CNC Machines Repair

CNC Machines Being Used In Industrial Settings

2008-08-22T02:42:00.002-07:00

In various industrial settings and woodworking shops CNC machines are used. For personal use nearly all are out of the price range. But it can be purchased second-hand for about half the cost. When doing large jobs or repetitive tasks these machines are just perfect in case of speed and accuracy.

Usability

In various industrial settings, manufacturing processes and woodworking shops CNC equipment is used. To drill holes CNC routers are used. A number of machines have the capacity of holding several apparatus. Thus at a time they make more than one function and save time and offer accurateness.

Computer Numerated Control is the full name of CNC. In the 1970s this technology was introduced. Before operation the machines require to be programmed and arranged appropriately. When the primary set up is finished, they are quite easy to activate and go on operation.

CNC routers can be arranged to drill holes in an automatic manner. In comparison to manual drilling this is faster and more perfect over a number of pieces and the outcome is more consistent. For larger jobs this technique is very helpful where a lot of drilling is required. Physical drilling can become exhausting and when the machinist becomes tired, the outcome can become conflicting.

Various types

For cutting wood a CNC lathe is an excellent piece of apparatus. Different ranges from 15 to 40 horsepower of different models can be found in the market. You will use the amount of power according to the amount of wood you will be using with the lathe machine. Top quality models operate in several different modes, from entirely manual to all CNC lathe and lets you tailor the machine's operations for every function.

In milling technology a Bridgeport mill is the top. In many industries both large and small shops, mills are used. These are proficient and dependable. They are built to last a life span though they are very costly. It is so out of range that most people cannot afford a milling machine.

In milling technology the CNC mill is a specialty piece of apparatus. To provide accurate function it uses computer programming and robotics and the results are more perfect than any individual could ever do. Thus, Bridgeport mills are often used in the airline engineering. Once you enter the specs, it's up to the CNC to decide the particular tools that will be needed and it will also change the tools automatically when needed.

If you want a better option, you should look for renovated apparatus. Machines that are inspected at the factory, replaced if any part is broken. The machine is also painted and new decals are even applied in many cases. Thus you can get a new machine in a much low-cost. Also you may get a one year warranty with repaired apparatus which will make you sure that it is functioning accurately and if not, you will have it fixed at no cost.

Greg Hansward's long articles are published on a variety of websites related to woodworking tools and cnc machinery. His writings on cnc machines and tools are found on http://www.insidewoodworking.com

Article Source: http://EzineArticles.com/?expert=Greg_K._Hansward

CNC Equipment Buying Guide

2008-08-22T02:42:00.001-07:00

CNC machines have revolutionized the entire manufacturing industry, no longer do you have to spend ages setting up a machine. A computer is able to control it for you. These CNC machines are often too expensive for private use, however it is possible to buy smaller machines at a fraction of the cost.

How do CNC Machines Work

CNC machines are used in a number of industrial applications, from metal fabrication businesses to woodwork workshops. CNC routers can be used in order to drill accurate holes. Some CNC machines are capable of a number of different tasks as they can use different tools. These save a lot of time and are also very accurate.

CNC actually means Computer Numerated Control. This was developed in the 70's. Before use the machines must be programmed, however once it's set up it can continue doing the same job all day long. The back stops and guides will continually adjust themselves to each operation, this means you do not need to continually adjust the machine for each stage.

CNC routers can be programmed using a computer program to drill holes in specific locations without anybody having to do anything other than supervise the machine. You need someone to set up the machine, however after that you only need someone to push buttons! These machines are great for jobs that are normally labor intensive or require accuracy.

Types of CNC Machines

CNC is a type of technology which is available in a number of different machines. It is for example available in a lathe. This is very useful when cutting wood. Most of these lathes will be able to operate in a number of different modes, from manual to CNC. This allows you to use the one machine in different ways.

The best mills are thought to be Bridgeport machines. Many industries require mills, from small shops to large businesses. Bridgeport mills are very reliable and should last for a very long time. These mills are however very expensive, and are out of most people's reach!

CNC mills are specialist equipment, they use robotics alongside computer programming in order to get accurate results. These are more accurate than a mere mortal could ever hope to achieve! Bridgeport mills are commonly used to manufacture parts for the airline industry as they are so accurate. The machines can change tools themselves so that they can do a number of different processes without having to move to different machines.

You can also purchase CNC engravers which can engrave a number of different materials such as stone, glass wood, metal and composites.

Buying Used CNC Machines

CNC machines are extremely expensive, especially if you buy brand new ones. This makes it impossible for many people to afford them, however you could consider buying used CNC equipment. By buying these machines you can normally save 50% or more on the price of a new machine. You must to be careful when you are buying used machines, otherwise you could be buying into trouble.

The collaborator Johnathan Bakers is specifically passionate about news associated to Bridgeport mill and Bridgeport company. Sharing his passion in works on bridgeport mill and Bridgeport mills the writer affirmed his capability on the topic.

Article Source: http://EzineArticles.com/?expert=Johnathan_H._Bakers

INVESTMENT REDUCES BOTTLENECKS

2008-02-15T04:26:00.000-08:00

Like many similar businesses, Fylde Precision has had a lean time through the recession, and has been forced to modify its investment plans. Firmly believing that the worst is over, the first significant purchase in 18 months has been made in the form of a Jones and Shipman Format 5 CNC Surface Grinder. Bought primarily to improve productivity on the seven machine existing .

Mold shop equips and dresses for success: the domestic die/mold industry is today going through considerable change. Here's how one shop combines skil

2008-02-15T04:25:00.000-08:00

Laitram Machine Shop, Inc. (New Orleans, LA) produces a wide array of parts ranging from one-off engineering prototypes to parts in lot sizes in the thousands for such diverse applications as automated seafood processing equipment and digital marine seismic instruments, sprockets and shafts for modular plastic conveyor belts, as well as components for the oil and gas and biomedical industries.[ILLUSTRATION OMITTED] It's a high-end shop with a technology list that includes CNC lathes, vertical machining centers, horizontal machining centers, and a fully qualified

Laciny Bros., Inc. Completes 85th Year of Business

2008-02-14T02:19:00.000-08:00

Laciny Bros., Inc., St. Louis, Missouri, has just completed its 85th year of business.

The custom fabrication company was started in 1916 by three brothers with a total investment of $23 each.

Today, with its 3rd generation of the Laciny family at the helm, the company operates in a 65,000-sq.ft. facility with 38 employees.

"We get the job done," stated Bob Laciny, president (and grandson of one of the founders). "Our service and delivery have been key to our success. We strive to build strong relationships with our customers, many of which we have served for decades.The company's services include custom process equipment; custom machinery; engineering/design; CNC machining; prototype/ research & development; brake/ forming; repair work; sanitary fittings and raw materials.

The company handles a wide range of projects from producing individual parts or tanks/hoppers to designing and manufacturing complete automated conveying systems.

"We can provide complete systems/lines, modify existing equipment, or integrate individual pieces of equipment," commented Laciny.

Laciny Bros. serves a diverse range of industries throughout the Midwest including: food and beverage; pharmaceutical; baking; chemical; conveying equipment; material handling and packaging.

The company works with such materials as stainless steel, carbon steel, aluminum, nickel alloys, copper, brass, titanium and other special alloys.A large inventory of stainless steel, aluminum and carbon steel in sheet, bar and shapes is maintained and also available for sale. Pipe, sanitary fittings, fasteners and miscellaneous hardware are also stocked.

The company has been recognized numerous times by its customers for its superior service.

Always looking for ways to expand its services, Laciny Bros. has recently increased its engineering and design staff.

Tools of the Trade

2008-02-14T02:17:00.000-08:00

Available for 1993-98 turbo and nonturbo Toyota Supra models, the No. 93066 cam gear is made of lightweight, machined 6061 T6 aluminum and comes in four color choices: clear, red, black or blue. CNC machined to exacting tolerances, the cam gear allows for 12° (both advance and retard) of laser-etched adjustments for proper tuning. Gear tooth edges are beveled to increase belt life. FidanzaProSet Fix-A-Thred stainless-steel helical wire inserts are available in sizes ranging from #8 to 1-½ in inch coarse and inch fine sizes, and from M3 to M24 in metric coarse and metric fine sizes. The line also includes all necessary STI (screw thread insert) taps and installation tools, plus a number of kits that include a selection of inserts and related tools to enable technicians to repair a variety of thread sizes. In addition to its complete selection of inserts, tools and general-use kits, the company also offers kits for spark plug port repair, spark plug port repair in Ford Triton engines and oxygen sensor port repair. Alcoa Fastening SystemsDiesel Power System

Stinger is a complete power system with engineered intake, turbo, exhaust and fuel tuning upgrades for 2003-07 5.9L Dodge Cummins Diesel pickups. The system is claimed to deliver rearwheel gains of up to 75 hp and 175 ft.lbs. of torque. The system's OttoMind6 Diesel Tuner has six levels of power, and can be easily adjusted on-the-fly. Also included are the Ram-Air Intake System and Monster Exhaust. All modifications are fully compatible with Dodge's factory warranty, and the Stinger system is covered by a lifetime warranty. Gale Banks Engineering Brake Pad Sets

Wagner EDGE brake pads feature laser-shaped friction technology that optimizes the interaction among the rotor, pad and caliper, according to the manufacturer. Each pad is designed for a specific application to eliminate pad vibration noise, while ensuring the precise transfer of caliper force. A patented Integrated Insulating Shim dissipates residual heat and vibration. A complete pad installation kit features Silent Guide clips and all other required hardware. Federal-Mogul LED Flashlight

The Stylus Pro flashlight uses a .5-watt high-flux LED and special Micro Optical System (MOS) technology to deliver twice the light output of the company's Stylus penlight. The light can be carried in a pocket or on a tool belt and used as a secondary light source when looking under a hood or chassis. The Stylus Pro measures 5.3 in., weighs 1.64 oz., provides an output of 24 lumens typical and a continuous regulated runtime of 7.5 hours. Streamlight Drill Bit Set

The No. 6338DSA Cobalt Drill Bit Set is well-suited for drilling operations in hardened steel and tough alloy applications. Drill bits are available in 13-, 21- and 29-piece sets, in three materials: titanium, cobalt and high-speed steel. A complete cobalt drill bit set includes a new steel box case with an easy-open Hd with locking mechanism, a hard plastic bit holder to eliminate wear on bit flutes and hard rubber inserts to prevent work surface damage and provide skid protection on the workpiece. Mac Tools

Embroidery Machines

2008-02-02T02:03:00.000-08:00

Creativity, imagination, and hands and finger skills are the keys to unlocking the success of embroidery. This art form started during the early times as a means to put designs on bare pieces of fabric by sewing or weaving pieces of threads to come up with a certain design or pattern. Anyone has to go through the painstaking process of needlework to produce the desired work of art. It was first done by drawing figures or any desired pattern on the fabric which will serve as the guide as to what types of stitches or threads were to be used.

The same creativity and imagination the paved way to the invention of embroidery machines which can be traced back in 1800s through Joshua Heilman who laid the foundation of the embroidery machine industry. It was later on followed by more advanced embroidery machines that made use of the shuttle embroidery and chain stitch embroidery methods. Embroidery sewing machines are still operated manually using the hands and fingers through the aid of other types of fabrics and materials like plastic, wire, metallic strands, and leather.

Further advancement in technology brought corresponding improvements in the embroidery industry through computerized sewing embroidery machines that can automatically come up with a design from a built-in pattern program. Using computerized embroidery machines is much easier and less costly as compared to hand and manually operated sewing machines.

Aside from the ready-made designs, users can use their creativity and imagination to make their own designs and patterns. Ready-made patterns are transferred in the computerized embroidery machines in varied means and ways, although it may depend on the design file format of the machines. CDs, special cards with features similar to compact cards, floppy discs, or cables are just a few of the things that can be used.Creativity, imagination, and hands and finger skills are the keys to unlocking the success of embroidery. This art form started during the early times as a means to put designs on bare pieces of fabric by sewing or weaving pieces of threads to come up with a certain design or pattern. Anyone has to go through the painstaking process of needlework to produce the desired work of art. It was first done by drawing figures or any desired pattern on the fabric which will serve as the guide as to what types of stitches or threads were to be used.

History of Vending Machines

2008-02-02T02:01:00.000-08:00

It’s likely that you’ve probably never taken the time to sit back and consider vending machines. In fact, you have probably never taken the chance to contemplate the history of vending machines. After all who would? I know I didn’t, until I wrote this article and found the history to be surprisingly……well, fascinating. The next time you stop at a vending machine and purchase your favorite sweet, cold soda or that big caramel candy bar you’ll remember that even a vending machine is full of history.

What is Vending?

Vending is automatic retailing. Basically a vending machine allows someone to sell their products when he or she is not present to supervise the sales. It is really quite an ingenious concept (after all, we all want more money and more time), and doesn’t seem to be a new one either. A certain Greek—a mathematician by profession and interest—whose name was Hero created a vending machine of sorts, which would vend water within Egyptian temples. Many centuries later, vending machines were offered commercially in London. In the 1880s vending sales in London included vending machines that would dispense post cards or books.

Vending Machines Take on a Sweeter Flavor in the United States In 1888 vending machines and vending services and sales were offered commercially in the United States as well. The vending machines in the United States were first introduced by the Thomas Adams Gum Company, whose owners were of course interested in taking advantage of vending machines for the sake of selling their gum. The gum’s flavor? Tutti-Fruiti.

Additional Vending Machines is the U.S.A.

As most retailers do, vending machine retailers and buyers began to realize that just vending gum was not exactly a way to capitalize on the concept of vending. In 1897 the Pulver Manufacturing Company began to vend animated figures in addition to gum in order to increase their sales. Spherical vending machines were also introduced in 1907 complete with lots of candy coated gumballs that could be found inside the sphere. American vending machines also offered cigars, stamps and postcards. A vending machine restaurant was also invented in Pennsylvania in 1902 and managed to stay open until 1962. The restaurant’s name? Horn & Hardart.

Music to the Ear: The Juke Box Vending Machine

Vending machines provided everything from sweets to books but they didn’t produce sound, until the advent of the juke box, which like vending machines had a variety of predecessors. One of the earliest forerunners to the juke box was the nickel-in-the slot machine, which was invented by Louis Glass and Willam S. Arnold in 1889. This machine was actually a phonograph, which would play a recording through sound or listening tubes when a coin was inserted into the apparatus. The tubes soon became a nuisance and juke boxes were invented. Juke boxes allowed listeners to enjoy recordings without tubes and in addition to select from a wider variety of music. Some of the juke boxes, which were commercially available were the Rock-Ola juke boxes (Rockola is a noun, not an adjective), the Seeburg juke boxes, and the Wurlitzer juke boxes.

Discount Vending and Vending Repair

Vending machines soon became a big business in the United States and in other areas around the world as well. New jobs and positions were created in retail vending such as discount vending, vending sales, vending suppliers and vending services. As most inventions do when they help us save time, vending machines made life a little easier for the general population and became a part of the mainstream American lifestyle and culture.

Italian Espresso Machine – How To Find The Best Italian Espresso Machine

2008-02-01T02:00:00.000-08:00

Italian espresso machines are considered to be the best espresso machines currently available. They have the best looking designs in my opinion and some of the highest quality espresso machines in the world. Though they are expensive compared to other brands of espresso machines, I do feel it is value for money.

How To Find Italian Espresso Machine

Find an Italian espresso machine isn’t really difficult. All you need to do is go online and check some of the coffee websites or any of the shopping comparison websites such as Shop.com or Bizrate.com. Some of the well known Italian espresso manufacturers are Saeco, La Pavoni and Delonghi.

It is quite easy to order an Italian espresso machine from any of the online merchants these days. However, before purchasing, you might want to check out some of the reviews on the particular brand and model of espresso machine before purchasing. Also check the online coffee forums. Not all espresso machines work the same and you certainly do not want to spend a week figuring out how to make a cup of espresso with your new espresso machine.

Which Is The Best Italian Espresso Machine

The best Italian espresso machine depends on your own preferences. For me, I prefer Saeco espresso machine particularly the Saeco Vienna. It’s easy to use and maintain and pretty cheap.

I would recommend if you are a beginner to espresso machine to pick cheaper Italian espresso machines. Most espresso manufacturers have products suited for beginners which are cheap and easy to use.

Do your research online and check out the reviews of Italian espresso machines before purchasing.

Auto Repair Advice

2008-02-01T01:59:00.000-08:00

Auto repair advice gives you simple and practical solutions for questions regarding your vehicle. There are numerous web sites providing comprehensive information on auto repair. These sites also feature links to auto repair service centers, shops and garages near your place.

You are given instruction on auto parts and their functioning. Online advice resources provide the service of experts who pinpoint the exact cause and suggest possible repairs before you visit the shop. You can even post car care or repair questions on their message boards. Car owners and mechanics exchange advice and help through these forums. Auto repair advice given on these sites is often free of charge.

Auto repair advice is sometimes provided in manuals given along with your vehicle. Whether opting for online advice or depending on repair manuals, the vehicle owner should have a clear understanding of the terms and techniques involved. In case you are taking your vehicle to a service centre, a written estimate should be sought and the history of the shop should be checked out with the Better Business Bureau. One has also to check whether the repairs provided have any guarantees. If so, get the details in writing.

It is important to verify whether your car is still under warranty before venturing to repair the car yourself. For cars under warranty, the repair work must be performed by a mechanic or a technician certified by the manufacturer. The repair in this case is usually carried out at the dealer's service center. Some manufacturers do not offer to perform repair work and you may have the provision of carrying it out elsewhere. Read your warranty carefully to find out how you can get the repair costs reimbursed.

You can get repair advice from mechanics and experienced persons in the automobile industry. Repair advice is given for almost all models and types of vehicles, whether domestic or imported.

Computer Aided Manufacturing Applications

2008-01-31T03:14:00.000-08:00

Computer Aided Manufacturing (CAM) refers to an automation process, which accurately converts product design and drawing or the object into a code format, readable by the machine to manufacture the product. Computer aided manufacturing complements the computer aided design (CAD) systems to offer a wide range of applications in different manufacturing fields. CAM evolved from the technology utilized in the Computer Numerical Control (CNC) machines that were used in the early 1950s. CNC involved the use of coded instructions on a punched paper tape and could control single manufacturing functions. CAM controlled computer systems, however, can control a whole set of manufacturing functions simultaneously.

CAM allows work instructions and procedures to be communicated directly to the manufacturing machines. A CAM system controls manufacturing operations performed by robotic milling machines, lathes, welding machines and other industrial tools. It moves the raw material to different machines within the system by allowing systematic completion of each step. Finished products can also be moved within the system to complete other manufacturing operations such as packaging, synthesizing and making final checks and changes.

Some of the major applications of the CAM system are glass working, woodturning, metalworking and spinning, and graphical optimization of the entire manufacturing procedure. Production of the solids of rotation, plane surfaces, and screw threads is done by applying CAM systems. A CAM system allows the manufacturing of three-dimensional solids, using ornamental lathes with greater intricacy and detail. Products such as candlestick holders, table legs, bowls, baseball bats, crankshafts, and camshafts can be manufactured using the CAM system. CAM system can also be applied to the process of diamond turning to manufacture diamond tipped cutting materials. Aspheric optical elements made from glass, crystals, and other metals can also be produced using CAM systems. Computer aided manufacturing can be applied to the fields of mechanical, electrical, industrial and aerospace engineering. Applications such as thermodynamics, fluid dynamics, solid mechanics, and kinematics can be controlled using CAM systems. Other applications such as electromagnetism, ergonomics, aerodynamics, and propulsion and material science may also use computer aided manufacturing.

CNC Router Buying Guide

2008-01-31T03:13:00.000-08:00

CNC router tables are used for cutting wood, plastic, or metal, depending on the machine. They can be used for sign making or general routing jobs. The router doubles as engraving equipment. This versatility allows you to get more from one machine.

The interest in these machines for home use and small shops has grown rapidly in recent years. As people become aware of the accuracy and versatility, this demand will surely increase. Many people are choosing used equipment in an effort to save money, while owning this machinery.

Although they are still expensive for most users, there are plans available on the internet to make your own table. These save money and allow you to choose sizes from 15 by 15 to 50 by 60 inches, according to your needs.

Uses of a CNC Router

With cnc routers, you can do projects that would otherwise take too much time or be too difficult to accomplish. This includes cutting elaborate designs and creating metal inlays in wood. Complex designs come out smooth and accurate. You can do things that you could never do by hand.

These machines are great for furniture making. You will get professional results every time. The software allows you to program the depth per pass for even better results. You can engrave anything from a large sign to very small lettering. These machines are versatile and easy to use, once you’ve been trained on the software.

Smaller machines work on 120 voltage and can be run on typical household current. These are the best choice for the home workshop. The motors are generally either one or two horsepower. These smaller, table top models are more affordable, costing about $7000 new, as opposed to $20,000 for a larger machine. A used machine is even more affordable, costing about $3500. This is still very expensive, but can be cost effective if you are making furniture that you will sell.

Buying a Used CNC Router

Purchasing a used cnc router is a great value for the money. You can save 50% or more compared to the cost of a new machine. Take your time when shopping. Do some research to find the best machine for your needs. Keep in mind that a used machine will probably not be as fast as brand new. However, in a small shop, this may not matter.

Many used machines have been reconditioned. The machine is inspected and any damaged parts are replaced. Ask about the work that was done to your router. Find out what was repaired or replaced. Ask about a warranty. Many come with a one year warranty, which is a big plus.

Find out about the support that is offered by the company. Many will offer help with installation and train you for using the software. This is important if you’ve never used one before. Look for professional advice and support. Whenever possible, choose a dealer that offers on going support. Make sure to get a manual for your router. You will need the information contained in the manual for operation and maintenance.

Treadmills For Great Cardio

2008-01-30T01:21:00.000-08:00

Treadmills machines are one of the best cardio vascular exercise machine and the most popular too. With the whole nation embracing the idea of fitness, treadmills machines are an essential part of the workout. They are easy, convenient to use, suit all budgets and can be used at home too. Therefore one doesn't necessarily have to visit he gym to stay fit. You can also operate the treadmills machine at any time of the day. Therefore it's an ideal way to lose the calories and stay in shape, especially for stay at home moms, busy executives, older people and even an athlete.

There are innumerable options that are available. There are manual treadmills machines as well as motorized or which need electricity to run. Of course the manual treadmills machine is convenient and can easily be folded away and kept. However these machines don't have many programs or resistance levels. Compared to that, motorized treadmills machines are more bulky, but these treadmills machines offer a variety of resistance levels, speeds and other functions. They are also more expensive. The options that are offered are a control panel, which shows the heart rate, the pulse rate, the speed as well as the number of the calories burnt on the treadmills machines.

There are also various inclines and speeds as well as programs that suit all age groups and types of workouts. Usually the more expensive treadmills machines will have more features. Treadmills machines start at $500 and can cost up to $3000. It's important that when you buy treadmills machines, you should have looked at many treadmill machines and their features as well as the cost factor. Therefore it's important to note the minimum and the maximum speeds of the treadmills machine, the incline levels as well as the type and the number of workouts that are provided. Check for the warranty period of the machine as well as the parts of the machine. This will ensure that the treadmills machines that you purchase gives you the optimum workout.

Gumball Vending Machines – A Great Way To Break Into The Vending Business

2008-01-30T01:20:00.000-08:00

Gumball vending machines are the best known of all vending machines. They are the basis of every vending business because most people get started in this business with one or more gumball machines. This is because they are the cheapest of the machines and they do generate a lot of profit. You can sell giant bubblegum, candy and fun prizes from gumball vending machines.

Even as more and more vending machines come on the market, the gumball vending machines have remained. They come in a wide variety of styles and designs, such as the classic globe shaped gumball machine or the spiral shaped models. When you contact a business, gumball machine owners find that these are the easiest machines to place. Business owners know that both children and adults like to use them and they can even spur along the sales by offering prizes for a certain colored gumball. This makes using them more fun. Gumball machines usually take a quarter so the product is not costly for the customer.

You can have single gumball vending machines or models with two or three machines in one. Experts on the vending machine business will tell you that you should not have more than three different products or three machines selling gumballs and candy in one location. The small number of choices helps to increase the sales of gumballs for your business. Gumball machines are also very colourful which makes them very noticeable, along with the colourful gumballs inside.

Along with selling gumballs, you can sell many products for fun. Gumball machines can be used to sell bouncy balls, toy capsules or even small souvenir mugs. As long as the products can fit through the dispenser in the gumball vending machines you can use them in the machines. You will also have to adjust the price to reflect the product because some products are more expensive than others. You do have to price the products to sell, but also be able to make a profit in your business. Gumball machines are so popular because they are the most profitable of all vending machines.

The spiral gumball vending machines seem to work best in a vending machine business. This is because these machines are very attractive to children, who love to watch the gumball spin around the spiral in the machine. Parents don’t mind spending the quarter for the gumball and quite often they will end up spending more than one in the fun gumball machines. Business owners don’t mind having them on their premises either because they get a commission based on the amount of money that comes out of each machine. If you are thinking of getting started in the vending machine business, you will enjoy great success with gumball vending machines.

Candy Vending Machine - Profitable and Fun

2008-01-05T04:27:00.000-08:00

Have you ever seen a vending machine full of colorful candies? Yummy, as most children would say. Vending machines always attract young kids.

Vending machines have been popular for some time. People saw it has a great use in the market and the potential profit it may bring to people. Vending machines dispense certain kinds of merchandise after the customer deposits money.

At present, various types of vending machines are placed for selling snacks and beverages. Each type has a specific product in stock. Some are for selling candies and newspapers. There are also vending machines used for selling bottled water.

In different countries on the planet, vending machines are used for dispensing several products. You can find all types of products sold through vending machines like sandwiches, beverages and snacks.

Vending machines are operated by the owner in most cases. This is a common business in the United States because it is easy to operate; you can stock the machines with merchandise and earn money. You don’t even need a store clerk to sell the products.

If you are leery of the safety of these vending machines, don't worry because most of the machines today are extensively tested. They are also designed to lessen the risk of theft.

On the other hand, despite the safety of vending machines, the machines may experience maintenance problems or breakdowns. This happens occasionally.

After knowing all the necessary information regarding vending machines, it is quite interesting to deal in the type of vending machine that charms children. This is the candy vending machine.

It is a mechanical or electronic machine that sells varieties of candies by simply inserting coins or paper money. It is very eye catching for kids because the candies they can purchase here are assorted and they have so many choices to choose from.

Having a small business of your own can be profitable. You can make it possible by opening your own Candy Vending Machine route. Maybe a year from now you can add soda vending machines to your locations. This can be the start of profitable small business for you, it was for me.

A Look at DVD Shrink Wrap Systems

2008-01-05T04:26:00.000-08:00

Shrink wrap machines use plastics to protect items from moisture and dirt during storage or transport. The plastic film is wrapped around the item and then the film is heated. It shrinks and conforms to the shape of the item, forming a barrier between the product and outside hazards. Shrink wrap systems may be small and manually operated for the home business, or large-scale automated machines used by shipping companies. Automatic machines can process more items and hour than their smaller counterparts.

DVDs can be easily shrink wrapped for a professional look that protects the DVD from the environment. Machines designed to shrink wrap DVDs work more efficiently than generic hand-held shrink wrapping systems. Some machines shrink wrap only DVDs; others can shrink wrap both DVDs and CDs. Machines specifically designed for DVDs are typically cheaper than dual systems, and can be purchased for under $5,000.

To shrink wrap a DVD with a shrink wrap machine, place a precut plastic cover on the machine's platform, and then place the DVD on top of the plastic. Close the machine's cover to heat seal the DVD. The sealing temperature is electronically controlled by the machine. These semi-automatic machines can shrink wrap about 200 DVDs an hour. Automated machines work twice as fast, shrink wrapping about 400 DVDs an hour.

More expensive, fully automatic machines can shrink wrap about 55 CDs or DVDs a minute, or about 3000 an hour. These machines cost about $16,000, but can also handle films other than plastic. Paper or cardboard could also be used, for example. Automated high throughput machines are portable and can sit on tables, taking up less space than floor-bound machines, but the table-top machines can shrink wrap DVDs and a comparable rate.

Several online stores sell all kinds of DVD shrink wrap systems at wholesale prices. These Web sites sell both the machines and the films need to shrink wrap DVDs. There you will find everything you need to package DVDS with a professional look

Dealing With Electrical Problems

2007-12-19T23:11:00.001-08:00

As any veteran do-it-yourselfer knows, there are lot of mistakes made before you can call yourself an expert on anything. We all have experiences of home improvement projects that proved to be anything but an improvement. Usually these kind of mistakes just make us laugh and learn. But there are some home projects that cannot be done wrong because they are too dangerous to have a mistake with. Electrical repairs fall within this category. But if you follow these steps, you can make sure you keep yourself and your family safe when you do an electrical repair. Before you even take any of these steps, however, find out if your local community requires you to have a permit in order to do any electrical work. But these laws are different in each state, and even in each municipality, so check first.

The first thing you should do before you work on electricity is to turn the electric power off at the source. This must be done at the circuit breaker, since just turning off a wall switch will still leave you with hot wires.

Make sure the electric is off by using a voltage meter. After you have turned the electricity off at the circuit breaker, test the wire in the room you are working in and make sure nothing registers. Keep the power off until you have completed the job. You should not touch any of the electrical wires that bring electricity into the house. If you think there is something wrong With this service, make sure you contact your power company.

When you are working on electricity, never stand in water or even on a damp floor. Water conducts electricity, and it will go through you if it has to. If the floor is damp, put down a rubber mat.

Make sure you know what materials you are working with. In general, you have to be careful of metal, but rubber is safe. Since metal conducts electricity, do not touch metal at the same time you are touching a live wire, because you will become the conductant.

Since rubber is a nonconductive material, it will insulate you. So you should use tools with rubber or plastic handles, and wear rubber soled shoes or sneakers. While we are on the subject of what to wear, you should also wear safety goggles and gloves.

Now that you have completed the repair, flip the circuit breaker back on to turn on the power. Use you voltage meter once again to see if there is power, and there is the right amount of voltage. Smaller items such as lights, a receptacle or a small appliance will need 120 volts. Big appliances (air conditioners, ovens, etc.) will require 240 volts. There are some appliances that need such small voltage, such as doorbells or telephones that they will have a transformer to convert the power to a smaller voltage.

If you want to make sure you know what you are doing before you start an electrical repair job, you may consider taking advantage of the clinics or workshops that many do-it-yourself centers offer. You will learn a lot and feel more confident when you tackle the next job. If you don't feel that you know what you are doing, don't take a chance: call an expert electrician to do this kind of work. There are plenty of other jobs you can do, such as painting, hanging shelves, or trimming branches. Just ask your wife. She probably has a "honey do" list as well as cnc routers and used cnc electronics all ready and waiting for you.

Inexpensive PCs as CNC Machine Controllers

2007-12-19T23:10:00.000-08:00

There are two main groups that can take advantage of today’s low cost PCs as an effective and inexpensive CNC controller.

• Retrofits to existing CNC machines with outdated or proprietary controls in need of service.

• Shop built and home built CNC machines.

Inexpensive PCs can cost as little as $150.00 and yet provide a dependable and effective CNC machine controller. Some sources to consider for obtaining such a system are outpost.com and dell.com. Oupost.com is an outlet for Fry’s electronics. They have one PC on sale ranging from $150.00 to $199.00. Several have successfully used this PC in conjunction with MACH2 CNC controller software.

Tradeoffs: Price vs. Quality. With the lowest cost PCs there a tradeoff in performance, quality, and reliability. The manufacturers of these machines use low cost hardware in their manufacture and they make compromises in the design of the systems to keep their costs down. Inexpensive hardware translates directly to a higher failure rate and more difficult to obtain manufacturer support. This can be a deciding factor by itself if you rely on this machine for production.

Design compromises which are common in low cost PC have an impact on performance. The primary concerns are: insufficient memory, the use of shared memory, and on-board graphics devices. The primary hardware requirements for a PC based CNC controller are sufficient memory, and sufficient processor speed. You can see that the compromises present in these systems are in direct opposition to the requirements for CNC controller.

At the bottom end of the Inexpensive PC market there are off the self solutions that will function well as a PC based CNC controller. As with all things, you tend to get what you pay for, so the buyer is advised to be aware of the requirements and limitations that are in play.

Part II in this series of articles will examine an alternative to buying an off the shelf solution and explore building a PC to meet your specifications.

Timely Investments - Brief Article

2007-07-25T04:50:00.000-07:00

On the surface, the recent slowdown in manufacturing activity might be viewed as a justification for delaying capital investments. But a cooler economy presents some valuable opportunities for machine shop managers to prepare for better times to come. When a shop is operating near its maximum capacity, it's difficult for managers to think about cultivating new business or buying equipment. But a decline in one industrial sector may coincide with increased activity in another. Thus, pursuing a new direction is often beneficial for a company's long-term development, and shifting gears may require equipment upgrades.
Arelated opportunity in a cool economy is the reduced cost of financing. As the Federal Reserve Board continues to cut short-term interest rates to stimulate consumer spending, loans for metalworking equipment (typically amortized over 5-7 years) have become substantially more attractive. As a result, it's a propitious time for businesses to finance or refinance capital equipment. This situation enhances the resources of borrowers and creates additional options for obtaining the equipment necessary to keep pace with current technology. Furthermore, astute managers understand that seeds planted in difficult market conditions can represent the distinction between tomorrow's winners and losers.

Tooling Triad - CPC Tooling Technologies - Company Profile

2007-07-25T04:41:00.000-07:00

To build exceptionally effective extrusion dies, this shop brings together strengths in three key areas: CNC machining, EDMing and tool room operations.

Unless you are in the middle of a forest, it's hard to look around and not see something made of extruded plastic--the siding on a house, the trim on a car, the frame of a window sash. And even if you are in the middle of a forest, the trees you see are the source of a key ingredient in many of the most advanced and complex extruded products--wood. Wood fiber and wood flours are blended with plastic resin and extruded to make a wide variety of products such as deck planking, hand rails and architectural trim. To add to the growing use of plastic extrusions, emerging techniques allow materials to be extruded as foam and encapsulated in an outer layer that is rigid and weather resistant. Shapes with hollow cross sections in complex configurations are also possible.
CPC Tooling's strategy for meeting this challenge is based on a simple concept. The company must be able to build tooling not only for customers pioneering new applications, but also for customers whose conventional applications require faster running, longer wearing, more flexible and economical tooling. In-line tooling that turns extrusions into finished pieces ready for shipping is one of the shop's specialties.

All For One, One For All

"Designing and building extrusion dies is as much an art as it is science," declares Bob White, tooling manager at CPC Tooling. Mr. White, who has overall responsibility for the production of extrusion dies and related hardware for forming and cooling extrusions, explains: "You have to understand how material behaves as it undergoes the extrusion process and then use that knowledge to design a die and the tooling that goes with it. And you have to understand all of the machining processes that enable you to build that tooling."

At CPC Tooling, those machining processes are available in three key areas, each located in its own facility within the sprawling Crane Plastics plant in Columbus, Ohio. Each one of those areas must be efficient and productive. Each must leverage the capabilities of the other two areas. Each must keep up with current techniques and equipment.

The CNC machining area is anchored by two vertical machining centers. These machines do the three-axis milling of complex die contours often referred to as coat hangers because of their distinctive spreading triangle shape, as well as two-axis milling of tool and die components.

The EDM (electrical discharge machining) area features one ram and six wire machines, whose ability to cut steep tapers in four axes is essential to the extrusion process, which converts material from a simple shape to a complex one. Wire cutting replaceable inserts, which greatly extend the life of a tooling system, is another critical job for this area.

A staff of skilled tool and die makers supplies all of the components that allow dies and other hardware to be assembled into a working system. Two toolroom areas equipped with precision mills, lathes and grinders provide the flexibility and expertise to build, troubleshoot and repair almost any die or tooling that comes their way.

"Every one of these areas is important," stresses Mr. White. "Each one is vital to our strategy. Yet each area requires its own management style and has its own technology needs," he says.

Capable And Productive

CNC machining has proven to be a key asset to CPC Tooling. CNC machining is both capable and productive. It is "capable" because it allows complex die contours to be machined in 3D. It is "productive" because it allows 2D work to be handled on a production basis, with pallet changers and shopfloor programming to keep the machine fully occupied.

Van-Am Tool & Engineering Celebrates 25th Anniversary

2007-07-04T03:37:00.000-07:00

an-Am Tool & Engineering, St. Joseph, Missouri is proud to begin celebrating its 25 th Year of providing quality solutions to their customers' tooling, stamping, machining and manufacturing needs. An achievement not many can claim in today's tooling industry.

When discussing the company's 25 years; Ivan Russell, VanAm's president and co-founder stated, "Great employees and customers with good management are the main factors in our success. You just can't do this type of work without a good crew and we have very little employee turnover." Russell also noted that providing exceptional customer service and being diversified in the services offered and industries served is also important. Van-Am's specialized services include: design and build of progressive, transfer, louver, blank, form and draw dies (these can range from 6" x 6" up to 9' or longer); die maintenance and repair; production stamping and fabrication; general and custom machine work; CNC machining and wire EDM; design and build of jigs and fixtures; machine design, build and repair; custom fabrication and welding; robotic welding and plasma cutting; vibratory finishing; laser cutting and CNC press braking.

With the recent addition of several pieces of equipment, including a new Wire EDM, the company's equipment now includes: four wire EDM's; four vertical CNC machining centers; 13 milling machines; seven drill presses; five lathes; ten grinders including a 24" x 60" surface grinder; six saws; 16 punch presses (up to 600 ton); two robotic welders; three press brakes including a 220-ton 12'6-axis CNC press brake; two shears; a 1500-watt CNC laser cutting system; a 24 cubic foot vibratory finishing machine; and a host of supporting equipment.
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The company operates in a modem 55,000-sq.-ft. facility with 36 employees. Their equipment and talented work force allows Van-Am to serve a wide range of industries including: agriculture, automotive, construction, electrical, fuel/oil, government, HVAC, pharmaceutical and transportation.

From Manual To CNC Mills: A Three-Phase Transition - V & G Dynamic Machine & Tool Inc

2007-07-04T03:35:00.000-07:00

V & G Dynamic Machine & Tool, Inc. of Marble Falls, Texas, uses high-end VMCs and CNC mills and employs skilled machinists and CNC operators to support the development of new instrumentation and technology for the semiconductor industry.

When Volker Steffen founded V & G Dynamics in 1988, the company was doing mainly repair work using two manual mills. Mr. Steffen knew that if he had CNC there was the promise of longer runs and production of complex parts--giving access to new markets and increasing sales and profitability. But these benefits come with a cost in terms of capital, training and learning. Mr. Steffen was looking for a way to implement GNC gradually--a transition that took the characteristics of his shop and people into consideration. He discovered an opportunity at an open house held by his local dealer. "I was at an open house at a machine dealer one weekend, and I saw a manual mill with some sort of external motors mounted on the table," Mr. Steffen says. "The dealer showed me how the mill was doing CNC work by having the power feeds move the table, under the control of a PC. Best of all, I didn't have to start using a computer right away. I could just use the power feeds in the 'Teach Mode.' You move the table to a desired position, press 'set' on the pendant, move to the next position, press 'set' again, and so on. At the end of the sequence you press 'run,' and the machine plays back exactly the moves you told it to execute. It's that simple."
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On seeing this, Mr. Steffen first began considering doing more than just manual mill work. V & G had grown to include a lot of small-volume (1 - 500 piece) production work, but Mr. Steffen was not at the point where he needed to spend tens of thousands of dollars on a single CNC. So in 1993, he decided to first retrofit one of his manual mills with the "intelligent power feeds"--a basic two-axis Servo II automated control system with the "Teach" pendant, made by Servo Products Company of Pasadena, California--which he mounted himself on a Summit manual mill with a Sargon digital readout. The cost of the retrofit was well within his reach, and the promise of increased production made the whole deal attractive. Within days, production was at levels he had never seen before, and both he and his machinists were using the "Teach Mode" feature without problems.

Such use of a basic retrofit package makes sense for shops where owners and operators don't have prior experience with CNCs. In the case of V & G, its manual mills had essentially become three different machines with one simple retrofit: one that still does manual work, one that uses the Teach Pendant and one that can perform CNC work (when connected to a dedicated PC). The DRO interface adds accuracy to the Acme lead screw by using the scale for positioning accuracy instead of the encoder on the motor, In addition, the DRO enhances the machinist's productivity.

With the Servo II control system used for the retrofit, one-of-a-kind or production run parts can be machined, and the table can be moved either using the pendant or handwheels. The "taught" programs are limited to straight line and angle cuts. The system cannot be taught to machine a circle. Subroutines can be called up, and program steps can be changed, added or inserted. It's easy to delete entire programs from pendant memory, or delete a subroutine call--which is useful when "programming" on the fly. An operator also can set, clear or drag axes travel limits (for example, reset limit beyond current position) and can playback a program held in the pendant's memory.

The Servo II control system can be made more productive by hooking up a PC, which simply can be used to transfer programs between the PC and the pendant; with Servo CNC software and a dedicated PC, the machine has full CNC capabilities. This comprises the second step in the gradual conversion to CNC machining. Programs "written" on the pendant can be transferred to the PC for storage and for re-use at a later time. The transferred pendant programs arc converted to common CNC codes. Conversely, programs can be written and edited on the PC and transferred later to the pendant, though only a limited set of CNC codes are available. This means two things: Operators can generate CNC code without knowing programming, and they can execute previously written CNC code without using the control (it's done via the pendant). Production goes up, and accuracy and repeatability improve. The absence of a steep learning curve makes training the operators brief and inexpensive.

V&G began by doing most of its CNC work using the conversational mode programming on the control. By going through a step-by-step process, the operator answers simple questions about the current job, and the control automatically develops a program, which is then seamlessly translated into G-code that can be used on any Servo CNC machine. Even if the operator makes a mistake in the programming, he or she can easily edit the specific line that needs correction

Cole National Corporation

2007-06-19T02:05:00.001-07:00

Once an optical retailer with nearly 3,000 outlets in the United States, Canada, and the Caribbean, Cole National Corporation was acquired by Italy's Luxottica S.p.A. in 2004. Luxottica proceeded to fold Cole's operations into its North American Retail Group, and while Cole's holdings (such as Pearle Vision) continued to thrive, the Cole structure was dissolved. Over the course of its history, Cole National had dabbled in specialty retail ventures ranging from key cutting services to children's toys to cookie-baking to shoe repair and watchbands. Optical retail, however, began to play a large role in the company's strategy in 1996 when it acquired Pearle Inc. in a deal that made it the second-largest optical retailer in the United States. In 2004, at the time of the Luxottica acquisition, the company operated as a leading provider of vision care products and services—including managed vision care programs—and personalized gifts through its Things Remembered stores.

Early History
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Company namesake and guiding light Joseph E. Cole was born in Cleveland in 1915, the youngest of nine children. He started his retail career with Cleveland's National Key Company in 1935 at the age of 20. He left National Key nine years later to establish the key division of Curtis Industries, another Cleveland business.

Cole's first key shop was set up in the parking lot of a local Sears, Roebuck & Co. store that same year. By the end of the decade, Cole had built his little sideline into America's second-largest key retailer. The self-made entrepreneur was coronated "king of keys" in 1950, when he acquired National Key and Curtis' key division, the industry's two top players. The newly unified firm took the name of its larger constituent, National Key. (Although National Key was founded in 1932, Cole National claimed 1944 as its inaugural year.)

Joe Cole's key-selling concept was predicated on the idea that keymaking was a highly specialized, service-oriented business. While mass retailers wanted a share of this segment's high profit margins, they did not want to deal with the equally high level of training, service, and inventory control it demanded. Cole leased space from such leading department stores as Sears, Roebuck and Co., Montgomery Ward, and Kresge's. He then installed key-making machines, trained store employees to cut keys, and oversaw the operations' complex 3,000-unit inventory. While Cole neither manufactured keys nor owned stores, Cole found a profitable niche in providing its services to customers and retailers.

A company executive would later characterize Cole's counters as "an oasis of service in a sea of self-service." The tiny selling areas emerged as the most productive areas—in terms of profits per square foot—in some stores. During the 1950s, the company expanded into the manufacture and sale of key chains and jewelry, and launched a while-you-wait shoe repair division.

Public Offering Leads to Growth in the 1960s

The explosion of automotive and home sales in the postwar era made expansion of the replacement key industry virtually inevitable. Less than a decade after assuming the helm of National Key, Joe Cole increased sales fourfold, from $2.33 million in 1950 to $10.52 million in 1959. When the firm went public that year, it sold out its entire offering in one day. The Cole family retained a 25 percent stake in their company, which by that time was netting over $635,000 annually.

That same year, Cole tested a new concept in optical retailing, establishing an eyewear counter within space leased from a Detroit Montgomery Ward store. This venture was based on the same concept as the company's key business. Company strategists recognized that mass retailers had the traffic, but not the expertise, to run such an operation. Masco Optical became the foundation of a chain of optical counters that numbered over 150 locations by the end of the 1960s. Optical centers had become Cole National's largest division by 1964, contributing about half of annual sales.

Although CNC retained a focus on retailing, it also diversified into manufacturing during the 1960s. It acquired Sterling Industries, a Cleveland manufacturer of aluminum, steel and plastic products in 1961, thereby winning an exclusive contract with Welcome Wagon. In 1966 Cole National merged with Susan Crane, producers of giftwrap, and acquired the Gene Upton Co., manufacturers of self-adhesive metal letters and numbers. Two years later it acquired Manco, Inc., a manufacturer of Topps and Everbest brand watchbands. The Manco purchase included Canadian, British, and Japanese retail outlets. Griffon Cutlery Corporation, a marketer of manicure tools, was added to the roster in 1969. These acquisitions more than quadrupled Cole National's sales to over $40 million, but also invited speculation from analysts that the company had over-extended itself. In 1970, in fact, the retail conglomerate's profits declined by half.

Company uses CAM to bring machining in-house

2007-06-19T02:04:00.000-07:00

For any company that designs new products, communicating its designs outside of its walls is always a source of anxiety. Outsiders who get proprietary information can use it to become a competitor.

This is the main reason why Jeff Smith, president of Triad Solutions LLC (Moorpark, California), decided to do some of his own machining in-house. The company made this transition without hiring a machinist, without making a large capital investment and without undergoing a big learning curve. Even though the shop had no machining experience, it has been able to machine its own parts quickly and efficiently, thanks, in large part, to the intuitiveness and accessibility of CNC technology today.We realized the most important thing for us to do is maintain complete control of certain critical parts that have earned us a lot of business," Mr. Smith explains. "We didn't want to reveal the details to competitors or vendors."

Triad is a developer of cryogenic test dewars, which are metal containers made like a vacuum bottle that allow infrared sensors and arrays to be tested at very cold temperatures. The shop machines the dewars' vacuum interfaces for electrical circuits, as well as internal components such as cold pedestals, heat-switch components, light baffles, device sockets and heater enclosures. It also prototypes parts for new designs. The company's customer base includes high-tech aerospace companies that work with infrared sensors and universities that require these devices to research materials.

Mr. Smith knew that he would have to find a CAM software program that would allow direct-to-NC-programming from 3D designs. At the time, the company was happy using TurboCAD, a program developed by IMSI (Novato, California) that allows the user to manipulate AutoCAD drawings. So when the time came, Mr. Smith inquired about the company's CAM capability.

With this new CAM capability, the shop uses a benchtop three-axis CNC milling machine from Taig (Chandler, Arizona).

After implementing TurboCADCAM, the company started producing parts within a couple of weeks. During that time, employees had to learn the specifics about formatting the software to work with the CNC machine. Then they had to optimize the machining steps to produce quality parts, which Mr. Smith says took time to perfect. "We produced many a scrap part in the process because of our ignorance in several areas, mainly with machine setup and proper settings for the material being machined," he says.

The company is now capable of machining 20 percent of its own parts that it couldn't machine without the CAM application. The company did not have to hire any more people to add to its five-person staff, nor did it have to purchase more than one CNC machine.

Although it didn't take the staff long to get up to speed with the new software, Mr. Smith explains that the company isn't working with complex parts, exotic materials or tight tolerances. The shop mainly machines aluminum, and tolerances are normally in the range of 0.005 inch.

Every job at the shop begins with the design of a product requested by a customer, typically in the form of written specifications. The shop translates the specifications into a 3D model that it reviews with the customer prior to fabrication.

Now that Triad has been machining parts for a while, it has discovered a range of benefits that go beyond protecting its own designs. Not only does the software aid in keeping company costs down, it also has improved Triad's customer service. For example, job turnaround time has improved because instead of sending a design out to be machined, it's possible to machine a part in one day. "We have literally talked about the design of a part with a customer and delivered the finished part all in the same day," Mr. Smith explains. "It takes maybe half an hour to set up the material on the machine, and then it's ready to go."

Repairing a customer's part is also much quicker in-house. A repair could take as long as 2 weeks when Triad outsourced its machining, but now the company can make its repairs on the spot.

Software is the CNC - includes related article on retrofits - computer numerical control

2007-06-18T05:31:00.001-07:00

Almost every longstanding shop has had a machine like this - good iron but the controller is shot. The difference is that Melling Manufacturing Group in Jackson, Michigan, was able to bring their vertical machining center back to life. And it didn't take an expensive maintenance program. All it took was replacing the old hardware-based CNC with a software-based system, running on a mail-order personal computer. This PC control not only resurrected the machine tool, but it also lets the machine run better than it ever did with the old controller.The way it was, the most we could get for that VMC as a trade-in was its scrap value," said Melling President Dave Horthrop. This 45-man shop had owned the machine since 1985, and relied on it for years. But over time, the control unit had experienced its share of problems, with downtime getting longer and longer and repair bills going higher and higher.

Even when it was running, the machine was very difficult to program. The proprietary control was badly out-dated and no longer supported by the builder.

"Eventually it got to the point where, at best, we could use it only as a programmable drill press. Even at that, our machinists avoided using this machine as much as possible - most of the time it just took up valuable floor space," Mr. Horthrop recalls.

Cole National Corporation

2007-06-18T05:29:00.000-07:00

Software is the CNC - includes related article on retrofits - computer numerical control

2007-06-07T05:32:00.000-07:00

Imagine a computer numerical control (CNC) system set free of proprietary hardware. Two shops discuss their experiences with software-based machine controllers.

The controller was as good as dead. The machine it was on couldn't even be traded in.

"The way it was, the most we could get for that VMC as a trade-in was its scrap value," said Melling President Dave Horthrop. This 45-man shop had owned the machine since 1985, and relied on it for years. But over time, the control unit had experienced its share of problems, with downtime getting longer and longer and repair bills going higher and higher.

Even when it was running, the machine was very difficult to program. The proprietary control was badly out-dated and no longer supported by the builder.

the shop found the new CNC, which made the turnaround possible, a little over two years ago. Called OpenCNC and produced.by Manufacturing Data Systems Inc. (MDSI) of Ann Arbor, Michigan, this CNC is a software-based system that uses a standard, off-the-shelf personal computer (PC) running a standard CNC software product. Only this software is proprietary; everything else is entirely independent of computer hardware. As soon as the old CNC was replaced with the new, this same machine was running, and running at faster feed rates and better accuracies than it did when brand new. It has become a very productive resource on the shop floor and there is no hesitation among operators when they are assigned to this machine.

"Besides turning what we thought was just a piece of junk into a valuable production asset, software-based CNCs are going to help us get into a new business that we couldn't otherwise compete in," says Mr. Horthrop.

A Different Kind Of CNC

Mr. Horthrop had heard about the new kind of CNC from Great Lakes Industry, Inc., a company also located in Jackson, near Ann Arbor in the southeastern corner of the state. GLI had retrofit several of its machine tools with these software-based CNCs. Almost out of desperation, Mr. Horthrop visited GLI to check it out. What he saw appeared to be the answer to the problems with his shop's VMC, even though the retrofit CNCs he looked at were radically different from the CNCs he was used to encountering. With little to lose, he had the old CNC replaced on the VMC in August, 1995.

The new CNC runs on an office-grade PC interfaced directly to the existing servo system of the machine tool. There is no separate motion control card, programmable logic controller, or other hardware in or attached to the PC. It has standard processors inside, exactly the way it came out of the box.

What it does have is software designed and written to allow an off-the-shelf PC to function as a CNC. This software handles everything that a CNC normally handles, such as the human-machine interface and I/O control, but it also closes the servo loop, a task usually relegated to add-on hardware such as a motion control card in some CNCs using a PC platform.

The reason Melling's VMC is now performing better than ever is that the old control did not have the processing power to keep up with the full potential of the axis drives on this particular machine. The drives' speed and accuracy were limited by the inability of the old CNC to process motion commands and position feedback signals very quickly. The new CNC is considerably faster.

"And when faster and more powerful PCs become available, we can upgrade by simply swapping out the old for the new," notes Mr. Horthrop. "The same control software will be loaded on the new PC. Likewise, if the control software is upgraded, the hardware will not prevent us from moving to the new version."

Hardware Independence

Having CNCs that are completely independent of hardware is an important consideration for both Melling and GLI, though their reasons are different. "We are interested in adding capacity to manufacture timing sprockets and similar workpieces for our parent company," explains Mr. Horthrop at Melling. "But we can't justify the cost of new equipment to produce these parts competitively in a mature market where margins are very low. The problem with used equipment is the controllers. They're either outdated to start with or if they're not, getting repair parts or future upgrades may not be easy or affordable

Upgrade Grinding Machines—Precision Balancing & Analyzing, Booth 6327 - Brief Article

2007-06-06T06:18:00.001-07:00

he company is now offering a complete package to upgrade grinding machines with belt-driven grinding spindles to wide speed range high frequency spindles. Due to today's production requirements that demand machines handle a wide range of parts, requiring constant changing of grinding wheel speeds, the company developed a new service package. With the new upgrade service package a company can replace the several belt-driven spindles on a machine with one or two high frequency spindles and handle the jabs that require power and stiffness at 5,000 rpm and have speed capability to 30,000 or 72,000 rpm.The package is complete with a control station that includes the high frequency drive, lubrication unit, chiller Unit and control interface for CNC or manual control of functions. The control station is mounted on a roll around platform that occupies a minimum amount of floor space and can be conveniently located. Each package is configured to meet specific customer requirements.

Portable CMMs speed turbomachinery repair

2007-06-06T06:15:00.000-07:00

Repairing steam turbines is all about efficiency, quality, and precision. Customers in the petrochemical, oil and gas, and power-generation businesses may be losing hundreds of thousands of dollars a day if a key piece of turbomachinery is down. And, for equipment that may weigh several tons, rotate at high speeds, and run at high temperatures, quality is an absolute requirement.

To add to the challenge, there are almost never original drawings to go by, at least not for independent repair companies such as Hickham Industries (La Porte, TX). A unit of Sulzer Turbomachinery Services, Hickham claims to be the largest and most diverse such facility in North America.More often than not, drawings have been lost over the years. Even when available, they may not be very helpful. Because of modifications made during manufacturing, no two pieces of turbomachinery are ever exactly the same-even if they have identical model numbers. Problems are multiplied by the effects of wear and corrosion; overheating and crashes that leave key components bent, cracked, or broken; and multiple rebuilds.

In light of these challenges, Hickham personnel have become experts in reverse engineering. Work at La Porte always starts with careful measurement using portable coordinate measurement machines (CMMs) to establish nominal dimensions.

"The first step is to establish what we have, where we are, what we know and do not know, and what we have to do," project engineer Jaime Valdez explains. "For that, the portable arms are essential."
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Hickham has conventional CMMs, but most of the machinery it refurbishes is too big to be dimensioned anywhere but out on the shop floor. For that task, the company uses portable arm CMMs from Romer/ CimCore (Farmington Hills, MI). Hickham purchased four of the company's 3000i arms in early 2002-three with a 9' (2.7-m) measuring envelope, and one with a 12' (3.7-m) envelope. Hickham is now looking at adding accessories such as Romer's Linear Rail and GridLok systems to further expand measuring envelope and versatility.

"These are close-tolerance, high-speed, high-horsepower, high-temperature machines that generate high revenues for our clients," explains project manager Dave Dixon. "With equipment like this, the margin for any type of error is very small and the price of an error is extremely high. The Romer arm is one of Hickham's key tools to verify our efforts in maximizing the machine's output and minimizing the chance for error."

The portable arms are used to measure casings, shafts, shaft supports, disks, diaphragms, and bladed turbine rotors, plus impellers for centrifugal compressors. "Data from our reverse engineering efforts supports all the key decisions on what repairs are needed, how they will be done, how long it will take, and which parts must be replaced," Valdez explains. "Also very important is getting measurements quickly."

Speed is a factor in Hickham's success. Turbomachinery repair is a competitive business, and jobs are taken on fixed-price bids with demanding delivery times. "On one rush job, we had just 27 days to disassemble the entire turbine, dimension it, weld the case and repair cracks, fix the rotors, repair a lot of the blades, and fix the stationary parts," Valdez recalls.

"With the portable CMMs we can get axial and linear measurements-bearing areas, rings, stators, and vanes-all at the same time with just a few quick changes in the setups," explains operator Jesse Haver. "We do it all with just one man rather than two or even three. It will take eight man-hours rather than 32."

According to Haver, the device's reverse engineering software aids data collection. "One thing about the arm's software, PowerInspect, is the ease with which reference planes can be changed even after points have been gathered," he points out. "Often, we need to be able to relocate geometry planes and move points between them. With PowerInspect, there's no need to go back and remeasure. We know the data was good." All dimensional measurements are checked at least three times by Hickham personnel in various departments, he adds.

Accurate measurements made with the portable CMMs mean Hickham machinists no longer do trial-and-error machining.

Surfaces measured range from simple flats and arcs to volute surfaces of centrifugal pump impellers. "Our machinists then cut these parts to our numbers," Haver says. "The accurate measurements mean they no longer have to do trial-and-error machining. We can now do in two days what sometimes took weeks."

Rotating stages of turbines are often up to 52'' (1.3 m) diam, and the full assemblies may be 35' (10.7 m) long. "But, we are often working in confined spaces, and the arm's almost unlimited rotation is a big help," Valdez says. "It always takes a while to get the measuring setup oriented and maneuvered into just the right position and locked down.

PC-based CNC revives vintage machines

2007-06-02T03:18:00.001-07:00

SHOP SOLUTIONS

They just don't build machine tools like they used to, according to Andy Vige, president of Machine Specialty and Mfg. (Youngsville, LA).

Vige couldn't find a new machine tool that could take the punishment that one of his 20-- year-old Warner & Swasey lathes could. He'd been buying used W&S machines for years, then driving them hard to make pipe pressure fittings and flanges for the oil industry. The iron in them was still good, but the original controls were not. Aging hardware-based CNCs on the lathes had become obsolete, and because they were proprietary, closed systems, the controls were starting to cost the company plenty.

"When a motion board goes on one of these, it takes weeks to repair or replace them," Vige says.

"Frequently, the original control company can't help us at all. When a machine goes down, and you fail to produce 300-400 pieces of flange that you would normally sell during the day, you feel it." To top it off, Machine Specialty and its competitors were in the middle of a two-year price war, and the company couldn't afford to lose ground.

The solution Vige found was so successful that, 18 months later, he has transformed almost every CNC machine he owns and improved production by 30%. And he did it without buying a single new machine.

That solution was OpenCNC software from MDSI (Ann Arbor, MI), an open-architecture CNC package that uses no proprietary hardware or motion control cards. Because it runs on off-the-shelf PCs and Microsoft Windows operating systems, users are not locked into proprietary arrangements for hardware, control repair, or control upgrades.

Vige credits the package with helping him:

* Reinvigorate his old machine tools

* Gain access to machine data that helps him manage his company

* Avoid having to buy new machines

* Gain control over production

* Stay competitive.

* OpenCNC gave me a jump on everybody I compete against," he says.

Machine Specialty has been in business more than 20 years. With about 75 employees, the company makes pipe Ranges and fittings for a variety of oil and gas applications, from deep-water drilling in the Gulf of Mexico to the North Sea, where they perform critical applications such as containing high-corrosion fluids or withstanding pressure of up to 20,000 psi (138 MPa). The business is competitive and global.

As company president and coowner, Vige constantly looks for manufacturing solutions to help him optimize profits and resource utilization. Machine downtime costs money-$8500 per day per machine, Vige estimates. He figured his Warner & Swasey lathes were down about 20% of the time with control problems. When he realized he was spending $2,000-- $3,000 per machine per month to keep the old controls going, plus what it was costing him every time a machine stopped, enough was enough.

Besides upgrading his old machines, Vige was looking for answers to several manufacturing problems. He wanted to decrease cycle times. He wanted a control that in-house maintenance personnel could service. He wanted to use existing servos and drives. And most of all, he wanted access to data.

"I needed a better tracking system for what was going on with each machine," he says. "How long is the machine running each day? How long does it take to do a batch of parts? How many parts can be done in one day per machine? I can't get this information from traditional controls."

When Vige heard about OpenCNC, he knew it was what he wanted. "It was software that let me use any drives that I wanted or any PC," he said. "I didn't have to buy a whole package. I could buy the best drives or the best PC I wanted. The MDSI control doesn't care which one you use. It's software, so we can put it into any package we choose."

The first machine retrofitted with the software was a W&S 2 SC lathe. Eldon Richardson, an MDSI integrator out of Meridian, MS, performed the retrofit, which involved pulling all the wiring from the old cabinet, removing the old control, installing OpenCNC on a new PC, rewiring the panel, and programming the machine. The old servos and drives were in good shape, so he left those in place.

Machine Specialty machinist Mike Thibodeaux worked with Richardson to learn about the software. Since that first machine, they have refined the retrofit process so that Thibodeaux and other Machine Specialty employees strip out the old control and remove all the wiring. At his shop, Richardson builds a bolt-on case for the monitor and PC, loads the OpenCNC onto the PC, and programs it. He then takes the completed package back to Machine Specialty, where he re-wires the machine and puts the new control in place.

Richardson says the process goes quickly if existing servos and drives are kept, which is what Machine Specialty chose to do on most of its machines. "The first machine took about two weeks," he says. "Now, it's much faster. We have actually taken four machines down at the same time, retrofitted them with OpenCNC, and had all four of them up and cutting parts in just eight days."

Jet Engine Repair Flies High With CNC

2007-06-02T03:17:00.000-07:00

CASE HISTORIES OF MANUFACTURING PROBLEM SOLVING

Engine components for Air Force One, aircraft parts riddled with bullet holes, jet engine cases ripped open by ice and other projectiles-these are just some of the repair and overhaul jobs that Component Repair Technologies Inc. (Mentor, OH) has handled in its more than 20 years in business.

CRT was founded in 1985 by Tom Wheeler and Chuck Bart as an independent turbine engine overhaul shop. Over the years, the company has expanded its facility and process capabilities to perform all repair work inhouse. Messrs. Wheeler and Bart pride themselves on their extensive capabilities that enable them to control costs, minimize turn times, and deliver quality work to a customer list that includes major OEMs, commercial air carriers, and large engine shops.

The company, which occupies a 115,000-ft2 (10,683-m2) facility, is segmented into three business units according to product category: cases (turbine sections of engines), rotating workpieces (shafts, disks, and spools), and small parts for both small and large engines. Each unit is set up in cellular configuration with its own machining, assembly, and inspection capabilities.

CRT initially depended on large manual boring machines and manual lathes for its machining. As the need for more complex machining capability became apparent, the company has moved to adopt the latest in CNC technology to improve productivity, quality, and production flexibility.

In 1999 the company expanded its capability to handle large duct replacements and flange replacements in the cases unit. "We needed the ability to contour using CNC technology," explains General Manager Andrew LaTourette.

"You can contour manually, but it's very time-consuming if you don't have the capability to do pick feeds and repetitive back and forth necessary for stock removal." For CRT, this work is especially challenging because the cases are thin-walled and made of high nickel 718 and 625 Inconel. "These are gummy and unforgiving materials," LaTourette points out.

Most of CRT's jobs don't lend themselves to pushing off a lot of stock. Instead, the company does a lot of skim-and-trim finesse machining. "When you are doing flange replacements or replacing large duct segments, you have to keep things round and parallel," LaTourette explains. "The problems crop up when you get to the finish size because the parts will have a residual stress, and that's tricky to machine and keep round-especially when you have ±0.003'' [0.08-mm] tolerances on a 43'' [1.1-m] diam."

The need for the capabilities that CNC machining could provide was apparent to CRT. "In the aircraft repair business, we have to stay sharp, offer excellent quality, and really keep pushing ourselves on our process capabilities so we can compete and stay in the game," says LaTourette.

"We're both a job shop and a custom manufacturer. Even though 65% of the parts go through the same work scope, all bets are off because you never know how someone is going to treat an airplane engine. We think of everything as a one-off. Our turnarounds are tight, so the flexibility of our CNC machines is critical," he explains.

Over the last six years, CRT has invested in four CNC machines from Absolute Machine Tools Inc. (Lorain, OH): two You Ji YV-1200ATC vertical turning lathes; a Johnford VMC-1600SHD for its cases unit; and a Johnford DMC-1500H bridge mill, which was recently installed in its small parts unit.

The YV-1200ATCs turn all the angular geometry on duct and flange replacements. "The grooves are whittled out on the You Ji VTLs," says LaTourette. "You plunge the slots, cut to size on the drop, cut the shelves, and once all that cutting is finished, a right-angle head takes over. Then we machine the slots, the scallops with a straight mill, and the hole patterns. We also do the geometry on the other side of the case."

All this work could be done on manual machines with form tools, LaTourette admits, "but not economically or even competitively."

The You Ji machines also helped CRT move certain parts out of the grind room. The company formerly ground a particular hub component to tight tolerances on its ID/OD grinders. Now it single-points the part to size on the You Ji VTLs, reducing grinding time by about 12 hr. The two You Ji VTLs are set up so that only one operator is needed to run both machines.

Grouped next to the two You Ji VTLs is the Johnford VMC-1600SHD. The VMC is equipped with a 31.5'' (800-mm) precision turntable that provides a fourth axis. It also includes right-angle heads that supply a manual fifth axis. The additional axes allow CRT to do bolt circles without changing tools, and the VMC also has probing capability.

The flexibility of the Johnford VMC has allowed CRT to pursue additional duct and flange replacement work. One such job calls for the Johnford to drill 102 holes in a flange for rotation pins and tackle all the scallop work on the part.

"You can do a large flange replacement like this manually and drill all the holes, but not competitively," says LaTourette. "You really have to push the envelope today if you want to stay in business."

HEDG plunge grinding saves crankshaft costs

2007-04-21T05:14:00.000-07:00

Cranfield University's production trials have revealed potential costs saving using High Efficiency Deep Grinding - or HEDG - technology in the plunge grinding of automotive crankshafts.

Cranfield University's School Of Industrial and Manufacturing Science, Cranfield, UK, has employed a Holroyd Edgetek SAT super abrasive grinding machine as part of a three year programme to develop a deeper understanding of the mechanisms of metal removal using HEDG (High Efficiency Deep Grinding technology). The investigation culminated in a series of tests on a Cinetic Landis LT2 used to cylindrically plunge grind automotive crankshafts with metal removal rates up 1000mm3/mm.s. No thermal damage to sidewalls was recorded.

Achieving these increased removal rates has unlocked the potential of rough grinding to make the HEDG process competitive against more traditional methods.

The study at Cranfield was a collaborative project sponsored by EPSRC between the University, Holroyd, Cinetic Landis Grinding, St Gobain, Liverpool JMU, Castrol, Stesstech, and Element 6.

It was organised and undertaken under the direction of Professor David Stephenson, a world authority in grinding technology.

'The objective of our research was to establish a model which explains the thermal characteristics of metal removal under HEDG conditions and then apply this to machining standard automotive crankshafts,' said Prof Stephenson.

'Many production engineers are aware of the potential that exists to optimise existing industrial process chains using today's high performance grinding machines and the latest super-abrasive technology'.

'HEDG is one such example; its high material removal rate offers the potential to improve cycle times whilst maintaining surface integrity, form and finish requirements.' One of the key requirements on automotive crankshafts is that the pins and mains both require journal diameters and web sidewalls to be ground.

The pins require wide short path grinds, typically using high spindle power levels, while the mains need narrow and longer path grinds, which are not normally limited by the available spindle power, but by issues of thermal damage.

The major ramification of this is that the webs or sidewalls of the crankshaft are particularly suitable for the application of HEDG technology.

HEDG delivers improved 'Burn Threshold' qualities that result in lower grind temperatures of the workpiece, and overall improvement in the quality of the finish itself.

In addition, HEDG offers great potential to improve process times and, as a consequence, helps manufacturers to gain a competitive advantage.

The Cranfield research comprised grinding trials, which were carried out in two stages: initially utilising test-pieces in a laboratory environment, followed by automotive crankshafts on production machinery.

The test pieces themselves were selected steel and cast iron materials.

One of the major issues faced by the research team was that, in order to increase specific material removal rates (Q'w) to levels far higher then currently used commercially, it was necessary to understand how the heat energy is partitioned to the workpiece.

This was achieved using thermal models specifically developed for high removal grinding; and by employing a novel temperature measurement technique adapted for cylindrical grinding.

During the initial work, tests were carried out over a range of Q'w from 100 to 2000mm3/mm.s on steel samples.

Power data were recorded and then used to predict surface temperatures using the thermal model.

A second set of trials was then carried out on production machinery with both steel and cast iron crankshaft components.

A similar range of Q'w rates was investigated.

In this case the simple shaped grinding wheels were replaced with two fully profiled left and right hand wheels, to enable the production of the undercut form, blending sidewall and diametrical features, and any differing width requirement.

The initial set of trials was conducted using a Holroyd Edgetek SAT super abrasive turning machine, while the second set, which were validation trials, took place on an LT2 machine at the Cinetic Landis factory, under actual production conditions.

The CNC controlled Edgetek system provides cutting speeds of up to 12,200m/min, courtesy of a high power, variable speed 37kW spindle motor operating at 9000 rev/min max, and CBN electroplated wheels, which provide long wheel life.

Coolant nozzle design had to be improved too.

Delivery of the correct amount of workpiece coolant and lubricant to the work zone is important to reduce the heat being transferred into a workpiece.

The Edgetek machine is fitted with a very stiff grinding spindle, which uses hybrid ceramic bearings that facilitate the very large cuts possible with HEDG.

In addition, the granite polymer composite base offers excellent damping properties, virtually neutralising resonant frequencies within the machine that could impair its accuracy.

The result of this synergy is a machine that allows heavy stock removal on straight outside diameters (ODs) or special form diameters to grinding machine tolerances on virtually any difficult material or Rockwell hardness.

* Results - the results for both the initial and production stages of the trials correlated well.

The industrial application of the process initially considered a small number of steel crankshafts ground over a range of Q'w, and then a batch of 1000 with a constant stock removal rate.

The batch run demonstrated process stability with grinding power levels remaining consistent throughout.

Crankshafts were checked for form and surface finish requirements and remained well within specification; typically 50 micron for concentricity and 2.3 micron Ra for surface finish.

The application of the increased removal rates - 1000mm3/mm.s for sidewall and 200mm3/mm.s for diameters on the crankshafts, offers the potential to save cycle time in full production for both steel crankshafts and cast iron crankshafts.

In addition, even with the increased removal rates, the specific grinding energy (SGE) versus Q'w relationship showed a similar trend to previous surface HEDG investigations, with the SGE reducing at higher Q'w values.

This means that a greater proportion of the energy is removed by the grinding chips, resulting in a reduced energy input to the workpiece within the HEDG regime.

Summing-up the results of the trials, Prof Stephenson said: 'Our study has shown that the performance level of standard production machinery currently in use within the automotive industry can be extended to provide a number of major advantages'.

'These are, firstly, more efficient grinding regimes that compete with conventional cutting processes in terms of stock removal rate; secondly, reduced manufacturing costs as a result of higher production rates and lower capital investment; and thirdly, improved surface integrity and, therefore, better component performance and reliability due to relatively low workpiece temperatures.

CNC punch press choice based on experience

2007-04-14T03:46:00.001-07:00

A generous specification for a cost-effective price and a short delivery time led to the choice of another CNC punch press by a switchgear manufacturer, based on past experience.

Howarth Switchgear has built its business on providing exactly what customers want when they want it, and to give it the capacity and flexibility to meet these demands it has just invested in a new LVD Parma 1212 CNC punch press. Director Chris Howarth says that the key arguments for the Parma were that it gave a generous specification for a cost-effective price and a short delivery time. He was also convinced it would be reliable, as the company had been running a punch press from LVD's predecessor Shape Machines for the past twenty years with very few problems - and those problems that did occur were fixed very quickly.

'The Shape machine has worked well for us with very few breakdowns, but we thought it was time to move on,' he said.

Howarth's business is building electrical switchgear systems for all kinds of non-domestic premises - from banks and call centres to chemical plants, food processors and military installations.

And even though they try and incorporate standard elements, no two systems are the same.

'Every building is different and the system requirements in buildings are changing all the time,' said Howarth.

'If you are refurbishing a building you are going to need 100 to 150% more power because everything now is IT-oriented.

And if you have more computers you need more air conditioning to deal with the heat they give out.

The result is that they end up trying to get much more switchgear into the same space as they used before.

So it all has to be specially built.

The other problem is that sometimes the switchgear may be in a basement or on a roof and you have to design it in sections so that you can get it through the existing services.' Co-director Anthony Howarth added, 'Because we have a bespoke product we feel we have to do all of our own sheet metal.

Although systems may look similar there are always small differences that would make it very difficult for someone working with standard cut parts or bought-in frameworks.

If we relied on anyone else's casework we wouldn't be flexible - we give the customer what they want rather than what someone else stocks.' As well as this flexibility, the other factor that allows Howarth Switchgear to offer a premium service is its speed of delivery - and again, the only way to ensure that is to manufacture the critical components in house.

'We are mass producing one-offs, but that is what you have to do.

The Parma might seem quite a big machine for what we do, but the way we see it is that if you can do what the customer wants and react more quickly you will get more work in.

Because we can deliver on time with what the customer wants, they will be able to get the plant up and running sooner.' The LVD Parma punch press offers the speed and flexibility of programming and production that Howarth Switchgear needs.

With a 21-station turret including three direct-drive 50.8mm auto-index stations it gives a wide range of options with a standard tooling setup - and it needs it as Howarth designs and makes around 250 new parts every month.

The Parma 1212 features GE Fanuc 0iP CNC control, and rugged frame and table design to achieve tight tolerances and consistent punching accuracy.

LVD says that it can deliver up to 300 hits/min on 25.4mm centres, and nibble at up to 650 hits/min with a finished part accuracy of +/-0.1mm and +/-0.05mm finished part repeatability.

As Anthony Howarth explained, 'Auto-indexing isn't new technology but it will offer a lot more possibilities, and the programming is much more flexible and faster.

We aren't stubborn and are very prepared to grow into the capabilities of the machine and the software.

One of the things I liked about the Parma was that the punch press and the software came as a package, and the Cadman P 3D software has an unfolding module so that you can flat pack your parts from a 3D file.' The speed and quality of the manufacturing process is extremely important to Howarth's work and cash flow, said Chris Howarth.

'These can be really large installations and a considerable amount of cash (in components) can be tied up on the shop floor.

What we were looking for with the Parma was performance and flexibility at a cost effective price and we are now applying the Parma's advanced technology to speed up our work flow which in turn can only benefit our customers.'

Slitting die tooling offers longer regrind life

2007-04-14T03:45:00.000-07:00

Slitting die tooling system for CNC punch presses uses a tough and wear-resistant premium tool steel for the slitting die blade to offer twice the regrind life of standard tooling.

The Wilson 2-4-1 Slitting Die system is the latest innovation developed by Wilson Tool. The 2-4-1 Slitting Die system offers twice the regrind life over a standard solid die. The Slitting Die blade is manufactured from Ultima, a premium tool steel which is tough and resistant, excelling in applications which demand long-term wear resistance and toughness.

Ultima can further extend the tool life by up to 400% compared with a standard die, representing considerable cost-savings on replacement tooling.

The special die insert, exclusive to Wilson Tool, is fully supported by the die base which is made of a special shock-absorbent steel designed to resist the repeated impact that can sometimes cause conventional dies to crack.

As the die insert is reground, the shims supplied with the assembly can be used to return the die assembly to the correct height.

When the die insert wears out, a new 2-4-1 insert can be purchased for less than the price of a standard replacement die.

CNC punch presses have large turret capacity

2007-04-14T03:44:00.002-07:00

Robust, thick turret tooling style CNC punch presses, 200 and 300kN, offer a large turret capacity with a versatile mix of stations and the largest feed clearance in the industry.

LVD introduces the Verona Series of CNC turret punch presses offered in 200 and 300kN models (20 and 30 tonf). Verona turret punch presses are robust, full-featured machines designed for high production demands. These Thick turret tooling style punch presses offer a large turret capacity with a versatile mix of stations and the largest feed clearance in the industry.

Powerful control capabilities and programmable features make Verona punch presses easy to set up and operate.

Engineered for high productivity and long life, Verona punches materials up to 6.4mm with a maximum hit rate of 1000 hits/min at 1mm pitch.

A state-of-the-art positioning system combines heavy sheet carrying capacity with accurate motion control to produce a finished part accuracy of 0,10 mm with a repeatability of 0.05mm over the entire table.

Bridge frame construction provides accuracy and durability.

LVD's latest punch presses handle workpieces up to 1524 x 2500mm depending on model.

Larger workpieces are handled with clamp repositioning.

Smart Clamp, a standard feature, automatically determines exact clamp locations to provide the smallest possible no-punch zone.

* Advanced hydraulic ram technology - an advanced servo hydraulic press drive and easy-to-use interactive software optimize Verona's high-speed operation while reducing noise and shock.

Fully programmable stroke profiles and patented Smart Stroke feature maximize punching performance and provide flexibility for punching and forming applications.

Smart Stroke automatically optimizes the punch cycle by determining the hover height based on material thickness and distance between holes, maximizing productivity without operator or programmer intervention.

Up to 48-station turret capacity - Verona's large and versatile double-track turret provides flexibility and easy set- up.

Every station accepts shaped punches and dies, reducing set-up time.

A unique mix of turret stations provides exceptional capacity.

Verona 20 tonf models offer a 34-station configuration with four 88,9 mm auto-index stations.

The 30 tonf machines offer 48 stations with three 88.9mm auto-index stations and one fixed 88.9mm station or 114.30mm station.

The 114.30mm station is ideal for producing large louvers, special forms or using full-size parting tools.

Turret capacity can be increased with the addition of indexable Multi-Tools to expand the number of auto-indexable tools.

* Feed clearance of 25mm - Verona also provides enhanced forming capabilities with a full 25mm feed clearance between the upper and lower turret.

This generous feed clearance allows for the production of higher forms such as lances, louvers, embossments or card guides.

The punch press accommodates the latest in tooling technology for high-performance fabricating.

These capabilities further reduce set-up time, enhance productivity and promote long life with minimal maintenance costs.

Wheel tooling, including rollcut and rollform capabilities, permits quick and efficient cutting and/or forming of straight or curves shapes without nibbling.

Verona machines also employ part marking technology for part number or sheet marking requirements and can utilize tapping tools.

* Powerful PC-based control - Verona is equipped with a state-of-the-art, PC-based GE Fanuc 180i control that speeds set-up and delivers powerful features such as diagnostics, increased program storage capacity and networking.

Optional CADMAN programming software provides full support for all standard and advanced punching functions, including Auto-Index stations, Multi-Tools, standard and special punches, forming, embossing, tapping, stamping and wheel-style tools.

* Robotic pick-sort material handling system - material/part handling can be automated with the addition of an automatic sheet loading/unloading system and parts sorting device.

LVD's automatic load/unload system reduces manual worksheet handling and provides fast, efficient processing of materials up to 3.5mm thick.

Verona may be integrated with a robotic Pick-Sort material handling system.

The robotic system loads full size sheets and automatically retrieves and stacks individual punched parts with dimensions up to 1000 x 2000mm.

The Pick-Sort system converts the Verona into a freestanding, lights-out production cell.

* About LVD - LVD is a leading manufacturer of a comprehensive range of sheet metal/plate working machine tools and software solutions, including laser cutting systems, punch presses, press brakes, guillotine shears and automated flexible manufacturing systems, integrated and supported by its CADMAN PC-based Windows compatible software.

Tool systems fit punching requirements

2007-04-14T03:44:00.001-07:00

Danobat Punch Press users can select from a full range of high performance Mate tooling systems to fit the exact nature of their punching requirements.

Danobat punch press users can select from a full range of high performance Mate tooling systems to fit the exact nature of their punching requirements. These include Mate Ultra TEC, Mate Ultra XT, Mate original style thick turret tooling, and the Mate Ultraform forming tool system. Mate Ultra TEC is a full-featured, highest performance thick turret punching system that increases tool performance and flexibility, offers extended tool life, and allows interchangeability with existing systems.

Features of the Ultra TEC system include: premium high speed tool steel, quick tool change, easy click length adjustment (no shims or tooling required), grooved guides for best lubrication, Slug Free Die design, and relieved strippers for extended grind life.

Mate Ultra XT is a new tooling alternative with more features than original style thick turret tooling but not as full-featured as the Ultra Tec line.

Designed to give press operators extra setup convenience, the system is another choice to achieve the highest quality punching at the lowest cost per part.

Ultra XT has these high performance features: premium high speed tool steel, quick tool change, easy click length adjustment, grooved guides for best lubrication and Slug Free Die design.

Mate Original Style Thick Turret Tooling is an economical thick turret tooling system that is fully OEM compatible with design enhancements that include: premium high speed tool steel punches, hexagon shaped 1/2' A and 1-1/4' B station punch heads for easy adjustment and maintenance, and Slug Free Die design.

All three tooling systems are available in sizes for 1/ 2' A station, 1-1/4' B station, 2' C station and 3-1/2' D station.

All Mate Tooling systems are 100 percent unconditionally customer satisfaction guaranteed.

Danobat users can gain a competitive advantage by using exclusive Mate Ultraform special assemblies to expand their fabricating capabilities while eliminating expensive secondary operations.

Examples include the new Mate HexLock system, which provides an alternative to self-clinching fasteners, and the Mate SnapLock assembly, which creates fabricated joints without secondary welding operations.

Convert power press into flexible punching

2007-04-14T03:42:00.000-07:00

A CNC punching tool converts an existing mechanical power press into a 2-axis high capacity flexible punching unit by adding a numerically controlled roll feeder and traverse slide.

Shear-Form Machine Tools, Coventry based sheet metal and plate working machinery supplier and the sole UK representative for Dimeco Groupe, the French coil processing equipment manufacturer has launched 'Decopunch' a new CNC punching tool that converts an existing mechanical power press into a 2-axis 'Flexipunch' high capacity punching unit by adding a numerically controlled roll feeder and traverse slide. The slide is used to move a removable cassette, which is fitted with cartridge tooling, actuated by built in selectors. It is suitable for manufacturing punched or embossed components without any limitation on length and up to 800mm wide, such as cable trays, storage racks and computer racks as well as Z and C purlins and building structures.

It can also be used for nesting and stamping circular components producing up to 10% savings in material costs.

Features of 'Decopunch' include flexibility with components with the same width but different lengths being produced in a row one after each other, thereby reducing down times.

It can be adapted to fit to 'C' frame or straight sided presses, whilst the tooling cassette can hold up to 12 cartridge tools and be change in less than 3 min.

The Siemens servomotor with its twin pitch control system produces a +/-0.1mm component length accuracy.

Dimeco's user friendly Simostar 12in graphic touch screen control terminal supplies the operator with manufacturing data such as parameterised product lists, maintenance requirements and instruction manuals, whilst production programs can be prepared offline using the installed software.

CNC sliding head automatic lowers batch sizes

2007-03-27T03:51:00.001-07:00

Connector parts are produced within tolerance and at lower cost on a CNC sliding head automatic and economical batch sizes are 200-off and less.

A recent convert to CNC sliding-head mill-turning, Hampshire, UK subcontractor Croft Engineering supplies a local electronic equipment manufacturer with connector parts that were previously produced by another contract machinist in the UK to a lower standard on cam automatics. For years the customer thought that the poor quality was normal; then it approached a subcontractor in India to try to obtain a better price and was disappointed at the quality of the samples that came back. The parts are now produced within tolerance and at lower cost on Croft's multi-axis Star SR-32J sliding head automatic lathe, according to Jason Mortara, joint owner of Croft with his parents, Paul and Judy.

Furthermore, economic batch size is down to 200-off or less and delivery is fast, factors that are of considerable benefit to the customer, as it specialises in bespoke electronic instruments for niche markets.

The arrangement has worked so well that in the first seven months, over 50 different styles and sizes of connector from 6 to 16mm diameter and up to 30mm long had been produced on the Star.

What was originally envisaged as GBP 15,000 of business annually will in the 12 months to March 2007 be at least double that figure.

So pleased is the customer that its proprietor has written a letter to Mortara stating, 'The improved quality and delivery times from Croft, together with keener prices, have enabled us to give a better service to our existing clients and to gain new business from our competitors.' Croft found that there was little money to be made using its manually operated machine tools, so a few years ago the company invested in a CNC chucking lathe and milling machine.

However, staff costs were high because most parts still needed subsequent operations, and overheads such as rates and electricity were climbing.

Competition was fierce and profit margins remained slim.

It became obvious that a change of direction was needed.

Enquiries were being received for components that were more suitable for sliding-head machining.

So a study was carried out which showed that the best lathe for the type of work under discussion was the Star SR-32J.

An investment of over GBP 100,000 in a machine tool is a big step for a family-owned company, but Croft was getting all the right signals from potential customers, such as the electronic equipment manufacturer which happened to call in for a simple manual job to be done, and a press shop in Oxford that needed low cost, threaded inserts in quantities of 4,000-off.

Discussions with these two prospects, coupled with on-going machining of concrete drill adapter components up to 32mm diameter for another party, eventually persuaded Croft to take the plunge.

A second-hand sliding head machine was rejected, as Croft was new to the technology and needed the reassurance of having a comprehensive service package including warranty, cycle time estimates, programs, training, tooling advice and telephone helpdesk.

'All have been readily forthcoming from Star GB,' said Paul Mortara.

'It has been a very good experience.

We were comfortable with the Star lathe, Fanuc control and FMB bar magazine three months after installation - earlier than we thought.' He added: 'Star even recommended the finance house, which was able to offer good terms as it is familiar with the higher-than-average residual value of the machines.' Since the SR-32J was installed in March 2006, the situation at Croft Engineering has been transformed.

Few subcontractors in the area have such a capable mill-turning facility, so competition is much less.

Once set, the bar-fed machine works around the clock with minimal attendance during the day and unmanned overnight, turning out top quality components.

Paul Mortara sums up the advantage of the SR-32J using the example of the concrete adapter parts that the firm has been making since 1993.

Initially the components were machined entirely manually; then using the CNC chucker followed by manual drilling, tapping and hexagon milling on three separate machines; and finally in automatic, 'one-hit' cycles on the Star.

Where it used to take approximately 40h to machine a batch of 500-off, it now takes a third of the time with very little manual intervention, added to which quality is greatly improved.

Full use is made of the SR-32J's capabilities.

Tolerances within 10 micron are routinely held, whereas that was far more difficult on Croft's other production plant.

All parts are transferred to the opposed sub spindle for reverse endworking and around half undergo driven tool operations.

Of the other 50% of components, some can be extremely simple, prompting people to suggest one does not need a CNC slider to produce them.

Croft's experience is that these are machined just as cost effectively as more complex parts.

Jason cited the example of valve guides they produce in various sizes for classic cars.

Each guide requires only a short cycle, but all are very price-sensitive.

The job was referred from another subcontractor that was unable to be competitive.

Croft's view is that even if a majority of work is relatively simple and only the occasional part requires a complicated machining sequence, there is no problem justifying the purchase of a CNC sliding head automatic.

Unit production cost will always be an issue for customers, yet a subcontractor must be able to amortise a machine tool over a reasonable period.

One method that Croft uses to assist in meeting these conflicting needs is to suggest to a customer that design changes are made to a component so that it can be produced in a shorter cycle time on the Star, and perhaps in one operation rather than in two or three.

Another cost-down technique is to offer to fulfill a non-urgent order during the following week, say, when the correct size and type of bar is scheduled to be in the magazine.

This saves set-up time and reduces the price per part.

Paul Mortara concluded by commenting, 'Manufacturers in the UK often do not want to have their components made abroad, but feel that they are forced to by customers demanding ever lower prices.

Now there is another option to consider.' He said: 'Highly automated, multi-tasking machine tools like the Star are the answer to keeping work in Britain.

We will probably buy a 16mm or 20mm model next, which will be even more economical at producing smaller parts and increase our competitiveness further.'

CNC 8mm bar automatic lathe has live tools

2007-03-27T03:50:00.002-07:00

An 8mm capacity, single spindle, CNC automatic lathe now has a motorised unit to power live tooling and there is also an option of a workpiece conveyor with the machine.

The world's first 8mm capacity single-spindle, automatic lathe with tailstock - the Deco Sigma 8 (Previously Deco 8sp) from Tornos has undergone product enhancements. Since its launch in 2005, the highly successful Deco Sigma 8 with five basic linear axes now incorporates a motorised unit for live rotary tools and a workpiece conveyor belt to deliver additional productivity options for customers. The new motorised unit enables the user to install a front-mounted and a rear-mounted live rotary tool for simultaneous main and counterspindle operations respectively.

This allows customers to conduct drilling, face milling on or off axis, tangential milling on the diameter with polygon cutting, thread whirling and thread milling currently being researched.

This development brings significantly improved capability to the Deco Sigma 8 allowing customers to achieve relatively complex component manufacture without the cost of a high specification machine.

This development enables the workpiece to be machined on its front and rear faces within compact dimensions whilst retaining every tool position.

It also allows rotational speeds to be set digitally as it is powered by the same S11 motor used to drive transverse spindles.

This new development has a maximum rotational speed of 10,000 rev/min and is suited to ER8 collets with a maximum 5mm tool shank diameter.

The unit can be mounted right at the back of the tool system X1/Y1 and can replace the 'L-shaped' tool support for 2 x 4 fixed turning tools (front and back).

Whenever this equipment is being employed, an 'L-shaped' bracket can be mounted to hold 6 fixed-position axial tools, three at the front and three at the back.

* conveyor system - the Deco Sigma 8 developed from extensive market research enables Tornos to address markets such as the electronics and medical.

The second development, the workpiece conveyor belt lends itself to these specific sectors and enables customers to enhance productivity and simplifies post operation handling of components.

This option enables workpieces to be conveyed from the workpiece separating unit, which is located outside the machine.

The machined workpieces are collected in a perforated tray and when another sorting system is used such as a turntable or a bucket distributor, a workpiece slide can be mounted in place of the tray.

The conveyor belt enables the end user to remove workpieces safely with a conveyor belt speed that can be adjusted to suit the work cycle.

The belt feed rate is fully adjustable and can operate from 1.2 to 21m/min.

This unit can be adapted to work with the customer's choice of external workpiece retrieval and sorting system, making it a truly universal system.

Powered spindles and complex machining

2007-03-27T03:50:00.001-07:00

The MultiAlpha 8x20 and 6x32 machines with their powered spindles and complex reverse face machining capability are well suited to machining complex components in a single operation.

The ongoing product implementation strategy for multi-spindle turning units at Tornos is progressing in giant steps. The recently launched MultiAlpha 8x20 and 6x32 machines with their powered spindles and complex reverse face machining capability are well suited to machining complex components right through to completion in a single operation. To enhance this capability even further, four additional units are being fitted to the new machines with immediate effect.

The first of the new innovations is the Y axis on the slide-rest.

This is an ideal addition for manufacturing complex components as it simplifies challenging operations such as offset transverse bores, the milling of surfaces with transit functions, the milling of slots and the deburring of transverse bores.

An extensive and diverse range of macros are provided to make these functions easy to program, giving the end user the immediate benefits.

The Y-axis on the slide rest has a 12mm stroke with a torque of 1.5Nm delivering a maximum speed of 8,000rpm.

For customers requiring more speed, a 0.75Nm unit is available to deliver 16,000rpm with gearboxes being readily available to enhance spindle speeds further.

The Y axis frontal unit is an option that exists in two versions - one as a driven unit and the other one not driven.

The non-driven unit is used primarily for internal machining.

This makes it possible to perform processing steps directly from the front, which were previously carried out using the slide-rest.

This leaves the slide-rest free to perform other machining operations simultaneously.

Here too, macros can be employed for operations such as internal thread whirling to simplify the task.

The second variant takes the form of a frontal Y axis with drive unit.

Complex components frequently require several drilling operations from the front with relatively narrow diameters.

This equipment is ideally suited to this purpose.

Thanks to the powered spindles, bar stock can be positioned virtually anywhere.

This unit, like the Y axis on the slide rest has 1.5Nm of torque with a maximum speed of 8,000rpm with the option of a 0.75Nm unit with a maximum speed of 16,000rpm.

The new transverse drilling unit is proving to be the icing on the cake for Tornos customers.

It is a small and powerful unit that can be fitted in any position without problem thanks to its intelligent symmetrical design.

This equipment can be retrofitted to existing MultiDECO units as well as the new MultiAlpha 8x20 and 6x32.

The modularity of this unit is further enhanced by equipping it with a diverse range of heads, either in the form of a direct drilling unit or with a 90 degree head for performing lateral drilling/milling operations.

The drill has 2Nm of Torque with a maximum speed of 8,000rpm, however there is the option of a gearbox that will provide a torque output of 10Nm with a maximum speed of 1,250rpm.

With these standard items of equipment, Tornos is consistently striving to enhance its multi-spindle product strategy, enabling complex components to be machined through to completion in a single fixture setting.

CNC automatics replace cam-driven lathes

2007-03-27T03:49:00.000-07:00

Replacing cam-driven automatic lathes with CNC sliding head automatic lathes means a couplings maker can benefit on delivery and price and run machines 'lights out'.

The replacement of cam-driven turning with high-technology citizen cnc mill/turning machines has given John Elliot, the 83-year-old managing director of Quality Couplings, a new lease of life. 'The new machines have transformed the company,' he said, 'Giving me completely renewed interest - you could say I've developed a totally new outlook on life.' Following the installation of two Citizen C-Series CNC sliding head automatic lathes Elliot reflected: 'One immediate benefit of CNC technology is that we know exactly where we are with production, quality, delivery and price, and the company is already benefiting from reduced cost of production per part as the new machines are run unmanned at night.' That's a 'far cry' from the situation 12 months ago when he was facing the spectre of a future lack of skills for his traditionally bread-winning, but ageing, cam-driven machine based turning operation as four of his key autosetters (with 75 years service between them) look forward to retirement next year. He decided then it was time for a change and to adopt high technology mill/turning.

After spending some time looking at the leading CNC sliding head machines on the market, he decided in 2005 to buy the two Citizen C-Series machines from NC Engineering in Watford, UK.

These were installed in a refurbished factory unit just four units away from his cam machine shop and arrangements were made for NC Engineering to retrain an autosetter, Dave Reynolds, (who can tell the tales of some 50 years of being around automatic lathes) while 26-year-old CNC setter/operator, Paul Holliman, was recruited to run the new Citizen C16-VII and C32-VIII machines.

Born in 1923, Elliot left school at 14 to serve a seven-year apprenticeship as a pattern maker, followed by several years in the Merchant Navy during the war.

When he was 58, he bought Quality Couplings from The Receiver - at a time when many would rather be thinking of retirement rather than building a business - and moved the company from Birmingham to its current base in High Wycombe, Buckinghamshire.

He set about using traditional cam autos to produce turned parts for pipe fittings, and over the years progressively built a very successful business.

Today, he runs the two machine shops from an office on the shopfloor.

He wakes at 5 am every morning, arrives at work by 7 am and most evenings leaves at 4.45 pm on the dot.

In March next year, he is due to be featured in a Channel 4 television documentary.

Quality Couplings has a customer base of some 600 clients spanning heating and ventilation, gas burner, valves, pipe and hose fittings, pneumatics, heating, hydraulics and automotive suppliers, and it manufactures batches ranging from 500 to 10,000 parts.

CNC machining now takes priority at the firm ('Once established with the Citizens we despatched 11 cam machines to a company in Birmingham,' he said) though six cam machines continue to be used.

However, capability to mill and turn parts of various levels of complexity in a single operation is dictating as much work as possible through the Citizen C16 and C32.

This is confirmed by Holliman, who reckons over 700 programs have been written since the machines were installed in April 2005.

Machines are often reset in the afternoon ready for the next job to run through the night and when the batch is completed, the machine switches off and is reset in the morning for the next part.

Due to the wide variety of batch sizes Holliman prefers to program at the machine while its running, working to the scheduled work load laid down by Elliot.

Far from sitting contemplating his life, Elliot is continuously busy.

He still goes to see customers, takes most of the phone calls to Quality Couplings and ensures all the machines are fully loaded with jobs.

'I issue the job cards manually - but early in 2007 we will be computerised, which will also help me control stock,' he said.

Computers will be an important addition to the citizen machines as with such a large customer base and a big demand for production call-off from stores for quick delivery, Quality Couplings has around GBP 1 million of finished stock components.

Other tasks performed by this most senior of managers is the raising of invoices and checking invoices from suppliers.

'There is no hierarchy in this business,' he said, 'I also do most of the quotes working with the setters to establish cycle times - well at least for CNC - I can still do cam machine quotes with my eyes almost shut, a factor of doing it for so long.' Both Citizen C-Series machines installed at Quality Couplings have main and sub spindles with two-gang tool slides enabling simultaneous machining with three tools.

The C32-VIII has an 8,000 rev/min main and 7,000 rev/min sub spindle with 14 tools and eight driven tools powered by 1kW motors.

The C16-VII has 18 tools plus eight driven by 1kW motors.

What has impressed Elliot is the support from NC Engineering.

'We had a couple of problems on a parts-catcher and for some reason a troublesome platen on the C16.

NC Engineering was able to locate and replace the platen the next day,' he said.

'Now that's what I call service,' he maintained.

While Elliot runs the day to day operation of Quality Couplings, his son, John 'junior', runs a submersible and surface pump supply operation from the same premises.

While not involved in his father's production interests, the two do vie for storage space and, with a knowing wink and a definite pride in his son's achievements, Elliot said he enjoys keeping the younger businessman on his toes.

'He's got to make space for my expansion,' maintained Elliot, 'Because I've got the bit between my teeth to adopt new technology and there will be more CNC machines installed soon.

Sliding head automatic lathe deep-hole drills

2007-03-27T03:48:00.000-07:00

CNC sliding head automatic lathe has a deep hole drilling facility and a motion control that allows very high speed cutting cycles for relatively simple turning operations.

A defining feature of the new Star SR-20RIII lathe compared with the RII model is its ability to drill a hole down the center of a 20mm diameter bar to a depth of 100mm, using the 3.7kW / 10,000 rev/min main spindle in conjunction with two additional front-facing tools mounted next to the opposed spindle. Another key feature is the Fanuc 300iS CNC with motion control, capable of very high speed cutting cycles for relatively simple turning operations when running programs created and optimised off-line using powerful computer-aided manufacturing software from Star. Conventional ISO programming and computer numerical control is reserved for producing more complex components.

The SR-20RIII will be demonstrated for the first time in the UK at customer launch days to be held at Star Micronics GB's technical centre in Melbourne, Derbyshire, on April 24-26 2007.

Star is also keen to point out that there will be special offers on certain machine models during the three-day event.

In addition, Iscar tooling will feature and Delcam will be making presentations on its Partmaker CAM software.

Managing director, Bob Hunt, is particularly pleased that the Japanese parent company has priced the new 7-axis mill-turn centre at a similar level as the original cost of an SR-20RII, so the additional RIII features are available at almost zero cost.

The specification of the RII has been reconfigured and will be offered alongside the RIII.

Further promoting high productivity are 35m/min rapid feeds in all linear axes, higher than on the RII and equivalent to the fastest machine in Star's range, the SR-10J.

C-axis positioning of the main and sub spindles in 0.01 deg increments is similarly fast at over 9 rev/s.

Despite the RIII's agility, it is a robust machine weighing 2.2 tonnes, capable of achieving very high accuracy and surface finish.

Spindle cooling ensures thermal stability and also contributes to high precision machining.

The working area can accommodate a large number of cutters in addition to the deep hole drills and the usual six ganged turning tools above the guide bush.

They include four front-facing and four rear-facing end-working tools in the main sleeve holder; up to 10 live cross-working stations, some of which may be swapped for more end-working tools or other attachments such as for angle drilling, hobbing or roller burnishing; and an independent, four-spindle back-working unit with live and stationary positions.

The design of a new product is not complete these days without measures to reduce its environmental impact.

Manual/CNC lathe expands turning capacity

2007-03-22T23:28:00.002-07:00

Subcontract machinist said his customers knew he had acquired a manual/CNC (combination) lathe because he could make several parts in the time needed previously to machine one.

Chris Evans has been running Buckwood Engineering on his own for the past 20 years, and that is just the way he likes it. 'After 15 years in the family business, which employed 350 people, I decided I could do without the aggravation and set up on my own. I like being hands-on and will machine anything that comes my way.

I am never going to be a millionaire but I enjoy what I do.' Half of Buckwood Engineering's 1000ft2 premises at Markyate, Hertfordshire, is leased to another one-man engineering business, while the remainder is home to manual machines and, more recently, two manual/CNC machines supplied by Burlescombe, Devon-based XYZ Machine Tools.

Evans said: 'I bought an XYZ Edge 1500 manual/CNC turret mill as a replacement for an old manual turret mill and thought it would be my last machine tool purchase.

It proved to be an unbelievably good machine and I found myself taking a third of the time to complete a job, even though I had no previous CNC experience.

I did not even go for training because it is so easy to use.' Despite this success Evans continued to rely on a manual lathe until he realised that he was losing out on turning work from existing customers and decided to do something about the situation.

One month later, in January 2005, he took delivery of a new XYZ ProTURN VL 355 lathe equipped with ProtoTRAK CNC.

'My customers know I have the ProTURN because I can now make several parts in the time needed previously to machine one.

This allows me to quote lower prices while still earning enough to pay for the machine and to put money in my pocket.' According to Evans, he opted for the 5.75kW, 360mm swing over bed XYZ ProTURN VL 355 because it matched the capacity of his DRO-equipped manual lathe while offering a choice of manual machining or, courtesy of the ProtoTRAK VL control, partial or full CNC control.

This flexibility is ideal for a small business like Buckwood Engineering that is called upon to machine a wide range of work pieces in varying batch sizes.

'There is not a turning job I can not do on the ProTURN because it is so simple to program, usually taking two to three minutes, and the program can be stored and recalled if I get a repeat order.

Although a one-off takes around a quarter of the time needed on a manual machine, a production batch probably takes 10 to 20% of the time, with a guarantee that every part will be identical.

I have just completed a 120-off job in a cycle time per part of six minutes compared with about an hour on the manual lathe, and within those six minutes I completed a second operation milling and drilling cycle on the ProtoTRAK mill.' Although adamant that the ProTURN lathe, definitely, is his final machine tool purchase, Evans says the move to CNC has made a very real difference to his life.

'I can now go home earlier that before, which allows me to indulge in my passion for chess, and I take regular holidays.

Manual/CNC lathe can also perform milling

2007-03-22T23:28:00.001-07:00

The latest generation of advanced customised controls and conversational programming systems feature on the first Harrison manual/CNC lathe to have a milling facility.

The new Alpha X Series lathes from British lathe manufacturer T S Harrison, which was premiered at EMO 2005, features the latest generation of advanced customised controls and programming systems developed by Harrison design engineers in partnership with the industry-leading automation technology specialist, GE Fanuc. The Alpha X Series, comprising the XT, XS and top-of-the-range, 3-axis XM - the first Harrison lathe produced with milling capability - takes the Harrison range into a new era of performance, with significant enhancements in the crucial parameters of turning speeds, power and reliability. All new Alpha X Series lathes incorporate Fanuc's latest conversational programming software facility and offer the fastest, easiest set-up of any lathes in the market.

* Controls and control features - the 'entry-level' Alpha XT models (comprising the 1350XT, 1400XT, 1460XT and 1550XT) are all equipped with the GE Fanuc Oi Mate TC control.

This is loaded with the new Fanuc Turn Mate i conversational system.

The new controls for Harrison Alpha XT lathes feature: * 7.2in LCD mono operator touchscreens.

* ISO standard CNC.

* Full Fanuc CNC keyboards.

* One-click-one-micron feel handwheels.

* Sliding operator console for maximum convenience during loading and set-up.

* Rapid traverse joystick.

The Turn Mate i system on the XT models enables up to 40 separate operations to be stored in the software, allowing multiple options for profiling, grooving, facing, threading, drilling and tapping, radii and chamfers, boring, tapering and simple stops.

For the first time on the Alpha T range of machines it allows full contour programming at the control.

Another 'first' for the Alpha XT range, compared with the previous Alpha T models, is the ability to switch the control to full ISO functionality (CNC).

This empowers more experienced operators to run programmes previously used on other machines and/or to generate programs in the CNC format.

This is also the first time that any Alpha T model has been available with an eight-station bi-directional turret which increases its automation capability.

As with all previous Alpha machines, Harrison's Alphalink CAD/CAM software is supplied to customers free of charge.

The Windows-compatible system allows simple generation of standard ISO (CNC) programs and the use of previously-generated DXF files.

David Smith, Harrison's sales director, explained that the customized control system for the Alpha XT models has been extensively developed to provide a 'total system solution' for optimum integration of all key systems: servos, spindle, drives, control, operator panel and electrical components.

'Like all versions of the X Series, the Alpha XT lathes are perfectly suited to producing 'one-offs' and small-batch turned parts.

No other lathes on the market today, including full CNC machines, can compete with the X Series for speed of production when it comes to these small volume turning applications,' he said.

The new Harrison Alpha XS line-up (comprising the 1350XS, 1400XS, 1460XS, 1550XS, and 1800XS), was similarly developed between Harrison and GE Fanuc.

The Alpha XS lathes have the GE Fanuc 21i TB control, loaded with custom-written Alpha mode programming software, which is unique to Harrison Alpha lathes, and the Fanuc Manual Guide i conversational programming system.

The key specifications are: * Ultra high-speed GE Fanuc 21i TB CNC control.

* 10.4in colour operator touchscreen.

* Two software systems (Alpha system + GE Fanuc Manual Guide i).

* Industry standard ISO programming.

* High-speed fibre optic data transfer.

* PCMCIA (flash card) and RS232 communication ports.

* Twin MPG handwheels.

* Rapid traverse joystick.

'The Alpha system software is well-recognised as the easiest control in the world to both learn and operate by a manual-lathe trained operator.

Its functions start with electronic stops, which directly mimic the familiar manual stops, and progress to automatic machining of complex forms.

At no time does the operator require any knowledge of CNC programming,' explained Smith.

'Manual Guide i is an easy-to-use, intuitive programming system designed to assist the less experienced operator to gain full advantage of the features of even the most complex of machining functions.

It is important to note this has been customised by Harrison to make the Manual Guide i fitted to these XS machines absolutely unique to the Alpha products and faster to programme than any other similar lathe.' The customised control system fitted to all Alpha XS lathes are designed to allow operators to utilize the machines to their full potential and capability with minimal training.

The Manual Guide i system offers a full range of easy, conversational cycles for direct 'at the machine' component set up.

Following programming the cycles may be simulated using 3D solid model graphics.

The new Alpha 1550XM lathe is identical in operation to the XS range, but has the additional functionality of a C axis and driven tool capability.

These machines utilise a standard headstock and newly-developed servo-driven worm and wheel drive.

Engagement of the drive to establish C-axis control is achieved via an electrically-driven actuator.

The tool-mounting options offered with the Alpha 1550XM are a Duplomatic 8-station turret (4 driven tool positions) or a Sandvik Capto driven tool-post allowing manual change of standard, Capto or driven tool holders.

To utilise the total C-axis capabilities of the machine, comprehensive C-axis programming cycles are available through both the Manual Guide i conversational system and the enhanced version of AlphaLink CAD/CAM software.

This total C-axis functionality allows milling, PCD (pitch-circle-diameter) and radial drilling, tapping, keyways, cam profiles etc to be generated off-line.

High value offered in manual and CNC lathes

2007-03-22T23:27:00.003-07:00

Manual and CNC lathes include three 'value-for-money' models of heavy duty, geared head manual lathes with 400mm, 500mm and 560mm swing-over-bed dimensions respectively.

MACH 2006 sees the world launch of a completely new range of 'value' manual and CNC lathes from 600 Group - the Clausing CV-Series. Three of these affordable, versatile lathes will be shown to MACH visitors on Clausing's stand (Hall 4, Stand 4578), with new and existing UK-based distributors having the first opportunity in Europe to offer the new machines to their customers. Based in Michigan, USA, Clausing Industrial , is a world-leading machine tool manufacturer and importer, which has been part of 600 Group - the UK's largest machine tool company - for over 20 years.

Clausing's latest CV-Series lathes are products resulting from a 600DMTG project which is a collaboration between 600 Group, its specialist subsidiary 600 Lathes, Clausing and 600 Group's manufacturing partner Dalian Machine Tool Group (DMTG), based in China.

All the new export-quality lathes are being built to 600 Group's performance specification and every machine will pass through 600 Group's own pre-delivery quality inspection process at the factory in China.

The Clausing CV-Series machines will be available in the UK market within four to six weeks after MACH 2006, and will be launched in the USA later this year.

Clausing CV-Series Heavy Duty Geared Head Lathes The new Clausing CV-Series will consist of three value-for-money models of heavy duty, geared head manual lathes with 400mm (16in), 500mm (20in) and 560mm (22in) swing-over-bed dimensions respectively.

Machines will be available in the UK with a choice of distances between centres, namely 1m (1000mm/40in) 1.5m (1500mm/60in) and 2m (2000mm/80in).

All versions feature large spindle bores 105mm (4.13in across the range), high-precision Gamet tapered roller bearings, hardened and ground heavy duty head stock gears and the flexibility of 16 spindle speeds, ranging from 26-1700 rev/min.

Further standard technical features of Clausing CV-Series manual lathes are as follows.

* Spindle bearings, gears and shafts lubricated by a forced lubrication system.* Easy-to-read index plate for fast selection of the correct feed or thread.* Extra-wide bedways 395mm (15.5in) for maximum accuracy and minimal wear.* Chuck guard, saddle-mounted chip guard, full splash guard and leadscrew cover.* Clutch drive, reverse leadscrew with spindle turning for faster thread cutting.* Clutches operated by levers on apron and headstock for forward/reverse.* Wide range of standard and optional accessories Options include quick-change tool-post and digital read-out.

Clausing CNC CV-Series Lathes Engineered for CNC performance, wedded to maximum affordability and versatility to handle a wide variety of turning applications, the new Clausing CNC CV-Series machines being unveiled at MACH 2006 are available in four models with 350mm (14in), 400mm (16in), 500mm (20in) or 560mm (22in) swing-over-bed.

As with the manual Clausing CV models, the two larger CNC machines offer customers a choice of three distances between centres, namely 1m (1000mm/40in), 1.5m (1500mm/60in) and 2m (2000mm/in).

The new series is equipped with the advanced FANUC Oi-TC Mate control system, offering great value and reliability, to simplify operation and maximize productivity.

All Clausing CNC CV-Series lathes benefit from heavy duty, flat-bed construction, a wide range of variable spindle speeds with automatic speed range change for more efficient parts turning and horizontal four-position electrical toolpost, among a host of advanced, standard features.

Ideal for first-time CNC buyers and workshops wanting to increase output - as well as operators such as education and training facilities requiring a low-cost lathe with CNC facilities normally only found on higher priced machines, the brand new Clausing CV-Series is especially suited to producing highly accurate one-offs and low-to-medium production runs.

Stephen Le Beau, product strategy and marketing director of 600 Group, said: 'These exciting new Clausing CV lathes have been developed with the expertise of three leaders in the world machine tool industry - 600 Group, Clausing and DMTG - which means customers can order with total confidence.

They represent a fantastic opportunity to acquire the latest quality-built, advanced design lathes at a highly attractive and affordable price.' The launch of the Clausing CV-Series at MACH 2006 means that lathes featuring 600 Group's long-established know-how, reliability and technical excellence are now within the reach of many more tool-rooms and workshops than ever before.

They offer true value for money.

Clausing CV-Series lathes making their world debut at MACH 2006 will be the CV-1640 and CV-2280 manual lathes and the CV-2060 CNC The Clausing stand at MACH will be staffed by Clausing Industrial , and 600 Group personnel from 600 Machinery International who will be pleased to meet potential new distributors for the Clausing CV-Series lathes, and details of product pricing, full specifications and availability will be supplied.

Toolroom CNC lathe is powerful, flexible, simple

2007-03-22T23:27:00.001-07:00

Toolroom Lathe has a proprietary conversational operating system that makes cutting parts and creating part programs nearly effortless, and operation ranges from manual to CNC.

With a functional range from manual turning to full CNC, the Haas TL-1 Toolroom Lathe features a proprietary conversational operating system that makes cutting parts and creating part programs nearly effortless. The operator chooses an operation, touches off the X and Z surfaces, and is then prompted to enter basic dimension information. Default values for feed per revolution, spindle speed and depth of cut are automatically entered by the control, but may be changed by the operator.

Once all necessary information is entered, a push of the Cycle Start button performs the desired operation.

A Recorder function allows information to be saved for future retrieval.

The TL-1 operates in four modes.

In all modes, the Haas control provides extremely accurate digital read-out (DRO) of position, displayed to 0.0005in when using the manual handwheels or to 0.0001in when using the electronic jog handle.

Electronic soft stops may be set to limit the travel of the lathe.

In manual mode, the X and Z axes are moved via standard handwheels.

In semi-automatic mode, the TL-1 performs simultaneous linear interpolation for both axes using a single handwheel.

ID/OD chamfers and tapers, for example, are easily cut in semi-automatic mode.

In automatic mode, built-in machining cycles (both single- and multi-pass) are available for rough and finish profiling, chamfering, grooving, parting off, threading, drilling and tapping.

In full CNC, the TL-1 is programmed using standard G code, and all axis motion is regulated by the Haas control via a G-code program.

Operations that would be difficult or impossible on a manual machine, such as radii, tapers, profiles, grooving, ID and OD threading, and rigid tapping, are all possible on the TL-1 - without knowledge of G-code programming.

Help menus are available directly on-screen, and a dry-run graphics feature allows operators to check their work before running a part.

MACH 2006 witnessed several new machines from Haas Automation, the largest CNC machine tool manufacturer in the world.

Haas demonstrated machines and metal cutting technology for aerospace, automotive, medical, mould and die and general machining industries.

More than 25 CNC technology products were on show demonstrate vertical and horizontal machining and turning applications.

Budget-priced lathes and millers introduced

2007-03-22T23:26:00.001-07:00

A budget priced series of turret millers and lathes, with prices starting at GBP 4950 for a milling machine are fitted with European bearings and electrical components, and all have CE approval.

Manual machine tools remain a popular choice for training organisations and maintenance departments but price is always a constraining factor. With this in mind XYZ Machine Tools has added the budget priced e series of turret mills and lathes to its product portfolio. Sourced from China, prices start at GBP 4950 for the eMILL 2000 and the smallest of the three models of eTURN.

Despite their ultra low price tags, these machines are of solid ribbed cast iron construction and are fitted with European-sourced bearings and electrical components.

All have full CE approval and are backed by a UK company that has become synonymous with quality, reliability and value for money.

Standard on the 3HP eMILL 2000 is a dual speed range 60-4200 rev/min spindle, power feed to the 1270mm by 254mm table and two-axis digital readout.

Options include a 5000 rev/min inverter driven spindle, power feed to the cross slide and 3- or 4-axis digital readout.

The three models in the eTURN range - 1430, 2060 and 2680 - offer spindle speed ranges from 45-1800 rev/min to 26-2000 rev/min, a swing over the bed from 356mm to 660mm and a between centres distance from 750mm to 2000mm.

Manual/CNC lathe has large 104mm spindle bore

2007-03-22T23:25:00.002-07:00

A manual/CNC lathe has a large 104mm spindle bore, which combined with a 560mm swing over bed and a choice of 1000mm, 1750mm or 3000mm between centres, gives maximum flexibility.

The vital statistic of the new XYZ ProTURN SLX 555 manual/CNC lathe is its large 104mm spindle bore. This, combined with a 560 mm swing over bed and a choice of 1000mm, 1750mm or 3000mm between centres, guarantees maximum flexibility, whether machining one-off components or in small batch production mode. However, it is not just the physical dimensions and structural integrity of the ProTURN SLX 555 that prompts XYZ Machine Tools to describe its new lathe as ideal for such applications.

With just a few hours training even someone with little or no CNC experience will be confident of producing complex parts, because the unique 'traking' feature of the ProtoTRAK SLX control ensures that the operator is always in control.

This feature allows the operator to physically wind the hand wheel and so to move the machine through the program at a speed proportional to the speed at which the hand wheel is moving.

Stop or reverse the hand wheel and the machine will do the same.

This allows the operator to check the programmed toolpath before switching to computer control, thereby avoiding collisions and boosting operator confidence.

Standard machine equipment includes a 300mm diameter three-jaw chuck, Dickson quick change toolpost with six holders, air-assist 'floating' tailstock, interlocked chuck and swarf guards, and joystick control for rapid movement.

The ProtoTRAK SLX control contributes constant surface speed, tool tip radius compensation and a host of other features.

Precision CNC toolroom lathe works manually too

2007-03-22T23:25:00.001-07:00

A compact precision toolroom lathe has full CNC, but can also be operated manually - the machine's distance between centers is 18in, cross-slide travel is 8in and spindle speed is 0-3000 rev/min.

As technology advances toward miniaturization, machines and machine components get smaller and more efficient. Many shops are purchasing smaller-size lathes to produce these parts. Haas Automation's new compact HHLV-1 precision toolroom lathe is a perfect choice for producing high-quality small- to medium-sized parts without the expense of purchasing a larger machine.

The new HHLV-1 is a hybrid precision toolroom lathe that has a full CNC control, but can also be operated manually.

The distance between centers is 18in, and the cross-slide travel is 8in.

The machine has a part swing of 14in over the guide rail, with 6in over the cross slide.

For versatility, spindle speeds are infinitely variable from 0-3,000 rev/min, and the 5C collet nose accepts a variety of workholding options.

The HHLV-1 has a compact 77' x 32.5in footprint that occupies very little floor space, and the machine is slim enough to fit through a standard 36in doorway.

Haas Automation designed the HHLV-1 to be easy to use and efficient.

A No 3 Morse-taper tailstock and 10-gallon coolant tank are standard equipment.

The heavy steel base includes a utility cabinet with a built-in tooling rack, utility shelf and plenty of room for storage.

The cabinet also allows easy access to the coolant tank.

Options for the HHLV-1 include 4in and 5in 3-jaw chucks, a cam-lock tool post for 1/2in tooling, a steady rest and an 8-station automatic tool turret.

The famous Haas CNC control makes the HHLV-1 easy to program and operate, even for beginners.

Its bright, color LCD display and thoughtful keyboard layout make it a pleasure to use.

The machine comes standard with the Haas Intuitive Programming System, a conversational operating system that guides the operator through basic CNC operations - from initial set up to pressing the Cycle Start button.

You don't have to know G-code to cut make parts, and that makes it one of the most user-friendly CNC controls in the industry.

In manual mode, the standard handwheels and precise digital readout ensure high accuracy and ease of operation.

Manual machinists will be making parts almost immediately.

The tough HHLV-1 is a small, high-precision CNC lathe that incorporates the design philosophy and high quality that make Haas the largest machine-tool manufacturer in North America.

And because it's built in the USA by Haas, it's backed by the worldwide Haas Factory Outlet network of support and service.

* Haas Automation at IMTS 2006, Chicago, USA, September 6-13, South Hall, Booth A8000.

Instrument makers' lathe has sensitive feed

2007-03-22T23:24:00.000-07:00

A compact clock, watch and instrument makers lathe accepting the 8mm horological collets in both headstock and tailstock spindles. Constructed from cast iron and steel, individually built and issued with an Engineers Test Certificate, the 90 CW is mounted on a cast aluminium base with integral thyristor speed control and is a portable unit. * Lathe bed - a one piece massive iron casting of cantilever form ground on all faces.

The bed has a central tee slot providing a positive and accurate location for the tailstock, incorporating a gap permitting the accommodation of large diameter clock wheels, total swing is 120mm (4.7in), the bed is in dovetail form.

* Saddle and slides - the cast iron saddle can be rapidly or sensitively traversed via the saddle lever feed (a leadscrew can be fitted if preferred).

A long tee slotted steel crosslide permits the mounting of accessories such as the Jacot (RG59) unit or Roller (RG53) filing rest, for example.

The crosslide has an etched angular scale 45-0-45 deg and carries the swivelling topslide to permit taper turning.

A quick change height adjustable tool holder is fitted.

All slides are fitted with full length adjustable gib strips.

Handwheels are steel and incorporate laser etched, re-set to zero calibration dials, clearly marked and graduated in 0.025mm increments.

* Tailstock - the tailstock is cast iron, bored and honed to accommodate the hardened ground steel barrel.

The barrel accepts the 8mm horological collet, which is secured in the conventional manner with a draw-in bar.

The barrel is lever fed to facilitate high sensitivity drilling.

Locking handles are fitted to both body and barrel.

The tailstock may be off-set for the turning of long and shallow tapers.

Turning can be manual, electronic or CNC

2007-03-22T23:23:00.002-07:00

Combination' or 'half-NC' lathes combine conventional turning, electronic cycle turning and full CNC turning in one machine and the user needs no CNC training to use electronic turning cycles.

Centre lathe turning has progressed at an impressive rate since the conception of electronics, driving axis and spindles, and computer driven programming. The Ajax Evolution range of machines, combines all the virtues of conventional turning, electronic cycle turning and full CNC turning all in one machine. The Ajax Evolution machines can be used as a manual lathe by using the electronic handwheels and axis joy stick, the control is used as a simple DRO measuring system.

For the 'one-offs' and small batch production the Ajax Evolution can be programmed, using the flexible electronic turning cycles, its quick, its convenient and you do not have to be CNC trained to use the electronic cycles.

You can produce tapers, radii, grooving, multi point profiles and screwcutting by answering simple questions direct from the Fanuc screen.

These electronic cycles can then be linked together to give a complete electronic programme.

For complicated shapes and batch production, full ISO programming on the Fanuc Oi Turn Mate control is possible.

The Ajax Evolution machines include fully enclosed guarding, meeting CE regulations, automatic four-way indexing toolpost, automatic speed range change and new Fanuc touch screen control and monitor on sliding pendant.

Machine programs can be up and downloaded through the RS232 port or saved directly to the PMCIA card.

The range starts at 165mm centre height to 325mm centre height, with bed lengths varying from 750mm to 5000mm, spindle speeds vary for sizes of machines but all have CSS fitted as standard.

Axis and spindle drives are all Fanuc to give reliability and longevity of service.

* Prices - for example - Evolution 200 x 1000mm BC is GBP 23,500.00 + carriage + VAT and Evolution 260 x 1500mm BC is GBP 28,650.00 + carriage + VAT.

Operations software boosts manual/CNC lathe usage

2007-03-22T23:23:00.001-07:00

British lathe specialist T S Harrison has significantly enhanced its successful Alpha XT Manual/CNC lathe range with the introduction of 'Operations Link' software, which now offers operators further important advantages in time-saving, automatic linking of operating cycles and workshop efficiency. Technical designers at Harrison, part of the internationally-renowned 600 Group machine tools company based at Heckmondwike, West Yorkshire, have worked closely with the market-leading control systems provider, G E Fanuc, to develop this new software. 'Operations Link' will be incorporated on all newly-supplied Alpha XT machines.

It is also being offered to existing Harrison XT customers free of charge as an easily-installed update.

The four-version Alpha XT range (XT 1350, XT 1400, XT 1460 and XT 1550), is equipped with Fanuc's latest Oi TC Mate control which enables no fewer than 40 advanced, individual machining cycles to be programmed and stored, using the system's Fanuc TurnMate i conversational shop floor programming.

Now, thanks to the launch of 'Operations Link' these cycles can be linked together to create a fully-automatic and continuous machining sequence from start to end, without the need for the lathe operator to tend the machine or switch between cycles.

Philip Stockdale, technical support engineer at T S Harrison, said: 'The early versions of the Alpha XT required the operator to complete each operation and then move from one cycle to the next.

For example you might want to create cycles for a facing operation, followed by a rough and finish turning cycle, and then a threading cycle.' He said: 'Fanuc and Harrison engineers have created the ability to link together these separate operations to produce a complete program, which operates the whole sequence completely automatically with just one press of a button which makes it more like a CNC machine.' The second major benefit of 'Operations Link' is that multi-cycle programs can be transferred via a memory card and stored on a PC for future use - or, crucially, for off-line programming/simulation of complex parts and safety-checking prior to machining.

Furthermore, up to five of these complete programs can be stored on the Alpha XT's Oi Mate control itself, for maximum operating flexibility.

Stockdale explained: 'For small to medium numbers of turned components, the new software speeds up the all-important 'floor-to-floor' time, especially when the Alpha XT lathes are used with the multi-station tool turret.

For these types of turning operations, the quicker and easier it is to complete the machining, the better and more cost-effective it becomes for the toolroom.' He added: 'There are also important benefits in programming time, because large numbers of complete turning programs can be stored.

Operators can create a directory of complete programs on their PCs, which can be downloaded onto the lathe again and again.' As well as Fanuc TurnMate i conversational programming, the advanced Alpha XT lathe range features the ability to switch to full ISO (CNC) functionality.

All Alpha XT customers also receive Harrison's 'Alphalink' CAD/CAM software which is a fully Windows-compatible system for flexible off-line programming.

Composites components for Airbus A400M

2007-02-15T21:29:00.002-08:00

An expert, international team has designed, prototyped, and successfully tested a composite fuel tank access cover (FTAC) for the new Airbus A400M military aircraft.

The various members of the team have brought to the project, skills in composites components design, materials technology, process tooling and composites manufacture, to ensure that the innovative finished product totally complies with the Airbus specification, especially in terms of its light weight, its damage resistance and cost-effectiveness. Brookhouse has itself worked closely with Airbus and bae systems for many years on projects from the Canberra bomber to the JSF and on various aircraft within the Airbus series.

However, in order to win the contract for the design and manufacture of the Fuel Tank Access Cover for the next generation of composite wings for the A400M, the Darwen company brought together a team comprising Sener, a Spanish company, who have an expertise in aeronautical design composites structures, Cytec, a US-based carbon fibre company, and Degussa, who manufacture a leading brand of core material for composite structures.

This team then designed, built and tested prototype models prior to the contract award to demonstrate that they had in principle a design that that could fulfil the stringent A400M design requirements.

All pre-production tooling required to support this task was manufactured by Brookhouse Tooling.

The qualification programme is now well advanced with the delivery of the production Fuel Tank Accces Covers scheduled to be in the last quarter of this year, in line with the schedule requirements.

The effective handling and efficient completion of this exciting project is a demonstration of Brookhouse's ability to offer a comprehensive, design/ make packaged composite product.

Acting as overall project manager, Brookhouse can supply aerospace companies with the capability to take responsibility and assume the risk for complete packages of composites development and manufacture work.

Working with global partners, it can develop the materials and techniques to design, manufacture and test prototype composite components and it can then design and manufacture the required production tooling before producing the finished components in-house.

As a result, Brookhouse is ideally placed to help aircraft manufacturers meet the challenges and opportunities afforded by composites components and structures.

President for tool and mould maker

2007-02-15T21:29:00.001-08:00

Sil-Pro has announced the appointment of Kevin Carver to the position of president. He succeeds his father, Lee Carver, who will continue on with company in a realigned role as part of the company's strategic management transition process. Lee Carver, one of the founders of Sil-Pro in 1998, announced the management changes and said that his son's appointment will provide continuity to Sil-Pro's rapid growth as a leading supplier of precision silicone components and assemblies to the medical device community.

Lee Carver said as part of the management transition, he will continue on with the company and focus primarily on Sil-Pro's customer and supplier relationship programs while turning over company-wide management to his son.

'With over four very successful years in his previous position at Sil-Pro as vice president, Kevin is ideally qualified to move into the position of president,' stated Lee Carver.

'He served the company well as vice president and was responsible for strengthening Sil-Pro's management team.

He guided the growth of the company's highly automated molding, part slitting and removal, and electronic vision inspection process capabilities.

He played an integral role in the tripling of Sil-Pro's sales volume and expansion of our customer base to include dozens of the world's leading medical device manufacturers.' Sil-Pro currently has over 100 employees with annual sales exceeding 8 million dollars.

The company is highly specialized in its field with ISO 9001:2000 certification providing CAD product development and class 10,000 cleanroom molding.

This includes fully automated molding cells and complete assembly services.

Included in Sil-Pro's capabilities are liquid silicone molding, gum stock molding, and bonding silicone parts to plastics, metal and other silicone parts using medical grade adhesives.

Sil-Pro's bonding and assembly capabilities include robotic equipment and part specific fixturing to aid in the manufacturing process.

Prior to joining Sil-Pro, Kevin Carver was founder and president of Acrylium, a successful contract fabricating manufacturer, which he sold in order to join Sil-Pro.

Design capability expanded at contractor

2007-02-15T21:23:00.000-08:00

Brookhouse has significantly increased its in-house design capacity with the addition of four more Catia seats at its Darwen manufacturing site. The extra design capability has been created to help the company meet increasing demands from the aerospace sector for composites mould tooling. In terms of volume, Brookhouse is Europe's leading independent supplier of mould tooling and its totally self-sufficient, multi-disciplined design department offers extensive experience and expertise in the production of 2D and 3D computer-aided designs using advanced software packages.

It has particular experience in the application of Catia, the preferred aerospace software, and the new seats comprise two Catia V4.2.4 and two Catia 5.14 seats, increasing the number of in-house Catia seats to twelve.

In addition, the company can call on more than 30 Catia contract design engineers, working off site.

The design department uses the latest Sun operating systems with a Fast Transfer Protocol server and high quality translation software packages.

It can also send and receive data by CD, tape and e-mail and has the ability to transfer data internally via electronic links to shop-floor machining centres.

The increase in design capacity continues a programme of focused capital investment, covering all aspects of Brookhouse's business from design and production of tooling to manufacture, assembly and finishing of composite components.

It also complements the significant investments that the company has made in quality, people and process technology which will help Brookhouse to maintain its dedicated concentration on its core aerospace business to provide its customers with innovative and cost-efficient solutions to composites problems.

5-axis CNC routing and trimming machine

2007-02-15T21:22:00.000-08:00

A new 5-axis CNC routing and trimming machine has been installed at Brookhouse to further improve the UK's largest independent composites assembly company's finishing expertise and capabilities.

The installation is one of a series of programmed capital investments to help Brookhouse meet the increasing global trend towards composite components and structures in the aerospace sector. The new CMS Ares Machining Centre will be used primarily for work on flying composite components, which have formerly been routed and trimmed by hand, using hard-edged jigs and fixtures.

It features two trimming tables, so that one table can be loaded while the other is in operation.

An 8-station tool rack, mounted on the carriage of the X-axis allows multiple operations and a 400MHz microprocessor can control up to 4 simultaneous processes and 8 axes, with dynamic pre-calculation of movement and controlled acceleration/deceleration to ensure very high quality finishing.

Other recent investments in Brookhouse's composites finishing facilities have included the introduction of an additional paint shop, while there has been comprehensive refurbishment of its extensive cleanroom capacity.

The company has also added a sixth, high specification autoclave to its already comprehensive autoclave capacity.

Brookhouse's tooling resources have been enhanced with two more CNC machining centres and further Catia seats.

The company recently gained Nadcap approval and is continually extending the scope and capability of its 'captive laboratory' status to new and existing customers.

In addition to its conventional composites manufacturing and repair expertise, Brookhouse is also developing 'out-of-autoclave' technologies for the aerospace sector.

These can often be applied to provide cost effective solutions to composites problems.

Brookhouse is totally focused on the aerospace sector.

It offers design and manufacturing for composites tooling, a facility for the repair of composite components and a capability for design, prototyping, manufacture, testing and finishing of complete composite components.

As a result, Brookhouse can offer its worldwide aerospace customers a global facility to take responsibility for complete packages of composites' development and manufacture projects.

Mould tools and mouldings for medical equipment

2007-02-15T21:20:00.001-08:00

The console housing and service trolley mould tools and mouldings for PlasmaJet, a new neutral plasma coagulator being developed by Plasma Surgical, are being manufactured by Midas Pattern.

The console housing and service trolley (front panel) mould tools and mouldings for PlasmaJet, a revolutionary new neutral plasma coagulator being developed by Plasma Surgical, are being manufactured by Midas Pattern following a competitive tender process. PlasmaJet consists of an electronic console mounted on a portable, floor standing service trolley that also houses the argon tank. Central to the success of PlasmaJet as a manufacturing project were the two largest mouldings - the console housing and service trolley front panel.

The appointed moulding company tasked with producing these parts had to fulfil many prerequisites, including: the ability to work closely with the client and its design agency; meet strict deadlines; manufacture tooling and moulded components of the highest quality; and, importantly, provide the most competitive quotation.

Midas Pattern Company won the contract based on its ability to match these requirements.

To help accelerate the development of its products, Plasma Surgical retains Greaves Best Design as its technical adviser.

Based at Lockerley in Hampshire, Greaves Best is a product and engineering design company that has been involved with PlasmaJet from the outset.

'Initially we produced 3D CAD models,' explains company partner Mike Best.

'Then we produced what we thought was the largest single piece SLA model in the UK at that time.

A set of rubber tools followed, which we shot with PU and produced six prototypes sets so we could prove-out the process.

Once we had done this we needed the input of a PU moulder to move the development to the next stage: the manufacture of production mould tools and the moulding of an initial 50 sets of parts.' Greaves Best has known of Midas Pattern Company since the mid 1990s and had no hesitation in including the Bedford company in a shortlist of companies invited to tender.

All Midas Pattern Company PU mouldings are manufactured using the company's own, specifically developed 'metallised' resin injection moulding (MRIM) process.

A metal-filled composite resin mould tool is manufactured directly from a CNC machined master model or pattern: this technique ensures the most complex of forms can be produced accurately and very quickly.

Complex forms can be generated using various coring, side action, and even multi part mould tool techniques.

Square faces, undercuts, metal inserts, bushes and features that would normally require machining can all be cast into Midas Pattern Company mouldings.

ISO9001:2000 accredited Midas Pattern Company believes that the highest quality rigid polyurethane mouldings can only be produced from tooling of equal quality.

By manufacturing accurate, hard wearing tooling Midas Pattern Company can offer ongoing repeatability without mould tool deterioration.

In fact the company guarantees its MRIM tooling for the life of the product.

Since being commissioned by Greaves Best to produce PlasmaJet mouldings, Midas Pattern Company has completed the tooling manufacture and to date has delivered further sets of parts - on time.

'Midas Pattern Company has always delivered on time,' confirms Mr Best.

'As a company I find them very responsive and I enjoy dealing them.' 'PlasmaJet has massive potential,' concludes Mr Best, 'but this potential could not be realised without the valuable input of Plasma Surgical's partner suppliers.

Midas Pattern Company have fulfilled our expectations and helped ensure this product is set to have a massive impact on the medical industry.

The technology deployed by Midas Pattern Company and the whole hearted support of the company's engineers have been of enormous benefit to Plasma Surgical.'

Real-time 'point-cloud' inspection to be shown

2007-02-10T02:53:00.001-08:00

A novel measurement system allows real-time, point cloud inspection of parts allows faster, more detailed inspection against CAD models by using a laser to collect large amounts of data.

Delcam will join forces with Cimcore and Perceptron to show a unique system allowing real-time, point cloud inspection of parts at the Russian Automotive Industry Forum to be held in Moscow from 13th -15th March 2006. The combination of Delcam's PowerINSPECT inspection software, the Cimcore inspection arm and the Perceptron laser head allows faster, more detailed inspection against CAD models by using a laser to collect the data. The use of a laser for inspection allows rapid collection of huge amounts of data and so is ideal for larger components and the associated tooling.

It also avoids any contact with the part that might cause marking of sensitive surfaces.

Using PowerINSPECT to analyse data produced from a Perceptron head fitted to a Cimcore arm gives the additional ability to undertake detailed real-time inspection, for example on a production line, so that any errors can be spotted more quickly and corrected at lower cost.

The main application of this approach is expected to be in the inspection of large sheet metal components, such as automotive bodywork.

These parts need to be produced to a high level of accuracy, particularly the external panels that must have a high quality finish.

It is also essential to ensure that they fit together successfully - an especially important factor when using robots for assembly and welding operations.

The combined Delcam/Cimcore/Perceptron solution is capable of collecting more than 20,000 points/s.

It allows far more detailed inspection of both geometric and surface features than would be practical with a physical probe.

Fitting the laser to a portable and flexible inspection arm ensures that data can be collected from all areas of the component in a single operation.

PowerINSPECT offers rapid methods for easy analysis of this large volume of data.

A filter can be applied to the points so that only those out of tolerance are displayed on the screen or included in the report.

Alternatively, the PowerINSPECT coloured dots, which indicate whether the point is in tolerance, above tolerance or below tolerance, can be used to produce what is effectively an instant colour map of the accuracy of the component.

The larger volume of data, together with the speed and ease of interpretation of the results, means that any trends in the measurements can be identified much earlier, possibly even before the parts have moved out of tolerance.

Any problem components can be removed from the line before any further work is completed on them.

Subtle defects across the whole of the part, such as a twist or warp in the surface, can be identified more easily with point cloud data than is possible with a series of discrete measurements.

Similarly, any drift in accuracy, for example as a result of worn tooling, can be identified before large numbers of defective items have been produced.

All data collected can be used for more detailed off-line analysis and reporting with PowerINSPECT's wide range of editing options.

Laser calibration reduces costs, ups accuracy

2007-02-10T02:52:00.002-08:00

Laser calibration reduces costs and gives four-fold accuracy improvement for CNC water-jet cutting machine manufacturer, which is experiencing rapid sales growth.

Czech manufacturer PTV, based in Prague, Czech Republic, has experienced a very rapid increase in sales of its CNC water-jet cutting machines. To help manage this growth, the company uses Renishaw's ML10 laser interferometer measurement system and QC10 ballbar, which has reduced manufacturing costs and increased machine accuracy by a factor of four. Precision water cutting has a huge number of applications, and particular advantages over traditional CNC machine tools in processing high specification metals, composites and other media.

Thin, flexible or sensitive materials, such as rubber, plastics and even paper, are especially difficult to 'machine' using traditional methods.

In these cases water cutting offers many of the advantages of laser cutting machines, but at a lower cost.

In the cutting process, the water is compressed to a pressure of over 4000 bar, then directed through specially designed nozzles.

For certain materials and for high-speed grinding, water is mixed with natural garnet abrasive prior to cutting.

PTV manufactures one design of machine, but is able to vary the X and Y dimensions over a large range, according to customer needs.

In effect, every machine is customised - PTV engineers can easily adapt machine components to different requirements, both in initial construction in Prague, and during installation at a customer's site.

* Alignment problems - the PTV machine was designed in 2002, originally with a magnetic linear encoder system and a MEFI CNC control.

Initially there were problems with maintaining the precise separation required between encoder and readhead, particularly over distances greater than 6m.

There were also dynamic problems in achieving the required machine accuracy, due to the lightweight aluminium structures for the X-axis and Y-axis.

PTV therefore sought advice from MEFI, who suggested using a laser interferometer to identify the causes of these inaccuracies.

* Renishaw's solution - PTV searched the Internet and, from a short list of possible systems, reviewed Renishaw's ML10 laser interferometer measurement system.

Explained Jan Kunert, CNC engineer, 'We visited one of our customers, where a Renishaw engineer demonstrated the ML10 system to us'.

'We realised that not only could we use it to identify the dynamic errors, but we could also use it to map errors during machine production'.

'We were only looking for someone to do a one-off study of our machines, as a sub-contract service, but very quickly knew that we had to have a system ourselves'.

'In fact, the system we bought is now used so extensively, both in the factory and during on-site installation, that we intend to buy another.' * Linear accuracy improved from 0.2mm to 0.05mm/m - PTV removed the magnetic linear encoders from the original design, instead taking positional feedback from the rotary encoders integrated onto the drive motors.

These encoders had always been there, but had been thought to provide inaccurate feedback, due to the variable distance and the resulting effects from the twisting of the ball-screw.

This is where the Renishaw ML10 laser interferometer measurement system and Laser10 software proves its worth.

The system's laser optics are mounted onto the structure of the finished machine and readings taken at every 20mm of axis movement.

This is compared to the value provided by the machine's rotary encoder, which is at least always repeatable, to generate a compensation value for that specific position.

The positioning uncertainty on the original design could be up to 0.2mm/m.

Kunert now knows that accuracy is always better than 0.05mm/m and provides customers with a certificate from Renishaw's Laser10 software to prove it.

* Proving quality through international standards - the ML10 laser interferometer measurement system is a reference standard on which PTV relies, using the highly stable wavelength of laser light, to provide performance verification to ISO 230-6 and traceability of the measurements in line with their ISO9001 certified systems.

PTV sees both these factors as crucial in winning new customers, especially in markets where it is unknown.

* Combining Renishaw solutions for maximum efficiency - in addition to the compensation provided by the ML10 laser interferometer for linear positioning, there are a series of other machine characteristics which PTV checks and adjusts through the use of a ten-minute test with a Renishaw QC10 ballbar.

During the test the water cutting machine is instructed to describe a circular path in the X-Y axis, with the QC10 ballbar coupled to the machine on special magnetic mounts.

Any variation from the normal test circle radius is picked up by the ballbar's highly sensitive transducer and data fed back to a PC running Renishaw's Ballbar5 analysis software.

This immediately provides exact error values for 21 different machine characteristics.

* Considerable time-saving - PTV finds that backlash and scale mismatch are two major sources of error, but provided with the exact values from the QC10 ballbar, the engineers can now adjust them immediately.

Jan Kunert estimates that the company used to spend half a day on a machine attempting to find and remove errors.

Now it can be done in 30-40 minutes.

Says Kunert: 'Without the Renishaw ballbar, even if we thought we knew the problem, we were not always right'.

'We often brought in service companies, for example for the motors, to find it was a waste of time'.

'We have one engineer here who is very good at guessing errors, but previously, if he was out sick, or at a customer when we had problems here, we were stuck.' * Rapid increase in business - the future is looking bright for PTV.

After long experience in this field, distributing machines from the USA, it is now selling an increasing number of its own machines.

Its largest customer, V.S.M.P.O.

in Russia, already has six machines and has ordered a special 5-axis machine, which it will use to cut titanium for military and aerospace applications.

660nm laser diode module is very stable

2007-02-10T02:52:00.001-08:00

A 660nm laser diode module with a very high, very stable output power of 70mW and adjustable AR coated glass optics is designed for machine vision applications.

UK optoelectronics device manufacturer and laser diode specialist, Photonic Products, has launched a new 660nm laser diode module with a very high, very stable output power of 70mW and adjustable AR coated glass optics. The 660nm Photon Laser Module, PM806G-GR, incorporates an Opnext HL6548FG high power laser diode (100mW absolute maximum optical output power), with internal monitor photodiode in a 9mm package. An internal monitor photodiode is a unique feature for a laser diode of this power and wavelength which enables the output power of the laser diode module to be accurately stabilised over its operating temperature range of -10 deg C to +50 deg C.

Designed for applications such as machine vision, graphic displays, medical imaging, inspection systems and industrial alignment and positioning, the 660nm laser diode module produces an elliptical output beam of 3.5 x 1.5mm with an output power of 70mW.

Operating voltage is from 3V to 6V DC with a typical operating current of 150mA.

Beam divergence is <0.6 x 0.3mrad and operating temperature range is -10 deg C to +50 deg C.

The module consists of an aluminium housing, laser diode, drive circuit and collimating lens and is stable and reliable.

All Photon Modules can be supplied in various colours, (red, green, blue, black, violet), to assist in wavelength or power identification.

The PMF version modules have a 25mm mounting flange.

Electrical connections are made via external flying leads.

The lens may be adjusted to produce either a collimated beam or focused spot.

The standard lens may be replaced by other optical systems such as line and cross generators.

The Photon range of elliptical beam laser diode modules has been designed as a complete laser diode solution for OEM use.

* About Photonic Products - Photonic Products was established in 1995 and has offices in the UK, USA and Germany.

It is an ISO9001:2000 certified manufacturer of electro-optical sub-assemblies and innovative optoelectronic components based on semiconductor laser diode technology and also a specialist distributor of high performance industrial laser diodes, LEDs and precision optical lenses.

Interface connects laser calibration to PC

2007-02-10T02:51:00.001-08:00

Interface is designed to connect Renishaw ML10 laser calibration system and EC10 environmental compensator unit to PCs via an industry standard USB connection.

Renishaw's new DX10 interface is designed to connect its market leading ML10 laser calibration system and EC10 environmental compensator unit to PCs via an industry standard USB connection. The DX10 is a reliable high speed communications device, transmitting data at 5kHz to Renishaw's Laser10 software and new QuickView motion analysis software. Suitable for both laptop and desktop PCs, the new DX10 interface avoids the need for PCMCIA or internal PCI interfaces, which are gradually being phased out of mainstream PCs in favour of USB connectivity.

For dual axis data capture from the ML10 laser interferometer, a user can simply use 2 DX10 interfaces which can be plugged into 2 separate USB ports or a separate hub.

Replacing Renishaw's existing PCM20 (PCMCIA) card as the standard system interface, the DX10 unit is compatible with Windows XP and service pack 1 and 2.

The new DX10 interface kit includes a 3m USB cable, DX10 driver and installation CD-ROM.

* Note - Renishaw's ML10 laser interferometer measurement system is used by some of the largest OEMs and end users in industries such as metal cutting, semiconductor processing, flat panel display production and biotechnology.

The ML10's unique properties ensure that the system provides a linear position reading resolution of just 1.24nm, a range of up to 40 m and accuracy better than 1 ppm.

This combination of resolution, accuracy and range makes the laser interferometer an ideal tool for characterising the performance of motion systems, both large and small.

One man can operate accurate alignment system

2007-02-10T02:50:00.002-08:00

Fixturlaser AB, Molndal has developed a new and highly accuratesystem for positioning and aligning machines and production lineinstallations. The new Fixturlaser Level is a laser based'one-man-level' system, which meets high mechanical andaccuracy levelling requirements. The one-man-level makes ahelping hand redundant, since the system consists of a selflevelling, scanning laser transmitter and a high resolutionreceiver.

The laser transmitter, T310, generates a laser planewhich is level or plumb to level.

The laser plane can also belocked to specific receiver values, the receiver then controlsthe transmitter by either IR or cable communication.

This featureis very helpful in unstable environments, e.g when performingmeasurements on-board ship and on high rising constructions, suchas harbour cranes.

The Level can be operated with one or morereceivers and can be fully integrated in the Fixturlaser systemutilising the display unit as a data collector.

All units arepowered by standard batteries or AC-adapter.

The receiver can bepowered by the Display Unit when connected.

Measuring dynamic movements in machinery alignment

2007-02-10T02:50:00.001-08:00

An off-line- to -running fixture combined with a shaft alignment system makes it possible to measure dynamic movements on machines from hot to cold or vice versa.

Dynamic changes in the rotating machinery from an Off Line toRunning condition, needs more attention. There is no such thingas 'identical' machines having identical dynamicmovements. One cannot ignore the possibility of horizontalmovement, assuming growth will be symmetrical and only accountingfor the thermal effects.

Shaft alignment has mostly been carriedout in off-line operating conditions.

However, machine conditionschange from the time they are off line to running under normaloperating conditions.

Some of these changes are due to processforces (fluid pressures, airflow, etc.).

The most notable ofthese changes is the change in the temperature of the machinebearings and supports.

Dynamic changes are difficult tocalculate.

Two 'identical' machines may showdrastically different alignment changes from Off Line to Running.Great care must be taken when calculating the changes in thealignment condition of machines.

Just because two machines appearidentical and serve the same function does not ensure they willexhibit the same operational characteristics.

Several methodshave been used to measure the changes in the shaft alignment oftwo or more machines.

Although widely used, 'hot aligningmachines', only measures changes in the shaft alignment duesolely to the changes in the machines' temperature.Discharge pressure, shaft torque, multiple machines operating inparallel, electrical loading of a generator, etc., can also playan important role in the change of the alignment condition fromOff Line to Running.

The changes will mostly be seen in theHorizontal Plane, but could also affect the Vertical Alignment.

Amachine that operates exposed to large changes in temperaturecould exhibit extreme changes in its shaft alignment as thetemperature changes.

Coupled machines need to be set to coldalignment targets that will reflect the actual changes in theshaft alignment.

This will lead to lower vibration levels,increased mean time between failures, decreased maintenancecosts, and increased production.

Fixturlaser's extensiveresearch into the problems of dynamic movement has resulted in arevolutionary new alignment method.

Fixturlaser L2R off-line- to-running fixture combined with a FixturlaserShaft alignmentsystem makes it possible to measure dynamic movements on machinesfrom hot to cold or vice versa.

Changes in machinery alignmentare mirrored by changes in the alignment of the L2R brackets.

Bymeasuring and documenting the initial position of the bracketsthe actual online changes in the alignment values can be measuredwhen the machine is online under normal operating conditions.Alignment costs are small compared to production loss, shouldcritical machinery fail.

Poor alignment is one of the leadingcontributors to premature rotating machinery failure, often as aresult of too little attention being paid to dynamic movements.Fixturlaser have, through extensive tests, showed that inaddition to cold alignments, the actual dynamic movements ofmachinery need to be considered when aligning.

Laser displacement sensor measures problem surface

2007-02-10T02:49:00.002-08:00

Laser displacement sensor measures problem surfaces MatsushitaElectric Works has enhanced its range of measurement sensors byintroducing the new SUNX HL-C1 laser measurement system. Usingcharged coupled device (CCD) based technology, the sensor is ableto quickly and precisely inspect surfaces that have historicallyposed problems for analogue based non-contact measurementequipment. Black rubber and specular objects, including glass andwafers, can now be reliably and accurately measured using the newSUNX HL-C1 laser based measurement system.

Suitable applicationsfor the HL-C1 series include measurement of the eccentricity ofsteel shafts, co-planarity of IC pins, thickness measurement ofbrake discs and tyre tread measurement.

Containing an extremelycompact controller, the unit can accept the connection of up totwo measurement sensor heads.

This allows thickness measurementto be carried out easily using built in calculation functions.The sensor heads themselves are available in two styles: one formeasurement of diffuse type surfaces, including black rubber andmachined metal; and the other for specular objects such as glassand highly reflective surfaces.

Both styles offer two measurementranges and are capable of measuring to accuracies of 1micron.Configuration of the controller can be performed using either acompact touch screen console or PC based configuration softwarevia the built in RS232C communications port.

This port can alsobe used to transmit measurement data to a third party device, orthe internal decision-making capability can be utilised andinformation accessed via digital I/O connections.

Laser scanner unseats templates and save money

2007-02-10T02:49:00.001-08:00

US-based Lear Corporation has realised savings of $240,000 injust one seat manufacturing programme by replacing atemplate-based inspection system with a laser scanning one. Using3D Scanners' ModelMaker software, Lear inspects automotiveseats during design and manufacturing. Before, Lear compared asample seat with a series of contoured plastics templates whichshoed the original styling guidelines.

Typically nine templateswere needed for each seat, and the seat had to line up within 6mmunder manual 'GO, NO-GO' inspection.

Total templatecost for a seat programme with 29 seat configurations was some$104,000.

An inspection stand could cost $22,000 and fivedifferent stands would be needed.

Two sets of stands - costing$220,000 - would be needed if a seat style were produced in twodifferent factories.

Lear chose the ModelMaker system, whicheliminated the templates and the stand cost is now $15,000instead of $22,000.

The system is based on a 3D laser sensor, aposition-sensing device on which the sensor is mounted, a PC andsoftware.

The software extracts displays and manipulates thesensor data.

Lear chose the FaroArm with seven degrees of freedomto reach any point in the seat.

In operation, the sensor ispositioned to show a laser light line across the seat, and ismoved across the area to be checked and the data is displayed onthe PC screen.

Laser scanning is much faster than making templatemeasurements, so Lear now scans a number of customer-approvedseats and averages the data to set manufacturing tolerances.Scanning provides real X, Y and Z co-ordinates.

If a seat area isout of tolerance, manufacturing personnel can see exactly howmuch it is in error.

The scanning system is more accurate thanthe template system (gaps between template surfaces and seatareas would have to have been measured manually) and readilywarns of any drift away from the 'mean'.

Also thescanning system is immediately adaptable to seat modifications.

HMC undergoes a second rebuild

2007-02-10T02:48:00.002-08:00

A heavy duty Cincinnati HMC has been rebuilt again,this time employing the capabilities of Renishaw's calibration and machine tool performance testing systems.

HMC undergoes a second rebuild In 1989, Leeds-based Dana Spicerneeded a large, heavy duty CNC machining centre, to mill, drill,and bore the ends of 2-metre long axle beams, for heavy off-roadvehicles. The ideal machine, with a bed length of 5-metres, wouldallow pendulum machining, thereby increasing production. However,new machines of this type were costly and resulted in the companyapproaching rebuild specialist Murrall and Lang for a solution.Ten years later, it was 'd‚j… vu' for theBirmingham-based company, when it welcomed the opportunity toonce again re-manufacture the machine, but this time employingthe capabilities of Renishaw's calibration and machine toolperformance testing systems.

Murrall and Lang had alreadymodified a 2-metre machining centre to accommodate pendulummachining in the summer of 1989 and convinced Dana Spicer of thecost benefits.

With a contract signed, a Cincinnati 20HC 2500(2.5 metre) travelling-column horizontal machining centre wasfound in the USA that would machine these parts, if equipped witha suitable front base.

The volume of the axle components dictatedthat a pallet shuttle system would be economic, allowingunloading and loading whilst machining continued.

To accommodatethis, Murrall and Lang designed a special shuttle table with twoindex tables and fixtures, and a CNC movement of 2.5m from oneposition to the other.

Suitable guarding protected the operator.Therefore, in addition to the usual horizontal axes of X(2500mm), Y (1000mm) and Z (600mm) and the shuttle axis, themachine has two indexing axes giving a total of 6 CNC axes.

Thisconfiguration was arrived at after joint discussions when themachine was first modified in 1990.

After producing axles fornearly a decade and having questioned the ability to maintain themachine, Dana Spicer - having once again considered new products,which still proved very costly - decided to have the machinere-manufactured by Murrall and Lang for a second time.

Havingexperienced the benefits of Renishaw's QC10 ballbar systemsin the 1990's, Murrall and Lang had no hesitation inutilising this technology and purchasing Renishaw's ML10laser calibration system to aid the re-manufacture 'asnew', of the Cincinatti HMC for a second time.

Partner, BobMurrall explained.

'We had successfully produced a machineto Dana Spicer's tolerance specifications in 1990 using asecond-hand Hewlett Packard (HP) calibration system.

Today, HPequipment is neither cost-effective nor comparable to thetechnological capabilities of the Renishaw systems.''It was our experience of the QC10 ballbar system, that ledus to invest in the ML10 laser calibration equipment,' addedMr Murrall.

'The ballbar is so reliable, it automaticallyidentifies, quantifies and prioritises machine tool errors.

Inseeing it used here, many of our customers, including DanaSpicer, have subsequently invested in the technology.' TheY2K re-manufacturing process included a complete mechanicalrebuild, with all worn parts being reconditioned or replaced, acomplete rewiring, the fitting of new digital axis and spindledrives, and a new Siemens 840D CNC control.

The process took lessthan six months and fully met customer specification.

To improvereliability, the customer wanted to maintain accuracy by axiscalibration and compensation.

This required the use of theRenishaw laser calibration system; part of Murrall andLang's quality control system.

'When you arere-manufacturing a machine, your alignments should be well withinachievable levels of adjustment, allowing the alignments set bythe original manufacturer to be achieved.

In fact, the QC10ballbar and ML10 laser system allow us to achieve tightertolerances than was possible when the machine was firstmanufactured.

Whatever we attain here, we can reproduce at thecustomers' premises.

The Renishaw ML10 laser calibrationsystem is portable, easy to use and has built-in temperaturecompensation, allowing our customers to machine components farmore accurately than once possible,' continued Mr Murrall.At Dana Spicer, the 20hp Cincinnati machine, with spindle speedsof 3300rpm, is fed by two 30-tool chain-based magazines.

Axlebeams are machined from forgings which tend to vary in size dueto the forging process.

To obtain the best metal conditions, oncethe component is mounted in the fixture, a spindle mountedRenishaw MP700 high accuracy probe is used to check length androtation.

Corrections are applied automatically to find thecomponent centre, and if necessary to rotate the programdimensions, so as to produce the best component from the forging.'The rebuild option allows a company to purchase a specificmachine at a third of the cost of a new machine.

Object dimensioning as easy as scanning barcodes!

2007-02-10T02:48:00.001-08:00

Datalogic's VS8000 is a device for object volume measurement representing a valid alternative to traditional automatic measurement systems for materials handling applications.

With Datalogic's VS8000 Dimensioning systems are becomingmore and more popular among parcel carriers and postal servicesaround the world. Goods are becoming lighter, and containers andtrucks are more often full before becoming too heavy. Volume, notweight is increasingly becoming the limiting factor.

The same istrue for warehouses where capacity is given in volume andconveyor systems are more often limited by volume rather than byweight.

In this scenario, traditional weight-based tariff systemsare no longer appropriate and carriers and postal services areincreasingly adopting volume based price tariffs.

Whereverparcels in different sizes, shapes and weight are collected,transported, stored and distributed, cost-effectiveness dependson achieving the optimal utilisation of the available space forwarehousing and of equipment for transportation.

Accuratelyestablishing the size of the various packages is always thebiggest bottleneck in parcel handling.

Datalogic's solutionis the VS8000 - a device for object volume measurementrepresenting a valid alternative to traditional automaticmeasurement systems for materials handling applications.

Based onthe mechanical and optical architecture of Datalogic'sDS8100 laser scanner, the VS8000 scans at speeds of up to 2000scans per second and covers a standard measurement area of 800mmx 800mm, providing an extremely fast and reliable dimensions andvolume estimation of objects moving along the conveyor.

The veryhigh scan speed and real time processing features allow beltspeeds of up to 5 metres per second, enabling the gap betweenparcels to be reduced to only 50mm.

The VS8000 can be rapidlyintegrated in omni-directional reading stations, with nomodifications to existing structures.

Set-up is fast and easywith the intuitive Monitor Configuration Program.

With theVS8000, Datalogic offers an excellent alternative to existingdimensioning systems.

The VS8000 is more cost-effective andeasier to use and install than traditional measurement systemsand, above all, makes new process automation and optimisationcapabilities available to all materials handling operators.

CNC universal grinder can mill and drill

2007-01-04T02:08:00.000-08:00

ANCA will debut its latest development, the TX7+Xchanger at the IMTS exhibition in September. The new machine has been designed with extensive customer input and incorporates an ANCA TX7+ universal grinder with a wheel pack exchanging system and magazine. The magazine holds 16 wheel packs instead of the customary two only found on most CNC grinders, which means the operator now has up to 64 wheels to select from.

This expanded selection holds productivity and cost-saving benefits for companies seeking to maximise automation in mass production of cutting tools or grind complex components that require several different wheel packs to complete.

Having multiple wheel packs set up in the Xchanger magazine provides several new benefits not possible with most grinding machines including the following.

* Immediate follow-on in mass production when the wheel pack needs to be changed due to wheel wear.

This means longer unmanned operation can be achieved.

* No downtime to change wheel packs when switching from one tool type to another, increasing production flexibility.

* Improved occupational health and safety conditions for operators as manual handling of wheel packs is reduced.

This limits exposure to oil and carbide and handling of heavy wheel packs.

* Minimal downtime to set up wheel packs as coolant manifolds and pipes are changed with the wheel pack.

Set-up is done off the machine in a set-up rig, which means production does not have to be interrupted.

All of this adds up to the possibilities of extended unmanned operation, which will deliver greater levels of productivity and lower-cost tools without compromise on precision.

To further increase the flexibility of the TX7+Xchanger, ANCA also built in milling capability.

Tools such as drills and endmills are driven by the spindle using standard Big Plus wheel arbours.

As the milling tools are also stored in the magazine and therefore also changed automatically, features such as holes, keyways and dovetails prove no problem for the TX7+Xchanger.

Although the new machine will be the flagship of ANCA's IMTS exhibit, it will certainly not be on its own.

Other products on show will include the following.

* TapX dedicated tap grinding machine, which can manufacture a complete tap.

* CLX compact loader, which provides an economical automated solution.

* iQual automatical wheel qualification system.

* iView tool measurement and compensation system.

* RX7 compact grinder demonstrating small diameter grinding and the VCS Precision V-block clamp and steady.

* About ANCA - ANCA is an Australian owned company that was founded in 1974 to design and manufacture high technology Computer Numerical Controls (CNCs) for the machine tool and metal-based industries.

Today, ANCA has become a world leading designer and manufacturer of complete, high precision grinding machines competing in a global niche market.

With its core values of precision, innovation, quality and technological excellence, ANCA is today an international organisation of more than 300 employees in 12 countries, with a robust set of technological and entrepreneurial skills.

Offices are located in major cities in Europe, North America and Asia; with dealerships represented in over 25 countries.

Low-cost dust extractors introduced for grinders

2007-01-03T02:08:00.000-08:00

Low-cost dust extractors introduced for grinders Low-cost dust extractors for an extensive range of metal grinding machines feature electronic start and stop delay and there is an optional motor brake for decelerating the grinding machine. In order to meet customers' requests, 'Flott' has developed two new low-cost dust extractors for the extensive range of metal grinding machines. The metal dust extractor MA 400 D has been designed for connecting to a 400V power supply and extracting dust from three-phase AC machines, whilst the metal dust extractor MA 200 W has been specifically designed for 230V operation.

Dust is extracted through two transparent PU spiral hoses with a diameter of 50 mm.

The extracted air is filtered via a progressively compacted, matted non-woven fleece (filter class G3 according to EN 779), which features not only a high degree of separation but also has a high dust storage capacity.

The change intervals for the filter insert were thus reduced considerably.

Both metal dust extractors feature electronic start and stop delay; they may be equipped with an optional motor brake for decelerating the machine connected to the unit.

Flott design engineers have attributed considerable importance to quick and easy attachment to the grinding machine.

As a result, it is no longer necessary to wire up the units separately.

The machine is bolted to the metal dust extractor, the plug is inserted in the socket to be used and the two suction hoses are connected up.

Touch screen cylindrical grinder has CNC benefits

2007-01-02T02:07:00.000-08:00

Jones and Shipman is showing at IMTS its new Suprema 'Easy' controlled cylindrical grinder a machine specifically aimed at manufacturers who believe they cannot afford to invest in CNC. Designed and produced at the company's Leicester, UK site, the all-new range is easy to use, fast to set up, versatile, and very competitively priced. Accuracy and repeatability are assured; changeover times are minimised because most operator intervention, normally necessary, has been removed by simple but sophisticated software.

The range replaces traditional CNC, microprocessor and hydraulically controlled machines as it retains a conventional layout and operating style.

Offering productivity advantages in areas such as aerospace, mold and die, automotive, medical, etc, the Suprema has particular benefits for medium/short batch work or even one-offs because of the ease and speed of change-over.

Combining the benefits of CNC with traditionally styled operation, it is easy to use even for operators unfamiliar with CNC grinding.

A major advantage of the new Suprema range is the incorporation of a GE-Fanuc Touchscreen control system utilising Jones and Shipman's easy-to-use proprietary self-teach software.

This powerful but simple multi-axis control system combination enables an inexperienced operator to quickly progress from manual single diameter applications to linked cycle/multi diameter single or batch operations.

The Suprema comes complete with embeded software to undertake single or multiple diameter and face grinding, plus dressing of left or right hand facing wheels and the ability to easily form dress profiles and vee forms without additional form dressing attachments.

Additional features such as taper traverse grind, contour grind and easy down/up load to and from PDA, PC, or Network are also included, as are Heidenhain 'Absolute' nano scales for both axes.

A second level of optional software provides solutions, through a grinding-specific PC-based CAD cam software suite which also accepts DXF files, and converts them into grinding or dressing programs incorporating features such as rapid wheel profiling, on screen simulations, collision detection etc Up-grades between software levels is easy and enables users to respond to changes in their work-profile and to develop their own expertise at their own pace.

The range is available in two grinding capacities of 12in x 25in or 12n x 40in (300mm x 650mm or 300mm x 1000mm) and is offered with plain/straight approach wheelhead or three-wheel universal swivelling wheelhead options.

The Suprema is a robustly constructed, one piece Tee bed design.

High geometrical accuracy is ensured by direct-coupled digital AC servo motors and rotary encoders from GE-Fanuc.

Hand-scraped Vee and Flat slideways are provided for the cast machine table underslide.

A high precision twin Vee configuration is used for the wheelhead backslide.

The air purged combined live and dead centre swivel base workhead contains high precision tapered roller bearings for stiffness.

It incorporates a synchronous belt variable speed drive that allows direct programmed speed (rev/min) or constant surface speed (CSS m/s) of the workpiece.

A robust lever operated plain bearing tailstock is provided as standard with a high accuracy taper correction tailstock available as an option.

Philosophy and architecture of the new range is complementary to other Touchscreen controlled machines in the Jones and Shipman portfolio, ensuring operators can switch between machines easily and without additional training.

'The Suprema is another important step forward for Jones and Shipman, and reflects both our ongoing and innovative approach to grinding and our commitment to produce competitively priced products.

Creep-feed grinding gets quicker change-over times

2007-01-01T02:07:00.000-08:00

The current surface/creepfeed production environment demands high productivity, accuracy and the minimum cycle times associated with CNC grinding. But many components whilst being perfect for CNC are currently machined on conventional machines due to a variety of reasons, such as smaller batch requirements which necessitate more frequent set ups, shortage of operator skills, or no budget for high cost CNC solutions. Jones and Shipman already a major supplier of CNC surface/creepfeed grinders has used this customer feedback to produce a grinder that has the required performance levels and also overcomes these perceived shortfalls of traditional CNC.

This machine, the Dominator 624 Easy, offers quicker changeover times, a very easy to use touchscreen control, is priced lower than traditional CNC and is now available and was shown in the US for the first time at IMTS 2006.

Jones and Shipman's latest model in the combined Surface and Creepfeed grinder market the Dominator 624 Easy, is ideally suited to either short batch or long production runs in industries as diverse as aerospace, automotive, electrical, medical and mold and die.

Control in either 3 or 4 axes gives the precision, repeatability and reliability of traditional CNC, for it employs the same axis motion control elements, precision ballscrews driven by GE-Fanuc AC digital servomotors coupled with 0.000004in (0.01 micron) Heidenhain 'Absolute' linear scale feedback.

However the Dominator Easy is faster and simpler to set up via the GE-Fanuc touchscreen using Jones and Shipman icon based grinding and dressing software.

This provides Easy models with the capabilities to interpolate axes simultaneously to provide precision grinding of complex shapes, angles, radii and surfaces, with quick and easy set-up.

Even operators with little or no CNC knowledge quickly become familiar with the 'self teach' software and are soon able to precision grind complex components as well as more standard multi surface work.

Once set up, fully automatic dressing and grinding cycles permit unmanned operation.

Alternatively as with all 'Easy' controlled models the Dominator can function as a simple manually controlled machine with manual dressing and no set-up procedures.

Completed programs can be simply and quickly uploaded to or downloaded from a PC, PDA or Network as required, using JandS software, for storage or recall.

The Dominator Easy is available as a standard model or can be tailored to suit the requirements of individual applications.

A wide range of optional equipment is also offered, including permanent or electro-permanent magnetic chucks, wheel dressers and rotary indexing units.

Wheel dressing is by table mounted fixed diamonds, diamond disc dresser or via a diamond roll dresser.

Rotary indexing units include inline, vertical or cross table mounting, with tailstock if required.

On start-up, the Easy control offers the operator three simple options: Manual mode, Dress mode or Grind Cycle mode.

In manual mode, the Dominator Easy operates as a simple hand operated machine with control for the table and infeed via an electronic handwheel with position shown via a readout on the touchscreen.

Work speeds and feeds are also easily adjustable via the touchscreen, should the operator wish to set an area grind, or auto downfeed in place of manual movement.

When formed diamond rolls are not used to dress the wheel the operator can access Dress mode which offers five standard wheel shape macro's including flat, slot, facing, Vee form and full ISO with one or two diamond discs.

Dressing increments, speeds and frequency allow for roughing and finishing to optimise wheel performance.

A feature in the full software package is 'intelligent roughing out' of the wheel, - the system can automatically quickly and efficiently 'chop out' the basic form and then finish dress using the exact profile.

Wheel dressing can be initiated In or Out-of-Cycle and Dress-On-Demand for plain or complex wheelforms is standard.

The 'Dress-On-Demand' feature basically means that the operator can press the Dress button at any time and the machine will stop wherever it is, dress the wheel with full compensation and return to continue from where it left off.

Grind mode allows from One to 20 grind cycles to be linked as the complexity of the component dictates from cycles including plunge, multi plunge, area (intermittent or continuous), face grind, plunge and face, multi plunge and face, and plunge and creepfeed with or without taper.

Production/toolroom grinding made much easier

2006-12-31T02:06:00.000-08:00

The Jones and Shipman 524 Easy surface and profile grinder meets the requirements of the production environment as well as the accuracy, quick set up and change over demands of the toolroom. It also fulfils the criteria of both CNC and manual operation thanks to a GE-Fanuc control system and Jones Shipman 'Easy' software. Complex shapes, angles, radii and ultra flat surfaces can be precision ground quickly and easily.

Even inexperienced operators can obtain immediate improvements in set up and changeover times and in overall productivity for more complex work.

This is due to the combination of GE-Fanuc Touchscreen technology with Jones and Shipman's proprietary 'Easy' icon based software, which offers numerical control without the inherent complexity or cost penalties of traditional CNC systems.

In fact the 524 Easy can function as either a simple hand/hydraulic controlled machine with manual dressing and no set-up procedures or, once set using the easy-to-use 'self teach' software, can perform fully automatic dressing and grinding cycles.

With levels of functionality comparable to CNC but at lower cost all 'Easy' models are fast and simple to set-up via the touchscreen and easy-to-use Jones and Shipman icon-based software.

The control possesses the capabilities to interpolate two axes simultaneously to provide the creation of complex shapes, angles, radii and surfaces, with quick and easy set-up.

Y and Z axis control is via ballscrews driven from GE-Fanuc AC digital servomotors with 0.000004in (0.01 micron) Heidenhain 'Absolute' linear scale feedback.

On start-up, the 'Easy' control offers the operator three simple options: Manual mode, Dress mode or Grind Cycle mode.

In Manual mode the 'Easy' operates as a simple hand operated machine with hydraulic or manual table movement and handwheels for the crossfeed and downfeed which show position via a scale readout on the screen.

Work speeds and feeds are simply adjustable via the touchscreen should the operator wish to set an area grind or auto downfeed in place of manual movement once he has touched on.

Dress mode offers five standard wheel shape options flat, slot, facing, Vee form and full ISO with one or two diamonds as needed.

Dressing increments, speeds and frequency allow for roughing and finishing to optimise wheel performance.

A great feature when the full software package is incorporated is 'intelligent roughing out' of the wheel, - the system will automatically 'chop out' a basic form and then finish dress using the exact profile.

Wheel dressing can be initiated in or out of cycle and dress-on-demand for plain or complex wheel forms is provided as standard.

Dress-On-Demand allows the operator to press the Dress button at any time and the machine will stop wherever it is, dress the wheel with full compensation and return to continue from where it left off.

Grind mode allows from one to 20 grind cycles to be linked as the complexity of the component dictates including plunge, multi plunge, area (intermittent or continuous), face grind, plunge and face and multi plunge and face.

The 524 Easy has been designed from scratch to give improved productivity.

With a new bed, saddle, table, column etc, it offers increased precision, geometry and rigidity and continues a long-established tradition of excellence in manufacture.

Generously proportioned high-grade cast iron major units all combine to create greater rigidity for optimum performance in terms of grinding accuracy and repeatability.

The wheelhead slide moves vertically on low friction, preloaded ball and roller bearings, thereby ensuring extreme sensitivity, while the hand scraped table and saddle slideways are Turcite coated and lubricated automatically to reduce friction to the minimum possible.

'Sliding dogs', which are simply moved by hand without the need for tools, set the table reversal length, their positions being detected by proximity switches sited in the saddle.

Innovative design, high build quality and a rigid and stable machine structure combine to ensure accuracy and productivity and makes this the product of choice for both old and new to the art of precision surface grinding.

The 524 Easy forms the cornerstone of Jones and Shipman's all new range of Surface Grinders.

CNC cylindrical grinder improves product roundness

2006-12-30T02:05:00.000-08:00

Accura Technics announces advancements in precision grinding applicable to aerospace, automotive, bearing and optics manufacturing. In capability tests, Accura's Model 1210G CNC grinder produced 0.000010in (0.25 micron) roundness in ball bearing outer races and 0.000006in (0.15 micron) roundness in inner races. This multi-surface grinder was delivered to the USA's Adcole Corporation (Marlborough, Massachusetts; Pompano Beach, Florida) for grinding spindle components for camshaft and crankshaft measuring machines.

Roundness of these components directly impacts axial and radial run-out of the assembled spindle.

Excellent run-out is crucial to the measuring machines' performance.

Upon inspection of the first spindle processed on the 1210G, Adcole's general manager, Patrick Cole, said, 'Needless to say, we are impressed.

And it will only get better from here.' The 1210G is equipped with a hydrostatic bearing workhead, and two wheelheads: an air bearing ID/OD spindle, and a ball bearing rotary surface spindle.

The two wheelheads are mounted on independent CNC axes.

These axes are driven by ball screws and servomotors while the X-axis is driven by a linear motor.

The three slides are mounted on a thermally stable, natural granite base.

'Customers turn to us for creative solutions to their precision grinding needs,' said Patrick Hurst, president of Accura Technics.

'We work with our customers to develop robust processes that deliver higher precision at a competitive cost which saves them time and money.' The 1210G has a 12in (300mm) swing and 10in (250mm) workpiece height capacity.

Standard X-axis travel is 14in (350mm).

Standard Z-axis travel is 12in (300mm).

The machine can be fully automated with robot loader, conveyors and gauging.

Optional features include C-axis for non-round grinding and acoustic emission monitoring system.

Accura Technics other products include the MicroTol - a machine tool platform suitable for optics machining, hard turning, shoe centerless ID grinding, and miniature bore grinding.

Entry-level tool grinding and inspection

2006-12-29T02:04:00.000-08:00

The trio of new Walter Helitronic tool grinding and Helicheck tool inspection machines announced by Kandoumlrber Schleifring UK of Honiley near Kenilworth not only reinforces Walter's position as a world leader in the tool grinding and inspection field, but the developments also address user demands both for entry-level tool grinding and inspection equipment plus a machine specifically to grind micro tools. The new machines are: The Helitronic Basic - a budget-priced five-axis tool grinder; The Helitronic Micro - for the consistent production of tools of 0.1 mm to 12.7 mm diameter; and The Helicheck Basic - an entry-level, high-accuracy tool measurement machine. The new machines are based on similar high-quality construction principles to Walter's existing models and, likewise, also incorporate the company's renowned tool grinding software.

But importantly, the new machines feature CNC and drive hardware from Fanuc - 'ultra-reliable and globally standardised technology', says Neil Whittingham, sales director of Kandoumlrber Schleifring UK.

A derivative of the highly successful Helitronic Power, the new Helitronic Basic tool grinder offers an unrivalled route for cost-effective tool regrinding.

With Fanuc 310i CNC and 15 inch touch screen monitor, the machine features a 70 mm grinding spindle powered by 7 kW drive plus worm gear drive in the A axis.

As standard it is supplied with Walter Window Mode P1 and P3 grinding programs (end mills and drills), and options include coolant tank, Eco tool loading system, automatic clamping and worktable.

The new six-axis Helitronic Micro, on the other hand, has been developed from a clean sheet and is designed to meet the increasing production demands by, for example, the medical and electronics sectors of micro tools of 0.1 mm to 12.7 mm diameter.

Tools from 2 mm to 12.7 mm diameter can be reground.

Featuring an HSK 40, 5 kW spindle and utilising Fanuc 310i CNC that incorporates Walter's 'what you see is what you grind' Helitronic Tool Studio software, the machine's double-ended grinding head (optionally three-spindle, with one 5 kW and two 1.5 kW drives) has integrated cooling that combines with linear drives and torque motor (with integral cooling) and the machine's mineral cast base to help generate high precision, excellent surface finishes and longer wheel life.

An integrated Fanuc robot (double gripper) loading system also features, for fast - less than 10 secs - tool change, in conjunction with the four-pallet Pallet load system.

This provides unmanned working of up to 300 tools per pallet - three pallets for unground tools; one pallet 'empty' for ground tools - of tools from 1 mm to 6.9 mm shank diameter and 120 mm long.

Larger tools of 7 mm to 12.7 mm shank diameter and 120 mm long can be handled at 108 tools per pallet.

An optional, additional manual X axis is available to reduce grinding traverses, where appropriate.

The new Helicheck Basic tool inspection machine occupies 30 per cent less floorspace than the Toolcheck it replaces (by adopting vertical design principles rather than horizontal) and, like its stablemates the Helicheck and Helicheck Pro, it offers 3C Direct View camera technology with cameras for back, front and top light illumination.

The back light provides magnification of 50x, front and top of 100x; and combined with the solid granite base plate for temperature resistance and high stability, the result is a repeatability of 1.5 micron and an absolute accuracy of +/- 2.2 microns at a measuring length of 10 mm (VDI/VDE 2617: E1 = 2.2 microns + L/300).

These new machines are complemented by a new grinding wheel/electrode wheel changer for the Helitronic Power Diamond two-in-one machine for grinding/eroding PCD tools - where up to eight electrodes/wheel sets, with coolant distributor, can be changed in 10 secs - and follow hard on the heels of recently-announced the Helicheck Plus tool inspection machine for measuring standard and micro tools down to 0.1 mm diameter.

Cylindrical grinding machine finishes in one pass

2006-12-28T02:04:00.000-08:00

The New ShapeSmart NP4 by Rollomatic is a reinforced version of the existing CNC148P4 cylindrical grinding machine with a patented method of rough and finish grinding in one pass. This machine is ideal for cutting tool blank preparation and grinding precision punches and molding components. The grinding size range is from 16.0 mm (5/8') down to micro scale, with blank length capacity up to 300 mm (12') for automatic loading and 350mm (13.8') for manual loading.

The two grinding slides have been designed with a New technology known as the BoxSlide system, which enhances stability.

To eliminate any run-out on the grinding wheels, the ShapeSmart NP4 features a New arbor system called Perfect Arbor, which uses material compression as a means of centreing the arbor into the spindles.

The NP4 also features the user-friendly tool design software, P4Smart.

With drop-down windows that allow you to edit program text and graphically check the movement of both grinding wheels during machining, it's easier than ever to grind precision blanks, punches and pins.

Super abrasive peel grinding slashes cycle times

2006-12-27T02:03:00.000-08:00

Holroyd has employed its super abrasive machining technology to reduce the cycle time for producing turbo charger stators from 5.1/2min to just 46s. These improvements have been achieved using Peel Grinding of the stator shaft, removing as much as 5mm a side in a single cut. In addition, the super abrasive wheel used in the Holroyd process lasts up to 200 times longer than tool inserts used with in twin turret turning, providing a life of at least 10,000 parts to minimise tooling and machine set-up costs.

One of the direct results of Holroyd's expertise in helical rotor production is that the company has established itself as one of the leading suppliers to the turbocharger and supercharger industries; both as a manufacturer and supplier of high precision machine tools, and as a sub-contract manufacturer of components using the self-same machines.

Recently, Holroyd was approached by one manufacturer concerning a cycle-time problem with the machining of turbocharger stators.

The stators comprise an Iconel impeller attached to a mild steel shaft.

Previously, the time to machine the shaft, and the faces and OD of each impeller was 5.1/2 min; this being achieved using twin turret lathes.

However, there were a number of problems with this machine set-up.

First, the cycle time was too long to enable the manufacture to achieve his desired component cost.

Second, although a twin turret lathe was used to ensure full depth of cut on the shaft - without bending, this did not account for the resulting upset of the shaft during the deep machining process.

Third, the depth of cut required - 5mm a side - from the twin turret lathe, and the resulting chattering of the tools in operation, meant that the life of tool inserts was extremely poor, with commensurate high costs for replacement.

Holroyd's approach to solving these problems centred on its super abrasive machining capability: in particular the use of an Edgetek Super Abrasive Turning (SAT) Centre.

The Edgetek SAT employs CBN wheels to achieve productivity rates far in advance of those obtained with hard turning.

It is designed to remove stock from the OD of cylindrical parts (slot, groove, and forms) in all types of materials (from soft to hard) at rates 40% faster than a conventional lathe.

Because productivity with the SAT system goes far beyond that typically obtained with hard turning, the machines are ideal for machining inconel and heat treated powder metal workpieces with interrupted cuts.

They can be used for such typical turning applications as machining slots, interrupted cuts on impellers, gears, splines and facing cylindrical parts.

The use of thin CBN wheels means that the SAT machines are especially well suited to Peel grinding, where high wheel speeds and high workpiece speeds result in very high stock removal rates with low grinding forces.

Thin CBN wheels used in this way have cutting edges similar to turning tools, thereby reducing the cutting forces required between the wheel and the work piece.

Compared to conventional grinding processes, Peel grinding typically removes three times the stock with half the force within the same time frame, and allows contour-grinding of a part in the same way that conventional machining does.

Holroyd applied its SAT Peel grinding technology to the tubocharger rotors with impressive results.

The overall cycle time for machining shaft, faces and impeller OD was reduced from 5.1/2 min to just 46s - a reduction of nearly 88%.

In addition, the improved burn threshold qualities of the Edgetek SAT machine result in a lower finished surface temperature of the workpiece, which means no upset and no undesirable friction weld rings generated during the super abrasive turning process.

Finally, toolwear and, consequently, tooling and set-up costs, are much lower using the Edgetek SAT machine: the life of the CBN wheels extending to an average of 10,000 parts before re-tooling and machine set-up is required.

'We are not surprised by these findings,' said Neil English, sales director of Holroyd.

'In every case where we have performed machining trials with our Edgetek machines we have achieved at least a 40 to 50% increase in throughput, and in many cases it is much, much more.' In one recent application in the aerospace industry, an Edgetek super abrasive machine replaced seven conventional milling and grinding machines, and achieved a reduction in the throughput time for machining a highly complex and extremely hard Inconel part from 8 hours, to just 12 minutes.

English said: 'The large depths of cut and accompanying lower temperature work-piece characteristics that can be achieved with our Edgetek machines - even across difficult to work materials, are the key to achieving improved productivity, reduced process times and improved quality in highly competitive global markets.

There is no doubt that Edgetek technology is the future for machining, with the added benefit that it's available now.' Holroyd manufactures the Edgetek machines in all types and configurations to suit specific applications.

UK pressworker steps in as home supplier

2006-12-26T03:18:00.000-08:00

Corus Europressings (Cardiff), Harlow Pressings (Cwmbran) and West Riding Pressings (Brighouse), major manufacturers of pressed metal parts for the home entertainments and white goods industries, have recently closed down, giving Clamason a golden opportunity to step in as the alternative UK supplier who can meet all the necessary quality requirements and standards. On top of that, because Sharp Precision Manufacturing (UK) do not run a press shop any more at Wrexham, Clamason is manufacturing the top and bottom RFI shielding cans for the integrated digital tuner in the latest 42in and 50in plasma TV sets produced by Pioneer GB at Castleford, West Yorkshire, for the UK and Europe. Accordingly business is booming for Clamason Industries to the extent that the company quoted for a record £20m worth of presswork, and enjoyed record sales, in the first quarter of 2006.

As its guiding principle for 60 years, Clamason has always been prepared to refocus and diversify towards new areas of technical innovation and market growth, correspondingly investing in its manufacturing facilities to fulfil those needs.

And so the acquisition of tooling from factory closures has added Thomson Broadcast UK, Panasonic and Pioneer to Clamason's customer portfolio.

Their requirements are very similar in that they all need the painted covers, bases and backplates for home entertainment systems (DVRs, Sky and Freeview boxes).

Thomson and Panasonic no longer assemble these products in South Wales but, such is demand for replacement parts (1000's per week), the contracts will add significantly to Clamason's turnover.

Clamason has been able to intervene and help these household names in part because of its successful track record of having made the original BSkyB decoder box back in the 1990's, for which major project it installed a six-station transfer press line.

Further, with its new plant now open for business at Nitra, Slovakia, Clamason is discussing original equipment manufacture with Panasonic in the adjacent Czech Republic also.

Precision metal pressings fight back

2006-12-25T03:16:00.000-08:00

Clamason's precision metal pressings are now fighting back in all sorts of ways against plastics, providing superior solutions for many so-called 'traditional' plastics applications in the medical device sector. Accordingly, in comparison with metal pressings, plastics may suffer from shrinkage, joint line and RFI / EMI shielding problems, be degraded over time by heat, light and ultraviolet rays and hold lower dimensional tolerances. Then, unlike plastics, Clamason presswork is recyclable in 95% of cases.

The latest examples of how metals are effectively replacing plastics in medical equipment were displayed on Clamason Industries' Stand 711 at Medical Device Technology 2006, NEC, Birmingham, on February 15th - 16th.

Clamason Industries takes great care to safeguard customer confidentiality, so therefore cannot detail the growing number of medical devices incorporating its pressed metal, precision components, which go well beyond the more traditional pressed scalpel blades, pins, rods and implants.

Clamason Industries can, however, quote the capabilities and procedures which the company has in place to ensure that its engineering solutions meet the exacting standards demanded of medical device protocols.

In fact 50% of the cost of a medical component can be its validation cost.

Accordingly, all Clamason medical components are fully process validated using Design, Installation, Operational and Production Qualification protocols (DQ / IQ / OQ / PQ).

In addition, the Clamason team is trained in the use of URS (User Requirement Specifications), CAPA (Corrective and Preventative Actions) and GMP (Good Manufacturing Practice).

The new £40,000 Simac Masic 3D realtime vision system at Clamason measures and monitors in 3D 100% of thin and intricate healthcare components fed from a high-speed press in a continuous strip and requiring measurement of key features to 50-micron tolerances.

Partnership makes quality medical components

2006-12-24T03:19:00.000-08:00

Close co-operation at all stages between three companies Clamason Industries, Bruderer UK and Simac Masic has provided an exemplary engineering solution for a critical small precision component which exceeds the exceptionally stringent quality requirements of an international healthcare OEM. The growing number of medical devices incorporating Clamason's precision pressings go well beyond the more traditional pressed scalpel blades, pins, rods and implants. All Clamason medical components are fully process validated using Design, Installation, Operational and Production Qualification protocols (DQ / IQ / OQ / PQ).

In addition, the Clamason team is trained in the use of URS (User Requirement Specifications), CAPA (Corrective and Preventative Actions) and GMP (Good Manufacturing Practice) - all essential for medical industry approvals.

In this particular application, Clamason's new, state-of-the-art, £200,000 Bruderer press, model BSTA 250-75B, integrated with a decoiler and crop-off station, runs in a dedicated cell at high speeds of up to 800 strokes per minute, producing two parts per stroke.

The 25-tonne, PLC-controlled, Bruderer BSTA Series press has a bed length of 750mm and features quick-change tooling for JIT manufacture.

Plantmaker Bruderer is a world leader in stamping technology and a byword for precision, with a famous 60-year history dating back to its foundation in 1943 at Frasnacht, Switzerland, where Clamason's engineers were trained comprehensively on the new machine.

Most spare parts are held conveniently in stock at the Luton headquarters of Bruderer UK, who offer an impressive door-to-door service within 24 hours.

A £40,000 Simac Masic 'Stampede' 3D realtime vision system ensures zero-defect production of the intricate and highly toleranced healthcare components which are fed from this press in a continuous strip.

A world away from the previous UK-wide system of sample-based inspection, which was based upon periodic checks and charts of trends, the in-line inspection of 100% of the thin metal parts requires the measurement of four key features to a 50-micron tolerance.

For example, to analyse height characteristics, the system measures and monitors each component in 3D from the side.

A standard vision system can only measure in two dimensions but, by developing an innovative arrangement of a second camera, light and product strip, third-dimension features can also be checked with the required accuracy and repeatability.

In other applications for the Bruderer BSTA 250-75B, ten or more components can be stamped out per stroke at over 1000 strokes a minute and, if four or five measurements are required per part, the Simac Masic 'Stampede' inspection system has to perform up to 50,000 measurements per minute ! The company Simac Masic has been working since 1992 as an integrator with PPT Vision of Minneapolis, where their hardware and operating system are produced.

Precision pressworker competes with Far East

2006-12-23T03:18:00.000-08:00

Metalworkers in the cities of the People's Republic of China are thrilled to earn £1000 (15,000 yuan) a year, and 200 million rural workers can't wait to join them. So how can metal manufacturing companies in Britain's Black Country heartland compete with such low labour costs? Clamason Industries is a family owned and managed, precision presswork manufacturer with over 100 employees (75% of whom are in production functions), located on a two-acre site at Kingswinford.

The company currently has annual sales of £7.5 million, which it expects to increase year-on-year.

Clamason is in many ways the modern model for a family company, with business and family in close harmony.

Also, the 'people' side of the business lies at the heart of the management philosophy and underpins the company's commercial success.

As evidence, Clamason is proud to have achieved the Investor-In-People Award and a prestigious National Training Award.

Laser micromachining services boosted

2006-12-22T03:10:00.000-08:00

Oxford Lasers is a world leader in the provision of laser micromachining systems and services. Due to rapidly growing sub-contract demand from the electronics, bio-medical, automotive, semiconductor, sensor and other high technology sectors Oxford Lasers has commissioned a new laser micromachining facility for high volume production. At the same time, existing micromachining facilities are being upgraded to give even higher positional accuracy for certain extremely demanding applications.

Sub-contracting customers can take advantage of the latest infrared, visible and UV lasers with multi-axis part manipulation.

Trepanning heads, optical and electron microscopes, vision systems for part location, and CAD/CAM file conversion are all available for: - micro hole drilling: holes down to 1 micron diameter can be drilled in almost any material including stainless steel, hardened steel, refractory materials, ceramics, diamond, polyimide and ABS - micro cutting: cut widths down to 5 microns in almost any material - micro milling: feature sizes down to 5 microns Typical applications include: - production of bio-medical micro parts - drilling holes in chemical sensors - manufacture of fuel injector nozzles (both gasoline and diesel) - manufacture of semiconductor test components in alumina, silicon nitride or VespelTM - dicing and scribing silicon and sapphire wafers - drilling micro nozzles for microfluidic applications Oxford lasers team of specialist engineers can offer cost effective sub-contract micromachining services for batches of just few parts per month or many thousands of parts per week - all produced with equal care and precision.

Ultra high precision medical pressings in the UK

2006-12-21T03:08:00.000-08:00

A not so traditional Black Country 'metalbasher' is now manufacturing five precision metal pressings for Pfizer's revolutionary new insulin dispense system and providing a service to other international customers, too, as a World-class supplier to the medical industry. Pfizer's device for pulmonary delivery is claimed to provide the first non-injectable form of insulin available since the discovery of the drug in the 1920's. As its guiding principle for 60 years, Clamason Industries of Kingswinford near Stourbridge has always been prepared to refocus and diversify towards new areas of technical innovation and market growth, correspondingly investing in its manufacturing facilities to fulfil those needs.

In three years up to the end of 2007, the leading-edge medical industry will have grown from a negligible amount to some 30% of the company's turnover, second in value only to its first-tier automotive engineering contracts.

Clamason's five pressings - two in 5052 grade aluminium alloy and three in 301 grade stainless steel - are for Pfizer's ground-breaking insulin delivery system via the lungs.

It dispenses a dry powder, synthesized insulin called Exubera, the first inhalable insulin set to become available on the mass market.

Exubera is inhaled before taking food and acts rapidly and effectively.

Pulmonary delivery has been in development for a number of years.

It offers a potential alternative to injections, which may subject diabetes patients (including the many needle phobics) to risk and discomfort.

Reducing a reliance on subcutaneous injection is more patient compatible, clearly lessening pain and the possibility of infection.

The charity Diabetes UK estimates that 2.1 million people in Britain have the condition.

It is reckoned that nearly 230 million people worldwide have diabetes, and the global figure is expected to rise to 350 million by 2025.

If uncontrolled, diabetes can lead to a number of complications including blindness, heart disease, stroke, kidney failure and nerve damage.

Already the complications of diabetes cost the NHS approximately £5 billion a year.

The new device allows adult patients with Type 1 and Type 2 diabetes to breathe in their insulin as powder from a handy blister pack rather than inject it.

The action of loading the drug primes the pump, so that no propellant is necessary.

Appliance and molecular powder formulation - including ironically the use of sugars to carry the drug - were developed by designers Nektar Therapeutics (www.nektar.com) for the Exubera insulin produced in a joint development program between the pharmaceutical giants Pfizer and Sanofi-Aventis.

It is now manufactured and sold exclusively by Pfizer.

The plastic injection mouldings are made and final assembly of the Exubera inhaler is performed by Clamason's UK customer, Bespak plc at their custom-built facility in Milton Keynes (www.bespak.com), and US customer, the Tech Group, Inc which includes a 50,000 sq ft, contract injection moulding facility for medical products at Tempe, Arizona (www.techgroup.com).

Bespak, a fast-growing British technology company, is quoted on the London Stock Exchange and has been providing dispense solutions for the pharmaceutical, medical, health and personal care sectors for more than 40 years.

As a World leader in the production of pressurised metered dose inhalers, Bespak's appointment as principal contractor on the Exubera inhaler project was an obvious one.

The five Clamason pressings in the Exubera device are as follows.

Manufactured in 5052 grade aluminium alloy are a mainframe assembly (with two stainless steel studs outsourced and assembled by Clamason) and a link pump handle.

In 301 grade stainless steel come three further parts - a blister retainer, a customised flat washer (replacing an off-the-shelf version) and a transjector punch.

Pioneering shielding can for TV sets

2006-12-20T03:04:00.000-08:00

Privately owned British precision pressings manufacturer Clamason Industries of Kingswinford, West Midlands, is manufacturing a top and bottom RFI shielding can to house the digital tuner integrated into the latest 42in and 50in plasma TV sets being made for the UK and European markets by Pioneer GB at Castleford, West Yorkshire. The cover of tin-plated and the base of zinc-plated mild steel are essential for picture quality to shield against radio frequency interference (RFI) and electromagnetic interference (EMI). Clamason delivers the RFI screening cans in pairs on a JIT basis to Pioneer GB, always filling a timed delivery slot on a specific day.

Meanwhile plasma screens are flown in from one of the Pioneer Corporation's three plants in Japan for the sets to be built at Castleford - at a daily rate of up to 1800 units, 75% of which are expected to consist of the state-of-the-art 42in model.

The highly successful British operation employs 400 workers in a 12,000 sq ft factory and runs three assembly lines working 24/7, as it strives to meet the fast-expanding demand from retail and business sectors for the Pioneer and NEC brands which it manufactures.

Pioneer came to Clamason Industries as an alternative UK supplier able to meet all the necessary quality requirements and standards when their previous supplier Sharp Precision Manufacturing (UK) shut down its stamping operation at Wrexham.

In fact the current wave of press shop closures across Britain has meant that business is booming for Clamason, to the extent that this 'lean manufacturer' has quoted for a record £20m worth of presswork, and enjoyed record sales, in the first quarter of 2006.

Clamason has been able to intervene and help household names like Pioneer in part because of its successful track record of having made the original BSkyB decoder box for Pace in the mid-1990's, for which major project it installed a special Chin Fong Worcester transfer press line from Taiwan.

That line of six presses located together provides rapid transfer of pressings between stations by pick-and-place robots with careful handling.

The system allows the manufacture of highly complex parts with no carry strip and the automatic insertion of other components and has the facility to reverse the burr side automatically within the process.

It is ideally suited to complex and intricate set top box applications where the maintenance of excellent surface quality is an essential consideration.

Above and beyond other home entertainments uses (such as DVR bases and Sky and Freeview boxes) for Thomson Broadcast UK and Panasonic, Clamason makes similar RFI shielding components for automotive multinationals.

Those pressings are engine control unit (ECU) enclosures for its first-tier customers Delphi Worldwide (on a variety of vehicles assembled in Europe, Asia and Central America), Motorola ACES (soon to become Continental AG) in North America and France, and Hitachi Europe (on the Nissan Micra and Renault Clio).

Furthermore, in order to ease JIT deliveries to the Central European factories both of automotive first-tier suppliers such as Delphi and TRW and of home entertainments OEMs such as Panasonic and Thomson, Clamason Industries has opened a 10,000 sq ft satellite plant with a £300,000 investment at Nitra, on the motorway network 80km east of Bratislava, capital of Slovakia.

Heat exchanger benefits from welding technique

2006-12-19T03:03:00.000-08:00

Carr's Welding Technologies have developed a welding procedure for the manufacture of a flat heat exchanger for A K Industries . The Under-shower-tray-heat-exchanger takes out heat from the waste-water from the shower and pre-heats the cold water coming in to the shower, thus saving money and energy, of course. Carr's make the 4 part heat exchanger on their big Trumpf CW robot welding laser, which welds the 2 thin sheets of stainless steel together.

The complicated path welded into the sheet is then subject to a further process to create a lattice of water ways.

Mains cold water is fed through this heat exchanger and the warm waste water from the shower flows over the surface.

This has the effect of pre-heating the incoming water so that the instant shower element does not have to work as hard.

Thereby reducing energy consumption by the shower.

The Development programme carried out by Carr's over the summer, has perfected the art of jigging and welding the thin steel sheets together, so that good penetration is achieved all round the part.

Running at 2.5metres per minute the 5 metre weld path is welded in under 2 minutes.

The product is then leak tested and then packed for shipment to A K Industries of Hereford who complete the heat exchanger with the plastic surround and all the fittings.

This simple patented design, has been entered into a national competition for best energy saving product of the year and has been short listed for the final round of judging.

Manufacturer specialises in laser cutting

2006-12-18T03:02:00.000-08:00

Leading midlands manufacturer Moseley Brothers has announced the launch of a new subsidiary specialising in laser cutting. The new company, gf laser, has been set up to capitalise on an increasing need for low volume and prototype parts. Significant investment has been made by gf laser in the latest Trumpf cutting technology including a TLC Cut 5 machine, only the second of its kind in the UK.

The Cut 5 has the ability to cut 3D parts as well as traditional flatbed, it also uses a dedicated programming system that calculates cutting paths for optimal material utilisation.

The new venture is operating from dedicated, modern premises in the West Midlands and neighbours the existing site of Moseley Brothers.

This means it is able to work on an autonomous basis but still offer clients a mixed facility of machining methods when required.

Simon Tregillus, Commercial Director of gf laser commented 'There are numerous companies able to provide laser cutting but only a handful are able to offer a three dimensional service.

In addition, clients of gf laser can benefit from other services offered by the group such as toolmaking and part production'.

Laser cutting is used in a variety of different industries from aerospace to commercial catering equipment.

Latest 3D laser cutter added to service

2006-12-17T03:02:00.000-08:00

gf laser has announced that it has made a significant investment in the latest 5 axis Trumpf Laser Cutting machinery. This means they will be able to provide laser cutting of 3D workpieces and traditional flat components. The TLC Laser Cut 5 is only the second machine of its kind to be supplied by Trumpf in the United Kingdom.

The machine benefits from utilising a customised 3D programming system - ToPs 800.

This ensures that the laser and the programming system are optimally tailored to one another.

Simon Tregillus, Commercial Director of gf laser, commented 'We're delighted to widen the group's ability to provide 3D Laser cutting.

This investment underlines our commitment to provide a wide range of manufacturing services to existing and prospective clients

Move to new premises for laser cutting service

2006-12-16T03:01:00.000-08:00

gf laser has moved into a modern production facility housing some of its latest laser technology. The recently refurbished premises were chosen specifically for their suitability for laser cutting as they provide a clean and spacious working environment. Furthermore, the unit has ample office space for the programming team and is an ideal location for client meetings.

Simon Tregillus, Commercial Director of gf laser, said 'We're delighted to have secured a high quality unit of this calibre, as well as being close to the other companies within the group we are on a trading estate that has 24 hour manned security.

Undoubtedly, working in this environment will help us in our drive to become one of the top laser cutting companies in the UK'.

Versatile rods gas-weld non-ferrous metals

2006-12-15T02:10:00.000-08:00

Versatile rods gas-weld non-ferrous metals As well as gas-welding welding aluminium, welding rods can be used to weld almost all other non-ferrous metals and alloys - and galvanised steel and between dissimilar non-ferrous metals. Welding aluminium, usually a difficult task requiring expensive equipment and high levels of skill, is fast and straightforward with the revolutionary new Durafix Easyweld aluminium welding rods from Durafix. In addition to aluminium, the rods can also be used to weld almost all other non-ferrous metals and alloys - they can even be used to produce strong welded joints in galvanised steel and between dissimilar non-ferrous metals.

No special equipment is needed to make welds with Easyweld rods - their low working temperature of just 392 deg C means that they can be used in conjunction with almost any ordinary hand-held blow torch.

For the convenience of new users, Durafix offers the rods in the form of inexpensive kits, complete with a high-quality auto- or manual-ignition torch.

For users who already have a suitable torch, Easyweld rods can also be purchased separately, in a wide range of pack sizes.

Despite their convenience and ease of use, Easyweld rods produce dependable non-porous joints which are stronger than the parent metal, and which are entirely free from slag.

The quality and performance of the rods is confirmed by the US Army Engineering Corp, which has approved them under specification number MIL-R-4208 for use in an extensive range of military applications, including the repair of aircraft skins.

Among the many other applications for Easyweld rods are aluminium boat repair, which is usually impossible with conventional processes because of the thin gauge of the metal used for boat hulls; repair of die-cast components, which is also in most cases uneconomic by conventional means; and the maintenance of radiators, heat exchangers and cooling systems.

Because there are no toxicity hazards associated with the Easyweld process, it is equally suitable for use in domestic, workshop and industrial environments.

Whatever metals are being joined, the unique formulation of the Easyweld rods completely eliminates problems with oxidation at the weld, without the use of flux.

Not only does this mean that dependable joints can be readily produced even by users with no previous welding experience, it also avoids the environmental problems associated with the aggressive flux materials used in many other welding processes.

As well as being simple, safe and convenient, Easyweld system is also exceptionally economical.

Plasma-arc cutter is for manual operation

2006-12-14T02:10:00.000-08:00

Plasma-arc cutter is for manual operation At EuroBLECH, visitors can see a compact plasma-arc cutting tool which is portable yet powerful enough to efficiently cut through up to 10mm metals. Hypertherm has announced that it will unveil a new compact plasma cutting tool at the euroblech exhibition held October 23-29 in Hannover, Germany. The new tool is the latest addition to the Powermax family and combines compact size, low weight, minimal energy usage, with superior cutting power and quality.

The unit is small and light enough for an operator to carry while operating yet powerful enough to efficiently cut through a maximum 10mm (3/8in) metal up to ten times faster than oxy-fuel gas or other traditional methods.

It is ideal for a wide range of metal cutting applications in industries such as automotive, aviation, construction, farming, site maintenance, HVAC, and any other industry requiring flexible, 'on-the-spot' metal working.

Visitors to EuroBLECH can view live demonstrations of this new technology in Hall 13 Stand D54.

'EuroBLECH is an ideal show for us to stage the worldwide launch of this product,' said Bruce Altobelli, business team leader, Manual Systems, Hypertherm.

'This exhibition allows us to reach important industries that depend on efficient metal cutting technologies.

Our new system will certainly live up to the high expectations of EuroBLECH visitors who expect to see the latest leading edge technology.' Hypertherm's new compact cutting tool will feature many of the benefits of the company's other manual cutting systems.

These include low voltage, enhanced safety features, and minimal operating costs.

* About Hypertherm - for over 30 years, Hypertherm has been a pioneer in advanced high temperature metal cutting technologies.

Setting the standard for cut quality and weldability, the company produces a wide range of automated and manually operated laser and plasma-arc cutting systems.

Under the leadership of Hypertherm's founder, Richard W Couch, Jr, the company has grown from two associates working from a small garage to a worldwide organization with over 700 associates working in locations globally.

Powerful portable machine bevels plate edges

2006-12-13T23:31:00.000-08:00

Model SKF 2023 is the most powerful of a range of seven portable chamfering and bevelling machines available from Surtech. With its 2,5kW electric motor, variable cutting speed from 6500 - 8500 rev/min and the multi-bladed milling head it is the ideal machine for bevelling plate prior to welding. A large bearing guide on the end of the milling head and a large disc support make it easy to move the machine along both straight and contoured edges.

Bevel widths of up to 15mm at 30, 45 and 60 degrees are possible and with the correct choice of milling head and carbide inserts the machine will handle mild steel, stainless steel and aluminium.

Slightly hardened edges from thermal cutting are no problem.

Unlike standard bevelling machines which have milling heads with between one and four inserts Model SKF 2023 has a unique and patented milling head with two rows of eight inserts.

As a result metal removal rates are several times faster and the finish is smoother and more consistent.

Model SKF 2023 comes close in performance and results to dedicated bench and stationary bevelling machines with the benefit of costing considerably less and being more versatile.

Self-propelling bevelling tool prepares plate

2006-12-12T23:31:00.001-08:00

Surtech's Model 800 is used for high speed weld preparation of mild steel, stainless steel and aluminium plate from 5mm to 40mm thick. The 100mm dia. rotary shearing tool is driven by a 1,5kW, 2800 rev/min motor and operates virtually without noise at feed speeds up to 1500mm per minute.

It lasts up to 2000m, depending on bevel widths and material.

When worn it can be re-sharpened.

The max.

bevel width is approx.

15mm at angles from 15 to 50 deg.

While bevelling the machine propels itself along the edge of long plates without any effort by the operator.

Model 800 will also hold smaller parts without the operator having to support it.

Slag grinder can replace up to six angle grinders

2006-12-11T23:30:00.000-08:00

Surtech's Model LS 90 Slag Grinder offers an outstanding price versus performance ratio. One person using the LS90 can deslag as many flame cut blanks as up to six persons with angle grinders. This is possible because of the superior grinding ability of Model LS 90 and the considerably reduced handling.

Model LS90 consists of a table approx.

2000mm long and 800mm wide, an overhead abrasive belt head with a contact wheel carriage and electrical controls for motorised vertical table travel and for a two speed or reversible abrasive belt drive.

Flame cut blanks are laid out on the table.

By moving the contact wheel carriage left to right and right to left and the table back or forth all blanks can be ground in one operation.

The 6HP belt drive motor has ample power for even the toughest burr and the 6000mm long belt guarantees long life and little down time due to belt changes.

The Slag Grinder can be viewed and tested at Surtech's Abrasive Test Centre in Birmingham.

Cranable unit cuts plate edge bevels in-situ

2006-12-10T23:29:00.000-08:00

Model ASO 900 bridges the gap between portable and stationary bevelling machines. When parts are too large to handle and required bevels too wide for portable machines Model ASO fits the bill. At approx.

85kg it needs to be lifted into place with the help of a crane but once in position it is self propelled and can easily be controlled manually.' For smaller parts it can be mounted on a wheeled carriage allowing parts to be hand fed.

The powerful 2.2kW motor combined with the 63mm diameter milling head will bevel mild steel 8mm wide in a single pass and up to a max.

of 40mm wide in several passes.

Feed rate is approx.

600mm/min.

Bevel angles are adjustable from 15 to 45 degrees.

Model ASO 900 uses milling cutters to produce smoother bevels than machines with rotary shearing tools.

Surtech offer more than a dozen portable, transportable and stationary machines for producing bevels prior to welding.

Portable weld prepping tools produce 15mm bevels

2006-12-09T23:28:00.000-08:00

Surtech's SKF range of portable bevelling tools is claimed to be the fastest and most powerful available anywhwere. Whilst traditional bevelling tools have milling heads with 2 or 3 carbide inserts set at a fixed 45 degrees, SKF tools feature patented milling heads with 5 inserts at angles of between 10 - 80 degrees. As a result SKF tools will bevel up to a width of approx.

6mm in a single pass and up to a max.

of 15mm in three passes.

Faster and with a smoother finish than any other portable bevelling tool.

A 140mm dia support disc and a 28mm dia bearing guide allow accurate tracking of straight and contoured edges as well as holes with a min.

dia of 30mm.

There are five machines in the SKF range.

With motors from 1.2kW To 2.6kW, some with variable speeds suitable for all metals from aluminium to mild steel and from stainless steel to tool steels.

SKF machines can be viewed and tested at Surtech's Abrasive Test Centre or demonstrated in your works.

Plate machining systems combined in one

2006-12-08T23:28:00.000-08:00

TIPO B251 is an automatic CNC line for the processing of plates of medium to heavy thickness. Its working range is very wide and goes from punching, drilling, milling and pointing to marking and shearing (also in shapes) using oxy-fuel gas cutting and plasma-arc cutting systems. The plates are processed in a single step, so performing several operations automatically reduces working costs and material handling.

Polygonal or shaped plates are processed with accuracy at reduced production costs.

TIPO B251 can process plates up to 2540mm wide and 6000mm long (longer lengths are optional).

The hydraulic punching unit is fitted with a single punch and an automatic plate hold-down.

The line can profile shapes and they can be automatically unloaded using a device with a capacity of 2500mm x 500mm.

The TIPO B251 is an upgraded version of Ficep's earlier TIPO B machine and has the following innovations: * Punching operations are performed using a punching tool with punch, die and positive stripper integrated such that the best punching quality is achieved.

The circular stripper holds and clamps the material evenly and constantly.

* The line can be fitted with an automatic tool changer having four, eight or 14 tool holders in a shuttle system.

* Thanks to the use of special valves, the punching cycle is very fast - reaching 1s/cycle.

* The line can drill (also combined with oxy-fuel gas cutting) plates up to 100mm thick (minimum thickness is 6mm).

It can process plates up to 10 tonnes and punch up to 25mm thickness (also combined with plasma-arc cutting).

These features are assisted by the design of the roller ways and the 'master' and 'slave' carriages, which are electronically synchronised, thus keeping the feeding of the plate always aligned along the X-axis.

In this way, it is possible to process with accuracy bent plates and plates with uneven edges.

* It is possible to perform milling operations not only inside the shaped plates but also along their external profile, to produce bevels for weld preparation.

* The datum line can be programmed according to needs and does not need any horizontal hold-downs.

* Thanks to the plasma-arc cutting system - a modified Hypertherm HT 2000 HS system - it is possible to reach cutting speeds 20% higher than earlier machines and the TIPO B251 achieves a considerably better cutting quality.

Portable unit cuts tube precisely on-site

2006-12-07T23:27:00.000-08:00

Orbimatic (UK), the manufacturers of high quality automatic welding equipment have introduced the PS 4.5 Tube Cutting Machine into their product range which has been designed and developed for on-site use. The PS 4.5 is manufactured by Georg Fischer Piping Systems and works using the same 'Orbital Cutting' principle as the industry proven RA range of cutting machines. All Georg Fischer cutting machines use variable speed high powered motor units with a rotating carbide cutting blade to give high precision cut.

This system allows the PS 4.5 to be used prior to Orbital Welding application with no extra preparation work need on the tube end.

A simple cam system is used to introduce the cutting blade into the tube accurately and gently prior to the cutting process.

Because the cutting blade is introduced to the material gently its life expectancy will be extended.

Weighing in at only 19kg, the PS 4.5 is ideal for applications where it needs to be transported form one working area to another.

Tube end preparation machine is cordless

2006-12-06T23:26:00.000-08:00

Tube end preparation machine is cordless Tube end preparation machine is a cordless tube end squaring machine which can be used to produce a perfect weld preparation on tubes from 3mm to 38.1mm outside diameter. Orbimatic UK Limited, the manufacturers of high quality automatic welding equipment have introduced the Georg Fischer RPG 1.5B tube end preparation machine to their range. The RPG 1.5B is a cordless tube end squaring machine which can be used to produce a perfect weld preparation on tubes from 3mm to 38.1mm outside diameter.

The RPG 1.5B uses a carbide cutting tip, which is rotated and introduced to the tube end via a micrometer control to allow accurate material removal.

This combination ensures that tube ends are left perfectly square and with no burrs.

The precise profile of the carbide cutting bit ensures that the swarf produce curls away from tube face externally, which allows the RPG 1.5B to be used with electro-polished tubes.

A range of collets and tools allow the RPG 1.5B to be used for most applications including the facing and reclaiming of used micro-fittings.

3D cutting system machines weld preps

2006-12-05T23:24:00.000-08:00

Boiler making demands the assembly of complex components, but before this can be carried out all parts must be prepared as accurately as possible. Three dimensional parts such as pipes and dished ends can be particularly difficult and for high quality bevel and profile cutting of these components, ESAB Automation has introduced the VBA Wrist. This innovative 3D process technology can also be used for both normal 2D vertical weld and edge preparation of steel plate.

By totally eliminating manual measuring and manual cutting, as well as reducing workplace handling and post cutting operations, the VBA wrist will appeal to all boiler makers.

In combination with ESAB's Vision Control, extremely small bevel tolerances can be achieved and due to its compact design and low weight, the VBA Wrist can be used with the ESAB Suprarex SXE-P cutting machine.

The VBA Wrist operates on a new patented principle.

In contrast to conventional systems, the tool centre point (TCP) of the VBA Wrist remains fixed in space during swivelling.

Its high accuracy adapts perfectly to every cutting task and its integration into CNC cutting machines provides uncomplicated control of the cutting process.

Cutting parameters are automatically set for various material thicknesses as well as bevel angles, significantly reducing programming requirements.

Exactly repeated cycles in bevel cutting for X and Y cuts provide the highest cutting quality even on complex geometrics.

Quality centre lathe price cut by 40%

2006-12-04T23:32:00.000-08:00

The latest 'special edition' Triumph VS2500 variable speed centre lathe is now available from Colchester Sales from just GBP 12,750 a massive price reduction of 40 per cent from the previous model. Based on a world-wide resurgence in the conventional manual machine market for Colchester Lathe and extensive value engineering, the new Triumph has a 7.5kW motor with triple range, variable speed drive giving 14 to 2,500 revs/min. It has a 400 mm swing over the 1250mm long hardened and ground bed and has been regarded internationally as the 'best-known' model of centre lathe.

The machine weighs in at a hefty 1,610kg in standard trim which demonstrates the inherent rigidity of the basic machine design and potential for high accuracy turning tasks.

The price reduction is a result of a swing to traditional centre lathe manufacturers such as Colchester Lathe due to problems of long-term reliability, poor spares and service support and disastrous residual values associated with low cost suppliers over the last five years or so.

This has enabled Colchester Lathe to respond to rising demand especially in workshop, education and training schools and instigate value engineering and competitive sourcing to maintain the level of quality associated with the brand name and make it more affordable.

Demand for centre lathes brings prices down

2006-12-03T23:31:00.000-08:00

A dramatic turnaround in the demand for conventional lathes has enabled a lathe builder to reduce the price of selected models in its centre lathe range by up to 40 per cent.

A dramatic turnaround in the demand for conventional lathes which has improved the benefits associated with economies of scale has enabled Colchester Lathe to reduce the price of selected models in its centre lathe range by up to 40 per cent. The new pricing structure is in response to Colchester Lathes' distributors reporting a world-wide resurgence of training schools and workshops who are preferring to buy known brands such as Colchester. This follows bad experiences such as long-term reliability, poor spares and service support and disastrous residual values that are a growing problem associated with the newer breed of low-cost centre lathe suppliers.

The effect of the market shift in Colchester's favour is qualified by a recent surge in demand where some GBP 750,000 worth of centre lathes have been ordered from seven different countries in the Far East, America and Southern Ireland.

According to Sales Director, Mike Dawes: 'Sales of our traditional centre lathes have experienced a dramatic turnaround.

This has motivated us to rationalise machines in the range and certain key component parts while maintaining or improving quality of build.

With orders rising, we have been able to instigate value engineering and more competitive sourcing which also capitalises on the efficient production methods that are well-proven on our two and three-axis Tornado CNC lathe range.' Over the last five years or so, Colchester Lathe has grown its market share with its CNC range of slant bed Tornado and the Combi combination lathe.

Says Mike Dawes: 'Now with the new economies of scale, we have justified a total re-focus on our conventional machines which has resulted in a massive 40 per cent reduction in price on selected models.' When this is added to the world respected name of Colchester, built-up from over a century of centre lathe manufacture and being Europe's biggest lathe builder, distributors have already responded with a growing order book.