HOUSTEX 2015

ALL-ELECTRIC JOB SHOP TUBE HONE
In Booth 509, the new all-electric HTR job shop tube hone from Sunnen Products Company (St. Louis, MO) will be one of seven honing machines demonstrated by the company at the show. The new HTR combines servo precision and cycle-automation features with constant spindle power and 0.1 mm (0.004 in) stroke repeatability to efficiently hone blind bores or correct tight spots in a bore without operator intervention. Designed and equipped to hone the wide variety of parts encountered in a job shop, the machine handles bore IDs up to 900 mm (35.41 in). Its modular design can be configured for stroke lengths from 2.5 m to 14 m (8 ft to 46 ft).

Critical for job shop versatility and productivity, the 12 kW (16 hp) spindle motor, combined with a four-step gearbox, produces a constant power band through the entire speed range of 10 rpm to 470 rpm for fast metal removal. The standard servo rotary tool feed can also function as a push-feed system with an optional drive shaft that converts rotary to linear motion, allowing the machine to handle the full range of heavy-duty and two-stage tools. Tool overload monitoring ensures optimal stock removal rates, while protecting the tool and workpiece.

Precision stroke position and repeatability are ensured with a servo rack-and-pinion stroking system. It drives the spindle carriage at speeds of 0.1 m/min to 48 m/min (4 ipm to 157 fpm) on hardened and ground ways with a 10.2 kW (13.6 hp) servomotor, giving the machine plenty of power to handle superabrasives for fast material removal. This design eliminates all hydraulics to vastly reduce maintenance, noise, leakage and heat, as well as system hysteresis due to hydraulic oil heating up.

The machine’s 305 mm (12 in) Windows^® touchscreen PC control manages all machine functions, including stroke speed/position, tool feed, spindle speed, stone wear compensation and cutting pressure. Standard control features include size lock, automatic bore geometry correction, recommended setups, tool overload protection, spark out, spindle jog and short stroke. The control can store up to 900 different part programs and be configured for 13 languages.

The optional easy-to-setup fixturing is available in two ranges, for parts 40 mm to 600 mm (1.6 in to 23.6 in), and parts 50 mm to 800 mm (2 in to 31.5 in). Part weight capacity is 6,000 kg (13,230 lb) and 8,000 kg (17,640 lb) respectively. The fixtures ride on a linear bearing system to allow easy positioning. Multiple coolant system configurations are available to tailor for process requirements. Other options include in-process gaging, tapered-bore capability, various coolant systems, part rotation device, moving steady rests for 2 m and 4 m models, two-stage honing, air conditioned electrical cabinet and CE compliant safety system. The HTR is the latest addition to the HT tube hone series, which includes nine models suited for every job.

Other tube hones demonstrated at the show include the HTA model for light stock removal and repair work, the HTE for long small bores, and the HTG model for heavy stock removal in large parts. The company will also demonstrate the SV-20 vertical job-shop hone for bore diameters from 19 mm to 200 mm (0.75 in to 8.00 in), the SV-2560 vertical hone with 1520 mm (5 ft) stroke length, and the SH-4000 horizontal hone for bore diameters from 1.5 mm to 165.1 mm (0.060 in to 6.50 in).

Sunnen Products Company, 7910 Manchester Road, St. Louis, MO 63143, 314-781-2110 ext 2341, Fax: 314-951-2718, www.sunnen.com.

LOWER PRODUCTION COSTS ON PARTS FOR OIL AND GAS
In Booth 709 of Hartwig, Inc. (St. Louis, MO), GF Machining Solutions (Lincolnshire, IL) will spotlight its high-efficiency Mikron HEM 500U 5-axis machining center and high-speed AgieCharmilles CUT 200 Sp wire EDM machine. Through demonstrations of these machines, attendees will learn how today’s advanced Swiss manufacturing technology significantly lowers production costs when processing parts for the oil and gas industry.

Thanks to a newly developed rotary tilting table design, the HEM 500U provides high-performance, high-value 5-side machining of components in a single setup. A 20,000 rpm spindle and 60 tool changer are available. The trunnion table measures 19.7 in diameter and accommodates workpiece weights up to 440 lb, tilts +65 deg /-110 deg in the B-axis and rotates 360 deg in C for 3 + 2 machining as well as 5-side positioning. Axis travels in X, Y and Z measure 19.7 in, 17.7 in and 15.7 in, respectively, while a distance of 5.9 in between the machine spindle nose and rotary table surface allows for ample maneuverability around workpieces.

The highly robust HEM 500U works well under a variety of working conditions. Its C-frame structure supports a cross-sledge for the transversal X- and Y- movements. All three linear axes are located on a sturdy block that houses the B-axis. The vertical Z-movement, which contains the inline spindle, mounts to the rigid Y-axis column. Featuring a small footprint, this machine is ideal for tight setup areas. The attention to the ergonomics of the machine design allows for easy access to workpieces. Its highly accessible structure makes it possible to load and unload workpieces using a forklift as opposed to a crane.

The HEM 500U relies on a Heidenhain iTNC 530 control for quick and reliable machining. This versatile, workshop-oriented control for 5 (3+2)-axis machining features an integrated digital drive control with integrated inverter, enabling it to produce a highly accurate workpiece contour while machining at high velocity. The HEM 500U also comes equipped with smart machine modules that provide advanced levels of monitoring critical to oil and gas-related parts.

The AgieCharmilles CUT 200 Sp speed edition wire EDM provides fast spark-to-spark wire threading, energy efficiency and high productivity when cutting parts of variable heights. It also offers versatility through its ability to reliably hold tolerances measured in microns in both light and heavy parts. For ensuring high accuracy and speed as well as preventing wire breakage when machining parts with varying heights, the Power Expert smart module on the CUT 200 Sp continuously calculates part thickness, checking injection pressure and adjusting machine power accordingly.

The CUT 200 Sp accommodates wire diameters ranging from 0.013 in to 0.003 in and can handle part tapers of up to 45 deg, regardless of part thickness. The machine’s digital CC generator enables surface finishes as fine as Ra 0.1 µm and an optional power module can boost cutting speed to 37.2 sq in/hr with an adapted wire. For easy loading of workpieces, the CUT 200 Sp implements a drop door to provide access to the work area. Moreover, the machine’s small footprint measures just 79.53 in W x 86.65 in D x 79.33 in H, yet has room for ample X-, Y-, Z-, U- and V-axis travels of 13.77 in, 8.66 in, 8.66 in, 13.77 in and 8.66 in, respectively.

To obtain high-positioning precision, the axes are fitted with a linear glass scale with absolute coding at a resolution of 50 nanometers. Also, an optional touch probe allows the user to inspect a finished part inside the machine before its removal from the worktable, eliminating the need for part inspection with a CMM. Furthermore, the Integrated Collision Protection (ICP) makes the X- and Y-axis high-speed rapid traverse of the CUT 200 Sp possible by effectively absorbing the energy of a collision. Operators can safely move the machine’s axes at high speeds without threat of severe machine damage in the event of an error.

The CUT 200 SP achieves high energy savings via its Econowatt 2 smart module. This standard feature allows users to program the machine to automatically switch off at the end of unattended operation or awaken and complete thermostabilization prior to production. Econowatt 2 also automatically turns off the machine when a job is completed or the machining process is interrupted.

GF Machining Solutions, 560 Bond Street, Lincolnshire, IL 60069-4224, 800-282-1336, Fax: 847-913-5340, www.gfms.com/us.

SINKER EDM INCREASES MACHINING SPEED
In Booth 539, Sodick, Inc. (Schaumburg, IL) will be showing the all new AD55L Rigid Linear Motor Driven Sinker EDM machine, a high-performance machine that features no-flush technology, a user-friendly control and zero-electrode wear technology combined with increased machining speed. This latest EDM technology advancement will ensure higher manufacturing efficiency, drastic cost reduction and shortened delivery time. The machine uses a full-frame, floor-standing bed design. Heavily ribbed, high-strength Meehanite castings are used for the bed, table and column construction. The rigid construction ensures long-lasting accuracy.

Unique zero electrode wear technology is standard on all Sodick Sinker EDM machines and allows for the EDM machining of steel materials with virtually zero electrode wear when using graphite or copper electrodes.  Less electrode wear results in fewer electrodes, saving on production costs. In some cases, only one electrode is necessary. The ability to minimize wear is made possible by advanced control technology that stabilizes the use of extremely high discharge ON times. This reduces the amount of times the discharge is started and extinguished.

In the past, control technology was not as advanced, and the use of high discharge ON time resulted in an unstable EDM machining environment, which caused poor productivity. Today, however, thanks to SGF technology, the application of high discharge ON time can be stabilized, producing virtually zero electrode wear. The AD55L has an X, Y, Z travel of 23.62 in x 15.75 in x 15.75 in (600 mm x 400 mm x 400 mm) and can accommodate a workpiece weight of up to 2,204 lb (1,000 kg). The machine comes with a 10-Year Positioning Accuracy Guarantee on its Rigid Linear Motor Drives.

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