VALUE ADDED: MACHINING CENTERS

FLEXIBLE HIGH PRECISION MACHINING FOR AEROSPACE, MEDICAL, DIE/MOLD WORK
Hardinge Inc. (Elmira, NY) announces the newest member of the XR-Series of five-axis family VMCs, the XR 300 5AX. The fully-integrated 5-axis vertical machining center is offered in two configurations of Precision and High-Precision to suit manufacturing requirements. This machine is positioned in the top of Bridgeport?s machining center portfolio and is ideally suited for a diverse range of applications within the aerospace, automotive, motor sport, medical, mold, and tool & die sectors.

 

The 255 mm (10 in) diameter integrated dual-axis rotary table with 150 deg tilt and 5 arc-sec accuracy enhances the machine’s flexibility and high precision machining capability. The ability to machine complex shapes, undercuts and difficult angles in a single setup reduces tooling cost and labor time, resulting in lower cost per part in addition to maintaining parts conformity throughout production runs. The machining center is equipped with a 48 tool carousel-type automatic tool changer (ATC) features random access, bidirectional indexing and 4.6 sec chip-to-chip change time.

 

The standard 33.5 hp (25 kW) 12,000 rpm directly-coupled spindle offers long life, high metal removal rates, and the ability to run at high spindle speeds for long periods of time due to the unique grease replenishment system. The optional spindle speeds of 9000 and 15,000 rpm, with the 15,000 rpm spindle in directly coupled configuration. www.hardinge.com

HIGH SPEED HARDMILLING OF 50+ HRC LARGE PARTS
Makino (Auburn Hills, MI) upgraded its V56 vertical machining center with the new V56i, designed specifically for large part, high-speed hardmilling. It provides users with tighter accuracies, sustained dynamic performance, superior surface finishes, and long hours of continuous, unattended operation.

 

?Shops can’t afford to let an operator baby-sit a machine because their machine loses accuracy,? says Bill Howard, Makino product manager. ?Our new line of vertical machining centers, including the V33i and V56i, give shops the confidence to run complex, long-running jobs in hardened materials accurately, reducing scrap, reducing overhead, and making every job more profitable.”

 

The V56i?s refined spindle provides increased stiffness and rigidity to reduce potential chatter during machining of 50+ HRc materials. An enhanced machine design reduces potential machine movement and associated thermal growth, common errors that could induce inaccuracy during long die and mold applications. These additional features help retain superior accuracy during long periods of unattended operation.

 

The V56i’s worktable is 1,050 x 550 mm with associated travels of 900 mm (X) x 550 mm (Y) x 450 mm (Z). The machine workzone will accommodate a maximum workpiece size of 1,050 mm x 720 mm x 450 mm. The V56i is equipped with the latest version of Makino?s Super Geometric Intelligence (SGI.4) control software to improve feedrates, accuracy, and reduce part cycle times by 40 percent ? or more ? compared with the prior generation of software.

 

The V56i includes a shorter spindle for a stiffer, more rigid milling platform than other vertical machining centers of its size. The decreased spindle length allows the V56i to operate ? vibration free ? through a greater range of spindle RPMs with reduced chatter, improved surface finish, and extended tool life. Additionally, an improved lubrication system design provides greater control (or elimination) of spindle thermal growth which typically occurs during long and continuous, high-speed hardmilling of die and mold applications.

 

The V56i comes standard with a 25 hp, 20,000 rpm spindle. For higher speed machining, Makino offers an optional 30,000 spindle. Spindle nose configurations are available in Cat #40, HSK 63A and 63F and HSK ? E50 to support a wide variety of tooling and applications. The machine?s strength and accuracy is due in part to its massive castings. Integral, hardened and ground, hand-scraped guideways provide outstanding geometric tolerances and extremely precise positioning and repeatability. The no-overhang, fully supported construction insures peak motion performance with no lost motion or unsupported components during motion ? which guarantees tight dynamic tolerances for hardmilling of complex, three-dimensional, sculptured surfaces.

 

The V-series high speed spindle features a patented spindle core cooling system which circulates chilled coolant through the spindle and bearing packages, dramatically reducing spindle growth. The increased lubricant flow of the V56i further minimizes thermal growth for superior accuracy and increased bearing life.

 

Overall structural temperature control has been enhanced with advanced cooling technologies such as core-cooled ball screws, lubricated ball nuts, a servo motor cooling jacket system, temperature controlled passageways. Greater temperature control through-out the machine minimizes thermal growth during cutting, providing sustainable, long-term, dynamic accuracy. www.makino.com

HIGH PERFORMANCE MACHINING FOR MOLDS, DIES, SHORT RUNS
GF AgieCharmilles’ (Lincolnshire, IL) HPM 1200HD is a high performance machining center ideal for moldmaking, diemaking and industrial short run production of high quality components. The machining center offers dynamic, three-axis milling and is equipped with a 20,000 rpm in-line spindle that delivers high metal removal rates, exceptional geometric precision and superior surface quality.

 

The HPM 1200HD is designed to meet highly demanding requirements. Constructed with a load-optimized, rigid polymer concrete machine base, the machine easily accommodates heavy Z-axis thrusts to enable unlimited high performance cutting. Additional features include corner doors that allow a clear view of the workspace, as well as high-resolution glass scales on all axes that continuously measure axis positions to ensure the highest level of positioning and cutting accuracy. Large components can also be loaded easily into the HPM 1200HD by crane or forklift.

 

GF AgieCharmilles equipped the HPM 1200HD with a 60-position integrated tool magazine that accommodates tools up to 11.8 inches in length. Users also benefit from the inclusion of the latest generation Heidenhain iTNC 530 digital control system, which offers an Ethernet connection for fast CAM data flow, free contour and parallel programming, advanced high-speed functions and an optional mobile hand wheel that brings you close to the cutting point if required. www.gfac.com/us

CLOSE TOLERANCE PRECISION DIE/MOLD WORK
GBI Cincinnati (Cincinnati, OH) has built a reputation on providing customer-driven solutions to a broad array of precision milled-part challenges. The SMS SMV-40 Series is yet another step in providing these solutions ever more flexibly.

 

According to president Kevin Bevan, ?These SMS vertical machining centers are ideal for ultra precise die/mold work, as well as mixed volume, short run operations ? or, at the other end of the production scale, dedicated high-volume applications.? With an X-axis of 1,000 mm, Y-axis of 520 mm and a Z-axis of 505 mm, the SMV-40 combines high performance milling and large machining capacity within a compact 2,800 mm x 2,185 mm x 3,000 mm space-saving footprint. Table size is 1150 mm x 520 mm. Maximum table load is 500 kg and 5 table T slots are standard.

 

Rapid traverse rates are 60 m/min in X-axis, 60 m/min in Z-axis and 30 m/min in Y-axis. Maximum acceleration of three axes is up to 1G (10 m/sec²). Ballscrews in all three axes are pre-tensioned to increase accuracy. A fast arm-type dual servo-driven automatic tool changer (ATC) changes tools in 1 sec. Tool capacity, 24 tools; maximum tool weight, 8 kg, length, 300 mm, diameter, 80 mm (150 mm with no adjacent tool).

 

The SMS vertical machining centers include versatile high-speed linear guide ways in the X- and Y-axis and box ways in the Z-axis. Positioning accuracy is 8 µm, repeatability is 4 µm and circularity is 2.7 µm. A high-torque 18.5 kW Fanuc spindle motor with direct drive permits full horsepower at low spindle speeds. The 40-taper spindle delivers 50 to 12,000 rpm with semi-ceramic bearings to minimize heat. The headstock has been specifically designed to provide superior rigidity and precision cutting, even during full-power machining in steel.

 

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 column structure is reinforced by cross ribs to upgrade torsional torque resistant capability. No counter-balance weight on Z-axis design avoids vibration of chain, avoids oscillation caused by counter-balance weight that may affect movement stability on Z-axis. Another benefit is greatly reduced vibration when performing peck-drilling operations.

 

An automated lubrication system, a complete coolant system and splashguards with overlapping doors are standard. An optional rear flushing system provides powerful chip flushing and coupled with oversized chip disposal openings, eliminates chip deposit problems. 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 Fanuc 0i-MC features the latest technological advancements in a uniquely small space. The 8.4 in color LCD and full keyboard conveniently 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. Fanuc software in the 0i-MC 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-MC can be programmed offline or online, allowing the use of standard G code features available from Fanuc.

 

GBI Cincinnati is the exclusive U.S. distributor for Fair Friend Group?s Feeler and SMS lines of machine tools. SMS (Saginaw Machine Systems) has been manufacturing machining systems and cells and systems serving the medium and high production manufacturing industries for more than 40 years. All operations are located in a 100,000 sq ft headquarters and manufacturing facility located in Saginaw, MI. 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. www.gbicincinnati.com

VMCS FOR COMPLEX AEROSPACE, MEDICAL, DEFENSE WORK
Hardinge Inc. (Elmira, NY) announces the newest members of the GX-Series of vertical machining centers as a standard product offering in North America. These machines are designed and built for a production environment. The machine can literally overlap one another to better utilize valuable floor space and to promote cell manufacturing. The unique design provides service and operator interface to only the front or back of the machines. This design allows the machines to be stacked in a line side-by-side since there is no need to access the sides of the machines. Don?t let the small footprint fool you as the GX 300 and 510 packs a powerful punch.

 

A unique feature of this machine is the spindle torque and horsepower compared to other small footprint machines. With 20 hp and 99 ft-lb of torque the GX300 and 510 is able to provide a solution for the aerospace, medical, defense, 3C, automotive and other industries, requiring high-value, complex parts from difficult to machine materials. Some of the key differentiators of these machines are: Heavy-duty linear roller guide-ways ensuring a stiff machine design. High acceleration rates of the spindles and axes required for high production.

 

Standard with swing arm ATC, required for high production. Also, this machine is designed to support single piece flow and/or automated parts handling. The machines come standard with a Fanuc I Series OiMC control. The ATC magazine capacity is 20 tools. www.hardinge.com

HORIZONTAL CONTOURING EFFICIENCIES ON LARGE MONOLITHIC AEROSPACE PARTS
MAG Industrial Automation Systems (Hebron, KY) brings the efficiencies of horizontal 5-axis contouring (no chip attendant, blow-off or re-cutting) to long aerospace parts up to 12 x 2 meters with the introduction of its new H12000 HyperMach? processing cell.

 

The largest of three new models in the HyperMach H-Series, the new H12000 allows efficient horizontal part loading on a huge 12 x 2 meter (39.4 x 6.5 ft) pallet for large-part machining of wing spars, ribs, fuselage frames and floor components, or nested part groups. Joining the original HyperMach H4000, the new models for aluminum machining offer an expanded choice of 30,000 rpm 60 kW (80 hp) or new 100 kW (134 hp) HSK63A motorized spindles, or 20,000 rpm 85 kW (115 hp) HSK100A motorized spindle. The powerful high-speed spindles deliver high metal removal rates of 8066.5 cc/min (500 in3/min) on aluminum plate or forgings. New GTi titanium models in the H-Series offer a choice of two geared, high-torque HSK100A spindles delivering 850 Nm or 1050 Nm torque at 6000 or 4800 rpm.

 

All HyperMach H-Series machines feature a full-portal, open-center design, and industry-best horizontal machining productivity. Cutting operations are totally enclosed with chip fall-through to a high-volume conveyor, avoiding chip recutting and the need for a chip blow-off attendant. Full-portal “closed-loop” construction maximizes stiffness and ensures consistent cutting performance at any position of the pallet and spindle, while eliminating thermal drift and periodic realignment between column and pallet table.

 

Scale/encoder feedback on all five axes enables extreme accuracy beyond the capabilities of other horizontal machines currently on the market today. The 4, 6 and 8-meter machine models use a fixed-column, traveling-table/pallet design, while the 12-meter model use a traveling-column, stationary-pallet receiver. All H-Series machines are cell-ready for integration in multiple-machine, pallet-pool systems using MAG CINCRON® cell modules.

 

The HyperMach H-Series uses proven elements from MAG’s advanced line of HyperMach vertical profilers, only in different orientation. MAG aerospace senior product manager, Randy Von Moll notes, ?the larger range of the new models increases the machining capacity and cost-reduction efficiencies for longer aerospace parts that would normally be processed by vertical machines.?

 

Water-cooled servomotors are utilized on all five axes of H-Series machines to eliminate thermal influence of the motors and maximize performance for high acceleration/deceleration and feedrates. The X-Axis table/pallet receiver and the Y and Z axes are capable of speeds up to 50 m/min (2000 ipm), while the spindle carrier rotates at 150 degrees/sec (25 rpm) in A and C axes powered by direct drive permanent magnet torque motors ? no gears, belts or mechanical drive elements to wear or replace. The H-series comes standard with 96-tool automatic tool changer (HSK63A), field-expandable to 190-tool capacity.

 

H-Series machines can be set up for pallet load from the right or left side with chip conveyor discharge configured in either direction, enabling best-fit to shop layout and work flow. Compact design allows a larger machining envelope with a smaller footprint than competitive machines. A centrally located operator station gives the full view of machining area, automatic tool changer, tool storage, and critical utilities/services cabinet. The operator can check, load and exchange tools without walking around to the opposite side of the machine.

 

Flat floor installation reduces cost and installation time, avoids pits and multi-step foundations, allowing easy reconfiguration of the plant layout. CINCRON Cell Automation Modules allow near-infinite material handling and cell configurations for multi-machine, pallet-pool processing and highest production efficiency. www.mag-ias.com

?LIGHTS OUT MACHINING? WITH PALLET POOL PRODUCTIVITY
The EC-400PP HMC from Haas Automation Inc. (Oxnard, CA), with its fully integrated, 6-station pallet pool, brings true ?lights out? machining capability to small- and medium-sized manufacturers and production shops.

 

Designed for high-volume production and unattended operation, the Haas EC-400PP features a 20 in x 20 in x 20 in work cube, six-station pallet pool with 400 mm pallets, 8000 rpm spindle and 1 deg pallet indexing. Other standard features for extended operation include a 70+1 tool side-mount tool changer, 1000 ipm rapids, 300 psi through-spindle coolant, 1 MB of program memory, USB connectivity, a remote jog handle and a high-volume coolant system. To remove chips from the enclosure quickly and efficiently, the EC-400PP also has an auger-fed, belt-type chip conveyor system.

 

Each of the 400 mm pallets in the EC-400PP?s 6-station pool has a load capacity up to 1000 lb (660 lb with optional full 4th axis). The pallets can be scheduled individually according to priority and sequencing requirements that allow high-priority parts to be machined first and/or staged more often. Completed pallets are returned automatically to the holding location, or can be sequenced to a protected operator station for immediate unloading and re-loading.

 

For added performance, an optional 12,000 rpm spindle powered by a 30 hp vector dual-drive system is available for the EC-400PP. Like the standard spindle, it features an inline, direct-drive system that couples the motor directly to the spindle. This results in better surface finishes, extreme thermal stability and quiet operation. On-the-fly wye-delta switching provides plenty of low-end torque and a wide constant-horsepower band. Other available options include a 1000 psi through-spindle coolant system, and a full 4th-axis rotary system for shops requiring simultaneous 4-axis motion.

 

The EC-400PP has the power to easily cut stainless steel, cast iron and high-nickel alloys, yet it provides the speed essential for aluminum alloys. The inherent benefits of horizontal spindle orientation, including cleaner cutting conditions and extended tool life, simply enhance the machine?s capabilities. And because it?s a Haas, the EC-400PP is backed by the worldwide network of Haas Factory Outlets, protecting its production power with the best service and support in the industry. www.HaasCNC.com

5-AXIS MACHINING FOR LARGE COMPLEX GEOMETRY PARTS

The MAG Cincinnati (Hebron, KY) FTV 5 vertical machining center offers high productivity, versatility and earnings capacity in 5-axis machining. Heavy-duty fixed table/traveling column design ? available in 1800 mm, 2500 mm and 3700 mm X-axis models ? performs high-output cutting of a wide range of materials from aluminum to today’s hardest metals, particularly titanium alloys.

 

Precision 5-axis/5-sided processing avoids refixturing and error-stacking, while reducing work-in-process. The high structural strength and stability of the FTV 5 machine base and fixed table accommodate loads of 6000, 8000 and 10,000 kg respectively without deformation effects on accuracy, while enabling pendulum loading to reduce load and unload time resulting in high in-cut productivity. Optional dual front load doors allow tables to be zoned with a center partition, permitting in-cycle loading to the open zone while the other is in-cut for near-continuous spindle utilization. The FTV 5 comes standard with high-performance HSK63A 27kW (35.2 hp) 18,000 rpm spindle with an HSK100 spindle optionally available.

 

Versatile machine design allows FTV 5 machines to bring 5-axis processing to everything from extremely large workpieces to multiple batch fixtured parts. The FTV 5 lowers machining time and cost for industries like aerospace, automotive, die and mold, heavy equipment and power generation that produce large, complex geometry parts. Side doors aid loading of longer parts. Massive table capacity allows the FTV 5 to produce multiples of smaller contoured parts for specialty manufacturers and job shops or to perform flexible, mixed batch machining, while 5-axis simultaneous interpolation allows simplified fixturing.

 

The contouring head provides up to ±45 deg A-axis tilt and full 360 deg C-axis rotation per second. Robust construction and high-performance design provide speed and power (swivel torque up to 1300 Nm) to contouring cuts. Brushless spindle torque motors eliminate conventional gearboxes, backlash and maintenance issues, while providing longer wear, faster rotary motion, high torque and high accuracy. Exceptional Z axis travel of 800 mm allows use of shorter tools and higher rpm, reducing vibration for better tool life and part finishes.

 

The traveling column rides on high-capacity, maintenance-free caged roller guide ways to provide all axis motion in delivering 40 m/min fast rapid and 20 m/min max feed rate with ±3/4 µm positioning accuracy. Dynamically engineered with high strength to weight, the column configuration provides high Y-axis range of 1005 mm within a compact machine footprint. The machine configuration allows the operator to reach the table with ease and access the spindle while standing at floor level.

 

Full machine enclosure provides chip and coolant containment. All mechanisms are located behind guards to prevent contamination. Angled rear way guards combine with vertical side and front walls to eliminate chip traps and channel chips and coolant to chip conveyor. The tool changer offers 21 tool capacity standard with a 42 tool option. www.mag-ias.com

HIGH PRECISION PRODUCTION OF LARGE WORKPIECES
Mazak Corporation‘s (Florence, KY) versatile FJV-35/60 II is a double-column, vertical machining center designed for the high-speed, high precision production of large workpieces. Suitable for a wide range of industries, including aerospace, construction, die and mold, and heavy machine, the versatile FJV-35/60 II accommodates up to 5,500 lbs on a 59.1 in x31.5 in work table.

 

Mazak equipped the FJV-35/60 II with a powerful 50 taper, 40 hp, 10,000-rpm integrated spindle that generates up to 433 ft-lb of torque for heavy duty cutting of large cast iron, steel and aluminum workpieces. The FJV-35/60 II is also available with an optional 40 taper, 18,000rpm high-speed spindle. The FJV-35/60 II’s machining productivity is greatly improved from the previous model. In the manufacture of an aluminum (A5052) aircraft beam, the cutting time is significantly reduced by 40 percent. Similarly, the cutting time in the manufacture of a cast iron (FC300) sprocket is reduced by 20 percent. ATC tool chip-to-chip time is also reduced from 7.5 to 5.0 sec.

 

The new machining center is available with a 5-face machining option, which utilizes a spindle automatically indexable by 90 deg, a special angle tool capable of automatic tool change (ATC) and an angle tool holder that can be indexed in four positions. FJV-35/60 II utilizes roller guides on all axes for increased rigidity and high feedrates of 1574 ipm in the X- and Y- axes and 1181 ipm in the Z-axis. The machining center’s direct drive ball screw system boosts high accuracy roundness to 5 µm with a feedrate of 22 ipm over the previous machine. The FJV-35/60 II also features a larger envelope thanks to an extended Z-axis stroke of 25.98 in, enabling the machining of workpieces up to 25.20 inches in height, as well self-cuts of fixture plate surfaces.

 

FJV-35/60 II features Mazak’s sixth-generation CNC system, Mazatrol MATRIX NEXUS for advanced conversational programming and EIA input as well. It offers a 12 in LCD color display and the familiar QWERTY keyboard. A pointing device, acting like a mouse, and USB port for downloading programs are also at the operator?s fingertips. The environmentally friendly machine also uses energy-saving functions, including an LED work light, grease lubrication and an Inverter control for each conveyor that reduces electric power consumption by 15 percent. www.mazakusa.com

WORLD?S FIRST TWIN ATC B-AXIS MULTITASKING TURN/MILL SYSTEM
Methods Machine Tools Inc. (Sudbury, MA), a leading supplier of innovative precision machine tools, has introduced the Nakamura-Tome Super NTMX Multitasking Turn/Mill machining center. The Super NTMX is the world?s first system to offer dual 24-tool ATC magazines, a unique design to simplify complex multitasking machining. Full 5-axis milling capability via a Fanuc 31iA5 Control provides high precision and accuracy for manufacturing complex contoured components, including medical, aerospace and more, in large or small volume production.

 

?With the introduction of the cost-effective Super NTMX, today?s manufacturers have a simple, high performance 5-axis multitasking solution in a system which is very easy-to-operate,? said Richard Parenteau, director of application development at Methods Machine Tools. ?In addition, it offers shops a great deal of flexibility due to its 2 ATC magazines and programming, process versatility.?

 

The design of the dual 24-tool ATC magazines, including one for the left spindle and one for the right, enables tools to be separated from a central magazine and placed on the side closer to where they will be used. If 24 tools are insufficient for one side operations or the operator wants to use the same tool for similar operations on both spindles, tools may be used from the left magazine on the right spindle or the right magazine on the left spindle. Further, the programming or process is completely up to the operator and can be easily, fully optimized.

 

The new system offers several features for simplified operations, including easy access and faster set-up via the front location of the ATC Magazines and an easy-to-operate tool spindle. Faster tool changing is provided with the ability to change the inserts without stopping the machine. Minimal programming and checking via the Fanuc control make the Super NTMX easy-to-operate. And for increased profile milling accuracy, the tool spindle gage line is very close to the center of rotation.

 

The Super NTMX includes one lower turret with a 12 station bolt-on turret with ½ index capabilities for a total of 24 available tools. The turret enables turning, drilling, boring, grooving and threading. The dual 24 tool ATC magazines offer a maximum 48 tool capacity. The system provides a left and right spindle with speeds up to 5,000 rpm at 15/10 hp, and a 6 in (150 mm) chuck and 2 in (51 mm) bar capacity. A tool spindle is featured at 10/5 hp with speeds up to 12,000 rpm. The distance between the spindles is 38.58 in (980 mm) with a maximum turning diameter of 7.67 in (195 mm) and a maximum turning length of 30.70 in (780 mm).

 

The system is offered in a 102 sq ft footprint with dimensions (W x L x H) 112.4 in (2,855 mm) x 132 in (3,353 mm) 106.2in (2,697 mm). The Super NTMX weighs 31,972 lb (14,500 kg). www.methodsmachine.com

HMC FOR MEDIUM SIZE PRECISION PARTS
Mitsui Seiki (Franklin Lakes, NJ) recently introduced the HPX-63 4-axis CNC horizontal machining center. Some of the key design criteria included in this machine include a large work size capacity featuring a swing diameter up to 1050 mm and a work height (Y-axis) up to 1050 mm. Axis stroke is 1000 mm in X-axis and 900 mm in Z-axis. The pallet size is 630 mm. The B-axis rotary table offers 12 rpm and high torque, high acceleration properties. The rapid travel rates are 32 m/min with 0.5G acceleration/deceleration. The cutting feed rate is 12 m/min.

 

This machine is made for precision work. Its castings are metallurgically configured for the utmost stiffness, its box way axis slides are hardened, ground, and hand scraped. All assembly surfaces are hand scraped and fitted. The assembly is then meticulously inspected to ensure both geometric and positioning accuracy. Positioning accuracy and repeatability is 0.001 mm.

 

The ruggedness, rigidity, and precision of the HPX-63 make it ideal for the aerospace, energy, compressor, mold and die, fixtures and tooling, automotive prototyping, and general precision machining industries. Titanium, Inconel, tool steel, stainless steels, and aluminum are among the materials the HPX-63 can cut effectively. The spindle, Mitsui?s own, automatically compensates for thermal changes and does not require a ?warm up? period. The company offers several spindle options to meet user needs for direct or gear drives and the amount of torque and rpm requirements. Mitsui Seiki also has a choice of coolant and filtration options. www.mitsuiseiki.com

5-AXIS JIG BORER FOR HIGH PRECISION DIE/MOLD WORK
Yasda Precision America Corporation (Elk Grove Village, IL) unveils a 5-axis jig borer that exceeds all precision and productivity expectations. Featuring 5-axis machining technology, the YBM-Vi40 Jig borer is capable of high precision die and mold machining of extremely hard materials in complicated shapes.

 

In a study comparing general 3-axis machining to index 5-axis machining of an R1 ball end mill for finishing, the YBM-Vi40 reduced machining time to about 1/5th. The ability to tilt the work piece with the YBM-Vi40 also reduced cutter length requirements. With the YBM-Vi40, thanks to the shorter tool length, cutting feed rates were 2000 mm/min, contrasted with 400 mm/min with a 3-axis machine, and surface roughness was Ra 0.25 µm versus Ra 0.90 µm.

 

Designed with a structure based on Yasda?s world-class YBM series, the YBM-Vi40 performs with high precision and rigidity. The integration of a rotary B/C-axis on the Y-axis of the YBM-950V provides enhanced control and minimizes weight differences in movable bodies on each axis, while setting the heavy movable bodies to a lower center of gravity. A Yasda-built highly rigid worm gear mechanism with high reduction ratio is used for the tilting B-axis. This stabilizes the machine against tremendous changes in tilting moments depending on the position and heavy cutting loads. The B-axis is supported by three roller bearings and helps control performance in reverse motion. A Direct Drive (DD) motor is used for the rotary C-axis for highly accurate positioning without mechanical backlash.

 

To ensure high accuracy during long cycle times, Yasda has equipped the YBM-Vi40 with a Thermal Distortion Stabilized System. By circulating temperature-controlled oil through the machine body and trunnion frame, thermal displacement of each axis is minimized and stable precision machining is achieved. For improved operability and workability, the distance between the YBM-Vi40 spindle and the work piece and the distance between the operator and the machining point have been decreased.

 

5-axis machining options for the YBM-Vi40 include 3+2 axes (3 axes simultaneous machining by fixing the index angles of B/C-axes) and 4+1 axes (4-axes simultaneous machining by fixing the index angle of B-axes) and all axes simultaneous machining. Specifications for the YBM-Vi40 include spindle speeds up to 24,000 rpm, rapid traverse rates of 20,000 mm/min. (X, Y, Z-axis) / 100 rpm (C-axis) / 20 rpm (B-axis), travels of 900 mm (X-axis) / 500 mm with limitations (Y-axis) / 450mm (Z-axis), and a table working surface of 400 mm diameter (200 kg load capacity). www.yasda.com

HMC DELIVERS LARGE-PART CAPABILITIES IN A SMALLER FOOTPRINT

Toyoda Machinery (Arlington Heights, IL) announces its newest horizontal machining center, the FH1000SX. This smaller version of Toyoda?s FH1250SX is designed to provide the cutting power of a boxway machine with faster feed rates. Its smaller size makes it ideal for large-part manufacturers with less available floor space.

 

The FH1000SX can handle large parts and rugged cuts with ease. The machine?s maximum work envelope measures 70.9 x 63 in, making it well-suited for high-accuracy workpieces. The FH1000SX?s 40 hp, 6,000 rpm spindle allows for demanding material removal and superior finishes. The machine?s column is designed to support the spindle?s cutting power by utilizing dual ball screws that surround the spindle housing, maintaining rigidity and accuracy, and increasing tool life and performance. The FH1000SX accommodates up to 60 tools in its magazine, with a 2.7 sec chip-to-chip tool change time.

 

Toyoda sets the standard in excellence with engineering expertise and flexible systems for material handling and automation that help you innovate and increase production? with the reliability of proven technology. www.toyoda.com