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americanmachinist.com DECEMBER 2009 A Penton Media Publication
Power + Precision for High-Performanc Autos Page 14
FIVE-AXIS FRENZYTHE ABC’S OF BORINGPage 16
STRATEGIES:
PLANNING FOR LEAN, PART 2 Page 18
AUTOMATION:
LIGHTS-OUT SETUPS Page 29
Page 10
MACHINING :
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MACHINING PLASTIC :CUTTING
GEOMETRIES THAT WORK
Page 16
SAFETY:VIEWING PANELS
GET STRONGER Page 20
FINANCE:FOR BUYERS, LENDERS …
UNCERTAINTY Page 32MACHINING
RACES DOWNHILL
Planning the Lean Machine Shop Page 22
Page 12
americanmachinist.com DECBER 2009 A Penton Media Publication
Power + Precision for High-Performanc Autos Page 14
FIVE-AXIS FRENZYMACHINING :
THE ABC’S OF BORINGPage 16
STRATEGIES:
PLANNING FOR LEAN, PART 2 Page 18
AUTOMATION:
LIGHTS-OUT SETUPS Page 29
Page 10
CONTENTS
D E PA R T M E N T S
F E A T U R E SON THE COVER
22 MACHINE TOOLSIndependent subsystems double turn-mill production.
2 6 TOOLING & FIXTURING Holding small thin parts for milling on a CNC router.
2 9 AUTOMATIONMultiple pallets boost short-run, high-mix production.
31 SOFTWARE & CONTROLSProduct lifecycle software links to production systems.
47 SHOP OPERATIONSCMM training for higher caliber machinists.
V I E W P O I N T S
6 COMMENTARY
8 GOVERNMENT MATTERS
9 NTMA NOTES
48 CUTTING TOOL APPLICATIONS
AMERICAN MACHINIST(ISSN 104-7958), founded 1877, is published monthly by Penton Media, Inc., 9800 Metcalf Ave., Overland Park, KS 66202-2216.
Telephone: 216.696.7000. Fax: 216.931.9524. Printed in U.S.A. Copyright© 2009 by Penton Media, Inc. All rights reserved. Periodicals Postage Paid at Shawnee Mission KS and at addi-tional mailing offices. Can. GST #R126431964. Canada Post International Publications Mail (Canadian Post Publications Mail Agreement Number 40612608). Canada return address: Bleuchip International PO Box 25542, London ON N6C 6B2 POST-MASTER: send address changes to American Machinist, Penton Media Customer Service, P.O. Box 2136, Skokie, IL 60076-7836 European delivery: Editeur Responsable (Belgique), Christian Desmet, Vuurgatstraat 92, 3090 Overijse, Belgique. Subscriptions: Solicited at no charge in the U.S. from corporate executives, manufacturing and manufactur-ing engineering managers, and manufacturing engineers in qualified metalworking plants. All others may subscribe at $90 per year or $140 for two years (single issue: $8) in the U.S. Canadian subscriptions: $100 per year or $170 for two years (single issue: $9). All other countries: $125 per year or $195 for two years (single issue: $12).Send subscription payments to Penton Media, Inc., Subscription Lockbox, P.O. Box 2135, Skokie, IL 60076-7835. Please allow 6-8 weeks to process order. Air mail available on request. Direct all paid subscription inquiries to 847.763.9670.
READER SERV ICE
45 AM PRODUCT EXPRESS
47 ADVERTISER INDEX
FIVE-AXIS MACHINING
Which machine configuration for which parts.
Mazak’s Vortex machine is one of many types of 5-axis machine configurations offered by the builder.
2 I AMERICAN MACHINIST I DECEMBER 2009 I americanmachinist.com
E D I T O R I A L M I S S I O N :American Machinist empowers self-determined m a c h i n e s h o p o w n e r s a n d m a n a g e r s to control their future. It does this by sharing tools, insights and best practices that managers use to embrace technology, innovate and systematically improve operations. American Machinist facilitates the leap from survival to growth for a community of owners and managers who operate metalworking businesses in the context of a global manufacturing economy.
MACHINING
What to check when good boring goes bad.
AMERICAN MACHINIST I Volume 153 I Number 12 I December 2009
18 OPERATING PRACTICE
Lean Flow cells make idle time productive.
16
10
< EDITOR’S NOTE: In our October 2009 issue we failed to credit Photographer Sébastien Desbordes for his impressive photo of Guillaume Labrie, of the LamaCycles downhill team. We regret the omission.
One Tool Body Carries Many Different Types of Heads
15,000 COMBINATIONS
PROFITABILITYBuilding Customer
Milling Intelligently
www.iscarmetals.com
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GOFIGURE.
You could do this: Set up operation 1. Then set up operation 2. Then set up operation 3. And then set up operation 4.
Or you could do one setup and run the job complete.
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With Haas Trunnion VMCs, you caneasily position parts for 5-sided workor full 5-axis machining. Smart.
As 2009 fades out, there are random indicators of economic recovery: the Federal Reserve Bank reports modest improvement in consumer
spending since October; the U.S. Dept. of Labor indicates the rate of unemployment has slowed; and November U.S. manufacturing orders increased almost 2%, the Institute for Supply Management says.
There are no boldfaced conclusions from these data points, but perfect clarity is rare. It was clear enough 15 months ago that the global economy was failing at some fundamental level, and before long it was clear too that everyone would be affected. Since then, nothing has seemed clear.
One of the signifying characteristics of this recession has been its thoroughness: no market segment, no organization, no worker has been unaffected. All of us have been on edge waiting for the next calamity. We’re unified in confusion and doubt, so we’re dubious that any small detail can undo so much damage. No one makes a move, so everyone is stuck.
Getting “unstuck” won’t be a unified effort. It demands individual initiative. Sooner rather than later each of us must acknowledge the confusion and reserve the doubt, and proceed using as much confidence and understanding as we can muster. Most economic advice involves managing perceptions anyway: why not assign all the bad news to 2009 and move ahead with confidence?
A more practical way forward is to understand better how and why the manufacturing market has changed, and how it continues to change. Tim Hanley, a Deloitte & Touche expert on manufacturing and industrial products markets, identifies six big factors in his industrial outlook:
(aimed at increasing bank lending and accelerating industrial spending) is disguising actual demand levels, so manufacturers cannot commit to capital spending plans.
supply chains and manufacturers’
“footprints” have become confused and less reliable
thanks to cost cutting, geographic shifts
and uncertain consumer demand.
manufacturers cannot forecast their needs and are fearful of future spikes when/if the global economy strengthens.
recovery means that manufacturers must continue to reduce structural costs, straining productivity.
global demand limits producers’ abilities to pass costs to customers.
workers, engineers, and executives complicates long-range planning and limits growth potential.
This may be his 2010 outlook, but other than the federal stimulus, each of these factors was in place prior to 2009. It’s a reminder that the world rarely changes in an instant: It evolves, and so must we.
The machining world is evolving too, of course. OEMs are assigning more of their precision manufacturing work to job shops, which is pressuring the shops to perform to higher standards. It’s also changing what they demand from machine tool builders, tooling manufacturers, software developers, and other dedicated suppliers. None of it is sudden, or certain, but it’s a change that’s happening apart from (and in spite of) all that confusion that we associate with 2009.
The way to overcome confusion is to identify your strength and be an expert at it. In this issue you’ll read about a machine shop that designs and manufactures custom tooling, and its creative effort to adapt to changing market conditions. The company president acknowledges they’re trying to change the way their market sector works. No shortage of confidence there.
This report, as we hope with every report in this and every issue, addresses the fact that every day presents machine shops with a series of challenges to their progress. More to the point, every day delivers reminders that we must use the resources and skills we have to improve our performance — or else, find the tools we need to improve. It’s not easy, but it’s progress.
FROM THE E D I TOR
On to something new
Robert BrooksEditor-in-Chief [email protected]
6 I AMERICAN MACHINIST I DECEMBER 2009 I americanmachinist.com
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n political folklore, a “yellow dog” Democrat is someone who could be counted on to
vote. That’s a problem for both Speaker Nancy Pelosi (D-CA) and Majority Leader Harry Reid (D-NV.) There are many more “blue dogs” than “yellow dogs” in their packs.
The federal budget deficit and proposals that could significantly increase that deficit, both for the current year and projected for the coming decade, are beginning to scare the more conservative blue dog Democrats and cause them to stray from the pack leader. For fiscal year 2009, the U.S. government ran a budget deficit of almost $1.4 trillion. Yes, that is trillion with a “t.”
It is not just a record. The $1.4-trillion deficit beats the old record by threefold. Moreover, by the Obama Administration’s own projections, the total budget deficit is projected to grow by an additional $9 trillion over the next decade. Remember when Ross Perot (who received 20 percent of the presidential vote in 1992) was campaigning on the position that it was irresponsible to allow the budget deficit to grow by several hundreds of
billions over the succeeding years? If only we had such small worries today, and our deficit could still be measured in billions rather than trillions.
In fairness, George W. Bush did nothing to alleviate the problem. Indeed, the budget deficit doubled during his tenure, and many of those years were times of good economic growth, when there was no need to run a deficit for economic stimulus purposes. Without getting much credit (or blame) for it, he signed a Republican-sponsored bill that added a prescription drug benefit for seniors, adding trillions to the unfunded liabilities of the U.S. government (which now amount to over $100 trillion or $900,000 for every U.S. household).
For 2009, the federal budget deficit is projected to be 11.2 percent of Gross Domestic Product (GDP.) This contrasts with a 3.2 percent of GDP in the previous year. Moreover, the Obama economic team does not see an opportunity to cut the deficit significantly during his tenure. In fact, they project a doubling of the deficit over the next eight years. We are already in debt to the Chinese alone for $1 trillion, and we are selling off our physical assets at a record pace to pay our bills. Direct foreign investment in the United States is $2.5 trillion, up 150 percent in just the last decade.
No wonder the “blue dog” Democrats are nervous. Many of them have to run for re-
election next year in states with conservative electorates, like Indiana, Arkansas, and North Dakota. That makes them skeptical of a near trillion-dollar price for the proposed healthcare bill.
Stories are already beginning to circulate about the billions of dollars of waste uncovered in the stimulus bill, and the promised jobs have yet to materialize in sufficient numbers to justify the $787 billion cost of that legislation.
Thus, the Senate deadline for healthcare is beginning to slip into early next year. And, Democrats are less and less eager to vote for a climate bill that could cost additional trillions and incrementally double electricity rates over the next decade. Senate Majority Leader Harry Reid (D-Nev.) is a good vote counter, and he knows he is asking some of his Democratic caucus to commit political suicide by backing the President’s legislative agenda.
The Republicans are counting on a conservative backlash to punish Democrats in 2010. “Blue dog” Democrats fear the same thing if they become identified in voters’ minds with the leaders of their pack.
Former Majority Leader Trent Lott (R-MS) wrote a book comparing his former job to trying to herd cats. Harry Reid and Nancy Pelosi are finding that herding “blue dogs” is not much easier.
GOVERNMENT MATTERS
You can help revitalize U.S. manufacturing! Send this page to your Congressman, local and state government leaders, or your local newspaper editor. Add your own comments on the importance of manufacturing innovation to the health of our economy. Your comments are also welcome at [email protected]
B Y D R . P A U L F R E E D E N B E R G
Blue Dog Revolt> >
Vice President-Government Relations, AMT—The Association For Manufacturing Technology
8 I AMERICAN MACHINIST I DECEMBER 2009 I americanmachinist.com
Ivote for a Democratic candidate even if the Democratic Party nominated a yellow dog. By contrast, in recent times there has been increasing reference to the “blue dog” Democrats in Congress. Those members are more discriminating about whom or for what they are willing to
NTMA NOTES
B Y J A M E S R . G R O S M A N N
JAMES R. GROSMANN IS MARKETING DIRECTOR FOR THE NATIONAL TOOLING & MACHINING ASSOCIATION
I have enjoyed contributing my opinion to American Machinist every month, and the opportunity
I thought I’d copy some of that lone negative response, so he can air his point of view.
“I read your article … and I had to laugh at the hypocrisy,” he began. “First using Khrushchev’s quote to demonize the present administration and then stating that 40% of Americans receive some sort of Federal aid, because we all know that is what’s killing the country. Just to be ‘fair and balanced’ why don’t you give us the ‘facts’ on how many businesses receive Federal assistance through tax breaks and credits while the rest of us pick up the tab?”
My friend misunderstood me. I didn’t say those on Federal assistance was what was killing this country. I’ve known people that have been on assistance and for a lot of them, it’s needed. But. I also know that there are billions of dollars wasted every year by people working the system, getting money they don’t deserve. The recent ACORN fiasco exposes a group organized to do just that.
We cannot afford to keep growing the federal government while losing jobs in the private sector. I think we should reconsider tax breaks for large corporations. Unfortunately, many of those tax breaks also help smaller companies to remain competititive. Maybe Congress will look in to that? Taxpayers fund all
of it. That’s the very reason why we can’t continue the practice.
Next, my friend criticized me for daring to address the number of illegal aliens receiving benefits paid for by taxpayers:
“… Go after those defenseless people on welfare, lastly point out that all those foreigners are getting stuff for free and they’re not even American. Oh and most importantly, do it while waving the American flag while remembering 9/11 and bellowing to take back America. Well, we’ve taken back America, back from the pack of liars and thieves that hijacked it for the past eight years.”
I welcome the immigrants who arrive here legally, work hard, and pay taxes. I spent many years living outside the U.S. and I know hard life is in many underdeveloped nations. I also know that many people who have entered the U.S. legally and approached citizenship the right way don’t appreciate others who don’t take the legal approach.
In more concrete terms, I recommend a visit to some of the counties in our Southwestern states that are overwhelmed by illegal immigration. The term “breaking the law” has to mean something, doesn’t it? Hospitals, welfare agencies, schools and other services are being strained, and compromised by excess demand. If it isn’t brought under control, those services won’t be available for anyone.
Next came his big conclusion: “Wealth is finite … if Wall Street is paying out huge bonuses that money comes out of someone else’s pocket, most likely ‘Joe Working Class.’ ”
It’s a pity our educational system doesn’t do a better job of teaching students how businesses really work. If “Wall Street” is paying huge bonuses, then the money ought to be coming out of the pockets of those that invested money in Wall Street. The bonuses should not be funded by tax revenue.
I believe it has been those officials now in office who have given taxpayers’ money to Wall Street. I’d also point out to my correspondent that the jobs he endorses and anticipates resulting from an expanded government will be funded by taxpayers’ money — including taxes paid by Joe working class, who he claims to defend with such passion.
But, there’s more to this exchange than the specific details in debate. My correspondent used some time-honored tactics: First, insult your opponent, and then change the subject. The point of my column was that our freedoms have been paid for with the blood of heroes. We must value their sacrifice even as we cherish our freedoms. We must be careful about what we allow to happen as our government expands, and asserts more control of our personal and business activities.
I should note that my corres-pondent is not a company owner; he’s a worker, like most of us. I hope that if government expansion threatened the viability of any of his plans or enterprises, he’d oppose that too. Our current leaders do not recognize small manufacturing as a worthy contributor to their project. For them, we’re an easy target to fund for their excessive spending. Manufacturing jobs, including my correspondent’s, will be lost if all this continues.
I appreciate my correspondent’s response because open debate is what America ought to be about, and what is threatened by an aggressive government. When elected representatives aim to legislate so fast that there can be no debate, we have lost a fundamental principle of our democracy. We must examine all these changes, before we “give it all away.” <<
Contact James R. Grosmann at the National Tooling & Machining Assn., [email protected].
Let’s Hear From the Other Side> >
americanmachinist.com I DECEMBER 2009 I AMERICAN MACHINIST I 9
to “inform” our industry about the realities of what is going on in Washington. My October column, “Will We Give It All Away,” expressed my concern that we are going to give away our country, if we aren’t careful. Among all the responses, just one reader disagreed with me, but nevertheless agreed that we need to have “serious debate.” That’s not going on in Washington today, but since American Machinist doesn’t present “letters to the editor,”
F IVE -AX IS
The number of shops that have caught on to the ben-efits of 5-axis machine tools has grown by leaps and bounds in recent years.
Still, there are many shops that, for the first time, are adopting 5-axis machin-ing, and for them, choosing a machine can be a daunting prospect – espe-cially when one machine tool builder reported having found hundreds of different possible machine configura-tions available for achieving 5-axis machining capability.
However, shops making their first foray into full simultaneous 5-axis ma-chining or 5-sided machining typically opt for either a vertical or horizontal-type machining center. And thankfully, with those two types, the choices are a bit more manageable.
Within the realm of verticals and
horizontals, there are basically four common configurations for five axes, and those four can be categorized into two groups. Group one configurations achieve a fifth axis through workpiece/machine table movement, and group two configurations through tool/ma-chine spindle movement.
The table-movement group in-cludes the A over B axis (dual trunnion table) and B over A axis (knuckle)-type machine configurations. Configurations within the spindle-movement group are the tilting-head and C-axis head-types.
Each type of 5-axis machine config-uration handles certain types of work-pieces better than others, which is the reason that practically every builder of 5-axis machines will agree that choos-ing the appropriate machine configu-ration is extremely “part driven.” So, shops need to know the size and weight
range of the parts they will be running, what material (soft or hard) those parts will be made from, what level of ac-curacy needs to be held, and what types of surface finishes are required.
According to Dave Lucius, vice president of sales at Methods Machine Tools Inc. (www.methodsmachine.com), the exclusive U.S. importer of Matsuura machines, the best configu-ration for rigidity and accuracy when machining hard materials is one where the machine’s table moves rather than its spindle. Machining hard materials is Matsuura’s forte, he said, which is why the builder focuses heavily on A over B-axis dual-supported trunnion-type machines with vertically oriented spindles for 5-axis machining. Mat-suura also produces B over A-axis knuckle-type machines, but recom-mends that shops move to a dual-sup-
10 I AMERICAN MACHINIST I DECEMBER 2009 I americanmachinist.com
The Five-Axis Frenzy SHOPS HAVE A LOT TO CONSIDER BEFORE DIVING
INTO 5-AXIS MACHINING. By Charles Bates I senior editor
Ph
oto
co
urt
esy
of M
akin
o
americanmachinist.com I DECEMBER 2009 I AMERICAN MACHINIST I 11
ported trunnion-type machine when part weights exceed 100 lb.
Lucius explained that Matsuura machines get their rigidity and robust-ness from vertically oriented spindles together with trunnions that are ba-sically mounted to a machine’s core base. He also said there are benefits concerning work envelopes and ma-chine automation.
“On trunnion-style machines, most of the work envelope is usable because it doesn’t have to be big enough to pro-vide enough room for a moving spindle to maneuver around a workpiece. So when considering a part’s size, a trun-nion-style machine’s work envelope for that particular size will be smaller, as compared with the required envelope a tilt spindle/C-head type machine will need to accommodate that same part size. With a trunnion type machine, shops can get closer to filling the work envelope with part size because the ma-chine design eliminates the interference issues associated with a moving-spindle machine,” said Lucius.
To date, Matsuura’s largest dual-supported trunnion machine provides a work envelope measuring 24.8 in. sq., handling parts weighing to 880 lb. And, the company soon will be presenting a larger horizontal version dual-sup-ported trunnion style 5-axis machine.
Responding to the belief that trunnion-style machines are difficult to automate, Lucius pointed out that just the opposite is true. “Automating a trunnion-type machine is actually easy to do. For example, the Mat-suura MAM72-35V can incorporate a simple pick-and-place robotic sys-tem, some with as many as 180 pal-lets. The machines are designed for fully integrated, simple off-the-shelf automation. In fact, the bulk of 5-axis machines Matsuura installs are ones with high-quantity pallet systems.”
Commenting on 5-axis machines, Tracy Ellis, machine group sales man-ager at Heller Machine Tools (www.heller-us.com), stated that all types of 5-axis machine designs provide accuracy, but there can be physi-cal drawbacks to each. For example, he pointed out that an A over B-axis trunnion-type machine design might limit operator accessibility.
Workpieces and workholding, on those types of machines, must rest
Many shops are so-lidifying their com-petitive standing by
incorporating 5-axis machin-ing and taking on low-vol-ume, high-accuracy complex jobs. But in this process some shops, especially those do-ing work with micron-scale features or surface-finish requirements in the single-nanometer range, often reach accuracy limits when using conventional machine tools.
In these situations, ma-chine tool builder Mori Seiki (www.moriseiki.com) recommends that shops con-sider “ultra-precise” 5-axis machines. Used in clean, temperature-stable environ-ments (at least +/- 1 degree C.), these machines easily match the most demanding standards for accuracy.
One of Mori Seiki’s ultra-precision 5-axis machines is the NN1000DCG for ultra-precise linear scribing and milling. The symmetrically configured machine fea-ture’s the company’s DCG (driven at the center of grav-ity) technology and a spe-cial, closed-loop structure.
According to Adam Han-sel, COO of Mori Seiki's Digital Technology Lab, the reduction of off-axis distur-bances is critical in ultra-precision machining. A DCG machine structure, and one
that is fully counterbalanced, ensures smooth machine movement. In addition, the NN1000’s closed-loop struc-ture increases machine stiffness.
“While other machines typically employ cantilevered spindles, the NN1000 closed-loop structure not only makes for a more rigid machine, but also provides excellent op-erator access to workpieces and tooling for in-machine measuring and job set up,” pointed out Hansel.
Mori Seiki equips the NN1000 with air bearings on linear and rotary axes to eliminate mechanical con-tact and provide the highest level of precision.
An air turbine that pro-vides precision and reduced thermal generation drives the machine’s milling spin-dle, which also spins on air bearings. For ultra-precision positioning, the machine’s linear axes feature 34-pi-
cometer-resolution scales.Although the X, Y, and Z-
axis travels on the NN1000 measure 4.7 in., 5.9 in., and 2.0 in., Zach Piner, general manager of Mori Seiki' Me-chanical Technology Group, said the machine’s design could definitely be applied to a larger format machine. But, he added that the exact construction of the machine would have to be evaluated based on the exact intended application.
“Some of the main target markets for the NN1000 are optical and micro molds. However, many markets are emerging as engineers learn that these kinds of machines ex i s t . Many eng ineer s would not have considered designing such complex and precise part features because they did not know that a machine existed that could achieve them,” com-mented Piner. <<
between the two (A-axis) trunnions, forcing operators to work around the trunnions. He also said that shops can fit only so much workpiece mass and weight between the two trunnions be-fore having to move to a larger ma-chine. But, he added that the trunnion machine design is a very reliable one.
“In my opinion, I don’t think a shop should go over an 800-mm pallet size in an A over B axis trunnion ma-chine. When workpiece mass/size ap-
proaches 2,500 kg/one meter or larger, it can be difficult to handle on a trun-nion machine because the trunnions would have to be spread out to the point where table sag might become an issue,” said Ellis.
He agreed that A over B-axis ma-chines are adaptable to pallet chang-ing. However, the pallet changer has to be either a shuttle or linear type, which may not be as fast as a rotary-type pal-let changer. Pallets must be lifted and
Ultra-Precise 5-Axis
Mori Seiki's NN1000DCG 5-axis machine.
12 I AMERICAN MACHINIST I DECEMBER 2009 I americanmachinist.com
F I V E - A X I S
shuttled and a new one pushed on, as opposed to lifted, rotated and set down with a rotary system.
Ellis added that pallet changing is possible and commonly done with B over A-axis type machines, but there can be an overhead connection to the machine’s B axis that can get in the way, especially with aftermarket add-ons. Builders can overcome this prob-lem by making the connection integral to the table.
Heller builds tilting head and C-head type five-axis machines with B axes as the rotary tables and the other rotary axis as either a swiveling workhead C axis or a tilting A-axis workhead. Ma-chine sizes run to 1.6 m by 2 m, and if a shop needs something larger than that, Heller recommends opting for a portal or gantry type five-axis machine.
Tilting head and C-head designs keep a machine’s work area accessi-ble and ergonomically friendly while allowing for a large work envelope, high table load capability and good adaptability to pallet changing. Op-
erators can easily reach workpieces, workholding, the spindle and tooling, and the machines’ tables carry the full load and workpiece size of traditional horizontal machining centers.
With a B over A-axis design, the ma-chine’s indexer takes up a large por-tion of the work envelope, and with an A over B-axis trunnion machine, there are potential collision zones with the trunnion, explained Ellis.
For its 5-axis machine models, Hel-ler offers a choice of three different workhead designs. There’s a power-cutting, high-torque universal head, a speed-cutting universal head, and a speed-cutting tilt spindle for high-speed cutting.
The power cutting heads use Hel-ler ‘zero’ spindle system spindles, car-tridge-type spindles that have a cou-pling between the spindle cartridge and the motor. This allows the cartridge to be changed in about two hours, as op-posed to motorized spindles where the task is a lot more involved.
Tilting head machines from Heller
sport higher speed spindles, primarily for cutting aluminum and cast iron. The company also offers a high-speed spindle on its C-head machine. The power cutting C-head delivers ample torque having a gear-driven headstock in 40 and 50 taper versions.
Makino’s (www.makino.com) ap-proach to various five-axis machine designs considers both the positioning of the workpiece relative to the spindle and the positioning of the cutting tool/spindle relative to the workpiece.
On some horizontals, for example, Makino uses a table-on-table design, where the B axis is under a horizon-tal pallet that has a vertical rotary C axis. The design provides stiffness and rigidity, and such operations as drill-ing and boring can be performed as single-axis operations versus multi-axis movements. On its verticals and some horizontals, the company also uses tilt trunnion-style tables.
Makino also designs five-axis ma-chines with the A and C axes on the spindle. However, those machines are
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americanmachinist.com I DECEMBER 2009 I AMERICAN MACHINIST I 13
for large parts, such as big flat plates.“Traditionally, the drawback to a
tilt trunnion design, or even the table-on-table one, has been the amount of rotational speed that can be generated on the rotary axis, whether B and C axes or A and C axes,” said Bill How-ard, product manager at Makino. “A relatively high table speed (rpm) is needed to get the most out of a high-speed spindle when machining, for ex-ample, the outside edge of a 30-in-di-ameter workpiece. Mechanical drives and elements can actually limit a ma-chine’s rotational speed.”
He pointed out that Makino, and other machine tool builders, overcome these table rotation drawbacks by us-ing direct drive motors that provide high rotational speed, resulting in higher machining feedrates.
Direct drive motors, such as those used on Makino’s D-500 vertical 5-axis machine with a tilt/trunnion table, eliminate backlash and provide the same accuracy and repeatability of mechanically driven tables. They also
eliminate the need for mechanical com-ponents linked to mechanically driven tables, along with the wear and tear associated with those components.
Machine tool bui lder Mazak (www.mazak.com) addressed 5-axis accuracy with a recently designed 5-axis machine that incorporates lin-ear motor technology to increase ac-curacy when doing fine incremental machining. Such a design eliminates the need for ballscrews, along with the backlash and starting/stopping re-versal errors that go along with them. And Chuck Birkle, marketing vice president at Mazak, said that more and more machine tool builders are turning to linear motor technology to boost overall machine accuracy.
According to Birkle, Mazak has no qualms about building machines with the fifth axis in either the tool or the table: more than half of the machines the company builds are five-axis.
On the company’s Vortex vertical machines, for example, the spindle provides the A and B axes, while its
Variaxis verticals, use an A over B-axis design via dual trunnion table.
“One advantage to the trunnion table design is that relatively short tool lengths can be used because the table can maneuver up close to the spindle. There’s better spindle rigidity, yet no need to use long tools for reaching certain part surfaces, even on complex geometries,” said Birkle. “And, the configuration tends to simplify programming in that the tool tip is always in a known posi-tion. It’s the A and B axes that are the variables.”
No matter the type of machine de-sign, today’s tougher part materials are placing a heavy burden on machine tool builders to increase machine rigid-ity and re-think how spindles are built.
“Four or five years ago, it was high-rpm machining of mostly alu-minum. That’s changing," said Birkle. "There’s an increased use of hard ma-terials, such as titanium, so the goal isn’t more rpm, per se, as it is more torque at lower rpm."
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PERFORMANCE AUTOMOT IVE
ALL VALUES ARE MINUTES
SETUPDATA
RETRIEVALPOST
PROCESSING
DIAL INDICATORS 30 45 20
STARRETT WIRELESS INDICATORS & DATASURE
30 35 0
In NASCAR racing, torsional stiffness of a car chas-sis is one of thousands of critical details that must be executed reliably, and Joe Gibbs Racing (JGR) (www.joegibbsracing.com) takes no chances.
To test chassis stiffness, technicians at JGR will lock down the car structure and place indicators at eight designated po-sitions. Then, a load is manually placed on the car, and the measurements are taken from the indicators. This procedure is repeated 12 times with different loads and different chassis configurations, for a total of 96 measurements.
It used to be necessary for a technician to walk around the chassis and write down each measurement after each setup and load placement. Also, the dial indicators used in this step would be upside down (positive and negative readings) and, because the car would be rising on one side and declining on the other, half of the dials would turn in the opposite direc-tion. The process was time-consuming and error prone.
Joe Gibbs Racing needed a faster — and more accurate — process. They approached The L.S. Starrett Co. (www.starrett.com), a company well known to JGR through spon-sorship agreements.
With the goal of automating the data-collection process, JGR recently replaced the dial indicators that had been used on the chassis twist rig with new Starrett wireless indicators
and a DataSure wireless data collec-tion system. Each indicator has an ac-companying DataSure end node, and a DataSure Gateway attached to a PC records the data.
The new package improves data gathering in several important ways. Rather than positioning himself awk-wardly around the twisting chassis, taking a reading and recording it, the technician now simply pushes the DataSure end node "send" button.
Also, the prior procedure required another step: the technician had to en-ter the measurement data into an Ex-cel spreadsheet, which added time and potential errors to the process. With DataSure, captured data is entered di-rectly once it’s sent from the end node for 100% error elimination.
At first, JGR expected that the indi-cators and DataSure would only save process time, but it became clear that they were also saving effort. While most of the time spent twisting a chas-sis is devoted to setup, which has noth-ing to do with the indicators, quite a bit of time is saved in post processing.
For now, the load is still applied
manually, which means that at each load setting, technicians can take eight measurements with the click of a button. Data-Sure and WinWedge (www.taltech.com) serial data-collection software ensure that all of the data is written directly into a prepared Excel worksheet. This eliminates any post process-ing and saves 15 to 20 minutes worth of extra work.
Starrett wireless indicators and DataSure have been a wel-come addition to the chassis twisting rig. As documented in the table, DataSure and the wireless indicators have made a chassis twist take almost 30 percent less time than using con-ventional dial indicators. The process is easier for the techni-cian and more reliable for Joe Gibbs Racing. <<
14 I AMERICAN MACHINIST I DECEMBER 2009 I americanmachinist.com
Twisting and Turning Straight to the Point
To test chassis stiffness, Joe Gibbs Racing technicians lock each car into place and locate indicators at designated positions. Then, a load is placed on the car and measurements are taken from the indicators. This procedure is repeated 12 times with different loads and different chassis configurations.
WIRELESS INDICATORS AND DATA COLLECTION MAKE MEASURING TORSIONAL STIFFNESS SIMPLER AND MORE ACCURATE FOR ONE NASCAR RACE TEAM.
americanmachinist.com I DECEMBER 2009 I AMERICAN MACHINIST I 15
MBE Cylinder Heads and Manifolds (www.mbellc.com) in Mooresville, N.C.,
designs and builds specialty compo-nents for powerful engines used by performance race teams in NASCAR, NHRA, and others, and head program-mer Mark Olson said his production plans achieve both power and preci-sion thanks to Delcam’s PowerSHAPE and PowerMILL software packages.
“It amazes me what it can do,” Olson said. “We do a lot of manual work, then we digitize the ports, chambers and whatever else needs to be machined for the engines, and we import it into Power SHAPE.”
He said “power” makes the Delcam products effective. “PowerSHAPE has a great, powerful surfacing engine. I have
yet to find something as good as Power-SHAPE to manipulate surface data.”
After perfecting the model in PowerSHAPE, Olson moves his design easily and flawlessly into PowerMILL. “They have a very powerful automatic porting routine,” he said, and that was a big reason they bought it. “Power-MILL keeps the edge of the tool in con-tact with the port, as opposed to the tool’s tip. Cutting with the side of the tool provides a much better finish.”
Another aspect of PowerMILL Olson likes is the way it sees models when creating tool paths. With clear-ances as small as 0.015 in., he said he has never had interference or a colli-sion using PowerMILL. He also likes the transparent interface between PowerMILL and PowerSHAPE.
“ Yo u c a n c u t and paste common geometry from one app to another very quickly without im-porting and export-ing.” Olson said. “You copy from one, paste it in the other, and I can be confident it will cut the port first time.”
“Without Del-cam, it would’ve been very hard for us to handle some of the projects we’ve taken on recently,” said MBE owner Matt Bieneman. <<
High-Horsepower Programming
Programmer Mark Olson shows one of the customized cylinder heads he produces at MBE Cylinder Heads and Manifolds, for NASCAR, NHRA, and other high-performance engines.
Optimizing a High-Performance Component Business
CP Pistons (www.cppistons.com), Irvine, CA, develops and manu-factures pistons for high-perfor-
mance race vehicles and the automo-tive aftermarket, including vintage cars, motorcycles, and marine and aircraft engines. Recently it bought Carrillo In-dustries, manufacturers of high-perfor-mance connecting rods, to expand its
portfolio of complex parts offered on short lead times.
The expansion caused CP Pistons to take a critical look at its manufacturing and business processes. It found that while its proprietary programming sys-tem was capable of standard machin-ing, the complexity of the market had advanced. This forced the shop to rely
too heavily on other CAM systems to perform time-consuming manual oper-ations for custom features on its forged racing pistons and rods. Repeat orders with small changes were being com-pletely reprogrammed in the old CAD/CAM system, leading to misinterpreta-tions and doubling process times.
It found better CAM programming in Geometric Technologies’ CAM-Works (www.camworks.com) soft-ware. CAMWorks produces efficient machining programs directly from solid models, and seamless integration between CAMWorks and SolidWorks provides interoperability and data in-tegration so that manufacturers can engineer, design and build products faster and more accurately.
While CAMWorks integrates with SolidWorks for design functions, it has an open Application Programming In-terface (API) platform that can be cus-tomized to work with CP Pistons’ order booking system. It also has feature recog-nition that allows it to identify ideal ma-chine toolpaths based on different piston geometries (e.g., holes, bosses, pockets, perimeter cuts), and a knowledge data-base (TechDB) feature that makes data storage/retrieval more efficient.
“CAMWorks was the only tool we found out there that could meet all our de-mands, and its flexible approach on APIs really helped us move forward,” said Karl Ramm, senior technology manager and project developer for CP Pistons.
“Before CAMWorks,” he contin-ued, “we programmed each custom piston order manually, slowing down our manufacturing. Each job would take approximately 10 minutes for non-complex pistons and up to 40 minutes for complex ones — and that’s programming time alone.”
CAMWorks simplifies complex programming tasks to assist with CP Pistons’ automation.
MACH IN ING
When boring perfor-mance falls off, the cause may be any one or a combina-tion of factors. These
include workpiece stability, adequate stock allowance, tooling rigidity, insert grade and geometry and the matching of speeds and feeds to cut-ter capability. When experiencing overly long cycle times, short tool life or poor part quality, any or all of these factors should be reviewed. In any application, one factor may be more significant than others, but they also may be closely linked to each
other. Changing one may mean an-other also has to be changed to get the desired results. However, when making test cuts, never change more than one thing at a time.
Part stabilityAlthough the machining center and
fixtures usually are not the first factors shops may consider, these can seriously impact tool performance if the part is not stable when being machined.
Once workholding rigidity is estab-lished, machine size and power influ-ence cutting parameters. Although the same roughing head can be put
on a CAT 50, CAT 40 and BT 30 taper, each will not be able to take the same cut. The same holds true for the depth of bore. A three-inch bore, 10- to 12-in. deep will work on a CAT 50, and can be done on a CAT 40 with extensions, but anything smaller than a 40-taper machine will not support the application.
Worn machine spindles and unstable fixtures are usually factors that can-not be changed and must be worked around. Sometimes these factors can kill an application altogether, but usu-ally changes in insert types or cutting parameters will provide a solution.
16 I AMERICAN MACHINIST I DECEMBER 2009 I americanmachinist.com
Rounding Up The Usual Suspects WHAT TO CHECK WHEN BORING PERFORMANCE GOES BAD. By Matt Tegelman
For long-reach limited clearance applications,
consider using a solid carbide bar instead of multiple
extensions. This set-up offers higher rigidity and better
control, but is generally limited to smaller diameter
bores.
(Opposite page) Tooling for an extended reach bore
where only the gage length and bore diameter are
considered (Fig. 1) lacks the rigidity of a modular system
that uses a larger connection size for reach and only
reducing the tool diameter when necessary (Fig. 2).
americanmachinist.com I DECEMBER 2009 I AMERICAN MACHINIST I 17
Stock allowanceOften, operators are unsure of how
much stock to leave for boring appli-cations. Users may be more familiar with the speeds/feeds and stock allow-ances needed in turning applications, which don’t always apply to boring.
This is especially true in rough bor-ing applications where a twin cutter is used. It is not uncommon to see drills that are so close to the final size of a part that only 0.020- to 0.030-in. of stock is left on diameter, which isn’t enough material to engage both in-sert tips on a twin cutter. This leads to chatter and poor tool performance. Parts without enough stock allow-ance and an open tolerance — plus or minus ten thousandths on the diam-eter — will work best with a single-point tool, or a twin cutter with one of its insert holders removed.
On the other hand, parts that have cored holes may have too much mate-rial to remove if the cored hole is not in the correct position. Even though the core diameter is within typical rough-boring standards for stock al-lowance, the core shift can produce a situation where the twin cutting tool is taking more material on one side of the bore than the inserts can handle.
Tool assembly rigidityOften, boring tools are selected for
an application based on a required bore diameter and gage length, with-out consideration for the actual boring depth and the extra reach required, if any. For example, an application may require 8 in. of reach through the part and/or fixture just to get to the bore, and only 2 in. of boring depth. This is quite different than an application that requires a boring depth of 10 in.
Modular tooling systems offer an in-finite number of combinations for max-imum rigidity and usage. In cases where tool length is needed, it is important to start with a larger base size and then reduce the tool diameter as necessary, rather than using the same bar diameter for the entire length of the tool.
Insert grade and geometryInserts are the critical contact point
between a workpiece and tool. The most rigid boring assembly, complete with a balanced boring head, can perform miserably if the insert is not
suited to the application. Insert grade means little if the
geometry does not provide a stable cut. Pressed geometry inserts usually have a less aggressive chipbreaker and hold up longer in stable conditions, but the radial depth of cut should be at least one-half of the insert nose radius. In applications that are critical due to factors such as deep or long-reach bores, long-chipping materials, or part instability in the machine and/or fixture, inserts with ground geom-etry will cut more freely.
Insert grades and coatings are con-tinually being upgraded for specific applications. For steels, Cermet and triple-coated carbide grades are most common. Coated carbide grades are also used in cast iron applications, but stable conditions will also permit the use of silicon nitride and some cubic boron nitride (CBN) grades. Alumi-num and other nonferrous materials can be run with uncoated carbide inserts, usually with highly positive ground chip breakers to prevent long strings of chips. For high-speed fin-ishing of these materials, inserts with poly-crystalline diamond (PCD) tips or coatings also may be an option. Remember that a stable cut is the first requirement for long insert life.
Speeds & feedsWhen all other factors have been
considered, it is time to determine the appropriate speeds and feeds for run-ning the tools. These parameters are important to obtaining optimum free-
cutting conditions. Ideally, the bor-ing bar is run at high speeds and more moderate feedrates; but again, this can be limited depending on the condi-tions previously cited.
A common mistake during rough boring is simply to multiply single-point feedrates by two when using a twin cutter. This usually is not an effective calculation; twin cutters can operate at feeds four times faster than those of finishing tools for the same diameter because a much larger nose radius can be used. For example, if fin-ishing with a 0.008- or 0.016-in. nose radius, a 0.031-in. nose radius insert could be used for roughing. This dou-bles the size of the nose radius and us-ing twin inserts doubles that to four.
Typically, roughing doesn’t require very fine, slow surface finishes so more rigid tools can be used at higher speeds. Feeding a twin cutter too slowly will lead to chatter without the right stock allowance. Rough cutters are designed for heavier cuts, requiring more mate-rial and harder feedrates.
When it comes to speeds, operators are sometimes hesitant to run proper surface footage when finishing. It’s im-portant to optimize speed for insert life. If heavier cuts are being taken, running at a very high speed will create a lot of heat, reducing insert life. Lighter cuts don’t produce as much heat, so they can be run at higher surface feeds.
Matt Tegelman is an application man-ager at BIG Kaiser Precision Tooling Inc. (www.bigkaiser.com).
OPERAT ING PRACT I CE
The first installment of this series on how Lean Flow is implemented for companies with machine-based processes focused on establishing cell-based manufacturing and linking machine cells to synchronize the processes. (See AM, Oct. 2009, p.22.)
Today’s productivity improvement goals, and the significant disparity in wages between U.S. manufac-turing and lower-cost countries,
require shops to use as much of a machine operator’s idle time as is possible. Machine cell design needs to create as much opportu-nity as is possible for one person to run mul-tiple machines, converting any wasted idle time during the machine cycle into value-adding work on another machine.
To use that idle time, we cannot return to large-batch manufacturing on inflex-ible machines that produce at high speeds, but are difficult to setup. We need flexible machines and operators who can run more than one machine — often, different types of machines.
Lean Flow machine cells are not a series of similar machines arranged in a functional layout. The Lean Flow machine cell may be a mixture of CNC and traditional manual machines arranged in the order required to flow materials through the processes re-quired to complete the product. Operators therefore may be operating a CNC lathe and a milling machine, or a horizontal ma-chining center and a drill press, or a lathe operation, some minimal cleaning process, and assembly and packing. Operators move from machine to machine according to the work that needs to be performed to keep the product flowing. Machinists in many companies have the capability, skills, and training to run different types of machines. Often though, employers have not created the expectations that machinists/operators need to run multiple machines at once.
The key to productivity gains (sales shipped per employee-hour paid) is not maximizing the machine utilization at a process level, unless the process is a capacity constraint. If the Lean Flow design calcula-tions require only 50% of a lathe’s capacity,
then it’s fine for a machine to be idle while an operator assembles and packs product. The focus is on the output of the cell, line, or ultimately the factory, not minimized to the output of the machine or process.
Tool and machine design technology improvements are always important as po-tential productivity opportunities, but the focus on these types of productivity im-provements can be overemphasized at the expense of the basic Lean Flow principles. Instead, the focus should be on getting the machinists/operators to be as productive as possible, using all of their idle time.
Reduce leadtime to the minimum pos-sible level to meet customer demand and optimize on-time delivery. Make the entire company as flexible as possible to be able to change swiftly from one customer need to another. Then, use the savings and in-creased revenues generated from the Lean Flow activities to pay for new technologies to further improve productivity.
This new-technology capital must be spent on the processes that will provide the overall greatest reduction in the leadtime, inventory, and product cost. Remember: volume drives down cost much faster than saving labor at one process. The way to in-crease volume is to meet or exceed custom-ers’ expectations.
Another focus of Lean Flow is improved on-time delivery performance. This is key to improving sales, reducing costs, improv-ing customer satisfaction, and growing the business and its revenues. In today’s global markets with the wide array of product choices, customers will not continue to pur-chase from companies that cannot deliver product as promised. U.S.-based companies have a geographical advantage to be able to supply product in the U.S. market, the world’s largest consumer market. Without excellent on-time delivery, that advantage is lost to global competitors.
How do Lean Flow companies improve on-time delivery performance while reduc-ing inventories and cost? By using a pull system to ensure raw/purchased material and finished goods inventory (FGI) avail-ability. The pull or kanban system brings
material into the factory based on con-sumption from the on-hand inventory, not a forecast. Therefore, material availability is not driven by a guess at future needs but what is used right now.
Known consumption is a much better indicator of what, and how much, mate-rial should be replenished than the forecast (aka an educated guess.) Kanban works the same way for finished product, assuming that finished product is held in inventory: build additional FGI when some is shipped, not based on forecasted sales.
In addition, by dramatically reducing leadtime the machine cells can respond to new customer requirements in a timelier manner. This ability to respond quickly is made possible by linking processes in cells, by controlling the inventory between pro-cesses with engineered queues (called in-process kanban or IPKs), and by making sure that product is built in quantities as close to the customer demand as possible. This eliminates the waste of overproduc-tion as well as the loss of machine capacity producing unneeded product.
Machine-focused Lean tools
Another commonly used tool in a ma-chining environment is 5S. 5S is easy to im-plement in assembly operations, with most assembly lines being able to be organized in a few days. Machine cells require a greater level of detailed study and organizational effort to organize the machinists’ tools, fix-tures, jigs, clamps, vises, gages, and tooling used by the machines (milling cutters, bor-ing bars, drills, facing/turning tools, end mills, etc.), and miscellaneous stuff needed in a machine process. The reward here is a more organized process that is a more pro-ductive process, thus eliminating waste.
TPM (Total Productive Maintenance) is a Lean Flow tool that focuses on increasing the efficiency of machine processes to maxi-mize the output rate, to achieve optimal running conditions. To achieve this goal, machines need to produce at the specified design rates. If a machine is producing half of the output it was designed to achieve,
18 I AMERICAN MACHINIST I DECEMBER 2009 I americanmachinist.com
Productivity,Performance How to achieve productivity improvements, on-time delivery, and other Lean Flow
(SECOND OF TWO PARTS)
americanmachinist.com I DECEMBER 2009 I AMERICAN MACHINIST I 19
and that design rate is realistic, then labor resources and probably tooling are being wasted. Also, asset capital is wasted when machines run inefficiently (not producing at design specified operating rates), and additional machines are required to meet demand. In addition to wasted investment capital, labor costs are wasted when ma-chines do not run at designed output rates.
In a machine cell environment, if one machine goes down unexpectedly the whole cell could shut down. There is very little in-ventory in the cell to buffer for unplanned downtime. The minimal inventory designed in the cell maintains a flow and deals with imbalances of work content time between processes. The amount of WIP or product in the factory controls WIP inventory levels and leadtime. There is not enough inven-tory designed into a Lean Flow cell to buffer for a machine process to be down for hours, or days, or weeks. So, TPM is critical to keeping machines up because one machine down means all of the machines in the cell will be down in a very short period of time.
Setup reduction is a necessary Lean Flow tool for reducing long setups that extend leadtimes and increase batch sizes. Large batch sizes extend leadtime even more and cause additional excess inventory and wasted capital investment. Setup reduction also increases the percentage of machine uptime, therefore increasing the achieved rate of output for each of the machine pro-cesses. This makes the machine and the op-erator more efficient.
Lean vs. EOQ
A Lean Flow factory strives to run a mix of products every day, or every few days, to meet actual customer demand. This keeps inventories low, but requires cycling through the different products or compo-nents more often than may be normal under current environments. Setup reduction is a necessary Lean Flow tool for reducing long setups that extend leadtimes and increase batch sizes. Large batch sizes extend lead-time even more and cause additional excess inventory and wasted capital investment.
Setup reduction also increases the percent-age of machine uptime, therefore increasing the achieved rate of output for each of the machine processes. This makes the machine and the operator more efficient.
When designing a Lean Flow factory with machining processes, the differences between Lean concepts and the EOQ for-mula have to be addressed. What a disaster this old technology has been for Western economies. Even if you do not use this for-mula, so many companies think this way at
the operations management, planning, and production levels that the result is as if the formula is in use.
The premise of EOQ is to set the pro-duction quantity to minimize the total cost of setup and inventory-carrying cost. How-ever, the inventory-carrying cost is always understated, the costs of order manage-ment, setups, and other elements are always overstated, and the EOQ turns out to be a ridiculously high production quantity — weeks, months, or years of products pro-duced in a single batch.
Also, the EOQ does not address the real-ity that if you cannot supply product to your customers because the machines are not being operated to meet customer demand, then the setup cost per piece is meaning-less. The greatest potential cause for an in-
crease in setup cost is reduced volume or sales. Lose sales to the competition because of long leadtimes and wasted capacity, then expect to watch setup costs to skyrocket!
The EOQ results in large quantities that waste machine capacity, making product that is not required now, and therefore wastes capital on more inventory and machines that would not otherwise be re-quired. As an example: if an EOQ calcu-lation determines the quantity to be 500 pieces, and the cost of machine setups is $500, the setup cost per piece is $1. If the cost of the part is $50, the setup is 2% of the part cost. If the order quantity is re-duced by 50% to 250 pieces, the setup cost in the EOQ jumps to 4%.
This is a false assumption, because the fixed costs did not increase per product shipped. Also, it assumes that there are no reductions to setup times, that TPM did not improve the operating rates of the ma-chines, and that there is no benefit to get-ting products out to customers on time. To reduce the overall cost of the product, focus on on-time delivery performance, and watch sales revenues easily increase by 5-10%. Do this while utilizing the working capital (cash, inventory and receivables) better, and leverage the fixed costs across the increased sales. An incremental, 10% increase in sales from improved on-time delivery and reduced leadtimes will make the product costs drop like a rock.
Lean Flow is different in a machining environment than in assembly, and defi-nitely more complex, but it can provide greater benefits and a higher return on the investment. The focus for the Lean Flow implementation team and management must be to break down the paradigm that Lean Flow is for assembly operations, and that machines require a different set of manufacturing principles. The Lean Flow tools are the same, some of the applications change, the complexity is higher, and the transformation process takes longer — but the benefits are significant.
The question is not whether a machine-based manufacturer should adopt a Lean Flow business strategy, implement Lean machine cells, and drive to eliminate the waste. The question is: What will happen to the business, sales, customer satisfaction, and profitability if you do not implement a Lean Flow business strategy?
Preston J McCreary is a consultant and partner
with FlowVision, LLC. Contact him at mccreary@
flowvision.com, or tel. 303-886-2852.
and Machines tools for machining operations I By Preston J. McCreary
Make the entire company as flexible as possible, to be able to change from one customer need to another. Then, use the savings and increased
revenues generated from the Lean Flow
activities to pay for new technologies that will improve productivity."
E D I T E D B Y C H A R L E S B AT E S I S E N I O R E D I T O R
M A C H I N E T O O L S
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Touted as a “new genera-tion” of turn-mill machining centers, the R200 turn-mill center cuts complex parts
from tough materials in half the time required by a conventional type turn-mill machine, reported Index Corp.(www.index-usa.com), the R200’s builder. To accomplish this, the com-pany equipped the R200 with two powerful motorized milling spindles and two movable work spindles for performing machining operations in two independent subsystems, and each subsystem is capable of full five-axis machining of bar stock to 65 mm in diameter.
The R200’s innovative axis arrangement produces directional
kinematics, which, in turn, enable comprehensive and complete machining of two parts simultaneously. Within the machine’s work area, its main spindle moves in the Z axis, the subspindle in the X axis and Z axis, the milling spindle 1 (top) in X, Y and B axes, and the milling spindle 2 (bottom) moves in the Y and B axes.
Because of its design, the R200 does full reverse-side machining as well as parallel machining. And operations include heavy-duty rough machining and highly accurate fine turning, done simultaneously on the machine’s main spindle and subspindle.
Within the vertical, cast machine bed of the R200, the two quill-guided motorized milling spindles are
centered, a diagonal arrangement that allows Index to omit the usual cross-slide. The milling spindles deliver 11 kW of power and 18,000 rpm.
The machine’s B axis swivels in a range from 270 to 230 degrees. This, together with a rapid traverse rate of 45 m per minute, gives the R200 its speed and flexibility. Identically rated work spindles on the machine provide 33 kW of maximum power, 5,000-rpm maximum speed and 150 Nm of peak torque.
To reduce chip-to-chip times, two separate shuttle units independently load the R200’s two motorized milling spindles with the required HSK-A40 tools from a common chain tool magazine. With 80 or
TURN AND MILL PARTS TWICE AS FAST
Index’s C200 turn-mill machine is basically two independent subsystems.
americanmachinist.com I DECEMBER 2009 I AMERICAN MACHINIST I 21
120 places, the machine offers an extensive stock of tools.
Chip-to-chip times of about 4 seconds contribute significantly to minimizing secondary processing times. While machining happens on the main spindle, the machine’s lower milling spindle can be loading a new tool, and the operation is protected from falling chips and coolant.
Two linear tool carriers affixed to the side of each milling spindle allow for fast, precise access to six stationary tools without a tool change. Index’s exclusive W-toothing in the bases of the toolholders lessens the associated set-up effort and ensures a force-locking and form-locking tool fit that
provides conditions for more precise turning operations as compared to those of a turret.
A material guide channel feeds barstock to the R200. This guide channel is mounted in such a way as to allow for movement in the Z-axis direction, and is permanently connected to the machine’s main spindle. Index’s SBL (sliding bar loader) accommodates barstock diameters from 20 to 65 mm and lengths to 3,000 mm, and supports unmanned machine operations.
An Index C200-4D SL control, based on the Siemens Sinumerik S840D Solution Line (www.automation.siemens.com), provides the R200 with user-friendly functions. Specially developed cycles simplify the most complex machining operations and support multi-axis milling and turning operations.
Software packages within Index’s VirtualLine support economical use of the machine from the initial workpiece to the last. These packages
complement each other in terms of their functions and guide programmers and operators to the best way to approach a machining task – both on the PC during the preparation stage and at the machine on the shop floor.
In conjunction with Index’s Virtual Machine 3D simulation software, machining programs are created, checked, and optimized on a PC. In addition, CNC Programming Studio delivers advanced support for programming and operation of the R200.
Energy efficiency is built into the R200. Weight-optimized components not only increase dynamic response, but also reduce energy consumption. Regenerative drives further recover energy, and units that consume large amounts of energy can be set to enter a stand-by mode. Other energy-saving components/practices include low-friction bearings, intelligent cooling of the machine, and economical use of waste heat, or climate-neutral heat discharge. <<
Family Shop Thrives on Families of Parts
Ansco Machine supports its families-of-parts business strategy with a whole line of different size horizontal machining centers from Makino.
Ashop that focuses on just one part or one niche could be in
line for trouble, according to Mike Sterling, owner and founder of Ansco Machine Co. (www.ansco-machine.com). He said that,
in today’s manufacturing environment, a shop has to have a large base of customers, then dig deep into those customers’ product lines and supply whole families of parts, as opposed to single items
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M A C H I N E T O O L S
22 I AMERICAN MACHINIST I DECEMBER 2009 I americanmachinist.com
here and there.As part of its philosophy, Ansco
Machine invests heavily in a wide range of equipment, from turning centers to horizontal machining centers, in a wide range of sizes to suit nearly any application.
“We go into a lot of shops and see a whole line of machines dedicated to one part size,” explained Sterling. “That’s not our strategy. We want a machine that fits the part so we can leave the other machines open for different-size work.”
He started Ansco Machine with his sons, Jeff, Jon, and Dave. His son-in-law Tom Cook is the finance manager. With 43 employees, Ansco Machine is a full service contract machine shop specializing in milling and turning up to 63-in. diameters to produce hydraulics, press rings, steel mill components, and automation/motion control components. The shop works in both high-volume production and small lots, in materials ranging from carbon and alloy steels to ductile and gray irons, plastics and exotics.
According to Cook, the shop handles a wide range of part sizes due to its families-of-parts philosophy/strategy. “We need machines that can handle everything from the small components to the largest ones. The parts are often nearly the same, just scaled up to fit a larger application,” he said.
To provide this service to customers and fulfill its business philosophy, Ansco Machine invested in a whole line of different size horizontal machining centers. These included two a51s from Makino (www.makino.com) that are capable of handling workpieces as large as 24.8 in. by 35.4 in., and a Makino a92 for parts measuring up to 59 in. by 59 in. This wide range of machines allows Ansco Machine to produce the same part in many different sizes – at the same time and without wasting workzone space on its machines.
In addition to the two a51s and the a92, the shop has an a81 and
a82, both from Makino. Such an array of machines lets the shop quote and deliver any size part, and with pallet sizes ranging from 15.7 in. to almost 40 in., and an ability to accommodate a variety of tools sizes on the machines, it can easily match the appropriate machine to the appropriate job without over investing in capital equipment. Plus, the machines provide the redundancy the shop needs if production volume should increase.
“We come from a background of doing larger steel mill work. Our first priority was to cover the size range we wanted, which we’ve done. Our second goal was to be redundant in every size so we can run jobs on any machine. I don’t like to refuse jobs. A machine can’t hold us back from quoting a job,” said Sterling.
In addition to helping Ansco Machine secure more business, the Makino machines have contributed greatly to the shop’s consistency and its reduction in set-up and production times. Sterling explained that improving set-up times is critical because complex parts typically require complex machines, and he cited one example, a rotary actuator housing, where a Makino machine came into play.
The housing is made from aluminum, and machining on a 4-axis vertical machining center took an hour and 20 minutes to complete the part. On one of its Makino horizontals, running two operations on two pallets, the shop produces the same part in 22 minutes. Sterling said that the machine’s speed allows them to leave the parts in the machine to process longer, reducing set-ups.
The Makino machines also deliver consistency for the long part runs at Ansco Machine. When building 770 units of a part, which had 81 features, for one of its customers, the shop provided the part with zero defects, thanks to its skilled machinists and the Makino machines, said Sterling. <<
Like many other countries, Italy’s machine tool industry has experienced significant
drops in machine orders, from both traditional and emerging markets, for most of 2009. However, the end of 2009 looks a tad better, with an ever-so-slight uptick in machine orders expected. Still, the level of orders is predicted to remain well below normal for the start of 2010.
During a recent press conference at EMO, the European manufacturing tradeshow held this year in Milan, Dr. Giancarlo Losma, president of UCIMO, the Italian Machine Tool, Robots and Automation Manufacturers’ Association, discussed a few actions that could help to jump start the machine tool industry. Of those, he suggested that there has to be a “harmonization” of economic actions between all European Union countries. On the Italian front, he called for a government sponsored machine-scrapping program, the motivation being that over 20 percent of machine tools in Italy are more than 20 years old. This program is actually being considered by the Italian government.
Yet, through trying economic times, Italy has a firm hold on its fourth-in-the-world ranking (after Germany, Japan and China) in terms of machine tool production; it ranks third for export sales, after Japan and Germany. And, according to Dr. Losma, the size of Italy’s machine tool companies has a great deal to do with maintaining these standings.
Italy’s machine tool industry is quite fragmented, and most of its machine tool builders are small to medium-size family-owned companies. Their average employment total is only 50 people, as compared with, say, large German builders with average labor forces of 200 employees.
Being smaller and family owned has its benefits. Italian builders are agile and can quickly respond to changing customer needs. They are also reactive in terms of research and development and investing in technology to remain
Italian
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competitive on a global level. Going global is keeping the Italian machine tool industry strong.
“The Italian machine tool market is changing. It’s more global, and Italian builders are now making headway into countries such as the United States, China, Germany and Russia,” commented Ettore Batisti, president and CEO of machine tool builder Pama Spa (www.pama.it).
Batisti added that different markets, countries and sectors within those countries can have different machine and part surface specifications. He mentioned one
market trend that has many Italian builders cashing in: the surge in large part machining, especially within the energy (wind power), oil and gas, aerospace, and ship building.
Pama specializes in big boring and milling machines, both table and floor types. Most are standard machines but with special components matched specifically to certain markets and customers. For example, the company’s Speedram series of machines can be built with vertical strokes from 6.56 ft. to as high as 26.25 ft.
For Colgar SpA (www.colgar.it), another family-owned machine tool builder, going global and specializing in large machines has allowed it to survive in a bad economy. The company continues to invest in its product line by developing machines that will expand its exports business.
“We need to keep developing machines to handle bigger and bigger parts, which is completely customer-driven. On the plus side, there’s less competition in building large machine tools. There’s maybe 10 worldwide,” explained Alberto Vigano of Colgar.
One of Colgar’s latest machines is a traveling-column gantry machine with a 16.40-ft.-cube working capability and a 5-axis head for both hard and soft materials. It’s a rigid machine that combines power for hard materials and speed for the softer ones. Plus, some of company’s
Machine Tools: A Family Affair
Jobs, an Italian machine tool builder, specializes in incorporating linear motor technology into large-format machine tools (above). Gruppo Riello Sistemi, among other Italian machine tool builders, believes today’s machine tools must be multifunctional and handle both hard and soft materials (below).
M A C H I N E T O O L S
gantry machines can include a turning table for both turning and milling parts on one machine.
“Customers try to concentrate their investments in one machine with more capabilities. They want to be able to work on every type of component with that one machine. The philosophy of different machines for different part types and materials is no longer in practice,” said Vigano.
Doing more with fewer machines and constantly developing new technologies to meet customer needs has always taken top priority at Jobs SpA (www.jobs.it), an Italian builder specializing in big and high-speed machine tools. In fact, Jobs reported that it was the first to incorporate the use of linear motor technology in large format machine tools to generate rapid traverse speeds up to 2,756 ipm.
Jobs’ latest innovation comes as part of its Linx series of machines. This newest Linx model, according to Fernanda Tesolin of Jobs, is the first linear motor-driven machine that can both mill and turn parts.
The machine’s work area is equipped with a standard fixed table together with a rotating one for turning part diameters up to 13.12 ft. Shops that can mill and turn on one machine eliminate the need for two separate machines.
Breton Spa (www.breton.it) is another Italian machine tool builder offering a machine with multiple functionality. The company’s new Maxima
not only turns and mills, but also can grind parts. Its maximum turning diameter measures to 11.48 ft, and it handles part lengths to 26.25 ft. and longer.
Two other Italian machine tool builders meeting customer demands for large-part machining are Gruppo Riello Sistemi (www.riellosistemi.it) and Pietro
Carnaghi SpA. (www.pietrocarnaghi.it). From Gruppo Riello Sistemi comes the company’s Mandelli brand Spark 2600X with a reversed T structure and Z-axis movement on its table and X-axis movement on its column. Designed for cutting both hard and soft materials, the Spark 2600X accommodates components measuring 8.53 ft. in diameter.
Pietro Garnaghi produces very large vertical turning centers, flexible manufacturing systems, vertical grinding machines and gantry-type milling-turning machines for markets that include energy, jet engine, defense and aerospace. Turning a part diameter measuring as much as 24.61 ft. is not a problem on some of the company’s vertical turning machines. <<
Italian machine tool builders such as Pama are surviving by meeting the needs of large-part machining.
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americanmachinist.com I DECEMBER 2009 I AMERICAN MACHINIST I 25
Toyoda Machinery (www.toyodausa.com) has made
available a special tool changer that can maximize machine tool productivity and reduce cycle times, and the company has introduced its most economical and smallest horizontal machining center for high-speed cutting.
The tool changer is a four-position changer, or “revolver,” within horizontal machining centers equipped with Toyoda’s Matrix Magazines. This four-position revolver eliminates wait time typically experienced on chain magazines when a series of short-cycle time tools are processed sequentially.
By staging tools in the revolver for the current part process, time usually lost waiting for pocket index is virtually eliminated. The
company’s large-capacity Matrix Magazines allow storage for multiple-part processing and additional back-up tooling as required to reduce time-consuming trips to tool rooms.
In operation, the system works like this. When the part program starts, tools in the magazine are called in process order and staged in the revolver, indexing
as needed during the part process cycle. As soon as a tool completes its cycle, it transfers back into the magazine to its assigned pocket. Any ready tool waiting for a place in the revolver then transfers to the open pocket in the revolver.
Toyoda offers its OP Supporter software that oversees tool management
and provides a convenient overview, at the machine tool CNC screen, of all tools within the magazine. The software also monitors tool time usages and tracks the tool loading station, revolver, back up tool and all stored tools while the machine keeps running.
Job shops looking for a small, affordable high-speed horizontal machining center may consider Toyoda’s FH400J. Sporting a small footprint, the machine features a 15,000-rpm spindle for high-speed machining.
The FH400J’s work area measures 23.6 in. by 22 in. by 24.8 in. for X, Y and Z axes, and its table handles loads up to 880 lb. Other machine features include a CAT 40 spindle, GE Fanuc control, 40-tool magazine, and 2.4-second chip-to-chip tool change time. <<
Toyoda Machinery’s “revolver” style tool changer and its small-footprint high-speed FH400J horizontal machining center.
Tool Charger and Job Shop Horizontal
The CT450L from Fritz Studer AG and the Kronos S 250 from Schaudt Mikrosa GmbH, available
in North America through United Grinding Technologies (www.grinding.com), offer two distinct benefits for grinding operations. As an entry-level model machine, the CT450L delivers low cost per-part production for general internal grinding applications, grinding spring collets, or machining brittle materials. On the other hand, the Kronos S 250 is flexible and provides multifunctional capabilities.
Shops can undertake simple grinding tasks such as bores, surfaces and tapers, as well as complex contours on the CT450L. A special machine concept of fixed grinding spindles and movable workhead on a generously dimensioned cross-slide make set ups, part loading and measuring easy on the machine, which also includes
a linear spindle arrangement and uses one or two belt spindles with speeds of 28,000 to 60,000 rpm.
The Kronos S 250 performs infeed and throughfeed grinding using both conventional and CBN grinding wheels with a diameter range of 1.5 mm to 35 mm and an infeed width to 245 mm. With an enlarged maximum allowable wheel diameter of 400 to 450 mm, the machine increases wheel life by 30 percent.
Cross-slide units are located on the grinding wheel and regulating wheel sides, and combined with dynamic digital drives and high-precision ballscrew unit, the machine operates from only four CNC axes, yet provides the same functionality and flexibility of a six axis machine.
High-performance grinding wheel spindles and maintenance-free hybrid roller bearings on the Kronos S 250 make it possible for the machine to use CBN wheels at peripheral speeds to 150 m/s. An innovative dressing system for the grinding and regulating wheels works by using four CNC axes in the center on the workpiece level.
For grinding wheel dressing, there are optional stationary or rotating dressers available, which can quickly be changed. The stationary grinding gap allows for the use of low-cost automation equipment without any follow-up axis.
Entry Level, Multifunctional and Flexable Grinding
The Kronos S 250
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As routers become more accurate and capable they are used increasingly
to machine parts that, in the past, typically were machined on CNC milling machines. Routers with large machine tables and coupled with high-speed spindles are ideal for
machining thin and small parts from sheet or plate material.
The challenge has been the workholding. A vacuum table is a good way to hold a sheet in place. However, because of the insufficient surface area of the part to render the vacuum-holding power effective, it does not allow for small parts to be
cut in one setup.Keeping the parts attached
to the sheet with tabs is also common. This requires the extra steps of removing the tabs to separate the parts from the sheet plus handwork to de-burr the parts. Tab removal often leaves unacceptable marks on the part contour. Also, tabs require more space between the parts so more material is required. For high-volume production, such as aerospace components, this is a major cost factor.
Sometimes, marginally sized parts can be held in place by vacuum and routed in one step without using tabs if the feedrate is reduced sufficiently. Unfortunately this also reduces the production rate.
Double-sided tape is also often used to hold small parts securely in place. The disadvantages are the difficulty of removing the often very fragile parts from the tape without distorting them, and the residue from the tape’s adhesive requires a cleaning step. Adhesive spray is another option, but this is messy and residue on the parts also requires a cleaning step.
“A product is now available in the U.S. that overcomes many of the difficulties of holding small, thin and delicate parts when machining,” Gerd Bode president of Stackmaster Engineering Corp. (www.stackmaster.com) said. Vilmill, available in North America
Holding Small Parts for CNC Routing
E D I T E D B Y J I M B E N E S I A S S O C I A T E E D I T O R
T O O L I N G & F I X T U R I N G
Vilmill increases the holding power of a vacuum chuck or router vacuum table and can be used to load and unload parts for machining.
T O O L I N G & W O R K H O L D I N G
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exclusively from Stackmaser, is used as a substrate between the sheet or plate material to be machined and a suitable vacuum table or vacuum chuck where it is held securely in place by the vacuum. “It acts as a holding fixture and can double as a conveyor belt for automatic loading and un-loading. With vilmill, the feedrate of appropriately powered machines can be significantly increased over that possible with other holding techniques,” Bode explained.
Vilmill is only 0.010-in. thick and has an adhesive coating on one side. The adhesive is activated by the heat generated in the machining process. Parts are bonded to the vilmill approximately 0.025 in. around the periphery and are held firmly in place during machining. They can be peeled off easily when machining is finished. The adhesive leaves no detectable residue.
“Vilmill is becoming increasingly popular not only in the aerospace and electronics industries and for routing control panels, but also for machining name tags and with users of small routers and engraving machines, as well as with jewelry makers,” Bode explained.
For machining metal, a lean mist is used to keep the chips from building up on the router bit. For plastic, only a soft air blast is used to blow away the chips. Since the heat that is generated in the milling process is needed to activate the vilmill adhesive, no coolant can be used. This limits the use of vilmill to machining non-ferrous materials, such as aluminum, brass and plastics.
Vilmill is available in 100-meter rolls in widths of 1.22 m (48 in.), 1.5 m (59 in.) and 1.8 m (71 in.). The 1.8-m wide product is available by the yard. If purchased by the roll, vilmill costs 50 cents per square foot. <<
Fairlane Products’ Sof-Top Urethane Grippers, available
from Fixtureworks (www.fixtureworks.net), combine secure workholding with protection for finished surfaces, particularly in assembly, machining, inspection or repair operations. The non-marking, non-staining Sof-Top grippers feature a bubbled urethane surface that provides a non-slip grip. The bubbled texture of the urethane top offers firm holding and allows air to escape so no suction is created between the contact surface and the top of the rest pad as it is compressed. The urethane surface, providing abrasion and wear resistance, is available in three durometers
(strength ratings).Sof-Top grippers are
available in several sizes and mounting configurations to meet a wide array of application needs. With the fixed-gripper configuration, the urethane surface is permanently bonded to a 300 series stainless steel pad. They are blind-hole tapped for backside mounting and are offered in sizes ranging from 0.3125 in. to 1 in. (8 mm to 25 mm).
The replaceable swivel ball configuration features a cylindrical body that makes installation in tight areas possible. The replaceable ball swivels to allow self-alignment on uneven surfaces. A Viton O-ring holds the ball in place while
keeping contaminants out and providing smooth ball movement. The housing is made from a smooth alloy steel, heat treated to Rc 43 to 46 with a black oxide finish, is tapped for backside fastening.
The thrust screw assembly configuration allows straight-line static load thrust without transmitting torsional or radial force to the contact area. The free-floating ball design allows the thrust screw to continue to rotate while the ball remains stationary against the contact surface. This configuration is good for irregular shaped or contoured applications. The housing is made from alloy steel, heat-treated to Rc 43 to 46 with a black oxide finish. <<
Soft-Touch Gripperss
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T O O L I N G & F I X T U R I N G
Vibration Damping Shell Mill Holders
Seco Tools Inc. (www.secotools.com) has developed its Steadyline
vibration damping shell mill holders that feature a passive dynamic damping system offering up to three times the
rigidity of equivalent solid holders,.The result is greater productivity, longer tool life, and improved quality. Vibration becomes a concern as the size and complexity of components creates
the need to machine difficult-to-reach areas and deep cavities, resulting in common use of long-overhang tools that tend to introduce vibration into the machining process.
The Steadyline holders are well-suited for:
overhangs and predominantly radial forces.
workpieces.
monolithic workpieces, particularly in aerospace, automotive, and power generation applications.
The holders are designed with the vibration absorber positioned at the front of the bar where the deflection is the highest. This feature dampens vibrations as soon as they are transmitted by the cutting tool to the bar body and prevents the vibration from spreading, thus limiting deflection of the tool at up to five-times-diameter overhang. This allows for cutting speeds and depth-of-cut to be increased up to four times that of a modular system.
Featuring coolant channels and made of high-tensile coated steel, the shell mill holders are dynamically balanced and ready to use out of the box. They are available in a wide range of types and sizes — cylindrical
Capto, DIN and BT. <<
T O O L I N G & W O R K H O L D I N G
Mac Machine Co. Inc. (www.macmachine.com) implemented multi-pallet horizontal
machining centers over 20 years ago and quickly discovered the ability to run them unattended, unheard of at the time. But more important for the shop, the new equipment marked the beginning of its specialization in short-run, high-mix production, a practice for which set-up time often makes or breaks meeting delivery times and turning a profit.
Among the components produced by Mac Machine are mechanical parts used in space suits for the Space
E D I T E D B Y C H A R L E S B AT E S I S E N I O R E D I T O R
A U T O M A T I O N
Fast Setups, Short Runs and Lights-Out Machining
Mac Machine relies on Matsuura machines with multi-pallet systems to reduce set-up times and cutting cycles for parts such as this aerospace component machined from a solid aluminum billet.
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30 I AMERICAN MACHINIST I DECEMBER 2009 I americanmachinist.com
Shuttle and components for the Joint Strike Fighter, as well as items for submarines, missiles, rocket motors and ejector seats. Other work includes components for diagnostic medicine and surgical implants, along with parts for commercial satellites and aircraft. All 60 of the shop’s employees are keenly aware of the human safety issues connected with the perfect functioning of every component produced there, and they are dedicated to producing top quality work and delivering jobs on time.
Prior to switching to multi-pallet systems, Mac Machine used single- and twin-spindle vertical machines that required lengthy set-up times and were unsuitable for lights-out operations. Today, the shop has 13 highly automated Matsuura 4-axis and 5-axis multi-pallet horizontal and vertical machining centers supplied by Methods Machine Tools (www.methodsmachine.com), Matsuura’s North American importer.
The transition to multi-pallet systems eliminated over 50 percent of the shop’s previously required operations by completely machining a part in just one cycle. This type of machining has also increased the shop’s competitiveness in all the markets it serves.
Among Mac Machine’s Matsuura 13 multi-pallet machines is the MAM72-63V 5-axis machine that processes large geometrically complex components within a work envelope of 24.8 in. by 17.7 in. high, with a weight capacity of 770 lb. The shop also uses a MAM72-35V, a smaller 5-axis machine for work measuring to 13.7 in by 9.44 in., and an H.Plus-300 Series horizontal machining center.
Matsuura specializes in stand-alone multi-pallet systems for processing complicated workpieces with unattended handling for as few as two pallets to as many as 32 pallets. With 32 pallets, Mac Machine can make up to 32 completely different parts, one right after another, on one milling machine.
With the Matsuura machine configurations, Mac Machine automates the machining of its most difficult pieces because of the machines’ abilities to virtually
eliminate interference areas. By way of a fixed spindle and tilting table configuration, the rigidity of the tool and toolholder is maximized when milling awkward or otherwise impossible workpiece features, even when machining an irregularly shaped piece as large as 24.8 in. in diameter.
But according to George McNab, president of Mac Machine, it is the ease and flexibility of set-up that give the shop its edge within its demanding core competencies. Plus, with 12,000 to 20,000-rpm spindles and advanced Matsuura servo drive systems, the MAM72 series machine helps reduce cycle times by 60 percent.
Mac Machine also depends on CAMplete TruePath software furnished with the Matsuuras for bridging the gap between CAM input and the machining centers. Instead of blindly sending the output of a CAM system through a post-processor to its 5-axis machines, the shop uses TruePath to analyze, modify, optimize and simulate 5-axis toolpaths in a seamless five-view 3D environment to avoid problems on the machine.
John Leonard, Mac Machine shop foreman, believes that the CAMplete TruePath software has played a piv-
otal role in the success of the shop’s lights-out machining. Operators can preview the entire routine, and an-ticipate and correct potential issues before any machining even starts, thus drastically reducing set-up time and providing an invaluable edge over the competition.
The combination of Matsuura multi-pallet systems and CAMplete software has reduced set-up times by 85 percent and slashed cycle times up to 70 percent by reducing the number of operations required to machine a part at Mac Machine. Even with these cycle time savings, the biggest benefit has been automating short run, high-mix jobs.
“Unattended machining has allowed us to operate second and third shifts with fewer machinists. This effectively reduces our labor rate by 30 percent and makes us more competitive,” said McNab.
With a high number of projects
constantly churning, he believes the biggest challenge for the shop is to keep set-up times as short as possible. And, he said that the shop’s core competency is using multi-pallet machining systems to reduce set-up times for small production lots, continuously.
Building on that core competency, Mac Machine has earned a reputation for taking on the work most other shops might decline. While doing so creates strong customer relationships, it also has led to a consistent demand for smaller lots, lower pricing and zero tolerance for error.
“We must anticipate problems in advance and take corrective action before the green button is pushed,” said McNab. “We have to make good parts right the first time.”
He added that today’s products essentially need to be error-free, and his shop has a percent parts-per-million (ppm) rate of less than 1,000, which means, for example, it might have a “smudged” part number on one part out of 1,000 parts. To maintain this near-error-free output, Mac Machine also depends on a climate-controlled quality lab for compliance with strict quality control measures.
Besides having capable automated machining centers, consistently achieving near perfection requires highly skilled people. The shop operates on three shifts running lights-out 90 hours per week, out of an available 168 production hours.
Specialized “set-up machinists” help meet the needs of lights-out production at Mac Machine. These machinists work the first shift to get new work prepared for the multi-pallet production line. The second shift is a much smaller crew consisting of seven or eight individuals who monitor the automated systems and make certain they are in order for the lights-out third shift.
In addition, Mac Machine relies on Methods Machine Tools to supply and support the shop’s Matsuura systems. McNab credits the supplier with providing the equipment, expertise, programming assistance and responsive support needed to make lights-out production work.
A U T O M A T I O N
S O F T W A R E & C O N T R O L S
At EMO Milano 2009, Siemens PLM Software (www.siemens.com/plm)
and Siemens Drive Technologies aimed to show that more linkage between product lifecycle software and production systems/equipment improves design and makes machining more productive. Siemens PLM demonstrated its Virtual Machine technology: it’s a machine tool on a PC, with virtual controller functions and machine tool simulation, and it’s expected to maximize productivity by eliminating the need to use real machines for non-production tasks, e.g., prototyping.
CNC turning machine builder INDEX Group (www.index-werke.de) used Virtual Machine to improve multi-function production center set-up, programming, and validation. Reportedly, it was able to improve machine tool utilization, eliminate collisions, and reduce set-up time by up to 90 percent, with no extra training.
“The main idea was to install a one-to-one copy of the machine tool on a PC and make it available as a tool to the machine operator,” said Eberhard Beck, INDEX Group head of Electronic Control Systems.
Siemens PLM also showed how the “virtual world” of engineering and design is linked to the real world of the shop floor, via its NX digital product-development program. NX 7.0 introduces HD3D, “an open and intuitive visual environment to help global product development teams unlock the value of PLM information and “make efficient and effective product decisions.”
NX 7.0 has more of the synchronous capabilities added with the previous release, benefitting CAD/CAM/CAE users across the process chain — analysts and manufacturing engineers, andproduct designers. With a simplified interface, individuals who normally work with 3D models created by someone else can modify them to their specific requirements, so they can add value by focusing on their areas of expertise. Siemens predicts that the combination of NX and synchronous technology will establish “a new modeling paradigm throughout the product lifecycle.” <<
Linking Virtual to Real Opens a World of Possibilities
americanmachinist.com I DECEMBER 2009 I AMERICAN MACHINIST I 31
E D I T E D B Y R O B E R T B R O O K S I E D I T O R
32 I AMERICAN MACHINIST I DECEMBER 2009 I americanmachinist.com
S O F T W A R E & C O N T R O L S
The 5-Axis Route to Developing New MarketsTooling manufacturer digs deep into CAM for new capabilities and a competitive edge.
Last year’s economic collapse set custom-toolmaker E.W. Tooling Inc., Princeton, Minn., on a
hunt for new business, to expand its customer base from woodworking into aerospace and automotive. It has had some initial successes designing tooling for aircraft structural prototypes and a production run of automotive clutch discs, and E.W. Tooling president Todd Wallin credits his employees’ skills and productivity, as well as the company’s five-axis metalcutting capability, and 15 years of experience with polycrystalline diamond (PCD) tooling.
Most of E.W. Tooling’s (www.ewtooling.com) market has shifted dramatically around it. But, Wallin is confident the shop will continue to transfer its focus to contract machining and tooling for carbon-fiber composites for aerospace and for interior/exterior trim in newer vehicles in development by domestic automakers.
Transferring AdvantagesWallin is convinced that the company
can serve all three customer groups, and transfer insights and skills from one sector to another. Tools for composite materials are similar to woodworking tools, he says by way of example. “Our new auto customers will benefit from our toolmaking skills, our cost-effectiveness in small quantities for low-initial-rate production, and in fast turnarounds for prototypes.”
E.W. Tooling’s five-axis machining capability is centered on a 5-axis Hermle C600 U trunnion-type machining center. Guiding production on that equipment is Edgecam Advanced Production Milling, Edgecam Solid Machinist from Planit Solutions (www.planitsolutions.com), and Autodesk’s Inventor for solid modeling.
“We could not produce for our customers without Edgecam and Inventor,” said Wallin. “Solid Machinist and Tool Store keep us competitive
in time and cost. I have been using Edgecam since 1999,” he added. “I regularly take it to its limits, going beyond what the software developers intended it to be able to do.”
Most E.W. Tooling products have insertable carbide or brazed-in-place PCD cutters. The latter were developed for heavy-duty vinyl for weatherproof doors and windows: now, the cutters work on the clutch disks, which are a composite material impregnated with graphite and iron powder.
Wallin plans to grow the shop’s industrial woodworking business by changing the way tooling is developed and delivered. Many customers complain about other tooling suppliers’ poor quality products and late delivery, so he hopes to win their business by raising their expectations. And, he expects Edgecam will help in this with speedier programming, faster setups, and more prototypes.
For its core market, kitchen cabinetmaking, E.W. Tooling makes tools for tongue-and-groove and mortise-and-tenon joints, dovetails and mitred window frames and exterior doors. Other tooling is for various decorative pieces, like windowpane dividers, crown moldings, and hand
railings. All this tooling falls into a dozen product families, with hundreds of small variations. In addition to the five-axis Hermle, the company has two three-axis milling machines — a Mazak and a Milltronics — plus a two-axis Okuma turning center, a five-axis Schneeberger cutting tool grinder, and four wire EDMs.
Building FlexibilityThe challenge is to “retool” E.W.
Tooling for the end of the housing boom. Given his cost structure, Wallin is focused on building flexibility with automation: Edgecam five-axis plays a central role.
“What we are really talking about here is flexibility,” said Wallin. “That determines our ability to prosper in
a difficult economy, not just to get by, not just to survive. We have to get as much flexibility into the operations as possible. We never know when our search for new opportunities will turn up something completely unexpected. We have to be ready to run with it.”
He expects that five-axis programming and machining “will drastically increase our capabilities for making complex tooling and give our core customers greater productivity.” Five-axis machining — “full five” or “three plus two” — creates the ability to design and machine tooling that is much more complicated than anything three-axis methods can achieve.
Part of E.W. Tooling’s ability to innovate comes from Solid Machinist, which moves new tool designs into Edgecam. “We use it all the time, multiple times a day, because it lets us access all the CAM functionality from within Inventor,” Wallin said. This ensures that the Edgecam programmer always works with the precise geometry from Inventor and that changes made in Inventor will be reflected in Edgecam, thanks to Solid Machinist associativity.
As for productivity, five-axis machining helps the shop to eliminate
E.W. Tooling’s expertise is five-axis machining of complex tooling for cabinet manufacturers. It relies on Edgecam CAM programming to help it transfer its capabilities effectively into new market segments.
>> on 46
TO ADVERTISE IN THE USED EQUIPMENT DIRECTORY CONTACT: BOB SCOFIELD AT 973-400-1790 OR [email protected]
americanmachinist.com I DECEMBER I AMERICAN MACHINIST I 33
Machinery, Inc.
O-M VC-6NR, CNC Vertical Boring Mill, 31” Swing,(2) 24” 4-Jaw Chucks, Pallet Changer, 1,000RPM,
12ATC, 40HP, Fanuc 21T, 1998, Ref. # 51203
Phone: 516-922-7977 Fax: 516-922-9691Email: [email protected]
Contact Steve Brenner
MORI SEIKI NL2500/700, New 2004, 10” Chuck, 36” Swing, 28” Turning Length, 4,000RPM,MSX 850 Control with Mapps, Ref. # 48450
OKK VM5 II, 40”X, 20“Y, 20”Z, CAT 50, 13,000RPM,20ATC, 40HP, Neomatic 635, New 2000, Ref. # 51087
HURCO TM6, 6"Chk,Tailstock, 9" Swing, 16" CC, Hucro Win Max CNC. Parts Catcher,
Tool Eye. 2006 - Low Hours, Ref. # 523044.3 TOSHIBA BTD-11ER16, Tosnuc 777,
1994, 79”X, 59”Y, 60 ATC, 2,500 RPM, CTS,Rotary Table, Ref. # 49004
60” WEBSTER & BENNET, Fanuc 0, 64’ Swing, 127RPM,16ATC, 75HP, 60” 4-Jaw Chuck, Chip Conv, Ref. # 51301
KITAMURA MYCENTER H400, 24”X, 20“Y, 20”Z,(2) 15.75“ Pallets, Full 4th, 100 Position ATC,
Probe, 10,000 RPM, Fanuc 15MB, Ref. # 52054
RAVENSBURG KH-100 CNC, 70" Faceplate, 79" Swing,90 HP, 300 RPM, 78" Z -Axis Travel, 57" X-Axis Travel,
Seimens 810T CNC Control, (2 Avail.), Ref. # 50544
HARDIGE CONQUEST T-42, Fanuc 18T, 6” Chuck, 6,000 RPM, Live Milling, Sub Spindle,
Bar Feeder, Parts Catcher, Ref. # 49253
72” WEBSTER BENNET EH, 84” Swing, 48” UnderRail, Turret, 83 RPM, 72” 4-Jaw, 1961, Ref. # 51734
North Cove Plaza, Unit 10 Oyster Bay, NY 11771
Visit us on the web:www.primemach.com
O-M CNC Vertical Boring Mill, Live Milling, Fanuc 15CNC Control, C-Axis Table, Scale Feedback, 48"
3-Jaw Chuck, 63" Swing, ATC, Ref. # 50678CALL FOR MORE DETAILS AND SEE UNDER POWER
TOSHIBA TX-16, 63” Table with 4-Jaws, Turret, DRO,79” Swing, 59” Height Under Rail, 160 RPM, Ref. # 52186
JustIn!
Call UsFor Details
on Our ManyMachines
For Sale
Visit OurWebsite
primemach.comFor More
Machines
912AMA33.eps 12/7/2009 12:11:29 PM
USED EQUIPMENT DIRECTORYUSED EQUIPMENT DIRECTORYUSED EQUIPMENT DIRECTORYU S E D E Q U I P M E N T D I R E C T O R Y
TO ADVERTISE IN THE USED EQUIPMENT DIRECTORY CONTACT: BOB SCOFIELD AT 973-400-1790 OR [email protected]
USED EQUIPMENT DIRECTORY
34 I AMERICAN MACHINIST I DECEMBER I americanmachinist.com
Grinders Clearing House Has Many Remanufactured Machines in StockReady for Immediate Delivery!
18” x 72” Model DE Universal CylindricalRemanufactured 2001
Excellent Machine
INTERNAL GRINDERSBryant • Heald • Parker Majestic“Many Remanufactured in Stock”
SURFACE GRINDERSHorizontal - Rotary
Blanchard • Thompson • MattisonG&L • Parker • Reid • Brown &Sharpe
TOOL & CUTTERBrown & Sharpe • K.O. Lee
Cincinnati • Makino
Call or Fax for our New 2009Brochure with color Photosof Many Different Machines
ALWAYS BUYING (1) ONE MACHINE OR ENTIRE PLANTS!
#220-8 Cincinnati CenterlessRemanufactured 2001
Ready for immediate service
10” x 36” Norton CTU Plain Cylindr icalRemanufactured 2001-Warranty
BEARING GRINDERSInner-Outer • Races • BoreCENTERLESS GRINDERSBryant • Cincinnati • Koyo
“Many Remanufactured in Stock“ DISC GRINDERSGardner • Besley • Koyo
CYLINDRICAL (PLAIN & UNIVERSAL)
ANGLE HEADCincinnati • Landis • NortonParker • Brown & Sharpe
Much More!
WORLD’S LARGEST STOCKING DEALER OF GRINDERSOver 1200
Machines in Stock“Call On Our Exchange Program
For All Types of Grinders”“Many Other Models of Machinery
Available. Call Our Experienced Staff toAnswer All Your Questions”
Visit Our Web Page for Our Up-To-Date Inventory“FROM A SINGLE TOOL TO AN ENTIRE PLANT BOUGHT, SOLD, APPRAISED AND LIQUIDATED”
TOOLROOM PRODUCTION GRINDERSOnly 30 Minutes from Detroit’s Metro Airport or 5 Minutes from City Airport
#171 Heald Sizematic InternalRemanufactured 2001
18-36 Rotary SurfaceRemanufactured 2001
#13 Brown & Sharpe Tool & CutterExcellent Tool!
13301 E. Eight Mile Rd., Warren, Michigan 48089-3238 (586) 771-1500 Fax (586)771-5958www.grindersclearinghouse.com email: [email protected]
912AMA34.eps 12/7/2009 12:12:56 PM
TO ADVERTISE IN THE USED EQUIPMENT DIRECTORY CONTACT: BOB SCOFIELD AT 973-400-1790 OR [email protected]
americanmachinist.com I DECEMBER I AMERICAN MACHINIST I 35
USED EQUIPMENT DIRECTORY
DANILUK REMANUFACTURINGDANILUK REMANUFACTURINGThe Daniluk Corporation stocks used Cincinnati Milacron MO Series “Cinturn” lathes ready for remanufacture to your specifications. These lathes are available with 15”, 18”, and 24” chucks and center distances ranging from 60” to 120”. Our remanufacture package includes delivery and installation, operator and maintenance training, and a full one-year parts and labor warranty.
888-745-6647 [email protected] CITY OKLAHOMA
Regrinding of WaysReplacement of BallscrewsNew Automatic Lube SystemReplacement of Hydraulic SystemNew Chip ConveyorRe-Engineered Axis Drive SystemNew Controls and Axis DrivesNew Spindle DriveRebuild of Tool TurretsRebuild of Chuck and Chuck Actuator
REMANUFACTURES INCLUDE:
REMANUFACTUREDCINCINNATI
CINTURN
LEASE/PURCHASETHESE MACHINES
AS LOW AS$5000
PER MONTH
912AMA35.eps 12/7/2009 12:13:11 PM
TO ADVERTISE IN THE USED EQUIPMENT DIRECTORY CONTACT: BOB SCOFIELD AT 973-400-1790 OR [email protected]
USED EQUIPMENT DIRECTORY
36 I AMERICAN MACHINIST I DECEMBER I americanmachinist.com
REX SUPPLY CO.WORKHOLDING PRODUCTSCALL TODAY FOR YOUR COPY OF THE
REX SUPPLY CATALOG !
1-800-369-0669
ASK FOR EDDIE LAYTONWORKHOLDING MANAGER
COMPLETE REPAIR, SERVICEAND INSTALLATION
SPECIAL APPLICATIONS CAPABILITIESNEW, USED AND SURPLUSWORKHOLDING PRODUCTS
(WE BUY SURPLUS !)WE REPRESENT THE FOLLOWING LINES:ATS Collect ChucksAUTOBLOK Power Chucks and AccessoriesBERGMAN’S Face Plate and Boring Mill Jaws
BISON 3 & 4 Jaw Manual ChucksBUCK Adjust - Tru Chucks
CUSHMAN INDUSTRIES
DUNHAM TOOLCO. Collect ChucksFAIRLANE Carbide GrippersFORKARDT, INC. Power and Index Chucks
GAMET Power Chucks
H&R Hard & Soft Top Jaws
HEINRICH Power Vises
HOWA Power chucks
HURON Top Jaws
KITAGAWA Power Chucks
LNS AMERICAN Bar Feeds and AccessoriesLOGANSPORT High Speed Power ChucksMATSUMOTO (MMK) Power ChucksMAXI-GRIP Power and Special Design ChucksMICO-CENTRIC Precision ChucksMID-STATE Tombstones Angle Plates and FixturesNIKKEN Rotary TablesNOBEL Manual Chucks Face Plate and Boring Mill JawsPOWERHOLD Power ChucksPLATT BURNERDPRODUCTION DYNAMICS
Self-Contained Collet ChucksQU-CO Quick Change Fixture PlatesRANSOME
R E X H A S I T !R E X H A S I T !
ROHM Power Chucks (Self Contained & Manual)ROYAL PRODUCTS CNC Collet ChucksSCA 3 & 4 Jaw Manual ChucksSHEFFERSpecial Design ChucksTHE SP MFG CORP Power ChucksS.M.W.SYSTEMS, INC.SPEED GRIP Rotating Chucks Stationary ChucksSTACE ALLEN ChucksSUPERIOR CINCINNATI ColletsTROYKE Rotary and Index TablesTSUDAKOMA CNC Rotary TablesWALKER Magnetic ChucksYUASA Super Spacers Rotary and Index Tables
• NeNew •w • UsedUsed• RemanufacturedRemanufactured
• ProductionProductionBroachingBroaching
• PartParts •s • ServiceService• Toolingooling
2518025180 SEELEYSEELEY RDRD.NOVI,NOVI, MIMI 48375-20448375-2044
eVV rtical, Surface, (Dual Ram) 6 Ton, 54” Str, U.S. Broach, Tilt Tables15 Ton, 66” Str, Colonial15 Ton, 90” Str, Colonial, Tilt TaTT bles, Exc.25 Ton, 66” Str, Detroit, Excellent25 Ton, 90” Str, Detroit, Tilt25 Ton, 120” Str, Detroit30 Ton, 110” Str, Detroit
VeVV rtical, Surface (Single Ram)10 Ton, 66” Str, Detroit, Will ToolTT10 Ton, 78” Str, LaPointe, Tilt TaTT ble, Exc.15 Ton, 90” Str, Colonial, Exc.20 Ton, 100” Str, LaPointe30 Ton, 90” Str, Colonial, Exc., Will ToolTT
VeVV rtical, Table-UpTT 6 Ton, 42” Str, Detroit, (2) 1995
10 Ton, 48” Str, American, 199815 Ton, 54” Str. BMS Cell-Mate, 1996
VeVV rtical, Tri-TT Way 6 Ton, 24” Str, American10 Ton, 36” Str, American, Will ToolTT15 Ton, 36” American
Grinders, Broach 36” Colonial, Round Grinder 48” Colonial, Flat Grinder 72” Colonial, Combination Grinder 84” Colonial Univ., For Round & Flat Broaches100” LaPointe, Comb., Round & Flat Sharpening
VeVV rtical, Hi-Speed 3 Ton, 24” Str, Miles, 1985 6 Ton, 36” Str, “Cruiser”, Hi-Speed, 90 FPM, New12 Ton, 48” Str, Miles, 1982
Continuous Chain 36” to 180”, 40 in stock
Horizontal 2.5 Ton, 30” Str, LaPointe 4 Ton, 30“ Str, American 7.5 Ton, 60” Str, LaPointe 10 Ton, 54“ Str, Oilgear 20 Ton, 100” Str, LaPointe, Will ToolTT 25 Ton, 90” Str, Colonial, W/ Retriever, Late 35 Ton, 100” Str, Detroit W/Power Retriever 60 Ton x 72” American100 Ton x 120” Colonial
Horizontal, Surface180” Str, Detroit, tooled for Discs.180” Colonial, Two Way (2)180” LaPointe, Tooled for Discs
VeVV rtical, Pull Down 5 Ton, 30” Str, Detroit # VP-5-30, Will ToolTT (6)10 Ton, 42” Str, Detroit, Pull Down, In Stock10 Ton, 54” Str, Colonial, Retriever, Will ToolTT10 Ton, 66” Str, Detroit15 Ton, 72” Str, Colonial25 Ton, 66” Str, Detroit25 Ton, 90” Str, Detroit50 Ton, 72” Str, Colonial, SD-50-7250 Ton, 90“ Str, Detroit, Excellent Cond.60 Ton, 102” Str, U.S. Broach, Oilgear Power
VeVV rtical, Pull Up 8 Ton, 24” Str, American20 Ton, 48” Str, Colonial, Pull-Up, Will ToolTT
Website:ebsite: wwwww.BroachingMachine.co.BroachingMachine.comPhone:Phone: 248-471-450248-471-4500 •0 • Toll-Free:oll-Free: 800-229-466800-229-4666 •6 • Fax:Fax: 248-471-0745248-471-0745
Email:Email: [email protected]@broachingmachine.com
See inventories for these dealersand many more
in this month’s issue ofUsed Equipment Directory
at www.ued-ed.com
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912AMA36.eps 12/7/2009 12:14:06 PM
TO ADVERTISE IN THE USED EQUIPMENT DIRECTORY CONTACT: BOB SCOFIELD AT 973-400-1790 OR [email protected]
americanmachinist.com I DECEMBER I AMERICAN MACHINIST I 37
USED EQUIPMENT DIRECTORY
Vertical, Pull Down 3 Ton x 24” Detroit VP-3-24, 1969 10 Ton x 42” Colonial SD-10-42, 1965 10 Ton x 54” Detroit VP-10-54 15 Ton x 42“ Detroit VP-15-42, 1958 15 Ton x 48” Colonial SD-15-48, RB 1993 15 Ton x 54” Broach VP-15-54, 1997 20 Ton x 42“ US Broach VP-20-42, 1995 25 Ton x 66” Colonial SD-25-66, 1979 25 Ton x 72“ Detroit VP-25-72, 1968 30 Ton x 66” US VP-30-66, 1979 35 Ton x 72“ Detroit VPD-35-72, 1981 35 Ton x 78” Federal VPD-35-78, 1995
Vertical, Table, Up 20 Ton x 48” Federal Broach VRT-20-48, 1995 35 Ton x 78” Detroit VTU-35-78, 2002
Vertical, Surface, Single Ram 10 Ton x 36“ Colonial UV-10-36, 1978 10 Ton x 54” Detroit VS-10-54, 1956 10 Ton x 66” Detroit VS-10-66, 1973 (2) 15 Ton x 54“ Detroit VS-15-54, 1957 15 Ton x 78” Detroit VS-15-78 15 Ton x 110” Detroit VS-15-110, 1965 25 Ton x 90“ Detroit VST-25-90, 1964 25 Ton x 100” Detroit VST-25-100
Vertical, Surface, Dual Ram 5 Ton x 54” Detroit VTT-5-54, 1974 10 Ton x 66“ Detroit VT-10-66 (3) 10 Ton x 66” U.S. Broach TS-10-66, ‘65, 1986 10 Ton x 90“ Ferderal Broach, VT-10-90, 2000 15 Ton x 42” U.S. Broach TS-15-42, 1978 15 Ton x 54” Detroit VT-15-54, 1965 15 Ton x 66” Detroit VT-15-66, 1977 (5) 15 Ton x 90“ Colonial RVT-15-90 (2) RB 1996 25 Ton x 120” Colonial RVT-25-120, 1974 25 Ton x 130“ VT-25-130 Detroit New 1984
Pot Broach 25 Ton x 54” Federal DVPU-25-54, 1998 40 Ton x 72” General DPUP-40-72, 1989
MACHINE-R-E-SALES INC.21020 Coolidge Hwy., Oak Park, MI 48237
Call Ed Egrin 248-541-0733 FAX 248-541-6929E-Mail: [email protected]
Horizontal, Pull 6 Ton x 54” Colonial HAS-6-54 7-1/2 Ton x 48” Detroit Model H-7.5 x 48, 1975 10 Ton x 48“ American, 4-10-48 10 Ton x 56” Detroit, H-10-56, 1968 16 Ton x 64” Oilglenn, XL-32-64 20 Ton x 72“ LaPointe HP-40 w/Ret, 1969 37 1/2 Ton x 72” LaPointe, HP-75 50 Ton x 72” Detroit H-50-72 Hyd. Ret.
Horizontal, Surface 15 Ton x 120“ Colonial HR-15-120
Press Broach 6 Ton x 24” Colonial Pbh-6-24 6 Ton x 36“ Colonial PB-6-36
Broach Sharpener 10” x 36“ LaPointe BS-36
Triway 4 Ton x 24” American T-4-24 6 Ton x 24” American T-6-24
Chain Broaches CH-25-144 Detroit, New 1970 CH-35-200 Detroit, 1972
Hi-Speed Broach 3 Ton x 36” Ty-Miles MB-6-36-90, 1974 4 Ton x 24” Ty-Miles (1) 3 Ton x 24” Astro (1) 3 Ton x 24” Ohio (1) 2-5 Ton & 1-8 Ton x 36” Ty-Miles (3) 5 Ton x 36” Ohio VSHD-5-36, 1990 (2) 4-6 Ton & 1-4 Ton x 36” Astro (5) 5 Ton x 48 “ Ohio (2) 6 Ton x 54” Ohio VSHD-5-36, 1986 8 Ton x 48” TyMiles MBLD 16-48-60, 2003
DANILUK REMANUFACTURINGAs one of the largest machine tool remanufacturers inthe U.S., The Daniluk Corporation stocks machines forsale, as-is, and for remanufacture. We will evenremanufacture a machine from our extensive stockand exchange it for your machine in order to eliminatedown time and the cost of new foundations and tooling.
DANILUKDANILUK888-745-6647 FAX: 405-745-6646OKLAHOMA CITY www.daniluk.com OKLAHOMA
BLAST CLEANING EQUIPMENTUSED, REBUILT & CUSTOM DESIGN
METALWORKINGMACHINERYCOMPANY“The Blast Cleaning Specialists with 50 Years Experience”700 Constitution Blvd., New Kensington, PA 15068724/335-1155 FAX 724/335-1621Web Site: www.blastcleaningequipment.comE-Mail: [email protected]
TUMBLASTS AND BARRELS 1 Goff 1-1/2 BB 3 Wheelabrator 20x27 Tumblasts 1 Wheelabrator 3 cube rubber belt, low hrs, new ‘07, Like New 2 Pangborn 3GNR - rubber belt 1 Pangborn 6GNR rubber 1 Wheelabrator 27x36 Rubber Belt Tumblast 1 Wheelabrator TBR6 rubber belt, new ‘95 1 Wheelabrator WMT 6’ rubber belt, New Belt New Cond. ‘03 1 Wheelabrator 36x42 Rubber Belt, Rebuilt 1 Goff 12 cu. ft rubber belt & loader 1 Wheelabrator TBR12, rubber belt 2 Wheelabrator 7 Super, Rebuilt 1 Wheelabrator 14’ Super, Rubber Belt 1 Wheelabrator 14’ Super, manganese flights 1 Wheelabrator 14 Super II, manganese flights, rebuilt 1 Wheelabrator 22 Super II, manganese flights, good cond. (1) rebuilt 1 Wheelabrator 28’ Super Tumblast, mang. flights 1 Wheelabrator 34 Super II, manganese flights 1 Wheelabrator 34 Super III (2) 60 HP DD whls, new ‘96, excell. condition 1 Wheelabrator 50 Super Tumblast-mang. flights 1 Pangborn 12GN, mang. belt 1 Pangborn 15GN4, manganese flights 1 Pangborn 34 GN, manganese flights 1 Pangborn 34GN2 (2) 40 HP DD wheels, manganese flights
TABLES 3 Wheelabrator #1 Multi-tables, 12” & 18” tables, new ‘98 2 Wheelabrator #1A Multi-table, 22” & 26“ tables 1 Wheelabrator #1A Multi-table w/side mount whls, new 1988 1 Wheelabrator #2 Multi-table, seven 30” tables 1 Wheelabrator 48“ Swing Table, 40” wk. ht., rebuilt, new warranty 1 Wheelabrator 96” Swing Table - 64” wk. ht. 10’ dia. swing 1 Pangborn 8LK - Rebuilt
SPECIALS 1 Pangborn 12-wh. Vertical Plate & Structural, mid 90’s, cleans up to 11’ X 48“, excell. cond. 1 Goff 2-Wheel 12” x 44”L Carousel Spinner Hanger 1 Wheelabrator Carousel Spinner Hanger, 24” dia. x 40“ L opening 1 Wheelabrator 2-wh. LE-750 Spinner Hanger, 30” dia. x 48” H 1 Wheelabrator/BCP 2-wh. 30 HP Spinner Hanger, 48“ dia. X 72” H 1 Guysom 2-Wh 15HP Downblast Belt Conveyor 1 Wheelabrator 2-wheel Downblast Belt Conveyor, 15HP, 18”H x 26”W, New 2000 1 Pangborn 8-wh. DD Wh. pass-thru Roll Conveyor Beam Cleaner, passes 6’H x 3’W, mint. cond. 1 Pangborn 4-wh Pass-thru 24’H x 36” W opening, (4) 15 HP DD whls, new cond.
Save UP to 55%“New Machine”Warranty
912AMA37.eps 12/7/2009 12:14:21 PM
TO ADVERTISE IN THE USED EQUIPMENT DIRECTORY CONTACT: BOB SCOFIELD AT 973-400-1790 OR [email protected]
USED EQUIPMENT DIRECTORY
38 I AMERICAN MACHINIST I DECEMBER I americanmachinist.com
NATR ION
INDUCTIONMELTING and HEATING
Since 1979EQUIPMENT
G
800) 828 9788 88 8888 88 8800) 828 979999 999800) 828-97992800) 8282222 999999228-97998828-97988 880000 8888 88000(80 ) 828-9799) 828-9799(800)(800(800) 828-8 990088 998822 99( 0)0)(( 828-9799828-9799(800(800(800) 828-9799“CALL with your equipment requirements!”
www.inductiontech.comWE BUY USED INDUCTION MELTING AND HEATING EQUIPMENA T
9 9 2 4 R a n c h o R d , A d e l a n t o C A 9 2 3 0 1
Above can be supplied with furnaces, heating coils and water systems as needed to suit speci c requirements.
E MANUFACTUREFF , REPAIRPP , AND REBUILD INDUCTION POWERSUPPLIES, INDUCTION FURNACES, HEATINGA COILS, W TERA COOLEDPOWER CABLES AND W TERA COOLING AND RE-CIRCULATINGA SYSTEMS.
WE SERVICER WHATA WE SELL.
POWER SUPPLIES
Inductotherm Box Furnaces up to 4000 lb. CapacityFURNACES
Steel Shell Furnaces from 2000 lb. to 6 TonTT
Inductotherm 75Kw, 3KHz VIP PowerP Trak TT
Inductotherm 125Kw & 175Kw, 3KHz VIP PowerP TrakTTInductotherm 75Kw, 9.6KHz VIP PowerP Trak TT
AND MUCH MORE!
SALE/RENT
wabash444 Carpenter Avenue, Wheeling, IL 60090
POWEREQUIPMENT CO
BOILERS & DIESEL GENERATORSImmediate Delivery-On Call
24 Hours 800-704-2002
Package Boilers10 HP to
300,000 #/HR
Mobile Boilers300 HP to 75,000 #/HR
Diesel Generators50 KW to 2750 KW
WE ALSO STOCK A LARGE SELECTION OF:
ECONOMIZERS DEAERATORS WATER TREATMENT &FEED SYSTEMS PUMP MOTORS TURBINES FUELHANDLING SYSTEMS INSTRUMENTS & CONTROLS
VALVES COMPRESSORS PULVERIZERS DIESEL &TURBINE GENERATORS RENTAL MOBILE BOILERS &
DIESEL GENERATING PLANTS
TEL: 847-541-5600 FAX: 847-541-1279
E-mail: [email protected] WEB SITE: www.wabashpower.com
Centerless Grinder Repair
Complete line of parts and machines in stockDressers, feed wheel heads & spindlers available on an exchange basisAssist in designing or retooling our machine or one of oursProvide in-plant operating instructionsTrain inexperienced help to set up/grindPurchase leases available
Ask for Bill Magee or Jason MageeEmail: [email protected]
www.CenterlessGrinderRpr.com28300 Groesbeck Hwy. Roseville, Michigan 48066
Phone: (586) 774-4660 Fax: (586) 774-3051
We Buy, Sell, Trade & Completely Rebuild
Cincinnati Centerless Grinders (No. 2, No. 3 & 200-300 Series)
Repairmen on Call 24 Hours a Day50 Grinders Under Power in Plant
LUCAS MACHINERY COMPANY, INC.J.L.
Mailing address: P.O. Box 4220Waterbury, CT 06704-4220429 Brookside Rd. Waterbury, CT 06708
Tel: (203) 597-1300 - Fax: (203) 597-8268
WHEN THE SPECIALISTS LET YOU DOWN-COME SEE THE DISC GRINDING EXPERTS
MDNAMDNAFor All Your Disc Grinding Applications:Double or Single Horizontal or VerticalGARDNER BESLY LUCAS/GARDNER
Large Inventory - 12” Dia and UpThru Feed - Rotary - Gunfeed - Special Fixturing Available
And For All Your Disc Grinder Parts:
LUCAS DISC GRINDER PARTS & SALES CO., LLCP.O. Box 4219 Waterbury, CT 06704-4219
Tel: (203) 753-DISC (3472) - Fax: (203) 591-9043
BESLY & GARDNER PARTSDisc Grinder Replacement Parts
Thrufeed, Rotary & Gunfeed AttachmentsRebuilt Spindle Assembly Exchange Program
Large Inventory - All Components Available - Seals to Spindles
Visit us on the webhttp://www.jllucas.com - email [email protected]
912AMA38.eps 12/7/2009 12:15:08 PM
W
NDUCTIOR
ECHNOLOGYORPOR
TO ADVERTISE IN THE USED EQUIPMENT DIRECTORY CONTACT: BOB SCOFIELD AT 973-400-1790 OR [email protected]
americanmachinist.com I DECEMBER I AMERICAN MACHINIST I 39
USED EQUIPMENT DIRECTORY
Why should I buy Used Equipment?
Where can I find Used Equipment?
Used equipment is often less expensiveUsed equipment is usually available immediately
The best dealers list their available equipmentin Used Equipment Directory, the leader in the field since 1949. Browse dealer inventories in this month’s issue at: www.ued-ed.com
Sign up to receive UED monthly via email!
DANILUK REMANUFACTURINGAs one of the largest machine tool remanufacturers inthe U.S., The Daniluk Corporation stocks machines forsale, as-is, and for remanufacture. We will evenremanufacture a machine from our extensive stockand exchange it for your machine in order to eliminatedown time and the cost of new foundations and tooling.
DANILUKDANILUK888-745-6647 FAX: 405-745-6646OKLAHOMA CITY www.daniluk.com OKLAHOMA
WALK IN OVENSPartial Listing of Available Equipment
Walk In Ovens 30”W 42”L 72”H NEW ENGLAND 650F 36 36 47 ACE 230-RKG BURN OFF 36 36 75 NEW ENGLAND 650F 36 72 72 LYDON 200F 38 38 63 DESPATCH 500F 39 66 96 GRIEVE 200F 42 36 48 BAYCO BB42 BURN OFF 48 36 60 DESPATCH 500F 48 48 72 JPW 500F 48 48 72 PRECISION QUINCY 1000F 48 72 72 JENSEN 750F 54 68 66 DESPATCH 500F 54 68 66 DESPATCH 850F 60 70 96 LANLY 450F 60 72 72 STEELMAN BURN OFF 60 120 72 STEELMAN 450F 72 72 96 BINKS (WISCONSIN) 500F 72 72 104 POLL. CONTROL BURN OFF 72 120 84 BINKS (WISCONSIN) 500F 72 180 72 GRIEVE 450F 78 124 80 DESPATCH 850F 7’ 7’ 7’ POLL. CONTROL BURN OFF 7’ 14’ 10’ EJ CALLAHAN 500F 8’ 10’ 9’ ACE BURN OFF 8’ 42’ 7’ WISCONSIN 400F 10’ 20’ 9’ EJ CALLAHAN 500F 11’ 13’ 8’ GEHNRICH 500F
BELT AND CABINET OVENS ALSO IN STOCK
Call Us With Your NeedsF U R N A C E B R O K E R S I N C .
40 Industrial Park Rd. East Tolland, CT 06084(860) 875-3712 Fax (860) 875-1393
W W W. F U R N A C E B R O K E R S . C O M
912AMA39.eps 12/7/2009 12:15:24 PM
TO ADVERTISE IN THE USED EQUIPMENT DIRECTORY CONTACT: BOB SCOFIELD AT 973-400-1790 OR [email protected]
USED EQUIPMENT DIRECTORY
40 I AMERICAN MACHINIST I DECEMBER I americanmachinist.com
847.541.8300 / [email protected]
Call to inquire on our extensive line of Industrial Power Plant Equipment available!
RENTLEASESELL
BOILERS GENERATORS CHILLERS
Mobile Boilers(10HP - 250,000PPH)
Rental Diesel Generators(125KW - 2200KW)
Chillers(Water Cooled: 75-1000 tons
Air Cooled: 75-400 tons)
Boilers (various sizes & styles)Boiler Parts & AccessoriesBurner Management SystemsChillersCombustion Control SystemsConstruction ServicesDeaerators
Design & BuildDiesel Generators
EconomizersEngineering
Fuel SystemsPumps
Water Treatment Systems
FAST! NEW & USED UNITS AVAILABLEAll major credit cards acceptedFlexible leasing plans available
IN STOCK - READY TO SHIP5 YEAR COMPRESSOR WARRANTY
NEW PORTABLES - AIR COOLED(FOB Houston, Texas)
NEW STATIONARY / CENTRAL(Includes shipping)
2-TON . . . . . . . . .$5,8053-TON . . . . . . . . .$6,9255-TON . . . . . . . . .$7,5407.5-TON. . . . . . .$10,13510-TON . . . . . . .$12,01915-TON . . . . . . .$19,233
Other Sizes Available
15-TON . . . . . . . $15,801.0018-TON . . . . . . . $17,056.0022-TON . . . . . . . $20,491.0030-TON . . . . . . . $22,677.0040-TON . . . . . . . $27,693.0050-TON . . . . . . . $31,960.0060-TON . . . . . . . $37,940.0080-TON . . . . . . . $46,393.00100-TON . . . . . . $55,296.00
Other Sizes Available
COLD SHOT CHILLERS800-473-9178 281-227-8400
FAX: 281-227-8404Website: waterchillers.com
Email: [email protected]
http://www.highlandmachinery.com
Highland Machinery & Crane1170 Cornerstone Place Benton Harbor MI 49022
Ph: 877-921-9600 F: 269-926-9601E-mail: [email protected]
WANTED: Used Bridge& Overhead Cranes
Highland Machinery & Craneis looking to buy all types
and sizes of bridge cranes:
• 1 - 100 Tons • 0 - 120’ Span• Crane Only or Full System
We buy and remove NATIONWIDE!
For Complete Specifications and PricingVisit Our Web Site:
http://www.whkay.come-mail: [email protected]
30925 Aurora Rd. Cleveland, OH 44139Phone: 440-519-3800 Fax: 440-519-1455
The W. H. Kay CompanySince 1936
The “Elder Statesman” ofUsed Ovens & Heat Treating Furnaces
Over 150 in StockReady for Inspection & Delivery
We Buy/Sell/Trade Furnaces, such as:Walk-In Ovens Box Pit Type Belt Atmosphere Generators
Box Type Draw Internal Quench Vacuum Combustion Air Blowers
GENSETS & POWER PLANTS
INTERNATIONALAA [email protected]
904.494.1058Lyndon.Schultz@RingPoweLL r.com
904.494.1278
NORTH AMERICAN & CARIBBEAN SALES
Contact us for a complete listing of available generators, power systems and engines.
EGUHYROTNEVNI
LOW-HOUR USEDCOMPLETE REBUILDSIMMEDIATE DELIVERY
Y
We purchase surplus and used gensets and engines, too!
w w w . r i n g p o w e r - s y s t e m s . c o mg y
G E N E R AT O R S S A L E / R E N T
wabash444 Carpenter Avenue, Wheeling, IL 60090
POWEREQUIPMENT CO
IMMEDIATE SHIPMENT 90kw - 2,865kwSKID or ENCLOSED
125kw - 2,200kwTRAILER MOUNTED
www.wabashpower.com
AVAILABLE VOLTAGES:120/208/1/60, 240/480/2400/4160/(11.5/13.8KV)
FEATURES:LOW EMISSIONS AUTOMATIC PARALLELING AND SYNCHRONIZATION
SOUND ATTENUATED TRAILER UTILITY GRADE
C A L L : TO L L F R E E 1 - 8 0 0 - 7 0 4 - 2 0 0 2PHONE 1-847-541-5600 FAX 1-847-541-1279 [email protected] OUR WEBSITE FOR ADDITIONAL IN-STOCK EQUIPMENT LISTINGS
912AMA40.eps 12/7/2009 2:33:25 PM
TO ADVERTISE IN THE USED EQUIPMENT DIRECTORY CONTACT: BOB SCOFIELD AT 973-400-1790 OR [email protected]
americanmachinist.com I DECEMBER I AMERICAN MACHINIST I 41
USED EQUIPMENT DIRECTORY
Disc Grinder HeadquartersC & B Giustina Besly Gardner Mattison Blanchard
Vertical - Horizontal, Single - DoubleThrufeed, Rotary, Swing Arm, Special Fixtures
Spindle - Rebuilt or ExchangeReplacement Parts & ServiceOEM - Rebuild / Remanufacture ServiceRetool - Control Retrofits21css Field Conversion for Beslys (see web for full description)
C & B Machinery Co.12001 Globe, Livonia MI 48150
www.cbmachinery.com see our complete inventoryCall (734) 462-0600 or Fax (734) 462-0604
Email: [email protected]
TRANSFORMERSNEW SURPLUS RENEWED & GURANTEED
ALL TYPES - ALL SIZES - ALL VOLTAGESBuck & Boost - Isolation - Drive Isolation “K” Factor-etc.
Bruce Electric can ship immediately from its stock of tensof thousands of transformers from .250 to 2500 KVA,
all voltage combinations.Generators Circuit Breakers Switches
Rectifiers Fuses Power Line Conditioners Etc...Call, Write or Fax For Our Low Prices!!!
BRUCE ELECTRIC EQUIPMENT CORP.131 AKRON ST. P.O. BOX 558 LINDENHURST, NY 11757
Toll Free: 800-262-2204631-226-2424
FAX 631-226-8772E-Mail: [email protected]
www.brucelectric.com
CHILLERSWater Cooled: (75 - 1000 Tons) Air Cooled: (75 - 400 Tons)Call to ask about our extensive line of Industrial Power Plant Equipment Available!
ph: 847.541.8300 / 800.446.3325fax: 847.541.9984 email: [email protected] www.indeck.com
NATIONALMACHINERYEXCHANGE, INC.“If it’s machinery, we have it” sm
158 PARIS STREET NEWARK NJ 07105TELEPHONE: 973-344-6100
FAX: 973-589-0944WEBSITE: WWW.NATIONALMACHY.COME-MAIL: [email protected]
LARGE SELECTIONOF PRESSES
OBI / GAP / SS / HYDFORGING / KJEXTRUSION
EYELET-TRANSFERTRY-OUT
COIL PROCESSINGEQUIPMENT
SLITTING LINES / C-T-LROLL FORMERSSTRAIGHTENERS
LEVELLERSUNCOILERS
TUBE & PIPE MILLSMACHINERY
MILLS / END FINISHERSSTRAIGHTENERS
CUT-OFFSDEBURRERS
BENDERS
Steel Processing Systems & EquipmentWe carry a complete inventory of new and remanufactured Cut-To-LengthLines Slitting Lines Terminal Lines Plate Lines Pay-Off Reels PressFeed Lines. We build and remanufacture to your specifications with newelectricals and hydraulics. We maintain the flexibility to provide machinerytailored to maximize the profits of each production situation. Over 45 yearsof Quality, Service and Value.
3171 N. Republic Blvd.Toledo, Ohio 43615-1515Phone (419) 843-7262Fax (419) 843-7229www.cauffiel.com
Looking for Used Equipment?
See it all at www.usedequip.com
Choose from over 2700 lathes, 1500 machiningcenters, or 1800 grinders. Need punching/shearing equipment? We have over 1100 listed.With over 33,000 metalworking listings alone,UEN is the place to go for used equipment!We’re not just metalworking either: we haveover 9,000 pieces of electrical equipment, too,as well as construction, ships, airplanes, andmore! New listings added daily, and most havepictures and detailed specifications!
912AMA41.eps 12/7/2009 12:16:37 PM
TO ADVERTISE IN THE USED EQUIPMENT DIRECTORY CONTACT: BOB SCOFIELD AT 973-400-1790 OR [email protected]
USED EQUIPMENT DIRECTORY
42 I AMERICAN MACHINIST I DECEMBER I americanmachinist.com
ALL PARTS, INC.Specializing in Quality
COMPRESSORS & PARTSBUY / SELL NEW & USED COMPRESSORS
P.O. Box 4025 Wheaton, IL 60189630-653-5678 Fax 630-653-5680
E-Mail: [email protected]
World’s Largest Stock ofBalancing Equipment
Specializing in:Schenck Hofmann IRD CEMB
Used & Rebuilt, Parts & Service for All MakesE-T BALANCING INC.
12823 Athens Way, Los Angeles, CA 90061Tel: 310-538-9738 Fax: 310-538-8273
E-Mail: [email protected]
GENERATORS125KW - 2200KW *IN STOCK!*
Call to ask about our extensive line of Industrial Power Plant Equipment Available!
ph: 847.541.8300 / 800.446.3325fax: 847.541.9984 email: [email protected] www.indeck.com
BULLARD V.T.L. SPECIALISTSREPLACEMENT PARTS & TOOLING FOR ALL
TYPES OF BULLARD V.T.L.’SREBUILDING & RETROFITTING
Complete Assemblies in StockOVER 100 BULLARD V.T.L.’S IN STOCK
O‘CONNELL MACHINERY COMPANY, INC.175 GREAT ARROW AVE BUFFALO, NEW YORK 14207
(716) 877-3666 FAX (716) 877-1136www.oconnellmachinery.com
e-mail: [email protected]
OPTICAL COMPARATORSSpecializing in Used & Reconditioned Jones & Lamson Optical ComparatorsOPTICAL GAGING PRODUCTS (OGP) Top Bench 14”; 20X; 8” x 6” Tvls; Computational DRO- 1999OGP Avant AV400 Smartscope Video Measuring Machine; 18“ x 18” x 8“ Tvls; 3-Axis Joystick; Computer & Software-Updated 2002SCHERR-TUMICO Mdl. 22-2500; 30”; 12” x 9“ Power Tvls; Surf. Illum; 10X, 20X, 450X Lens; S/T DRO- 1981STARRETT Model HCS800; 31.5”; CNC; 20” x 10“ Power Tvls; Surf. Illum; Quadra Chek 4205 Controls w/ Edge Detect- 1997
PIEDMONT MACHINERY of Charlotte Inc.2218 N. Brevard St. P.O. Box 4264 Charlotte, NC 28299
(704) 334-4609 Fax (704) 375-3874www.piedmontmachinery.com E-Mail: [email protected]
Cold Rolling Mill Equipment & Systems
3171 N. Republic Blvd.Toledo, Ohio 43615-1515Phone (419) 843-7262Fax (419) 843-7229www.cauffiel.com
New, Used & RemanufacturedOver 100 machines to choose from.
We sell what you want2-High, 4-High, “Z-Mill” & Sendzimir
We own and operate a cold rolling plant.
MACHINES TOOLINGRIGGING
BUY SELL TRADE
800-535-8331
SPECIALISTS IN BARBER-COLMAN MACHINE TOOLSRepair Parts, Inc.
Contact: Terry McDonald
2415 Kishwaukee St., Rockford, IL 61104
PHONE: 815-968-4499 FAX: 815-968-4694
Service Training Reconditioning SalesFactory Trained Personnel
We Also Will Buy Your Surplus B-C Equipmentwww.repair-parts-inc.com e-mail: [email protected]
HI-HEAT CO. INC.32 GLENDALE RD., SOUTH WINDSOR, CT 06074
INDUSTRIAL OVENS - HEAT TREATING FURNACESWalk-in Ovens - Cabinet Ovens - Box Furnaces - Vacuum Furnaces, Etc.
Please visit our website: www.hi-heat.comCALL: 860-528-9315 FAX: 860-528-0421 EMAIL: [email protected]
Visit our warehouse to inspect our large inventory
SPECIAL BUY!DC MOTORS
AT DEEP, DEEP DISCOUNTS
DUTCH ELECTRIC CORPTEL 610-582-2870 FAX 610-582-6942
EMAIL: [email protected]
BUY A BARGAIN WHILE THEY LAST!
13855 W. Polo Trail Dr. Ph: 847/918-9797Lake Forest, IL 60045 Fax: 847/918-9733
VICTORY MACHINERY EXCHANGE, INC.
WE BUY, SELL & APPRAISE USED MACHINERY
“ I f y o u d o n ’ t c a l l u s w e b o t h l o s e m o n e y . ”
WE REBUILD FOUR SLIDES“Your Supermarket For Spring &
Wire Forming Machinery”
FOUR SLIDES IN STOCK
Nilson - #S-00, S-2, S-3, S-4, S-0F, S-1F, S-2F, S-3F, S-320, S-436, 752Baird - #00, #1, #2, #3, #5, #104, #28, #33, #35, RW1, 3-24, 4-30TORIN - V81, V82 Vert. Slide
S-5 Nilson
8Z0 Baird
NEW US INDUSTRIAL SHEARS10’ X 1/4” 10’ X 3/8” 12’ X 1/4” IN STOCK !
N E W E Q U I P M E N TUNBELIEVABLE PRICECall Before You Buy Used
Machinery Sales CompanyMachinery Sales CompanyP.O. Box 2098 Memphis, TN 38101
Phone: 901-527-8671 Fax: 901-526-2339
912AMA42.eps 12/7/2009 2:13:17 PM
TO ADVERTISE IN THE USED EQUIPMENT DIRECTORY CONTACT: BOB SCOFIELD AT 973-400-1790 OR [email protected]
americanmachinist.com I DECEMBER I AMERICAN MACHINIST I 43
USED EQUIPMENT DIRECTORY
NATIONALMACHINERYEXCHANGE, INC.“If it’s machinery, we have it” sm
158 PARIS STREET NEWARK NJ 07105TELEPHONE: 973-344-6100
FAX: 973-589-0944WEBSITE: WWW.NATIONALMACHY.COME-MAIL: [email protected]
60” x .135” x 55,000# BRANER TURRET HEAD SLITTING LINENew 1990
IN PLANT, available for inspectionContact us for technical specifications and/or quote
USED & NEWFURNACES& OVENS
1-336-784-4800 Fax: 336-784-0634 E-Mail: [email protected]. Box 12037 3950 Overdale Rd. Winston-Salem, NC 27117-2037
SEE COMPLETE LISTING OF EQUIPMENT ON OUR WEBSITE AT:www.thermcraftinc.comNew: Live E-bay AuctionsDirect Link on home page
See Website for Pictures!All used equipment sold with 30 day warranty
http://www.highlandmachinery.com
HIGHLAND MACHINERY & CRANE1170 Cornerstone Place, Benton Harbor, MI 49022e: [email protected] ph: 877.921.9600 fax: 269.926.9601
Large Selection of Cranes Available!!! All Taken Down!40/10T x77’3” DESHAZO, 1999, 27' Lift, VFD Bridge/Trly, 300'(x2) Rail/Run
25/25T x 71’ KONE, 2001, Dual Trlys, VFD Br/Tr, 320’(x2) Rail/Run/Cols20T x 26’ STAHL, 2004, 26’ Lift, VFD Br/Tr, 520’(x2) Rail/Run, 2 AVAIL18T x 43’ KONE, 2001, 33' Lift, 2 Spd All, 180’(x2) Rail/Run, 2 AVAIL.
15T x 71’ KONE, 2001, VFD Bridge/Trly, Radio, 250’ Rail/Run/Cols10T x 44’ STAHL, 1999, 20’ Lift, 108’(x2) Rail/Run/Cols
2T - 5T x 38’ KONE, ‘90s, 20’ Lift, 1200’(x2) Rail/Run, 5 AVAIL
PETER FLESCH, INC.146 MEADOW STREET
GARDEN CITY, NEW YORK 11530-6600TEL (516) 741-7835FAX (516) 747-1272
S & GS & G PRESS & MACHINERY SALESP.O. Box 537, Fraser, MI 48026
800 Ton Verson S4-800-168-84, 20” Str., 48“ SH., 15-40 VSPM, 58” Windows, Rolling Bolster, 1995
300 Ton Minster E2-300-72-42, 3” Str., 28” SH., 0-200 VSPM, Windows, FIR-STD (2)
250 Ton Komutsu Gap, OBW-250-2, 11.8” Str., 21.6“ SH., 20-40VSPM, 1987
200 Ton Minster P2-200-72, 6” Str., 24” SH., 45-90 RSPM, 23” Windows, FIR-STD
Phone: (586) 563-5000 Fax: (586) 563-5005e-mail: [email protected] http://www.sandgpress.com
GIBSON Parts & Equipment, Inc.New & Used
Abrasive Blast EquipmentTables, Tumblers, Spinner HangersToll Free 888-867-1619Fax (317) 758-6775 www.Gibson-Parts.com
E-mail: [email protected]
WWW.GIBBSMACHINERY.COM21500 Hoover Rd. Warren MI (Detroit Suburb)
Phone: 586-755-5353 Fax: 586-755-0304
18x96 Lees Bradner Spline Hobber16-36 Barber Colman C Frame Collet - 1947-1978 (4)Liebherr L301 & L252 Crowning - 1973 & 1979PE 200 & 150 Pfauter CNC 15M Fanuc (3)175HC Gleason CNC Spiral-Gear Generator, 199410-4 & 10-2 Fellows CNC Shapers Factory Rebuilt - 1997
USED ---- BLAST EQUIPMENTBLAST EQUIPMENT ---- REBUILTBUY WHEELABRATOR + PANGBORN + GOFF + BCP SELL
SHOTBLAST AMERICASHOTBLAST AMERICA412 BAYBERRY DR., CHAPEL HILL NC 27517PHONE: 919PHONE: 919-928928-0071 FAX: 9190071 FAX: 919-928928-01790179
web site: www.shotblastamerica.comemail: [email protected]
PARK THERMAL (1996)INTERNATIONAL CORPORATIONNew / Reconditioned OvensFurnaces - Quenching OIls -Heat Treating Salts -Comonent Parts -- StainlessSteel Foil -- Refractory Products
62 Todd RoadGeorgetown ON L7G 4R7Tel: (905) 877-5254Fax: (905) 877-6205
Toll Free: (877) 843-HEAT (4328)Web Site: www.parkthermal.comE-Mail: [email protected]
WARNER & SWASEY AC, AB & SC
4661 Jaycox Rd. Avon, OH 44011440-937-6241 www.pmr4ws.com
INC.
Remanufacture Electrical RetrofitParts Tooling Service
Used Machines
RIVETERSTHINK AARON’S
The Nation’s No. 1 Source for Rebuilt - Retooled RivetersCHICAGO MILFORD NATIONAL TRS ORBITALS
ADTECH TOMKINS-JOHNSON J.L. THOMAS
AARON’S MACHINERY CORP.170 N. Halsted St,. Chicago, IL 60661
312-421-2334 FAX 312-421-7035
CNC Swiss, Turning & Machining CentersCit izen Star Tsugami Tornos Nomura
Hanwha Gi ldemeister NexTurn KSI MaierBar feeds (New & Used) CNC Turning & Machin ing Centers
800-543-7666 Fax: 303-651-6556www.automatics.com
[email protected] [email protected]
912AMA43.eps 12/7/2009 2:13:25 PM
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USED EQUIPMENT DIRECTORY
44 I AMERICAN MACHINIST I DECEMBER I americanmachinist.com
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S O F T W A R E & C O N T R O L S
nearly all time-consuming secondary setups so that many tool bodies are completely machined in one fixturing. “With our small quantities, staying competitive is all about set-up time,” Wallin pointed out. “Almost all our work is one of a kind. Four or six pieces is a huge order for us, so we are always setting up new jobs.”
Programming with Edgecam offers other dramatic gains. “Edgecam allows us to easily align tool surfaces in the program, then graphically flatten and rotate them until they are perpendicular to the machine tool spindle,” Wallin said. “You just click on the different surfaces, and Edgecam aligns them for you, a big time saver in programming.”
Currently, Wallin is creating programs that are fully post-processed for “lights out” machining. Nearly all his products start as pre-hardened AISI 4140 steel rounds and bar stock, which must be cut slowly, so unattended machining is quite beneficial. But, with no machinists to watch for program errors, “perfect” programs are mandatory. Perfection also means jobs must be machined exactly as programmed. At-the-machine changes by operators can eat into productivity and may even stretch delivery times.
Changing the GameE.W. Tooling is “attempting to change
the way this industry works,” Wallin said, “and we are succeeding. We are deliberately raising the bar on firms that try to compete solely on price.”
The shop is doing that, he continued, “by making sure customers know how much ‘free’ engineering they have been getting from us” — which they would lose if they bought solely on the basis of purchase price. “There is a tendency among some toolmakers in wood and wood-products to look down on these kinds of tooling. Their attitude seems to be, ‘Hey, it’s just a piece of wood’ and ‘This job is way over-engineered.’ We don’t see it that way; we never have.”
The trick in this is to design the new tooling families so that their complexity doesn’t impact E.W. Tooling’s own productivity. Thanks largely to Edgecam’s five-axis capabilities and Solid Machinist with Autodesk Inventor, they don’t.
>> from 32
Software Proves to be a Valuable Fixture
M&M Manufacturing in Tulsa is a CNC machine shop producing parts, assemblies
and tooling for the energy, healthcare, and manufacturing sectors. But, the shop’s specialty is in complex-geometry aerospace components. It uses four- and five-axis machines to manufacture parts that often have three controlling datum surfaces, as well as many contoured surfaces blending into each other.
These parts are programming challenges that M&M addressed with a switch to DP Technology’s ESPRIT CAM (www.dptechnology.com). The software makes it possible to apply toolpaths directly to a customer’s solid geometry and view simulations of the resulting program, with the machine, tools, fixturing, etc., included, to avoid crashes.
Creative Workholding, Machining“A key difference that we bring
to our customers comes through our creativity in developing a strategy for holding and machining the part,” said Ken Statton, president of M&M Manufacturing. Statton said the shop developed expertise in fixturing as it worked to meet tight tolerance requirements, but these efforts have advanced to using fixturing to reduce machining cycle time. He pointed to a four-station fixture that M&M developed for a four-axis machine that
makes it possible to perform a tool change then proceed sequentially through all the operations with that tool on all four parts. “This fixture allows us to machine four parts with only a single sequence devoted to changing, advancing, and retracting the tool,” he said. “The result is substantial time savings.”
M&M began to move to four- and five-axis machining because of the increasing complexity of the aerospace parts it is producing, and this
meant it needed a software package that could import complex geometries. It chose ESPRIT because of its programming simplicity and optimizing ability. “ESPRIT gives us the optimum level of control to make sure the cutter stays in the cut as long as possible and that the program works the first time we run it,” according to Statton.
Automatic Feature RecognitionIn the past, for example, if the
company was making a composite layup tool with many changing contoured surfaces, it had to define each surface independently and generate toolpaths. The cutter had to move around to reach each of the different toolpaths, typically taking several days to generate the program. With ESPRIT, programmers simply import the solid model and access the full functionality for the solid model. Then, the CAM software is used to integrate the solid model to automatically identify the part features.
The next step is to assign metalcutting operations to the features that have been defined. ESPRIT lets users create a knowledge base of pre-optimized machining operations that include a particular tool, cutting speed, feedrate, depth of cut, etc. Programmers choose from several different machining strategies that automatically develop an efficiency approach for machining the feature.
Machining plan for a Gulfstream G-650 fitting, as demonstrated by ESPRIT software.
ADVERTISER PAGE
American Machinist .................................................................................7
American Machinist ...............................................................................12
American Machinist ...............................................................................24
American Machinist ..............................................................................BC
2L Inc. .....................................................................................................23
Gibbs and Associates ..............................................................................1
Gradient Lens Corp. . .............................................................................13
Haas Automation, Inc. .............................................................................5
Iscar Metals, Inc. ......................................................................................3
Mastercam, CNC Software, Inc. ............................................................31
Mfg.com .............................................................................................. IFC
Monster Tool ...........................................................................................21
Sandvik Coromant Co. . ...................................................................... IBC
Scientific Cutting Tools, Inc. . .................................................................28
This index is a service to readers. Every effort is made to maintain accuracy,
but AMERICAN MACHINIST cannot assume responsibility for errors or omissions.
AM PRODUCT EXPRESS ADVERTISINGPage 45
Send all AM PRODUCT EXPRESS advertisements to: CLASSIFIED DEPT., Penton Media, Inc.,
1300 E. 9th Street, Cleveland, OH 44114-1503.
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americanmachinist.com I DECEMBER 2009 I AMERICAN MACHINIST I 47
I E D I T O R
O P E R A T I O N S
With the economy slowed, enrollment is picking up
at the Moraine Park Technical College Advanced Manufacturing & Technology Center (AMTC) in West Bend, Wis. Students want to gain the skills that could land them jobs in high-tech, Lean Manufacturing shops, or that would make them more valuable to their current employers.
AMTC offers 2-year degrees in CNC Manufacturing and Tool & Die Manufacturing. “One of the things that we preach is that the more skills a person can bring to the table the fewer reasons a company will have for letting them go in a down economy,” instructor Tim Clemens said.
One way the school helps its students become more versatile, and thus more valuable, is to integrate inspection training with course work in CNC Programming, GD&T (Geometric Dimensioning and Tolerancing), and Tool & Die Manufacturing. For example, in the CNC programming course, students must write about 11 increasingly difficult CNC manufacturing programs for mills and lathes. Then, they check their work on a Brown & Sharpe DCC CMM (direct computer control coordinate measuring machine) with PC-DMIS (www.pcdmis.com) measurement software.
The programs show the students what they did right or where they went wrong. As they assess their progress as CNC programmers, they learn CMM basics. Later, they’ll learn to write their own CMM programs in PC-DMIS, and their familiarity with the equipment will place them ahead of the curve.
Moraine Park’s three DCC
CMMs (at its two campuses) and the software were acquired as part of the Hexagon Metrology (www.hexagonmetrology.com/) Metrology Equipment Grant program. It helped Moraine Park acquire the equipment and software at affordable terms, and the school receives technical assistance from Brown & Sharpe sales engineer Rick Schaeffer.
Clemens spends a great deal of time on essentials in his introduction to CMM Programming class. “Before students can move to writing a fully automated DCC program, they have to really understand how to calibrate probes correctly and how to do proper alignments. Without these skills, you’ll never get good measurements,” he said.
Recently, AMTC began incorporating CMM surface scanning into the curriculum. Clemens was given a grant to study the subject at a local shop, RAM Tool & Die. He worked with one of RAM’s programmers to learn to write measurement programs using both touch-trigger and laser probes to check curves and surfaces. At present, Clemens teaches students scanning with a touch probe, and the college hopes to acquire a vision probe for teaching more advanced applications.
Does broadening the students’ base of skills with CMM training actually make them more marketable? Clemens is sure of it. In fact, several of his students in recent years have found work as CMM operators and programmers, and many more are employed by shops that recognize that a greater understanding of quality standards will earn more profitable business. <<
Machinists with CMM Training Know More, Earn More
EDITED BY ROBERT BROOKS
48 I AMERICAN MACHINIST I DECEMBER 2009 I americanmachinist.com
The condition and physical properties of the work material have a direct
influence on its machinability. The various conditions and characteristics described as “condition of work material,” individually and in combinations, directly influence and determine the machinability. Operating conditions, tool material, and geometry and workpiece requirements exercise indirect effects on machinability and often can be used to overcome difficult conditions presented by the work material.
The following factors determine the condition of the work material: microstructure, grain size, heat treatment, chemical composition, fabrication, hardness, yield strength and tensile strength.
Physical properties of work materials will include those characteristics included in the individual material groups, such as the modulus of elasticity, thermal conductivity, thermal expansion and work hardening.
“Machinability” is a relative measure of how easily a material can be machined when compared to 160 Brinell AISI B 1112 free-machining, low-carbon steel. The AISI ran turning tests of this material at 180 surface feet and compared its results for B 1112 against several other materials. If B 1112 represents a 100% rating, then materials with a rating less than this level would be decidedly more difficult to machine, while those that exceed 100% would be easier to machine.
The machinability rating of a metal takes into consideration the normal cutting speed, surface
finish and tool life. These factors are weighted and combined to arrive at a final machinability rating.
There are four methods used to judge machinability:
be cut without rapid tool wear are generally thought to be quite machinable, and vice versa. A workpiece material with many small hard inclusions may appear to have the same mechanical properties as a less abrasive metal. It may require no greater power consumption during cutting. Yet, the machinability of this material would be lower because its abrasive properties are responsible for rapid wear on the tool, resulting in higher machining costs.
One problem arising from the use of tool life as a machinability index is its sensitivity to other machining variables. Of particular importance is the effect of tool material. Machinability ratings based on tool life cannot be compared if a high-speed steel tool is used in one case and a sintered carbide tool in another.
Tool life may be defined as the period of time that the cutting tool performs efficiently. Many variables such as material to be machined, cutting tool material, cutting tool geometry, machine condition, cutting tool clamping, cutting speed, feed, and depth of cut, make cutting tool life determination very difficult.
When using tool forces as a machinability rating, either the cutting force or the thrust force (feeding force) may be used. The cutting force is
the more popular of these two because it is the force that pushes the tool through the workpiece and determines the power consumed.
The quality of the surface finish left on the workpiece during a cutting operation is sometimes useful in determining machinability rating. Some workpieces will not ‘take a good finish’ as well as others. The fundamental reason for surface roughness is the formation and sloughing off of parts of the built-up edge on the tool. Soft, ductile materials tend to form a built-up edge rather easily. Stainless steels, gas turbine alloy and other metals with high strain-hardening ability also tend to machine with built-up edges. Materials that machine with high shear zone angles tend to minimize built-up edge effects.
There have been machinability ratings based on the type of chip that is formed during the machining operation. The machinability might be judged by the ease of handling and disposing of chips. A material that produces long stringy chips would receive a low rating, as would one that produces fine powdery chips. Materials that inherently form nicely broken, chips, a half or full turn of the normal chip helix, would receive top rating.
B Y G E O R G E S C H N E I D E R J R . I C M f g E , C M f g T , L S M E
C U T T I N G T O O L A P P L I C AT I O N S
Chapter 3: Machinability of Metals
Each month American Machinist presents an abstract of Cutting Tool Aplications, George Schneider’s essential handbook to machine tool materials, principles, and designs. For a complete summary of each chapter, visit www.americanmachinist.com
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