EASTEC 2015 (Second Tour)

EASTEC is the place that manufacturing ideas, processes and products – highlighted through exhibits, education and networking events – make an impact. With more than 500 exhibitors, complimentary conference sessions, industry keynotes and much more, this event is dedicated to keeping manufacturers in the Northeast competitive. Here are some additional reviews of selected machinery, tooling, systems and accessories that will be exhibited to help you navigate the show floor and manage your time while you’re there.

VERSATILE ABRASIVE WATERJET TECHNOLOGY
In Booth 1106, OMAX® Corporation (Kent, WA) will share real world results of advanced abrasive waterjet technology by demonstrating the speed, accuracy and versatility of their MAXIEM 1515 JetMachining® Center as it cuts a variety of materials and thicknesses. They will also highlight the power and ease of use of their Intelli-MAX® Software Suite.

The 1515 represents the all-new line of MAXIEM machines built in the United States. The MAXIEM JetMachining Center is robust and highly versatile, making it ideal for fabrication shops, metal service centers, trade schools and job shops. With cutting travels that range between 2.6 in by 2.6 in and 53.5 in by 13.5 in, MAXIEM JetMachining Centers productively cut components from a wide variety of materials, including metal, plastic, glass, ceramics, stone and composites. At the show, the 1515 will be paired with an optional A-Jet® multi-axis cutting head that adds two motion axes for complete five axis machining, makes it easy to cut beveled edges, angled sides, 3D shapes, and countersinks while compensating for taper. On display will also be the optional Rapid Water Level Control, which allows for quiet and clean submerged cutting.

MAXIEM machines are equipped with the Intelli-TRAX® linear drive system that utilizes brushless servo motors, integrated servo drives and high precision linear encoders that provide constant and continuous feedback on the actual cutting head position. In addition to increased part cutting accuracy, the advanced drive system delivers much faster and smoother motion. MAXIEM machines build on more than 20 years of direct-drive pump experience by using 50,000 psi pumps that include variable frequency drive (VFD) technology to regulate electricity input to the motor and reduce overall energy costs. The pumps deliver high nozzle horsepower, or JetPower, for more cutting power per kilowatt than intensifier-type pumps, which increases operating efficiencies. The pumps are available in 20 hp, 30 hp and 40 hp versions for MAXIEM machines, with a DualPUMP package also available that boosts the horsepower to 80.

The new all-in-one Windows® 8 controllers on the MAXIEM machines come pre-loaded with the powerful Intelli-MAX Software Suite and feature large 23 in display screens that provide easy viewing of part files and tool paths. The Intelli-MAX software makes it easy to generate complex geometries and produce quality parts from virtually any type of material. The software is extremely user friendly for both the novice operator and the skilled machinist. The software also features Intelli-VISOR®, a system monitoring for predictive machine maintenance capability.

OMAX Corporation, 21409 72nd Avenue South, Kent, WA 98032, 800-838-0343, Fax: 253-872-6190, www.omax.com.

OPERATOR SAFETY AND TOOL SECURITY
In Booth 5320, Rego-Fix Tool Corporation (Indianapolis, IN), the inventor of the original ER collet system and a world leader in the manufacture of Swiss precision tooling, will feature two of its newer precision tooling products. On display will be intRlox, a small, but mighty innovation for effective tool locking, and secuRgrip®, an anti-pullout tool holding system.

The slip-proof intRlox mini clamping nuts feature a frontal milled slot on their outside diameter that mates perfectly to a corresponding wrench to prevent slippage during the tightening or loosening process. These new clamping nuts, which are suitable for the company’s sealing or cooling disks, have a special surface treatment for increased clamping force and a unique coating that prevents corrosion. intRlox is currently available in ER 11, 16 and 20 sizes for standard versions, and ER 16 and 20 for coolant version. It offers many benefits including improved operator safety due to slip-proof clamping, internal and external cooling, improved chip removal, reduced tool costs and improved productivity.

Part of the powRgrip® product line, secuRgrip brings simple, effective tool locking to challenging metal removal applications. This anti-pull system, locks the collet and cutter to the toolholder body to eliminate cutter slippage. It does so via a patented locking system that includes a small, profiled locking key insert that fits into a standard Weldon endmill flat. powRgrip secuRgrip has a TIR of 0.0001” and enables manufacturers to preset their tool heights. REGO-FIX customers can modify their existing powRgrip holders for use with the system. The secuRgrip locking system is now also available for milling chucks.

Rego-Fix Tool Corporation, 7752 Moller Road, Indianapolis, IN 46268, 317-870-5959, Fax: 317-870-5955, www.rego-fix.com. 

TOOLING PROGRAM FOR THREADING DEMANDING TITANIUM ALLOYS
In Booth 5358, Emuge Corporation (West Boylston, MA) introduces a comprehensive line of high-performance tools for threading demanding alloyed titanium materials. Ranging from taps with unique new geometry designs to solid carbide thread mills, the new program provides solutions for the most demanding titanium challenges such as in aerospace, defense and medical machining applications. A full line of tap sizes from no. 0 to 1 in are available in UNC, UNF and from 3 x 0.5 to 24 x 3.0 in metric, 222 tools in total. For additional product details, including a comprehensive brochure, please click here.

The new Titanium Program features C-Ti and D-Ti taps with new High Relief Geometry (HRG) technology that increases space between the friction surfaces for enhanced lubrication and reduced torque load in both forward and reverse direction. HRG counteracts the high compressive forces produced by the extreme elastic memory of Titanium. An optimized flute angle and profile create tough, long chips that evacuate axially in one direction. Taps are manufactured with premium HSS-E steel for exceptional heat and wear resistance, and a modified bottoming chamfer provides reduced torque and increased tool life. With Advanced Left-Hand Helical Flute Form and chamfer geometry, C-Ti taps optimize chip evacuation in the forward direction and add strength to the cutting teeth for enhanced tool life and process security.

The D-Ti taps are available in STI thread sizes for jet engine components. Both C-Ti and D-Ti taps are available in a special NT2 coating with nitriding that provides increased edge hardness and a steam layer over the nitriding that promotes lubricity to prevent cold welding. Taps are also available with a TiCN multi-layer PVD coating for increased edge hardness and surface lubricity. “Our new HRG technology is ideal for threading tough, long chipping titaniums,” commented product director Mark Hatch of Emuge. “The optimized geometry provides extraordinary tool life, superior thread finish, and excellent guiding properties for true-to-gauge fit and significantly reduced chipped teeth or tap breakage.”

The Titanium Program also offers a variety of thread mills. THREADS-ALL Z-GF style thread mills require only eight stock standard tool sizes to produce 100+ commonly produced screw thread designations. They provide easy machining of difficult materials, one tool for through and blind holes and total control over pitch diameter limits. SHUR-THREAD GFI-IKZ thread mills with internal coolant offer an exceptional balance of performance and price with specially engineered multiple-spiral flutes to eliminate chatter, a large cutter diameter with high profile correction to ensure true-to-gauge threads and an extended milling portion which allows for 2xD length of cut. For optimal results, the company recommends that tools from the Titanium Program run on a CNC machine with a synchronous spindle utilizing a tap holder with minimal compensation, such as Softsynchro®, which features patented construction separation of the transmission of torque and axial force for the best imaginable tool life and thread surface quality.

Emuge is a wholly owned subsidiary of the 1,500+ employee German company EMUGE-Werk Richard Glimpel GmbH & Co. KG (Lauf, Germany) that has been a product technology and performance leader in their field for nearly 100 years, manufacturing an extensive line of taps, thread mills, end mills, toolholders, clamping devices and other rotary cutting tools, with over 100,000 items sold through distributors worldwide. End-user technical support is offered through a network of in-the-field engineers and in-house product specialists, all with extensive tooling and application experience. Over 10,000 types of cutting tools and accessories are stocked in the company’s U.S. and Canadian headquarters in West Boylston. The 21,000 sq ft state-of-the-art facility also serves as a technology center with a machining and tooling demonstration showroom and classroom.

Emuge Corporation, 1800 Century Drive, West Boylston, MA 01583-2121, 800-323-3013, www.emuge.com. 

CNC TOOL GRINDER WITH WHEEL/NOZZLE CHANGER
In Booth 1606, Rollomatic Inc. (Mundelein, IL), a leading machine tool manufacturer based in Le Landeron, Switzerland, is exhibiting its series of multi-axis tool grinding machines and peel grinding machines with the first EASTEC appearance of the GrindSmart 528XW 5-axis CNC tool grinding machine with wheel/nozzle changer. This machine also features a synchronous grinding spindle with a new technology that allows higher torque and better surface finishes. Also being showcased is the well-proven ShapeSmart NP5 5-axis “pinch/peel” cylindrical grinding technology that includes thread grinding and flat grinding in the same clamping. Both machines have earned remarkable market recognition since their inception.

Together with new software developments, the GrindSmart 528XW multi-axis tool grinding machine offers versatility and capability for all kinds of rotary and stationary cutting tools, such as endmills, drills, form tools, indexable inserts, taps, reamers, routers, as well as medical instruments. ShapeSmart NP5 5-axis Peel Grinding uses pinch grinding that offers the highest concentricity, even on long and thin parts. The rough and finish grinding are performed in one pass (patented) by using the peel grinding method. This innovative way to grind roughing and finishing simultaneously eliminates a separate process and reduces cycle time. Thread and flat grinding can be included in the same clamping.

Rollomatic Inc., 1295 Armour Boulevard, Mundelein, IL 60060, 866-713-6398, solutions@RollomaticUSA.com, www.RollomaticUSA.com.

MACHINE TOOL SOLUTIONS INCREASE AEROSPACE PART MANUFACTURING PRODUCTIVITY
In Booth 2012, the Sinumerik 840D sl from Siemens Industry, Inc. (Elk Grove Village, IL) offers the latest in CNC technology that increases machine tool performance and user productivity for the aerospace market. The 840D sl is a universal and flexible CNC system based upon the innovative Sinamics S120 drive platform that can be used for up to 31 axes. It is a distributed, scalable, open and inter-connecting system offering a wide range of specialized functions for milling, drilling, turning, grinding, handling and robotics technologies. It offers users innovative features that increase productivity on the manufacturing floor, especially the challenging aerospace segments of high-speed and five-axis machining.

https://youtu.be/llhnU20sz3A

For the job shop, the Sinumerik 828D numerical control is the ideal CNC solution for mid-range machine tools. It is designed to address the needs of complex milling and turning machines in the job shop segment by combining CNC, PLC, operator panel and axis control for six CNC measurement circuits into a single, robust operator panel. The 828D is capable of full graphical, high-level language command and supports ISO programming that is customary in the United States. Programming time can be further reduced for small-batch production with the use of the ShopMill and ShopTurn graphical workstep programming system, while high-level language programming can be used in conjunction with programGuide to significantly reduce programming times for large-scale serial production.

With the introduction of the Sinumerik 828D, extensive online help animations and a new type of input prompting system with moving picture sequences provide the basis for exceptional user convenience. USB, Compact Flash (CF) card and Ethernet ports enable high-speed data transfers onto storage media or integration of the control system into corporate networks.

Siemens Industry Inc., 390 Kent Avenue, Elk Grove Village, IL 60007, 847-357-0845, SiemensMTBUMarCom.industry@siemens.com , www.usa.siemens.com/cnc.

INNOVATIVE HIGH SPEED EDM TECHNOLOGY
In Brooks Associates (Norwell, MA) Booth 1206, Sodick Inc. (Schaumburg, IL) will be featuring its latest innovative technology, including the AG60L Sinker EDM, SL400Q Wire EDM and TT1-400A Electrode Machining Center. The AG60L Sinker EDM features high speed and high acceleration rigid linear motor drives, enabling an even and natural flushing condition that leads to perfect part accuracy. The AG60L can reduce EDMing time by as much as 50 percent. The menu-driven control automatically writes the NC code for the operator while inserting optimum cutting conditions. With its instantaneous responsive control and no flush technology, the AG60L makes what appears to be impossible, possible. It comes standard with a 10-year positioning accuracy guarantee.

The SL400Q raises the bar in Wire EDM technology, featuring a high quality design, rigid cast construction and a ceramic work-zone. The SL400G includes the revolutionary 10-year positioning accuracy guarantee and is rigid linear motor driven. The TT1-400A is a High Speed Electrode Machining Center that is designed and built for precision graphite and copper electrode productions; designed to achieve maximum speed and acceleration by utilizing the latest in motion control and rigid linear motor drive technology.

https://youtu.be/C5Wwfv-TZ3Q

Sodick, established in 1976, has sold over 60,000 EDMs worldwide and has had over 35,000 linear motor EDM deliveries. Their machines are used for the production of dies and molds, as well as other various applications that cannot be produced by standard machining methods. With five ISO-certified manufacturing facilities, over 3,100 employees worldwide and technical centers located in Illinois, New Jersey and California, the company offers the industry’s first 10-year positioning accuracy guarantee on all of its rigid linear motor driven EDM machines.

Sodick Inc., 1605 N. Penny Lane, Schaumburg, IL 60173, 847-310-9000, info@sodick.com, www.sodick.com.

MOBILE AND SYNCHRONIZED NC SIMULATION SOLUTION
In Booth 5859, SPRING Technologies Inc. (Cambridge, MA), a developer of software solutions that enable manufacturers to optimize their CNC machines, will highlight the latest features, benefits, and applications of company’s flagship simulation software, NCSIMUL Machine and NCSIMUL Player 9.2. Specifically, with the growing adoption of remote and mobile software accessibility, the company will demonstrate its recently introduced mobile system called WYSIWYC® (What You See Is What You Cut).

NCSIMUL Player 9.2 will be embedded on a fully rugged, mobile Panasonic Toughpad IP65 and shown how it is connected to machine tool controllers such as Fanuc CNCs. With this capability, shop floor operators and managers are able to interact remotely – in 3D and in real time using intuitive touch controls – with one or several CNC machines and their machining processes, as they execute the CNC program on the machine. 3D animations of CNC machining processes, as well as related work instruction sheets are directly accessible from the mobile application. “What WYSIWYC means to manufacturers is that we are changing the way operators interact with CNC machines and rethinking the way procedures are accomplished on the shop floor,” explains Philippe Solignac, the corporate marketing director for SPRING Technologies. “We’re offering a unique user experience, which is very attractive to Generations Y and Z, with true shop floor-dedicated mobility with the ultra-rugged Toughpad tablet PC. It’s fun, it uses touch technology, and everything is digitized, including worksheets. It’s also a very effective methodology for conducting training modules without an additional large investment.”

Solignac adds that customers are achieving at least 25 percent higher productivity by using the combined three technologies comprising WYSIWYC. He credits that because so much information about the program and process is immediately available that there are fewer errors, better decision making, smoother changeover between shifts, and easier multi-machine supervision.

Established in 1983 and based in France, Germany, China, and the U.S., SPRING Technologies collaborates with manufacturers in aerospace and defense, transportation, energy, industrial equipment and medical devices sectors worldwide to optimize their use of CNC machine tools and maximize their productivity. Their “smart” solutions are integrated, intelligent, instrumented, and based on its “NCEXPERIENCE” philosophy. Their NCSIMUL SOLUTIONS portfolio integrates the complete machining process, in real time, including cutting and tool libraries, post-processing, NC simulation, technical content publishing and DNC Monitoring.

SPRING Technologies Inc., 50 Milk Street, 16th floor, Boston MA 02109, 617-401-2197, Fax: 815-425-2197, sproisy@springplm.com, www.springplm.com.

HORIZONTAL MACHINING OF MID-RANGE STEEL, CAST IRON AND LIGHT METAL PARTS
In Booth 1830, SW North America, Inc. (Canton, MI), a leading manufacturer of precision metalworking production machines, will display the compact BA 322 twin-spindle horizontal machining center targeted for 4- or 5-axis machining of small to medium-sized steel, cast iron, and light metal workpieces. Typical examples include brake calipers, hydraulic valves, and turbocharger components including compressor wheels. The double swivel table design allows workpieces to be loaded/unloaded in cycle. The BA 322 name represents the 300 mm distance between the two spindles and two tables. It is the smallest frame size of SW’s heavy-duty machining centers.

The BA 322 is equipped with two spindles, a specially developed twin swivel trunnion, and twin or quadruple 5-axis modules to suit the actual machining requirement. Five-axis machining takes up about 50 percent of SW’s applications because today’s components are more complex and intricate in design. To ensure precise machining and a rigid framework, the BA 322 incorporates a patented SW monobloc machine bed. This stiff cube carries the 3-axis unit equipped with a maximum four spindles. The simultaneously machining of four spindles provides great efficiency and maximizes workpiece throughput. This spindle arrangement provides optimum chip flow.

The machining center was designed to be highly productive. In lieu of synthetics, SW relies on lost-wax-cast collets in high-alloyed steel, controlled by a cylinder and monitored to confirm the tool is correctly locked. A choice of three different magazine sizes, with up to 128 tools per machine, can be chosen. Tools are changed using the pick-up system. The un-tensioned chain of the magazine reaches speeds of up to 80 m/min and runs in a link rail. Retightening is not necessary. A hydraulic pack is required because SW not only offers the clamping fixtures with its components, but also provides the elements necessary to control them. Each of the two work holding units on the twin swivel trunnion of the BA 322 is controlled by up to eight hydraulic pipes and an additional five pneumatic ones, all featuring rotary distributors.

SW North America, Inc. is a wholly owned subsidiary of Schwäbische Werkzeugmaschinen GmbH (Schramberg-Waldmössingen, Germany), a designer and manufacturer of high-precision multi-spindle horizontal machining centers and manufacturing solutions for the metalworking industry. The company specializes in providing solutions for machining high volume, prismatic components utilizing their 4- and 5-axis multi-spindle technologies in the industrial, aerospace and defense, alternative energy, transportation, consumer products, and medical sectors. In addition to the main facility in Germany, the company operates two technical centers that include sales, engineering, service and spare parts. One is in Canton to serve the North American market; the other is the soon-to-open facility in Suzhou, China, that will support the Asian market.  Additionally, the company has sales offices in 15 other countries worldwide. More than 2,250 SW machines and manufacturing solutions are running successfully in multi-shift operations in 40 countries around the world.

SW North America, Inc., 40615 Koppernick Unit 2, Canton, MI 48187, 248622-9725, info@sw-machines.com/de, www.sw-machines.com/en.

VIDEO MEASURING MICROSCOPE WITH IMAGE PROCESSING
In Booth 3019, Mahr Federal Inc. (Providence, RI) will feature the MarVision MM 320, a new video measuring microscope with image processing capability. Designed for the measurement and/or dimensioning of geometric elements, the MarVision MM 320 incorporates an integrated CCD color camera with zoom lens, a 23 in touchscreen PC with keyboard and mouse, and easy to use Windows 7-based M3 software. Automatic edge detection allows even low contrast features to be measured, and a Multi Touch function provides quick and continuous variable magnification using either touchscreen or mouse.

“MarVision optical measuring instruments offer a quick and reliable solution to many different 2D measurement and inspection tasks,” said George Schuetz, the director of precision gages for Mahr Federal. “Applications range from cutting tools and precision products for manufacturing, plastics, and medical technology, to miniaturized electronic components. These extremely precise measuring instruments are designed to meet the highest quality and production requirements.” The MarVision MM 320 rests on a robust hardened granite base with a precision mounted XY table. An optical incremental measuring system assures quick and fine adjustment of the axis, and a laser pointer assists with part positioning. The CCD camera and Navitar Zoom lens with 0.7-4.5x magnification are mounted on a stable Z-column with 200 mm vertical movement. Coarse and fine height adjustment knobs are mounted on both sides for precise focusing. Illumination is provided by a quadrant LED ring top light with four individually controlled segments, and table mounted Telecentric LED transmitted light for more focused measurement of rotationally symmetric parts.

Also on display will be a broad line of MaraMeter mechanical comparative gages, which can now be configured for wireless data transmission with the addition of a MarCator 1086 or 1087 wireless digital indicator. The line includes a wide array of snap gages, bore gages, ID & OD comparators, thickness gages, fixed and adjustable bore gages, as well as depth and comparator stands. The addition of wireless digital indicators provides easy operation, a large display, powerful application features, and a built-in wireless system for simple transmission of measurements.

Visitors can also examine the extremely broad line of MarCal calipers for a wide range of outside, inside, depth, step, and compound measurements. Mahr Federal has built wireless data transmission into its family of MarCal Digital Calipers, making them available for the same price as a typical wired caliper. Using proven wireless technology, new MarCal digital calipers send data to a small i-stick receiver, resembling a common USB flash drive. MarCom software makes data acquisition even simpler: just take a measurement and transmit your measuring data directly into MS Excel or via a keyboard code into any Windows program without cumbersome cables. It’s even possible to apply the 16 EWRi wireless data collection capabilities to existing SPC applications.

In the booth will be the line of Dimensionair air gaging products for orthopedic and other non-contact applications. Air gaging is a proven, highly precise and accurate way of measuring bores and tapers often found in orthopedic implants. It is quick and easy to use, requiring little skill on the part of the operator, and is highly adaptable to measuring special features for both dimensional and geometric tolerances. Selections from the company’s broad line of surface measuring instruments will be on display, including both portable roughness measurement devices and computer based stationary surface measuring systems. Portable devices include the new PocketSurf IV; the MarSurf PS1, which measures 24 parameters; and a growing line of Application Specific surface measuring fixtures. Mahr’s stationary system line includes the MarSurf XR 1, which combines mobile surface metrology with the advantages of MarWin evaluation software, and the XCR 20 MarWin, a new generation of combined roughness and contour measurement systems.

Mahr Federal, a member of the Mahr Group, has been providing dimensional measurement solutions to fit customer application needs for over 150 years, manufacturing and marketing a wide variety of dimensional metrology equipment, from simple and easy-to-use handheld gages to technically advanced measurement systems for form, contour, surface finish and length. The company also produces custom-designed gages and a provider of calibration and contract measurement services. Mahr Federal calibration laboratories are accredited to ISO/IEC 17025:2005 NVLAP Lab Code 200605-0.

Mahr Federal Inc., 1144 Eddy Street, Providence RI 02905, 401-784-3100, Fax: 401-784-3246, information@mahr.com, www.mahr.com.

VERSATILE VERTICAL HONING SYSTEMS
In Booth 2128, Ohio Tool Works Corporation (OTW; Ashland, OH)), an innovative and trusted manufacturer of honing machines, tooling, and abrasives, has launched their newest line of honing products – the OTW VersaHone Family. Leading off the line-up, the VersaHone Vertical Honing System is designed to be their most adaptable and easy to use honing system yet, engineered to offer the most value to shops that demand quality, precision and versatility no matter how large or small their operation is. This machine is ideal for use in many industries including automotive, aerospace, hydraulic and much more.

VersaHone Verticals offer an unmatched “turn-key” package of proprietary honing technologies and advantages, including:

• Highly versatile and customizable for specific applications
• Specialized tooling and cutting fluid formulations, tailor-made to ensure straightness and surface finish
• Independent feed systems for adjusting stock removal rates between parts on multi-spindle versions
• Automated touchscreen PLC controls for easy operation in the high production environment
• Superior construction and durability of system, tooling, and abrasives
• Integrated gaging and part handling options available
• Comfortable and intuitive operation

Specifications:
ID Capacity                 .25 in – 5 in (6.35 mm – 127 mm)
OD Capacity               11 in (280 mm) – Single, 7.25 in (184 mm) – Twin
Stroke Capacity          12in (305 mm), 24 in (610 mm), 36 in (915 mm)
Spindle Drive              7.5 hp (5.6 kW), 10 hp (7.4 kW)
Spindle Speeds           Infinitely variable packages to 1,500 rpm
Reciprocation Rate     Infinitely variable 10-120 fpm (3-36.6 m/min)
Special Features         Multi-Spindle Configurations

• Custom Fixturing
• Touch Screen PLC Controls
• Multiple Tooling Options
• Vitrified & Metalbond Abrasives

Available in both single and multi-spindle configurations, this platform is capable of accommodating a wide variety of applications in its standard form but is also highly flexible in its ability to be customized to meet special requirements.

Ohio Tool Works Corporation, 1374 Enterprise Parkway, Ashland, OH 44805, 419-281-3700, Fax: 419-281-3707, sales@ohiotoolworks.com, www.ohiotoolworks.com.