Home / IMTS 2014: Abrasive Machining, Sawing, Finishing

IMTS 2014: Abrasive Machining, Sawing, Finishing

Here are solutions for applications requiring high tolerance and precision surface finish, including grinding technology, sawing and cutoff machines and a variety of finishing systems, such as lapping, balancing, honing and polishing machines. You’ll also find advancements in abrasive size, shape or composite materials, and nano-materials for improved surface finishes in more constrictive areas.

Posted: August 1, 2014

Booth N-7200: The peeling grinding method, well proven on other types of the ShapeSmart® series from Rollomatic, provides the ability to grind tools with extreme length /diameter ratio as well as complex profiles.

Booth N-7353: The GPV-10 Cylindrical Grinder (shown) and the GAV-10 Angular Cylindrical Grinder from Shigiya are designed to grind small workpieces with precision. An innovative gate structure ensures accurate grinding by counter measuring against vibration, thermal displacement and noise. A top beam securely connects the upper portion of the two columns. The superior rigidity of these machines ensures extreme precision after a cold start, and even during post-process grinding.

Booth N-7353: Grinder speeds on the GSU-40B Universal Grinder from Shigiya can be changed steplessly on the AC servo motor within a range of 15 to 600 rpm. A user-friendly and flexible interactive programming system automatically determines the optimal rotational speed for each workpiece.

Booth N-7163: The new diamond impregnated composite hub wheel brushes from Brush Research Manufacturing are ideal for producing edge radii on hard materials including diamond, CBN, Ceramic and Glass. They are ideal for polishing the flute relief on carbide and high speed steel drills, end mills and reamers and producing an edge radius on carbide inserts. A polished flute relief on end mills and reamers greatly enhances chip removal and promotes better finishes and longer tool life. An edge radius on carbide inserts prevents fracturing and premature insert wear.

Booth N-6800: The new Mägerle MFP 100 flexible grinding center from United Grinding is available as a 5-axis or 6-axis system and stands out for its high working speed and expandable tool changer system that can hold up to 60 tools. Among the industry’s most precise and versatile surface and profile machines, the MFP 100 can grind, mill and drill heavy, complex parts in a single clamping.

Booth N-7200: The GrindSmart 628XW® with SmartChanger® from Rollomatic has a 6-station wheel changer with HSK50E arbors, tested for repetitive concentricity of less than two microns, and a 20 hp synchronous direct-drive grinding spindle that offers constant rpm with no chatter marks in flutes, as opposed to conventional asynchronous motors. (first view)

Booth N-7200: The SmartChanger® on the GrindSmart 628XW® from Rollomatic changes wheel packs during automatic tool change without losing cycle time.

Booth N-7200: The ShapeSmart® NP3 single-wheel cylindrical grinder from Rollomatic is particularly suited as a versatile peel grinder for manufacturing blanks for the cutting tool industry, precision punches and other similar parts. (first view)

Booth N-7200: The modified GrindSmart 528XW® with SmartChanger® from Rollomatic performs fluting with a Tyrolit D54 XP-P grinding wheel and a razor-sharp cutting edge with the polish wheel to achieve feed rates of 80 mm/min first pass, 160 mm/min second pass, and a cutting speed of 18 m/s. (first view)

Booth N-6563: Bluco specializes in modular fixturing for machining, welding, inspection and assembly.

Booth N-6740: The lifehone from Gehring is alternatively equipped with a six- or eight-sided inner column so that an operator can fix up to seven honing spindles to insure short cycle times and multistep processes.

Booth N-6740: The innovative powertrainhone from Gehring uses a modular design system comprised of standardized functional components that can be combined with tailor-made honing centers in a groundbreaking configuration that enables new freedom and flexibility in production when compared to modern hone systems with a conventional layout.

Booth N-7472: The new Band Saw Blade Simulator Program from Simonds will significantly improve the performance, productivity and ROI of a shop’s sawing operation and turn the conventional method of specifying band saw blades by catalog selection upside down.

Booth E-5510: The PLC-controlled SV-20 from Sunnen utilizes a color touch screen, with a toggle switch to jog for fast setup. The swiveling operator panel can be adjusted for viewing from a variety of positions. A hand wheel on the machine allows left/right positioning of the column on its 760 mm (30 in) X-axis. The machine comes standard with a 208 L (55 gal) internal coolant system equipped with two standard canister filters. The rotary servo tool feed system can be used with two-stage hone heads to complete roughing and finishing without stone changes for faster processing times.

Booth E-5510: PG Bore Gages from Sunnen can be used to examine the entire bore for diameter, taper, barrel, bell mouth, out-of-round and lobing. A sliding faceplate with adjustable stops permits end-to-end examination of bores. Stops can be set to allow examination of a particular section of the bore, with accuracy right up to the edge of ports, lands and ends.

Booth N-6748: Ceramic grain Burr-Rx brushes from Weiler are especially well-suited for deburring tough materials such as Inconel, stainless steel, and titanium, but with an assortment of filament configurations and product fill densities, there is a high performance tool available for use on practically any material.

Booth N-7358: The Bunting Magslide is fitted with powerful magnets that reliably move ferrous parts and material in the manufacturing environment.

Booth N-7358: Bunting Magnetic Lifters make moving heavy metal items on the factory floor safe, simple, and quick.

Booth N-7429: The OMP KR3 Fully Automatic Circular Miter Saw from Pat Mooney can replace up to three band saw machines in high production shops, retaining amazing speed and burr-free cut quality. Its upcut design provides a large cutting capacity of 8.5 in and the ability to cut angles in the automatic cycle from 75 deg to the left to 60 deg from the right. The miter function is fully automatic and allows for multiple different angle cuts to be programmed within the same job. (first view)

Rollomatic will also launch their new ShapeSmart® NP3 peel grinding machine, a single-wheel cylindrical grinder with peel and traverse-grinding capabilities. This machine tool is the best choice for competitive grinding houses to produce the highest quality round products with total cost efficiency. The rigid design of this machine is equipped with a powerful 8.5 kW spindle motor and a wheel diameter of 250 mm (10 in) that allows grinding of parts requiring high material removal. Other features include:

Standard integrated 3-axis pick-and-place parts loader
Renishaw probe as on option to touch on the end of finished cutting tools
Neck grinding of finished cutting tools such as long-reach necked molding endmills
Form grinding of cutting tools blanks for the industrial, medical and dental market

The company will also display a 5-axis CNC tool grinder for large endmills/drills that enables shops to achieve sustained competitive advantage. Using larger hp and higher rigidity of the machine base, the modified GrindSmart 528XW® with SmartChanger® is ideal for increased feedrates, higher productivity and these features:

Carbide 4-flute end mill cycle time of 11 min
Diameter 20 mm (3/4 in) with 27 mm (1.1/8 in) cutting length
Sticking of wheel each five pieces; spindle load between 27 percent and 34 percent
6-station wheel changer with HSK50E arbors, tested for repetitive concentricity of less than two microns
20 hp “synchronous” direct-drive grinding spindles offer constant rpm, no chatter marks in flutes (as opposed to conventional “asynchronous” motors), and a super-sharp cutting edge
Enlarged coolant supply 30 gpm
SmartChanger® changes wheel packs during automatic tool change without losing cycle time

Rollomatic provides outstanding service and support from their North American headquarters in Mundelein and another office in California. www.rollomaticusa.com

FOAM-FREE HIGH-PRESSURE METALWORKING FLUIDS
In Booth N-7227, QualiChem (Salem, VA) will feature their premium cutting and grinding fluids for high-pressure applications. Their XTREME series of premium metalworking fluids have been formulated to overcome the problems that often occur with high-pressure fluid delivery systems. These fluids are designed to:

Eliminate foaming
Minimize downtime and maximize productivity
Improve surface finish and overall part quality
Extend tool life
Reduce coolant usage by 25-60 percent

“Our XTREME series of premium metalworking fluids are designed to help users get the most out of their cutting and grinding processes with high-pressure coolants,” said Mike Forest, the director of metalworking. “We are seeing significant increases in the occurrences of foam as a result of more machine tools taking advantage of the benefits of high pressure. Metalworking fluids that foam reduce the efficiency of the machining process as well as increase operating cost due to machine downtime, increased coolant usage and decreased tool life. We see numerous incidents of high-speed automated machines working at a fraction of their design capacity because their metalworking fluid foams at high pressure. The technology advances in our XTREME series of metalworking fluids result in low to no foam in all high-pressure applications, whether it’s ChipBlaster, MP Systems, CoolJet or other high-pressure equipment manufacturers. That’s why we’re putting a special focus on our high-pressure metalworking fluids at IMTS 2014.”

“We have numerous case studies documenting measurable cost savings and productivity gains from switching high-pressure machines to our fluids,” added Forest. “For instance, in one field test, our XTREME CUT 292 was found to double tool life, reduce coolant usage by 77 percent, cut downtime for tool changes by over 50 percent and eliminate foaming, staining and residue, when compared to another popular brand of water-based cutting fluid.” To get the most out of a machine tool investment, QualiChem invites visitors to come to their booth at IMTS and let their experts show them why “The Fluid Matters.” The company manufactures a complete line of metalworking fluids, including cleaners and rust preventatives. www.qualichem.com

MODULAR FIXTURING FOR MACHINING, WELDING, INSPECTION AND ASSEMBLY
In Booth N-6563, Bluco Corporation (Aurora, IL) displays 24 years of expertise in specialized modular fixturing for machining, welding, inspection and assembly. Whether you have a specific program that needs tooling, or want to discover the newest fixturing technologies to make improvements to your manufacturing capabilities, visitors to the booth can learn how modular tooling can benefit your company. Hands-on tooling displays will be available and application engineers will be on-site to discuss your customized application. www.bluco.com

http://youtu.be/uaFnijKRbhc
An overview of Bluco Corporation’s Modular Fixturing for Welding.

MODULAR HONING SOLUTIONS
Small bore diameters often place different demands on production technology than large ones. In Booth N-6740, Gehring LP / Gehring Honing Technologies (Farmington Hills, MI) invites manufacturers to discuss production honing solutions for the automotive and commercial vehicle, aerospace and defense, oilfield, job shop and other metalworking industries and examine its new line of modular honing machine tools for precision metal components.

Being showcased on display is the new lifehone machine with inner column construction that combines modern design with optimized accessibility. The rotary table is placed around the inner column for quick access to the process stations, a good overview and a quick and easy changeover. Pre- and post-gauging stations are fixed on the opposite side to optimize the interior space. The compact design requires a low amount of space. The Operator Panel can be led around the machine so it is easily visible from any location, ensuring optimum flexibility and ease of use. All lifehone machines are characterized by ease of use and high performance. The lifehone can be constructed as a multi-spindle transfer solution for mass production, or as a single-spindle design for small production batches.

Gehring will also present its entire portfolio of honing technologies and services, from position and form honing, laser structuring to contract honing, along with displays of tooling and abrasives, as well as a technical presentation titled “Honing of a Thermal Coated Cylinder Bores” on Tuesday, September 9 at 11:00 am by Gerhard Flores at the IMTS technical conference. www.gehring.de

WORLD’S FIRST BAND SAW SIMULATOR
In Booth N-7472, Simonds International (Fitchburg, MA) will be introducing and demonstrating the world’s first Band Saw Blade Simulator Program. The Simulator enables a user to model their sawing application and compare the results obtained with conventional saw technology to unique blade / tooth configurations designed specifically by Simonds/WESPA for the user’s application. This is accomplished via a formula referred to as IPC (Individual Performance Cutting).

Simonds will also be showcasing a variety of specialized carbide and bi-metal band saw blade technologies, all which feature the reliability and innovation that define Simonds/WESPA quality, The Professionals’ Edge.™ “Our new Saw Simulator Program is an excellent solution for the increasingly growing demand for customized cutting to optimize production efficiency. This will undoubtedly offer the user the most compelling, productive and profitable sawing solution for their specific application,” said David Miles, the vice president of sales and marketing at Simonds International.www.simondsint.com

LARGE-PART HONING MACHINE FOR JOB SHOP VOLUME
In Booth E-5510, the new SV-20 honing system from Sunnen Products Company (St. Louis, MO) is the first competitively priced large-part machine for job shop part production with a true linear, vertical, servo-stroking system to produce precision bore geometries on compressors, oilfield components, automotive/truck blocks and similar parts.