IMTS 2014: Fabricating, Laser, Additive

Take a journey through fabricating, metal forming, laser and waterjet-based machining and additive manufacturing, including displays of welding, metal treating and marking equipment that highlight in-process monitoring, multi-functional beam capabilities, as well as community collaboration on design, simulation, materials and quality to produce the most capable systems to support industrial manufacturing applications.

LARGE FORMAT, HIGH-SPEED MILLING MACHINE
In Booth N-6021, Datron Dynamics, Inc. (Milford, NH) will launch the MLCube high-speed milling machine. This is the second machine in Datron’s new “Cube” series which represents the next generation of their German-engineered, high-speed machining technology – designed for greater speed, accuracy, flexibility and industrial durability. This will be the first public demonstration of this machine in North America.

The MLCube is the big brother of the M8Cube, which will also be demonstrated this year. The main difference is that MLCube has a larger 60 in x 45 in work area, compared to 40 in x 32 in on the M8Cube. According to Robert Murphy, the vice president of the company, “Our machines excel at machining metals and engineered plastics. Because of its very large work area, the MLCube is ideal for nested or batch milling of many small parts from sheets of these materials and it can also accommodate long aluminum extrusions.” When working with sheet material, Datron has a line of vacuum tables that can be integrated into the machine configuration for quick setup and workholding during the milling process.

HSK-E 25 tool holders, available with the 1.8 kW and 3 kW spindles, offer additional precision and <1 micron run out. Added functionality like palletized work-holding and advanced probing is available for manufacturers looking to reduce set-up time and increase part quality and uniformity. The MLCube is positioned for applications requiring a large work area and high spindle speed such as defense, aerospace, electronics, energy, medical part prototyping and production.

Datron Dynamics is the North American representative of Datron AG (Mühltal, Germany), a manufacturer of innovative, high-speed machining centers. Datron Dynamics is a complete sales, service and support division with locations in Milford and Livermore, CA, that provide complete machining, workholding, tooling and automation solutions the electronics, aerospace, automotive, dental and medical device industries and more, including micro fluidics, research and development laboratories, and clean-room facilities. www.datron.com

TABLE TOP AQUEOUS PARTS WASHER
In Booth N-6476, ADF Systems, Ltd. (Humboldt, IA) will be exhibiting its new Model 8 Table Top Aqueous Parts Washer that is designed for use in maintenance operations or production work stations. For production applications, cutting fluids and chips can be quickly removed for subsequent or secondary application. For maintenance work, hard-to-remove material can be soaked by letting the solution flow over the parts. www.adfsys.com

REVOLUTIONARY WATERJET CUTTING
In Booth N-6217, Flow International Corporation (Kent, WA), the world’s leading developer and manufacturer of industrial waterjet machines for cutting and cleaning applications, will run live demonstrations of three precision Mach Series waterjet cutting systems that offer technology leadership and superior performance at every price point. The Mach 4c is designed to optimize the production environment, the Mach 3b is the world’s most popular waterjet, and the Mach 2c combines accurate part cutting with a machine tool of exceptional value. Examples of the variety of pumps designed and manufactured by Flow will also be running live.


An overview and demonstration of the Mach 4 Series with exclusive HyperPressure™ Technology and advanced Dynamic Waterjet® XD technology for faster, more accurate bevel and 3D cutting.

The exclusive roller pinion system in the Mach 4c provides fast, accurate cutting with zero backlash. The system is ergonomically designed to improve operator convenience and productivity with lighting to enhance work piece visibility, efficient abrasive removal, and easy access to material and parts with full four-sided accessibility.The Mach 4c will combine Flow’s HyperJet® pump, rated at 94,000 psi, with dual cutting heads. Each cutting head will demonstrate the patented Dynamic Waterjet® technology with Active Tolerance Control, which sets the waterjet industry standard for highly accurate cutting. Dynamic Waterjet with FlowMaster® software, specifically designed for waterjet cutting, provides manufacturers a powerful and accurate, yet easy to use cutting system.

At the show, the Mach 3b will combine an intensifier rated at 60,000 psi and Dynamic Waterjet® XD, high-precision flat stock and 3D cutting technology. The Dynamic Waterjet XD will demonstrate the newest in waterjet height sensing technology, the DynaBeam™ Laser Height Sensing System.

John Force and Robert Hight of John Force Racing will join Flow in the booth on Wednesday, September 10, for a signing. The company first partnered with John Force Racing in 2012 when the racing team added a Mach 4c to their shop for custom parts production. In over 30 years of competition, John Force Racing has won 18 NHRA Funny Car championships.

Application specialists will be on hand to answer questions and demonstrate how Flow’s waterjet technology provides fast and highly accurate cutting at every price point. www.FlowWaterjet.com

ADVANCED BRAZING AND SOLDERING
In Booth N-6433, Fusion Inc. (Willoughby, Oh) will be displaying the Rotary Index 100 a very compact machine for brazing and soldering, with dimensions of 48 in W x 48 in D. Rates are typically between 100–250 parts per hour, depending on assembly mass and configuration. Brass, copper, steel, stainless, and aluminum can all be joined on the machine.

The production sequence begins with an operator who loads the assembly into a stainless steel fixture. A deposit of Fusion Paste Filler Metal is applied to the joint area with an automatic dispenser. The assemblies then index through two or three flame heat stations and an air and water cooling sequence before unloading. The machine is also available with induction heat. The Rotary Index 100 is equipped with clear, acrylic guarding on three sides. Utilities required are 120 VAC, natural gas or propane, 80 psi air, water, and drain. www.fusion-inc.com

ROBOTIC BLAST SYSTEM WITH TOOL CHANGER
In Booth N-6066, Guyson Corporation (Saratoga Springs, NY) will demonstrate the latest tool changing technology for robotic blasting systems. Automatic selection and changing between multiple straight blast nozzles and lance nozzles, based on the blasting process recipe for each component, extends the multi-tasking capabilities of the robotic blast machine and enables unmanned operation of the surface preparation or shot peening system.

In executing the programmed blasting routine, the robotic blast system constantly maintains the correct nozzle, stand-off distance and surface speed, even as it follows the contours of complex-shaped parts, to ensure the most consistent surface treatment results. www.guyson.com

CAMERA-BASED 3D MEASURING SYSTEM FOR PLIERS FOR ROBOT GRINDING CELLS
In Booth N-6472, Heinz Berger Maschinenfabrik GmbH & Co. KG (Wuppertal, Germany) will display a robotic grinding station using Series RSP4B2L1M machines with pliers for Type BSS10 belt grinding stations. The station is equipped with a camera measuring station so that it is possible to measure the workpiece tri-dimensionally. The pliers are stored in a circulating chain magazine and can be fed to a cleaning station after the grinding process. www.heinzberger.de

WATERJETS CUT PRECISE PARTS FROM VIRTUALLY ANY MATERIAL
In Booth N-6618, Jet Edge, Inc. (St. Michael, MN), a leading manufacturer of ultra-high pressure waterjet technology, will perform live 5-axis abrasive waterjet cutting demonstrations on its premiere 90,000 psi (6,200 bar) EDGE X-5™ 5-axis waterjet with Aquavision Di control and Closed Loop Filtration System. The waterjet manufacturer will also showcase its new low-cost BOSS-CUTTER™ waterjet system, its 90,000 psi X-Stream intensifier pumps, and eco-friendly and economically priced 55,000 psi (3,800 bar) Eco-Jet direct drive pumps.

The EDGE X-5 5-axis waterjet system is designed to provide years of dependable service in harsh industrial environments. Its sturdy design separates the motion system from the catcher tank, eliminating vibration and ensuring maximum part quality. The EDGE X-5 utilizes an industrial PC controller and a ball-screw drive for optimal precision and features direct-couple AC brushless digital servo motors and single or double carriages. Critical bearing components are protected with heavy metal covers with brush seals and positive air pressure. The EDGE X-5 waterjet is available in many sizes, from 5 ft x 5 ft (1,500 mm x1,500 mm) to 24 ft x 13 ft (7,300 mm x 3,900 mm). An optional second cutting head can be added to double productivity.

The BOSS-CUTTER is available in two sizes: 40 in x 40 in (1,000 mm x 1,000 mm) or 60 in x 60 in (1,500 mm x 1,500 mm). It can be configured for both abrasive waterjet cutting and water-only cutting (abrasive is added when cutting hard materials such as metals; soft materials such as foam can typically be cut with water only). The system comes standard with a 30 hp ECO-JET direct-drive pump, but can be upgraded to any of Jet Edge’s 55,000 psi (3,800 bar) pumps. Jet Edge offers both direct-drive pumps or hydraulic intensifier pumps, available in 30 hp to 280 hp models. The BOSS-CUTTER is controlled with a Windows® PC and includes FlashCut Pro-Series Stepper Controller, FlashCutCNC software and IGEMS path generation software.


An overview and demonstration of the BOSS-CUTTER waterjet system.

The 100 hp, 90 ksi (75 kW, 6,200 bar),  X-Stream xP90-100 waterjet intensifier pump is capable of producing 90 ksi (6,200 bar) and supports 75 ksi (5,200 bar) continuous operating pressure. The X-Stream achieves much faster cutting speeds and drastically lowers operating costs compared to traditional 60 ksi (4,100 bar) water jet pumps, enabling users to increase productivity and reduce part costs. The X-Stream produces 50 percent more pressure than a 60 ksi (4,100 bar) intensifier pump, resulting in a 40 percent to 50 percent increase in productivity for many materials.

Compared to a 60 ksi (4,100 bar) pump, typical operating pressures of 75 ksi (5,200 bar) use 30 percent less water, 30 percent less power, and up to 50 percent less abrasive, resulting in a 40 percent reduction in operating costs. The xP90-100 is capable of producing flow rates of 1.45 gpm (5.49 L/m) and supports up to a .017 in (.43 mm) orifice. Fittings and tubing are rated for 100 ksi (6,900 bar). The X-Stream is backed by nearly 10 years of extensive research and development in hyper-pressure technology. The X-Stream also is available in a 50 hp (37 kW) model.

Eco-friendly and budget-friendly, the 30 hp, 55 ksi (22 kW, 3,800 bar) ECO-JET waterjet pump features an efficient direct drive pump design that consumes up to 40 percent less electricity than a 50 hp (37 kW) hydraulic intensifier pump, but produces the same output. The ECO-JET produces up to 1 gpm (3.78 L/m ) of 55 ksi (3,800 bar) ultra-high pressure (UHP) water for precision cutting, cleaning and surface preparation applications.  It runs a .015 in (.38 mm) waterjet orifice and can power most manufacturers’ waterjet cutting systems and waterjet tools.

Jet Edge offers the widest range of waterjet pumps in the industry, including hydraulic intensifier pumps and direct drive pumps, with 36 ksi (2,500 bar), 60 ksi (4,100 bar) and 90 ksi (6,200 bar) models available from 30 hp to 280 hp (22 kW to 208 kW).  Electric and diesel models are available. The Waterjet Closed Loop Filtration System eliminates the need for a drain by filtering and reusing water. A closed-loop filtration system prevents the introduction of hazardous materials into drainage systems, protects the waterjet pump, maximizes orifice life and reduces water/sewage costs.

Established in 1984, Jet Edge is celebrating its 30th anniversary in 2014 as a global designer and manufacturer of waterjet systems for precision cutting, surface preparation and coating removal. These systems are used around the world in a broad range of industries, from the world’s leading airlines to automotive, aerospace, industrial manufacturers, machine and job shops. Jet Edge waterjets are proudly made in U.S. www.jetedge.com

ADVANCED EDM AND ADDITIVE MACHINING
In Booth N-6825, MC Machinery Systems (Wood Dale, IL) will display its latest technologies in Additive Machining, Wire EDM, Sinker EDM, Press Brake, Laser and Milling through multiple demos. Particular focus will be placed on the newest MV Series machine, the MV4800 Advance, and the first metal laser sintering hybrid milling machine on the North American market, the LUMEX Avance-25.

Celebrating more than 10,000 EDM installs, Mitsubishi EDM is proud to introduce the MV4800 Advance, the latest addition to the popular MV Series EDM family. This machine’s new standout features are its cylindrical drive and its increased travel, making it ideal for larger part production. The MV4800 Advance features an extensive travel of 31.5 in x 23.6 in x 20.0 in, and can machine workpieces up to 53.1 in x 43.3 in x 20.0 in. Submerged, it can cut 20 in deep. This added size combines with cost-saving design elements to make the MV4800 Advance the best dollar-per-sq-ft EDM investment on the market.


An overview and demonstration of MV series Wire EDM technology.

The LUMEX Avance-25 metal laser sintering hybrid milling machine is one of the only machines in the world which relies on one-machine, one-process manufacturing of complex molds and parts by fusing metal laser sintering (3D SLS) technology with high-speed milling technology. The machine enables production of complicated parts through total manufacturing using digital engineering and 3D data.


An overview and demonstration of the Lumex Avance-25 Metal Laser Sintering Hybrid Milling Machine.

Mitsubishi’s superior Wire EDM, Sinker EDM, Laser, Waterjet, Press Brake, Milling, Additive Manufacturing, High-Speed VMC, EDM Drill and Consumable Products are backed by industry-leading service and support. www.mcmachinery.com

AFFORDABLE MICRO WATERJET RAISES THE BAR IN MACHINING
A next generation product line from OMAX Corporation (Kent, WA), with the best price-to-performance ratio in abrasive waterjet technology and advancements in waterjet-based micromachining, will take center stage in Booth N-6228. Visitors will experience the speed, accuracy and versatility of a range of abrasive waterjet solutions and have an opportunity to discuss their manufacturing challenges with applications experts.

Perfect for job shops, metal service centers and trade schools, the 1530 JetMachining® Center will be among the newest machines on display, representing the next generation line of MAXIEM® abrasive waterjet systems. Building upon the cost-effective, yet high-performance technology of its predecessors, these all-new models offer faster cutting speeds, more cutting power, easier control software and greater accessory options for an overall increase in productivity and profitability. At the show, the 1530 will be paired with an optional A-Jet® multi-axis cutting head to demonstrate how easy it is to cut beveled edges, angled sides and countersinks, compensate for taper and create 3D complex shapes.

Visitors to the company’s booth will also experience the fast, precise cutting performance of the 60120 JetMachining Center with a Tilt-A-Jet® cutting head accessory that achieves virtually zero taper with no reduction in cutting speed for the precision cutting of parts with square, taper-free edges, including interlocking pieces and dovetail fittings.

Also being showcased is the new generation Intelli-MAX® Software that improves ease of use and productivity on both OMAX and MAXIEM JetMachining Centers as well as the unveiling of the latest in EnduroMAX® direct-drive pump technology. With so many diverse offerings in its American-made product portfolio, OMAX offers the broadest range of table sizes, pumps, accessories and software. Moreover, this abrasive waterjet technology provides a flexible and beneficial alternative to conventional machining operations so that shops can accomplish quick turnaround of accurate parts without the need of tool changes or complex fixturing, as well as achieve smooth surface finishes without heat-affected zones, reducing the need for secondary machining.


An overview and demonstration of Intelli-MAX® Software.

OMAX designs and manufactures the world’s most advanced abrasive waterjet technology in a variety of table sizes and price points at its headquarters in Kent. Backed by unmatched support and powered by the company’s intuitive control software, OMAX and MAXIEM® JetMachining® Centers bring affordable performance to a continuously expanding range of industries. www.omax.com

HOLD, POSITION, CLAMP AND FIXTURE MATERIALS
In Booth N-6049, Strong Hand Tools® (Pico Rivera, CA), the manufacturer of innovative Strong Hand Tools® Welding Clamps, Magnets, Pliers and BuildPro™ Welding Tables, is proud to introduce the new Third Hand Modular Clamp, a fully articulated, fully adjustable Modular Clamp for holding parts at ANY position for hands-free access while you tack weld, cut, grind, sand, or paint.

The compact Third Hand Modular Clamp, with its slim profile (1−1÷2 in wide), is portable enough to be used anywhere in the shop, or carried along for work out in the field. The universal C-Clamp base (2 in opening) allows for mounting on any flat, square, or angled surface. Mount the Third Hand shaft to the C-Clamp base either vertically or horizontally for even greater options in work positioning and clamping for worker comfort, and workpiece access. Place parts, or stock, directly in the slotted Adaptor Head, or mount Pliers or Sliding Arm Clamps for holding irregular shaped, square, flat, or angled stock.

Also being introduced is the new Grinder Rest for convenient tabletop, or table edge, storage of handheld (4−1÷2 in or 5 in) grinders. The compact Grinder Rest holds the Grinder, wrench, and spare discs. A cable wrap hook allows safe storage of the Grinder electrical cord. The spare disc hook keeps discs within easy reach for quick changeouts, and helps prevent discs from getting lost or damaged. The Grinder Rest bracket has an open design that allows the Grinder to be easily placed for storage, yet retrieved quickly when needed. The four-hole wrench storage pattern accommodates a wide variety of wrenches.

The easy-to-spot brilliant yellow Grinder Rest is available in two models; choose from the strong magnetic base for placement on any flat steel surface, such as a worktable, or the universal c-clamp base for mounting on a table edge, or table leg.

Also on display is the new BuildPro Adjustable (Variable Height) Rest. This easy-to-use Rest is operated manually, by hand adjustment, with a turn of an easy-grip knurled band for complete control in precise, minute height adjustments (2 in height with ¾ in stroke. Range: 2 in to 2−3÷4 in).


A one-year review of the BuildPro welding table and Strong Hand Tools.

BuildPro V-Blocks press fit into the top cavity of the Adjustable Rests to support round pipes. The Adjustable Rests have three mounting options: (1) press fit into any hole on the BuildPro table with the standard 5/8 in post, (2) securely fasten to BuildPro accessories such as Riser Blocks or Straight Edge Stops for repetitive applications using the adaptor post with cap screw (included), or (3) “free float” the Rest for temporary usage by removing both the standard post and the adaptor post.

BuildPro V-Block Spacers also press fit into the top cavity of the Rest, adding .45 in height, and supporting flat stock or square tubes. BuildPro Modular Welding Tables feature a tabletop surface of CNC machined 5/8 in holes in a 2 in grid pattern on precision ground steel plates for fixturing at any point on the table. www.stronghandtools.com

ADVANCED LASER MARKING AND CUTTING TECHNOLOGY
In Booth N-6223, TRUMPF Inc. (Farmington, CT) will show the latest advancements in laser marking with the TruMark 1110, TruMark 5010 Mobile Marker, TruMark 5020 and TruMark 6030. The TruLaser 1030 fiber, now with an integrated laser, will provide visitors with a look at the company’s latest development in 2D laser cutting, while the TruLaser Cell 3000 will highlight 5-axis precision cutting and welding.

The TruMark 1110 diode-pumped vanadate laser forms the basis for a new, cost-effective series of entry-level marking lasers. This laser is ideal for marking metals, plastics and even leather. Its pulse-to-pulse stability facilitates perfect and fully repeatable marking while high peak pulse power and superb repetition frequencies enable the TruMark 1110 to process medium-sized batches with great reliability.

The TruMark 5010 Mobile Marker from TRUMPF is an innovative portable laser marking unit that will make its North American debut at the show. While other conventional marking processes tend to be slow and limited, the TruMark laser provides a faster and more flexible solution for laser marking large or heavy components.


An overview and demonstration of the TruMark 5000 marking station.

In addition, the TruMark 5020 fiber laser marker in a TruMark Station 5000 will be on display. This laser is known for its exceptionally high processing speeds and accelerated marking. High pulse frequencies and superior pulse-to-pulse stability make this fiber laser marker the ideal solution for metal or plastic applications where high speed and superior quality are required.

The TruMark 6030 high power laser is ideal for automotive, aerospace, and medical applications when traceability is essential. It will be shown integrated into the TruMark Station 7000 workstation with the largest and most accessible work area in the TruMark product line.

The TruLaser 1030 fiber laser 2D cutting machine provides fabricators with a cost effective, productive laser cutting system in a small footprint. Requiring half the floor space of a typical 5 ft x 10 ft machine, it was designed and is built in the U.S. Now with an integrated solid-state laser, the TruLaser 1030 fiber is more compact than ever before.

The TruLaser Cell 3000 5-axis laser machine offers precision cutting and welding and is the ideal solution for processing a wide range of applications, from one-off prototypes to high-volume production. Thanks to its solid-state laser options, available with up to 8 kW of laser power, the machine is also suitable for processing nonferrous metals.


An overview and demonstration of the TruLaser Cell 8030 compact laser system for cutting 3D parts produced by hot-stamping.

TRUMPF is a world market and technology leader in fabricating machinery and industrial lasers for flexible sheet metal processing. Products manufactured with the company’s technology can be found in almost every sector of industry. TRUMPF Inc. is the largest subsidiary of the TRUMPF Group and is dedicated to serving the U.S., Canadian and Mexican markets. www.us.trumpf.com

SIDE-LOAD ROBOTIC WELDING CELL WITH HIGH-SPEED TANDEM SWIFT ARC TRANSFER™
In Booth N-6129, ESAB Welding & Cutting Products (Florence, SC) showcases the Swift Arc SL system, a side-load robotic cell featuring a new tandem Swift Arc Transfer (SAT) MIG welding process. This robotic cell, in combination with the tandem SAT process, achieves travel speeds well beyond the limits of normal spray arc welding for high productivity automated welding.

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An overview and demonstration of the Swift Arc Transfer MIG welding process.

Enhancing the speed and productivity of the robotic cell is a new tandem SAT process that uses twin welding wires running simultaneously through the cell’s robotic torch to deliver exceptionally high deposition rates. This high-productivity MIG welding process produces flat welds with good penetration and without undercut. Its low heat input results in less deformation. Less part deformation and limited spatter minimizes post-weld labor helping lower production costs.

The SAT process uses AristoRod™ non-copper coated wires to reduce contamination of the feed system with copper particles for dependable feeding properties and a consistently stable arc at high welding currents and wire feed speeds. The Swift Arc SL is equipped with the Aristo RT robotic torch that has the highest TCP (tool center point) of any robotic torch, ensuring reliable operation.  The robotic cell also comes with a supply of the Endless Marathon Pac™, a bulk wire drum system that provides a continuous, in-line wire supply source, which virtually eliminates the need to stop for wire changes.

The Swift Arc SL is part of the Swift Arc series of pre-engineered, robotic welding cells available in four models: Swift Arc AL (angle-load), Swift Arc FL (front-load), Swift Arc SL (side-load) and Swift Arc ML (mobile learning) robot cells. Each system is an economic configuration for a complete work cell that is delivered ready-to-weld.  ESAB is a recognized leader in the welding and cutting industry for time-honored processes in welding and cutting to revolutionary technologies in mechanized cutting and automation. www.esabna.com

FLEXIBLE LASER SYSTEM FOR CUTTING, ETCHING
In Booth N-6466, Kern Laser Systems (Wadena, MN) will be exhibiting their flagship HSE Laser System that is capable of cutting and etching many materials, including woods, metals, acrylic, and more. This versatile machine can cut 10 in per second, and engrave up to 150 in per second. Each HSE laser system can be custom built based on your unique needs. This year, Kern Lasers will also have signage, graphic applications, and various other samples and videos on display. www.kernlasers.com


A demonstration of the Kern HSE 150W laser system cutting stainless steel.

MINIMUM QUANTITY LUBRICATION SYSTEM INTEGRATES WITH CNC MACHINES
In Booth N-7088, Unist, Inc. (Grand Rapids, MI) will unveil its new Quantum™ MQL system, a highly-configurable, user-friendly package designed to integrate with CNC machines and other automated equipment using discrete inputs or serial communication. The serial communication allows Quantum™ users to easily program controlled amounts of lubricant for their automated machining processes. The Quantum is built around Unist’s proven positive-displacement pumps, which provide accurate and consistent lubricant output. The pumps are available with flow sensors to monitor fluid delivery in critical applications.

Unist has been manufacturing Uni-Max MQL (minimum quantity lubrication) solutions for metal cutting since 1957. Unist MQL solutions apply a minute amount of a high-quality lubricant, such as Coolube®, directly into the cutting tool/workpiece interface, resulting in decreased fluid usage, cleaner & safer shops and floors, and improved cut quality and tool life. Other benefits include clean, dry chips for easy and more profitable recycling, the elimination of costly coolant treatment equipment and coolant disposal costs, as well as a potential 20 percent to 50 percent increase in production rates. Pairing a Unist System with a high-quality, 100 percent natural, vegetable-based Coolube™ lubricant makes for machining operations which are as friendly to the environment as they are to workers’ skin. www.unist.com

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