In the development of machining centers and cells,

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1 Hwacheon s H6 HMC is designed for heavy-duty machining of steel, titanium, and iron parts in either short or longer runs. Integrated adaptive software suite optimizes performance for machining efficiency and quality. Game-Changing Technology on a Roll Robust design, data communication, advanced CNCs lead the way Jim Lorincz Senior Editor In the development of machining centers and cells, we re always looking for game changers. Most recently, marrying 3D printing to standard machine platforms has been all the rage. Mazak Corp. (Florence, KY) is the latest entrant into the 3D printing/ hybrid sweepstakes with the introduction of the Integrex i-400am (additive manufacturing) Hybrid Multi- Tasking Machine for small-lot production from powder metals of difficult-to-cut materials such as those used in the aerospace, energy, and medical industries. Together with DMG MORI s (Hoffman Estates, IL) Lasertec 65 that uses laser sintering and milling of powder metals and MC Machinery Systems Inc. s (Wood Dale, IL) Lumex Avance 25 metal laser sintering hybrid milling machine, these machines are surely forerunners of yet-to-be-conceived innovative additive manufacturing machine designs. December 2014 ManufacturingEngineeringMedia.com 49

2 But what of traditional material-removing machining centers like heavy-duty horizontals for automotive production, high-speed verticals for precision mold-and-die work, and multitasking and five-axis machines for production of complex workpieces? At IMTS 2014, developments in each of these technology categories were shown along with the latest digital communication to and from the shop floor. Data collection from machines operating in real-time on the factory floor using the MT Connect standard and proprietary CNC control software is just such a game changer for management control and analysis. It enables 80 Models of Borescopes and 18 years of experience helping you select the right one! manufacturers to monitor performance, improve productivity, and boost bottom line profitability. Hawkeye Rigid, Flexible, MT Connect enables manufacturers and Video Borescopes to calculate overall equipment efficiency [OEE], monitor all equipment from one system, reduce production losses, and identify lean manufacturing strategies, said Neil Desrosiers, software developer, Mazak Corp. Mazak introduced its latest evolution in CNC control called Mazatrol SmoothX CNC technology, including machine hardware and servosystems. Smooth technology integrates the entire part production from programming and setup to actual material removal operations to automation to monitoring/data collection and transfer. Think of it as a hybrid born from the marriage of a CAM system and conversational programming, said Desrosiers. Any Hawkeye Rigid or Flexible Borescope can quickly become a videoscope by simply attaching our Luxxor Video Camera, allowing high-quality video inspection SmoothX technology, which is said images to be displayed on portable video monitors, or, laptop and desktop to essentially quadruple the new CNC s computers. Those images can be saved, documented and ed. Our newest interpolation speed, eliminating two of Hawkeye V2 Videoscopes are fully portable, and offer 4-way articulation. We manufacture over 80 models of rigid, flexible, and video borescopes. Most are in stock and ready for overnight delivery. the most common CNC bottlenecks sluggish hardware and slow processing Button rifled.204 Ruger as seen with a Hawkeye Pro Slim 17 Diesel injector body taken with a Hawkeye Pro Hardy 7 Burr in a cross hole viewed with a Hawkeye Pro Slim 7 speeds, incorporates features that were formerly supplied through thirdparty software. Intelligent pocket milling engages a high-efficiency toolpath when milling-out part cavities by maintaining a constant angle of tool engagement and cutting loads to ensure optimum machining conditions. Seamless corner control reduces vibrations and shortens gradientlens.com Made in USA part-machining cycle times through cutter path adjustments made when 50 ManufacturingEngineeringMedia.com December 2014

3 machining into corners. Rather than moving the cutter directly into a 90 corner, the function inserts a preset radial tolerance that eliminates any dwell resulting from a rapid deceleration in the axial movements, producing smoother corner surfaces, reducing the risk of cutter gouging, and cutter feed much faster. spindle type (fixed or articulating), table length, and table configurations that can feature a fourth axis built into the table, or placed on top of the table. Finally, a center divider can also be installed to create two distinct work areas, so parts can Advanced Technology Pushes Machine Builder s Envelope The focus of new technologies from Doosan Infracore Machine Tools (Pine Brook, NJ) is on a large-capacity travelling column vertical machining center (VCF 850LSR), a five-axis linear drive machining center (FM 200/5AX Linear), and a third-generation mill-turn multitasking machine (SMX 3100 S) with a more rigid 90 vertical axis. Doosan machines have MT Connect capability and were demonstrated streaming off-site created machining live data from Doosan turning centers on the factory floor of Bobcat in North Dakota, as well as from machines and robots inside of Doosan s IMTS booth. For one Doosan customer, Joe Gibbs Racing, a new design of a drag link machined as a single part on a Puma MX2600ST nine-axis VMC and horizontal turning center took the handnumbing vibration out of a race car s steering wheel. The drag link connects the power steering box to the spindles and was formerly produced by welding three pieces together. The VCF 850LSR travelling column VMC is a completely new platform from Doosan and offers our customers the expanded capacity required for machining large size and large mass parts, especially for applications as challenging as those in the oil industry, said Ron Kilgore, product manager-machining centers. As many as 14 configurations of the machine are possible, varying in RTC Engineered For Success December 2014 ManufacturingEngineeringMedia.com 51

4 Photo courtesy Doosan Infracore Machine Tools NFL Hall of Fame Coach and Founder of Joe Gibbs Racing, Joe Gibbs holds a vibration-damping steering drag link that was machined as a single part on a Puma MX2600ST. Formerly the drag link was a weldment of three pieces. Power-GriP Precise zero point clamping system Reduction of setting up time by up to 90% Repeatability of mm Palletizing and clamping devices from a single source RÖHM Products of America office@rohm-products.com I be loaded and unloaded on one side, while the spindle continues making chips in the other. With 850 mm in Y-axis travel, the VCF is ideal for machining the top half and bottom half of molds together. When configured with a fourth axis table mounted horizontally at one end and a tailstock on the other, you have the perfect platform for machining pipe up to 3 meters in length. And in its standard three-axis configuration the VCF can machine a wide range of aluminum spars for aerospace, said Kilgore. The new Puma SMX 3100S, Doosan s third-generation mill-turn multitasking machine is distinguished by a more rigid 90 vertical axis and a forward positioned ATC for improved milling capabilities, making it more of a milling machine with turning, than previous generations that featured a 45 slant bed, said David Barber, general manager-marketing. In fact, these new characteristics in the Puma SMX as compared to the new platform we have in our VCF 850LSR allow manufacturers to consider two different platforms for long shafts featuring complex angles and multiple bores. The Puma SMX series will initially be made available in two sizes, the Puma SMX2600 with a 10" (254-mm) chuck or the Puma SMX3100 with a 12" (305- mm) chuck. Both Puma SMX models have the capacity to machine parts up to 60" (1524 mm) in length and 26" (660 mm) in diameter. Typical applications are long shafts with a lot of angle in them that require milling features. Heavy-Duty HMC with Integrated Software According to Michael Huggett, president, Hwacheon Machinery America s (Lincolnshire, IL) new H6 horizontal 52 ManufacturingEngineeringMedia.com December 2014

5 machining center is designed to meet the requirements of machine shops for an affordable heavy-duty 630-mm pallet machine that can produce various lots of steel, titanium, and iron parts in either short or longer runs. The machine integrates the mechanical strengths of the Hwacheon stable box-way machine design and its adaptive software suite for machining efficiency and quality at a cost approximately 20% less than similarsized machines from other leading machine builders, said Huggett. Features of the H6 HMC include a geardriven 29-hp (22-kW), 8000 or 15,000-rpm, 50-taper spindle for powerful high-torque cutting, and a twin drive system for the X and Y axes for precise and faster cutting Port of an engine is being machined by the B-axis spindle head of the rates. An oil-jet cooling system ensures Doosan VCF 850LSR. heavy-duty cutting performance and precision motion even after long periods of machining. Axis strokes are mm with a B-axis rotation of 360 on a table with a working surface of mm and load capacity of 1600 kg. A 41" (1041-mm) swing inside the machine allows 80-mm pallets to be used. A 40-tool magazine is standard with options to 150 tools. Hwacheon casts its own bases and columns, hand scrapes boxways, and designs frame structures with 3D CAD and FEM analysis to support workpiece quality. According to Robert Nedler, vice president-sales, Hwacheon integrates its own unique software developed in conjunction with the latest Fanuc CNC to measure thermal displacement control and compensation. In this way, Hwacheon can control the kinematics of the machines for contour machining, optimizing machine performance for roughing, semifinish, and finish machining. Included in the software suite are tool load detection software LET STILES BE YOUR PARTNER IN (HTLD), high-efficiency contour control (HECC), and a cutting AEROSTRUCTURE MANUFACTURING. feed optimization routine (Optima). Tool load detection software provides real-time measurement of tool load ensuring consistent and safe machining by monitoring tool damage and deterioration for prevention of complete tool failure to prevent tool failure Talk to us. We re ready to help. causing workpiece damage and ensuring accuracy and performance. Tool load is measured as frequently as every 8 msecs. Contact Dave McFarland at or dmcfarland@stilesmachinery.com. Hwacheon's high-efficiency contour control (HECC) Visit us at software offers an easy-to-use programming interface system Software. Education. Training. Parts. Service. Support. Leasing. Rebuild. that provides a precise, custom contour control for the 54 ManufacturingEngineeringMedia.com December 2014

6 workpiece while supporting longer machine life and reduced process time. HECC offers different options for cutting speed and accuracy, and for surface finish and geometry. The customizable display provides real-time monitoring and easy access, and the software may be used with existing NC systems and is compatible with G-Code programming. To sustain a consistent cutting load while machining, the H6 features a cutting feed optimization routine (Optima) that uses an adaptive control method to regulate the feed rate in real time. The result is that cutting tools are less prone to damage and machining time is reduced. The system controls the feed velocity to maintain consistent cutting load. Sensors at various locations in the machine castings where thermal displacement is possible permit software monitoring and correction of detected thermal displacement. Hwacheon spindle displacement control (HSDC) software monitors temperature at a number of points within the spindle assembly and then makes necessary adjustments to prevent Z-axis error due to taper expansion as the spindle rotates at high speed. This axis accuracy is vital to precision mating of die components in mold-anddie machining applications, said Nedler. Maximum Flexibility for Varying Volumes/Mixes of Parts OEMs and job shops that are manufacturing precision components from difficult-to-machine materials need a highly accurate machining solution, one that will make their operations more productive and cost effective. Many precision manufacturers today are taking on a variety of jobs some high-volume, low-mix and others a lowvolume, high-mix of part with differing part geometries and materials, said Steve Previti, YASDA product manager, Methods Machine Tools Inc. (Sudbury, MA). Because part requirements are so broad, machine tool providers must answer with solutions that provide flexibility as well as the required accuracy. At IMTS 2014, Methods Machine Tools and YASDA unveiled a high-preci- 56 ManufacturingEngineeringMedia.com December 2014

7 sion, automated five-axis vertical machining center, the PX-30i engineered to meet challenging OEM and job-shop requirements. The Methods-YASDA PX-30i features extensive design and engineering by Methods in a five-axis machining center manufactured by YASDA, a Japanese builder of high-precision machining centers and jig borers. Previti said that combining five-axis machining with automation offers manufacturers many advantages for the efficient manufacture of high-precision, complex components. The PX-30i offers an automated turnkey machining center solution that features a full complement of 32 storage pallet positions plus one in the work zone providing the capability to do lights-out or untended manufacturing, The automatic tool changer (ATC) and automatic pallet changer (APC) feature a Methods-developed software program for efficient tool/pallet management and advanced scheduling functions. The ATC has a standard capacity of 300 tools and can be retrofitted for additional tool capacities of up to 500. Methods and YASDA engineers worked closely together during the design and manufacture of the five-axis PX-30i. We focused on precision, reliability and versatility, all at a cost-effective price, said Previti. The PX-30i features a newly designed direct-drive spindle with self-adjusting preload, which is designed to improve performance and increase spindle life. The YASDA in-house built spindle delivers the rigidity, torque, speed and horsepower to facilitate the efficient machining of a wide range of materials from aluminum to high-temperature alloys, including Inconel, titanium and steels with high-hardness ratings. A two-axis rotary table offers flexibility and speed with a wide range of movement. Protect High Value Parts Penetrating Customer Shops with Even More Machining Capability Our main strategy at MC Machinery is to offer our valuable customers a singlesource supply chain of quality manufacturing solutions. By adding more technology, we can build upon our core businesses where we have over 13,000 machines installed, across EDM, laser, press brake, Roku Roku and waterjet equipment in North America. This represents a total of more than 8000 customers, said Alan Hallmann, North American sales manager, MC Machinery Systems Inc. (Wood Dale, IL). Twelve years ago, MC Machinery introduced its Roku Roku line of high-speed graphite and hard milling machines to complement its EDM technology in moldand-die shops. Three years ago, we introduced five new lines of milling machines to complement not only our EDM customers, but also our fabrication customers. We have since expanded by adding five-axis milling and a line of small-to-medium-size CNC lathes in our product mix, said Hallmann. IMTS was an eye opener that brought on a whole resurgence of interest and orders for MC Machinery, according to Hallmann. Our focus now is on penetration into the mold industry, with production machines aimed at the aerospace, oil tool, and medical applications, and milling and turning for the Tier Two automotive suppliers. With current forecasts of a 17-million car market, we ll be setting up a supply chain and products to participate fully in that market by the end of 2015, said Hallmann. To achieve these goals, MC Machinery is upgrading existing products with more productive features while they also expand and develop new product lines. For TRU TEMP 30 minute process. Smart option for in-house black oxide on iron and steel components. Nothing like it. Safe, simple, 30 minute TRU TEMP process operates at 200 o F and contains no pollutants. Non-dimensional fi nish is RoHS and Mil spec compliant. Ideal choice for Job Shops or OEM manufacturers whose customers need quick delivery of high quality fi nished components at low cost. Comprehensive Factory training and on going tech support to keep you fi nishing in the black. Call us today: Buy online today. December 2014 ManufacturingEngineeringMedia.com 57

8 example, thermal compensation option for moldmakers in an affordable package DM (die mold) series of milling machines is on track for early 2015 release. This is expected to further penetrate the mold-and-die market where the company has PERFORMANCE PRODUCTS, INC. discover innovate solve Stop Toolholder Taper Deformation Optimize Milling Machine Performance Increase Toolholder Taper Contact Improve Spindle Life High Torque Retention Knobs - Drawbar Gages - Taper Shank Test Fixture Spindle Cleaners - Taper Restoration Kits - Retention Knob Sockets - Torque Wrenches a strong EDM presence. Linear technology for the high-end Roku Roku line is being introduced as well, said Hallmann. Our strong market areas continue to be in the oil tool and related energy industry, electronic goods, and mold and die. General-purpose machine platforms account for our greatest number of orders. Our MCV line is our number one platform for good reasons. It s a heavy-duty VMC with Mitsubishi CNC control, drive and motor package for faster processing, faster cycle time, and longer longevity than products that are typically more expensive, said Hallmann. Our goal is to place ourselves at the top of the quality platform with other leading high-precision, multiaxis machining center suppliers while maintaining great value in terms of pricing. Our advantage is in performance where the Mitsubishi control can mean a difference of up to 30% faster cycle times than many other value priced machines and with higher reliability, said Hallmann. ME Want More Information? Instant 5% spindle load reduction on titanium job Curtis Sampson, Shop Lead-Man, Hansen Engineering Co "High Torque retention knobs doubled our tool life.." James Lytle, Daystar Machine High Torque knobs lower runout Lee Knowlton, Northwest Machine Technologies Try A Free Sample Today! Proudly Manufactured In Ohio Since or DMG MORI Ph: Web site: Doosan Infracore Machine Tools Ph: Web site: Hwacheon Machinery America Inc. Ph: Web site: Mazak Corp. Ph: Web site: MC Machinery Systems Inc. Ph: Web site: Methods Machine Tools Inc. Ph: Web site: 58 ManufacturingEngineeringMedia.com December 2014