CNC NEWS

Special 2008
INDEX and Fanuc GE CNC: A partnership that benefits machine tool users

A partnership that benefits machine tool users

For the first time, INDEX is installing FANUC CNC controllers in its SpeedLine series The INDEX SpeedLine series of automatic production lathes is designed for fast, cost-optimized manufacturing of typical automatic turned parts as well as complex NC turned parts. Located in Swabia, INDEX is a specialist in the manufacture of such machines particularly the Type ABC, the Type C100 and the Type C200. The company has entered into a working relationship with FANUC, the world market leader in CNC technology, in order to introduce these machines into the American and Asiatic markets, as well as into the European market.

The premiere of INDEX machines equipped with FANUC CNCs will take place in Chicago at IMTS 2008. INDEX will present a Type ABC and a Type C100, each of which will be fitted with a FANUC Series 31i CNC controller. Dipl.-Ing., Dipl.-Wirt.-Ing. (FH) Eberhard Beck, head of controls technology, explained: Last year, we began to equip our base SpeedLine series machine the Type ABC with FANUC controllers and drives after initial contacts were made between INDEX and FANUC in 2006. Recently, two ABC machines started test operations at well-known contract manufacturing companies that produce turned parts. Another ABC machine will be seen at the Fanuc GE CNC booth at AMB 2008, and a fourth machine is going to Chicago for IMTS. The decision to equip the Type C100 automatic production lathes with FANUC Series 31i CNC controllers, and to take them along to the trade fair, was not made until the fourth quarter of 2007 when FANUC signaled that it was ready to undertake special development work to accommodate the special kinematics of the automatic lathe. Eberhard Beck admitted that the time schedule established by IMTS was tight, saying But FANUC had finished the software 14 days earlier than was planned. That was really a great performance by all the parties involved. INDEX machines with the familiar FANUC Look & Feel INDEX attributes particular importance to IMTS 2008 as well as its presence there with both FANUC controlled machines. After all,
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INDEX can now meet the demands for machines equipped with FANUC CNC controllers. Controller specialist Beck said: We equipped our machines as FANUC as possible, because FANUC controllers are operated everywhere according to a uniform approach in which many operators are already highly experienced. Our goal is to address this target group by explaining that no additional training is necessary to operate our SpeedLine machines. Machine operators can begin working immediately with the familiar FANUC Look & Feel and the typical FANUC interface. INDEX has even abandoned its own machine control panel that would normally be used on all INDEX machines. INDEX has also reinstalled the manual wheel so that operators who are experienced with FANUC machines could be accommodated as much as possible. The Type ABC a compact, automatic production lathe INDEX picked the compact Type ABC automatic production lathe, which is suitable for simple turned parts as well as for complex CNC machined parts, as being the ideal machine for starting up the working relationship with FANUC. This lathe is equally suited for machining parts from bar stock as well as from chucked components. The steel ABC machine sub-frame supports a cast metal slant bed with two independent tool turrets. This type of construction provides outstanding damping characteristics and therefore the most favorable conditions for precision work. It is impressive because of its high rigidity against bending and torsional movements.
CNC News Special 2008 | Fanuc GE CNC

The upper tool turret is preferred for interior machining and the lower is preferred for exterior machining. Up to five back drilling stations complete the tool system for complete backworking. A synchronized spindle is mounted on the upper tool turret, located above the main spindle. Eberhard Beck emphasized that it is particularly effective, saying: Since the synchronized workpiece spindle lies on the pitch circle of three rear side quills, it is possible to use two tools to machine two workpieces via the upper tool turret. This means that while the next workpiece is being centrally bored or turned on the main spindle, backworking on the most recently manufactured part in the synchronized spindle is taking place simultaneously. The workpiece in the main spindle can also be machined in parallel using the second lower tool turret. With a clever task distribution, three tools can be in constant use on two workpieces. This minimizes the time required to manufacture a part and significantly increases productivity. The C100 very rigid and precise because of the SingleSlide The C100 can also be used to produce parts in extremely short periods of time by simultaneously machining with up to three tools because this automatic production lathe is equipped with main and counter spindles as well as three tool carriers. The bar sizes that can be used are between 30mm and 42mm. The INDEX C100 is also suited to producing very complex and demanding parts because it is equipped with 14 tools per turret and the tool carriers are on opposing Y-axes. It is suitable for suppliers to automobile companies as well as in medical technology, valve and industrial fittings manufacturing, and in fluid power applications. A noteworthy feature of the C100 is the SingleSlide, an innovative guide system developed by INDEX, which sets new standards in damping, rigidity and tool service life. The tool carriage for the X- and Z- movements consists of only one single part: it operates the tool

A world power in turning

The INDEX Group, Esslingen, together with its subsidiary TRAUB in neighboring Reichenbach/Fils, is among the leading manufacturers of CNC lathes. The Group is established throughout the world with its six production locations and six international sales and service companies, as well as its 80 authorized dealerships that represent it. With its nearly 2,300 employees, the Group generated sales of almost a half a billion euros in 2007. Among other factors, a wide product offering is responsible for the rapid growth of the Group, a product portfolio that includes automatic production lathes, turn-mill centers, turn-grind centers, vertical lathes and multi-spindle automatic CNC lathes. The main customers for INDEX lathes are mainly the automotive and automotive supply industries, machinery constructors, the electrical and electronics industry as well as manufacturers of valves and industrial fittings and equipment for fluid power applications. Growing markets include medical technology as well as the aerospace industry.

turret not on rolling guide elements but rather on flat sliding guides. Tool carriers 1 and 2 have coated sliding elements which slide on hardened steel plates that are bolted to the machine bed. Exact placement ensures that the other associated sliding elements will be free of play. This type of construction combines the well-known advantages of sliding guides such as good damping characteristics and high rigidity with acceleration and fast traverse values that were previously only to be found in machine tool construction that used linear guides with rolling elements. Because of the small masses that have to be moved, accelerations up to 1 g are attained. A perfect working relationship Eberhard Beck is enthusiastic about this kinematic solution which required special development work on the CNC controller. He said: The machine-specific controller adjustments were accomplished perfectly by Fanuc GE CNC Germany. For the SingleSlide system, the German controller specialists obtained additional development support from headquarters in Japan. A solution was thus very quickly available to us and we were able to send the C100 to IMTS in the USA. The FANUC Series 31i CNC controllers were chosen because of the demanding technology of the two INDEX automatic production lathes. For example, the C100 uses three channels as well as 14 axes, which are divided among eight cutting axes (including the two Y-axes); a portal loading setup; for each drive of the the three tool turret
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Fanuc GE CNC | CNC News Special 2008

(indexing and tool drive); and a main and counter spindle. A crucial design element of the ABC is that the upper tool turret has a permanent position for the synchronized spindle, in addition to places for the cutting tools. The controller must be able to switch between tool machining and spindle functions using one and the same drive. Eberhard Beck continued: In addition, we need functions such as Polygon Turning as well as expanded functionalities for tool drives, spindles and synchronized spindles. These are available in the latest software versions for the Series 31i. For this reason, this controller type was chosen for future proofing. Availability an important factor for success Particularly in the USA and Asia, INDEX will impress the job shops by having FANUC as its new controller supplier. The ABC and the C100 will benefit from the strengths that are typical of FANUC such as, for example, the reliability of their CNC controllers. This reliability is not only widely known and confirmed again and again by end users but is also verified by facts statistical investigations have indicated that only one error, which leads to a failure of the machine tool and that is caused by the controller, occurs every ten years (Mean Time Between Failures MTBF). For long term use, the supply of drive and controller replacement parts must also be taken into consideration. Even the finest components are subject to a certain degree of wear. Here, FANUC has its advantages because anyone who chooses a machine with FANUC controller and drive technology receives a guarantee that during the entire machine service life, each original replacement part can be supplied. Because of FANUCs worldwide onsite service, FANUC customers receive replacement parts in almost every country in the shortest time possible.

A familiar interface for new SpeedLine customers By equipping the Type ABC and the Type C100 with FANUC CNC controllers, they cover a wide manufacturing spectrum. Both machines are equipped with the function Dual Check Safety, a safety system integrated into the CNC to protect the operator and the machine. Soon, the C200 will also be available with the FANUC Series 31i CNC. This machine is the bigger version of the C100 and can accommodate bar stock in sizes of 65mm or 90mm. With this machine and with its FANUC controller, INDEX now has a complete manufacturing line of high performance machines in its portfolio for part diameters of 30mm to 90mm. For INDEX managing technical director Dr.-Ing. Bernd Walker, this is a promising selection: We are convinced that end users throughout the world will benefit from the working relationship between INDEX and FANUC. The use of FANUC as standard offers many machine users, such as contract machining companies already familiar with this controller from other machines, easy access into our highly productive SpeedLine series. Dr. Walker also sees the co-operative project work as enjoyable and efficient, saying: FANUC carried out its job perfectly. That goes for the onsite modifications by the CNC specialists from Neuhausen, as well as for the support from the corporate site in Japan.

The CNC market leader

For over 50 years, FANUC has been the leading trendsetter for the CNC industry. By the end of 2007, more than 2 million FANUC controllers and over 8.25 million motors had been installed throughout the world numbers that indicate innovative products and high quality since so many users are continuing to use FANUC products in the long term. These users particularly appreciate the high reliability of FANUC products and that they can obtain packaged solutions that are optimally matched to each other from a single source. For higher degrees of automation, customized solutions using robots from FANUC Robotics can be implemented.

INDEX Corporation 14700 North Point Boulevard Noblesville, IN 46060, USA Tel.: (317) 770-6300 Fax: (317) 770-3166 sale@index-usa.com www.index-usa.com

Fanuc GE CNC Europe S.A. Zone Industrielle L-6468 Echternach, Luxemburg Tel.: (+352) 72 79 79-1 Fax: (+352) 72 79 79-315 info@fanucge.com www.fanucge.com