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Mills CNC unveiled a new range of Doosan Puma lathes at the recent Mach exhibition.
The machine structure of the new Pumas has benefited from the application of Finite Element Analysis (FEA) to determine static and dynamic stiffness, leading to a more stable, better damped structure for increased accuracy.
Another key feature is that the range is modular, seeing the use of common parts across all models.
This has helped keep costs down and means that, despite a significant improvement in technology and performance, the Puma lathes don’t cost much more than the older models they have replaced.
The new Pumas’ machine base casting has been increased by up to 158 per cent; their box guideways have been made 50 per cent thicker; and the saddle width along the Z-axis has been increased, as has the distance between Z-axis slideways.
Other design-and-build mechanical improvements have seen the mounting area for the headstock being increased by 90 per cent and the mounting area for the sub-spindle increased by 50 per cent, increasing overall rigidity.
In addition to these improvements, the effect of heat-generating elements has also been considered.
So, the heat generated by the hydraulic power pack is directed away from the machine and hot air is driven upwards out of the control cabinet with a heat wall between it and the machine.
Heat from the main spindle’s hydraulic cylinder is similarly driven up and out of the machine.
Other features include air/oil lubrication for the machines’ driven tooling gear train and ball screws, which reduce heat generation, while X and Y servos have their own cooling fans.
Angular contact spindle bearings further reduce thermal effects.
Finally, all sub-spindle models supplied in the UK will have 15kW (134Nm) motors, which allows heavy-duty turning on second operation work.
The new range of 36 machines replaces the existing Puma 1600, 2000, 2500, 240, 280 and 300 ranges - a total of 40 machines - and eliminates the model overlap that previously existed.
The range consists of three machine series - 2100, 2600 and 3100.
The Puma 2100 (8in/65mm bar) has two bed lengths - 520 and 760mm - and there are six models for each bed length: 2100 - plain turning; 2100M - with driven tooling; 2100S - with sub-spindle; 2100MS - with sub-spindle and driven tools; 2100Y - with driven tools and Y-axis; and 2100SY - with driven tools, Y-axis and sub-spindle.
This represents an extension of the technical options available over previous generations.
The Puma 2600 (10in/76mm bar) again has two bed lengths - 750 and 1,250mm - and the same six model types in each.
The Puma 3100, a true 12in chuck machine (102mm bar), has four bed lengths - 750, 1,250, 2,000 and 3,000mm - and three models in each length; there are no sub-spindle variations for this large-capacity machine.
The Puma 3100 can also support a 15in chuck.
All new Pumas have the option of being supplied with belt-driven or built-in motor spindles - except for the Puma 3100 series, which is belt-driven only.
Sub-spindles can be belt-driven or built-in, and tailstocks can be tow-along or servo-driven.
The tool turret is common across all new Pumas features 12 positions, but has the ability to half index such that, with special tool holders, two tools can be fitted within a single station.
In the case of end-working tools on machines with Y-axes, there is the possibility to have three tools located at a single station.
The new Pumas are equipped with Fanuc CNC systems, but there are special Doosan elements included.
One feature is the automatic compensation for inertia when interpolating C-axis with others to generate surfaces, which takes account of the different characteristics associated with parts of different weight.
Tool-load monitoring is provided, allowing thresholds for tools to be set during an initial cycle.
There’s also a CNC feature that allows for the logging of different operators’ performances, while maintenance-support information has also been enhanced.
A utility to help users recover from turret malfunctions is another offering, while an on-screen calculator is yet another addition.
The machine light turns off if the operator panel is not touched for a prescribed length of time, and the machine goes into sleep mode if idle and the operator panel has not been touched for a set length of time.
Trouble-free maintenance has also been given attention, with, for example, sub-spindle alignment made simple through easily accessible adjustment screws.
Access to the sub-spindle itself is also straightforward and the coolant tank can be removed from the front of the machine without the requirement to remove the chip conveyor.

Tags: CNC Machining, Puma lathes

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Hardinge Machine Tools has launched a 42mm-capacity, super-precision turning centre that achieves high-accuracy (nano) production for the medical, aerospace and defence industries and more.
The T-42 turning centre will be launched at IMTS in Chicago and is able to achieve roundness values of 0.25 microns while maintaining overall accuracies within three microns.
The T-42 will be pre-configured for customer requirements to create a dedicated high-precision turning platform able to produce demanding, multi-featured components.
The machine’s modular construction means it can be supplied as a two-axis version with tailstock up to a multi-axis variant with C- and Y-axis and up to 16 live tool turret positions, sub-spindle and automatic offload.
Each version is controlled by Fanuc 31i.
Critical in achieving the level of accuracy within three microns, 0.25 micron in roundness, axis repeatability of 0.76 micron and surface finish within 0.15 micro metres is the strategically rubbed, 45-deg true slant cast iron base.
This is purpose-designed to maintain a precision machining cycle and its reinforcement with Hardinge’s Harcrete polymer composite enhances its vibration-damping ability and higher surface finish capability.
Mounted on the bed is Hardinge’s specialist BMT-45 turret top plate, which carries the 16-station, all-driven bi-directional turret.
The machine has the added versatility of half-indexing positions that capitalise on a range of Hardinge-developed toolholders, which can double the fixed and driven tool carrying count to 32.
In addition, while standard rotary tool speeds are 8,000rev/min from a 3.7kW motor delivering 33Nm of torque via a belt drive to accommodate ultra-small tools and the use of CBN or diamond cutters, ratio upgrades can increase rotational speeds to 16,000rev/min.
Turret index time (clamp to clamp) is within 1sec, and 80 bar high-pressure through-coolant supply is available.
The Hardinge BMT-45 toolholding system has a run-out within three micron.
Hardinge said an advantage is its development of an independent Y-axis with some 84mm of travel and providing ultra-fine adjustment.
This enables pinpoint tool alignment and machining consistency with lower offset error when compared with a conventional machine’s ‘wedge’ design.
The inclusion of the Hardinge collet-ready spindle technology optimises the relative positioning of the cutting tool close to the spindle bearings.
Both main and sub-spindles have the benefit of fast acceleration and deceleration through wraparound high-voltage motors with both having identical 11kW, 101Nm of torque delivering 6,000rev/min with 150mm chuck or 42mm bar capacity.
A bespoke sub-spindle component retrieval system is able to remove the most delicate high-precision component without scratching or marking.
The part gripper has special nylon inserts that can be machined for ’soft’ removal and placement on the part conveyor integrated into the machine.

Tags: Turning centre

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The CSD-300 parallel spindle lathe from Fuji Machine offers maximum material handling from a compact footprint, designed for the quick and accurate turning of a variety of parts.
To securely handle heavy parts of 200mm diameter x 100mm and 5kg plus 5kg, the CSD-300 features a Fuji-engineered hydraulic clamping loader and 8-10in capacity work-holding chucks.
A hardened box-way slide and a 2260mm-width machine base allows for heavy cutting.
The CSD-300 is designed for the quick and accurate turning of a variety of parts.
The turret achieves speeds of 0.26sec/index, while the CSD-300’s dual 100mm diameter spindles (A2-6) are equipped with 15/20hp high-output spindle motors.
Robot alignment to spindle centre line is achieved with the CSD-300’s three-axis gantry robot control.
Environmentally friendly, the CSD-300 features an energy-saving auto shut-off LED light.
User-friendly features include a rear (or optional side positioned) discharge chip conveyor, and maintenance items all conveniently located in one section on the machine.

Tags: spindle lathe

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A Hyundai-Kia turning centre supplied by Ward CNC is enabling Roballo Engineering, a manufacturer of slewing bearings, to enhance its cost effectiveness and levels of production flexibility.
The machine is allowing the company, which produces slewing bearings measuring up to 2.8m in diameter, to bring the manufacture of components in house.
The Hyundai-Kia SKT-300M’s C-axis and driven tooling are highlighted by Peterlee-based Roballo’s works manager, Joe Peacock, as being major features of the overall machine specification, price and support package that saw Ward CNC win the order.
He said: ‘Importantly, we are finding that the machine’s driven tools are proving especially beneficial for the single setup work we require.
‘Like every manufacturing engineering company, we have taken a very close look at everything we do and part of that process has seen a lot of previously subcontracted work brought back in house.
‘In the case of the Hyundai-Kia turning centre, this has meant a lot of one-hit turn/mill/drill components that are for our slewing bearings, which can measure up to 2.8m in diameter,’ added Peacock.
The 90mm-bar-capacity Hyundai-Kia SKT-300M has a maximum turning diameter and length of 500mm and 660mm respectively.
The machine has a spindle speed of 3,000rev/min (22/18.5kW motor) and has a 12-tool station tool turret driven at 5.5/3.7kW to achieve 4,000rev/min.
Travels in X and Z are 290mm and 750mm respectively, with corresponding rapid traverse rates of 20m/min and 24m/min.
Control is by Fanuc 21iTB CNC with Manual Guide-I routines.

Tags: Turning centre

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Fuji Machine’s new large VTP-1000 vertical lathe is suitable for use within the gear, construction, wind power energy, aerospace and shipbuilding equipment industries.
Featuring gearless spindle technology and an RS-Slide structure, the VTP-1000, which performs precise hard turning, realises contour- and profile-cutting accuracies within +/-1um on up to 40in (1m) OD gears and bearing components.
With the VTP-1000, precise roundness on high-hardness materials (HR60 plus) is possible.
A variety of features further contribute to the VTP-1000’s high-accuracy operation, according to the company.
Twin Capto C6 receivers, for instance, ensure optimum tool tip rigidity, while a magnetic chuck eliminates the distortion associated with conventional workholding methods.
For thermal stability, this lathe has an optional coolant chiller and its heat sources are insulated with containment covers - all of which are located externally.
The VTP-1000’s heightened finishing accuracies result in up to 75 per cent shorter manufacturing times.
Each tool holder contains microchips to prevent offset errors and to verify that it is in the correct pocket.
The table diameter of the VTP-1000 is 1,000mm, the maximum swing is 1,200mm and the table load is 4,000kg.
Although it features a small footprint, this new lathe is rigidly constructed.
The column and the bed (75 per cent of the total machine weight) are made of heavy cast iron.
These components are not affected by thermal growth.
The VTP-1000 is designed for integration into an automated work cell.

Tags: Vertical lathe

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Rather than spend thousands of dollars on new machinery, consider CNC retrofitting, which can provide accuracy similar to new machinery at a fraction of the cost.

If you are experiencing excessive machine down time with a machine that is mechanically sound, perhaps it’s the control system that is obsolete.

Rather than tossing your old machine and getting a new one — which can be a costly endeavor — consider retrofitting the computer numerical control (CNC). This process entails the replacement of the CNC, servo motors and drives, spindle system and associated wiring.

Retrofit costs are typically between one-third and two-thirds the cost of a new machine, according to an American Machinist Webcast. It also avoids the “hidden costs” of new equipment such as transportation, tooling, training and start-up times.

Steve Colasanti, systems integrator at Dual Electric & Refrigeration Services, agrees, saying in a recent case study at Modern Machine Shop:

The cost of upgrading a machine tool to almost new is typically a fraction of the cost of buying new. If you have a solid machine base to work with, retrofitting machines with digital CNC and servo technology can yield large decreases in cycle time while providing accuracy similar to that of new machinery.

According to the Webcast, along with being less costly than new machinery, other benefits of a CNC retrofit include:

* Typically a 20 percent increase in performance due to the faster CNCs, higher-speed motors and machining technologies;
* Machine electricity usage reduction by as much as 50 percent;
* Increased plant capacity because of smaller CNCs;
* Improved mean-time to repair and mean-time between failures; and
* Better data accessibility and support through upgraded Ethernet communications.

To determine the full value of a retrofit, the Webcast instructs shop owners to perform a standard return on investment (ROI) analysis of the anticipated revenue improvements and the savings from cost reductions in conjunction with all quoted and hidden costs of the project.

While the benefits are appealing, there remain a few key considerations to keep in mind before committing to a retrofitting project. One of these is that benefits will be delivered only by upgrading the servo and spindle system to a high-speed digital interface as well. “It does not matter how fast the CNC can process blocks of part program data if the servo and spindle systems cannot keep up,” according to American Machinist earlier this year.

When you’ve decided to commit to the project, the first step is to investigate the mechanics of the machine and determine the feasibility of a digital upgrade, Modern Machine Shop suggests. “Proper inertial matching calculations for each axis drive system is essential to peak high speed operation,” Colasanti adds. Next, the retrofitting project manager must get an understanding of the electrical system so the retrofitted CNC can be integrated properly.

Once the viability of a retrofit has been established, it’s time to select a retrofitter or retrofit kit provider. A retrofitter selects the CNC and determines the correct-sized drive systems, writes the programmable machine controller (PMC) ladder, mounts and wires electrical components and motors, sets the machine parameters and does basic servo tuning, Bruce Vernyi at American Machinist writes.

Due to their numerous responsibilities directly tied to the success of the retrofit, it is important to be extremely selective when selecting a retrofit partner. The American Machinist Webcast suggests machine shop owners:

* Establish their potential partner’s competency in machine type;
* Ask for documentation of quality;
* Ask for references;
* Get multiple quotes; and
* Make apple-to-apple comparisons.

Some red flags to watch out for when appraising the quotations are a disproportionately low price, smaller servos or spindle systems and a poorly detailed quote.

Once you’ve chosen your partner, make sure to specify the exact CNC model you need and want, plus all the optional contents and additional enhancements you require, the Webcast presenter adds.

http://news.thomasnet.com/IMT/archives/

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World Lasers has announced the first retrofit of a HAAS Automation VF-4 vertical machining centre (VMC) with a 3000W laser.

The retrofit offers the following.

* The durability and the capability of a quality CNC with laser technology.

* The speed, accuracy and versatility to give them the ‘competitive edge’.

* A simple machine interface known and used by operators world-wide.

World Lasers sales manager, Greg Rawley, said: “Existing CNC owners can transform their machines into laser cutting machines for a relatively low cost.

We’ve listened to their needs and are delivering at prices that even the competitors can’t believe”.

The laser retrofit kits are available for all sizes VF VMCs sold by Haas Automation.

World Lasers is an independent OEM and not affiliated with Haas Automation.

Contact World Lasers for more information.

http://www.manufacturingtalk.com/news/woj/woj100.html

Tags: laser cutter

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Plasma Technologies, a leader in CNC plasma systems integration is pleased to announce a low-cost high-value retrofit kit for Cybermation and Lockformer plasma cutting machines. The retrofit is an ideal solution for HVAC shops that have a failing Cybermation or Lockfomer system and don’t want to purchase a new machine.

The kit includes everything necessary to replace all the old electronics with brand new motors and controls. A Hypertherm Automation Edge Ti is at the heart of the system. This controller features a 15″ color touch screen with a single station operator’s console and built in servo amplifiers. The Edge Ti with its compact size and easy to use software is ideal for sheet metal applications. Also included in the package is MTC software’s Design2Fab and Turbo Nest programs, which give customers the necessary tools to easily create complete duct-fitting layouts while reducing the scrap generated. The software package includes a complete library of shapes and generates flat pattern sheet metal layouts and all necessary labels.

http://news.thomasnet.com/fullstory/558856

Tags: Plasma Cutting

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In a small garage in Cedar Park, Texas outside of Austin, there is the start of a new company that reflects an emerging trend in small business. Russell Andersen is using the post-industrial refuse of America’s computer-aided manufacturing revolution to create a new type of microenterprise–one that is built around aging high-tech tools and very niche markets enabled by Internet-based social networks and GAAP accounting.

He is using a fully-depreciated, 20-plus-year-old CNC (computer-numeric-controlled) milling machine he sourced from Craigslist for less than one-tenth of its cost new, and he’s running it with equally antiquated computer hardware and software. With that minimalist equipment, he builds very specific custom bike components that he sells around the world to a very unique customer.

An emerging trend in mountain biking is to build bikes with 29-inch wheels (called 29ers) instead of the more prevalent 26-inch wheels. Riders began to discover that the front gears (chain rings) designed for the smaller wheels were not as suitable on the bigger wheels. They needed smaller chain rings which were hard to fit on the crank sets designed for 26 bikes. But this market is so small most manufacturers simply do not make them, so passionate riders got together in bike shops and social networks to discuss this dilemma, creating a convergence of need, demand, and opportunity.

DiPaolo CNC Retrofit Limited (DiPaolo), the pre-eminent resource for North American manufacturers seeking precision machinery rebuilding and retrofitting services, announced today that ABLE Machine Tools Incorporated (ABLE) will be their representative in Massachusetts, Vermont, Connecticut, New Hampshire, Rhode Island and Maine. The premier machinery dealer in New England, ABLE’s expert field service technicians will provide after sales service and support while a team of outside sales engineers will traverse and tend to this territory.

“Manufacturers have a laser-like focus on the bottom line so when scouring the market for machining solutions that’ll meet the business need without bruising the budget, they’re often frustrated. But we know how to solve their problems. With ABLE representing us in New England, we’ll continue to revitalize and build machines for countless businesses across North America,” points out Nelson Martins, DiPaolo’s GM.

DiPaolo provides a one-stop shop for the entire machine user cycle - whether sourcing, buying or selling new or used, repairing and maintaining machinery. Many rebuilt or retrofitted machines are running accurately and productively after many years of constant use. Their finished machines equate new ones in performance, appearance and reliability with the only difference being a significantly reduced price.

Experience with almost every machine part, piece and problem out there has meant a loyal, diverse customer base for both of these economically stable companies - companies who share a long term view to business relationships. Significant, ongoing investment in research and development keeps these companies abreast of emerging technologies. An important addition to the marketplace, ABLE will bring DiPaolo to those manufacturers in New England requiring improved equipment performance, technically superior products and an increased market position.

“We’re pleased that ABLE has been selected as DiPaolo’s New England representative. We’ll help companies choose machines and incorporate processes that’ll satisfy their manufacturing requirements now and for years to come. Our technical staff will get things into production quickly by providing the employees with the support and training they’ll need in order to easily, and successfully, install and operate their equipment,” explains Alan Lockery, ABLE’s President.

http://news.thomasnet.com/companystory/563278

Tags: Machine Tools

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Siemens Industry, Inc. announced today a new, economical CNC machine tool retrofit package based upon its Sinumerik 802D sl system platform that will bring end-users new levels of efficiency and productivity for less cost. This retrofit service is ideal for three-axis milling or true two-axis turning machines.

The Sinumerik 802D sl is an operator panel-based control system that combines the numerical control (NC), the programmable logic controller (PLC) and the human machine interface (HMI) in a single, maintenance-free unit. It has been engineered with a 10.4-inch color TFT display, graphical support for machining cycles and simulation, a USB-interface built into the enclosure for simple program handling and transfer, intuitive help screens and remote diagnostic capabilities.

Pre-configured to meet the majority of current applications in the market, this space-saving and cost-effective retrofit package consists of a control-only retrofit, which maintains and integrates a machine’s current motors and drives. A complete Sinumerik 802D sl CNC package with new Siemens motors and drives is also available to meet specific customer needs.

Professional installation by a certified Siemens machine tool retrofit solution partner makes the Sinumerik 802D sl retrofit package virtually “plug-and-play” with reduced machine downtime.

For more information about the Sinumerik 802D sl retrofit package or general product inquiries, please call +1 800 879 8079 ext. Marketing Communications or send an e-mail to SiemensMTBUMarCom.industry@siemens.com.

About Siemens
A division of Siemens Industry, Inc. (SII), the Drive Technologies (DT) Division is the world’s leading supplier of products and services for production machinery and machine tools. DT’s integrated electrical and mechanical technologies cover the entire drive train and include standard products as well as industry-specific control and drive solutions for metal forming, printing and electronic manufacturing. DT also provides solutions for the glass, wood, plastics, ceramics, textiles, packaging equipment and crane system industries as well as mechatronics support to online services for web-based fault management and preventive maintenance. With nearly 40,000 employees worldwide, the Drive Technologies Division posted worldwide revenues of $13.4 billion in fiscal year 2008.

http://news.thomasnet.com/fullstory/575894

Tags: CNC Retrofit

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