March 2011 Product Spotlight
In 2008, Hardinge introduced a low-profile rotary table as a standard, no-frills unit to compete against other 210mm tables on the market. Now, the company has redesigned the model to include the famous Hardinge collet-ready 16C spindle that provides the high-precision gripping options for which Hardinge is known. They’ve also extended the spindle nose for additional tooling clearance.
Part quality begins at the spindle. Minimal overhang from the spindle bearings assure that spindle accuracy is transferred directly to the part being machined. Most brands of rotary tables use a collet adaptation chuck, moving the cutting several inches away from the spindle bearings. Hardinge rotary spindles are collet-ready for gripping parts of all shapes, sizes and materials. High-precision gripping options for the GD210LP include standard 16C collets, step chucks for larger diameters, Sure-Grip® expanding collets and custom collets with the use of an optional collet closer. Special accuracy FlexC™ collet systems, chucks and the precision-ground faceplate (included) will mount on the A2-5 spindle.
What does this mean to the programmer and machine operator? Higher accuracy jobs can be run, less tooling interference, length control options, internal gripping capability, no time-consuming fixtures, and lightweight alternatives for a heavy chuck. The added versatility and the ability to share tooling with other machines in the shop is highly advantageous.
The Hardinge enhanced GD210LP rotary table indexer provides rigidity, speed, accuracy, repeatability and flexibility. High stiffness and super rigidity are accomplished with large diameter bearings and a fail-safe clamp system allowing part weight of up to 220 pounds. Radial load testing indicated a stiffness of 4x greater than a competitive model. The GD210LP uses up to 233ft-lb/315Nm of clamping torque to handle off-center drilling, cross-axis milling and other high-force cutting applications. A fast clamp and release in milliseconds reduces cycle time. Hardinge’s hardened and ground steel cross-axis helical gear provides a longer life and continued accuracy. Based on true bidirectional testing, Hardinge guarantees ±15 arc-second accuracy and 10 arc-second repeatability.
“With this redesign, all of our rotary products incorporate the collet-ready spindle, states Al Comstock, Rotary Product Manager at Hardinge Inc. The Hardinge GD210LP is the most flexible 210mm rotary solution on the market.”
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Hardinge
CIMtek LLC and its partner, Heimatec, have announced a radical change in the world of driven tools with Heimatec's unique "HT" quick change tooling system for live tool lathes.
This new system features a simple, yet durable and strong, precision ground taper, combined with a positive ground locating face and an orientation pin providing exceptional stability and repeatability. In order to actuate the “HT” coupling, you simply tighten down the conical screw on the periphery of the “HT” interface. The “HT” interface repeats within .0002” in the z-axis, and provides axial runout of ,0002” as well.
“Comparable quick change tooling systems use socket head cap screws, or expensive proprietary couplings” CIMtek LLC’s Vice President of Sales Brian Nowicki says. “The HT” system is the most common sense, accurate, versatile, and overall most cost effective system we have seen in the market to date”.
The Unique “HT” system in available in nearly every axial, and radial driven tool offered in the Heimatec assortment including adjustable angle heads. In addition, a complete assortment of standard tools available for Mori Seiki, Mazak, Okuma, Miyano, Samsung, Haas, and Nakamura-Tome lathes. The Heimatec “HT” system is also incorporated into their right angle heads and adjustable angle heads as well.
To add to the versatility of the “HT” system, Heimatec offers the customer a broad array of attachment options for the “HT” system including ER collet chucks, shell mill holders, Weldon-style end mill holders, and even shrink fit holders in a varying lengths.
Pricing wise, the new “HT” system is priced to revolutionize the industry. Standard axial and radial “HT” units are priced directly the same as Heimatec’s already competitive ER collet chuck product. “The fact is that with the pricing established by Heimatec with the “HT” system and its incredible versatility, it makes no sense for a customer to buy a dedicated axial, radial, or adjustable live tool unit” Nowicki says.
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Heimatec
Vishay Precision Group, Inc. announced that its VPG Process Weighing division has introduced a new-generation roll force measurement system for use in hot and cold rolling mill applications with its BLH-Nobel Weighing Systems G4 family of multi-channel weight/force indicators.
Designed for new and existing rolling mills, the RFS-4 system provides the mill operator with continuous monitoring and display of the roll separating force and differential forces indicating balance. In addition, the system automatically cancels temperature-induced drift during the period that the mill is empty and provides local and remote indications if metal is accidentally introduced into the mill or the mill becomes overloaded.
Easy to set up and use, the new RFS-4 measures rolling mill separation forces accurately and conveniently, and with a high degree of repeatability, using extensometers on the mill posts or load cells in the screw to provide an electrical signal proportional to the mill separation force. A single G4 instrument with customized software reads signals from both sides of the mill and amplifies them.
In the rare event of an extensometer failure during rolling operation, system software highlights the failing channel and electronically compensates for the loss until the unit is replaced, eliminating lost production time.
Compared with the previous-generation system, the new RFS-4 requires only one external G4 signal conditioning unit. The G4 has up to eight channels to provide accurate and reliable information on sum (total), difference (work-drive), work total, and drive total values that can be displayed on the graphic color display. Analog signal outputs for each value are available on the read panel rack terminals, with separate relay outputs provided for "Metal in the Mill" and "Mill Overload" conditions.
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VPG
The L.S. Starrett Company, a global manufacturer of precision tools and metrology equipment and other tools, has announced its portable SR100 Surface Roughness Tester, the first in a new line of state-of-the-art material testers. The SR100 determines surface roughness of large components, structures, and is a great tool to audit batch production prior to shipment and production line process control.
Weighing only seven ounces, Starrett’s easy to use SR100 features a gauge range of 0.008” and an accuracy of 5% of reading plus 4µin. The innovative SR100 separates into two pieces to measure surface roughness. Using a wide base to ensure stability, the bottom half of the unit travels across the measurement surface and sends an electrical signal to the SR100’s upper half. The SR100’s hand-held upper has a large LCD display and controls. It digitizes the signal from sensor unit and sends it to a microprocessor where it calculates the parameters using standardized algorithms.
“The SR100 uses an infra-red (IrDA) link between the upper and lower units to provide remote, cable free operation up to a distance of one meter,” said John Richardson, Starrett Precision Tool Product Manager. “In addition to measuring basic roughness parameters Ra and Rz, the SR100 also measures advanced Rp, Rv and Rt parameters. It is easy to use, right out of the box and requires little or no operator training.”
Other features include a five second cycle time, switch between inch and metric mode without re-measuring, and automatic shut-off after five minutes. The SR100 is user friendly with initial configuration set to minimize problems of use by multiple operators and a simple, reliable calibration routine. The complete SR100 package includes the two-piece assembly, calibration standard, batteries, operation guide and a carrying case.
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L.S. Starrett
Sunnen's new HTG series tube hones are designed as oil field workhorses with high-volume throughput and increased part capacity. The standard HTG-10000 is capable of handling standard part lengths up to 30 feet (9.14 m) and weights up to 17,600 lbs. (8000 kg). The HTG's ID range is 2 to 24 inches (50.8 to 609.6 mm), double that of previous generation machines, with an OD capacity of 26 inches (660.4 mm) standard, and up to 48 inches (1219.2 mm) as an option. The machine is ideal for instrument piping and down hole equipment applications, such as pumps/motors and hangers, and large hydraulic cylinders like those found on offshore oil platform stabilizers. A new proportional load control hydraulic system enables maximum utilization of hydraulic power, delivering power where needed during operation for maximum efficiency. The system can deliver up to 40 hp (29.83 kW) to the spindle and up to 18 hp (13.42 kW) to the tool stroking system, for metal removal rates of 200+ in3/hr (3500 cm3/hr) using superabrasives in steel as needed.
For increased speed and accuracy, the HTG uses a new precision hydraulic feed system that combines the brute force of hydraulics with the finesse of a sophisticated control. This includes servo position control of the feed system actuator, electronic pressure control, closed loop feedback, and ability to operate both standard tooling as well as two-stage tooling. The machine features a 100-foot/min (30.48 m/min) maximum stroke velocity, 0-300 rpm spindle, and a tool feed force of up to 2500 lbs. (11,200 N). The new servo system on the feed axis provides increased accuracy, as well as improved maintenance, service and setups with no tuning required.
Another upgrade is a next-generation two-stage hone head capable of roughing and finishing without changing abrasives. The two-stage hone head is available with conventional abrasives or superabrasives. The U.S.-made HTG is available in two standard model sizes – the HTG-4000 with 4-meter (13.12 ft) stroke length and the 10-meter (32.81 ft) stroke HTG-10000. Built-to-order machine sizes include 6-, 8-, 12-, 14- meter stroke lengths, and custom-length designs can be quoted.
To save floor space, the HTG's electrical panel is mounted with the hydraulic power unit. The power unit is designed for ease of maintenance with accessible components, an easy-to-clean tank, cleanable air filters on the oil heat exchanger, and oil temperature/level indicators on the machine and on the control. A new work base has an improved design sloped to the center of the machine for removal of honing "mud," and includes standard full-time coolant flush. This means operators spend less time shoveling out the base of the machine during high production runs.
The HTG features a new easy-to-use Siemens PLC touch-screen control system with zero shutoff, feed pressure control, cross hatch angle calculator and a joy stick to allow the operator to move the honing tool over the stroke length. The new control system features complex software to maximize process efficiency in the background while providing easy-to-use, intuitive touch-screen operation. The power of the hydraulic system is controlled with precision, enabling better control for tough parts such as blind bores and shoulders. A load meter enables detection of tight bore conditions and the bore profile is included on the display. Other features designed to increase productivity include feed system soft start, and integral load meter and recommended settings based on part dimensions and material.
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Sunnen
For saving time and money, EXSYS Tool, Inc. has developed rotary and static tool holding concepts specifically for Mazak Corp. turning centers. The concepts streamline machine operations through the use of rigid, accurate and efficient PRECI-FLEX tooling products.
The tooling concepts are heavy duty (CAT 40-taper and Standard ER Collet) configured specifically for Mazak Horizontal CNC Lathes. The different models that EXSYS supports tooling solutions for include Mazak QUICK TURN NEXUS 200/250/300/350/400/450 machines and previous SQT 15/18/200/250 M-MS/28 M-MS. EXSYS Tool offers the H and V-type drill/mill heads with Standard ER32 Collet, ER40 Collet, and CAT40 capability.
EXSYS Tool’s PRECI-FLEX is the first tooling system on the market with a single base holder and multiple tooling adapters that utilizes the ER collet pocket, making lathe tooling changeovers quick, accurate and cost-effective. The product’s compact design ensures maximum torque transmission and rigidity, resulting in increased machining accuracy and improved productivity. Additionally, the modular system’s conical and flat face planar interface allows the use of either an adapter or a standard ER collet, and enables collets, endmill holders, expanding collet chucks and shrinks fit tooling to be mounted on a single base holder.
The PRECI-FLEX system’s Adapter Collet Chuck features an inside nut that enables operators to use the adapter to make the collet pocket smaller. The adapter can then clamp onto the endmill while remaining compact during machining. The chuck also allows the adapter to be utilized as a pre-settable option offline to increase set-up capability. PRECI-FLEX provides unsurpassed repeatability, with every toolholder offering repeatability within 10 microns. The system also virtually eliminates machine downtime, and allows tooling adapters to be interchanged between fixed and rotary base holders for fast, economical machining.
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Exsys
For exceptional drying of machined parts after washing and for removing surface oil and grease, ALMCO, Inc., has developed a round-bowl vibratory dryer that uses dry maize, which also polishes the parts during their submersion.
The OR-CD Series is specifically designed for high-volume, in-line production applications where time-savings and equipment reliability are critical. Parts can be fed into the ALMCO machine individually or in batches, for once-around-and-out drying before the next production step.
Available with tub capacities of 3, 5, l0 and l5 cubic feet, the dryer offers variable time-cycles by adjusting progression of the parts in ALMCO’s natural-contour tub. It features a vertical-shaft vibrator which can easily be reached for maintenance, a rugged l5 hp, l800 rpm totally enclosed motor, and sound-deadening material to comply with EPA and OSHA standards.
Operation of the dryer is from a separate pedestal where a NEMA Type l2 panel enclosure houses remote machine electrics. Controls are in conformance to NMTBA specifications, with the motor operating on either 230- or 460-volt current.
Options available are a maize-heating feature for even greater efficiency, an elapsed-time recorder, an automatic lubrication system, and extra screen sections for internal separation.
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ALMCO