Académique Documents
Professionnel Documents
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for SolidWorks
com-
bines the worlds leading modeling
software with the worlds most wide-
ly-used CAM software. Now you can
program parts directly in SolidWorks,
using toolpaths and machining strat-
egies preferred the most by shops
around the world.
Mastercam for SolidWorks includes a
suite of the most sought-after cutting
strategies, including High Speed Ma-
chining (HSM) toolpaths. In addition,
Mastercam for SolidWorks delivers a
powerful set of automated toolpaths
that get parts off the machine faster,
with little or no handwork.
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
H
ealthcare
dominates the
market for silicone
materials from Shin-Etsu
Silicones of America Inc.
(www.shinetsusilicones.
com)), a U.S. subsidiary
of Shin-Etsu Chemical
Co. Ltd. in Japan. The
materials innate physical
properties make it ideal for
modern medical product
applications, and Eric
Bishop, North American
marketing manager,
expounded on those
properties at a Liquid
Silicone Injection Molding
Symposium.
When asked why
silicone, Bishop answered
that the material displays
broad thermal stability
from 65 degrees F. to 500
degrees F. with additives.
He also mentioned that
it is electrically and
thermally nonconductive,
A Perfect Medical Material
americanmachinist.com I NOVEMBER 2009 I AMERICAN MACHINIST I 33
The healthcare industry has proven to be a shot in the arm for
silicone injection-molded parts.
Adjustable Multiple
Spindle Heads
Standard & Special Purpose
*Flexible*Durable*Cost Effective
Suhner Industrial Products, Rome, GA 30161
Phone: (706) 235-8046, Fax: (706) 235-8045
Info.usa@suhner.com
www.suhner.com
M A C H I N E T O O L S
34 I AMERICAN MACHINIST I NOVEMBER 2009 I americanmachinist.com
naturally elastomeric, and offers a
wide range of hardnesses.
Because silicone is chemically
inert, it doesnt react with blood
or pharmaceuticals and can be
safely cleaned in a dishwasher, said
Bishop. He added that the material
is naturally translucent but can be
colored for quick identification for
medical operating room applications.
Shin-Etsus key silicone grades
for healthcare include KE1950,
KEG2000, KE2090/2095 Select-
Hesive, KEG2003 and KE2004 Series.
The KE2004 Series combines low-
end durometer (5-20: Shore-A) with
enhanced physical properties and
processing control. Its low-hardness/
high tear strength combination
allows manufacturers to achieve a
soft feel without sacrificing strength,
generating excessive flash, or tearing
during demolding. In addition, the
company offers an anti-microbial
Liquid Injection Molding System
(LIMS) product.
Transitioning to the integrated
processes of silicone manufacturing
for medical components, Bishop
pointed out that the LIMS process is
a closed-loop, automated system that
minimizes the risk of contamination.
He further noted that using his
companys Select-Hesive LIMS, multi-
component parts could be molded in
a single 2-shot injection process that
improves consistency and increases
productivity. Also, when proper
planning, tooling, and machinery are
combined, flash-free molded parts are
possible for eliminating the need for
post operations. <<
T
he Barnes Bore
Honing & Finishing
Systems (www.
barneshoning.com)
HH line of horizontal
spindle bore-honing
machines sport
rigid structural box
beam base designs,
combined with easy
access open-face
configurations, that
make the machines
ideal for very long
and/or very heavy
components, such
as those found in
oil-patch and military
applications.
The machines
spindle structure
and power, and
its clamping and
tool design aspects
are all engineered
to work well with
both conventional
and superabrasive
tooling. Honing tool
expansion can be
activated with either
hydraulic or servo-
motor drives. All
aspects of the tooling
expansion are totally
programmable.
Updated features
include an Allen
Bradley PLC control
interfaced with an
operator-friendly color
touch screen panel. <<
Oil-patch Bore Honing
The Drilling Doctor
Problem:
Tooling inventories are getting
out of control.
Diagnosis
End-users are losing time and
money through purchases of
multiple tooling designs.
Solution:
The Allied
REVOLUTION DRILL
.
Adjustable
.
Indexable
.
Able to drill from solid
.
Available today
The Drilling Doctor Tips
are brought to you by:
Allied Machine & Engineering Corp.
Contact an Allied metal cutting
expert for your drilling solutions
Allied Machine & Engineering Corp.
120 Deed Dr.
Dover, Ohio 44622
(330) 343-4283
www.alliedmachine.com
M A C H I N E T O O L S
36 I AMERICAN MACHINIST I NOVEMBER 2009 I americanmachinist.com
H
igh-Brilliance Laser technology is
quickly becoming common and
desirable as it essentially simplifies the
generation and management of the
laser beam. Specifically, when used
for sheet metal, plate or pipe cutting,
the power requirements of the system
are substantially less, while attainable
cutting parameters are comparable to
a traditional CO2 laser generator.
Two Italian companies Campana
Livio S.r.l. and Finsomac S.r.l
produce the High-Brilliance Laser
technology. Cy Laser LLC (www.
cy-laser.com) sells and services Cy
Laser High Brilliance Laser systems
in North America.
Cy Laser High-Brilliance Laser
systems cut 20-mm mild steel, 10-mm
stainless steel, 10-mm aluminum,
and can be employed to cut brass
and copper. In addition, the higher-
quality laser beam produced can be
carried through a fiber optic cable
to eliminate the need for complex
and costly mirror sets. Consequently,
High-Brilliance laser systems are
virtually maintenance free.
The systems laser cutting head is
extremely simple, consisting of one
focalizing lens, and there is no need
to maintain and swap cutting heads
when changing set up.
Since High-Brilliance laser systems
use fiber optic laser sources, the
systems present many advantages
over traditional laser sources. For
example, there can be high power
generated within a reduced overall
perimeter/layout of equipment, high
system yield, less power needed for
cooling, no moving components and
no laser gas.
High-Brilliance Laser systems incorporate
fiber optic laser sources.
Brilliant Laser
Technology
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
C U T T I N G P R O D U C T S
38 I AMERICAN MACHINIST I NOVEMBER 2009 I americanmachinist.com
A
ce Precision Industries of
Akron, Ohio, produces several
variations of small components
for mining equipment, such as cowl
arms and traction reducer cases. The
company recently invested in a single-
spindle Niigata HD80 horizontal
machining center that enables them to
run larger parts with high feed/speed
capabilities. Initially, Ace transferred the
conventional tooling and methodology
it had been using to the new equipment.
The process worked, but was not opti-
mizing the capabilities of the Niigata.
Distributor George Whalley Co. of
Cleveland has been a one-stop resource
for Aces tooling needs. Larry Wragg,
the George Whalley representative,
together with Tom Batchelor, Seco
Tools Inc. (www.secotools.com)
application expert, suggested that Ace
try using a Seco Power Turbo, a heavy-
duty square shoulder mill designed to
provide maximum metal-removal
with free-cutting inserts.
The cowl arms are made of
A514 steel that is flame-cut to
shape, but the hardening caused by
this process has always made these
components tough on tooling, Tom
Stugymer, manufacturing manager
at Ace, said. We were eager to make
improvements.
The part is 62-in. long by 34-in.
wide by 4.5-in. thick. Seven steps are
required to produce the component.
Seco initially concentrated on the first
step roughing a bore area that is
4.5-in. deep with an inside diameter
HIGH-FEED MILLING CUTS BORING TIME AND COST
www.ati-ia.com/qc/
919.772.0115
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e.ert u oi| u|essu|e luss-wit|uut o su|ir. T|is rusu|ir Jesir
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Why ATI sells more
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than anyone else
in the world.
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|i| auaert couocit] ir luc|ir aec|orisa
ROBOTIC END EFFECTORS
americanmachinist.com I NOVEMBER 2009 I AMERICAN MACHINIST I 39
range of 25 in. to 36 in. Ace had been
using a 32-insert endmill to hog out
the metal, which was taking over an
hour on average, but they knew this
method worked.
Given the speed capability of
the Niigata, and considering the
space constraints of the enclosed
machine, Batchelor was confident
they could improve the process
with a helical interpolation method
using Secos high feed milling cutter.
In addition to being enclosed, the
Niigata machines have internal
tool changers, making it nearly
impossible to get a big boring head
inside the machine. Even though
conventional wisdom says we
should be boring a hole, we cant
get a boring bar inside the machine
due to the tool changer, explained
Stugymer. Thus, our need to
develop a more efficient method.
High-feed milling (HFM) quickly
removes a lot of material. With HFM,
the cutting forces are directed axially
back into the spindle. This method
provides outstanding performance
Cowl arm production begins with machining
a bore 4.5-in. deep and from 25-in. to 36-in.
inside diameter.
800.536.0790
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C U T T I N G P R O D U C T S
40 I AMERICAN MACHINIST I NOVEMBER 2009 I americanmachinist.com
T O O L I N G & F I X T U R I N G
when machining with large overhangs.
Ace was using a helical endmill
with 32 inserts, Batchelor said. We
applied a 4-in. diameter, high-feed
mill using 218.19 inserts in Secos
Duratomic grade MP2500.
With this switch, the boring time
was reduced by over 50 percent, to
only 28 minutes. Plus, this cutter only
requires seven inserts, versus thirty-
two. Stugymer added. So, we cut
the machining time in half with one-
quarter the number of inserts.
Another aspect Seco thought it could
improve operations involved the boring
of two corners for stress-relief where the
rod connects to the round cowl head.
Ace had been machining a 1.1875-in.
radius using a boring bar, because a
correct-sized diameter cutter did not
exist for this operation. To tackle this
T O O L I N G & W O R K H O L D I N G
S
chunk Inc. (www.schunk.com)
has extended its toolholder
product range with the introduction
of the new Sino-R that is well
suited for heavy-duty metal cutting
and rough milling. The universal
toolholder is based on the
expansion technology system with
a solid body as a pressure medium
and is quickly clamped using a
simple actuation key. This saves
the user set-up time and reduces
unproductive machine down-times.
The interaction of high radial
rigidity and good dampening
characteristics is a special
highlight that reduces machining
noises and increases the smooth
running of the tool. This results
in high service life of the tool and
surface quality of the workpiece.
Toolholder
For Heavy Cutting
americanmachinist.com I NOVEMBER 2009 I AMERICAN MACHINIST I 41
task, Seco made a 2.375-in. diameter
Power Turbo mill with five teeth using
the M14 geometry in grade F40M.
This new Power Turbo mill reduced
machining time from 50 minutes
to 5 minutes. Again, a plunging
methodology was employed by taking
0.100-in. steps in many passes with
no more than 0.05-in. depth-of-cut
per pass to produce a 1.1875-in.
corner radius. Spindle speed remained
constant at 804 rpm, but the feedrate
increased from 0.015 ipr to 0.283 ipr.
Ace is now able to manufacture
about one cowl arm per day. With the
switch to Power Turbo, the company
saves about $28,000 per year just in
machining cost on the component.
This does not account for the reduced
number of inserts now needed to
complete the first boring operation. <<
This eliminates unwanted chatter
marks that frequently appear with
conventional toolholder systems
and expensive reworking.
Sino-R holds tools securely,
thanks to maximum torque
transmission of 850 Nm, at a
clamping diameter of 32 mm.
Also, with the use of intermediate
sleeves the toolholder can be used
flexibly, and almost all common
shank diameters can be clamped.
The toolholders are precision-
balanced to protect both the
machine spindle and the lip
of the tool.<<
A
line of bits that will not fall
out when inserted into a six-
point socket has been introduced
by Bondhus Corp. (www.bondhus.
com). ProHold Socket bits are half
the cost of traditional socket bits
because users can utilize them with
their own six-point sockets, and
Protanium steel makes each bit up to
20% stronger than competing tools,
said the company. Two non-magnetic
buttons on the sides of each bit locks
it securely into the socket.
All ProHold Socket bits carry the
Bondhus lifetime warranty and feature
the ProGuard finish, which offers five
times more corrosion protection when
compared with competitor finishes.
A full range of inch, metric and star
tools are available.
Bits turn standard
socket into bit holder
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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 WA R E & C O N T R O L S
M
astercam X4, a
new release from
CNC Software
(www.mastercam.com),
introduces a cutting motion
called Dynamic Machin-
ing that the developer said
adapts toolpaths to create
more consistent processing,
constantly.
This new motion is said
to work equally well with
closed and open parts,
creating efficient entry
methods and customizable
entry speeds and feeds.
CNC Software
emphasized that the new
technique allows shops
to use the entire tool flute
length, increasing machine
flexibility and saving
production time and cost.
Also, Dynamic Machining is
designed to take a full depth
cut, so the need for multiple
depth cuts may be eliminated
in many instances.
Another aspect of this de-
velopment is flexibility in tool
retraction, to keep the tool
down in smaller components
and to allow rapid retraction
on larger parts.
There also is a micro
lift option that allows
slight retraction off the
bottom when moving to
the next cut, decreasing the
level of heat in the part and
aiding chip evacuation.
Recently, CNC Software
also introduced a new
part-modeling and EDM
programming software,
Mastercam X4 Wire.
For modeling parts, each
geometric piece is live so
programmers can modify
them quickly to achieve a
desired shape.
For programming, X4
Wire has streamlined
features for 2- and 4-axis
machining, including
2-axis contouring (with or
without taper angle), no-
core cutting, and straight
and tapered cutting (with
or without land) from
either direction.
More new program
features include contouring
for multiple parts using a
single window selection;
automatic wirepath corner
filleting; and an ability to
create lead-ins and lead-
outs with optional lead
trimming. Programmers can
create tabs automatically
with user-definable stop
types. There is also an
optional No Drop Out tab.
CNC Software says
Mastercam X4 Wire
creates new efficiencies that
will reduce programmer
interaction and increase
machining flexibility. <<
Charting New Paths for More Consistency
Introducing Dynamic Machining; plus, part modeling and EDM programming functions get streamlined
americanmachinist.com I NOVEMBER 2009 I AMERICAN MACHINIST I 43
According to CNC Software, its new cutting motion works equally
well with closed and open parts, creating efficient entry methods
and customizable entry speeds and feeds.
>> on 46
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americanmachinist.com I NOVEMBER 2009 I AMERICAN MACHINIST I 45
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CNC POWER CHUCKS
S O F T W A R E & C O N T R O L S
46 I AMERICAN MACHINIST I NOVEMBER 2009 I americanmachinist.com
C
NC Metal Fabrication Inc., in
Toronto, builds electronic instrument
cabinets. It acquired its first JETCAM
Expert CAD/CAM software (www.jetcam.
com) license with a Finn-Power press
in 1992, but also acquired other CAM
systems with other machines that, over
time, needed consolidating.
Chandrakant Patel, Engineering
Manager explained; Weve replaced the
first Finn-Power twice since 1992, and
with each new Finn-Power machine weve
90% scrap reduction, with high-performance nesting
used JETCAM without problems. We
had an old CAM system that was driving
another punching machine, but this had
no automatic tooling capability and was
difficult to use.
Another system also proved too
difficult to learn and did not have the
same level of functionality as JETCAM
for parts that require both laser and
punching operations, and thus needed
programming on two separate systems.
By this time CNC Metal had used
JETCAM Expert with high-performance
rectangular nesting to drive three Finn-
Power punch presses and a Danobat
punch press. After replacing the Mitsubishi
with a newer model they standardized on
JETCAM, and purchased postprocessors
for their two licenses to drive the new laser.
Comparing JETCAM to the two other
systems, Patel cited several examples of
savings resulting from efficiencies the
software has delivered. The biggest
saving has been in programming time.
The old system had no auto-tooling, so
tooling up punched parts is 50-70%
faster now, with programming reduced
overall by around 30%. Although most
of our runs are short, our sheet utilization
has improved by up to 20%, which has
reduced our scrap levels by up to 90%.
He said JETCAMs ablity to store
tooling data on the part, not the nest,
means the shop can store both punch and
laser information, and then generate a
nest for any of the machines immediately.
Patel said newer features have further
reduced programming time and improved
the quality and speed of getting to a
finished part.
>> from 43
This Toronto shop manufactures cabinets for
electronic instruments. It uses a single CAM
system to drive different brands and types of
machines, and no longer reuses its CNC pro-
grams: the programs are nested just in time.
Valercar lor So||dwor|