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Laser cutting technology is no longer costly for mainstream sheetmetal fabrication due to rapid developments in speed, cutting quality and manufacturing. The laser beam is now efficient enough and has been quantified as a universal tool for cutting, welding, surface treatment and coating.

Not only does it enhance OH&S standards by operating silently and without wear and tear; laser cutting technology produces burr-free edges with narrow kerfs and minimal heat-effected zones. Its advantages include minimal heat input, low distortion and high feed rates.

Integrateability has been a key factor in laser cutters crossing into the realm of mainstream cost effectiveness. With the worldwide increase in versatility of turret punch presses, fabrication companies at all levels have greater possibilities to add laser cutting manufacturing solutions for their applications.

Laser cutting machine specialist, Maxitec , says that in the upper market segment, both ultra-fast flying optics laser cutting machines and punch-laser combinations have been gaining ground.

The company’s marketing director, Andrew Bentrup, said that now the integration of several work stages in the punching unit, the manufacturing of sophisticated components becomes possible at a lower cost/component ratio.

The share of ultra fast laser cutting systems, featuring linear drive technology is increasing due to fabricators’ demand for faster part processing time combined with enhanced accuracy and reduced setup times. Today, many manufacturers are looking closer at lasers to meet low run, high part number needs because of a disappearing need for higher volumes of the same part numbers and it is important to understand how the features of the present technology will last into the future.

Anticipating what the best features of a laser cutting system is important, but more vital is the evaluation of which features will become ‘obsolete’ and costly in the years to come. The basics of laser cutting have not changed for the past 20 years. There is an energy source (the laser) that removes material by thermally vaporising it. The mechanism to do this is controlled by five major elements: power, feed rate, focus, assist gas pressure, and type of assist gas.

Feed rate controls either the material or the laser movement at a speed that will allow the laser to consistently vaporise the material. Focus places intensity of the laser beam either on the surface, above, or into the material to achieve the desired cutting condition. The type of assist gas and pressure will remove the molten material and achieve the desired edge quality.

Recent Developments: According to Bentrup, high technology machine tools are what most manufacturers are looking for.

Lower set up times, high part quality and accuracy have been a natural benefit of laser cutting systems. Fast cycle times on lasers have always been related to geometry. Large radius parts cut on a laser have always outperformed other manufacturing methods.

With the latest in new linear drive technologies, the cycle time margin on traditional sheet metal systems is narrowing. A completely new type of laser design needs to be provided to accept the speed of acceleration that the new drive technology offers.

This new speed of process combined with the existing trend of the laser industry towards automation make the future of this manufacturing technology bright. Technologies like DpM and DpMplus are examples and make it easy to understand how fabricators can benefit from those new developments.

Control of axis movement has improved over the early systems, especially over stationary beam style lasers. Yet, most machine tool manufacturers still embrace either ball screw or rack and pinion drives.

Focus point is automatically changed through a cutting database or technology table. Assist gas change and pressure are system controlled as well. In fact, most of the internal functions of laser cutting have been automated. The NC cutting database has taken over almost all of the operational commands, leaving simple functions like nozzle or focus lens alignment or change to the operator.

Higher laser powers have advanced the technology as well. Thicker capacities of metals can now be processed, but the real advantage of higher power (3,000W and above) has been the increased feed rates on thin metals.

By using an inert gas, cutting speeds of metal are almost three times faster than earlier wattage systems. However, in efforts better to maximise speed of cutting more and more attention has been paid to nozzle design and beam collimation.

Punch-Laser Combination Machines: The development of laser cutting systems in recent years and the benefits associated with laser fabrication have increased interest in the use of laser cutting in many sectors of industry. Laser technology, in combination with punch press machines, has been used in the industry since 1980s.

Product designers are able to consider the opportunities of punch presses with the ‘four-in-one’ solutions, i.e. using forming, tapping, punching and laser cutting in one system to have different manufacturing methods available within one fabricating cell. However, various sheet metal components can be made using different machines, but also with one common manufacturing tool – laser cutting.

Manufacturing Benefits of Punch/Laser Combination: In recent years, machine tool builders have managed to economically integrate different manufacturing methods in a system through punch/laser combination systems. Fast axial flow CO2 lasers up to – 3,000 Watt laser power play the dominant role as an additional tool in the turret punch press. The integration of a diffusion cooled 2,500 Watt SLAB CO2 laser with its outstanding beam quality equals even 3,750 Watt laser power in comparison with conventional fast axial flow CO2 lasers. The heart of the machine is the robust O-frame of welded construction. The rigid construction of machine frame and the coordinate table permit the use of high axis speed and acceleration.

The punching operation can be generated either with a hydraulic system, with the possibility for more than 1,000 hits on 1mm axis movement, or by a servo-motor-driven mechanism. Its principle is made possible by a combination of electrical servo technology and mechanical power transmission.

Further enhancements also include linear drive motor technology allowing the punch/laser combination to become not only as fast as the 3-axis high speed laser systems but making the new combination machine the most universal sheet metal fabrication centre in the market, capable of punching, forming, contouring, marking, and tapping in one single set up without releasing the sheet metal fro the work holder.

More Integrated Work Stages – More Automation: Besides punching, nibbling, forming, marking, even bending and tapping operations are possible. For outside part contouring and special inner contours, in order to avoid nibbling marks, sharp edges or buying special tools the laser is used to increase part quality in one operation with no additional material handling.

Additional increases of productivity for punch laser systems are modular extensions in the overall system, like loading/unloading, part sorting or stacking.

The laser cut parts will be guided outside the working area via trap doors and conveyor systems. From this point or even straight from the cutting position a sorting and stacking robot transfers the part to its programmed sorting address.

High-Speed Laser Cutting Systems:

Flat bed laser cutting systems have been established technology in the sheet metal industry for more than a decade. The flexibility of the laser cutting process in producing components with various contours, with varying thickness and materials, has led to the world-wide use of these systems.

High speed laser cutting has been accepted by sheet metal manufacturing shops throughout the years as several studies of institutes have shown the possibility of cutting materials such as 1mm aluminium at 50 m/min or even faster.

Many sheet metal applications have been solved with punch presses due to manufacturing costs for the component. With the integration of linear drive technology, new and rigid machines had to be developed to achieve positioning speed up to 300 m/min and acceleration of more than 20 m/s2. In addition to this, the laser cutting speed could be set up to 25 m/min for 1mm mild steel without a negative influence to path accuracy. In aluminium even 50m/min cutting speed is a standard parameter in the system cutting data base.

The high-speed laser cutting system can be designed also for flexibility. With the use of, for example, 4,000 Watt laser power mild steel can be cut up to 25mm.

Higher cutting speed for thin material and the repositioning speed from one cutting point to the next contour have led to higher productivity in comparison with conventional flat bed laser cutting systems.

The laser cutting process is a complex one, which is why a more sophisticated and user-friendly operator interface for the CNC control was developed for the system. All necessary parameters are available, and functions from the system can be activated through a Windows-based touch screen operator panel.

The process time for a complete sheet has been drastically reduced. Also more and more material handling devices like loading and unloading from the sheet are installed in high-speed laser cutting systems.

A further step towards more sophisticated material and component handling is Finn-Power’s laser cutting centre LC6. This automation for laser cut components helps the customer integrate laser operation and part handling for fabricating high-quality components within one system.

The LC6 Laser Centre utilises a fixed laser beam system, combining the unique C-series turret punch press drive concept with the latest generation of diffusion cooled CO2 SLAB laser.

Laser Automation: The biggest trend towards laser cutting over the last 10 years has been one towards automation. This trend promises to continue. The reasons are varied and this trend promises to continue.

Bentrup says that the consistency of operation of an automated cell, especially with a laser at the heart of it, offers complete flexibility to the manufacturer. Reaction time to the customer’s demands is minimal.

There is no costly tooling inventory to manage, nor need pallets be chased down to be prepared for processing.

More and more companies are implementing lean manufacturing strategies to minimise wasted movement and overproduction of parts and thus reducing inventories. An automated laser cell is the suitable tool to achieve these goals.

Developments in laser power control and technology tables have reduced cycle time and set up. The new developments in linear drive technology are causing manufacturers to rethink the basic design of laser cutting equipment.

Laser automation and the new advancements in laser processing are likely to bring the production cost-per-part lower than ever before, with less set up and higher throughput.

The future of any technology depends on how that technology best serves its end user, the customer. With this thought in mind, the future of the laser technology is moving in the right direction.
Maxitec Website

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Optimized for rigidity and accuracy, TC-S2D machining center comes in 3 models with 300 kg max table load and 300, 500 or 700 mm X-axis; 360-400 mm Y-axis; and 300 mm Z-axis travels. Servo-driven tool turret, together with spindle acceleration/deceleration rates, allows one tool rotating at 10,000 rpm to be replaced in 1.6 sec with adjacent tool accelerated to same speed. Furthest tool in turret, necessitating 180° indexing, is exchanged in 2.4 sec.
Compared with 40-taper machining centres, Brother’s new 30-taper model is 40 per cent more productive and four times less polluting

The Japanese machine tool manufacturer, Brother, which specialises in building machining centres that use 30-taper spindle tooling, has unveiled a new model that takes speed of operation and power consumption to unrivalled levels of efficiency. Celebrating its 100th anniversary in 2008, Brother sold its 50,000th machine in July despite having started production as recently as 1985.

Sole UK agent, Whitehouse Machine Tools, which was present at the launch of the new TC-S2D machining centre during JIMTOF 2008 (Tokyo, 30th Oct - 4th Nov), reports on the attributes of the faster and greener Brother model. Traditionally, such machines were called tapping or drill/tap centres, but raised specification over recent years has endowed them with sufficient milling power and rigidity for them to be regarded as machining centres.

A key benefit for the TC-S2D user is the servo-driven tool turret, which together with rapid acc/dec of the spindle allows one tool rotating at 10,000 rpm to be replaced in 1.6 seconds with the adjacent tool accelerated to the same speed, compared with typically 2.9 seconds on competitors’ machines. Even the furthest tool in the turret, necessitating 180 degree indexing, is exchanged in 2.4 seconds, around one-third faster than average. Chip-to-chip times are also fast, as tool change takes place without stopping the Z-axis feed.

Tim Whitehouse, a member of the second generation management team at Whitehouse Machine Tools, points out that even on quick machining centres, automatic tool change accounts for approximately 20 per cent of overall cycle times. The TC-S2D is consequently capable of substantially raised levels of productivity.

In one test, albeit machining a component that played to the strengths of the TC-S2D, production output was 40 per cent higher than on the fastest 40-taper machining centre on the market. The cycle used nine tools and involved drilling 12 holes of 5.1 mm diameter, M6 rigid tapping of all holes, spot facing in seven locations and boring in two locations.

Other factors leading to short idle times are 50 m/min rapids in all linear axes, cutting feeds of 10 m/min in X / Y and 20 m/min in Z, and a 16,000 rpm spindle option.

As far as the environment is concerned, the TC-S2D is one of the least polluting machine tools in the world. It uses 60 per cent less electricity to produce the compressed air consumed, compared with the pre-existing Brother TC-S2C; and 70 per cent less than the best of the 30-taper competition. Power consumed by other machine functions is down by 40 per cent.

These figures translate into 15 per cent lower CO2 emission than the TC-S2C and 45 per cent less than the greenest 30-taper machine from other manufacturers.

Compared with equivalent 40-taper machines, the reduction in this greenhouse gas is fourfold. Based on annual production of 50,000 components, Brother calculates that whereas the amount of CO2 emitted by a 40-taper machine would be 6.8 tonnes, a TC-S2D produces just 1.7 tonnes, a saving equivalent to the absorptive capacity of 720 mature cedar trees.

Various other improvements have been made to the latest model, including a redesign of the machine structure using finite element analysis to improve rigidity and accuracy. Roundness of 1.1 microns can be achieved when boring a hole in aluminium, for example. There has been a significant reduction in the number of parts used in the construction of the new machine, leading to increased reliability. Swarf removal from the working area has also been improved.

Extra safety features have been introduced in terms of additional limit switches and interlocks, while at the control, access to functions is hierarchical according to the seniority of the operator. The CNC-B00 can control five axes, including the two rotational axes of a compound table. Both conversational and G-code programming are possible.

There are three TC-S2D models in the range with X-axis travels of 300, 500 or 700 mm. The smallest machine, a new version with 14 positions in the turret but no 21-tool option, was not available in the -S2C series. The Y-axis on all models is up from 360 to 400 mm compared with the TC-S2C, while the vertical Z-axis movement of the turret remains the same at 300 mm. Maximum table load has been increased from 250 to 300 kg.

On behalf of: Whitehouse Machine Tools Ltd,
Princes Drive, Crackley Industrial Estate,
Kenilworth, Warwickshire, CV8 2FD.
Tel: 01926 852725. Fax: 01926 850620.
E-mail: timw@wmtcnc.com
Web: www.wmtcnc.com
Contact: Tim Whitehouse.

Issued by: THE RIGHT IMAGE Ltd,
PO Box 42, Twickenham, TW1 1BQ.
Tel: 020 8891 0603.
E-mail: therightimage@aol.com
Contact: Chris Wright.

Contacts:

Public Relations:
The Right Image Ltd
Chris Wright
PO Box 42
Twickenham TW1 1BQ
INTL
Phone: 020-8891-0603
Send email E-mail this person

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Built on box slant bed with thermo-friendly design, Model LB3000EX SPACE TURN CNC Lathe achieves machining dimensional change over time of less than 5 µm. It features compact PREX motor, has 16.14 in. max machining diameter, and max machining length of 19.69 in. Up to 10 pairs of NC tailstock positions can be set, enabling continuous machining of workpieces with 10 different lengths without setup, along with X and Z rapid traverse rates of 984 and 1,181 ipm, respectively.

Okuma’s LB3000EX SPACE TURN CNC Lathe builds upon the high performance standards set by the successful LB series product. One of four new models offering 66 option variations, the machine provides the highest quality multi-tasking capacity for a 2-axis lathe in its class. Built on a box slant bed with a thoroughly tested thermo-friendly design, the LB3000EX is able to achieve machining dimensional change over time of less than 5µm.

Equipped with a new high-power, compact PREX motor, the LB3000EX offers super rigidity and top rotation speed, horsepower and torque. Achieve excellent accuracy and flexibility through a max machining diameter of 16.14″ and max machining length of 19.69″. Up to 10 pairs of NC tailstock positions can be set, enabling continuous machining of workpieces with 10 different lengths without setup along with X and Z rapid traverse rates of 984 and 1,181 ipm, respectively. In addition, the LB3000EX can be equipped with Milling (M) capability, a sub-spindle (W), (Y)-axis, two bed sizes (500 and 1,000 mm) and two spindle sizes, making the machine capable of fitting your diverse application requirements.

The LB3000EX features the operator-friendly THINC-OSP control - a true PC, Windows-based platform with open architecture, plug and play USB capability and 40GB of memory.

For more information, or to contact your local distributor, please visit www.okuma.com.
Company Information:
Name: Okuma America Corp.
Address: 11900 Westhall Dr.
City: Charlotte
State: NC
ZIP: 28278
Country: USA
Phone: 704-588-7000
FAX: 704-588-6503
http://www.okumaamerica.com

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December 18, 2008 - With 343 mm max turning dia and 560 mm max swing, Feeler FTC-20 suits mixed-volume, short-run operations as well as dedicated high-volume applications. It occupies 2.63 x 1.54 m footprint and offers rapid traverse rates of 24 m/min for X and Z axes, while 12-station bi-directional turret offers 0.3 sec tool indexing time. Other features include 18.5 kW Fanuc spindle motor with variable-speed drive; 4,500 rpm A2-6 spindle nose with 51 mm through hole; and Fanuc 0i-TC control panel.

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Ultimate sporting achievements are rewarded with the accolade “world-class
athlete”. For machining centers, too, it is only the outstanding results which count: they are required to produce even faster, more powerfully, more exactly and with greater cost-efficiency. The latest generation of large-scale machining centers - HEC 1000 Athletic, HEC 1250 Athletic and HEC 1600 Athletic - addresses precisely these demands.

The manufacturing of large and heavy workpieces with edge lengths of up to 3,000 mm and weights of up to 13,000 kg is now even more economical and flexible. Features of the new HEC Athletic Series are:

o Increased interference ranges (to 3,000 mm)

o Optimum work space conditions with improved traverse end positions of the workspindle (225 mm before pallet center)

o Rapid traverse rates up to 40 m/min

o Higher spindle power (up to 53 kW) and speed (up to 7,500 rpm)

o Suitable for tools up to 800 mm in length

o Optimum coolant preprocessing and swarf disposal

Flexibility and modular construction are characteristics of tool and workpiece handling, as well as the main spindle design. It is possible, for example, to choose between a horizontal main spindle with AC motor or motor spindle, an extendable NC quill and a swivelling horizontal / vertical head for 5-sided machining. This enables the machining center to be matched ideally to customer requirements.

Whether as a stand-alone machine, as a production cell with additional pallet storage, or integrated into flexible manufacturing systems, the HEC machining centers of the Athletic Series guarantee cost-efficient and highly accurate production.

The HEC 1600P is especially versatile, starting with its compact footprint (14,500 x 9,800 x 5450 mm) with optimized subassemblies in crossbed design for tailor-made solutions. X-axis travel is 2,800 mm, Y-axis is 2,000 mm and Z-axis, 2,100 mm. The interference range is up to 3,000 mm, and the extendable NC quill stroke is 500 mm. High dynamic response in the displacement axes at rapid traverse rates up to 40 m/min in the linear axes is through digital servodrives

The work spindle is powered by a 50 kW AC motor with a stepless speed range of 20..4,000 rpm. The toolholder taper is HSK-A 100 (SK 50, CAT 50). Outstanding machine accuracy of linear axes - positional deviation of <0.007 mm, repeatability of <0.004 mm and max. backlash of <0.004 mm - translates to greater precision of complex parts.

Adding to the flexibility and versatility of the HEC 1600 is an NC quill, which provides a quantum leap in machining large gearbox housings, torque support and planetary gear carriers (think aerospace and power generation: very large components.) The NC quill has the following productivity parameters: Torque, 2,150 Nm; drive output, 56 kW; speed, 4,000 rpm, with a 5 sec warm-up time; NC quill travel, 750 mm and rapid traverse, 1,000 mm/min.

The NC quill’s accuracy is largely the result of automatic temperature compensation for thermal influences and thermal stability of the quill by cooling the quill and the quill bearing with a separate cooling unit.

The HEC 1600’s NC rotary table has a clamping area of 1250 x 1600 mm, a backlash on reversal of 3°, a resolution of 0.001° and an interference range to 3,000 mm. Maximum table load is 13,000 kg and maximum workpiece height is 2,200 mm.

The HEC Athletic Series of precision machining centers offers different variants of automatic pallet changers - either a double pallet changer (standard on the HEC 1600) or triple/quadruple changers as an option. This kind of flexibility is critically important as business demands grow and parts proliferate.

The automatic tool changer (ATC) handles tools to 325 mm in diameter (340 mm with tower) and 800 mm in length. Maximum tool weight is 35 kg (50 kg with tower). Tool handling with chain magazine has 60 or 80 magazine locations for tools up to 325 mm in diameter (T-type tools up to 500 mm in diameter). Tool change: 12 sec. with a tool weighing 15 kg. An optional tower magazine has up to 240 tool locations.

The HEC 1600 offers optimum conditions for dry and wet machining. Contributing factors include extraordinarily fast swarf disposal thanks to two swarf conveyors, minimal quantity lubrication for dry machining, external coolant supply via nozzles at 120 l/min and internal supply through the spindle center at a pressure up to 60 bars. The coolant reservoir is 2,500 l. Flexible coolant preprocessing at the cutting material either with a reversible flow filter, turbo filter or fleece gravity filter. Low maintenance through grease lubrication for workspindle, ballscrew and sectional rail roller guides.

State-of-the-art process control and monitoring with Sinumerik CNC 840 D (Fanuc 31i optional) and integrated PLC. Tool life monitoring, 3D sensing probe and direct tool breakage monitoring through laser light-barrier. Tool gauging is via laser, in addition to tool speed monitoring, power and the torque monitoring and tool coding and remote diagnosis.

The HEC 1600 provides a high degree of user-friendliness through a swing-type operator panel, good accessibility at the load-unload station, a completely closed work space paneling, wave shower in the work space for workpiece cleaning and work space emissions extraction.

This new HEC Athletic Series machine also provides the potential for expansion of your fields of application through a mold kit for the tool and die industry, as well as through the existing control options, such as shaping, milling of cylinder paths and spline interpolation. Further, a highly increased degree of automation is possible through the attachment of semicircular magazines with five or six locations for workpiece pallets and linear magazines in one or several planes which facilitates the seamless expansion into flexible manufacturing systems.

For more information, contact StarragHeckert Inc., Skyport Business Park, 2379 Progress Drive, Hebron, KY 41048 USA. (859)534-5201 (v), (859) 534-5212 (f), ussales@starragheckert.com

An even faster, stronger Athletic HEC, the 1600 offers greater flexibility and optimum precision while tackling the really tough, large jobs.

StarragHeckert GmbH

StarragHeckert is a leading company in the field of production technology. We offer our customers a broad range of highly sophisticated precision milling machines, comprehensive engineering and software solutions for process optimization and a perfectly adapted range of special tools and services.

Our demanding customers come from different high-tech industries such as aviation, power generation, vehicle industry and mechanical engineering. Using state-of-the-art technology and all our expertise we will support you to produce in a more productive and efficient, a more precise and innovative manner today and in the future.

StarragHeckert includes production plants in Rorschacherberg, Switzerland (Starrag); Chemnitz, Germany (Heckert); Geneva, Switzerland (SIP) and Haddenham, UK (TTL), as well as sales and service companies in China (Beijing and Shanghai); USA (Hebron, KY, Dallas TX and Laguna Hills, CA); France, the UK and Russia.

Contacts:

General Information:
Greg Dunkley
USA
Phone: 859-534-5201
Company Information:
Name: StarragHeckert Inc.,
Address: Skyport Business Park
City: Hebron
State: KY
ZIP: 41048
Country: USA
Phone: 859-534-5201
FAX: 859-534-5212

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Cincinnati, OH - GBI Cincinnati, an industry leader in supplying machine tool technology, has built a reputation on providing customer-driven solutions to a broad array of precision turned-part challenges. Feeler FTC-20 CNC lathes are yet another step in providing these solutions ever more flexibly and are ideal for mixed volume, short run operations as well as dedicated high-volume applications.

With a maximum turning diameter of 343 mm and a maximum swing of 560 mm, the FTC-20 combines high performance turning and large machining capacity within a compact 2.63 m x 1.54 m space-saving footprint. Rapid traverse rates of 24 m/min (X- and Z-axis) mean accelerated machine cycle times and reduced non-cut time, which increases overall throughput. An automatic 12-station bi-directional slotted disc-type turret offers a fast 0.3 sec tool indexing time (1.2 sec 180° index optional) for use with L.H or R.H. OD toolholders.

A high-torque 18.5 kW Fanuc spindle motor with a variable speed drive permits full horsepower at low spindle speeds. The A2-6 spindle nose has a through hole of 51 mm and a speed range up to 4,500 RPM. The specially designed headstock eliminates heat from the spindle bearings, prolonging the life of bearings and ensuring spindle reliability.

To assure the rigidity required for heavy-duty cutting, the spindle is supported by angular contact ball bearings at the nose and a double-row of cylindrical roller bearings at the rear. The spindle cartridge is lubricated for life, and the special designed headstock eliminates the need for oil recirculation or systems to maintain spindle temperature, thus offering years of reliable performance with reduced operating and maintenance costs.

A rigid hydraulic tailstock has a quill diameter of 65 mm, a stroke of 90 mm, an MT4 center taper and a thrust of 400 kgf.

An automated lubrication system, a complete coolant system and splashguards with overlapping doors are standard.

The Fanuc 0i-TC features the latest technological advancements in a uniquely small space. The control panel includes an 8.4″ color LCD and full keyboard conveniently positioned on a swivel for ease of operation. Fanuc CNCs and associated spindle and servo drives have an exceptional reputation for reliability. For example, according to Fanuc, sub-system failures per month are nearly unheard of - 0.00495 on the CNC, 0.00099 on the servo drive and 0.00376 on the spindle drive.

Feeler software in the 0i-TC is ideal for operators with varying levels of CNC experience, as it simplifies the transition from manual programming to G code programming. As the operator’s skill level rises and/or part geometry complexity increases, the operator can easily move through various levels of part programming generation. The 0i-TC can be programmed offline or online, allowing the use of standard G code features available from Fanuc.

GBI Cincinnati is the exclusive United States distributor for Fair Friend Group’s Feeler line of machine tools. Fair Friend Group is the number one producer of CNC machine tools in Taiwan and China and one of the largest in the world, producing over 6,000 units per year.

Fair Friend Group’s Feeler division is committed to continual advancements in machine tool technology. Research and development make up one-third of the total workforce, with 4% of Feeler’s annual revenue reinvested in R&D.

Utilizing only leading edge technology, each Feeler machine is designed and analyzed using advanced Finite Element Analysis (FEA) for dynamic simulation and structural analysis. All Feeler machines are laser calibrated and inspected to JIS (Japanese Industrial Standards) to ensure the final product is of the absolute finest quality.

Feeler is committed to providing the best quality machines at the lowest possible cost. Its significant purchasing power combined with advanced, integrated manufacturing facilities enable Feeler to build machines and assemblies at lower costs and drive “global competitiveness”. Master distributor GBI in Cincinnati, Ohio provides an unparalleled degree of training, service and support for all Feeler machine tool products in the USA.

For more information, contact GBI Cincinnati, Inc, 6899 Steger Drive, Cincinnati, OH 45237. Tel: 513/841-8684. Fax: 513/841-7381. Web: www.gbicincinnati.com. E-mail: info@gbicincinnati.com

The FTC-20 Series of turning centers offers turning, boring, milling and tapping - all in one setup. The FTC-20 Series is designed to fit the needs of mid- and high-volume production, offering flexibility with consistent accuracy from the first to the last part.

Contacts:

Marketing:
Robin Bergstrom
USA
Phone: 859-689-9551

General Information:
Kevin Bevan
USA
Phone: 513-841-8684
Company Information:
Name: GBI Cincinnati, Inc.
Address: 6899 Steger Dr.
City: Cincinnati
State: OH
ZIP: 45237
Country: USA
Phone: 513-841-8684
FAX: 513-841-7326
http://www.gbicincinnati.com

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The SPC (Super Precision Center) 7120 SIP horizontal machining center (HMC)
features a compact design, highly productive tool and workpiece handling and is
ideally suited for a broad spectrum of production applications - while routinely
achieving 4µ precision and accuracy. The new SPC 7120 SIP features hand scraping of critical contact surfaces (guideways, etc.) for absolute smooth, accurate and repeatable operation and long life, as well as complete temperature control through thermo-symmetrical configuration and isolation and expansion compensation of the machine’s crucial components (main subassemblies, machine bed, table and stands).

Copyright ZF Luftfahrtechnik GmbH

The SPC 7120 SIP is equipped with a horizontal spindle and offers flexibility, the high degree of modification and far-reaching options ensure
complete customer satisfaction.

The SPC 7120 SIP’s horizontal main spindle provides the muscle for maximum cutting power. The variable AC 50 kW main drive motor delivers speeds up to 10,000 rpm (optional). During power milling C 45 steel, cutting volumes of 1,800 cm3/min are routine. Spindle taper is HSK-A 100 or ISO 50, BT 50 or CAT 50.The tools are hydraulically released and chucked via a plate spring package.

The compact, bending and torsion resistant horizontal main spindle, with four high precision bearings and low maintenance grease lubrication, guarantees high speed, quiet running and consistent accuracy. Standard features include cleaning of the spindle cone during tool changes by compressed air, blowing out the inner coolant feed line of the tools and the electronic alignment of the spindles for oriented spindle holding. Direct path measurement systems are used to measure the absolute length of all linear axes. Encapsulated and charged with compressed air, the measurement systems are safely protected against contaminants.

The SPC 1720 SIP’s travel values are 1,200 mm in X, 950 mm in Y and 1,200 mm in Z. Working feed rates are 40 m/min (X, Y and Z), while rapid traverse rates are 40 m/min in all three axes. Rapid traverse rate of the B-axis is 25 U/min. Acceleration rates are 6.5 m/sec2 in X and Y and 3.5 m/sec2 in the Z-axis. Accuracy of linear axes: positioning deviation of <0.004 mm; repeatability of <0.002 mm and maximum backlash width Umax of <0.001 mm.

Wet machining is performed with maximum coolant flow of 30 l/min. In the SPC 7120 SIP, coolant is fed through adjustable conical nozzles or through the center of the spindle and tool - max. 80 bar, programmable. Adapted to the material being machined, the coolant supply unit is equipped with a back flushing filter, a nonwoven gravity filter or vacuum rotary filter. Options include coolant temperature control, emission evacuation and fire safety devices (for machining magnesium, for example). The 750 mm wide chip conveyor arranged centrally beneath the machine bed assures maximum volume chip discharge, while providing the best conditions for dry working.

The SPC 7120 SIP’s direct drive NC rotary table and absolute angle measurement system present ideal conditions for the multi-sided machining. Feeding precision of 0.0001°, and rotational speeds of 25 rpm are standard. Automatic adjustment of acceleration of the circular axis based on workpiece mass is available as an option. The two advancing drives for workpiece pallets correspond perfectly to the requirements of the weight of heavy pallet loads and the dynamics of adjusting to movement. Workpiece pallets up to 630 x 800 mm2 can be equipped with a quick-coupling unit which handles clamping pressures up to 240 bar. Maximum pallet load is 1,500 kg.

Workpieces are loaded and unloaded on the clamping plate while machining proceeds uninterrupted. The rotary design of the clamping site, with 4 x 90° indexing, substantially facilitates work setup. A hydraulic stroke/swiveling device changes the pallets from mounting site to work site. Pallet change takes 25 sec.

The SPC 7120 SIP’s automatic tool changer (ATC) is optimally designed for reducing non-productive idle times. Tool changes between chain magazine and main spindle take 8 sec., chip-to-chip. The chain magazine has 60 (80 optional) tool pockets for tools up to 325 mm in diameter, 600 mm in length, and individual tools weigh 25 kg. With tool lengths to 600 mm, inaccurate and time-consuming reverse boring is dispensed with. For higher tool requirements, SPC 7120 SIP HMCs are equipped with tower magazines for 180, 240 and 320 tools. Tower magazines have room for tools to 600 mm in length and 325 mm in diameter.

The SPC 7120 SIP is equipped with the Sinumerik 840 D (Fanuc 31i optional) control. The CNC control in combination with integrated PLC and the digital SIMODRIVE 611 D assures highest productivity, machining accuracy and process stability.
End

For more information, contact StarragHeckert Inc., Skyport Business Park, 2379 Progress Drive, Hebron, KY 41048 USA. (859)534-5201 (v), (859) 534-5212 (f), ussales@starragheckert.com

SIP is pleased to introduce a new high precision machining center at IMTS: the Super Precision Center (SPC) 7120 SIP is a high precision CNC HMC configured for 4 axis machining. The first of its kind, the SPC 7120 SIP combines the proven production know how of StarragHeckert with unique manufacturing techniques only available from SIP Switzerland. The result is a highly productive, 4µ machine tool designed for challenging production applications.

Societe d’Instruments de Precision SA, Geneva, Switzerland

The name SIP is synonymous with the highest technical precision in manufacturing technology. Anywhere, anytime where quality and precision cannot be compromised, SIP machines are in operation.

The SIP product range features horizontal and vertical ultra-high precision machines in 3-, 4- and 5-axis models. Thus, SIP offers an optimal solution for every technical challenge for which even a 1 micron is crucial. SIP proudly enjoys leadership recognition by the aerospace industry, the precision machine industry, tool and mould manufacturing as well as the prototyping of high performance motors.

While construction attributes and special machine components certainly contribute to the extraordinary accuracy and repeatability of SIP technology, the proficiency of our Swiss staff is a rare and unique factor. All critical surfaces are hand scraped, thus ensuring a life span of perfect geometry and an investment that pays off, maintaining -and increasing - its value over decades.

StarragHeckert additionally has been for years an industry leader in the machining of titanium and nickel-based alloys, in particular Inconel, monel, nimonic and Hastealloy. In conjunction with metallurgists and metals scientists, StarragHeckert SIP has taken the lead in machinability studies of these not-so-common metals, alloys and super alloys. As a result, StarragHeckert has been selected by the government of China to be the officially preferred supplier of milling technology.

Contacts:

General Information:
Greg Dunkley
USA
Phone: 859-534-5201
Company Information:
Name: StarragHeckert Inc.,
Address: Skyport Business Park
City: Hebron
State: KY
ZIP: 41048
Country: USA
Phone: 859-534-5201
FAX: 859-534-5212

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CINCINNATI, OH - GBI Cincinnati, an industry leader in supplying machine tool technology, has built a reputation on providing customer-driven solutions to a broad array of precision turn/milled-part challenges. The new matec-30 HV/K is yet another step in providing these solutions ever more flexibly. According to Kevin Bevan, president, “These 5-axis traveling column machining centers have torque drives in the swiveling axes (swivel head and rotary table) and are ideal for very precise mold work, as well as mixed volume, short run operations.”

With an X-axis of 1,300 mm, Y-Axis of 600 mm and a Z-axis of 800 mm, the HV/K Series combines high performance milling/turning and large machining capacity within a compact 4,900 mm x 4,355 mm x 3,250 mm space-saving footprint. Table size is 1515 mm x 635 mm. Maximum table load is 1,000 kg and 5 table T slots are standard.

Rapid traverse rates of 30 m/min (48/100 m/min optional) mean accelerated machine cycle times and reduced non-cut time, which increases overall throughput. Also increasing cycle time is an automatic tool-change magazine offering a fast 3.5 sec (vertical) or 6.5 sec (horizontal) tool-to-tool index time. The tool changer holds 36 tools (up to 128 optional) with a maximum tool weight of 3 kg to 10 kg. Maximum tool diameter is 70 mm - 130 mm and length is 360 mm.

The matec-30 HV/K 5-axis machining centers include versatile high-speed linear guide ways in all axes. A high-torque 30 kW AC spindle motor with direct drive permits full horsepower at low spindle speeds. The standard 40-taper spindle delivers 12,000 RPM (42,000 RPM optional) with through-the-spindle coolant at 20 bar (70 bar optional) which helps keep the spindle cool. To assure the rigidity required for heavy-duty cutting, the machine base is manufactured from high-quality mehanite cast iron, ensuring stability for years to come.

The multi-functional machining area is the result of a fixed machine table with integrated rotary table. A 630 mm diameter CNC torque rotary table permits machining on 5 sides, with a speed range of 1,800 RPM. The swing circle of the CNC torque rotary table has a diameter of 1,000 mm. The CNC torque swivel head has a range of ± 105° for horizontal and vertical machining.

An automated lubrication system, a complete coolant system and splashguards with overlapping doors are standard. The electrical cabinet is dust-proof. All wire through-holes are protected by water-resistant fittings to prevent oil moisture from entering. This extends electronic parts service life and assures maximum dependability.

The machining area is completely enclosed with electrically locked sliding doors. Bellows with steel lamellas, chip conveyors and centralized lubrication are all standard, as are glass scales in X-, Y-, and Z-axis.

The matec-30HV/K is equipped with the Heidenhain iTNC 530 control for optimized results in turning, milling and 5-axis machining. Siemens 840 D is optional.

Utilizing only leading edge technology, each matec machine is designed and analyzed using advanced Finite Element Analysis (FEA) for dynamic simulation and structural analysis. All matec machines are laser calibrated and inspected to VDI (German Industrial Standards) to ensure the final product is of the absolute finest quality.
Matec produces a wide range of traveling column machines with X-axis up to 12 m. Using a modular design approach, machines can be customized to suit the end-user’s specific application.

Master distributor GBI in Cincinnati, Ohio is the exclusive United States distributor for the matec Maschinenbau GmbH line of machine tools and provides an unparalleled degree of training, service and support for all matec machine tool products in the USA.

For more information, contact GBI Cincinnati, Inc, 6899 Steger Drive, Cincinnati, OH 45237. Tel: 513/841-8684. Fax: 513/841-7381. Web: www.gbicincinnati.com. E-mail: info@gbicincinnati.com

According to Kevin Bevan, president, “These matec 5-axis machining centers are ideal for ultra-close tolerance precision mold work, as well as mixed volume, short run operations.”

Contacts:

Marketing:
Robin Bergstrom
USA
Phone: 859-689-9551

General Information:
Kevin Bevan
USA
Phone: 513-841-8684
Company Information:
Name: GBI Cincinnati, Inc.
Address: 6899 Steger Dr.
City: Cincinnati
State: OH
ZIP: 45237
Country: USA
Phone: 513-841-8684
FAX: 513-841-7326
http://www.gbicincinnati.com

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As part of a recent new facilities investment, NC Engineering has purchased an ESAB Suprarex SXE-P1 high-precision cutting system with plasma-arc unit, fume extraction table and Columbus software.

This is providing many benefits in terms of improved product quality, higher productivity and less rework.

NC Engineering was drawn to the advantage of modern plasma-arc that now rivals lasers in terms of quality of cut and surface finish, precision cutting and minimal dross.

It also has the advantage of lower investment costs.

Most plates processed by NC Engineering are 5m long and range in thickness from 2-30mm.

The Suprarex machine was therefore specified with a cutting capability of 32mm and a bed size of 12 x 3m, which enables a plate to be cut on one end of the machine at the same time as profiled components are being unloaded from the other end.

While the vast majority of plates are mild steel, small quantities of galvanised plates are also processed.

To minimise the risk of dust and to comply with all current legislation, NC Engineering specified a filter bed as an alternative to a more costly water table.

As part of the package, ESAB also supplied a copy of its Columbus part processing software, which works well in combination with NC Engineering’s existing 2D/3D CAD software.

The Columbus Data Manager readily imported the 5-6000 standard part files and 5-600 standard nests that NC Engineering has developed over a number of years for its products.

When remnants are being used, the auto-nesting facility within Columbus is useful for maximising material utilisation and minimising waste.

Gordon Moffitt, the assistant works manager, said: ‘The Suprarex has given us a step-change in quality and speed in comparison with the older machine.

‘The software is also significantly better in terms of managing the database of parts and nests.

‘Currently the machine is operating 12-13 hours per day and is proving to be extremely reliable and making a major contribution to our productivity.’.

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ESAB Cutting Systems’s m3 plasma-arc cutting machine can now both cut and mark material with the same plasma torch, offering higher productivity from a simple-to-use system.

Users can now carry out high-speed, low-cost standard plasma cutting, precision cutting and marking, or just thick plate cutting - all with a single PT-36 Plasma torch.

200, 300, 400 and 600A systems are available with the facility to upgrade at any time.

The m3 system consists of the Plasma power supply, PT-36 Plasma torch, m3 flow control and quick-change consumables.

The m3 system has both ‘quality’ and ‘production’ cutting modes and can produce precision cuts on material as thin as 2mm and production standard cuts on material up to 160mm without any sacrifice of quality.

The plasma-arcv system produces a consistently superior cut face with low dross and requires minimal secondary operations.

The m3 plasma-arc system is also highly suited to bevelling operations, as the PT-36 torch design has high standards of concentricity and accuracy, leading to more consistent bevel angles and part size.

The torch is also robust with heavier, thicker nozzles, cups, shields and retainers suited to demanding bevelling applications.

The m3 system is fully integrated with the Vision CNC Controller, simplifying plasma-arc setup and operation.

This also allows fully automatic process switching from cutting to marking mode.

The operator simply selects the material type and thickness and the Vision CNC automatically selects and mixes the optimal start, cut and shield gas combination.

Process parameters for most plasma-arc cutting and marking applications are preloaded in the Vision CNC and custom parameter files can be easily created as needed.

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