Multitasking Machines and Software Provide Versatility and Boost Capabilities
It’s all about speed and accuracy in machine shops. The less time spent on fixturing and part handling, along with customizable features and the latest in automation, take metal cutting to elevated levels.
Posted: March 15, 2023
New High-speed Horizontal Machining Centers
JTEKT Toyoda Americas Corp. (Arlington Heights, IL) has introduced its FH5000 series of three high-speed horizontal machining centers (HMC), including the FH5000S HMC with 800-x-800-x-880 mm (X, Y, Z) strokes, 900 mm workpiece diameter, and 1100 mm workpiece height capacity. The FH5000 series machines include a 500 mm table capable of handling 1,000 kg loads.
“With this series, Toyoda meets the growing demand for producing components with high metal removal rates, short cycle times and superior surface finishes,” said a company spokesperson.
Toyoda’s FH5000S HMCs with 60-tool ATC capacity are designed for speed and production reliability, featuring a 15,000 rpm, 50 hp (37 kW), 303 Nm (223 ft-lbs.) high acceleration spindle. The 40-taper spindle is designed with four ceramic bearings at the front of the spindle for increased rigidity and reduced vibration. Its patented hydraulic preload system brings the spindle up to 15,000 rpm less than one second without spindle warm-up, ideal for aluminum processing. The larger machines in the FH5000 series are equipped with a 50-taper spindle, 45 tools, and a longer X axis travel.
This machine is equipped with a direct drive B-axis table featuring an index time (90°) of 0.7 seconds. The FH5000 machining centers with the spindle design, preload system and high torque features, allows machine shops to take advantage of more aggressive, high-volume machining in a compact footprint.
Easily programmed, the H5000 series features the TOYOPUC-Touch panel through which the operator can monitor the machine, see operating data including energy consumption, and edit as required.
New Digital Software-as-a-Service
myFastems is a complementary service for all Fastems (Township, OH) customers, providing more advanced digital services for customers using Fastems’ Manufacturing Management Software (MMS) version 6 and above. Considered a software-as-a-service, myFastems supplies all the digital tools needed to support customers in making sure their systems are up and running 24/7 for continuous availability and productivity.
The digital service is built as a progressive web application for easy access via web browser on a PC, tablet or smartphone. It can also be combined with other services such as 8760 support, preventive maintenance, and software maintenance agreements for optimized solutions throughout the entire life cycle.
myFastems brings transparency to any Fastems systems service history and spare parts usage and includes a comprehensive system overview for connected systems, as well as alarm-based recovery instructions and support request tickets. The system overview provides an updated status of all connected Fastems systems, making it easy for users to stay on top of production activities and solve any issues in a timely manner. Support is only one click away. With all necessary system information readily available, Fastems’ technical support can understand the situation on site better and faster, reducing critical downtime.
For connected systems, myFastems provides more advanced digital services. These include access to alarm history, key performance indicators such as utilization rate, tools for advanced trouble shooting, and analyses via Incidents view. The Incidents groups system-wide alarms are based on the actual root cause and provide specific recovery instructions. Therefore, users can attempt to solve problems before contacting Fastems support for more flexibility.
GibbsCAM and Sandvik Collaboration Delivers Productivity Boost
CAMBRIO (Cincinnati), a leading CAD/CAM innovator in the production machining industry, offers several new software developments focusing on core capability, and new technology in collaboration with Sandvik Coromant in the GibbsCAM 2023 release. GibbsCAM, located in Thousand Oaks, Calif., continues to lead the industry in the programming of advanced machining centers for end-user productivity.
Turning enhancements include the highly effective implementation of Sandvik Coromant’s PrimeTurningTM strategies. These new cutting methodologies permit turning and facing in all directions, delivering dramatic increases in high volume production. PrimeTurning has proven to deliver cycle time reductions of up to 50%, and more than 500% increase for insert tool life. PrimeTurning uses the slope of the insert for chip thinning to allow you to make heavy cuts and spread cutting forces and heat over a larger portion of the cutting edge, which in turn contributes to longer tool life. In addition, PrimeTurning adapts the feed rate (excellent for cutting on a taper) to constantly manage chip thickness which is ideal for high-volume and unattended environments.
PrimeTurning supports two new tool types (CoroTurn® Prime Type-A with three 35° corners for finishing and fine roughing/getting into grooves etc., and CoroTurn Prime Type-B with two strong corners for bulk roughing/heavy cutting), which both utilize a low lead angle to improve surface finish.
Other enhancements include a new option in most Turning processes to control Cutting Load Variation to suppress resonance-induced chatter and improve chip breaking for CNC machines. VoluTurn functionality has also been extended to manage the active control of chip thickness during the cut by varying the feed rate instantaneously with any changes in cut depth.
Thread Turning operations have been expanded with Face Threading, Variable Pitch Threading, Multi-pitch, and Position Tool Front options. Users can produce a spiral thread on the face of a part, vary pitch threads incrementally per revolution, or generate different pitches on a continuous thread, with easy control of exact start/end specs in the tool dialog.
New 5-axis Machines Combine Milling with Jig Grinding Capabilities
GF Machining Solutions (Lincolnshire, IL) now offers Micron MILL S/X Series 5-axis machines that combine milling with jig grinding capabilities. This two-in-one combination along with extremely high machine dynamics and consistent thermal stability and accuracy ensure significantly reduced part and mold processing times and improves quality while providing the shortest machine ROI possible.
The MILL S/X Series includes the 400/400 U, 500, 600/600 U and 800 models, all featuring linear, rotating and swiveling axes. The machines allow users to clamp parts once and perform both milling and grinding operations to not only shorten cycle times but to also eliminate the risk of stacked tolerances from having to transfer parts from one machining process to the next. Linear axis motors and rotary swiveling torque tables provide either a smooth or dynamic milling process for machining accurate parts during short, medium and long milling operations.
For further machining optimization, MILL S/X machines are equipped with the Operator Support System extreme (OSS extreme) smart machine software module developed and patented by GF Machining Solutions. The module lets users select various settings that take into consideration the machining priorities and the machine parameters.
As standard, GF Machining Solutions outfits MILL S/X machines with its Automated Machine Calibration software that allows users to calibrate their machine in minutes as opposed to hours. This reduces downtime between cycles while with the push of a button ensures stable, long-term precision needed for high-quality parts.
Available advanced spindles for the MILL S/X machine Step-Tec spindle speeds include 30,000 rpm, 36,000 rpm and 42,000 rpm. On the grinding side, a grinding tool dressing spindle speed adjusts from 3,000 rpm to 20,000 rpm for added dressing flexibility, efficiency and reliability.
Customizable, Flexible Tower Pallet Storage System Well-suited for Small Shops
GROB Systems, Inc. (Bluffton, OH), a global leader in the development of manufacturing systems and machine tools, offers a new versatile and customizable automation solution which further improves machining productivity on a range of GROB machining centers. The PSS-T300 Tower Pallet Storage System, which enables automation and increases part production throughput, is the latest entry to the wide range of GROB automation solutions for creating flexible manufacturing cells.
Especially well-suited for smaller shops where one operator is responsible for running multiple machines, the PSS-T300 Tower Pallet Storage System automatically removes and loads pallets, offering unmanned 24/7 operations or lightly attended shifts when paired with GROB G150, G350 and G350a 5-Axis Universal Machining Centers.
Easily retrofitted, the PSS-T300 provides excellent access to the work area while offering space-savings via its tower design. The new pallet storage system offers flexible setup options and can be paired with one or two machines, and configured with one or two setup stations. The PSS-T300 can handle a variety of pallet sizes including Erowa ITS148/ PC210 and GROB standard 320-x-320 mm/400-x-400 mm, and has storage capacity of up to 81 round pallets and up to 38 square pallets. For ease of operation, integrated software enables intuitive cell control.
Accessory Center Aligns Drills on CNC Multi-spindles
As part of INDEX Corp.’s (Noblesville, IN) sustained investment in R&D focused on streamlining the setup and changeover process for CNC multi-spindle lathes, the CenterMaster accessory reduces the time needed to align a drill by up to 90%.
Previously, center alignment of a drill required specialized knowledge by the operator and a challenging, manual process that could take up to 30 minutes per holder. With CenterMaster, the user simply clamps a radio dial gauge into the workspace and sets it to the quill. The gauge and machine wirelessly communicate, automatically adjusting the holder along the X axis. The system then guides the operator through adjusting the Y axis via the machine’s touchscreen display.
The CenterMaster system allows operators with no specialized knowledge or experience to set up a drill in two-to-three minutes. Additionally, it provides a repeatable accuracy of <5μm.
“Over the past several years, we have introduced multiple innovations to make CNC multi-spindles more flexible,” said Cris Taylor, president and CEO of INDEX. “We had already taken a lot of the time out of setups and changeovers via presetting and our quick clamping system with W-serration locating. CenterMaster eliminates another time-consuming aspect of setups so that customers can truly optimize their machine utilization.”
Mastercam Mill Solutions Target a Streamlined Manufacturing Process
CNC Software, LLC (Tolland, CT), developers of Mastercam, the world’s leading CAD/CAM software, has expanded Mastercam Mill, which offers increased machining flexibility and an increased emphasis on speed and automation. Multiaxis features, 3D enhancements, and 2D high-speed toolpaths combine with dozens of additional new enhancements in a software package intended to improve shop floor productivity.
Highlights include:
Multiaxis Improvements: Morph, Parallel, Along Curve, and Project Curve are no longer individual toolpaths. Instead, users can now find the same functionality inside the Multiaxis Unified toolpath, which allows for more flexibility in cut pattern when programming multiaxis, all within a new advanced feature set and consolidated, easy-to-use interface. A new Feed Rate Control page consolidates the feed rate control options, making the options easier to find and simplifying your workflow.
3D Enhancements: The Dynamic OptiRough and Area Roughing toolpaths can now be aware of undercut stock conditions, resulting in improvements to the toolpath motion, including less air cutting. Equal Scallop is now a fully stock-aware, semi-finishing toolpath that now identifies material left in corners and will machine with a single pass or with multiple passes to ease into the material. With the new linking parameters in OptiRough toolpaths, you can control and optimize your air cuts, which allows for greater efficiency in roughing toolpaths when transitioning between passes or when in air.
2D Enhancements: The Slot Mill toolpath no longer requires two parallel walls when selecting the machining geometry. You are now able to select any closed chain. 2D Contour Profile Ramp now supports the Override feed rate option, which allows you to specify a feed rate for the entry or exit move, allowing you to slow down feed rates as you are engaging material. When you drag and drop items in the Toolpath Hole Definition panel, Mastercam now provides visual cues for the drop location. Also, the drag-and-drop icon now indicates whether you are dragging a single item or multiple items.
There are also additional improvements to the Mastercam Mill.
www.mastercam.com/solutions/mill
Multi-tasking Center Emphasizes Part-processing Versatility
Mazak Corp.’s (Florence, KY) INTEGREX i-450H ST Multi-Tasking Center features the power of a full CNC turning center and the versatility of a full-function machining center. It features a second turning spindle (S) for DONE IN ONE® machining, along with a milling spindle and lower turret (T) with optional rotary tool capabilities. The configuration minimizes fixturing, part handling and non-cut time to boost productivity.
The main spindle incorporates a 12″ chuck and produces a maximum speed of 3,300 rpm from a 50 hp, 37 kW 40% ED spindle motor. Maximum machining diameter is 26.380″ (670 mm), and the main spindle’s 4.4″ (112 mm) diameter bore accommodates bar stock up to 4″ (101 mm) in diameter. The second turning spindle further expands processing flexibility with a 10″ chuck, 35 hp (26 kW) and 4,000 rpm cutting, and the milling spindle provides B-axis travel of 240° with cutting speeds up to 12,000 rpm. An automatic tool changer supplies the milling spindle from a 38, 74 or 112-tool magazine. For fast part changeovers, the INTEGREX i-450H ST features an optional auto chuck changer with 10-jaw stockers located on each spindle and operated via program commands.
The machine’s parallel-type 12-tool lower turret offers a rotary tool option with 10,000 rpm and 10 hp (7.5 kW). This enables manufacturers to employ balance cutting with the milling spindle and lower turret or carry out simultaneous machining with two tools. The turret accommodates 1″ (25 mm) turning tools or 1.5″ (40 mm)-diameter boring bars.
The machine enclosure, tool magazine and optional auto jaw changer are designed to accommodate a comprehensive range of automation technologies, including gantry loaders, bar feeders and articulating robots. The machine’s MAZATROL SmoothAi CNC enables the INTEGREX i-450H ST to carry out standard specialized operations such as crankshaft inclined drilling and gear skiving.
VMC Offers Jig Milling/Boring Accuracy with Machining Center Productivity
Mitsui Seiki USA, Inc.’s (Franklin Lakes, NJ) popular PJ812 VMC travels X-1200 mm, Y-800 mm, Z-500 mm. Max work size is 1200 mm-x-800 mm-x-450 mm. Table load accommodates 1,500 kg. The VMC provides positioning accuracy and repeatability of +/- 1µm. A thermal compensation system employs sensors on the machine faceplate and inside the spindle to minimize the effects of temperature changes on part accuracy and cut temperature-generated displacement by 60%. This system also reduces Z-axis thermal growth and deflection by 30%. Cooling systems for slide way lubrication and ball screw cores stabilize axis feed precision.
Mechanical design features that maximize machine rigidity and accuracy include hardened and ground tool steel box slideways as well as contact elements that enhance acceleration, reduce stick-slip, and allow for feed accuracy of 0.1 µm. Another proprietary engineering detail drastically improves the static rigidity of the Z-axis to more than six times that of conventional Z-axis arrangements.
This ultra-precision machine allows for more complete machining of precision components including precision boring, milling, drilling and tapping. Machining center technology and jig borer precision in one machine.
CAD/CAM Software Suite Features New Capabilities, Optimizations for Higher Productivity
OPEN MIND Technologies USA, Inc. (Needham, MA) a leading developer of CAD/CAM software solutions worldwide, has introduced its latest hyperMILL® 2023 CAD/CAM software suite which offers users new and enhanced features for even more powerful and simplified NC programming in applications ranging from 2.5D machining to 5-axis milling. “We are pleased to introduce hyperMILL 2023 to provide our customers with new, powerful CAD/CAM programming strategies, in addition to a wide range of enhancements — all designed to simplify and accelerate programming, improving the user experience,” said Alan Levine, managing director of OPEN MIND Technologies USA.
For easy programming of recurring shapes with a single click, hyperMILL 2023 has a new General Transformation Pattern feature. The feature uses a selected reference geometry and searches for the same reference in all other models regardless of its spatial orientation, creating a general transformation pattern including associated frames. This is useful when there are multiple components.
To ensure the highest level of safety while providing reliable programming when back boring, a new 2.5D Back Boring machining strategy enables back boring tasks to be programmed on machines with different kinematics conveniently and easily. Toolholders and inserts, as well as monobloc tools, are displayed one-to-one in the virtual machine and checked for collisions. Now programming the controller for countersinking, deburring and milling tools on the once inaccessible back side of a hole can be done with ease.
There is also a new Smooth Overlap feature for hyperMILL MILL-TURN for optimizing finishing paths in turning. This function enables flawless transitions when multiple tools or orientations are required for machining, and approach/retract macros can be used normally.
Virtual Product Expert for CNC Enables Direct Interaction with SINUMERIK CNC Product Expert
Siemens (Chicago, IL) offers the Virtual Product Expert (VPE), a support program for its CNC machine tool users, machine builders, dealers and importers. Through the VPE program, customers can now interact directly with a SINUMERIK CNC product expert and have their specific operation and programming questions answered — from the basic functions of the control to the most advanced machining technology aspects of the hardware and software suites. Best of all, this service is offered to all Siemens CNC community members at no cost.
Machine tool customers can contact Siemens to arrange an online session, tailored to their specific needs, regardless of where the programmer, operator or the machine are located. Sessions are typically one-hour in length and are being scheduled on a first-come, first-served basis.
John Meyer, the marketing communications manager for the Siemens Machine Tool Business, noted, “With the rapid advancement in our SINUMERIK CNC technology on both the automation hardware and software sides, we see our Virtual Product Expert program as a vital part of our support offering. We know it will benefit our machine tool users, who are looking for immediate answers to their operation and programming challenges in order to keep their production running. It’s like having a Siemens CNC expert in your back pocket.”
Universal Spindle Milling and Gundrilling Machines for Mold Manufacturers
To help mold makers achieve the highest levels of milling and deep hole drilling productivity, UNISIG (Menomonee Falls, WI) offers the USC-M series of machines that handle the rigors of both milling and gundrilling metals of all types, but do so with a single, powerful universal spindle. Both models feature rigid, robust frames along with their universal spindles for the toughest applications, all of which helps mold makers minimize machining time and maximize throughput.
With CAT 50 spindles up to 40 hp, these machines deliver high-torque milling capabilities for aggressive metal removal and shorter cycle times. Thanks to the single, universal spindle designs, mold makers will significantly reduce changeover times when switching between gundrilling and milling operations. Additionally, a 60-position automatic tool changer helps further minimize nonproductive time. USC-M machines have the capability to run oil and water-soluble coolant as well, and for further time and cost savings, they feature fully enclosed machining envelopes that are installed above the shop floor, allowing customers to avoid time-consuming, costly below-ground installations.
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