American Machinist 12

americanmachinist.
com DECEMBER 2009 A Penton Media Publication

Power + Precision for High-Performanc Autos Page 14
FIVE-AXIS
FRENZY
THE ABCS
OF BORING
Page 16
STRATEGIES:
PLANNING FOR
LEAN, PART 2
Page 18
AUTOMATION:
LIGHTS-OUT
SETUPS
Page 29
Page 10
MACHINING :
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MACHINING PLASTIC :
CUTTING
GEOMETRIES
THAT WORK
Page 16
SAFETY:
VIEWING PANELS
GET STRONGER
Page 20
FINANCE:
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LENDERS
UNCERTAINTY
Page 32 MACHINING
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Planning the Lean Machine Shop Page 22
Page 12
americanmachinist.com DECBER 2009 A Penton Media Publication
Power + Precision for High-Performanc Autos Page 14
FIVE-AXIS
FRENZY
MACHINING :
THE ABCS
OF BORING
Page 16
STRATEGIES:
PLANNING FOR
LEAN, PART 2
Page 18
AUTOMATION:
LIGHTS-OUT
SETUPS
Page 29
Page 10
CONTENTS
DE PART ME NT S
F E A T U R E S
ON THE COVER
22 MACHINE TOOLS
Independent subsystems double turn-mill production.
26 TOOLING & FIXTURING
Holding small thin parts for milling on a CNC router.
29 AUTOMATION
Multiple pallets boost short-run, high-mix production.
31 SOFTWARE & CONTROLS
Product lifecycle software links to production systems.
47 SHOP OPERATIONS
CMM training for higher caliber machinists.
V I E WP OI NT S
6 COMMENTARY
8 GOVERNMENT MATTERS
9 NTMA NOTES
48 CUTTING TOOL APPLICATIONS
AMERICAN MACHINIST
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READER SERVI CE
45 AM PRODUCT EXPRESS
47 ADVERTISER INDEX
FIVE-AXIS MACHINING
Which machine configuration for which parts.
Mazaks Vortex machine is one of many
types of 5-axis machine configurations
offered by the builder.
2 I AMERICAN MACHINIST I DECEMBER 2009 I americanmachinist.com
E D I T O R I A L M I S S I O N :
American Machinist empowers self-determined
ma c h i n e s h o p o wn e r s a n d ma n a g e r s
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MACHINING
What to check when good boring goes bad.
AMERICAN MACHINIST I Volume 153 I Number 12 I December 2009
18
OPERATING PRACTICE
Lean Flow cells make idle time productive.
16
10
< EDITORS NOTE: In our October 2009 issue we failed to credit
Photographer Sbastien Desbordes for his impressive photo of Guillaume
Labrie, of the LamaCycles downhill team. We regret the omission.
One Tool Body Carries Many
Different Types of Heads
15,000
COMBINATIONS
PROFITABILITY
Bui l di ng Customer
Milling Intelligently
www.iscarmetals.com
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GO
FIGURE.
You could do this: Set up operation 1. Then set up operation 2.
Then set up operation 3. And then set up operation 4.
Or you could do one setup and run the job complete.
These times call for a cool head and smart business decisions. Manufacturing businesses
need to be efficient and resourceful to survive and prosper. One way to be better than your
competitors is by being very efficient. Reduce setups, handling and cycle times, and you can cut
prices while increasing profits. Contact us, we can help. 800-331-6746 | www.HaasCNC.com
With Haas Trunnion VMCs, you can
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or full 5-axis machining. Smart.
A
s 2009 fades out, there are random indicators
of economic recovery: the Federal Reserve
Bank reports modest improvement in consumer
spending since October; the U.S. Dept. of Labor
indicates the rate of unemployment has slowed; and
November U.S. manufacturing orders increased almost
2%, the Institute for Supply Management says.
There are no boldfaced conclusions from these
data points, but perfect clarity is rare. It was clear
enough 15 months ago that the global economy was
failing at some fundamental level, and before long it
was clear too that everyone would be affected. Since
then, nothing has seemed clear.
One of the signifying characteristics of this
recession has been its thoroughness: no market
segment, no organization, no worker has been
unaffected. All of us have been on edge waiting for
the next calamity. Were unified in confusion and
doubt, so were dubious that any small detail can
undo so much damage. No one makes a move, so
everyone is stuck.
Getting unstuck wont be a unified effort. It
demands individual initiative. Sooner rather than
later each of us must acknowledge the confusion
and reserve the doubt, and proceed using as much
confidence and understanding as we can muster.
Most economic advice involves managing perceptions
anyway: why not assign all the bad news to 2009 and
move ahead with confidence?
A more practical way forward is to understand
better how and why the manufacturing market has
changed, and how it continues to change. Tim Hanley,
a Deloitte & Touche expert on manufacturing and
industrial products markets, identifies six big factors
in his industrial outlook:
Ieueial srimulus senuing
(aimed at increasing bank
lending and accelerating
industrial spending) is
disguising actual demand
levels, so manufacturers
cannot commit to capital
spending plans.
Nanuacruiing
supply chains and
manufacturers
footprints have become
confused and less reliable
thanks to cost cutting,
geographic shifts
and uncertain consumer demand.
Commouiry anu eneigy iices aie volarile, so
manufacturers cannot forecast their needs and are
fearful of future spikes when/if the global economy
strengthens.
Peisisrenrly veak anu unceirain economic
recovery means that manufacturers must continue to
reduce structural costs, straining productivity.
Imioveu gloLal comeririon anu veakeneu
global demand limits producers abilities to pass costs
to customers.
A sliinking ool o aoiuaLle anu caaLle
workers, engineers, and executives complicates long-
range planning and limits growth potential.
This may be his 2010 outlook, but other than the
federal stimulus, each of these factors was in place
prior to 2009. Its a reminder that the world rarely
changes in an instant: It evolves, and so must we.
The machining world is evolving too, of course.
OEMs are assigning more of their precision
manufacturing work to job shops, which is pressuring
the shops to perform to higher standards. Its also
changing what they demand from machine tool
builders, tooling manufacturers, software developers,
and other dedicated suppliers. None of it is sudden,
or certain, but its a change thats happening apart
from (and in spite of) all that confusion that we
associate with 2009.
The way to overcome confusion is to identify your
strength and be an expert at it. In this issue youll read
about a machine shop that designs and manufactures
custom tooling, and its creative effort to adapt to
changing market conditions. The company president
acknowledges theyre trying to change the way their
market sector works. No shortage of confidence there.
This report, as we hope with every report in this
and every issue, addresses the fact that every day
presents machine shops with a series of challenges to
their progress. More to the point, every day delivers
reminders that we must use the resources and skills we
have to improve our performance or else, find the
tools we need to improve. Its not easy, but its progress.
FROM THE E DI TOR
On to something new
Robert Brooks
Editor-in-Chief
robert.brooks@penton.com
The 2010 PROGRAM is carefully constructed to equip you with the knowledge
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for the future...
n political folklore, a yellow
dog Democrat is someone
who could be counted on to
vote. Thats a problem for both
Speaker Nancy Pelosi (D-CA)
and Majority Leader Harry Reid
(D-NV.) There are many more
blue dogs than yellow dogs
in their packs.
The federal budget deficit and
proposals that could significantly
increase that deficit, both for the
current year and projected for the
coming decade, are beginning to
scare the more conservative blue
dog Democrats and cause them
to stray from the pack leader.
For fiscal year 2009, the U.S.
government ran a budget deficit
of almost $1.4 trillion. Yes, that
is trillion with a t.
It is not just a record. The
$1.4-trillion deficit beats the old
record by threefold. Moreover,
by the Obama Administrations
own projections, the total budget
deficit is projected to grow by
an additional $9 trillion over the
next decade. Remember when
Ross Perot (who received 20
percent of the presidential vote
in 1992) was campaigning on the
position that it was irresponsible
to allow the budget deficit to
grow by several hundreds of
billions over the succeeding
years? If only we had such small
worries today, and our deficit
could still be measured in billions
rather than trillions.
In fairness, George W. Bush
did nothing to alleviate the
problem. Indeed, the budget
deficit doubled during his tenure,
and many of those years were
times of good economic growth,
when there was no need to run
a deficit for economic stimulus
purposes. Without getting much
credit (or blame) for it, he signed
a Republican-sponsored bill that
added a prescription drug benefit
for seniors, adding trillions to the
unfunded liabilities of the U.S.
government (which now amount
to over $100 trillion or $900,000
for every U.S. household).
For 2009, the federal budget
deficit is projected to be 11.2
percent of Gross Domestic
Product (GDP.) This contrasts
with a 3.2 percent of GDP in
the previous year. Moreover, the
Obama economic team does
not see an opportunity to cut
the deficit significantly during
his tenure. In fact, they project a
doubling of the deficit over the
next eight years. We are already
in debt to the Chinese alone for
$1 trillion, and we are selling off
our physical assets at a record
pace to pay our bills. Direct
foreign investment in the United
States is $2.5 trillion, up 150
percent in just the last decade.
No wonder the blue dog
Democrats are nervous. Many
of them have to run for re-
election next year in states with
conservative electorates, like
Indiana, Arkansas, and North
Dakota. That makes them
skeptical of a near trillion-
dollar price for the proposed
healthcare bill.
Stories are already beginning
to circulate about the billions of
dollars of waste uncovered in the
stimulus bill, and the promised
jobs have yet to materialize in
sufficient numbers to justify
the $787 billion cost of that
legislation.
Thus, the Senate deadline
for healthcare is beginning to
slip into early next year. And,
Democrats are less and less
eager to vote for a climate
bill that could cost additional
trillions and incrementally
double electricity rates over the
next decade. Senate Majority
Leader Harry Reid (D-Nev.)
is a good vote counter, and he
knows he is asking some of his
Democratic caucus to commit
political suicide by backing the
Presidents legislative agenda.
The Republicans are counting
on a conservative backlash to
punish Democrats in 2010. Blue
dog Democrats fear the same
thing if they become identified in
voters minds with the leaders of
their pack.
Former Majority Leader
Trent Lott (R-MS) wrote a book
comparing his former job to
trying to herd cats. Harry Reid
and Nancy Pelosi are finding
that herding blue dogs is not
much easier.
GOVERNMENT MATTERS
You can help revitalize U.S. manufacturing! Send this page to your Congressman, local and state government leaders,
or your local newspaper editor. Add your own comments on the importance of manufacturing innovation to the health of
our economy. Your comments are also welcome at pfreedenberg@AMTonline.org
B Y D R . P A U L F R E E D E N B E R G
Blue Dog Revolt > >
Vice President-Government Relations, AMTThe Association For Manufacturing Technology
I
vote for a Democratic candidate
even if the Democratic Party
nominated a yellow dog. By
contrast, in recent times there
has been increasing reference
to the blue dog Democrats in
Congress. Those members are
more discriminating about whom
or for what they are willing to
NTMA NOTES
B Y J A M E S R . G R O S M A N N
JAMES R. GROSMANN IS MARKETING DIRECTOR FOR THE NATIONAL TOOLING & MACHINING ASSOCIATION
I
have enjoyed contributing my
opinion to American Machinist
every month, and the opportunity
I thought Id copy some of that lone
negative response, so he can air his
point of view.
I read your article and I
had to laugh at the hypocrisy, he
began. First using Khrushchevs
quote to demonize the present
administration and then stating
that 40% of Americans receive
some sort of Federal aid, because
we all know that is whats killing
the country. Just to be fair and
balanced why dont you give us
the facts on how many businesses
receive Federal assistance through
tax breaks and credits while the
rest of us pick up the tab?
My friend misunderstood
me. I didnt say those on Federal
assistance was what was killing
this country. Ive known people
that have been on assistance and
for a lot of them, its needed. But. I
also know that there are billions of
dollars wasted every year by people
working the system, getting money
they dont deserve. The recent
ACORN fiasco exposes a group
organized to do just that.
We cannot afford to keep growing
the federal government while losing
jobs in the private sector. I think we
should reconsider tax breaks for
large corporations. Unfortunately,
many of those tax breaks also
help smaller companies to remain
competititive. Maybe Congress will
look in to that? Taxpayers fund all
of it. Thats the very reason why we
cant continue the practice.
Next, my friend criticized me for
daring to address the number of
illegal aliens receiving benefits paid
for by taxpayers:
Go after those defenseless
people on welfare, lastly point
out that all those foreigners are
getting stuff for free and theyre
not even American. Oh and most
importantly, do it while waving the
American flag while remembering
9/11 and bellowing to take back
America. Well, weve taken back
America, back from the pack of
liars and thieves that hijacked it for
the past eight years.
I welcome the immigrants who
arrive here legally, work hard, and
pay taxes. I spent many years living
outside the U.S. and I know hard life
is in many underdeveloped nations.
I also know that many people who
have entered the U.S. legally and
approached citizenship the right
way dont appreciate others who
dont take the legal approach.
In more concrete terms, I
recommend a visit to some of the
counties in our Southwestern states
that are overwhelmed by illegal
immigration. The term breaking the
law has to mean something, doesnt
it? Hospitals, welfare agencies,
schools and other services are being
strained, and compromised by excess
demand. If it isnt brought under
control, those services wont be
available for anyone.
Next came his big conclusion:
Wealth is finite if Wall Street is
paying out huge bonuses that money
comes out of someone elses pocket,
most likely Joe Working Class.
Its a pity our educational system
doesnt do a better job of teaching
students how businesses really
work. If Wall Street is paying
huge bonuses, then the money ought
to be coming out of the pockets of
those that invested money in Wall
Street. The bonuses should not be
funded by tax revenue.
I believe it has been those
officials now in office who have
given taxpayers money to Wall
Street. Id also point out to my
correspondent that the jobs he
endorses and anticipates resulting
from an expanded government will
be funded by taxpayers money
including taxes paid by Joe
working class, who he claims to
defend with such passion.
But, theres more to this
exchange than the specific details
in debate. My correspondent used
some time-honored tactics: First,
insult your opponent, and then
change the subject. The point of
my column was that our freedoms
have been paid for with the blood
of heroes. We must value their
sacrifice even as we cherish our
freedoms. We must be careful about
what we allow to happen as our
government expands, and asserts
more control of our personal and
business activities.
I should note that my corres-
pondent is not a company owner; hes
a worker, like most of us. I hope that
if government expansion threatened
the viability of any of his plans or
enterprises, hed oppose that too.
Our current leaders do not recognize
small manufacturing as a worthy
contributor to their project. For them,
were an easy target to fund for their
excessive spending. Manufacturing
jobs, including my correspondents,
will be lost if all this continues.
I appreciate my correspondents
response because open debate is
what America ought to be about,
and what is threatened by an
aggressive government. When
elected representatives aim to
legislate so fast that there can be no
debate, we have lost a fundamental
principle of our democracy. We
must examine all these changes,
before we give it all away. <<
Contact James R. Grosmann at the
National Tooling & Machining
Assn., jgrosmann@ntma.org.
Lets Hear From the Other Side > >
americanmachinist.com I DECEMBER 2009 I AMERICAN MACHINIST I 9
to inform our industry about
the realities of what is going on in
Washington. My October column,
Will We Give It All Away,
expressed my concern that we are
going to give away our country, if
we arent careful. Among all the
responses, just one reader disagreed
with me, but nevertheless agreed that
we need to have serious debate.
Thats not going on in Washington
today, but since American Machinist
doesnt present letters to the editor,
FI VE- AXI S
T
he number of shops that
have caught on to the ben-
efits of 5-axis machine
tools has grown by leaps
and bounds in recent years.
Still, there are many shops that, for the
first time, are adopting 5-axis machin-
ing, and for them, choosing a machine
can be a daunting prospect espe-
cially when one machine tool builder
reported having found hundreds of
different possible machine configura-
tions available for achieving 5-axis
machining capability.
However, shops making their first
foray into full simultaneous 5-axis ma-
chining or 5-sided machining typically
opt for either a vertical or horizontal-
type machining center. And thankfully,
with those two types, the choices are a
bit more manageable.
Within the realm of verticals and
horizontals, there are basically four
common configurations for five axes,
and those four can be categorized into
two groups. Group one configurations
achieve a fifth axis through workpiece/
machine table movement, and group
two configurations through tool/ma-
chine spindle movement.
The table-movement group in-
cludes the A over B axis (dual trunnion
table) and B over A axis (knuckle)-type
machine configurations. Configurations
within the spindle-movement group are
the tilting-head and C-axis head-types.
Each type of 5-axis machine config-
uration handles certain types of work-
pieces better than others, which is the
reason that practically every builder of
5-axis machines will agree that choos-
ing the appropriate machine configu-
ration is extremely part driven. So,
shops need to know the size and weight
range of the parts they will be running,
what material (soft or hard) those parts
will be made from, what level of ac-
curacy needs to be held, and what types
of surface finishes are required.
According to Dave Lucius, vice
president of sales at Methods Machine
Tools Inc. (www.methodsmachine.
com), the exclusive U.S. importer of
Matsuura machines, the best configu-
ration for rigidity and accuracy when
machining hard materials is one where
the machines table moves rather than
its spindle. Machining hard materials
is Matsuuras forte, he said, which is
why the builder focuses heavily on A
over B-axis dual-supported trunnion-
type machines with vertically oriented
spindles for 5-axis machining. Mat-
suura also produces B over A-axis
knuckle-type machines, but recom-
mends that shops move to a dual-sup-
The Five-Axis Frenzy
SHOPS HAVE A LOT TO CONSIDER BEFORE DIVING
INTO 5-AXIS MACHINING.
By Charles Bates I senior editor
P
h
o
t
o

c
o
u
r
t
e
s
y

o
f

M
a
k
i
n
o
ported trunnion-type machine when
part weights exceed 100 lb.
Lucius explained that Matsuura
machines get their rigidity and robust-
ness from vertically oriented spindles
together with trunnions that are ba-
sically mounted to a machines core
base. He also said there are benefits
concerning work envelopes and ma-
chine automation.
On trunnion-style machines, most
of the work envelope is usable because
it doesnt have to be big enough to pro-
vide enough room for a moving spindle
to maneuver around a workpiece. So
when considering a parts size, a trun-
nion-style machines work envelope for
that particular size will be smaller, as
compared with the required envelope
a tilt spindle/C-head type machine will
need to accommodate that same part
size. With a trunnion type machine,
shops can get closer to filling the work
envelope with part size because the ma-
chine design eliminates the interference
issues associated with a moving-spindle
machine, said Lucius.
To date, Matsuuras largest dual-
supported trunnion machine provides
a work envelope measuring 24.8 in. sq.,
handling parts weighing to 880 lb. And,
the company soon will be presenting
a larger horizontal version dual-sup-
ported trunnion style 5-axis machine.
Respondi ng to the bel i ef that
trunnion-style machines are difficult
to automate, Lucius pointed out that
just the opposite is true. Automating
a trunnion-type machine is actually
easy to do. For example, the Mat-
suura MAM72-35V can incorporate
a simple pick-and-place robotic sys-
tem, some with as many as 180 pal-
lets. The machines are designed for
fully integrated, simple off-the-shelf
automation. In fact, the bulk of 5-axis
machines Matsuura installs are ones
with high-quantity pallet systems.
Commenting on 5-axis machines,
Tracy Ellis, machine group sales man-
ager at Heller Machine Tools (www.
heller-us.com), stated that all types
of 5-axis machine designs provide
accuracy, but there can be physi-
cal drawbacks to each. For example,
he pointed out that an A over B-axis
trunnion-type machine design might
limit operator accessibility.
Workpieces and workholding, on
those types of machines, must rest
M
any shops are so-
lidifying their com-
petitive standing by
incorporating 5-axis machin-
ing and taking on low-vol-
ume, high-accuracy complex
jobs. But in this process some
shops, especially those do-
ing work with micron-scale
features or surface-finish
requirements in the single-
nanometer range, often reach
accuracy limits when using
conventional machine tools.
In these situations, ma-
chine tool builder Mori
Seiki (www.moriseiki.com)
recommends that shops con-
sider ultra-precise 5-axis
machines. Used in clean,
temperature-stable environ-
ments (at least +/- 1 degree
C.), these machines easily
match the most demanding
standards for accuracy.
One of Mori Seikis ultra-
precision 5-axis machines is
the NN1000DCG for ultra-
precise linear scribing and
milling. The symmetrically
configured machine fea-
tures the companys DCG
(driven at the center of grav-
ity) technology and a spe-
cial, closed-loop structure.
According to Adam Han-
sel, COO of Mori Seiki's
Digital Technology Lab, the
reduction of off-axis distur-
bances is critical in ultra-
precision machining. A DCG
machine structure, and one
that is fully counterbalanced,
ensures smooth machine
movement. In addition, the
NN1000s closed-loop struc-
ture increases machine stiffness.
While other machines
typically employ cantilevered
spindles, the NN1000 closed-
loop structure not only makes
for a more rigid machine, but
also provides excellent op-
erator access to workpieces
and tooling for in-machine
measuring and job set up,
pointed out Hansel.
Mori Seiki equips the
NN1000 with air bearings
on linear and rotary axes to
eliminate mechanical con-
tact and provide the highest
level of precision.
An air turbine that pro-
vides precision and reduced
thermal generation drives
the machines milling spin-
dle, which also spins on air
bearings. For ultra-precision
positioning, the machines
linear axes feature 34-pi-
cometer-resolution scales.
Although the X, Y, and Z-
axis travels on the NN1000
measure 4.7 in., 5.9 in., and
2.0 in., Zach Piner, general
manager of Mori Seiki' Me-
chanical Technology Group,
said the machines design
could definitely be applied
to a larger format machine.
But, he added that the exact
construction of the machine
would have to be evaluated
based on the exact intended
application.
Some of the main target
markets for the NN1000
are optical and micro molds.
However, many markets are
emerging as engineers learn
that these kinds of machines
exi s t . Many engi neer s
would not have considered
designing such complex
and precise part features
because they did not know
that a machine existed that
could achieve them, com-
mented Piner. <<
between the two (A-axis) trunnions,
forcing operators to work around the
trunnions. He also said that shops can
fit only so much workpiece mass and
weight between the two trunnions be-
fore having to move to a larger ma-
chine. But, he added that the trunnion
machine design is a very reliable one.
In my opinion, I dont think a
shop should go over an 800-mm pallet
size in an A over B axis trunnion ma-
chine. When workpiece mass/size ap-
proaches 2,500 kg/one meter or larger,
it can be difficult to handle on a trun-
nion machine because the trunnions
would have to be spread out to the
point where table sag might become
an issue, said Ellis.
He agreed that A over B-axis ma-
chines are adaptable to pallet chang-
ing. However, the pallet changer has to
be either a shuttle or linear type, which
may not be as fast as a rotary-type pal-
let changer. Pallets must be lifted and
Ultra-Precise 5-Axis
Mori Seiki's NN1000DCG 5-axis machine.

F I V E - A X I S
shuttled and a new one pushed on,
as opposed to lifted, rotated and set
down with a rotary system.
Ellis added that pallet changing is
possible and commonly done with B
over A-axis type machines, but there
can be an overhead connection to the
machines B axis that can get in the
way, especially with aftermarket add-
ons. Builders can overcome this prob-
lem by making the connection integral
to the table.
Heller builds tilting head and C-head
type five-axis machines with B axes as
the rotary tables and the other rotary
axis as either a swiveling workhead C
axis or a tilting A-axis workhead. Ma-
chine sizes run to 1.6 m by 2 m, and if a
shop needs something larger than that,
Heller recommends opting for a portal
or gantry type five-axis machine.
Tilting head and C-head designs
keep a machines work area accessi-
ble and ergonomically friendly while
allowing for a large work envelope,
high table load capability and good
adaptability to pallet changing. Op-
erators can easily reach workpieces,
workholding, the spindle and tooling,
and the machines tables carry the full
load and workpiece size of traditional
horizontal machining centers.
With a B over A-axis design, the ma-
chines indexer takes up a large por-
tion of the work envelope, and with an
A over B-axis trunnion machine, there
are potential collision zones with the
trunnion, explained Ellis.
For its 5-axis machine models, Hel-
ler offers a choice of three different
workhead designs. Theres a power-
cutting, high-torque universal head,
a speed-cutting universal head, and
a speed-cutting tilt spindle for high-
speed cutting.
The power cutting heads use Hel-
ler zero spindle system spindles, car-
tridge-type spindles that have a cou-
pling between the spindle cartridge and
the motor. This allows the cartridge to
be changed in about two hours, as op-
posed to motorized spindles where the
task is a lot more involved.
Tilting head machines from Heller
sport higher speed spindles, primarily
for cutting aluminum and cast iron.
The company also offers a high-speed
spindle on its C-head machine. The
power cutting C-head delivers ample
torque having a gear-driven headstock
in 40 and 50 taper versions.
Makinos (www.makino.com) ap-
proach to various five-axis machine
designs considers both the positioning
of the workpiece relative to the spindle
and the positioning of the cutting tool/
spindle relative to the workpiece.
On some horizontals, for example,
Makino uses a table-on-table design,
where the B axis is under a horizon-
tal pallet that has a vertical rotary C
axis. The design provides stiffness and
rigidity, and such operations as drill-
ing and boring can be performed as
single-axis operations versus multi-
axis movements. On its verticals and
some horizontals, the company also
uses tilt trunnion-style tables.
Makino also designs five-axis ma-
chines with the A and C axes on the
spindle. However, those machines are
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for large parts, such as big flat plates.
Traditionally, the drawback to a
tilt trunnion design, or even the table-
on-table one, has been the amount of
rotational speed that can be generated
on the rotary axis, whether B and C
axes or A and C axes, said Bill How-
ard, product manager at Makino. A
relatively high table speed (rpm) is
needed to get the most out of a high-
speed spindle when machining, for ex-
ample, the outside edge of a 30-in-di-
ameter workpiece. Mechanical drives
and elements can actually limit a ma-
chines rotational speed.
He pointed out that Makino, and
other machine tool builders, overcome
these table rotation drawbacks by us-
ing direct drive motors that provide
high rotational speed, resulting in
higher machining feedrates.
Direct drive motors, such as those
used on Makinos D-500 vertical
5-axis machine with a tilt/trunnion
table, eliminate backlash and provide
the same accuracy and repeatability of
mechanically driven tables. They also
eliminate the need for mechanical com-
ponents linked to mechanically driven
tables, along with the wear and tear
associated with those components.
Machi ne t ool bui l der Mazak
(www.mazak.com) addressed 5-axis
accuracy with a recently designed
5-axis machine that incorporates lin-
ear motor technology to increase ac-
curacy when doing fine incremental
machining. Such a design eliminates
the need for ballscrews, along with
the backlash and starting/stopping re-
versal errors that go along with them.
And Chuck Birkle, marketing vice
president at Mazak, said that more
and more machine tool builders are
turning to linear motor technology to
boost overall machine accuracy.
According to Birkle, Mazak has no
qualms about building machines with
the fifth axis in either the tool or the
table: more than half of the machines
the company builds are five-axis.
On the companys Vortex vertical
machines, for example, the spindle
provides the A and B axes, while its
Variaxis verticals, use an A over B-axis
design via dual trunnion table.
One advantage to the trunnion
table design is that relatively short
tool lengths can be used because
the table can maneuver up close to
the spindle. Theres better spindle
rigidity, yet no need to use long tools
for reaching certain part surfaces,
even on complex geometries, said
Birkle. And, the configuration tends
to simplify programming in that the
tool tip is always in a known posi-
tion. Its the A and B axes that are
the variables.
No matter the type of machine de-
sign, todays tougher part materials are
placing a heavy burden on machine
tool builders to increase machine rigid-
ity and re-think how spindles are built.
Four or five years ago, it was
high-rpm machining of mostly alu-
minum. Thats changing," said Birkle.
"Theres an increased use of hard ma-
terials, such as titanium, so the goal
isnt more rpm, per se, as it is more
torque at lower rpm."
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PERFORMANCE AUTOMOTI VE
ALL VALUES
ARE MINUTES
SETUP
DATA
RETRIEVAL
POST
PROCESSING
DIAL INDICATORS
30 45 20
STARRETT
WIRELESS
INDICATORS &
DATASURE
30 35 0
I
n NASCAR racing, torsional stiffness of a car chas-
sis is one of thousands of critical details that must be
executed reliably, and Joe Gibbs Racing (JGR) (www.
joegibbsracing.com) takes no chances.
To test chassis stiffness, technicians at JGR will lock down
the car structure and place indicators at eight designated po-
sitions. Then, a load is manually placed on the car, and the
measurements are taken from the indicators. This procedure
is repeated 12 times with different loads and different chassis
configurations, for a total of 96 measurements.
It used to be necessary for a technician to walk around the
chassis and write down each measurement after each setup
and load placement. Also, the dial indicators used in this step
would be upside down (positive and negative readings) and,
because the car would be rising on one side and declining on
the other, half of the dials would turn in the opposite direc-
tion. The process was time-consuming and error prone.
Joe Gibbs Racing needed a faster and more accurate
process. They approached The L.S. Starrett Co. (www.
starrett.com), a company well known to JGR through spon-
sorship agreements.
With the goal of automating the data-collection process,
JGR recently replaced the dial indicators that had been used
on the chassis twist rig with new Starrett wireless indicators
and a DataSure wireless data collec-
tion system. Each indicator has an ac-
companying DataSure end node, and
a DataSure Gateway attached to a PC
records the data.
The new package improves data
gathering in several important ways.
Rather than positioning himself awk-
wardly around the twisting chassis,
taking a reading and recording it, the
technician now simply pushes the
DataSure end node "send" button.
Also, the prior procedure required
another step: the technician had to en-
ter the measurement data into an Ex-
cel spreadsheet, which added time and
potential errors to the process. With
DataSure, captured data is entered di-
rectly once its sent from the end node
for 100% error elimination.
At first, JGR expected that the indi-
cators and DataSure would only save
process time, but it became clear that
they were also saving effort. While
most of the time spent twisting a chas-
sis is devoted to setup, which has noth-
ing to do with the indicators, quite a
bit of time is saved in post processing.
For now, the load is still applied
manually, which means that at each load setting, technicians
can take eight measurements with the click of a button. Data-
Sure and WinWedge (www.taltech.com) serial data-collection
software ensure that all of the data is written directly into a
prepared Excel worksheet. This eliminates any post process-
ing and saves 15 to 20 minutes worth of extra work.
Starrett wireless indicators and DataSure have been a wel-
come addition to the chassis twisting rig. As documented in
the table, DataSure and the wireless indicators have made a
chassis twist take almost 30 percent less time than using con-
ventional dial indicators. The process is easier for the techni-
cian and more reliable for Joe Gibbs Racing. <<
Twisting and Turning Straight to the Point
To test chassis stiffness, Joe Gibbs Racing technicians lock each car into place and locate
indicators at designated positions. Then, a load is placed on the car and measurements
are taken from the indicators. This procedure is repeated 12 times with different loads and
different chassis configurations.
WIRELESS INDICATORS AND DATA COLLECTION
MAKE MEASURING TORSIONAL STIFFNESS
SIMPLER AND MORE ACCURATE FOR ONE
NASCAR RACE TEAM.
M
BE Cyl i nder Heads and
Manifolds (www.mbellc.
com) in Mooresville, N.C.,
designs and builds specialty compo-
nents for powerful engines used by
performance race teams in NASCAR,
NHRA, and others, and head program-
mer Mark Olson said his production
plans achieve both power and preci-
sion thanks to Delcams PowerSHAPE
and PowerMILL software packages.
It amazes me what it can do,
Olson said. We do a lot of manual
work, then we digitize the ports,
chambers and whatever else needs to
be machined for the engines, and we
import it into Power SHAPE.
He said power makes the Delcam
products effective. PowerSHAPE has a
great, powerful surfacing engine. I have
yet to find something as good as Power-
SHAPE to manipulate surface data.
After perfecti ng the model i n
PowerSHAPE, Olson moves his design
easily and flawlessly into PowerMILL.
They have a very powerful automatic
porting routine, he said, and that was
a big reason they bought it. Power-
MILL keeps the edge of the tool in con-
tact with the port, as opposed to the
tools tip. Cutting with the side of the
tool provides a much better finish.
Another aspect of PowerMILL
Olson likes is the way it sees models
when creating tool paths. With clear-
ances as small as 0.015 in., he said he
has never had interference or a colli-
sion using PowerMILL. He also likes
the transparent interface between
PowerMILL and PowerSHAPE.
You c an c ut
and paste common
geometry from one
app to another very
quickly without im-
porting and export-
i ng. Ol son sai d.
You copy f rom
one, paste it in the
other, and I can be
confident it will cut
the port first time.
Wi t hout Del -
cam, i t woul d ve
been very hard for
us to handle some
of the projects weve
taken on recently,
sai d MBE owner
Matt Bieneman. <<
High-Horsepower Programming
Programmer Mark Olson shows one of the customized cylinder heads he produces at MBE
Cylinder Heads and Manifolds, for NASCAR, NHRA, and other high-performance engines.
Optimizing a High-Performance Component Business
C
P Pistons (www.cppistons.com),
Irvine, CA, develops and manu-
factures pistons for high-perfor-
mance race vehicles and the automo-
tive aftermarket, including vintage cars,
motorcycles, and marine and aircraft
engines. Recently it bought Carrillo In-
dustries, manufacturers of high-perfor-
mance connecting rods, to expand its
portfolio of complex parts offered on
short lead times.
The expansion caused CP Pistons to
take a critical look at its manufacturing
and business processes. It found that
while its proprietary programming sys-
tem was capable of standard machin-
ing, the complexity of the market had
advanced. This forced the shop to rely
too heavily on other CAM systems to
perform time-consuming manual oper-
ations for custom features on its forged
racing pistons and rods. Repeat orders
with small changes were being com-
pletely reprogrammed in the old CAD/
CAM system, leading to misinterpreta-
tions and doubling process times.
It found better CAM programming
in Geometric Technologies CAM-
Works (www.camworks.com) soft-
ware. CAMWorks produces efficient
machining programs directly from
solid models, and seamless integration
between CAMWorks and SolidWorks
provides interoperability and data in-
tegration so that manufacturers can
engineer, design and build products
faster and more accurately.
While CAMWorks integrates with
SolidWorks for design functions, it has
an open Application Programming In-
terface (API) platform that can be cus-
tomized to work with CP Pistons order
booking system. It also has feature recog-
nition that allows it to identify ideal ma-
chine toolpaths based on different piston
geometries (e.g., holes, bosses, pockets,
perimeter cuts), and a knowledge data-
base (TechDB) feature that makes data
storage/retrieval more efficient.
CAMWorks was the only tool we
found out there that could meet all our de-
mands, and its flexible approach on APIs
really helped us move forward, said Karl
Ramm, senior technology manager and
project developer for CP Pistons.
Before CAMWorks, he contin-
ued, we programmed each custom
piston order manually, slowing down
our manufacturing. Each job would
take approximately 10 minutes for
non-complex pistons and up to 40
minutes for complex ones and
thats programming time alone.
CAMWorks simplifies complex
programming tasks to assist with CP
Pistons automation.
MACHI NI NG
W
hen boring perfor-
mance falls off, the
cause may be any
one or a combina-
tion of factors. These
include workpiece stability, adequate
stock allowance, tooling rigidity,
insert grade and geometry and the
matching of speeds and feeds to cut-
ter capability. When experiencing
overly long cycle times, short tool
life or poor part quality, any or all of
these factors should be reviewed. In
any application, one factor may be
more significant than others, but they
also may be closely linked to each
other. Changing one may mean an-
other also has to be changed to get
the desired results. However, when
making test cuts, never change more
than one thing at a time.
Part stability
Although the machining center and
fixtures usually are not the first factors
shops may consider, these can seriously
impact tool performance if the part is
not stable when being machined.
Once workholding rigidity is estab-
lished, machine size and power influ-
ence cutting parameters. Although
the same roughing head can be put
on a CAT 50, CAT 40 and BT 30
taper, each will not be able to take the
same cut. The same holds true for the
depth of bore. A three-inch bore, 10-
to 12-in. deep will work on a CAT 50,
and can be done on a CAT 40 with
extensions, but anything smaller than
a 40-taper machine will not support
the application.
Worn machine spindles and unstable
fixtures are usually factors that can-
not be changed and must be worked
around. Sometimes these factors can
kill an application altogether, but usu-
ally changes in insert types or cutting
parameters will provide a solution.
Rounding Up
The Usual Suspects
WHAT TO CHECK WHEN BORING PERFORMANCE GOES BAD. By Matt Tegelman
For long-reach limited
clearance applications,
consider using a solid carbide
bar instead of multiple
extensions. This set-up offers
higher rigidity and better
control, but is generally
limited to smaller diameter
bores.
(Opposite page) Tooling
for an extended reach bore
where only the gage length
and bore diameter are
considered (Fig. 1) lacks the
rigidity of a modular system
that uses a larger connection
size for reach and only
reducing the tool diameter
when necessary (Fig. 2).
Stock allowance
Often, operators are unsure of how
much stock to leave for boring appli-
cations. Users may be more familiar
with the speeds/feeds and stock allow-
ances needed in turning applications,
which dont always apply to boring.
This is especially true in rough bor-
ing applications where a twin cutter is
used. It is not uncommon to see drills
that are so close to the final size of a
part that only 0.020- to 0.030-in. of
stock is left on diameter, which isnt
enough material to engage both in-
sert tips on a twin cutter. This leads
to chatter and poor tool performance.
Parts without enough stock allow-
ance and an open tolerance plus or
minus ten thousandths on the diam-
eter will work best with a single-
point tool, or a twin cutter with one of
its insert holders removed.
On the other hand, parts that have
cored holes may have too much mate-
rial to remove if the cored hole is not
in the correct position. Even though
the core diameter is within typical
rough-boring standards for stock al-
lowance, the core shift can produce a
situation where the twin cutting tool
is taking more material on one side of
the bore than the inserts can handle.
Tool assembly rigidity
Often, boring tools are selected for
an application based on a required
bore diameter and gage length, with-
out consideration for the actual boring
depth and the extra reach required, if
any. For example, an application may
require 8 in. of reach through the part
and/or fixture just to get to the bore,
and only 2 in. of boring depth. This
is quite different than an application
that requires a boring depth of 10 in.
Modular tooling systems offer an in-
finite number of combinations for max-
imum rigidity and usage. In cases where
tool length is needed, it is important to
start with a larger base size and then
reduce the tool diameter as necessary,
rather than using the same bar diameter
for the entire length of the tool.
Insert grade and geometry
Inserts are the critical contact point
between a workpiece and tool. The
most rigid boring assembly, complete
with a balanced boring head, can
perform miserably if the insert is not
suited to the application.
Insert grade means little if the
geometry does not provide a stable
cut. Pressed geometry inserts usually
have a less aggressive chipbreaker and
hold up longer in stable conditions,
but the radial depth of cut should be
at least one-half of the insert nose
radius. In applications that are critical
due to factors such as deep or long-
reach bores, long-chipping materials,
or part instability in the machine and/
or fixture, inserts with ground geom-
etry will cut more freely.
Insert grades and coatings are con-
tinually being upgraded for specific
applications. For steels, Cermet and
triple-coated carbide grades are most
common. Coated carbide grades are
also used in cast iron applications, but
stable conditions will also permit the
use of silicon nitride and some cubic
boron nitride (CBN) grades. Alumi-
num and other nonferrous materials
can be run with uncoated carbide
inserts, usually with highly positive
ground chip breakers to prevent long
strings of chips. For high-speed fin-
ishing of these materials, inserts with
poly-crystalline diamond (PCD) tips
or coatings also may be an option.
Remember that a stable cut is the first
requirement for long insert life.
Speeds & feeds
When all other factors have been
considered, it is time to determine the
appropriate speeds and feeds for run-
ning the tools. These parameters are
important to obtaining optimum free-
cutting conditions. Ideally, the bor-
ing bar is run at high speeds and more
moderate feedrates; but again, this can
be limited depending on the condi-
tions previously cited.
A common mistake during rough
boring is simply to multiply single-
point feedrates by two when using
a twin cutter. This usually is not an
effective calculation; twin cutters can
operate at feeds four times faster than
those of finishing tools for the same
diameter because a much larger nose
radius can be used. For example, if fin-
ishing with a 0.008- or 0.016-in. nose
radius, a 0.031-in. nose radius insert
could be used for roughing. This dou-
bles the size of the nose radius and us-
ing twin inserts doubles that to four.
Typically, roughing doesnt require
very fine, slow surface finishes so more
rigid tools can be used at higher speeds.
Feeding a twin cutter too slowly will
lead to chatter without the right stock
allowance. Rough cutters are designed
for heavier cuts, requiring more mate-
rial and harder feedrates.
When it comes to speeds, operators
are sometimes hesitant to run proper
surface footage when finishing. Its im-
portant to optimize speed for insert life.
If heavier cuts are being taken, running
at a very high speed will create a lot of
heat, reducing insert life. Lighter cuts
dont produce as much heat, so they
can be run at higher surface feeds.
Matt Tegelman is an application man-
ager at BIG Kaiser Precision Tooling
Inc. (www.bigkaiser.com).
OPERATI NG PRACTI CE
The first installment of this series on how
Lean Flow is implemented for companies
with machine-based processes focused on
establishing cell-based manufacturing and
linking machine cells to synchronize the
processes. (See AM, Oct. 2009, p.22.)
T
odays productivity improvement
goals, and the significant disparity
in wages between U.S. manufac-
turing and lower-cost countries,
require shops to use as much of a machine
operators idle time as is possible. Machine
cell design needs to create as much opportu-
nity as is possible for one person to run mul-
tiple machines, converting any wasted idle
time during the machine cycle into value-
adding work on another machine.
To use that idle time, we cannot return
to large-batch manufacturing on inflex-
ible machines that produce at high speeds,
but are difficult to setup. We need flexible
machines and operators who can run more
than one machine often, different types
of machines.
Lean Flow machine cells are not a series
of similar machines arranged in a functional
layout. The Lean Flow machine cell may be
a mixture of CNC and traditional manual
machines arranged in the order required
to flow materials through the processes re-
quired to complete the product. Operators
therefore may be operating a CNC lathe
and a milling machine, or a horizontal ma-
chining center and a drill press, or a lathe
operation, some minimal cleaning process,
and assembly and packing. Operators move
from machine to machine according to the
work that needs to be performed to keep
the product flowing. Machinists in many
companies have the capability, skills, and
training to run different types of machines.
Often though, employers have not created
the expectations that machinists/operators
need to run multiple machines at once.
The key to productivity gains (sales
shipped per employee-hour paid) is not
maximizing the machine utilization at a
process level, unless the process is a capacity
constraint. If the Lean Flow design calcula-
tions require only 50% of a lathes capacity,
then its fine for a machine to be idle while
an operator assembles and packs product.
The focus is on the output of the cell, line,
or ultimately the factory, not minimized to
the output of the machine or process.
Tool and machine design technology
improvements are always important as po-
tential productivity opportunities, but the
focus on these types of productivity im-
provements can be overemphasized at the
expense of the basic Lean Flow principles.
Instead, the focus should be on getting the
machinists/operators to be as productive as
possible, using all of their idle time.
Reduce leadtime to the minimum pos-
sible level to meet customer demand and
optimize on-time delivery. Make the entire
company as flexible as possible to be able
to change swiftly from one customer need
to another. Then, use the savings and in-
creased revenues generated from the Lean
Flow activities to pay for new technologies
to further improve productivity.
This new-technology capital must be
spent on the processes that will provide the
overall greatest reduction in the leadtime,
inventory, and product cost. Remember:
volume drives down cost much faster than
saving labor at one process. The way to in-
crease volume is to meet or exceed custom-
ers expectations.
Another focus of Lean Flow is improved
on-time delivery performance. This is key
to improving sales, reducing costs, improv-
ing customer satisfaction, and growing the
business and its revenues. In todays global
markets with the wide array of product
choices, customers will not continue to pur-
chase from companies that cannot deliver
product as promised. U.S.-based companies
have a geographical advantage to be able
to supply product in the U.S. market, the
worlds largest consumer market. Without
excellent on-time delivery, that advantage is
lost to global competitors.
How do Lean Flow companies improve
on-time delivery performance while reduc-
ing inventories and cost? By using a pull
system to ensure raw/purchased material
and finished goods inventory (FGI) avail-
ability. The pull or kanban system brings
material into the factory based on con-
sumption from the on-hand inventory, not
a forecast. Therefore, material availability
is not driven by a guess at future needs but
what is used right now.
Known consumption is a much better
indicator of what, and how much, mate-
rial should be replenished than the forecast
(aka an educated guess.) Kanban works the
same way for finished product, assuming
that finished product is held in inventory:
build additional FGI when some is shipped,
not based on forecasted sales.
In addition, by dramatically reducing
leadtime the machine cells can respond to
new customer requirements in a timelier
manner. This ability to respond quickly is
made possible by linking processes in cells,
by controlling the inventory between pro-
cesses with engineered queues (called in-
process kanban or IPKs), and by making
sure that product is built in quantities as
close to the customer demand as possible.
This eliminates the waste of overproduc-
tion as well as the loss of machine capacity
producing unneeded product.
Machine-focused Lean tools
Another commonly used tool in a ma-
chining environment is 5S. 5S is easy to im-
plement in assembly operations, with most
assembly lines being able to be organized in
a few days. Machine cells require a greater
level of detailed study and organizational
effort to organize the machinists tools, fix-
tures, jigs, clamps, vises, gages, and tooling
used by the machines (milling cutters, bor-
ing bars, drills, facing/turning tools, end
mills, etc.), and miscellaneous stuff needed
in a machine process. The reward here is a
more organized process that is a more pro-
ductive process, thus eliminating waste.
TPM (Total Productive Maintenance) is
a Lean Flow tool that focuses on increasing
the efficiency of machine processes to maxi-
mize the output rate, to achieve optimal
running conditions. To achieve this goal,
machines need to produce at the specified
design rates. If a machine is producing half
of the output it was designed to achieve,
Productivity,Performance
How to achieve productivity improvements, on-time delivery, and other Lean Flow
(SECOND OF TWO PARTS)
and that design rate is realistic, then labor
resources and probably tooling are being
wasted. Also, asset capital is wasted when
machines run inefficiently (not producing
at design specified operating rates), and
additional machines are required to meet
demand. In addition to wasted investment
capital, labor costs are wasted when ma-
chines do not run at designed output rates.
In a machine cell environment, if one
machine goes down unexpectedly the whole
cell could shut down. There is very little in-
ventory in the cell to buffer for unplanned
downtime. The minimal inventory designed
in the cell maintains a flow and deals with
imbalances of work content time between
processes. The amount of WIP or product
in the factory controls WIP inventory levels
and leadtime. There is not enough inven-
tory designed into a Lean Flow cell to buffer
for a machine process to be down for hours,
or days, or weeks. So, TPM is critical to
keeping machines up because one machine
down means all of the machines in the cell
will be down in a very short period of time.
Setup reduction is a necessary Lean Flow
tool for reducing long setups that extend
leadtimes and increase batch sizes. Large
batch sizes extend leadtime even more
and cause additional excess inventory and
wasted capital investment. Setup reduction
also increases the percentage of machine
uptime, therefore increasing the achieved
rate of output for each of the machine pro-
cesses. This makes the machine and the op-
erator more efficient.
Lean vs. EOQ
A Lean Flow factory strives to run a
mix of products every day, or every few
days, to meet actual customer demand. This
keeps inventories low, but requires cycling
through the different products or compo-
nents more often than may be normal under
current environments. Setup reduction is a
necessary Lean Flow tool for reducing long
setups that extend leadtimes and increase
batch sizes. Large batch sizes extend lead-
time even more and cause additional excess
inventory and wasted capital investment.
Setup reduction also increases the percent-
age of machine uptime, therefore increasing
the achieved rate of output for each of the
machine processes. This makes the machine
and the operator more efficient.
When designing a Lean Flow factory
with machining processes, the differences
between Lean concepts and the EOQ for-
mula have to be addressed. What a disaster
this old technology has been for Western
economies. Even if you do not use this for-
mula, so many companies think this way at
the operations management, planning, and
production levels that the result is as if the
formula is in use.
The premise of EOQ is to set the pro-
duction quantity to minimize the total cost
of setup and inventory-carrying cost. How-
ever, the inventory-carrying cost is always
understated, the costs of order manage-
ment, setups, and other elements are always
overstated, and the EOQ turns out to be a
ridiculously high production quantity
weeks, months, or years of products pro-
duced in a single batch.
Also, the EOQ does not address the real-
ity that if you cannot supply product to your
customers because the machines are not
being operated to meet customer demand,
then the setup cost per piece is meaning-
less. The greatest potential cause for an in-
crease in setup cost is reduced volume or
sales. Lose sales to the competition because
of long leadtimes and wasted capacity, then
expect to watch setup costs to skyrocket!
The EOQ results in large quantities that
waste machine capacity, making product
that is not required now, and therefore
wastes capital on more inventory and
machines that would not otherwise be re-
quired. As an example: if an EOQ calcu-
lation determines the quantity to be 500
pieces, and the cost of machine setups is
$500, the setup cost per piece is $1. If the
cost of the part is $50, the setup is 2% of
the part cost. If the order quantity is re-
duced by 50% to 250 pieces, the setup cost
in the EOQ jumps to 4%.
This is a false assumption, because the
fixed costs did not increase per product
shipped. Also, it assumes that there are no
reductions to setup times, that TPM did
not improve the operating rates of the ma-
chines, and that there is no benefit to get-
ting products out to customers on time.
To reduce the overall cost of the product,
focus on on-time delivery performance,
and watch sales revenues easily increase by
5-10%. Do this while utilizing the working
capital (cash, inventory and receivables)
better, and leverage the fixed costs across
the increased sales. An incremental, 10%
increase in sales from improved on-time
delivery and reduced leadtimes will make
the product costs drop like a rock.
Lean Flow is different in a machining
environment than in assembly, and defi-
nitely more complex, but it can provide
greater benefits and a higher return on the
investment. The focus for the Lean Flow
implementation team and management
must be to break down the paradigm that
Lean Flow is for assembly operations, and
that machines require a different set of
manufacturing principles. The Lean Flow
tools are the same, some of the applications
change, the complexity is higher, and the
transformation process takes longer but
the benefits are significant.
The question is not whether a machine-
based manufacturer should adopt a Lean
Flow business strategy, implement Lean
machine cells, and drive to eliminate the
waste. The question is: What will happen
to the business, sales, customer satisfaction,
and profitability if you do not implement a
Lean Flow business strategy?
Preston J McCreary is a consultant and partner
with FlowVision, LLC. Contact him at mccreary@
flowvision.com, or tel. 303-886-2852.
and Machines
tools for machining operations I By Preston J. McCreary
Make the entire company
as flexible as possible, to
be able to change from
one customer need to
another. Then, use the
savings and increased
revenues generated
from the Lean Flow
activities to pay for new
technologies that will
improve productivity."
E D I T E D BY C H A R L E S B AT E S I S E N I O R E D I T O R
M A C H I N E T O O L S
T
outed as a new genera-
tion of turn-mill machining
centers, the R200 turn-mill
center cuts complex parts
from tough materials in half the time
required by a conventional type turn-
mill machine, reported Index Corp.
(www.index-usa.com), the R200s
builder. To accomplish this, the com-
pany equipped the R200 with two
powerful motorized milling spindles
and two movable work spindles for
performing machining operations
in two independent subsystems, and
each subsystem is capable of full
five-axis machining of bar stock to
65 mm in diameter.
The R200s innovative axis
arrangement produces directional
kinematics, which, in turn, enable
comprehensive and complete
machining of two parts simultaneously.
Within the machines work area, its
main spindle moves in the Z axis, the
subspindle in the X axis and Z axis, the
milling spindle 1 (top) in X, Y and B
axes, and the milling spindle 2 (bottom)
moves in the Y and B axes.
Because of its design, the R200 does
full reverse-side machining as well as
parallel machining. And operations
include heavy-duty rough machining
and highly accurate fine turning, done
simultaneously on the machines main
spindle and subspindle.
Within the vertical, cast machine
bed of the R200, the two quill-
guided motorized milling spindles are
centered, a diagonal arrangement that
allows Index to omit the usual cross-
slide. The milling spindles deliver 11
kW of power and 18,000 rpm.
The machines B axis swivels in a
range from 270 to 230 degrees. This,
together with a rapid traverse rate
of 45 m per minute, gives the R200
its speed and flexibility. Identically
rated work spindles on the machine
provide 33 kW of maximum power,
5,000-rpm maximum speed and 150
Nm of peak torque.
To reduce chip-to-chip times, two
separate shuttle units independently
load the R200s two motorized
milling spindles with the required
HSK-A40 tools from a common
chain tool magazine. With 80 or
TURN AND MILL PARTS TWICE AS FAST
Indexs C200 turn-mill machine is basically two independent subsystems.
120 places, the machine offers an
extensive stock of tools.
Chip-to-chip times of about 4
seconds contribute significantly to
minimizing secondary processing
times. While machining happens on
the main spindle, the machines lower
milling spindle can be loading a new
tool, and the operation is protected
from falling chips and coolant.
Two linear tool carriers affixed to
the side of each milling spindle allow
for fast, precise access to six stationary
tools without a tool change. Indexs
exclusive W-toothing in the bases of
the toolholders lessens the associated
set-up effort and ensures a force-
locking and form-locking tool fit that
provides conditions for more precise
turning operations as compared to
those of a turret.
A material guide channel feeds
barstock to the R200. This guide
channel is mounted in such a way
as to allow for movement in the
Z-axis direction, and is permanently
connected to the machines main
spindle. Indexs SBL (sliding bar
loader) accommodates barstock
diameters from 20 to 65 mm and
lengths to 3,000 mm, and supports
unmanned machine operations.
An Index C200-4D SL control,
based on the Siemens Sinumerik
S840D Solution Line (www.
automation.siemens.com), provides
the R200 with user-friendly functions.
Specially developed cycles simplify
the most complex machining
operations and support multi-axis
milling and turning operations.
Software packages within Indexs
VirtualLine support economical
use of the machine from the initial
workpiece to the last. These packages
complement each other in terms of
their functions and guide programmers
and operators to the best way to
approach a machining task both on
the PC during the preparation stage
and at the machine on the shop floor.
In conjunction with Indexs
Virtual Machine 3D simulation
software, machining programs are
created, checked, and optimized
on a PC. In addition, CNC
Programming Studio delivers
advanced support for programming
and operation of the R200.
Energy efficiency is built into the
R200. Weight-optimized components
not only increase dynamic response,
but also reduce energy consumption.
Regenerative drives further recover
energy, and units that consume
large amounts of energy can be set
to enter a stand-by mode. Other
energy-saving components/practices
include low-friction bearings,
intelligent cooling of the machine,
and economical use of waste heat, or
climate-neutral heat discharge. <<
Family Shop Thrives on
Families of Parts
Ansco Machine supports its families-of-parts business strategy with a
whole line of different size horizontal machining centers from Makino.
A
shop that focuses on
just one part or one
niche could be in
line for trouble, according
to Mike Sterling, owner
and founder of Ansco
Machine Co. (www.ansco-
machine.com). He said that,
in todays manufacturing
environment, a shop has
to have a large base of
customers, then dig deep
into those customers
product lines and supply
whole families of parts,
as opposed to single items
THE LAST GREAT
AMERICAN CARBIDE
BRAND
THE LAST GREAT
AMERICAN CARBIDE
BRAND
MONSTER TOOL Co. MONSTER TOOL Co.
PHONE: 888-CARBIDE (227-2433)
www.monstertool.com
Boring Bars
Burrs
Countersinks
Drills
Endmills
Reamers
here and there.
As part of its philosophy, Ansco
Machine invests heavily in a wide
range of equipment, from turning
centers to horizontal machining
centers, in a wide range of sizes to
suit nearly any application.
We go into a lot of shops
and see a whole line of machines
dedicated to one part size,
explained Sterling. Thats not our
strategy. We want a machine that
fits the part so we can leave the
other machines open for different-
size work.
He started Ansco Machine
with his sons, Jeff, Jon, and
Dave. His son-in-law Tom Cook
is the finance manager. With 43
employees, Ansco Machine is a
full service contract machine shop
specializing in milling and turning
up to 63-in. diameters to produce
hydraulics, press rings, steel mill
components, and automation/
motion control components. The
shop works in both high-volume
production and small lots, in
materials ranging from carbon
and alloy steels to ductile and gray
irons, plastics and exotics.
According to Cook, the shop
handles a wide range of part
sizes due to its families-of-parts
philosophy/strategy. We need
machines that can handle everything
from the small components to the
largest ones. The parts are often
nearly the same, just scaled up to fit
a larger application, he said.
To provide this service to
customers and fulfill its business
philosophy, Ansco Machine
invested in a whole line of different
size horizontal machining centers.
These included two a51s from
Makino (www.makino.com) that
are capable of handling workpieces
as large as 24.8 in. by 35.4 in., and
a Makino a92 for parts measuring
up to 59 in. by 59 in. This wide
range of machines allows Ansco
Machine to produce the same part
in many different sizes at the
same time and without wasting
workzone space on its machines.
In addition to the two a51s and
the a92, the shop has an a81 and
a82, both from Makino. Such an
array of machines lets the shop
quote and deliver any size part, and
with pallet sizes ranging from 15.7
in. to almost 40 in., and an ability
to accommodate a variety of tools
sizes on the machines, it can easily
match the appropriate machine to
the appropriate job without over
investing in capital equipment.
Plus, the machines provide the
redundancy the shop needs
if production volume should
increase.
We come from a background
of doing larger steel mill work.
Our first priority was to cover the
size range we wanted, which weve
done. Our second goal was to be
redundant in every size so we can
run jobs on any machine. I dont
like to refuse jobs. A machine cant
hold us back from quoting a job,
said Sterling.
In addition to helping Ansco
Machine secure more business,
the Makino machines have
contributed greatly to the shops
consistency and its reduction
in set-up and production times.
Sterling explained that improving
set-up times is critical because
complex parts typically require
complex machines, and he cited
one example, a rotary actuator
housing, where a Makino machine
came into play.
The housing is made from
aluminum, and machining on a
4-axis vertical machining center
took an hour and 20 minutes to
complete the part. On one of its
Makino horizontals, running two
operations on two pallets, the
shop produces the same part in
22 minutes. Sterling said that the
machines speed allows them to
leave the parts in the machine to
process longer, reducing set-ups.
The Makino machines also
deliver consistency for the long
part runs at Ansco Machine. When
building 770 units of a part, which
had 81 features, for one of its
customers, the shop provided the
part with zero defects, thanks to its
skilled machinists and the Makino
machines, said Sterling. <<
L
ike many other countries,
Italys machine tool industry
has experienced significant
drops in machine orders, from both
traditional and emerging markets, for
most of 2009. However, the end of
2009 looks a tad better, with an ever-
so-slight uptick in machine orders
expected. Still, the level of orders
is predicted to remain well below
normal for the start of 2010.
During a recent press conference at
EMO, the European manufacturing
tradeshow held this year in Milan, Dr.
Giancarlo Losma, president of UCIMO,
the Italian Machine Tool, Robots
and Automation Manufacturers
Association, discussed a few actions
that could help to jump start the
machine tool industry. Of those,
he suggested that there has to be a
harmonization of economic actions
between all European Union countries.
On the Italian front, he called for
a government sponsored machine-
scrapping program, the motivation
being that over 20 percent of machine
tools in Italy are more than 20 years
old. This program is actually being
considered by the Italian government.
Yet, through trying economic
times, Italy has a firm hold on its
fourth-in-the-world ranking (after
Germany, Japan and China) in terms
of machine tool production; it ranks
third for export sales, after Japan
and Germany. And, according to Dr.
Losma, the size of Italys machine tool
companies has a great deal to do with
maintaining these standings.
Italys machine tool industry is quite
fragmented, and most of its machine
tool builders are small to medium-
size family-owned companies. Their
average employment total is only 50
people, as compared with, say, large
German builders with average labor
forces of 200 employees.
Being smaller and family owned has
its benefits. Italian builders are agile
and can quickly respond to changing
customer needs. They are also reactive
in terms of research and development
and investing in technology to remain
Italian
competitive on a global level. Going
global is keeping the Italian machine
tool industry strong.
The Italian machine tool market
is changing. Its more global, and
Italian builders are now making
headway into countries such as the
United States, China, Germany and
Russia, commented Ettore Batisti,
president and CEO of machine tool
builder Pama Spa (www.pama.it).
Batisti added that different
markets, countries and sectors
within those countries can have
different machine and part surface
specifications. He mentioned one
market trend that has many Italian
builders cashing in: the surge in large
part machining, especially within the
energy (wind power), oil and gas,
aerospace, and ship building.
Pama specializes in big boring and
milling machines, both table and floor
types. Most are standard machines
but with special components matched
specifically to certain markets and
customers. For example, the companys
Speedram series of machines can be
built with vertical strokes from 6.56 ft.
to as high as 26.25 ft.
For Colgar SpA (www.colgar.it),
another family-owned machine tool
builder, going global and specializing
in large machines has allowed it
to survive in a bad economy. The
company continues to invest in its
product line by developing machines
that will expand its exports business.
We need to keep developing
machines to handle bigger and bigger
parts, which is completely customer-
driven. On the plus side, theres less
competition in building large machine
tools. Theres maybe 10 worldwide,
explained Alberto Vigano of Colgar.
One of Colgars latest machines is
a traveling-column gantry machine
with a 16.40-ft.-cube working
capability and a 5-axis head for
both hard and soft materials. Its a
rigid machine that combines power
for hard materials and speed for the
softer ones. Plus, some of companys
Machine Tools: A Family Affair
Jobs, an Italian machine tool builder, specializes in incorporating linear motor technology into
large-format machine tools (above). Gruppo Riello Sistemi, among other Italian machine tool
builders, believes todays machine tools must be multifunctional and handle both hard and
soft materials (below).
gantry machines can
include a turning table for
both turning and milling
parts on one machine.
Customers try
to concentrate their
investments in one
machine with more
capabilities. They want to
be able to work on every
type of component with
that one machine. The
philosophy of different
machines for different
part types and materials
is no longer in practice,
said Vigano.
Doing more with
fewer machines and
constantly developing
new technologies to meet
customer needs has always
taken top priority at Jobs
SpA (www.jobs.it), an
Italian builder specializing
in big and high-speed
machine tools. In fact, Jobs
reported that it was the first
to incorporate the use of
linear motor technology in
large format machine tools
to generate rapid traverse
speeds up to 2,756 ipm.
Jobs latest innovation
comes as part of its Linx
series of machines. This
newest Linx model,
according to Fernanda
Tesolin of Jobs, is the
first linear motor-driven
machine that can both mill
and turn parts.
The machines work
area is equipped with
a standard fixed table
together with a rotating
one for turning part
diameters up to 13.12
ft. Shops that can mill
and turn on one machine
eliminate the need for two
separate machines.
Breton Spa (www.
breton.it) is another Italian
machine tool builder
offering a machine with
multiple functionality. The
companys new Maxima
not only turns and mills,
but also can grind parts.
Its maximum turning
diameter measures to
11.48 ft, and it handles
part lengths to 26.25 ft.
and longer.
Two other Italian
machine tool builders
meeting customer
demands for large-part
machining are Gruppo
Riello Sistemi (www.
riellosistemi.it) and Pietro
Carnaghi SpA. (www.
pietrocarnaghi.it). From
Gruppo Riello Sistemi
comes the companys
Mandelli brand Spark
2600X with a reversed
T structure and Z-axis
movement on its table
and X-axis movement
on its column. Designed
for cutting both hard and
soft materials, the Spark
2600X accommodates
components measuring
8.53 ft. in diameter.
Pietro Garnaghi
produces very large vertical
turning centers, flexible
manufacturing systems,
vertical grinding machines
and gantry-type milling-
turning machines for
markets that include energy,
jet engine, defense and
aerospace. Turning a part
diameter measuring as much
as 24.61 ft. is not a problem
on some of the companys
vertical turning machines. <<
Italian machine tool builders
such as Pama are surviving by
meeting the needs of large-part
machining.
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T
oyoda Machinery
(www.toyodausa.
com) has made
available a special tool
changer that can maximize
machine tool productivity
and reduce cycle times,
and the company has
introduced its most
economical and smallest
horizontal machining center
for high-speed cutting.
The tool changer is a
four-position changer, or
revolver, within horizontal
machining centers
equipped with Toyodas
Matrix Magazines. This four-
position revolver eliminates
wait time typically
experienced on chain
magazines when a series of
short-cycle time tools are
processed sequentially.
By staging tools in the
revolver for the current part
process, time usually lost
waiting for pocket index
is virtually eliminated. The
companys large-capacity
Matrix Magazines allow
storage for multiple-part
processing and additional
back-up tooling as required
to reduce time-consuming
trips to tool rooms.
In operation, the system
works like this. When the
part program starts, tools in
the magazine are called in
process order and staged
in the revolver, indexing
as needed during the part
process cycle. As soon as
a tool completes its cycle,
it transfers back into the
magazine to its assigned
pocket. Any ready tool
waiting for a place in the
revolver then transfers
to the open pocket in the
revolver.
Toyoda offers its OP
Supporter software that
oversees tool management
and provides a convenient
overview, at the machine
tool CNC screen, of all tools
within the magazine. The
software also monitors
tool time usages and tracks
the tool loading station,
revolver, back up tool and
all stored tools while the
machine keeps running.
Job shops looking
for a small, affordable
high-speed horizontal
machining center may
consider Toyodas FH400J.
Sporting a small footprint,
the machine features a
15,000-rpm spindle for
high-speed machining.
The FH400Js work area
measures 23.6 in. by 22 in.
by 24.8 in. for X, Y and Z
axes, and its table handles
loads up to 880 lb. Other
machine features include a
CAT 40 spindle, GE Fanuc
control, 40-tool magazine,
and 2.4-second chip-to-chip
tool change time. <<
Toyoda Machinerys
revolver style tool changer
and its small-footprint high-
speed FH400J horizontal
machining center.
Tool Charger and Job Shop Horizontal
T
he CT450L from Fritz Studer
AG and the Kronos S 250 from
Schaudt Mikrosa GmbH, available
in North America through United
Grinding Technologies (www.grinding.
com), offer two distinct benefits for
grinding operations. As an entry-level
model machine, the CT450L delivers
low cost per-part production for
general internal grinding applications,
grinding spring collets, or machining
brittle materials. On the other hand, the
Kronos S 250 is flexible and provides
multifunctional capabilities.
Shops can undertake simple grinding
tasks such as bores, surfaces and tapers, as
well as complex contours on the CT450L.
A special machine concept of fixed
grinding spindles and movable workhead
on a generously dimensioned cross-slide
make set ups, part loading and measuring
easy on the machine, which also includes
a linear spindle arrangement and uses one
or two belt spindles with speeds of 28,000
to 60,000 rpm.
The Kronos S 250 performs infeed
and throughfeed grinding using both
conventional and CBN grinding wheels
with a diameter range of 1.5 mm to 35
mm and an infeed width to 245 mm. With
an enlarged maximum allowable wheel
diameter of 400 to 450 mm, the machine
increases wheel life by 30 percent.
Cross-slide units are located on the
grinding wheel and regulating wheel sides,
and combined with dynamic digital drives
and high-precision ballscrew unit, the
machine operates from only four CNC
axes, yet provides the same functionality
and flexibility of a six axis machine.
High-performance grinding wheel
spindles and maintenance-free hybrid
roller bearings on the Kronos S 250
make it possible for the machine to use
CBN wheels at peripheral speeds to 150
m/s. An innovative dressing system for
the grinding and regulating wheels works
by using four CNC axes in the center on
the workpiece level.
For grinding wheel dressing, there are
optional stationary or rotating dressers
available, which can quickly be changed.
The stationary grinding gap allows
for the use of low-cost automation
equipment without any follow-up axis.
Entry Level, Multifunctional and Flexable Grinding
The Kronos S 250
A
s routers become
more accurate and
capable they are
used increasingly
to machine parts that, in the
past, typically were machined
on CNC milling machines.
Routers with large machine
tables and coupled with high-
speed spindles are ideal for
machining thin and small parts
from sheet or plate material.
The challenge has been the
workholding. A vacuum table
is a good way to hold a sheet
in place. However, because of
the insufficient surface area of
the part to render the vacuum-
holding power effective, it does
not allow for small parts to be
cut in one setup.
Keeping the parts attached
to the sheet with tabs is also
common. This requires the extra
steps of removing the tabs to
separate the parts from the sheet
plus handwork to de-burr the
parts. Tab removal often leaves
unacceptable marks on the part
contour. Also, tabs require more
space between the parts so more
material is required. For high-
volume production, such as
aerospace components, this is a
major cost factor.
Sometimes, marginally sized
parts can be held in place by
vacuum and routed in one
step without using tabs if the
feedrate is reduced sufficiently.
Unfortunately this also reduces
the production rate.
Double-sided tape is also
often used to hold small
parts securely in place. The
disadvantages are the difficulty
of removing the often very
fragile parts from the tape
without distorting them, and
the residue from the tapes
adhesive requires a cleaning
step. Adhesive spray is another
option, but this is messy and
residue on the parts also
requires a cleaning step.
A product is now available
in the U.S. that overcomes
many of the difficulties of
holding small, thin and delicate
parts when machining, Gerd
Bode president of Stackmaster
Engineering Corp. (www.
stackmaster.com) said. Vilmill,
available in North America
Holding Small Parts for CNC Routing
E D I T E D BY J I M B E N E S I A S S O C I AT E E D I T O R
T O O L I N G & F I X T U R I N G
Vilmill increases
the holding
power of a
vacuum chuck
or router
vacuum table
and can be used
to load and
unload parts for
machining.
T O O L I N G & W O R K H O L D I N G
exclusively from Stackmaser,
is used as a substrate between
the sheet or plate material to
be machined and a suitable
vacuum table or vacuum
chuck where it is held securely
in place by the vacuum. It
acts as a holding fixture and
can double as a conveyor
belt for automatic loading
and un-loading. With vilmill,
the feedrate of appropriately
powered machines can be
significantly increased over that
possible with other holding
techniques, Bode explained.
Vilmill is only 0.010-in. thick
and has an adhesive coating
on one side. The adhesive is
activated by the heat generated
in the machining process.
Parts are bonded to the vilmill
approximately 0.025 in.
around the periphery and are
held firmly in place during
machining. They can be peeled
off easily when machining is
finished. The adhesive leaves no
detectable residue.
Vilmill is becoming
increasingly popular not only
in the aerospace and electronics
industries and for routing
control panels, but also for
machining name tags and with
users of small routers and
engraving machines, as well
as with jewelry makers, Bode
explained.
For machining metal, a
lean mist is used to keep the
chips from building up on the
router bit. For plastic, only a
soft air blast is used to blow
away the chips. Since the heat
that is generated in the milling
process is needed to activate
the vilmill adhesive, no coolant
can be used. This limits the
use of vilmill to machining
non-ferrous materials, such as
aluminum, brass and plastics.
Vilmill is available in
100-meter rolls in widths of
1.22 m (48 in.), 1.5 m (59 in.)
and 1.8 m (71 in.). The 1.8-m
wide product is available by the
yard. If purchased by the roll,
vilmill costs 50 cents per square
foot. <<
F
airlane Products
Sof-Top Urethane
Grippers, available
from Fixtureworks
(www.fixtureworks.
net), combine secure
workholding with
protection for finished
surfaces, particularly in
assembly, machining,
inspection or repair
operations. The non-
marking, non-staining
Sof-Top grippers feature
a bubbled urethane
surface that provides
a non-slip grip. The
bubbled texture of the
urethane top offers firm
holding and allows air
to escape so no suction
is created between the
contact surface and
the top of the rest pad
as it is compressed.
The urethane surface,
providing abrasion
and wear resistance,
is available in three
durometers
(strength ratings).
Sof-Top grippers are
available in several
sizes and mounting
configurations to
meet a wide array of
application needs.
With the fixed-gripper
configuration, the
urethane surface is
permanently bonded to
a 300 series stainless
steel pad. They are
blind-hole tapped for
backside mounting
and are offered in sizes
ranging from 0.3125
in. to 1 in. (8 mm to 25
mm).
The replaceable
swivel ball
configuration features
a cylindrical body that
makes installation in
tight areas possible. The
replaceable ball swivels
to allow self-alignment
on uneven surfaces.
A Viton O-ring holds
the ball in place while
keeping contaminants
out and providing
smooth ball movement.
The housing is made
from a smooth alloy
steel, heat treated to
Rc 43 to 46 with a black
oxide finish, is tapped
for backside fastening.
The thrust screw
assembly configuration
allows straight-line
static load thrust
without transmitting
torsional or radial force
to the contact area. The
free-floating ball design
allows the thrust screw
to continue to rotate
while the ball remains
stationary against the
contact surface. This
configuration is good
for irregular shaped or
contoured applications.
The housing is made
from alloy steel, heat-
treated to Rc 43 to
46 with a black oxide
finish. <<
Soft-Touch Gripperss
T O O L I N G & F I X T U R I N G
Vibration Damping Shell Mill Holders
S
eco Tools Inc. (www.secotools.
com) has developed its Steadyline
vibration damping shell mill holders
that feature a passive dynamic damping
system offering up to three times the
rigidity of equivalent solid holders,.
The result is greater productivity,
longer tool life, and improved quality.
Vibration becomes a concern as the size
and complexity of components creates
the need to machine difficult-to-reach
areas and deep cavities, resulting in
common use of long-overhang tools
that tend to introduce vibration into
the machining process.
The Steadyline holders are well-
suited for:
Any milling oeiarion virl long
overhangs and predominantly radial
forces.
Naclining o uee molu anu uie
workpieces.
Naclining o comlex
monolithic workpieces, particularly
in aerospace, automotive, and power
generation applications.
The holders are designed with the
vibration absorber positioned at the
front of the bar where the deflection
is the highest. This feature dampens
vibrations as soon as they are
transmitted by the cutting tool to the
bar body and prevents the vibration
from spreading, thus limiting
deflection of the tool at up to five-
times-diameter overhang. This allows
for cutting speeds and depth-of-cut to
be increased up to four times that of a
modular system.
Featuring coolant channels and
made of high-tensile coated steel, the
shell mill holders are dynamically
balanced and ready to use out of the
box. They are available in a wide
range of types and sizes cylindrical
anu raeieu oim, CA1, HSK, Seco-
Capto, DIN and BT. <<
T O O L I N G & W O R K H O L D I N G
Pteuluu Mlcto 0taln 8olld tatblde tot longet
!ool Llte and |ncteased |eeds and 8eeds.
uundteds ot 8lzes ln 8tock.
tustou, Mlnlatute and
Lett uanded !ools /vallable.
!lu and !l/Lu
toated !ools
ln 8tock.
|ace 0toovlng
Lngtavlng !ools
Ptole 8otlng 8ats
88PP/88P! !htead Mllls
Undetcut 0toovlng !ools
UuJ Lxtetnal !htead Mllls
8ack thautet 8otlng 8ats
Mlnl 8otlng 8tattlng at 0.05 ulauetet
/cue and 8tub /cue |ntetnal !hteadlng !ools
! u L t u ! ! l u 0 L u 0 L
LlLNl!lL LUlN0 00L, lNL.
110 W. Lasg treet / |m| Va||eg, Lk 0808S / 800.888.2244 / 80S.S84.0820 |ax] / |nesct-usa.cem / www.sct-usa.cem
N0W kVklLk0LL - NLW LkkL00 kN0 800UL!
M
ac Machine Co. Inc.
(www.macmachine.
com) implemented
multi-pallet horizontal
machining centers over 20 years ago
and quickly discovered the ability
to run them unattended, unheard of
at the time. But more important for
the shop, the new equipment marked
the beginning of its specialization in
short-run, high-mix production, a
practice for which set-up time often
makes or breaks meeting delivery
times and turning a profit.
Among the components produced
by Mac Machine are mechanical
parts used in space suits for the Space
E D I T E D BY C H A R L E S B AT E S I S E N I O R E D I T O R
A U T O M A T I O N
Fast Setups, Short Runs and
Lights-Out Machining
Mac Machine relies on Matsuura machines with multi-pallet systems to
reduce set-up times and cutting cycles for parts such as this aerospace
component machined from a solid aluminum billet.
Shuttle and components for the Joint
Strike Fighter, as well as items for
submarines, missiles, rocket motors
and ejector seats. Other work includes
components for diagnostic medicine
and surgical implants, along with
parts for commercial satellites and
aircraft. All 60 of the shops employees
are keenly aware of the human safety
issues connected with the perfect
functioning of every component
produced there, and they are dedicated
to producing top quality work and
delivering jobs on time.
Prior to switching to multi-pallet
systems, Mac Machine used single-
and twin-spindle vertical machines
that required lengthy set-up times
and were unsuitable for lights-out
operations. Today, the shop has 13
highly automated Matsuura 4-axis
and 5-axis multi-pallet horizontal and
vertical machining centers supplied
by Methods Machine Tools (www.
methodsmachine.com), Matsuuras
North American importer.
The transition to multi-pallet systems
eliminated over 50 percent of the shops
previously required operations by
completely machining a part in just one
cycle. This type of machining has also
increased the shops competitiveness in
all the markets it serves.
Among Mac Machines Matsuura
13 multi-pallet machines is the
MAM72-63V 5-axis machine that
processes large geometrically complex
components within a work envelope
of 24.8 in. by 17.7 in. high, with a
weight capacity of 770 lb. The shop
also uses a MAM72-35V, a smaller
5-axis machine for work measuring to
13.7 in by 9.44 in., and an H.Plus-300
Series horizontal machining center.
Matsuura specializes in stand-alone
multi-pallet systems for processing
complicated workpieces with
unattended handling for as few as two
pallets to as many as 32 pallets. With
32 pallets, Mac Machine can make
up to 32 completely different parts,
one right after another, on one milling
machine.
With the Matsuura machine
configurations, Mac Machine
automates the machining of its
most difficult pieces because of
the machines abilities to virtually
eliminate interference areas. By way
of a fixed spindle and tilting table
configuration, the rigidity of the
tool and toolholder is maximized
when milling awkward or otherwise
impossible workpiece features, even
when machining an irregularly shaped
piece as large as 24.8 in. in diameter.
But according to George McNab,
president of Mac Machine, it is the
ease and flexibility of set-up that give
the shop its edge within its demanding
core competencies. Plus, with 12,000
to 20,000-rpm spindles and advanced
Matsuura servo drive systems, the
MAM72 series machine helps reduce
cycle times by 60 percent.
Mac Machine also depends
on CAMplete TruePath software
furnished with the Matsuuras for
bridging the gap between CAM input
and the machining centers. Instead of
blindly sending the output of a CAM
system through a post-processor to
its 5-axis machines, the shop uses
TruePath to analyze, modify, optimize
and simulate 5-axis toolpaths in a
seamless five-view 3D environment to
avoid problems on the machine.
J
ohn Leonard, Mac Machine
shop foreman, believes that
the CAMplete TruePath
software has played a piv-
otal role in the success of the shops
lights-out machining. Operators can
preview the entire routine, and an-
ticipate and correct potential issues
before any machining even starts,
thus drastically reducing set-up time
and providing an invaluable edge
over the competition.
The combination of Matsuura multi-
pallet systems and CAMplete software
has reduced set-up times by 85 percent
and slashed cycle times up to 70 percent
by reducing the number of operations
required to machine a part at Mac
Machine. Even with these cycle time
savings, the biggest benefit has been
automating short run, high-mix jobs.
Unattended machining has
allowed us to operate second and
third shifts with fewer machinists.
This effectively reduces our labor rate
by 30 percent and makes us more
competitive, said McNab.
With a high number of projects
constantly churning, he believes the
biggest challenge for the shop is to
keep set-up times as short as possible.
And, he said that the shops core
competency is using multi-pallet
machining systems to reduce set-up
times for small production lots,
continuously.
Building on that core competency,
Mac Machine has earned a reputation
for taking on the work most other
shops might decline. While doing so
creates strong customer relationships,
it also has led to a consistent demand
for smaller lots, lower pricing and
zero tolerance for error.
We must anticipate problems in
advance and take corrective action
before the green button is pushed,
said McNab. We have to make good
parts right the first time.
He added that todays products
essentially need to be error-free, and
his shop has a percent parts-per-million
(ppm) rate of less than 1,000, which
means, for example, it might have a
smudged part number on one part
out of 1,000 parts. To maintain this
near-error-free output, Mac Machine
also depends on a climate-controlled
quality lab for compliance with strict
quality control measures.
Besides having capable automated
machining centers, consistently
achieving near perfection requires
highly skilled people. The shop
operates on three shifts running
lights-out 90 hours per week, out of
an available 168 production hours.
Specialized set-up machinists
help meet the needs of lights-out
production at Mac Machine. These
machinists work the first shift to get
new work prepared for the multi-
pallet production line. The second
shift is a much smaller crew consisting
of seven or eight individuals who
monitor the automated systems and
make certain they are in order for the
lights-out third shift.
In addition, Mac Machine relies
on Methods Machine Tools to supply
and support the shops Matsuura
systems. McNab credits the supplier
with providing the equipment,
expertise, programming assistance
and responsive support needed to
make lights-out production work.
A U T O M A T I O N
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0assau|l 3yslers 3o||dwor|s Corporal|or.
S O F T WA R E & C O N T R O L S
A
t EMO Milano 2009, Siemens PLM
Software (www.siemens.com/plm)
and Siemens Drive Technologies aimed to
show that more linkage between product
lifecycle software and production systems/
equipment improves design and makes
machining more productive. Siemens
PLM demonstrated its Virtual Machine
technology: its a machine tool on a PC,
with virtual controller functions and
machine tool simulation, and its expected
to maximize productivity by eliminating
the need to use real machines for non-
production tasks, e.g., prototyping.
CNC turning machine builder INDEX
Group (www.index-werke.de) used Virtual
Machine to improve multi-function
production center set-up, programming,
and validation. Reportedly, it was able to
improve machine tool utilization, eliminate
collisions, and reduce set-up time by up to
90 percent, with no extra training.
The main idea was to install a one-to-
one copy of the machine tool on a PC and
make it available as a tool to the machine
operator, said Eberhard Beck, INDEX
Group head of Electronic Control Systems.
Siemens PLM also showed how
the virtual world of engineering
and design is linked to the real world
of the shop floor, via its NX digital
product-development program. NX 7.0
introduces HD3D, an open and intuitive
visual environment to help global product
development teams unlock the value of
PLM information and make efficient and
effective product decisions.
NX 7.0 has more of the synchronous
capabilities added with the previous
release, benefitting CAD/CAM/CAE
users across the process chain analysts
and manufacturing engineers, and
product designers. With a simplified
interface, individuals who normally work
with 3D models created by someone
else can modify them to their specific
requirements, so they can add value
by focusing on their areas of expertise.
Siemens predicts that the combination
of NX and synchronous technology will
establish a new modeling paradigm
throughout the product lifecycle. <<
Linking Virtual to Real Opens a World of Possibilities
E DI T E D BY R OB E R T B R OOK S I E D I T O R
S O F T W A R E & C O N T R O L S
The 5-Axis Route to Developing New Markets
Tooling manufacturer digs deep into CAM for new capabilities and a competitive edge.
L
ast years economic collapse set
custom-toolmaker E.W. Tooling
Inc., Princeton, Minn., on a
hunt for new business, to expand its
customer base from woodworking
into aerospace and automotive. It has
had some initial successes designing
tooling for aircraft structural
prototypes and a production run of
automotive clutch discs, and E.W.
Tooling president Todd Wallin credits
his employees skills and productivity,
as well as the companys five-axis
metalcutting capability, and 15 years
of experience with polycrystalline
diamond (PCD) tooling.
Most of E.W. Toolings (www.
ewtooling.com) market has shifted
dramatically around it. But, Wallin
is confident the shop will continue to
transfer its focus to contract machining
and tooling for carbon-fiber composites
for aerospace and for interior/exterior
trim in newer vehicles in development
by domestic automakers.
Transferring Advantages
Wallin is convinced that the company
can serve all three customer groups, and
transfer insights and skills from one
sector to another. Tools for composite
materials are similar to woodworking
tools, he says by way of example.
Our new auto customers will benefit
from our toolmaking skills, our cost-
effectiveness in small quantities for
low-initial-rate production, and in fast
turnarounds for prototypes.
E.W. Toolings five-axis machining
capability is centered on a 5-axis
Hermle C600 U trunnion-type
machining center. Guiding production
on that equipment is Edgecam
Advanced Production Milling, Edgecam
Solid Machinist from Planit Solutions
(www.planitsolutions.com), and
Autodesks Inventor for solid modeling.
We could not produce for our
customers without Edgecam and
Inventor, said Wallin. Solid Machinist
and Tool Store keep us competitive
in time and cost. I have been using
Edgecam since 1999, he added. I
regularly take it to its limits, going
beyond what the software developers
intended it to be able to do.
Most E.W. Tooling products have
insertable carbide or brazed-in-place
PCD cutters. The latter were developed
for heavy-duty vinyl for weatherproof
doors and windows: now, the cutters
work on the clutch disks, which are a
composite material impregnated with
graphite and iron powder.
Wallin plans to grow the shops
industrial woodworking business by
changing the way tooling is developed
and delivered. Many customers
complain about other tooling suppliers
poor quality products and late delivery,
so he hopes to win their business by
raising their expectations. And, he
expects Edgecam will help in this with
speedier programming, faster setups,
and more prototypes.
For its core market, kitchen
cabinetmaking, E.W. Tooling makes
tools for tongue-and-groove and
mortise-and-tenon joints, dovetails and
mitred window frames and exterior
doors. Other tooling is for various
decorative pieces, like windowpane
dividers, crown moldings, and hand
railings. All this tooling falls into a
dozen product families, with hundreds
of small variations. In addition to the
five-axis Hermle, the company has
two three-axis milling machines a
Mazak and a Milltronics plus a
two-axis Okuma turning center, a
five-axis Schneeberger cutting tool
grinder, and four wire EDMs.
Building Flexibility
The challenge is to retool E.W.
Tooling for the end of the housing
boom. Given his cost structure, Wallin
is focused on building flexibility with
automation: Edgecam five-axis plays a
central role.
What we are really talking about
here is flexibility, said Wallin. That
determines our ability to prosper in
a difficult economy, not just to get by,
not just to survive. We have to get as
much flexibility into the operations as
possible. We never know when our
search for new opportunities will turn
up something completely unexpected.
We have to be ready to run with it.
He expects that five-axis
programming and machining will
drastically increase our capabilities for
making complex tooling and give our
core customers greater productivity.
Five-axis machining full five or
three plus two creates the ability to
design and machine tooling that is much
more complicated than anything three-
axis methods can achieve.
Part of E.W. Toolings ability to
innovate comes from Solid Machinist,
which moves new tool designs into
Edgecam. We use it all the time,
multiple times a day, because it lets us
access all the CAM functionality from
within Inventor, Wallin said. This
ensures that the Edgecam programmer
always works with the precise geometry
from Inventor and that changes made
in Inventor will be reflected in Edgecam,
thanks to Solid Machinist associativity.
As for productivity, five-axis
machining helps the shop to eliminate
E.W. Toolings expertise is five-axis machining of
complex tooling for cabinet manufacturers. It relies
on Edgecam CAM programming to help it transfer its
capabilities effectively into new market segments.
>> on 46
TO ADVERTISE IN THE USED EQUIPMENT DIRECTORY CONTACT: BOB SCOFIELD AT 973-400-1790 OR BOB.SCOFIELD@PENTON.COM
americanmachinist.com I DECEMBER I AMERICAN MACHINIST I 33
Machinery, Inc.
O-M VC-6NR, CNC Vertical Boring Mill, 31 Swing,
(2) 24 4-Jaw Chucks, Pallet Changer, 1,000RPM,
12ATC, 40HP, Fanuc 21T, 1998, Ref. # 51203
Phone: 516-922-7977 Fax: 516-922-9691
Email: sales@primemach.com
Contact Steve Brenner
MORI SEIKI NL2500/700, New 2004, 10 Chuck,
36 Swing, 28 Turning Length, 4,000RPM,
MSX 850 Control with Mapps, Ref. # 48450
OKK VM5 II, 40X, 20Y, 20Z, CAT 50, 13,000RPM,
20ATC, 40HP, Neomatic 635, New 2000, Ref. # 51087
HURCO TM6, 6"Chk,Tailstock, 9" Swing,
16" CC, Hucro Win Max CNC. Parts Catcher,
Tool Eye. 2006 - Low Hours, Ref. # 52304
4.3 TOSHIBA BTD-11ER16, Tosnuc 777,
1994, 79X, 59Y, 60 ATC, 2,500 RPM, CTS,
Rotary Table, Ref. # 49004
60 WEBSTER & BENNET, Fanuc 0, 64 Swing, 127RPM,
16ATC, 75HP, 60 4-Jaw Chuck, Chip Conv, Ref. # 51301
KITAMURA MYCENTER H400, 24X, 20Y, 20Z,
(2) 15.75 Pallets, Full 4th, 100 Position ATC,
Probe, 10,000 RPM, Fanuc 15MB, Ref. # 52054
RAVENSBURG KH-100 CNC, 70" Faceplate, 79" Swing,
90 HP, 300 RPM, 78" Z -Axis Travel, 57" X-Axis Travel,
Seimens 810T CNC Control, (2 Avail.), Ref. # 50544
HARDIGE CONQUEST T-42, Fanuc 18T,
6 Chuck, 6,000 RPM, Live Milling, Sub Spindle,
Bar Feeder, Parts Catcher, Ref. # 49253
72 WEBSTER BENNET EH, 84 Swing, 48 Under
Rail, Turret, 83 RPM, 72 4-Jaw, 1961, Ref. # 51734
North Cove Plaza, Unit 10 Oyster Bay, NY 11771
Visit us on the web:
www.primemach.com
O-M CNC Vertical Boring Mill, Live Milling, Fanuc 15
CNC Control, C-Axis Table, Scale Feedback, 48"
3-Jaw Chuck, 63" Swing, ATC, Ref. # 50678
CALL FOR MORE DETAILS AND SEE UNDER POWER
TOSHIBA TX-16, 63 Table with 4-Jaws, Turret, DRO,
79 Swing, 59 Height Under Rail, 160 RPM, Ref. # 52186
Just
In!
Call Us
For Details
on Our Many
Machines
For Sale
Visit Our
Website
primemach.com
For More
Machines
USED EQUI PMENT DI RECTORY USED EQUI PMENT DI RECTORY USED EQUI PMENT DI RECTORY
U S E D E Q U I P M E N T D I R E C T O R Y
USED EQUI PMENT DI RECTORY
34 I AMERICAN MACHINIST I DECEMBER I americanmachinist.com
Grinders Clearing House Has Many Remanufactured Machines in Stock
Ready for Immediate Delivery!
18 x 72 Model DE Universal Cylindrical
Remanufactured 2001
Excellent Machine
I NTERNAL GRINDERS
Bryant Heald Parker Majestic
Many Remanufactured in Stock
SURFACE GRINDERS
Horizontal - Rotary
Blanchard Thompson Mattison
G&L Parker Reid Brown &Sharpe
TOOL &CUTTER
Brown & Sharpe K. O. Lee
Cincinnati Makino
Call or Fax for our New 2009
Brochure with color Photos
of Many Different Machines
ALWAYS BUYING (1) ONE MACHINE OR ENTIRE PLANTS!
#220-8 Cincinnati Centerless
Remanufactured 2001
Ready for immedi ate service
10 x 36 Norton CTU Plain Cylindr ical
Remanufactured 2001-Warranty
BEARING GRINDERS
Inner-Outer Races Bore
CENTERLESS GRINDERS
Bryant Cincinnati Koyo
Many Remanufactured in Stock
DISC GRINDERS
Gardner Besley Koyo
CYLINDRICAL
(PLAIN & UNIVERSAL)
ANGLE HEAD
Cincinnati Landis Norton
Parker Brown & Sharpe
Much More!
WORLDS LARGEST STOCKING DEALER OF GRINDERS
Over 1200
Machines in Stock
Call On Our Exchange Program
For All Types of Grinders
Many Other Models of Machinery
Available. Call Our Experienced Staff to
Answer All Your Questions
Visit Our Web Page for Our Up-To-Date Inventory
FROM A SINGLE TOOL TO AN ENTIRE PLANT BOUGHT, SOLD, APPRAISED AND LIQUIDATED
TOOLROOM PRODUCTION GRINDERS
Only 30 Minutes from Detroits Metro Airport or 5 Minutes from City Airport
#171 Heald Si zematic Internal
Remanufactured 2001
18-36 Rotary Surface
Remanufactured 2001
#13 Brown & Sharpe Tool & Cutter
Excellent Tool!
13301 E. Eight Mile Rd., Warren, Michigan 48089-3238 (586) 771-1500 Fax (586)771-5958
www.grindersclearinghouse.com email: gch1@voyager.net
DANILUK REMANUFACTURING
The Daniluk Corporation stocks used Cincinnati Milacron MO Series Cinturn lathes
ready for remanufacture to your specifications. These lathes are available with 15,
18, and 24 chucks and center distances ranging from 60 to 120. Our
remanufacture package includes delivery and installation, operator and
maintenance training, and a full one-year parts and labor warranty.
888-745-6647 sales@daniluk.com
www.daniluk.com
OKLAHOMA CITY OKLAHOMA
Regrinding of Ways
Replacement of Ballscrews
New Automatic Lube System
Replacement of Hydraulic System
New Chip Conveyor
Re-Engineered Axis Drive System
New Controls and Axis Drives
New Spindle Drive
Rebuild of Tool Turrets
Rebuild of Chuck and Chuck Actuator
REMANUFACTURES INCLUDE:
REMANUFACTURED
CINCINNATI
CINTURN
LEASE/PURCHASE
THESE MACHINES
AS LOW AS
$5000
PER MONTH
REX SUPPLY CO.
WORKHOLDING PRODUCTS
CALL TODAY FOR YOUR COPY OF THE
REX SUPPLY CATALOG !
1-800-369-0669
ASK FOR EDDIE LAYTON
WORKHOLDING MANAGER
COMPLETE REPAIR, SERVICE
AND INSTALLATION
SPECIAL APPLICATIONS CAPABILITIES
NEW, USED AND SURPLUS
WORKHOLDING PRODUCTS
(WE BUY SURPLUS !)
WE REPRESENT THE FOLLOWING LINES:
ATS
Collect Chucks
AUTOBLOK
Power Chucks and
Accessories
BERGMANS
Face Plate and
Boring Mill Jaws
BISON
3 & 4 Jaw Manual
Chucks
BUCK
Adjust - Tru Chucks
CUSHMAN INDUSTRIES
DUNHAM TOOL
CO.
Collect Chucks
FAIRLANE
Carbide Grippers
FORKARDT, INC.
Power and Index
Chucks
GAMET
Power Chucks
H&R
Hard & Soft Top Jaws
HEINRICH
Power Vises
HOWA
Power chucks
HURON
Top Jaws
KITAGAWA
Power Chucks
LNS AMERICAN
Bar Feeds and
Accessories
LOGANSPORT
High Speed Power
Chucks
MATSUMOTO (MMK)
Power Chucks
MAXI-GRIP
Power and Special
Design Chucks
MICO-CENTRIC
Precision Chucks
MID-STATE
Tombstones
Angle Plates and
Fixtures
NIKKEN
Rotary Tables
NOBEL
Manual Chucks
Face Plate and
Boring Mill Jaws
POWERHOLD
Power Chucks
PLATT BURNERD
PRODUCTION DYNAMICS
Self-Contained Collet
Chucks
QU-CO
Quick Change Fixture
Plates
RANSOME
REX HAS I T !
ROHM
Power Chucks
(Self Contained &
Manual)
ROYAL PRODUCTS
CNC Collet Chucks
SCA
3 & 4 Jaw Manual
Chucks
SHEFFER
Special Design Chucks
THE SP MFG CORP
Power Chucks
S.M.W.
SYSTEMS, INC.
SPEED GRIP
Rotating Chucks
Stationary Chucks
STACE ALLEN
Chucks
SUPERIOR CINCINNATI
Collets
TROYKE
Rotary and Index
Tables
TSUDAKOMA
CNC Rotary Tables
WALKER
Magnetic Chucks
YUASA
Super Spacers
Rotary and Index
Tables
New Used
Remanufactured
Production
Broaching
Parts Service
Tooling
25180 SEELEY RD.
NOVI, MI 48375-2044
e VV rtical, Surface, (Dual Ram)
6 Ton, 54 Str, U.S. Broach, Tilt Tables
15 Ton, 66 Str, Colonial
15 Ton, 90 Str, Colonial, Tilt Ta TT bles, Exc.
25 Ton, 66 Str, Detroit, Excellent
25 Ton, 90 Str, Detroit, Tilt
25 Ton, 120 Str, Detroit
Ve VV rtical, Surface (Single Ram)
10 Ton, 66 Str, Detroit, Will Tool TT
10 Ton, 78 Str, LaPointe, Tilt Ta TT ble, Exc.
15 Ton, 90 Str, Colonial, Exc.
20 Ton, 100 Str, LaPointe
30 Ton, 90 Str, Colonial, Exc., Will Tool TT
Ve VV rtical, Table-Up TT
6 Ton, 42 Str, Detroit, (2) 1995
10 Ton, 48 Str, American, 1998
15 Ton, 54 Str. BMS Cell-Mate, 1996
Ve VV rtical, Tri- TT Way
6 Ton, 24 Str, American
10 Ton, 36 Str, American, Will Tool TT
15 Ton, 36 American
Grinders, Broach
36 Colonial, Round Grinder
48 Colonial, Flat Grinder
72 Colonial, Combination Grinder
84 Colonial Univ., For Round & Flat Broaches
100 LaPointe, Comb., Round & Flat Sharpening
Ve VV rtical, Hi-Speed
3 Ton, 24 Str, Miles, 1985
6 Ton, 36 Str, Cruiser, Hi-Speed, 90 FPM, New
12 Ton, 48 Str, Miles, 1982
Continuous Chain
36 to 180, 40 in stock
Horizontal
2.5 Ton, 30 Str, LaPointe
7.5 Ton, 60 Str, LaPointe
10 Ton, 54 Str, Oilgear
20 Ton, 100 Str, LaPointe, Will Tool TT
25 Ton, 90 Str, Colonial, W/ Retriever, Late
35 Ton, 100 Str, Detroit W/Power Retriever
60 Ton x 72 American
100 Ton x 120 Colonial
Horizontal, Surface
180 Str, Detroit, tooled for Discs.
180 Colonial, Two Way (2)
180 LaPointe, Tooled for Discs
Ve VV rtical, Pull Down
5 Ton, 30 Str, Detroit # VP-5-30, Will Tool TT (6)
10 Ton, 42 Str, Detroit, Pull Down, In Stock
10 Ton, 54 Str, Colonial, Retriever, Will Tool TT
15 Ton, 72 Str, Colonial
50 Ton, 72 Str, Colonial, SD-50-72
50 Ton, 90 Str, Detroit, Excellent Cond.
60 Ton, 102 Str, U.S. Broach, Oilgear Power
Ve VV rtical, Pull Up
20 Ton, 48 Str, Colonial, Pull-Up, Will Tool TT
Website: www.BroachingMachine.com
Phone: 248-471-4500 Toll-Free: 800-229-4666 Fax: 248-471-0745
Emai l : bms@broachi ngmachi ne. com
See inventories for these dealers
and many more
in this months issue of
Used Equipment Directory
at www.ued-ed.com
Sign up
to receive
U
ED m
onthly
via em
ail!
Vertical, Pull Down
3 Ton x 24 Detroit VP-3-24, 1969
10 Ton x 42 Colonial SD-10-42, 1965
10 Ton x 54 Detroit VP-10-54
15 Ton x 42 Detroit VP-15-42, 1958
15 Ton x 48 Colonial SD-15-48, RB 1993
15 Ton x 54 Broach VP-15-54, 1997
20 Ton x 42 US Broach VP-20-42, 1995
25 Ton x 66 Colonial SD-25-66, 1979
25 Ton x 72 Detroit VP-25-72, 1968
30 Ton x 66 US VP-30-66, 1979
35 Ton x 72 Detroit VPD-35-72, 1981
35 Ton x 78 Federal VPD-35-78, 1995
Vertical, Table, Up
20 Ton x 48 Federal Broach VRT-20-48, 1995
35 Ton x 78 Detroit VTU-35-78, 2002
Vertical, Surface, Single Ram
10 Ton x 36 Colonial UV-10-36, 1978
10 Ton x 54 Detroit VS-10-54, 1956
10 Ton x 66 Detroit VS-10-66, 1973 (2)
15 Ton x 54 Detroit VS-15-54, 1957
15 Ton x 78 Detroit VS-15-78
15 Ton x 110 Detroit VS-15-110, 1965
25 Ton x 90 Detroit VST-25-90, 1964
25 Ton x 100 Detroit VST-25-100
Vertical, Surface, Dual Ram
5 Ton x 54 Detroit VTT-5-54, 1974
10 Ton x 66 Detroit VT-10-66 (3)
10 Ton x 66 U.S. Broach TS-10-66, 65, 1986
10 Ton x 90 Ferderal Broach, VT-10-90, 2000
15 Ton x 42 U.S. Broach TS-15-42, 1978
15 Ton x 54 Detroit VT-15-54, 1965
15 Ton x 66 Detroit VT-15-66, 1977 (5)
15 Ton x 90 Colonial RVT-15-90 (2) RB 1996
25 Ton x 120 Colonial RVT-25-120, 1974
25 Ton x 130 VT-25-130 Detroit New 1984
Pot Broach
25 Ton x 54 Federal DVPU-25-54, 1998
40 Ton x 72 General DPUP-40-72, 1989
MACHINE-R-E-SALES INC.
21020 Coolidge Hwy., Oak Park, MI 48237
Call Ed Egrin 248-541-0733 FAX 248-541-6929
E-Mail: broachnow@sbcglobal.net
Horizontal, Pull
6 Ton x 54 Colonial HAS-6-54
7-1/2 Ton x 48 Detroit Model H-7.5 x 48, 1975
10 Ton x 48 American, 4-10-48
10 Ton x 56 Detroit, H-10-56, 1968
16 Ton x 64 Oilglenn, XL-32-64
20 Ton x 72 LaPointe HP-40 w/Ret, 1969
37 1/2 Ton x 72 LaPointe, HP-75
50 Ton x 72 Detroit H-50-72 Hyd. Ret.
Horizontal, Surface
15 Ton x 120 Colonial HR-15-120
Press Broach
6 Ton x 24 Colonial Pbh-6-24
6 Ton x 36 Colonial PB-6-36
Broach Sharpener
10 x 36 LaPointe BS-36
Triway
4 Ton x 24 American T-4-24
6 Ton x 24 American T-6-24
Chain Broaches
CH-25-144 Detroit, New 1970
CH-35-200 Detroit, 1972
Hi-Speed Broach
3 Ton x 36 Ty-Miles MB-6-36-90, 1974
4 Ton x 24 Ty-Miles (1)
3 Ton x 24 Astro (1)
3 Ton x 24 Ohio (1)
2-5 Ton & 1-8 Ton x 36 Ty-Miles (3)
5 Ton x 36 Ohio VSHD-5-36, 1990 (2)
4-6 Ton & 1-4 Ton x 36 Astro (5)
5 Ton x 48 Ohio (2)
6 Ton x 54 Ohio VSHD-5-36, 1986
8 Ton x 48 TyMiles MBLD 16-48-60, 2003
As one of the largest machine tool remanufacturers in
the U.S., The Daniluk Corporation stocks machines for
sale, as-is, and for remanufacture. We will even
remanufacture a machine from our extensive stock
and exchange it for your machine in order to eliminate
down time and the cost of new foundations and tooling.
DANILUK
888-745-6647 FAX: 405-745-6646
OKLAHOMA CITY www.daniluk.com OKLAHOMA
BLAST CLEANING EQUIPMENT
USED, REBUILT & CUSTOM DESIGN
METALWORKING
MACHINERY
COMPANY
The Blast Cleaning Specialists with 50 Years Experience
700 Constitution Blvd., New Kensington, PA 15068
724/335-1155 FAX 724/335-1621
Web Site: www.blastcleaningequipment.com
E-Mail: mwm.co@verizon.net
TUMBLASTS AND BARRELS
1 Goff 1-1/2 BB
3 Wheelabrator 20x27 Tumblasts
1 Wheelabrator 3 cube rubber belt, low hrs,
new 07, Like New
2 Pangborn 3GNR - rubber belt
1 Pangborn 6GNR rubber
1 Wheelabrator 27x36 Rubber Belt Tumblast
1 Wheelabrator TBR6 rubber belt, new 95
1 Wheelabrator WMT 6 rubber belt, New Belt
New Cond. 03
1 Wheelabrator 36x42 Rubber Belt, Rebuilt
1 Goff 12 cu. ft rubber belt & loader
1 Wheelabrator TBR12, rubber belt
2 Wheelabrator 7 Super, Rebuilt
1 Wheelabrator 14 Super, Rubber Belt
1 Wheelabrator 14 Super, manganese flights
1 Wheelabrator 14 Super II, manganese
flights, rebuilt
1 Wheelabrator 22 Super II, manganese flights,
good cond. (1) rebuilt
1 Wheelabrator 28 Super Tumblast,
mang. flights
1 Wheelabrator 34 Super II, manganese
flights
1 Wheelabrator 34 Super III (2) 60 HP DD whls,
new 96, excell. condition
1 Wheelabrator 50 Super Tumblast-mang. flights
1 Pangborn 12GN, mang. belt
1 Pangborn 15GN4, manganese flights
1 Pangborn 34 GN, manganese flights
1 Pangborn 34GN2 (2) 40 HP DD
wheels, manganese flights
TABLES
3 Wheelabrator #1 Multi-tables, 12 & 18
tables, new 98
2 Wheelabrator #1A Multi-table, 22 & 26 tables
1 Wheelabrator #1A Multi-table w/side mount
whls, new 1988
1 Wheelabrator #2 Multi-table, seven 30 tables
1 Wheelabrator 48 Swing Table, 40 wk. ht.,
rebuilt, new warranty
1 Wheelabrator 96 Swing Table - 64 wk. ht.
10 dia. swing
1 Pangborn 8LK - Rebuilt
SPECIALS
1 Pangborn 12-wh. Vertical Plate & Structural,
mid 90s, cleans up to 11 X 48, excell. cond.
1 Goff 2-Wheel 12 x 44L Carousel Spinner
Hanger
1 Wheelabrator Carousel Spinner Hanger, 24
dia. x 40 L opening
1 Wheelabrator 2-wh. LE-750 Spinner Hanger,
30 dia. x 48 H
1 Wheelabrator/BCP 2-wh. 30 HP Spinner
Hanger, 48 dia. X 72 H
1 Guysom 2-Wh 15HP Downblast Belt
Conveyor
1 Wheelabrator 2-wheel Downblast Belt
Conveyor, 15HP, 18H x 26W, New 2000
1 Pangborn 8-wh. DD Wh. pass-thru Roll
Conveyor Beam Cleaner, passes 6H x 3W,
mint. cond.
1 Pangborn 4-wh Pass-thru 24H x 36 W
opening, (4) 15 HP DD whls, new cond.
Save UP to 55%
New Machine
Warranty
N
AT R ION
INDUCTION
MELTING and HEATING
Since 1979
EQUIPMENT
G
800) 828 97 88 88 88 88 88 8 800) 828 9799 99 999 800) 828-9799 2 800) 828 2222 99 99 99 228-9799 8828-979 88 88 0000 88 88 88 00 0 (80 ) 828-9799 ) 828-9799 (800) (800 (800) 828- 8 99 00 88 99 8822 99 ( 0) 0) (( 828-9799 828-9799 (800 (800 (800) 828-9799 CALL with your equipment requirements!
www.inductiontech.com
WE BUY USED INDUCTION MELTING AND HEATING EQUIPMEN A T
9 9 2 4 Ra n c h o Rd , Ad e l a n t o CA 9 2 3 0 1
Above can be supplied with furnaces, heating coils and water systems
as needed to suit specic requirements.
E MANUFACTURE FF , REPAIR PP , AND REBUILD INDUCTION POWER
SUPPLIES, INDUCTION FURNACES, HEATING A COILS, W TER A COOLED
POWER CABLES AND W TER A COOLING AND RE-CIRCULATING A SYSTEMS.
WE SERVICE R WHAT A WE SELL.
POWER SUPPLIES
Inductotherm Box Furnaces up to 4000 lb. Capacity
FURNACES
Steel Shell Furnaces from 2000 lb. to 6 Ton TT
Inductotherm 75Kw, 3KHz VIP Power P Trak TT
Inductotherm 125Kw & 175Kw, 3KHz VIP Power P Trak TT
Inductotherm 75Kw, 9.6KHz VIP Power P Trak TT
AND MUCH MORE!
SALE/RENT
wabash
444 Carpenter Avenue, Wheeling, IL 60090
POWER
EQUIPMENT CO
BOILERS & DIESEL GENERATORS
Immediate Delivery-On Call
24 Hours 800-704-2002
Package Boilers
10 HP to
300,000 #/HR
Mobile Boilers
300 HP to 75,000 #/HR
Diesel Generators
50 KW to 2750 KW
WE ALSO STOCK A LARGE SELECTION OF:
ECONOMIZERS DEAERATORS WATER TREATMENT &
FEED SYSTEMS PUMP MOTORS TURBINES FUEL
HANDLING SYSTEMS INSTRUMENTS & CONTROLS
VALVES COMPRESSORS PULVERIZERS DIESEL &
TURBINE GENERATORS RENTAL MOBILE BOILERS &
DIESEL GENERATING PLANTS
TEL: 847-541-5600 FAX: 847-541-1279
E-mail: info@wabashpower.com WEB SITE: www.wabashpower.com
Centerless Grinder Repair
Complete line of parts and machines in stock
Dressers, feed wheel heads & spindlers available on an
exchange basis
Assist in designing or retooling our machine or one of ours
Provide in-plant operating instructions
Train inexperienced help to set up/grind
Purchase leases available
Ask for Bill Magee or Jason Magee
Email: elise.cgr@gmail.com
www.CenterlessGrinderRpr.com
28300 Groesbeck Hwy. Roseville, Michigan 48066
Phone: (586) 774-4660 Fax: (586) 774-3051
We Buy, Sell, Trade & Completely Rebuild
Cincinnati Centerless Grinders (No. 2, No. 3 & 200-300 Series)
Repairmen on Call 24 Hours a Day
50 Grinders Under Power in Plant
LUCAS MACHINERY COMPANY, INC.
J.
L.
Mailing address: P.O. Box 4220
Waterbury, CT 06704-4220 429 Brookside Rd. Waterbury, CT 06708
Tel: (203) 597-1300 - Fax: (203) 597-8268
WHEN THE SPECIALISTS LET YOU DOWN-
COME SEE THE DISC GRINDING EXPERTS
MDNA
For All Your Disc Grinding Applications:
Double or Single Horizontal or Vertical
GARDNER BESLY LUCAS/GARDNER
Large Inventory - 12 Dia and Up
Thru Feed - Rotary - Gunfeed - Special Fixturing Available
And For All Your Disc Grinder Parts:
LUCAS DISC GRINDER PARTS & SALES CO., LLC
P.O. Box 4219 Waterbury, CT 06704-4219
Tel: (203) 753-DISC (3472) - Fax: (203) 591-9043
BESLY & GARDNER PARTS
Disc Grinder Replacement Parts
Thrufeed, Rotary & Gunfeed Attachments
Rebuilt Spindle Assembly Exchange Program
Large Inventory - All Components Available - Seals to Spindles
Visit us on the web
http://www.jllucas.com - email info@jllucas.com
W
NDUCTIO
R
ECHNOLOGY
ORPOR
Why should I buy Used Equipment?
Where can I find Used Equipment?
Used equipment is often less expensive
Used equipment is usually available immediately
The best dealers list their available equipment
in Used Equipment Directory, the
leader in the field since 1949. Browse dealer
inventories in this months issue at:
www.ued-ed.com
Sign up to receive UED monthly via email!
As one of the largest machine tool remanufacturers in
the U.S., The Daniluk Corporation stocks machines for
sale, as-is, and for remanufacture. We will even
remanufacture a machine from our extensive stock
and exchange it for your machine in order to eliminate
down time and the cost of new foundations and tooling.
DANILUK
888-745-6647 FAX: 405-745-6646
OKLAHOMA CITY www.daniluk.com OKLAHOMA
WALK IN OVENS
Partial Listing of Available Equipment
Walk In Ovens
30W 42L 72H NEW ENGLAND 650F
36 36 47 ACE 230-RKG BURN OFF
36 36 75 NEW ENGLAND 650F
36 72 72 LYDON 200F
38 38 63 DESPATCH 500F
39 66 96 GRIEVE 200F
42 36 48 BAYCO BB42 BURN OFF
48 48 72 JPW 500F
48 48 72 PRECISION QUINCY 1000F
48 72 72 JENSEN 750F
60 70 96 LANLY 450F
60 72 72 STEELMAN BURN OFF
60 120 72 STEELMAN 450F
72 72 96 BINKS (WISCONSIN) 500F
72 72 104 POLL. CONTROL BURN OFF
72 120 84 BINKS (WISCONSIN) 500F
72 180 72 GRIEVE 450F
78 124 80 DESPATCH 850F
7 7 7 POLL. CONTROL BURN OFF
7 14 10 EJ CALLAHAN 500F
8 10 9 ACE BURN OFF
8 42 7 WISCONSIN 400F
10 20 9 EJ CALLAHAN 500F
11 13 8 GEHNRICH 500F
BELT AND CABI NET OVENS ALSO I N STOCK
Call Us With Your Needs
FURNACE BROKERS I NC.
40 Industrial Park Rd. East Tolland, CT 06084
(860) 875-3712 Fax (860) 875-1393
WWW. FURNACEBROKERS. COM
847.541.8300 / 800.446.3325
info@indeck-power.com
www.indeck.com
Call to inquire on our extensive line of Industrial Power Plant Equipment available!
RENT
LEASE
SELL
BOILERS GENERATORS CHILLERS
Mobile Boilers
(10HP - 250,000PPH)
Rental Diesel Generators
(125KW - 2200KW)
Chillers
(Water Cooled: 75-1000 tons
Air Cooled: 75-400 tons)
Boilers (various sizes & styles)
Boiler Parts & Accessories
Burner Management Systems
Chillers
Combustion Control Systems
Construction Services
Deaerators
Design & Build
Diesel Generators
Economizers
Engineering
Fuel Systems
Pumps
Water Treatment Systems
FAST!
NEW & USED UNITS AVAILABLE
All major credit cards accepted
Flexible leasing plans available
IN STOCK - READY TO SHIP
5 YEAR COMPRESSOR WARRANTY
NEW PORTABLES - AIR COOLED
(FOB Houston, Texas)
NEW STATIONARY / CENTRAL
(Includes shipping)
2-TON . . . . . . . . .$5,805
3-TON . . . . . . . . .$6,925
5-TON . . . . . . . . .$7,540
7.5-TON. . . . . . .$10,135
10-TON . . . . . . .$12,019
15-TON . . . . . . .$19,233
Other Sizes Available
15-TON . . . . . . . $15,801.00
18-TON . . . . . . . $17,056.00
22-TON . . . . . . . $20,491.00
30-TON . . . . . . . $22,677.00
40-TON . . . . . . . $27,693.00
50-TON . . . . . . . $31,960.00
60-TON . . . . . . . $37,940.00
80-TON . . . . . . . $46,393.00
100-TON . . . . . . $55,296.00
Other Sizes Available
COLD SHOT CHILLERS
800-473-9178 281-227-8400
FAX: 281-227-8404
Website: waterchillers.com
Email: mmarrone@waterchillers.com
http://www.highlandmachinery.com
Highland Machinery & Crane
1170 Cornerstone Place Benton Harbor MI 49022
Ph: 877-921-9600 F: 269-926-9601
E-mail: sales@highlandmachinery.com
WANTED: Used Bridge
& Overhead Cranes
Highland Machinery & Crane
is looking to buy all types
and sizes of bridge cranes:
1 - 100 Tons 0 - 120 Span
Crane Only or Full System
We buy and remove NATIONWIDE!
For Complete Specifications and Pricing
Visit Our Web Site:
http://www.whkay.com
e-mail: sales@whkay.com
30925 Aurora Rd. Cleveland, OH 44139
Phone: 440-519-3800 Fax: 440-519-1455
The W. H. Kay Company
Since 1936
The Elder Statesman of
Used Ovens & Heat Treating Furnaces
Over 150 in Stock
Ready for Inspection & Delivery
We Buy/Sell/Trade Furnaces, such as:
Walk-In Ovens Box Pit Type Belt Atmosphere Generators
Box Type Draw Internal Quench Vacuum Combustion Air Blowers
GENSETS & POWER PLANTS
INTERNATIONAL AA SALES
Michael.Turwitt@RingPower.com
904.494.1058
Lyndon.Schultz@RingPowe LL r.com
904.494.1278
NORTH AMERICAN & CARIBBEAN SALES
Contact us for a complete listing of available
generators, power systems and engines.
E G U H
Y R O T N E V N I
LOW-HOUR USED
COMPLETE REBUILDS
IMMEDIATE DELIVERY
Y
We purchase surplus and used gensets and engines, too!
w w w . r i n g p o w e r - s y s t e m s . c o m g y
GENERATORS SAL E/ RENT
wabash
444 Carpenter Avenue, Wheeling, IL 60090
POWER
EQUIPMENT CO
IMMEDIATE SHIPMENT
90kw - 2,865kw
SKID or ENCLOSED
125kw - 2,200kw
TRAILER MOUNTED
www.wabashpower.com
AVAILABLE VOLTAGES:
120/208/1/60, 240/480/2400/4160/(11.5/13.8KV)
FEATURES:
LOW EMISSIONS AUTOMATIC PARALLELING AND SYNCHRONIZATION
SOUND ATTENUATED TRAILER UTILITY GRADE
CALL: TOLL FREE 1- 800- 704- 2002
PHONE 1-847-541-5600 FAX 1-847-541-1279 info@wabashpower.com
SEE OUR WEBSITE FOR ADDITIONAL IN-STOCK EQUIPMENT LISTINGS
Disc Grinder Headquarters
C & B Giustina Besly Gardner Mattison Blanchard
Vertical - Horizontal, Single - Double
Thrufeed, Rotary, Swing Arm, Special Fixtures
Spindle - Rebuilt or Exchange
Replacement Parts & Service
OEM - Rebuild / Remanufacture Service
Retool - Control Retrofits
21css Field Conversion for Beslys (see web for full description)
C & B Machinery Co.
12001 Globe, Livonia MI 48150
www.cbmachinery.com see our complete inventory
Call (734) 462-0600 or Fax (734) 462-0604
Email: main@cbmachinery.com
TRANSFORMERS
NEW SURPLUS RENEWED & GURANTEED
ALL TYPES - ALL SIZES - ALL VOLTAGES
Buck & Boost - Isolation - Drive Isolation K Factor-etc.
Bruce Electric can ship immediately from its stock of tens
of thousands of transformers from .250 to 2500 KVA,
all voltage combinations.
Generators Circuit Breakers Switches
Rectifiers Fuses Power Line Conditioners Etc...
Call, Write or Fax For Our Low Prices!!!
BRUCE ELECTRIC EQUIPMENT CORP.
131 AKRON ST. P.O. BOX 558 LINDENHURST, NY 11757
Toll Free: 800-262-2204
631-226-2424
FAX 631-226-8772
E-Mail: bee@brucelectric.com
www.brucelectric.com
CHILLERS
Water Cooled: (75 - 1000 Tons) Air Cooled: (75 - 400 Tons)
Call to ask about our extensive line of Industrial Power Plant Equipment Available!
ph: 847.541.8300 / 800.446.3325
fax: 847.541.9984 email: info@indeck-power.com www.indeck.com
NATIONAL
MACHINERY
EXCHANGE, INC.
If its machinery, we have it
sm
158 PARIS STREET NEWARK NJ 07105
TELEPHONE: 973-344-6100
FAX: 973-589-0944
WEBSITE: WWW.NATIONALMACHY.COM
E-MAIL: SALES@NATIONALMACHY.COM
LARGE SELECTION
OF PRESSES
OBI / GAP / SS / HYD
FORGING / KJ
EXTRUSION
EYELET-TRANSFER
TRY-OUT
COIL PROCESSING
EQUIPMENT
SLITTING LINES / C-T-L
ROLL FORMERS
STRAIGHTENERS
LEVELLERS
UNCOILERS
TUBE & PIPE MILLS
MACHINERY
MILLS / END FINISHERS
STRAIGHTENERS
CUT-OFFS
DEBURRERS
BENDERS
Steel Processing Systems & Equipment
We carry a complete inventory of new and remanufactured Cut-To-Length
Lines Slitting Lines Terminal Lines Plate Lines Pay-Off Reels Press
Feed Lines. We build and remanufacture to your specifications with new
electricals and hydraulics. We maintain the flexibility to provide machinery
tailored to maximize the profits of each production situation. Over 45 years
of Quality, Service and Value.
3171 N. Republic Blvd.
Toledo, Ohio 43615-1515
Phone (419) 843-7262
Fax (419) 843-7229
www.cauffiel.com
Looking for Used Equipment?
See it all at www.usedequip.com
Choose from over 2700 lathes, 1500 machining
centers, or 1800 grinders. Need punching/
shearing equipment? We have over 1100 listed.
With over 33,000 metalworking listings alone,
UEN is the place to go for used equipment!
Were not just metalworking either: we have
over 9,000 pieces of electrical equipment, too,
as well as construction, ships, airplanes, and
more! New listings added daily, and most have
pictures and detailed specifications!
ALL PARTS, INC.
Specializing in Quality
COMPRESSORS & PARTS
BUY / SELL NEW & USED COMPRESSORS
P.O. Box 4025 Wheaton, IL 60189
630-653-5678 Fax 630-653-5680
E-Mail: CompressorsAir@aol.com
Worlds Largest Stock of
Balancing Equipment
Specializing in:
Schenck Hofmann IRD CEMB
Used & Rebuilt, Parts & Service for All Makes
E-T BALANCING INC.
12823 Athens Way, Los Angeles, CA 90061
Tel: 310-538-9738 Fax: 310-538-8273
E-Mail: etbalance@earthlink.net
GENERATORS
125KW - 2200KW *IN STOCK!*
ph: 847.541.8300 / 800.446.3325
BULLARD V.T.L. SPECIALISTS
REPLACEMENT PARTS & TOOLING FOR ALL
TYPES OF BULLARD V.T.L.S
REBUILDING & RETROFITTING
Compl ete Assembl i es i n Stock
OVER 100 BULLARD V.T.L.S IN STOCK
OCONNELL MACHINERY COMPANY, INC.
175 GREAT ARROW AVE BUFFALO, NEW YORK 14207
(716) 877-3666 FAX (716) 877-1136
www.oconnellmachinery.com
e-mail: sales@oconnellmachinery.com
OPTI CAL COMPARATORS
Specializing in Used & Reconditioned Jones & Lamson Optical Comparators
OPTICAL GAGING PRODUCTS (OGP) Top Bench 14; 20X; 8 x 6 Tvls;
Computational DRO- 1999
OGP Avant AV400 Smartscope Video Measuring Machine; 18 x 18 x 8 Tvls;
3-Axis Joystick; Computer & Software-Updated 2002
SCHERR-TUMICO Mdl. 22-2500; 30; 12 x 9 Power Tvls; Surf. Illum; 10X, 20X,
450X Lens; S/T DRO- 1981
STARRETT Model HCS800; 31.5; CNC; 20 x 10 Power Tvls; Surf. Illum; Quadra
Chek 4205 Controls w/ Edge Detect- 1997
PIEDMONT MACHINERY of Charlotte Inc.
2218 N. Brevard St. P.O. Box 4264 Charlotte, NC 28299
(704) 334-4609 Fax (704) 375-3874
www.piedmontmachinery.com E-Mail: machines@piedmontmachinery.com
Cold Rolling Mill Equipment & Systems
Phone (419) 843-7262
Fax (419) 843-7229
www.cauffiel.com
New, Used & Remanufactured
Over 100 machines to choose from.
We sell what you want
2-High, 4-High, Z-Mill & Sendzimir
We own and operate a cold rolling plant.
MACHINES TOOLING
RIGGING
BUY SELL TRADE
800-535-8331
SPECIALISTS IN BARBER-COLMAN MACHINE TOOLS
Repair Parts, Inc.
Contact: Terry McDonald
2415 Kishwaukee St., Rockford, IL 61104
PHONE: 815-968-4499 FAX: 815-968-4694
Service Training Reconditioning Sales
Factory Trained Personnel
We Also Will Buy Your Surplus B-C Equipment
www.repair-parts-inc.com e-mail: rpi@repair-parts-inc.com
HI-HEAT CO. INC.
32 GLENDALE RD., SOUTH WINDSOR, CT 06074
INDUSTRIAL OVENS - HEAT TREATING FURNACES
Walk-in Ovens - Cabinet Ovens - Box Furnaces - Vacuum Furnaces, Etc.
Please visit our website: www.hi-heat.com
CALL: 860-528-9315 FAX: 860-528-0421 EMAIL: sales@hi-heat.com
Visit our warehouse to inspect our large inventory
SPECIAL BUY!
DC MOTORS
AT DEEP, DEEP DISCOUNTS
DUTCH ELECTRIC CORP
TEL 610-582-2870 FAX 610-582-6942
EMAIL: DLINEDRIVE@AOL.COM
BUY A BARGAIN WHILE THEY LAST!
13855 W. Polo Trail Dr. Ph: 847/918-9797
Lake Forest, IL 60045 Fax: 847/918-9733
VICTORY
MACHINERY
EXCHANGE, INC.
WE BUY, SELL & APPRAISE USED MACHINERY
I f y o u d o n t c a l l u s w e b o t h l o s e mo n e y .
WE REBUILD FOUR SLIDES
Your Supermarket For Spring &
Wire Forming Machinery
sales@victorymachinery.com
FOUR SLIDES IN STOCK
Nilson - #S-00, S-2, S-3, S-4, S-0F,
S-1F, S-2F, S-3F, S-320, S-436, 752
Baird - #00, #1, #2, #3, #5,
#104, #28, #33, #35, RW1, 3-24, 4-30
TORIN - V81, V82 Vert. Slide
S-5 Nilson
8Z0 Baird
NEW US INDUSTRIAL SHEARS
10 X 1/4 10 X 3/8 12 X 1/4 IN STOCK !
NEW EQUI PMENT
UNBELIEVABLE PRICE
Call Before You Buy Used
Machinery Sales Company
P.O. Box 2098 Memphis, TN 38101
Phone: 901-527-8671 Fax: 901-526-2339
NATIONAL
MACHINERY
EXCHANGE, INC.
sm
TELEPHONE: 973-344-6100
FAX: 973-589-0944
60 x .135 x 55,000# BRANER TURRET HEAD SLITTING LINE
New 1990
IN PLANT, available for inspection
Contact us for technical specifications and/or quote
USED & NEW
FURNACES
& OVENS
1-336-784-4800 Fax: 336-784-0634 E-Mail: sales@thermcraftinc.com
P.O. Box 12037 3950 Overdale Rd. Winston-Salem, NC 27117-2037
SEE COMPLETE LISTING OF EQUIPMENT ON OUR WEBSITE AT:
www.thermcraftinc.com
New: Live E-bay Auctions
Direct Link on home page
See Website for Pictures!
All used equipment sold with 30 day warranty
http://www.highlandmachinery.com
HIGHLAND MACHINERY & CRANE
1170 Cornerstone Place, Benton Harbor, MI 49022
e: sales@highlandmachinery.com ph: 877.921.9600 fax: 269.926.9601
Large Selection of Cranes Available!!! All Taken Down!
40/10T x773 DESHAZO, 1999, 27' Lift, VFD Bridge/Trly, 300'(x2) Rail/Run
25/25T x 71 KONE, 2001, Dual Trlys, VFD Br/Tr, 320(x2) Rail/Run/Cols
20T x 26 STAHL, 2004, 26 Lift, VFD Br/Tr, 520(x2) Rail/Run, 2 AVAIL
18T x 43 KONE, 2001, 33' Lift, 2 Spd All, 180(x2) Rail/Run, 2 AVAIL.
15T x 71 KONE, 2001, VFD Bridge/Trly, Radio, 250 Rail/Run/Cols
10T x 44 STAHL, 1999, 20 Lift, 108(x2) Rail/Run/Cols
2T - 5T x 38 KONE, 90s, 20 Lift, 1200(x2) Rail/Run, 5 AVAIL
PETER FLESCH, INC.
146 MEADOW STREET
GARDEN CITY, NEW YORK 11530-6600
TEL (516) 741-7835
FAX (516) 747-1272
PETERFLESCH@MSN.COM
*22'XVHG0DFKLQH7RROV
S & G S & G
PRESS & MACHINERY SALES
P.O. Box 537, Fraser, MI 48026
800 Ton Verson S4-800-168-84, 20 Str., 48 SH., 15-40 VSPM, 58 Windows, Rolling Bolster, 1995
300 Ton Minster E2-300-72-42, 3 Str., 28 SH., 0-200 VSPM, Windows, FIR-STD (2)
250 Ton Komutsu Gap, OBW-250-2, 11.8 Str., 21.6 SH., 20-40VSPM, 1987
200 Ton Minster P2-200-72, 6 Str., 24 SH., 45-90 RSPM, 23 Windows, FIR-STD
Phone: (586) 563-5000 Fax: (586) 563-5005
e-mail: info@sandgpress.com http://www.sandgpress.com
GIBSON Parts & Equipment, Inc.
New & Used
Abrasive Blast Equipment
Tables, Tumblers, Spinner Hangers
Toll Free 888-867-1619
Fax (317) 758-6775 www.Gibson-Parts.com
E-mail: sales@Gibson-Parts.com
WWW.GIBBSMACHINERY.COM
21500 Hoover Rd. Warren MI (Detroit Suburb)
Phone: 586-755-5353 Fax: 586-755-0304
18x96 Lees Bradner Spline Hobber
16-36 Barber Colman C Frame Collet - 1947-1978 (4)
Liebherr L301 & L252 Crowning - 1973 & 1979
PE 200 & 150 Pfauter CNC 15M Fanuc (3)
175HC Gleason CNC Spiral-Gear Generator, 1994
10-4 & 10-2 Fellows CNC Shapers Factory Rebuilt - 1997
USED ---- BLAST EQUIPMENT ---- REBUILT
BUY WHEELABRATOR + PANGBORN + GOFF + BCP SELL
SHOTBLAST AMERICA
412 BAYBERRY DR., CHAPEL HILL NC 27517
PHONE: 919-928-0071 FAX: 919-928-0179
web site: www.shotblastamerica.com
email: ptrainor@nc.rr.com
PARK THERMAL (1996)
INTERNATIONAL CORPORATION
New / Reconditioned Ovens
Furnaces - Quenching OIls -
Heat Treating Salts -
Comonent Parts -- Stainless
Steel Foil -- Refractory Products
62 Todd Road
Georgetown ON L7G 4R7
Tel: (905) 877-5254
Fax: (905) 877-6205
Toll Free: (877) 843-HEAT (4328)
Web Site: www.parkthermal.com
E-Mail: info@parkthermal.com
WARNER & SWASEY AC, AB & SC
4661 Jaycox Rd. Avon, OH 44011
440-937-6241 www.pmr4ws.com
INC.
Remanufacture Electrical Retrofit
Parts Tooling Service
Used Machines
RIVETERS
THINK AARONS
The Nations No. 1 Source for Rebuilt - Retooled Riveters
CHICAGO MILFORD NATIONAL TRS ORBITALS
ADTECH TOMKINS-JOHNSON J.L. THOMAS
AARONS MACHINERY CORP.
170 N. Halsted St,. Chicago, IL 60661
312-421-2334 FAX 312-421-7035
CNC Swiss, Turning & Machining Centers
Ci t i zen St ar Tsugami Tor nos Nomur a
Hanwha Gi l demei st er NexTur n KSI Mai er
Bar f eeds ( New & Used) CNC Tur ni ng & Machi ni ng Cent er s
800-543-7666 Fax: 303-651-6556
www.automatics.com
steve@automatics.com sue@automatics.com
NATIONAL
MACHINERY
EXCHANGE, INC.
sm
TELEPHONE: 973-344-6100
FAX: 973-589-0944
Recently purchased:
36 X .250 X 30,000# LOOPCO SLITTING LINE
16 X 18 X 16 UNITED 4-HI, 1 WAY COLD MILL
60 X .195 X 50,000# CINCINNATI SLITTING LINE
Contact us for technical specifications and/or quote
Steel Processing Systems & Equipment
We carry a complete inventory of new and remanufactured Cut-To-Length
Lines Slitting Lines Terminal Lines Plate Lines Pay-Off Reels Press
Feed Lines. We build and remanufacture to your specifications with new
electricals and hydraulics. We maintain the flexibility to provide machinery
tailored to maximize the profits of each production situation. Over 45 years
of Quality, Service and Value.
Phone (419) 843-7262
Fax (419) 843-7229
www.cauffiel.com
TRANSFORMERS
MANY SIZES IN STOCK!
ph: 847.541.8300 / 800.446.3325
REBUILT 3-PHASE RESISTANCE WELDERS
FORT LAUDERDALE, FLORIDA
800-331-2805
phone: 954-581-1418 fax: 954-792-7766

FOR INVENTORY LISTINGS & PICTURES GO TO:
www.alphatronindustries.com
PRESS USERS
BOLSTER PLATES -- PARALLELS -- RISERS
Hundreds to choose from, many Bolsters are T-slotted and Drilled
J.I.C., also Bull Rings and Riser Plates
Huge inventory, standard 9 wide, up to
36 high and 96 long
T-Slotted Floor Plates, Surface Plates, Cast Iron and Granite,
Angle Plates, Fixture Plates, Machine Base Plates
Bolster
Plates
Risers and
Parallels
Also
Call us for a complete list of current inventory
We Buy, Sell and Appraise Stamping Plant Machinery
HARON
METALS & EQUIPMENT CO.
3901 Christoper
(313) 923-4241
Hamtramck, MI 48211
FAX (313) 923-4287
Appraiser on Staff
10,000 HP INDUCTION MOTOR. 715 RPM,
13,200 VOLTS WPII ENCLOSURE.
ROLLER BEARINGS, TOP MOUNTED
COOLER. SEND FOR PIX AND DETAILS !!
DUTCH ELECTRIC CORP
TEL 610-582-2870 FAX 610-582-6942
EMAIL: DLINEDRIVE@AOL.COM
T. J. SNOW CO., INC.
6207 Jim Snow Way, POB 22847, Chattanooga, TN 37421
1-800-NOW SNOW ( 24 hours 800-669-7669 )
PH: (423) 894-6234 FX: (423) 892-3889
Home Page: www.tjsnow.com
Email: welders@tjsnow.com
Resistance Welding Equipment & Supplies
Snow SlimLine Welders Snow Heavy Duty Spot &
Projection Welders New, Used, Rebuilt, Special Design Welders
Robots & Automatic Arc Welders Service, Consulting & Seminars
13855 W. Polo Trail Dr. Ph: 847/918-9797
Lake Forest, IL 60045 Fax: 847/918-9733
VICTORY
MACHINERY
EXCHANGE, INC.
WE BUY, SELL & APPRAISE USED MACHINERY
If you dont call us we both lose money.
WE REBUILD SPRING COILERS
Your Supermarket For Spring &
Wire Forming Machinery
sales@victorymachinery.com
TORIN SPRING COILERS
IN STOCK
W100A, W10A, W11, W11A, W115A
W12, W12A, W125, W125A,
W125S, W125SA, W13, W13A
W22, W225, W23, W24
100 CNC, 115 CNC, 775 Ring Coiler
Weld Plus Inc. Welding Machinery
Call for our Brochure!
800-288-9414 513-941-4411
www.weldplus.com
sales@weldplus.com
Sell Recondition Rental Repair
welding positioners, weld manipulators, turning rolls, tank rotators
turntables, headstocks, tailstocks, welding lathes, seamwelders,
used orbital welders, machines and equipment
See inventories for these dealers
and many more
in this months issue of
Used Equipment Directory
at www.ued-ed.com
Sign up
to receive
U
ED m
onthly
via em
ail!
MACHINE COMPONENTS
Tramp Oil Skimmers!
F|ve types
Peooh 5-24
Cog/F|ot Po|y
SS be|ts, too
1 t or 1 Gph
Pr|oe Cho|oes
A|| |n stook
www.wayneproducts.com
info@wayneproducts.com
WIRELESS SCANNER
PRODUCT EXPRESS
205-669-7161
kathy.savage@penton.com
Find qualified candidates by
placing your job posting ad in
the Marketplace section of
American Machinist
contact:
Kathy Savage
508.238.6970
OlL MlST & SMOKE
lN YOUR SHOP?
www.misIcollecIors.com
Tel: 1-800-645-4174
EQUIPMENT
SCRAP CARBIDE WANTED
FOR OVER 30 YEARS!
800-321-6914
www.stalloy.com
WE BUY
SCRAP CARBIDE
Dont miss your chance to be
included in the next AM Product Express.
Reserve your space today!
Contact Kathy Savage
P: 205-669-7161
F: 205-669-7165
Feature your companys products
with your ad in the
AM Product Express...
THE PLACE to be seen!
CNC POWER CHUCKS
S O F T W A R E & C O N T R O L S
nearly all time-consuming secondary
setups so that many tool bodies are
completely machined in one fixturing.
With our small quantities, staying
competitive is all about set-up time,
Wallin pointed out. Almost all our
work is one of a kind. Four or six
pieces is a huge order for us, so we are
always setting up new jobs.
Programming with Edgecam offers
other dramatic gains. Edgecam allows
us to easily align tool surfaces in the
program, then graphically flatten and
rotate them until they are perpendicular
to the machine tool spindle, Wallin
said. You just click on the different
surfaces, and Edgecam aligns them for
you, a big time saver in programming.
Currently, Wallin is creating
programs that are fully post-processed
for lights out machining. Nearly
all his products start as pre-hardened
AISI 4140 steel rounds and bar stock,
which must be cut slowly, so unattended
machining is quite beneficial. But,
with no machinists to watch for
program errors, perfect programs
are mandatory. Perfection also means
jobs must be machined exactly as
programmed. At-the-machine changes
by operators can eat into productivity
and may even stretch delivery times.
Changing the Game
E.W. Tooling is attempting to change
the way this industry works, Wallin
said, and we are succeeding. We are
deliberately raising the bar on firms that
try to compete solely on price.
The shop is doing that, he continued,
by making sure customers know how
much free engineering they have been
getting from us which they would
lose if they bought solely on the basis
of purchase price. There is a tendency
among some toolmakers in wood and
wood-products to look down on these
kinds of tooling. Their attitude seems
to be, Hey, its just a piece of wood and
This job is way over-engineered. We
dont see it that way; we never have.
The trick in this is to design the new
tooling families so that their complexity
doesnt impact E.W. Toolings own
productivity. Thanks largely to
Edgecams five-axis capabilities
and Solid Machinist with Autodesk
Inventor, they dont.
>> from 32
Software Proves to be a
Valuable Fixture
M
&M Manufacturing in Tulsa
is a CNC machine shop
producing parts, assemblies
and tooling for the energy, healthcare,
and manufacturing sectors. But, the
shops specialty is in complex-geometry
aerospace components. It uses four- and
five-axis machines to manufacture parts
that often have three controlling datum
surfaces, as well as many contoured
surfaces blending into each other.
These parts are programming
challenges that M&M addressed with
a switch to DP Technologys ESPRIT
CAM (www.dptechnology.com). The
software makes it possible to apply
toolpaths directly to a customers
solid geometry and view simulations
of the resulting program, with
the machine, tools, fixturing, etc.,
included, to avoid crashes.
Creative Workholding, Machining
A key difference that we bring
to our customers comes through our
creativity in developing a strategy
for holding and machining the part,
said Ken Statton, president of M&M
Manufacturing. Statton said the
shop developed expertise in fixturing
as it worked to meet tight tolerance
requirements, but these efforts have
advanced to using fixturing to reduce
machining cycle time. He pointed
to a four-station fixture that M&M
developed for a four-axis machine that
makes it possible to perform
a tool change then proceed
sequentially through all the
operations with that tool on all
four parts. This fixture allows
us to machine four parts with
only a single sequence devoted
to changing, advancing, and
retracting the tool, he said.
The result is substantial time
savings.
M&M began to move to
four- and five-axis machining
because of the increasing
complexity of the aerospace
parts it is producing, and this
meant it needed a software package
that could import complex geometries.
It chose ESPRIT because of its
programming simplicity and optimizing
ability. ESPRIT gives us the optimum
level of control to make sure the cutter
stays in the cut as long as possible and
that the program works the first time
we run it, according to Statton.
Automatic Feature Recognition
In the past, for example, if the
company was making a composite layup
tool with many changing contoured
surfaces, it had to define each surface
independently and generate toolpaths.
The cutter had to move around to reach
each of the different toolpaths, typically
taking several days to generate the
program. With ESPRIT, programmers
simply import the solid model and
access the full functionality for the
solid model. Then, the CAM software
is used to integrate the solid model to
automatically identify the part features.
The next step is to assign
metalcutting operations to the features
that have been defined. ESPRIT lets
users create a knowledge base of
pre-optimized machining operations
that include a particular tool, cutting
speed, feedrate, depth of cut, etc.
Programmers choose from several
different machining strategies that
automatically develop an efficiency
approach for machining the feature.
Machining plan for a Gulfstream G-650 fitting, as
demonstrated by ESPRIT software.
ADVERTISER PAGE
American Machinist .................................................................................7
American Machinist ...............................................................................12
American Machinist ...............................................................................24
American Machinist .............................................................................. BC
2L Inc. .....................................................................................................23
Gibbs and Associates ..............................................................................1
Gradient Lens Corp. . .............................................................................13
Haas Automation, Inc. .............................................................................5
Iscar Metals, Inc. ......................................................................................3
Mastercam, CNC Software, Inc. ............................................................31
Mfg.com .............................................................................................. IFC
Monster Tool ...........................................................................................21
Sandvik Coromant Co. . ...................................................................... IBC
Scientific Cutting Tools, Inc. . .................................................................28
This index is a service to readers.
Every effort is made to maintain accuracy,
but AMERICAN MACHINIST cannot assume responsibility
for errors or omissions.
AM PRODUCT EXPRESS ADVERTISING
Page 45
Send all AM PRODUCT EXPRESS advertisements to:
CLASSIFIED DEPT., Penton Media, Inc.,
1300 E. 9th Street, Cleveland, OH 44114-1503.
AD I NDEX
I EDI TOR
O P E R AT I O N S
W
ith the economy slowed,
enrollment is picking up
at the Moraine Park Technical
College Advanced Manufacturing
& Technology Center (AMTC) in
West Bend, Wis. Students want
to gain the skills that could land
them jobs in high-tech, Lean
Manufacturing shops, or that
would make them more valuable
to their current employers.
AMTC offers 2-year degrees
in CNC Manufacturing and Tool
& Die Manufacturing. One of
the things that we preach is that
the more skills a person can bring
to the table the fewer reasons a
company will have for letting
them go in a down economy,
instructor Tim Clemens said.
One way the school helps
its students become more
versatile, and thus more valuable,
is to integrate inspection
training with course work in
CNC Programming, GD&T
(Geometric Dimensioning and
Tolerancing), and Tool & Die
Manufacturing. For example, in
the CNC programming course,
students must write about 11
increasingly difficult CNC
manufacturing programs for mills
and lathes. Then, they check their
work on a Brown & Sharpe DCC
CMM (direct computer control
coordinate measuring machine)
with PC-DMIS (www.pcdmis.
com) measurement software.
The programs show the
students what they did right or
where they went wrong. As they
assess their progress as CNC
programmers, they learn CMM
basics. Later, theyll learn to write
their own CMM programs in PC-
DMIS, and their familiarity with
the equipment will place them
ahead of the curve.
Moraine Parks three DCC
CMMs (at its two campuses) and
the software were acquired as
part of the Hexagon Metrology
(www.hexagonmetrology.com/)
Metrology Equipment Grant
program. It helped Moraine
Park acquire the equipment and
software at affordable terms,
and the school receives technical
assistance from Brown & Sharpe
sales engineer Rick Schaeffer.
Clemens spends a great
deal of time on essentials in
his introduction to CMM
Programming class. Before
students can move to writing a
fully automated DCC program,
they have to really understand
how to calibrate probes correctly
and how to do proper alignments.
Without these skills, youll never
get good measurements, he said.
Recently, AMTC began
incorporating CMM surface
scanning into the curriculum.
Clemens was given a grant to
study the subject at a local shop,
RAM Tool & Die. He worked
with one of RAMs programmers
to learn to write measurement
programs using both touch-
trigger and laser probes to check
curves and surfaces. At present,
Clemens teaches students
scanning with a touch probe,
and the college hopes to acquire
a vision probe for teaching more
advanced applications.
Does broadening the students
base of skills with CMM training
actually make them more
marketable? Clemens is sure of
it. In fact, several of his students
in recent years have found
work as CMM operators and
programmers, and many more are
employed by shops that recognize
that a greater understanding of
quality standards will earn more
profitable business. <<
Machinists with CMM Training
Know More, Earn More
EDI TED BY ROBERT BROOKS
T
he condition and physical
properties of the work
material have a direct
influence on its machinability.
The various conditions and
characteristics described as
condition of work material,
individually and in combinations,
directly influence and determine
the machinability. Operating
conditions, tool material,
and geometry and workpiece
requirements exercise indirect
effects on machinability and
often can be used to overcome
difficult conditions presented by
the work material.
The following factors
determine the condition of the
work material: microstructure,
grain size, heat treatment,
chemical composition,
fabrication, hardness, yield
strength and tensile strength.
Physical properties of work
materials will include those
characteristics included in the
individual material groups, such
as the modulus of elasticity,
thermal conductivity, thermal
expansion and work hardening.
Machinability is a relative
measure of how easily a material
can be machined when compared
to 160 Brinell AISI B 1112 free-
machining, low-carbon steel.
The AISI ran turning tests of this
material at 180 surface feet and
compared its results for B 1112
against several other materials. If
B 1112 represents a 100% rating,
then materials with a rating less
than this level would be decidedly
more difficult to machine, while
those that exceed 100% would be
easier to machine.
The machinability rating of a
metal takes into consideration
the normal cutting speed, surface
finish and tool life. These factors
are weighted and combined to
arrive at a final machinability
rating.
There are four methods used
to judge machinability:
1ool Lie: Nerals rlar can
be cut without rapid tool wear
are generally thought to be quite
machinable, and vice versa. A
workpiece material with many
small hard inclusions may appear
to have the same mechanical
properties as a less abrasive
metal. It may require no greater
power consumption during
cutting. Yet, the machinability
of this material would be lower
because its abrasive properties
are responsible for rapid wear
on the tool, resulting in higher
machining costs.
One problem arising from the
use of tool life as a machinability
index is its sensitivity to
other machining variables.
Of particular importance is
the effect of tool material.
Machinability ratings based on
tool life cannot be compared if
a high-speed steel tool is used in
one case and a sintered carbide
tool in another.
Tool life may be defined as the
period of time that the cutting
tool performs efficiently. Many
variables such as material to be
machined, cutting tool material,
cutting tool geometry, machine
condition, cutting tool clamping,
cutting speed, feed, and depth
of cut, make cutting tool life
determination very difficult.
r5PPM'PSDFTBOE1PXFS
$POTVNQUJPO When using tool
forces as a machinability rating,
either the cutting force or the
thrust force (feeding force) may
be used. The cutting force is
the more popular of these two
because it is the force that pushes
the tool through the workpiece
and determines the power
consumed.
r4VSGBDF'JOJTI The quality
of the surface finish left on the
workpiece during a cutting
operation is sometimes useful
in determining machinability
rating. Some workpieces will not
take a good finish as well as
others. The fundamental reason
for surface roughness is the
formation and sloughing off of
parts of the built-up edge on the
tool. Soft, ductile materials tend
to form a built-up edge rather
easily. Stainless steels, gas turbine
alloy and other metals with high
strain-hardening ability also tend
to machine with built-up edges.
Materials that machine with
high shear zone angles tend to
minimize built-up edge effects.
r$IJQ'PSN There have
been machinability ratings
based on the type of chip that
is formed during the machining
operation. The machinability
might be judged by the ease of
handling and disposing of chips.
A material that produces long
stringy chips would receive a
low rating, as would one that
produces fine powdery chips.
Materials that inherently form
nicely broken, chips, a half or
full turn of the normal chip helix,
would receive top rating.
BY G E O R G E S C H N E I D E R J R . I C M f g E , C M f g T, L S M E
C U T T I N G T O O L A P P L I C AT I O N S
Chapter 3: Machinability of Metals
Each month American Machinist
presents an abstract of Cutting Tool
Aplications, George Schneiders
essential handbook to machine tool
materials, principles, and designs.
For a complete summary of each
chapter, visit
www.americanmachinist.com
Presented by
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Its that simple. Think of American Machinist as your
primary resource for interactive manufacturing and
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Visit IndustrialProductDemos.com and Just Demo it.
rGet an inside look at the integral parts of products.
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