a white paper

12 Machine Tool
Accessories That
Boost Productivity
With 90 years of machine tool experience the Gosiger team has the
experience to help you determine which accessories will optimize the
performance of your CNC machine tools and provide the greatest ROI.

www.gosiger.com | (937) 228-5174

Manufacturers
invest in new
machine tools for
three main reasons.
To make a current process better,
faster and/or more cost-effective.
To add to their existing capacity.
To expand their capabilities.
In each case the goal is to realize the best possible return
on investment. Which means choosing the machine tool that
will most efficiently and effectively perform the tasks at hand.

Robots & Automated Pallet Systems

Many times manually loading, unloading or repositioning of
parts slows down the machining process and adds labor

However even the best machine tools cannot operate at

costs. These functions are often mind-numbingly repetitious

peak performance unless they are fitted out with appropriate,

for the machine operator who could be tending multiple

equally capable accessories. Unfortunately, because

machines or performing more productive tasks. Robots are

shoppers are so focused on selecting the right machine tool,

particularly adept at these and many other activities.

these peripheral products are often overlooked or given little

consideration. This is a serious mistake because adding
the right accessories can often dramatically improve overall
productivity and reduce manufacturing costs.
In this paper we will discuss 12 accessories
proven to optimize machine tool performance
in various applications:
Robots & Automated
Pallet Systems
Vacuum Unloaders

Tool Management Systems

Laser Marking Tools

Among the many benefits are:

Improved machine tool utilization by eliminating
wait times, missed cycles, and enabling more
consistent throughput.
Reduced cost-per-part through unattended operation
and by eliminating labor-intensive activities such as
part loading and unloading, excessive part handling
and inspection.
Reduced overhead by increasing CNC machine
productivity and amortizing skilled labor over greater
numbers of parts. By increasing the productivity of direct
labor per man-hour and square foot of factory space,
you effectively reduce overhead costs.

Bar Feeders

High-Pressure
Coolant Systems

Machine Tool Probes

Chip Conveyors

Shop Floor Inspection

Systems

Steady Rests

technologies and efficient programming techniques.

Custom Apps

Increased income potential by producing more parts

in less time, thus freeing spindle time for additional,
incremental parts production.

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Increased production flexibility by enabling machine tools

to produce diverse families of parts by using available

 Enhanced part quality through consistent part handling

and eliminating human error.
Lowering overhead because robots dont take vacations,
sick days or holidays, or require payroll taxes, insurance
and other benefits.resource.
Automated Pallet Systems are another way to optimize
throughput by managing production schedules, level loading
machining centers and enabling one operator to manage an
entire production line.

Vacuum Unloaders
Turning machines used in high production processes
may benefit by adding a vacuum unloader.
This device automatically removes
parts from twin spindle or sub
spindle machines with thruhole. After the first end of a part
is machined the part transfers
from the main spindle to the sub
spindle where the opposite end is
machined. Meanwhile, the first end of a new part is machined
in the main spindle. When the sub-spindle stops, the chuck
opens and the unloader moves into position and forms a
seal. It then uses vacuum pressure to pull the part out of the
sub spindle past a sensor that confirms the part is out of the
spindle so machining can resume as the part drops into the
unloaders tray.

Bar Feeders
Loading 12 or smaller bar stock into a turning machine is
more complicated than it appears. If the bar is not properly

Pallet systems come in a variety of

configurations to accommodate any size
manufacturing process from a single cell
to an entire factory.

supported it will lobe and create vibrations that are passed

on to the machine tool spindle. This vibration not only
makes it more difficult to hold dimensional and surface finish
tolerances, it can also cause excess wear on the turning
machine bearings, spindle and other components causing
premature failures. Manually loading bar stock is timeconsuming, labor intensive and causes machine downtime.

In many cases they can integrate a variety of machine

tool makes and models with robotics, inspection, material
management, warehouse functions and much more.
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Machine Tool Probes

Years ago touch-trigger probes were strictly used for postprocess part inspection, as on a Coordinate Measuring
Machine (CMM). Today, they can be mounted on a CNC
machines spindle to make it quicker and easier to set up
parts, detect a problem with tooling including worn, broken
or missing tools, prevent machine tool damage and even
perform in-process gauging to maintain part quality. There
are also software programs available that can use the data
from these probes to automatically make tooling adjustments
Modern, automatic bar feeding equipment stabilizes bar
stock to reduce vibrations, can hold and continuously feed
enough bars to enable unattended and even lights out
production, and frees machine operators for more important
activities. Many bar feeders have automatic, self-adjusting
features that make changeovers quick and easy, often by

or remotely alert operators of problems.

Shop Floor Inspection Systems

While in-process gauging has become more commonplace,
many applications still require post-process inspection to
certify part tolerances and comply with customer demands.

simply entering a few commands into the touch-screen

control. They also employ servomotors and synchronization
systems to prevent loading failures and machine crashes.
Some are even equipped with Internet connections that allow
them to communicate with the CNC machines program
schedule to optimize material usage and automatically
change parts programs on the fly.
There are a wide variety of automatic, magazine bar feeders
available in both 12 and short load models for fixed and

Inspection devices range from digital calipers, height stands

sliding headstock machines that cover an impressive range

and other manual gauges to sophisticated scanning CMMs,

of bar stock diameters and shapes.

dedicated dimensional measurement machines, surface

texture instruments and much more. To operate successfully
on the shop floor, these tools must be designed to resist
environmental forces including temperature, humidity and
airborne contaminants. Otherwise they must be used in a

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more controlled area such as a clean room.

Tool Management Systems

Controlling perishable tool inventories is an ongoing
issue for many CNC machine shops. Its important to
track tool usage to maintain an adequate stock of tools
and avoid overstocking that can impact cash flow.
Moreover an easily accessible tool crib may lead to
hoarding by machine operators who want to keep their
own stash in their work area.

One solution is a tool vending machine

One solution is laser marking

that uses laser beams to mark
a wide range of materials without
making contact with the part,
which makes it an ideal choice
for identifying all shapes and
sizes, and for placing markings
on hard to reach surfaces.
There are three types of laser marking methods for metal
parts. The most familiar form is engraving, in which the laser

that maintains inventory control records

beam cuts into the materials surface to create a marking.

to identify usage by employee.

If desired, the manufacturer can also introduce colored

These systems can be coupled with tool drawer monitoring

Another process, called ablation, is often used to laser mark

systems that use weight sensors or RFID technology to

anodized aluminum or other coated metals by removing

monitor tool inventory. The software that these systems use

layers of colored coatings to reveal the base material.

may also enable automatic tool ordering and flag changes in

The third method, typically applied to ferrous metals and

tool usage that could indicate machining problems.

titanium, uses the laser to heat the area to be marked, which

Laser Marking Tools

produces layers of oxide on the parts surface, thus creating

There is an increasing need for traceability of manufactured

oxides into the engraving to make the mark more noticeable.

a contrasting color to the base metal.

parts due to recalls, identifying the causes of product failures,

High-Pressure Coolant Systems

and thwarting counterfeiting. Most medical, automotive and

Various types of coolants have long been used in CNC

aerospace parts have long required indelible markings to

machining to reduce the amount of heat and friction at the

insure traceability, and many other industries are adopting the

cutting point to allow the machine tool to operate at higher

practice to help protect themselves from liability issues and to

speeds and to reduce tool wear. However if the pressure

hold contract suppliers accountable for meeting their quality

and fluid direction isnt precise, the coolant simply washes

standards. Additionally, counterfeit parts from overseas and

over the tool, tool holder and work-piece.

within the U.S. are now a billion-dollar plus business.

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While this cools the surfaces somewhat, it fails to remove the

This means the cutting tool spends less time re-cutting

intense heat within the cutting area, itself. This is especially

metal chips. The combination of reduced heat and more

important when working with difficult-to-machine materials

efficient evacuation of chips prolongs tool life and makes

such as titanium and exotic alloys that typically generate

cutting tool replacement more predictable because they

more heat during machining.

wear naturally, rather than failing prematurely due to

Manufacturers spend millions of dollars on liquid coolants

each year. In many cases the benefit of this coolant could be
greatly enhanced in some applications by 100% or more
by using a focused, high-pressure coolant delivery system.

excessive heat or chip damage. The new generation of

programmable, high-pressure coolant systems provides
variable pressures throughout the machining process so
just the right amount of coolant pressure is applied precisely
when and where needed.

Chip Conveyors
Removing chips from a machine tool seems like a no-brainer.
In many cases coolant flushes away the chips or the actions
of the machine tool pushes them along to the chip conveyor.
However if the chip conveyor is not properly matched to your
applications, you may experience backups, bottlenecks or
breakdowns, all of which require additional labor and can
bring your manufacturing process to a standstill.
Thats why its important to have
Heres why: Directing the coolant stream more accurately

the right chip removal system

and with the optimum amount of pressure removes much

for the specific kinds of

more heat from the cutting zone. This degree of cooling also

machining you perform.

enables the cutting tool to remove greater amounts of metal,

For example, multi-function

thus improving machine tool cycle times.

CNC machines that combine

Additionally, the high-pressure coolant stream helps break

milling, drilling, turning and

up troublesome chips including stringy chips or birds nests,

grinding create a variety of

and more efficiently removes them from the cutting area.

chip types, each with their own shape, weight and size
characteristics. Turning may produce stringy chips, while
milling creates a combination of large to very tiny chips,
depending on the operation.

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If the part undergoes both turning and milling, the

combination can cause problems for conventional hinge belt
conveyors. The tiny chips tend to remain suspended in the
quickly flowing coolant and end up washing into the coolant
sump, which can cause extra maintenance and possible
damage. In this case the answer may be to install a filtering
chip conveyor that removes the larger chips via a hinge belt,
but uses self-cleaning filters to remove the tiny chips from
the coolant, then returns the fluid to the sump. This not only
means the chips are efficiently removed, it also prolongs the
life of the coolant.

Steady Rests

Custom APPs
Anyone with a smart phone or tablet knows theres an
APP for that. What you may not know is that there are also
APPs that can help improve manufacturing productivity.
While there are a number of general purpose APPs available
for everything from reading CAD files on mobile devices to
scanning barcodes, users of Okuma CNC machines can use
the THiNC Applications Program Interface to create custom
APPS to monitor machine activities or to automate a wide
variety of machining functions.
Gosigers Aftermarket Support Department is an industryleading developer of these Windows-based Apps. Youll

As part of a work holding system, a steady rest is typically

find several examples in the free white paper Mobile APPS

used when the inherent strength of a work piece isnt

for CNC Machining available to download at gosiger.com.

sufficient to resist the force of the cutting tool, or to support

the end of a work piece without engaging a tailstock.
The benefits of steady rests include:

Health & Safety Products

Keeping your employees healthy and safe is not only the
right thing to do, it also makes excellent business sense.

Increased part stability

Last year US employees in private industry missed more

Faster feed rates and spindle speeds while

maintaining close tolerances

than 900,000 workdays, with Forbes magazine reporting

Extended tool life

over $2.8 billion.

Improved part finishes

One step toward keeping the workplace safe is to make sure

Depending on the application, steady rests can be controlled

manually or automatically controlled by the CNC machine
PLC. In many cases the steady-rest based automatic
workholding system is custom designed for your specific
application, with appropriate brackets, automatic oiling
systems and interfaces.

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that, in 2013, such absences cost American manufacturers

workers dont circumvent the many safety interlocks and

other devices built into CNC machine tools.

Another way to keep employees safe and healthy is by

adding such equipment as:
Vacuum parts washers clean baskets of parts in a sealed
chamber using hydrocarbons or modified alcohol-based
solvents that are internally recycled through a distillation
process, so the environment is protected, workers are
not exposed to volatile chemicals and users save money
by recapturing and reusing the cleaning solutions.
Oil mist collectors, some with HEPA filters, capture
harmful airborne contaminants to improve air quality,
provide a safer workplace and meet OSHA and NIOSH
standards. Because they return clean air to the factory
rather than exhausting it outside, they also reduce the
energy required to heat or cool the facility.
Tramp oil removal systems cleanse cutting fluids
of the residue that can breed harmful bacteria and
cause respiratory problems and skin damage. These
devices remove tramp oil droplets as small as 20
microns from machine coolant, returning fluid that is
99% free of contaminated oil to the machine sump. As
a result, workers are healthier and more productive,
and the filtered tramp oil can be disposed of in an
environmentally safe manner.
With 90 years of machine tool experience the Gosiger team
has the experience to help you determine which accessories
will optimize the performance of your CNC machine tools and
provide the greatest ROI.

www.gosiger.com | (937) 228-5174

www.gosiger.com | (937) 228-5174

www.gosiger.com | (937) 228-5174