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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.

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Intelligent NC captures the user’s knowledge of the machine process and recognizes the appropriate machining strategies.

While these two parts are geometrically different, a machinist recognizes that they are in fact machined using the same process. The colored regions show areas that would be machined using equivalent technology. Intelligent NC captures the machining process used on the first part, and automatically applies and adapts it to the second.

As the millennium approaches, CAM software developers have started to address the complete automation of the manufacturing process. Although they’ve solved many pieces of the puzzle — from macro capture, to generative NC, to automatic NC — no one has put the whole CAM story together in one package. Actually that is, until now.

Most attempts to automate started with simple 2.5-axis programs. These early attempts all focused on machining design “features.” For a sculptured surface model, the promise of full 3-axis automation seemed hopeless, because in general, CAM software development has not kept pace with its CAD counterparts. However, the introduction of Intelligent NC has changed that. Intelligent NC holds the key to completely automating the manufacturing process by combining the modern CAM software technologies like manufacturing feature recognition (MFR), automatic NC (ANC), and knowledge-based machining (KBM) with complete knowledge of stock remaining (KSR).

Intelligent NC captures the user’s knowledge of the machining process and recognizes the appropriate machining strategies. This new process plan automatically applies and adapts to any new geometry, in order to produce safe, efficient, high quality toolpaths. Intelligent NC promises to capture the manufacturing engineer’s experience and knowledge to allow a novice machinist to apply this knowledge to new jobs — automatically.

Intelligent NC is not feature-based machining. This would restrict machining to the geometrical features the designer had used to model the part. These geometrical features have nothing to do with the optimal method in which the part should be machined. MFR, on the other hand, automatically recognizes machining features with technologically similar attributes like slope, horizon-tal/vertical areas, curvature, and bounded or unbounded volumes. Based on the way previous jobs were machined, the system will decide which machining strategy to apply. One must machine the part the way a machinist sees it, especially if the machinist needs to override or modify the automatic strategy selection. MFR will make the cutting strategy decision process automatic.

The model should not have to be a solid to take advantage of Intelligent NC. Models in the automotive industry can be solid, surfaces, or a hybrid model of the two technologies. In fact, Intelligent NC must apply to wireframe geometry or to geometry which started as a cloud of points. It shouldn’t matter if the model is created native from within the CAD module of a particular package, or if the model is brought in from another system via IGES, VDA, STEP, or SAT. In fact, the CAD data source is irrelevant.

A faster machining process
ANC will provide companies with the tools to capture an entire machining process. The benefit is that the process can then be applied to technologically similar parts, cores, cavities, or electrodes. Furthermore, a “standard” is then established, forcing all similar parts/molds to be machined according to the most efficient and beneficial method. Once a library of machining strategies is in place, NC programming becomes a “one button” process. The learning curve shortens, allowing novice programmers to machine high quality molds fast, with complete safety. This technique captures the machining intent of top programmers, thereby capturing their knowledge.

A more efficient machining process
Knowledge engines optimize toolpaths and produce efficient NC code for the shop floor. With KBM, it is possible to eliminate extra cutting time, because systems actually analyze the geometry and determine regions to be machined with a similar milling strategy. KBM introduces additional toolpath movement or eliminates unnecessary motion to provide optimal material removal with good surface finish.

A safe machining process
KSR should not only calculate the stock remaining after each toolpath, it must use this information to optimize subsequent cutter movement. Toolpaths can also be optimized to account for high speed machining (HSM) techniques. The system will be able to fully gouge-check all cutter moves against the stock remaining as well as the part.

It has taken the CAM industry 20 years to catch up to the CAD industry. The advent of new algorithms to address MFR, ANC, KBM, and KSR will make Intelligent NC a reality. Early next century, several CAM software developers will be introducing this technology. For the mold-maker, these algorithms will let standards be applied in an automatic, fast, efficient, and safe manner. The worldwide shortage of moldmakers may well be addressed in these new technologies as they promise to shorten apprenticeship training.

Capturing the engineer’s knowledge in a database will be the next technological leapfrog for which the CAD/CAM industry is already preparing.

http://www.americanmachinist.com/304/Issue/Article/False/9160/Issue

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CNC Router designed specifically for foam packaging and foam cutting applications has a standard 19in gantry clearance and a 24in Z-axis stroke - assuring maximum tool reach and clearance.

Techno is proud to announce a new CNC Router designed specifically for foam packaging and foam cutting applications.

This machine is available in three sizes (X-Y travel): 59in x 50in, 59in x 96in and 59in x 120in.

Techno’s new Foam Router comes standard with 19in gantry clearance and a Z-axis stroke of 24in assuring maximum tool reach and clearance.

Minimal floor space is required because the machine design includes a moving gantry which saves valuable shop space.

In addition, these new machines can be equipped with an automatic tool changer, vacuum table for increased part hold-down, reverse engineering probes or scanners, 4th axis rotary table, and much more.

All of Techno’s CNC Routers come with Techno’s own GCode Interface which accepts industry standard GCode from all CAD/CAM programs.

This easy to use Windows-based CNC Software features: infinite look ahead capability, production logging, toolpath editing and previewer, and free lifetime upgrades via the internet.

The best part of these new machines is the starting base price of US$23,900.

http://www.manufacturingtalk.com/news/toi/toi113.html

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Techno, Inc. CNC Routers introduces the Techno Universal Knife System, all in one universal tool that uses one main drive capable of processing multiple applications through interchangeable heads. Using a common rotary drive, the Techno Universal Knife System can change between the Oscillating Knife, Tangential Drag Knife, Spring Loaded Pen, Vinyl Drag Cutter or Creasing Wheel Kit when needed.

“Our Universal Knife System was designed to target various industries that would benefit from an interchangeable tool, says Roy Valentine, CNC Routers Sales Manager. Whether the company is a Sign or Point of Purchase manufacturer that needs to cut graphic art sheets printed on a wide format flat bed printer, HVAC manufacturer that needs to cut acoustic liners or a packaging manufacturer that needs to cut and crease corrugated cartons, this one system is the right product.”

In addition to the interchangeable heads mentioned above, the Techno Universal Knife System can be combined with the Techno Vision (digital image verification package) to provide Sign and Graphics customers a complete and easy-to-use digital finishing solution. System functions allow the operator to load material on any Techno CNC Router, select the image for routing and press “Start”. The machine will then verify the linear and rotational distortion and proceed in routing the pattern of the desired image before your eyes.

http://www.designworldonline.com/articles/5689/11/Techno–Inc–CNC-Routers-introduces-the-Techno-Universal-Knife-System.aspx

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Techno CNC Routers’ New Universal Knife System Easily Processes Multiple Applications in One Setup

New Hyde Park, NY - Techno, Inc. CNC Routers proudly introduces the Techno Universal Knife System, all in one universal tool that uses one main drive capable of processing multiple applications through interchangeable heads. Using a common rotary drive, the Techno Universal Knife System can change between the Oscillating Knife, Tangential Drag Knife, Spring Loaded Pen, Vinyl Drag Cutter or Creasing Wheel Kit when needed.

“Our Universal Knife System was designed to target various industries that would benefit from an interchangeable tool, says Roy Valentine, CNC Routers Sales Manager. Whether the company is a Sign or Point of Purchase manufacturer that needs to cut graphic art sheets printed on a wide format flat bed printer, HVAC manufacturer that needs to cut acoustic liners or a packaging manufacturer that needs to cut and crease corrugated cartons, this one system is the right product.”

In addition to the interchangeable heads mentioned above, the Techno Universal Knife System can be combined with the Techno Vision (digital image verification package) to provide Sign and Graphics customers a complete and easy-to-use digital finishing solution. System functions allow the operator to load material on any Techno CNC Router, select the image for routing and press “Start”. The machine will then verify the linear and rotational distortion and proceed in routing the pattern of the desired image before your eyes.

http://news.thomasnet.com/fullstory/575092

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LMT’s Fette division has developed a combination hobbing and deburring tool for gear cutting.
The tool enables the functions of a roughing hob, the deburring of the top and bottom flanks of each tooth and the finishing of the gear into a single operation.
Available through LMT (UK), Coventry, the multi-functional twist-free hob enables finished spur and helical gears to be completed in a single hobbing operation using a standard CNC hobbing machine with each of the cutters mounted on a single arbour.
The tool system, which was developed in conjunction with Liebherr Verzahntechnik, eliminates tooth flank ‘twisting’ or convexity error, one of the major drawbacks when hobbing helical gears that creates the need for correction and separate finishing operations.
The system also improves production lead time by combining separate operations into one as well as any requirement for special finishing tooling.
It contributes to smoother running of the gear as well as helping to reduce transmission noise.
A single arbour carries the assembly of cutters comprising the roughing hob, two chamfer/deburring cutters and the finishing hob - each separated by spacers.
This arrangement provides flexibility when specifying the productive cutters and settings for effective metal removal, enabling choice of threads, gashes, tooth design, cutter material and surface coating.
In addition, it enables the final finishing cutter to be selected to precisely meet the design profile and finishing requirement specification for the gear.
During the hobbing operation, the tooling system allows the hob head of the machine to be programmed to swivel to different angles for roughing, deburring/chamfering and finishing.
This ensures the lead and helix angles are correct for the individual hobbing cutters while still maintaining the appropriate lead angle for deburring and chamfering the roots and side edges of each flank of the gear tooth.
In developing the tool, LMT was also able to blend a gradient change into the pressure angle of the finish hob, which creates a ‘corrected’ tooth profile at the bottom of the gear tooth that is different to the top.
When the finish hob is engaged in the cut, a diagonal axis feed under CNC control compensates for and eliminates any tendency to create twist in the tooth.
As a result, especially on helical gears, by eliminating twist from the hobbing process, additional operations such as shaving to correct the convexity error are no longer required.

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WNT (UK)’s new broaching system, designed for use on CNC lathes and machining centres, is allowing users to eliminate separate broaching operations and reduce manufacturing costs.
The range includes solid carbide tools (type NPU), certain sizes of which are compatible with WNT’s existing Mini-Cut toolholders, and a range of indexable insert type tools (type NPV); with both available to cut class C11 (DIN138), Class JS9 (DIN 6885) and Class P9 (DIN 6885) grooves.
The tools are available in a variety of widths, ranging from a nominal 4 to 10mm, with special widths available to order, using the straightforward order form in the WNT (UK) catalogue supplement.
The design of the clamping mechanism for the indexable NPV-type inserts is such that it overcomes one of the key issues with existing broaching systems, namely insert breakage.
As a result, cutting data can be increased and typically, when broaching a 42CrMo4 850N/mm2 steel, the feedrate will be 7200mm/min at a 0.072mm depth of cut.
The system is designed for use on lathes, machining centres and, in particular, sliding-head lathes, where slots that would normally be produced on stand-alone machine tools can now be completed in a single set-up.
By broaching as part of an existing machine cycle, users can also provide a more cost-effective solution to their customers.
For example, economical batch quantity for the process is now one-off, allowing work to be taken on that may previously have been turned down, due to the requirement of sub-contract broaching.
The rapid availability of special-width inserts and the ease with which they can be changed allows sub-contractors to react quickly to changes to customer requirements.

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Within 10 days of installing a 14-axis Citizen M32-V CNC sliding-head turning centre, precision turned parts specialist C and M Precision completed a contract of 10,000 hydraulic connectors.
This contract involved passing around two tonnes of 11/4in steel through the machine.
‘The M32 was installed within four days in the machine shop, which involved quite a lot of work by the Citizen Machinery team due to the high specification we had ordered,’ said John Cable, managing director, C and M.
‘It was then set up for the job and from pressing the start button, it ran continuously day and night including unmanned operation through the first and every other night,’ he added.
Cable and his team had already installed two M32-V machines over the past two years following earlier purchases of smaller capacity Citizen M16 and M12s.
The decision to add the third M32 was based on new orders.
‘We had a rising order book for up to 32mm components involving complicated milling operations that we could complete in single machining cycles and for which the machine is ideal,’ said Cable.
Cable also said that his setters are very familiar with Citizen’s M-series machines and they always specify options to ensure that maximum productivity and machine utilisation can be achieved.
‘This means we are able to be very competitive, maintain delivery promises and achieve the level of quality that is very consistent due to the repeatability of the machine,’ he added.
C and M Precision’s M32-V was ordered with IEMCA bar feed, a special LNS Turbo swarf conveyor able to accept both stringy and chipped swarf, Absolent filtration, fully programmable robotic unload coupled to a parts conveyor plus the Coolblaster 2,000 lb/in2 high-pressure coolant system.
‘If you plan to run unmanned then you need confidence the machine will repeat its cycle,’ said Cable.
The hydraulic connector component required 10 tools to complete the part but it was the added flexibility of the two Y-axis cross feeds on the machine that made the job cost effective by allowing the single production cycle to drill off-centre holes in the side of the component.
As well as turning, drilling, boring, grooving and threading, each component had to be roll marked with a code number.
The Citizen M32-V is able to carry up to 80 tools, 20 of which can be driven.
It is able to cut with three tools simultaneously at the main and subspindle - a feature that can contribute to reduced cycle times.

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Machine tool company is putting more investment into re-manufactured VTL’s - having acuired more ‘carcasses’ to offer competitive CNC vertical borers to the aerospace and turbine industry

To find competitive CNC vertical borer solutions for the demands of the aerospace and turbine industry, Pennine has expanded its ‘VTL Re-Engineering’ programme with the addition of seven vertical turning lathe (VTL) carcasses for its 2006 programme.

The seven machines are, three Morando VLN-12, two Schiess DE14 and two Schiess DE18 models.

The Morando type VLN-12 machines are elevating rail, ram machines with 1200mm tables (1600mm swing) and 12 station toolchangers.

Schiess DE 14 machines are elevating rail turret machines with 1250mm tables (swing 1400mm).

The Schiess DE18 are elevating rail turret machines with 1600mm tables (swing 1800mm).

All will be supplied with new CNC controls and drive systems (Fanuc) although a particular customer requirement maybe possible.

The re-manufactured stock build programme takes sound machine carcasses, which are subsequently rebuilt, re-engineered and retrofit with the latest CNC technology.

Result is large capacity, sturdy accurate machines at a reduced cost (compared with new) having as new accuracy and performance.

These machines are then sold with full warranty John Ginley, Pennine’s managing director, explains, “Typical parts which are produced on these VTLs are large rings with complex profiles to tight tolerances from exotic materials, such as titanium and nimonic alloys.

A significant priority is placed on accuracy, machine rigidity and high torque and power at relatively low cutting feeds and speeds.

Re-manufacturing and Re-engineering a sturdy carcass machine, such as the Schiess and Morando variants, provides an excellent base to achieve these priorities.

A re-manufacturing and re-engineering programme starts with a complete assessment of the machine condition, followed by dismantling of the machine for examination, logging and a quality audit of all the major sub assemblies.

At this stage, depending on the examination results, a decision is taken on which aspects of the machine will be retained and which will be re-engineered.” Typical areas that maybe re-engineered are: * Replace the existing axis drive arrangement with the latest digital servo motors, coupled to the ballscrews through torsionally rigid couplings or timing belt drives, to improve positioning response and reduce backlash.

* Replace an existing multi-speed table drive gearbox and fixed speed motor with a 2 speed electric change unit and modern digital spindle motor.

This gives infinitely variable speeds, a better power profile, less noise, less driveline backlash and allows the use of constant surface speed control.

* Fit a table encoder to provide screw cutting and feed per rev operation.

* Replace the axis lubrication system (pump, distributors, piping, etc.) and enhance monitoring to aid precise positioning and to minimise wear.

* Replace the original hydraulic installation with a new compact system to reduce oil capacity, lower power consumption and allow greater monitoring (levels, pressures etc).

The more compact tank can often be fixed to the machine carcass, removing the need to disconnect the hydraulics when the machine is moved.

f* Fit an enhanced guarding system to meet current health and safety requirements and provide improved coolant and swarf control.

The guarding arrangement can accommodate a swarf conveyor if required.

* Replace existing wiring with new to meet CE requirements.

* Select a new CNC control to suit machine type with digital control, to provide latest features at the machine and with enhanced communication capabilities to allow connection to customer networks.

* Add direct axis measurement, particular to the X (diameter) axis, for enhanced accuracy and improved repeatability.

j* Upgrade the toolholding arrangement to incorporate modern systems, such as Sandvik’s Capto.

k* Take advantage of modern compact electrical and electronic equipment to reduce the size of the electrical panels.

Where possible these are mounted on the machine carcass to ease maintenance, reduce floor space, remove the need to disconnect the machine when moving and provide a single machine lift.

* Decide on operator station type and position to provide flexible viewing and operation available with new compact CNC controls.

Fixed or portable handwheel arrangements can be incorporated to aid machine setting.

* Consider the fitment of tool setting and/or workpiece inspection probing systems.

The same care and attention to detail is applied to the elements of the machine that are being retained.

* After a thorough cleaning of all parts, the slideways are inspected and re-ground as necessary.

PTFE-based anti-friction material is fitted to the moving elements to reduce stiction and aid positioning accuracy and repeatability and/or linear bearings replaced or refurbished to return the machine alignments to British Standards for vertical CNC borers.

* Gearboxes (eg elevating rail and retained table drive components) are stripped and all bearings and any worn gearing replaced.

* Table bearings are inspected and, if required, replaced with new.

* The table bearing and gearbox lubrication system is overhauled and, where possible, improved and then checked for correct operation.

* Tool holding systems (turrets or toolchangers) are completely overhauled.

f* Ballscrews are refurbished or, if necessary, replaced with new.

New support bearings are fitted.

* Telescopic steel slideway covers are refurbished, with the fibre bellows type being replaced with steel telescopic units.

* The machine’s moving elements are precisely aligned and adjusted using calibrated granite artifacts, and finally checked with Pennine’s Renishaw laser interferometer.

* The re-assembled machine is now rewired using appropriate wiring, conduits and drag-chains and with due regard to CE requirements.

* Sensors and solenoid valves on the machine are wired directly to the CNC’s distributed I/O, which allows a comprehensive software interface to be written to control the machine and provide the necessary safety interlocking and enhanced diagnostic support.

* In addition to cable routing meeting new CE requirements, the latest cabling, tubing and drag-chains provide a more modern appearance.

* Finally, a suitable enclosed and interlocked guarding system is designed, manufactured and fitted.

At the end of the Pennine re-manufacturing process, the machines are ready to meet the customer’s 2006 production demands.

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Among second-hand machine tools currently available from a UK company are a large Craven travelling wheel head roll grinder and a Butler CNC floor-type, high power travelling column Elgamill.

The UK-built Craven Travelling Wheel Head Roll Grinder has a swing over bed of 2000mm, and a maximum grinding diameter of 1829mm.

Its maximum grinding length is 8600mm.

The machine accepts a maximum roll weight of 75 tonne and the machine tool price is GBP 175,000 (plus VAT if applicable), ex-site.

Gribben expects keen interest in this roll grinder.

The second machine is a UK-built Butler CNC Floor type Hi-Power Elgamill (serial number 28211) a travelling column type machine with up to 7000mm of X-axis travel.

The column’s universal, 2000 rev/min Huron-type machining head has 2000mm travel (Z-axis).

The floor plates are 8400mm x 1925mm.

Gribben advises that these details are approximate.

The CNC with the machine is a Heidenhain 360 system.

The price is GBP 80,000 (plus VAT if applicable).

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