April 2010 eNews

Water Jet Cutting Machine Cuts Virtually Any Material

A 5’X5’ Mid Rail Gantry Waterjet System is ideal for shops that cut smaller material or have limited floor space available for machine tools.

Powered by a 60,000 psi or 90,000 psi water jet intensifier pump (available in 30-200hp models), the system features an exposed 72”X72” tank that easily accommodates overhead loading. It is designed to cut virtually any material up to 60”X60”. If equipped with an optional second cutting head, it can cut two parts up to 30”X60”.

The water jet system utilizes an industrial PC controller and can be configured so that all three axes are fully programmable (Z optional). It also features direct-couple AC brushless digital servomotors and single or double carriages. Critical bearing components are protected with heavy metal covers with brush seals. The system also is available in 8’x5’, and 21’x5’, 8’X13’ and 21’X13’ and 5’x13’ work envelopes.

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Jet Edge

Heavy Duty Dry Vac™ Handles Abrasive Materials Quickly

A rugged, industrial duty vacuum cleaner is engineered to vacuum high volumes of dry materials in less time than ordinary vacs. The wear resistant design is suitable for the clean-up of abrasive materials like steel shot, garnet, metal chips, and sand, yet can be used for general purpose applications.

The Dry Vac is air powered and attaches to the user supplied 55 gallon open-top drum. It is quiet at 77 dBA (half the noise of electric vacs), making it suitable for a wide variety of applications. Surrounding air is kept clean by the 0.1 micron filter bag that traps particles when vacuuming dusty materials. There are no motors and impellers to clog or wear out.

The system comes complete with a lever lock drum lid, shutoff valve, reusable filter bag, 10' (3m) polyethylene static resistant hose (1-1/2"/38mm I.D.), hose hanger, 20' (6m) compressed air hose with swivel fittings, pressure gauge, and heavy duty aluminum chip wand.

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EXAIR Corporation

Work Cell Robotic Blaster Handles 100 Different Parts

The new Model RB-RSSA-6 incorporates a Fanuc LR Mate 200iC robot and is designed for work cell blasting operations, such as blast cleaning, cosmetic finishing and technical surface preparation.

The 42-inch wide blast chamber of the RB-RSSA-6 houses a single rotary spindle on which an interchangeable component-holding fixture is mounted. Parts are loaded in the blasting machine through an automatic vertical sliding door that is 18 inches in width. A full-depth hinged door on the side of the cabinet provides access for inspection and maintenance. Including the safety-interlocked perimeter enclosure surrounding the robot, the robotic blast machine is 74 inches tall and 72 inches deep.

When the blast cycle is initiated, the load door closes and the component is rotated at controlled and adjustable speed as a single suction-blast gun is directed at target surfaces by the 6-axis robot. Programmed robotic motion of the blasting nozzle ensures that a specific stand-off distance and angle of blast media impingement is constantly maintained, even as the blast gun manipulator follows the contours of complex-shaped components. The robot also directs a blow-off nozzle during the timed air wash cycle that follows media blasting. The rear of the RB-RSSA-6 robotic blast system is sealed by a custom-tailored skirt made of multi-layered laminated fabric. The protective suit fits tightly around the end of the robot arm, yet allows the full range of motion in all axes, as it isolates the precision manipulator from the potentially harsh abrasive environment of the blasting chamber.

The system's programmable logic controller (PLC) is capable of storing and recalling the automated blasting process routines for up to one hundred different components. A custom designed touch-screen interface allows the human operator to select the program for a particular component and also displays process data monitored by electronic sensors, such as spindle RPM, the duration and elapsed time of the blasting cycle and the levels of blast media and contents of the dust collector drum.

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Guyson Corporation

New Tooling Solutions Up Performance, Production & Quality

BIG Kaiser Precision Tooling Inc. will showcase a number of new products at Eastec 2010.

The CKN modular connection for large boring tools features a three-screw interface, providing high clamping forces for maximum torque transmission. The system utilizes both steel and aluminum components to offer weight reductions up to 50%. This allows for better machine performance, easier handling and eliminates manual tool changes in many instances.

Balancing accessories achieve a fine quality on the 112 Series EWN precision boring heads. Balance Rings and Radial Adjustable Insert Holders allow compensation for imbalance in tool assemblies for the entire range of Ø.078-2.125”. The Balance Rings work with standard boring bar components for diameters up to Ø.394”, and are attached at the front end of the boring head. For diameters up to Ø2.125”, the Radial Adjustable Insert Holders are designed to keep the boring head cartridge and boring bar close to the center position.

The Mega Synchro tapping holder compensates for synchronization error during rigid tapping by reducing the thrust load to both the tap and work piece by up to 90 percent. While improving thread quality and tap life, the error compensation is facilitated through a unique mechanism that absorbs the pitch difference between the tap and synchronous spindle.

The expanded C-Cutter Mini chamfer mill line with its compact design reduces the cutting diameter to the lowest limit, helping achieve ultra high spindle speeds and feeds. The C-Cutter Mini is now available with an offset body extension to achieve bolt hole and tap chamfers. The new design utilizes a single insert to achieve 45 degree top and bottom chamfers while the offset design avoids interference with the inside of the hole. Chamfer diameters range from .217” - .827” with tap sizes ranging from M8-M20 and bolt sizes ranging from M6 to M16. Multiple extension lengths are available to reach through holes as deep as 3.031”.

The Unilock workholding solution starter kit allows users to plug the components immediately into their production cell when it supports a Stevens Engineering mounting grid pattern to instantly eliminate setup time while increasing productivity. Its captured screw and captured dowel assemblies allow the kits to be installed in seconds. The kit also contains universal pallets that allow the user to quickly attach and detach their positioning and clamping components or workpieces.

The MAGIS is an ergonomically designed benchtop tool presetter system that has the following standard features included: Integrated Calibration Master, Pneumatic Axis Locks, X and Z Axis Fine Adjust, CCD Camera, and Integral ISO 50 Taper Spindle with Pneumatic spindle brake. It optimizes tool resources by reducing tool set-up time and improving machining production time, while also enhancing the production of quality components. The single-screen control (available with optional touch screen) is user-friendly allowing accurate tool measuring in minutes.

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BIG Kaiser Precision Tooling

Titanium Machine-Ready Blanks that Cut Part Costs By 15%

TCI Precision Metals announced the availability of Titanium Machine-Ready Blanks that cut the overall cost of producing parts. The titanium Machine-Ready Blanks are available in custom sizes from plate to forged block. TCI routinely supplies Machine-Ready Titanium Blanks for the aerospace/defense and medical communities and is certified to AS 9100B, one of the aerospace industry’s highest standards.

“Machine-Ready Blanks save as much as 20 percent of labor costs and cut part costs by 15 percent or more,” said John Belzer, president. “Buying raw stock may reduce the cost of materials, but the overall cost of the part will be higher than starting with Machine-Ready Blanks.”

They allow production to start immediately: i.e. load blanks directly into the machine without prep operations, such as sawing, grinding, flattening, or squaring. This results in less time spent on multiple setups and adjusting fixture offsets, which can save 15% per part and more. By ending prep time and minimizing setup time, operators and machines are more productive and throughput capacity is increased. In many cases, an entire month of machine time has been freed up for additional production.

The Blanks arrive with tolerances guaranteed as close as ± .0005” dimensionally and ± .0002” for flatness, squareness, and parallelism. Documented quality management and manufacturing processes certified by ISO 9001:2000 ensure repeatable quality from part to part. The blanks are processed using precision sawing, double-disc grinding, Blanchard grinding, duplex milling, and sub operations, such as flattening, deburring, and wet timesaving.

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TCI Precision Metals