for easy filling.
Sunnen Products Co.
Self-centering 5-axis vise
The V75100 self-centering 5-axis vise offers high rigidity and clamping force in a compact package that makes it suitable for smaller 4- and 5-axis mills.
The vise generates 4,000 lb of clamping force at 45ft-lb of torque and provides access to five sides of the workpiece. It features a built-in 45° dovetail and gripper teeth that bite into stock without the need for a stamping unit.
Built from heat treated steel, the V75100 is milled and precision ground to give it a centering accuracy of 0.0005". The removable and reversible master jaws allow for an increased clamping range of 0.05" to 3.5". The jaws are simple to remove, allowing for quick changeover between hard and soft jaws.
Two precision threaded shoulder bolts secure and locate the jaws of the V75100. The vise also utilizes a threaded centering hole and two self-centering clocking holes at 30mm.
5th Axis Inc.
Hybrid CMM with laser line scanner and touch probe
The COORD3 Benchmark CMM offers a small footprint, half-gantry, advanced alloy design that places its X and Y axis at the same level for increased rigidity and thermal stability. The metrology platform is designed for high accuracy small and medium part CMM inspection.
The ergonomic open structure is suited for inspection of high-volume production parts or single part inspection at smaller manufacturing operations. For production CMM or quality room applications, its compact size fits through a standard-width door.
The full air-bearing CMM, with accuracy of 2.5µm and a measuring volume of 600mm x 500mm x 440mm, comes equipped with both a Perceptron Laser Scanner and a Renishaw touch-probe. The laser line scanning sensor has been integrated into TouchDMIS software, allowing the multi-sensor CMM to perform reverse engineering and dimensional inspection.
The CMM is available in manual or CNC configurations, and manual units can be upgraded to full CNC in the field at a later date.
TouchDMIS CMM software offers full CAD capability with newly- added point cloud handling capability and can be learned in just a few hours of training.
Designed for the aerospace market, 8060/8065 CNC platforms include advanced features for high-speed machining while maintaining high surface finish and accuracy.
Offered with a 10" or 15" color or touch screen, Ethernet, USB, and a touch-sensitive mouse pad, the 8065 CNC platform can control up to 28 axes plus four separate spindles with four execution channels and auto-tuning system capability. The 8065 includes block processing speeds of <0.5ms while analyzing the tool path with high-speed block look-ahead using nanometric resolution. Combined with adaptive real-time feed and speed (ARFS) control, the CNC analyzes machining conditions – spindle load, servo power, and tool tip temperature – and adapts both the axis feed rate and the spindle speed for maximum machining performance. Results include reduced cycle time, consistent part finish, extended spindle and servo motor life, and improved tool utilization.
The aerospace-specific high-speed surface accuracy (HSSA) machining system reduces mechanical stress on the machine, increasing its lifespan. An onboard Bode diagram tool measures the machine’s frequency response and allows filtering of machine vibrations.
It processes CAD/CAM programs that use splines and polynomial transitions and interprets the NURB format to achieve high feed-rate machining.
The system can interface with Renishaw Inspection Plus software, which includes vector and angle measure options, print options, and an extended range of cycles. These options include an SPC cycle, 1- or 2-touch probing option, tool offset compensation by percentage of error, and output data stored in an accessible variable stack.
Using its volumetric compensation (FVC) feature, the 8065 maps the machine’s total work volume, ensuring the CNC understands the exact position of the tool at all times. Benefits include a 50% improvement in accuracy, and machine-to-machine uniformed accuracy improvements.
All 8060/8065 platforms are capable of using MT Connect for retrieval of process information. Its open protocol allows easy data exchange between shop floor equipment and monitoring and data analysis software. Ethernet communication lets the 8065 serve as another node in the computer network to facilitate data exchange or to execute programs residing on another PC.
Interactive Icon-based Pages (IIP) conversational programming allows operators to use an icon key to choose the operation. Operators enter data directly from the blueprint; no prior CNC programming experience is required. A single screen eliminates shuffling through screen pages to input machining-variable data.
Fagor Automation USA Corp.
Jet machining center
The center bridge-style 60120 JetMachining center can cut complex parts from a variety of materials, including advanced composites, exotic alloys, traditional metals, and rubber.
The center comes with Intelli-MAX software for higher cutting speeds and greater precision when combined with the EnduroMAX Pump. The machine accommodates components measuring up to 5ft x 10ft.
Intelli-MAX Software runs on Windows operating systems to calculate the velocity of a tool path at more than 2,000 points per inch and supports up to six axes of coordinated motion.
The EnduroMax Pump is offered in a variety of horsepower options and is able to deliver more than 85% of its power to the cutting nozzle.
Intelligent machining features in ESPRIT 2015 accelerate the machining process by providing 5-axis cycles that reduce cycle time. This makes it possible to completely machine blades in a single setup. The solution’s 5-axis blade roughing tool motion is morphed across the blade to uniformly offset stock allowance so it can be immediately followed by a finishing cycle. The system maintains awareness of stock removed by previous operations, reducing air cutting, which in turn reduces cycle time.
- Port roughing cycle removes material inside tool entry area
- Bottom-up strategy for small residual stock height
- Redesigned stock automation for multitasking machines
- Supports slot mill tools in port milling and composite cycles
- Barrel-shaped cutters for better surface finish than ball end mills
- MachiningCloud connection for tooling product data
DP Technology Corp.
Cutters with chip gullet design
MaxCut 651 cutters have a chip gullet design with 0.250" inserts for continuous heavy-duty work and high metal-removal rates. The inserts feature 45º lead angle for free cutting, easier part entry, and better corner strength. The cutters are available in 3" diameters and larger and in medium pitch configurations for general machining and fine pitch for short chip materials.
Lovejoy Tool Co. Inc.
Turbine end mills
Solid, carbide turbine end mills for milling turbine blades, impellers, blisks, and complex 5-axis components feature a variety of styles including tapered ball nose, barrel-shape designs, and selections from the Top-Cut, Tinox-Cut, Multi-Cut, and indexable insert tooling programs.
The line features barrel-shaped, oval form end mills for finishing high-strength materials. The barrel-shaped oval form simulates the attributes of ball nose end mills having a diameter range of 150mm to190mm, to provide double the axial cut for improved surface finish. End mills are offered with 3 and 4 flutes with aluminum-chromium (ALCR) coating.
Torus end mills
- 5 to 13 flutes with variable spacing
- 0.8mm, 1.0mm, and 2.0mm corner radius, straight, 8° taper angle versions
- Internal coolant capable
New applications for Sinumerik include Manage MyMaintenance (MMM), maintenance-tasks management, and AccessMy Data (AMD) – open interfaces that allow direct access to machine and process data.
AMD has an interface to access machine and process data of machine tools controlled by the Sinumerik 840D sl CNC. To allow data communication, the machine tool is directly connected to the Sinumerik Integrate server at the customer’s site. MMM enables small and medium-sized companies maintenance management without any additional investment. The application instructs the users as soon as a new maintenance date is scheduled for a machine, with the time and tasks to be performed presented in a clear list.
Siemens Industry Inc. Motion Control Business
Hydraulic expansion toolholders
Tendo Aviation combines hydraulic expansion technology with Weldon toolholders for high run-out accuracy, a balancing grade of G2.5 at 25,000rpm, better vibration damping, and a fast tool change using an Allen key. The mechanism prevents tool pull out, and positional tolerances can be held.
- High precision and process reliability
- Runout accuracy and vibration damping prevent cutting edge wear
- Uniform load profile allows a longer spindle and spindle bearing service life
- Available for interfaces: HSK-A63, HSKA 100, CAT 40, and CAT 50
Groove machining solutions
The SpiroGrooving method, used with the CoroBore XL system, uses a spirograph tool path to create close-tolerance seal ring grooves. The circular spirograph reduces chip thickness, enabling light cutting action, and increased feed. Parts of the insert cutting edge have an interrupted cutting behavior, eliminating long chips that can tangle the tool and spindle. SpiroGrooving can be programed with a CNC-code generator.
While this solution is suited for making seal ring grooves in pre-clad machining of steel and stainless steel, the internal coolant feature of CoroBore XL enables machining in advanced materials. Roughing and finishing are carried out in the same operation, reducing machining time and improving productivity.
Wet blasting system
The Model SS-10 SA rotary table wet blast system with manual and semi-automatic modes of operation is designed to use abrasive or bead-type media for dustless blast cleaning, descaling, surface preparation, and cosmetic finishing of components that are too damp or oily for dry-blast processing.
The 60" x 70" x 96" blast cabinet is fabricated from non-corroding composite material. The interior of the wet blasting chamber is lined with sheet rubber for abrasion resistance. A 50" x 50" swing door provides access to the blast enclosure. On the right side, a track extension and transfer cart allow the 49" diameter rotary table to be rolled out for loading and unloading. A drip tray beneath the track extension is standard.
Energy saving sinker EDM
The Mitsubishi EA8S Advance sinker EDM center features the new M700 series control with 15 " touch screen and FP80S energy saving power supply that reduces electrical consumption by 20% compared to the previous FP model. The Power Master GF2 Adaptive Control reduces graphite electrode wear by as much as 80%, and the addition of the new SS Jump 5 optimizes jump up acceleration control to stabilize high-speed, no-flush burning.
- 80A peak power supply
- Fixed table traveling column
- Direct-drive AC smart servo system
- 3D lateral servo system
- 3-sided drop tank work tank access
- Easy access filter
- Dielectric fluid emission
- Auto lubrication
- Fuzzy Pro Plus hands-off operation
MC Machinery Systems Inc.
Digital boring head
The Series 112 EWD 2-32 digital precision boring head with a concentric insert holder is made for small machines with tight work envelopes. Features include power management for optimized battery life, inch or millimeter display, IP 69K seal rating, minimized imbalance with tool carrier in center position, and optimized bore depth by a through-hole tool carrier.
BIG Kaiser Precision Tooling Inc.
CNC software with post-processor reference guide
PartMaker Version 2015 includes the ability to generate a post-processor reference guide – an on-command manual explaining how to program a given multi-axis lathe and take advantage of the machine’s capabilities. Using a cloud-based update utility allows customers to have the most recent post-processor.
The Multi-Channel Viewer is a free software application for users of multi-axis turn-mill centers and Swiss-type lathes to view their multi-channel NC programs side-by-side, for virtually any multi-channel machine/control combination. It includes improved support for modern multi-tasking machine tools, more powerful milling and turning functionality, and improvements in the software’s knowledge-based technology for storing optimal feeds and speeds for additional tools.
Shop floor software solutions
A new hardware module, the Freedom Digital Interface (FDI) with integral MTConnect, allows shops with legacy equipment to monitor machine tool performance using the company’s Freedom eLOG or other MTConnect monitoring software.
The software automatically extracts critical manufacturing data to produce web-based reports and analytics on asset utilization, availability, performance, quality, and overall equipment effectiveness. It is brand, asset, and process agnostic, and is MTConnect-compliant. The software integrates with ERP, MES, maintenance and quality business systems, and can be accessed via smartphone or tablet device.
Industrial series 3D printer
The Exerial 3D printing system allows customers to engage with indirect printing technology for industrial series production beyond rapid prototyping and small batch production. The printing system contains multiple industrial stations that allow for continuous production and simultaneous processing and is equipped with two job boxes, each 1.5x larger than the single job box in ExOne’s next largest model, the S-Max. The system offers a total build platform of 3,168L and is expected to be capable of printing output rates nearly 4x faster than the S-Max.
Vertical machining center
The MU-6300V vertical machining center is suitable for 5-axis, multi-sided machining.
The machine is available with a wide array of spindle options, providing a configuration for nearly any 5-axis job. The design places the pallet changes at the back of the machine, allowing easy connection to a Palletace flexible manufacturing system or pallet pool, delivering high productivity and accuracy. The MU-6300V has a rigid double column structure and low center of gravity in workpiece movement that enables heavy-duty cutting and high-speed finishing.
The MU-6300V can be used with Okuma’s exclusive Super-NURBS function, enabling high feed rates and ultra-fine finishes.
- Axis travels X/Y/Z: 1,450mm/1,050mm/600mm
- C-axis: 360º infinite
- Rapid traverse X, Y, Z: 50mpm
- Rapid A/C: 30rpm/90rpm
- Maximum load: 600kg
Okuma America Corp.
The Orange Line’s Extra RV-E keyless and Prima-L keyed drill chucks accommodate applications including hole drilling in steel, percussion drilling, and driving screws. Keyless clamping with the Extra RV-E involves a simple turn of its metal and plastic sleeve, while the Prima-L gets its clamping strength via DIN 6349 toothing.
RÖHM Products of America
CNC remote interaction
NCSIMUL Player 9.2, embedded on a Panasonic Toughpad IP65 and connected to machine tool controllers, enables shop floor operators and managers to interact remotely – in 3D and in real time – with one or several CNC machines and their machining processes. The 3D animations of CNC machining processes and work instruction sheets are directly accessible from the mobile application.
Laser marking workstation
The LMWS laser marking workstation, designed for benchtop operation, features a fresh, industrial design, with improved functionality, narrow width for lean manufacturing, and CDRH Class 1 safety. Integrated with a fiber laser marker, the LMWS is capable of marking metals, ceramics, and many plastics, and also has cutting, drilling, and welding capabilities. Requiring minimal workspace, the updated unit works in low-volume production and research and development environments.
- F 100, 160, and 254 lenses
- Industrial 10W to 50W fiber laser markers
- Manual door opens vertically for 180º access to parts and tooling
- Large viewing window for visual process monitoring
- Motorized Z that can be jogged by a rotary knob
- A rotary axis can be added for cylindrical part marking
Miyachi America Corp.
The ScopeCheck multisensor coordinate measuring machine (CMM) has a measurement range up to 3,500mm in the X axis and 1,750mm in the Y axis. Existing functions of the WinWerth 7.32 measurement software have been expanded and enhanced for increased performance, ease of operation, flexibility, and speed. Temperature compensation is standard.
- Image processing sensor
- Modular design
- Touch trigger and scanning probes with probe tip magazines
- Laser sensors for increased flexibility
The Aspect 375 delivers arc stability and uses AC Auto-Balance technology to adjust cleaning and penetration levels during aluminum welding. The system has Intellistart technology to automatically control arc starting intensity for thin or thick materials. The constant-current stick and TIG machine allows a TIG output range of 2A to 375A and is rated at 330A at 40% duty cycle, and 300A at 60% duty cycle.
- 4 AC wave shape controls for bead profile customization in aluminum welding
- TIG pulser minimizes distortion
- Automatic / manual override
- Ready-Pak option with cart, cooler, torch, foot pedal, and cables
FAA streamlines UAS authorizations
The Federal Aviation Administration (FAA) has established an interim policy to speed up airspace authorizations for certain commercial unmanned aircraft (UAS) operators who obtain Section 333 exemptions. Section 333 of the FAA Modernization and Reform Act of 2012 grants the Secretary of Transportation the authority to determine whether an airworthiness certificate is required for a UAS to operate safely in the National Airspace System.
Under the new policy, the FAA will grant a Certificate of Waiver or Authorization (COA) for flights at or below 200ft to any UAS operator with a Section 333 exemption for aircraft that weigh less than 55 lb, operate during daytime Visual Flight Rules (VFR) conditions, operate within visual line of sight (VLOS) of the pilots, and stay away from airports or heliports. The interim policy bridges the gap between the past process, which evaluated every UAS operation individually, and future operations after the FAA issues its final version of the proposed small UAS rule, expected later this year.
The 200ft COA allows flights anywhere in the country except restricted airspace and other areas, such as major cities where the FAA prohibits UAS operations. Previously, an operator had to apply for and receive a COA for a particular block of airspace, a process that can take 60 days. The agency expects the new policy will allow companies and individuals who want to use UAS within these limitations to start flying much more quickly.
Section 333 exemption holders will automatically receive a blanket 200ft COA. For new exemption holders, the FAA will issue a COA at the time the exemption is approved. As of March 26, 2015, the FAA had granted 69 petitions under Section 333. Most of these have been for UAS use in inspecting power transmission line, oil and gas, and electric grid infrastructures; wind turbine towers; photogrammetry; real estate and marine aerial photography; mapping; and precision agriculture. www.faa.gov
UAV captures Antarctic stratospheric aerosols
A balloon-assisted unmanned aerial vehicle (UAV) named Phoenix-S1, developed by Kyushu University and Fukuoka University, Japan, has successfully brought back stratospheric aerosol samples from an altitude of 22km and observed aerosol density 23km above Antarctica.
The observation on Jan. 24, 2015, was made during the 56th Japanese Antarctic Research Expedition under the leadership of National Institute of Polar Research Prof. Yoshifumi Nogi.
Suspended from a helium-filled rubber balloon, Phoenix-S1 climbed from its launch site on Antarctica’s ice sheet, sampling and observing aerosol density. After the balloon burst at an altitude of 23km, the UAV descended by parachute, was released, and glided back to the launch site autonomously. The researchers believe this is the highest observation altitude for a small UAV. They reported that the method was effective in retrieving the observation apparatus and aerosol samples from the upper atmosphere easily and at low cost. www.nipr.ac.jp
Raytheon to provide ground stations for South Korean Global Hawk UAS
Northrop Grumman Aerospace Systems has awarded Raytheon Co. a contract valued at up to $45.7 million for ground installations in support of four Global Hawk unmanned aircraft systems recently purchased by the Republic of Korea.
Under this contract, Raytheon will deliver one building-based and one mobile ground segment to locations in South Korea. Work under the contract will be performed at Raytheon’s Dulles, Virginia, facility and is expected to be completed by mid-2019.
Raytheon is the original developer and producer of the ground stations for Northrop Grumman’s Global Hawk, which is used globally to support antiterrorism, antipiracy, humanitarian assistance, disaster relief, airborne communications, and information-sharing missions. www.raytheon.com
Predator B achieves 1 million flight hours
General Atomics Aeronautical Systems Inc.’s (GA-ASI) Predator B/MQ-9 Reaper remotely piloted aircraft (RPA) fleet has achieved 1 million cumulative flight hours, with almost 90% of all missions flown in combat.
Predator B achieved this record on Feb. 20, 2015, after flying 78,606 sorties. The type’s first flight was at GA-ASI’s Gray Butte Flight Operations Facility in Palmdale, California, on Feb. 2, 2001. Predator B flight hours now account for approximately one-third of the 3.2 million total flight hours for GA-ASI’s RPA fleet, with an average rate of more than 22,000 hours a month. These aircraft support the U.S. Air Force, U.S. Department of Homeland Security, NASA, the Italian Air Force, the Royal Air Force, and the French Air Force. Missions include direct support to warfighters, assisting border agents, aiding first responders, and supporting Earth science missions. GA-ASI has delivered more than 230 Predator B aircraft to date and is currently building three aircraft per month, with the capacity to more than double production if needed. www.ga-asi.com
UAS launcher market to grow to $1.2B by 2021
Research company ReportsnReports has issued a study that predicts the global market for launchers of unmanned aerial vehicles (UAVs) will grow to $1.2 billion by 2021 from $151 million in 2014. The study, “Drone Launchers: Market Shares, Strategy, and Forecasts, Worldwide, 2015 to 2021,” notes that launchers are core to UAS implementation, and include field-mobile frames, submarine and ship-deck devices, and truck-bed launchers.
According to the study, “The defense budgets of the industrialized nations will fund the technology for launchers in order to create good enough surveillance and strike capacity. These capabilities are core in a world dominated by globally integrated enterprises.” www.reportsnreports.com
UAS research project on gas utility inspection
Pictometry, an EagleView Technology company, has received an unmanned aerial systems (UAS) research project to focus on the feasibility of using UAS to improve the overall safety and speed of routine and emergency surveys and inspections of gas utility pipelines. Awarded by NYSEARCH/Northeast Gas Association, a consortium of 19 natural gas companies in the U.S. and Canada, the project will bring together Pictometry and the Northeast UAS Airspace Integration Research (NUAIR) Alliance, headquartered at Griffiss International Airport, in Rome, New York.
The team will perform ongoing research experimentation in approved areas using a UAS with high-resolution cameras and potentially methane detection devices to enhance pipeline safety. www.eagleview.com; www.pictometry.com
Next-gen gas turbine engine for UAS
UAV Turbines Inc. (UAVT) has launched its gas turbine technology in the unmanned aerial vehicle (UAV) market. Ranging in power from 30hp to 150hp, UAVT’s engines address Group 3 and above UAV programs. The engines offer increased reliability, flight duration, payloads, and operational ceilings, while reducing noise. Fuel consumption is low, using a variety of heavy fuels.
Compared to internal-combustion UAV systems, many of which show mean-time-between-overhaul (MTBO) at less than 100 hours, UAVT engines are designed for MTBO in thousands of hours.
Based in Miami, Florida, privately held UAV Turbines is demonstrating prototypes of its engines to potential qualified buyers. www.uavturbines.com