Technology in Motion - EASTEC

EDM, 5-Axis Milling, and Vertical Drilling Technologies on Display
The GF AgieCharmilles CUT 200 Wire EDM provides faster spark-to-spark wire threading, increases energy efficiency, and boosts productivity when cutting parts of variable heights. The machine also offers higher flexibility through its ability to reliably hold tolerances measured in microns over a wide range of part sizes. The CUT 200 integrates GF Agie­Charmilles’ Power Expert smart module, which continuously calculates part thickness, checking flushing pressure and adjusting machine power accordingly. This prevents wire breakage when changing the part thickness being machined.

The machine also offers an optional Renishaw touch probe that allows users to inspect finished parts while still on the worktable in the machine, eliminating the need for part inspection with a CMM. The CUT 200 accommodates wire diameters ranging from 0.07mm to 0.33mm and can handle part tapers of up to 45°, regardless of part thickness. The machine’s digital CC generator enables surface finishes as fine as Ra 0.1μm and an optional power module can boost cutting speed to 37.2 in2/hr.

Additionally, the Econowatt 2 smart module provides energy savings by allowing operators to define conditions in which the machine will automatically shut down or awaken to complete thermal stabilization prior to production.

Also on display will be the FORM 20, a cost-effective solution that combines ease of use with exception performance; the HSM 400U LP, a 5-axis, high-speed milling center, and the DRILL 20 high-speed vertical drill.

EASTEC BOOTH #1224

GF AgieCharmilles
Lincolnshire, IL
gfac.com/us

Direct-Drive Rotary Systems
The Hardinge direct-drive rotary systems provide flexible, high-speed, super-precision rotary parts positioning. These rotary tables have zero backlash, permitting rapid bi-directional movement without the loss of time used to compensate for position over-travel, which means more time in the cut. A frameless torque motor wraps around the spindle, eliminating the need for a separate motor extension, resulting in a smaller footprint. An encoder capable of ±0.077 arc second resolution is mounted directly to the spindle enabling ±3.000 arc second system accuracy for extremely accurate positioning with 4.000 arc second repeatability. A rugged cross-roller bearing provides super rigidity.

Three sizes of the rotary systems are available. The DD100 high-speed positioner has a 5C, A2-4 spindle nose and is ideal for drill and tap and laser processing with speeds of up to 4,200°/second or 700 rpm continuous rotation. The DD200 and DD300 rotary tables include a spindle clamp to handle aggressive off-center drilling and other high-force machining operations. All three models have a Hardinge collet-ready spindle for quick changeover from collets, step chucks, expanding collets, jaw chucks, and face and fixture plates. The DD200 (254mm) and DD300 (305mm) rotary tables have a 16C, A2-5 spindle nose and come with a precision-ground slotted faceplate in the aforementioned size.

Fourth-axis integration supported by Fanuc and Heidenhain allow operators to take advantage of maximum machine capability including look-ahead programming for high speed machining.

EASTEC BOOTH #5045

Hardinge Inc.
Elmira, NY
hardinge.com

Profiling Small Parts: BallNose Endmills
A range of small CoroMill Plura ballnose endmills are for profiling in medium hard to hard steels. The endmills come in diameters from 0.1mm to 12mm and are perfectly suited for all small die and mold, electronic, fiber optic connector, and medical tooth implant manufacturing, where high precision is important. Produced in a fine-grained solid carbide grade with multi-layered PVD coating, the tools have a geometry design, which prevents the radius from deteriorating from uneven wear. The long neck of the tool allows for good accessibility, especially in pocket milling.

EASTEC BOOTH #1440

Sandvik Coromant
Fair Lawn, NJ
sandvik.coromant.com/us

Integrated CAM for SolidWorks
Delcam will feature its newest software, Delcam for SolidWorks, alongside new versions of the range of their more established software systems, such as PowerMILL for high-speed and 5-axis machining, FeatureCAM for feature-based programming, and PartMaker for the programming of turn-mill machines and Swiss-type lathes.

The 2011 version of Power­MILL makes the programming of safe toolpaths easier than before because of the new stock-model-engagement options that protect both the cutting tool and the machine from excessive loading. Other enhancements include new editing capabilities to simplify the machining of duplicate items; more versatile control of feedrates for leads and links; and extra functionality for sketching.

FeatureCAM 2011 incorporates support for 64-bit computers, improved data exchange from a wider range of design software, the ability to use stock models, and new strategies across the complete program, from turning to five-axis machining.

EASTEC BOOTH #5326

Delcam plc
Salt Lake City, UT
delcam.com

CNC Machine Simulation, Optimization Software
VERICUT is CNC machine simulation, verification, and optimization software that enables users to eliminate the process of manually proving-out NC programs. It reduces scrap loss and rework. The program also optimizes NC programs in order to save time and produce higher quality surface finish. VERICUT simulates all types of CNC machine tools, including those from manufacturers such as Mori Seiki, Mazak, Makino, Matsuura, Hermle, DMG, DIXI, and Chiron. VERICUT runs standalone, but can also integrate with leading CAM systems such as Catia V5, NX, Creo (Pro/E), Mastercam, Edgecam, hyperMILL, and GibbsCAM.

VERICUT 7.1 features significant enhancements to reduce the time required for manufacturing engineers to easily develop, analyze, inspect, and document the CNC programming and machining process. Along with proactively adding new features, CGTech developers and engineers focused on addressing hundreds of customer-driven enhancements. Version 7.1 contains more than 400 customer requests and further improvements to VERICUT’s user interaction, simulation capabilities and analysis, cutting tool creation, and CAD/CAM integration.

One of the new features added, at the request of customers, is a 3D Reviewer. With the VERICUT Reviewer, 3D simulations can be shared with anyone in the company – without using a license. The Reviewer can play forward and backward while removing and replacing material. Error messages and NC program text is highlighted when a collision on the stock or fixture is selected. A toolpath line display is optional. The user can rotate, pan, and zoom just like normal VERICUT, and the cut stock can be measured using all the standard X-caliper tools. 
 
EASTEC BOOTH #5344

CGTech
Irvine, CA
cgtech.com

Waterjets cut 50% faster, reduce operating costs
On display during the event will be the 90,000psi (6,200 bar) X-Stream waterjet intensifier pump and the Mid Rail Gantry precision waterjet cutting machine.

Capable of producing complex parts out of virtually any material, the Jet Edge Mid Rail Gantry waterjet cutting machine features an exposed tank that easily accommodates overhead loading. It comes standard with one abrasive-jet cutting head; while the option to add a second cutting head can allows increase in productivity. Optional mirroring capabilities make it possible to cut part cycle time in half.

The Mid Rail Gantry is ballscrew-driven for higher accuracy. Its sturdy heavy-wall tubular steel construction eliminates vibration and increases longevity. The Mid Rail Gantry utilizes an industrial PC controller and with all three axes fully programmable (Z optional). It also features direct-couple AC brushless digital servomotors and single or double carriages. Protection of critical bearing components with heavy metal covers with brush seals and positive air pressure ensure accuracy.

Also shown will be both models of the X-Stream waterjet intensifier pumps, the 50hp xP90-50 and 100hp xP90-100. Jet Edge’s X-Stream intensifier pumps are capable of producing 90,000psi and support 75,000psi continuous operating pressure. The X-Stream achieves much faster cutting speeds and drastically lowers operating costs compared to traditional 60,000psi pumps, enabling users to increase productivity and reduce part costs.

The X-Stream produces 50% more pressure than a 60,000psi intensifier pump, resulting in a 40% to 50% increase in productivity for many materials. Compared to a 60,000psi pump, typical operating pressures of 75,000psi use 30% less water, 30% less power, and up to 50% less abrasive, resulting in a 40% reduction in operating costs. The xP90-50 is capable of producing flow rates of 0.7gpm and supports up to a 0.011" orifice. The xP90-100 is capable of producing flow rates of 1.45gpm and supports up to a 0.017" orifice.

EASTEC BOOTH #1128

Jet Edge
St. Michael, MN
jetedge.com

Multi-Feed Technology OffersChoice of Tool Feed Methods
The Sunnen multi-feed honing technology gives users a choice of tool-feed modes to achieve the shortest cycle times, lowest part cost, and longest abrasive life. Multi-feed combines Sunnen’s controlled-force tool-feed with its controlled-rate feed system. The two different tool-feed modes allow the user to select the better option to suit the workpiece geometry, material, and tool type/size. Multi-feed technology is available as an option on new machines in Sunnen’s SV-1000 and SV-500 Series, as well as a retrofit for existing machines in these series.

Controlled-force honing, a new feature in multi-feed, works like cruise control to ensure the optimum cutting load on the honing abrasive throughout a cycle, irrespective of the incoming part’s hardness, geometry, or size variation. Depending on the application, controlled-force honing cuts cycle times by as much as 50%, lengthens abrasive life for lower consumable cost, and allows finer control of surface finish parameters than before. Controlled-force technology eliminates glazing of the abrasive, due to too little force, and maintains a steady, free-cutting, self-dressing condition for maximum metal removal in the shortest possible cycle time.

EASTEC BOOTH #2111

Sunnen Products Co.
St. Louis, MO
sunnen.com

Variety of Toolholding Solutions
A range of toolholding solutions, including the REGO PLUS line of toolholders for BIG PLUS spindles, will be on display. Fully compatible with all BIG PLUS spindles, the REGO PLUS line of toolholders, licensed by BIG Daishowa, includes a full line of ER system toolholders as well as a full line of powRgrip system toolholders. REGO PLUS offers manufacturers the advantages of better TIR, improved tool stiffness, increased quality of surface finishes, and higher machine accuracies.

Also on display will be the powRgrip system approach to toolholding, which offers better TIR, improved tool dampening, easy presetting, longer tool life, and unparalleled clamping forces.

REGO-FIX’s XL holder system features new (patent pending) Micro-Friction-Dampening (MFD) technology to absorb and dampen unwanted vibrations faster than standard long length holders. The toolholders will be offered with CAT, BT, TC, and HSK tapers in 2" increments up to a maximum length of 15.7" (400mm). Versions of the products will be available in the ER 16, ER 32, PG10, PG15, and PG25 series of REGO-FIX toolholders.

EASTEC BOOTH #5459

REGO-FIX
Indianapolis, IN
rego-fix.com

Three-Dimensional Waterjet Cutting Technology
The Flow Mach 4 cutting system combines Flow’s HyperJet pump, rated at 94,000psi, with Dynamic Waterjet XD, a high-precision flat stock and 3D waterjet cutting technology. This combination improves part cycle time and accuracy two to four times over standard non-Dynamic systems.

Flow’s HyperJet pump rated at 94,000psi, delivers a stream of water at nearly four times the speed of sound. Pressure equals productivity: waterjets equipped with HyperPressure systems, running continuously at 87,000psi, cut up to 50% faster while using less abrasive than conventional waterjets. Cutting parts with a lower cost per part enables completion of more jobs in less time.

EASTEC Booth #1412

Flow Int'l Corp.
Kent, WA
flowwaterjet.com

Capabilities in Dynamic Milling, Multi-Axis Machining, and More
Mastercam machining software, Mastercam X5, offers significant enhancments.

Dynamic milling constantly adjusts the toolpath to ensure the most efficient cut possible and allows use of the entire tool flute length, often eliminating the need for multiple depth cuts. Dynamic milling techniques include Dynamic Rest Mill and Dynamic Contour. Dynamic Rest Mill helps ensure maximum tool efficiency during cleanup routines. Dynamic Contour uses an intelligent, efficient high speed contouring strategy to remove material along walls. It supports multi-passes and can optionally include finishing passes.

Mastercam’s multi-axis suite has machining techniques and a new, easy, workflow-oriented interface, allowing the user to choose the basic type of work they are doing using clear illustrations. It then gives the user a clear, systematic process for defining how to cut the part.

Also being demonstrated is Smart Hybrid Finishing and Mastercam’s 3D surface high speed OptiRough toolpath.

EASTEC BOOTH #5249

CNC Software Inc.
Tolland, CT
mastercam.com

CNC Tool Grinding System
The MX7 next-generation CNC tool grinding system is for high flexibility and quick changeover, accommodating smaller batch sizes and higher volume capability for production houses. The MX7 can manufacture unattended a variety of tools up to 16mm (5/8") diameter.

Designed for rapid processing of batches of precision tools, it offers 10-second automated wheel exchange and 10-second workpiece change with its integrated loader. Six standard HSK 50 wheel packs offer production flexibility and the potential for unattended productivity.

In addition, a newly developed permanent magnet 20kW/27hp (S1) 10,000rpm spindle, delivering high torque at lower rpm, makes the MX7 particularly well suited for carbide grinding applications. Due to the lower current draw, less heat is generated – so less expansion – resulting in energy efficient operation and even greater accuracy.

EASTEC BOOTH #1318

ANCA Inc.
Wixom, MI
anca.com

Endmills Designed for Dental Machining Applications
The line of endmills developed for the advancing field of dental prosthetics manufacturing feature carbide construction, cutting geometries, and coatings that have been engineered specifically for use with today’s dental materials.

The Emuge tool line consists of solid carbide ballnose and torus endmills designed for optimum machining of zirconium oxide, Polymethyl Methacrylate (PMMA), wax, cobalt chrome, and titanium. Both types of cutters have a radius tolerance of up to ±0.005mm and a diameter tolerance of 0.01mm. Ballnose cutters are available in cutting diameters ranging from 0.4mm to 6.0mm. Torus endmills are available in cutting diameters of 3mm and 4mm.

Solid carbide ballnose endmills are ideal for roughing and finishing, and their optimized geometry provides greater stability in long reach applications. The tapered neck ballnose endmills provide greater rigidity against deflection, and are optimal for finishing and rest material machining. Torus endmills are available with two or four flutes, offering exceptional performance for roughing in cobalt chrome.

Emuge dental endmills are available with a variety of coatings including TiAlN, which protects the tool from premature wear when machining non-precious metal alloys; CrN, which prevents the material from sticking to the cutting edge of the tool when milling PMMA and wax; and a diamond coating, which ensures extremely long tool life when machining zirconium oxide.

The dental line is suitable for a variety of machine tools used for dental prosthetics manufacturing, from bench top systems to 5-axis machining centers. The tools are compatible with all software systems used in the dental prosthetics

EASTEC BOOTH #5228

Emuge Corp.
W. Boylston, MA
emuge.com

Advanced Fixturing Components, Workholding Solutions
Fixtureworks’ display of products will demonstrate the ability for OEMs, machine, forming, and fabricating shop designers to build application-specific fixtures with the economics and quick availability of standard, off-the-shelf parts and hardware – all from a single-source. Highlights will be the Abrasive Diamond Surface Grippers from Fairlane Products, and manual clamps from Imao.

The Abrasive Diamond Surface Grippers, with surface comparable to 100-grit sandpaper bonded permanently to a stainless steel pad provides excellent non-slip gripping on smooth or slippery surfaces with minimal clamping force and surface marking. The individual diamond particles transfer holding pressure to a very small and well-distributed area, in addition to providing unparalleled wear resistance. These high-strength grippers are available in various sizes and configurations.

The range of manual clamps from Imao include miniature, heavy duty, swing, pull, push, rocker, and snap clamps with forces from 150 lb to 2,250 lb. These retractable clamps are durable alloy steel; heat-treated with a black oxide finish and are ideal for repetitive or quick clamping operations.

EASTEC BOOTH #5758

Fixtureworks
Fraser, MI
fixtureworks.net

High-Tech Cutting Tools
On display will be the line of high technology cutting tools, including the three-flute coolant-through Mega Muscle carbide drill, the HY-PRO CARB 3D and 5D drills, and the VGx and UVX endmill series. The HY-PRO CARB VGx variable geometry endmill is a milling tool with capabilities of chatter-free and stable consistent milling in mild to severe milling operations.

OSG’s three-flute coolant-through Mega Muscle drill is designed specifically for drilling at feedrates one-and-a-half to two times faster than a two-flute drill. It may also be used at lower rpms, which decreases the amount of wear while prolonging tool life, while also leading to higher hole accuracy with less work hardening, giving secondary operations such as tapping even more tool life.

EASTEC BOOTH #5463

OSG Tap & Die Inc.
Glendale Hts., IL
osgtool.com

Program Multiple Parts, Re-Program in Minutes
Equator is an alternative to traditional dedicated gaging, allowing high-speed scanning and rapid moves between features, while retaining stiffness that is critical for accurate gaging. Equator systems are available with two levels of software. One is a programmable version for production engineers to create DMIS programs. The other is a shopfloor system, which allows execution of those programs, but prevents operators from making modifications. Included in the system is the Equator-specific stylus changing rack, which allows automated in-cycle changing of SM25 stylus modules. The SM25 modules couple to the industry-standard SP25 CMM probe.

EASTEC BOOTH #3128

Renishaw Inc.
Hoffman Estates, IL
renishaw.com

Technologies Advancing Manufacturing
The the latest in wire EDM, sinker EDM, hole popper, and waterjet technologies, all complement manufacturers looking for productivity. The FA10S Advance wire EDM features the M700 Series Mitsubishi control. This Windows-based system with 15" LCD touch screen display provides a simple menu configuration for easy navigation.

The EA12V Sinker has a space-saving footprint and multi-position work tank that allows the operator to set up while circulating the dielectric fluid. The E.S.P.E.R. II software can easily create programs for measuring, power settings for burning, and orbital paths for finishing.

Mitsubishi’s ED2000M small hole EDM drill’s low energy consumption combines high-speed with low wear. The patented power supply generates no bullet nosing on the electrode, creating cleaner holes and quicker breakthroughs.

The DX44 Mitsubishi Waterjet with 100,000psi pump is designed to complement EDM technology with the precision of Mitsubishi controls and servo system. The ultra high pressure 100,000psi KMT pump technology allows for faster cutting, and higher productivity.

EASTEC BOOTH #1116

MC Machinery Systems
Wood Dale, IL
mitsubishi-world.com
 

Solid-Based CNC Programming Solution
CAMWorks 2011 is a more focused upgrade in the CAMWorks line, providing significant capabilities including enhanced automation, improved knowledge-based machining information, smarter toolpaths, and more. CAMWorks 2011 introduces VoluMill, the ultra high-performance toolpath plug-in engine for high-speed milling for 2.5-axis and 3-axis roughing operations. It is ideal for prismatic parts and complex 3D shapes as its algorithms result in more intelligent toolpaths to machine pockets, slots, and arbitrary shapes.

For the mold and die industry, Geometric has introduced an optional electrode design solution labeled ElectrodeWorks that automates all aspects of the calculation and design of EDM electrodes including design, management, documentation, and manufacturing. Its seamless integration with SolidWorks/CAMWorksSolids assures complete parametric association of data.

Feature Recognition, which is used to identify areas to be machined, has been upgraded to find more features, while decreasing computation times by more than 50% over previous CAMWorks versions.

Additional enhancement with CAMWorks 2011 includes improved performance and enhanced feature recognition of slot features with fillet and taper as well as slots with islands. Users can now define customized turn inserts when it is not possible to machine, completely, a turn part using a standard turn insert. Such custom turn inserts can be defined for inner as well as outer diameter.

EASTEC BOOTH #5458

Geometric Technologies
Scottsdale, AZ
geometricglobal.com/products

Deep hole drill delivers productivity increase
As requirements on productivity increase, there continues to be a demand to reduce costs. Answering this demand is the CrazyDrill product range, with cutting lengths of 15xd, 20xd, and 30xd, starting from 1mm diameter and 40xd starting from 2mm diameter. Developed is a new cutting geometry to perfectly meet the particularly challenging conditions of deep hole drilling. What results, with the CrazyDrill, is a drill that produces short chips in all steel alloys while delivering trouble-free evacuation of chips. The drill reaches the full depth, without pecking, in one single stroke – allowing the highest speeds and feeds.

EASTEC BOOTH #5677

Mikron Corp. Monroe
Monroe, CT
mikron.com

5-Axis Machining, Machine Support
Various highlights during EASTEC will be:
5-Axis Hole-Making – A new routine for 5-axis hole-making operations, aided by enhancements to GibbsCAM’s automatic feature recognition, hole manager and hole wizard, makes programming 5-axis drill cycles much easier and much more efficient. Programming drill cycles at off-axis orientations will be very easy and will take a fraction of the time taken by other methods.

5-Axis Toolpath Conversion – A new Operation Modifier allows converting 2.5- and 3-axis toolpaths for machining in 5-axis, which enables use of shorter tools to achieve smoother toolpaths at certain surface intersections and other geometric conditions.

5-Axis Machining Styles – Additional swarf cutting capabilities have been added, as well as a new 5-axis trimming (wireframe) strategy.

5-Axis Milling on Turning Machines – Support for B-axis (tilting live tooling) enables programming of 5-axis milling with Y-axis offsets on lathes and multi-task machines equipped with a live-tooling B-axis.

EASTEC BOOTH #5433

Gibbs and Associates
Moorpark, CA
gibbscam.com

Sinker, Wire EDMs
The AG40L sinker EDM features high speed and high acceleration linear motor drives, this enables even and natural flushing condition that leads to perfect part accuracy. The AG40L can reduce EDM­ing time by as much as 50%. The menu-driven control automatically writes the NC code for the operator while inserting optimum cutting conditions. It offers instantaneous responsive control and no flush technology. The AG600L wire EDM is a high precision, high-speed CNC machine. The AG Series wire EDMs include direct drive linear motors with Hei­denhain absolute glass scale feedback, an energy saving circuit to save on power consumption, motion controller to provide simultaneous axis movement, and on-board user-friendly Heart NC cam system.

EASTEC BOOTH #1205

Sodick Inc.
Schaumburg, IL
sodick.com

Portable or Bench, External and Internal Thread Inspection Systems
The Johnson Gage Co. will feature its full range of Portable or Bench External and Internal Thread Inspection Systems that incorporate functional and pitch diameter size measurements for UN, Metric, NPT, and all other thread forms subject to virtually all thread acceptance standards. Also featured is the Centrax Runout and Concentricity Inspection System for verification of cylindrical runout or concentricity in manufacturing or inspection applications. For medical users, the Thread Inspection System for the verification and in-process control of reverse-angle buttress threads commonly used in anti-splaying medical devices such as orthopedic implants.

EASTEC BOOTH #3061

The Johnson Gage Co.
Bloomfield, CT
johnsongage.com

Micro Line Spindles
The compact and powerful high-speed Micro Line spindles for Swiss turning feature 20mm and 22mm to the 25mm diameter models, and also include a 63.3mm length new Model HT 25S 60 for compact tool zones. Right angle spindles are also available providing greater flexibility. Micro Line spindles eliminate secondary operations, utilize synchronous, DC motor technology, and operate up to 120,000rpm with high torque applications involving micro-milling and drilling tools, as well as engraving and fine milling, featuring high rigidity and ultra precision (less than 2µ runout) to enhance surface quality and machining accuracy.

In addition, on display at EASTEC will be a  new rotary coupling system that allows the use of Micro Line high speed spindles in turret style machines. The rotary coupling provides support for all electrical and pneumatic requirements for the high speed spindles, with models available to support two or four spindles.

EASTEC BOOTH #5720

IBAG North America
North Haven, CT
ibagnorthamerica.com

Thin Grooving, Micro-Turning Work
The UTILIS Multidec 1600 series thin grooving and micro-turning tools are capable of work under 0.125" in diameter utilizing insert widths from thickness of human hair (0.0019") up to 0.108" with cutting edge repeatability within 0.0004". Ideal for high precision machining of 316 L stainless steel and 6AL4V titanium in orthopedic, medical tools, and dental implants. The 1600 series is ground from premium carbide grades for enhanced tool life and is available with a variety of coatings. The small holder shanks, down to 7mm, are designed to suit the smallest Swiss machines. Toolholders for larger machines are also available. Additionally, these Swiss-type turning tools offer geometries that can be used for front turn, back turn, micro-threading, and cut-off work. Full radius grooving and turning tools are offered in standard increments as well.

EASTEC BOOTH #5341

Genevieve Swiss Industries Inc.
Westfield, MA
genswiss.com/multidec1600.htm