August 2012

August 2012 | Vol. 64 | Issue 8 www.ctemag.
com
Wild Ride
CTE Survey: salaries, benets go up, down and around
Plus:
Retrotting: Life extension for machine tools Creating slots via groove milling Vending machines keep tool use under control IMTS Preview: Show guide and product review
ISCAR is About to the World of Meta
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Cutting and grinding, cover to cover
contents
August 2012 | Volume 64 | Issue 8 Visit us at www.ctemag.com
cover story
50 Mixed Message CTEs 2012 Salary Survey reveals how much various metalworking professionals are making, and the results are mixed.
Cutting and grinding, cover to cover www.ctemag.com

40 Skokie Blvd., Suite 450, Northbrook, IL 60062 (847) 498-9100; Fax: (847) 559-4444
Main Office
Publisher
Don Nelson (847) 714-0173 dnelson@jwr.com
features
58 New Life for Old Iron Retrofitting is an effective and economical option to make new money with old machine tools.
Editorial
58
Editorial Director
Alan Rooks (847) 714-0174 arooks@jwr.com
Editor
72 When Grooving Met Slotting Groove milling can effectively perform slotting and slitting. 82 Viva Vending! Vending machines can help manage tool and supply usage and keep costs in check. Multi Grind Minnesota shop succeeds by being good at many different part-grinding methods.
Alan Richter (847) 714-0175 alanr@jwr.com
Senior Editor
Yesenia Salcedo (847) 714-0177 ysalcedo@jwr.com
Contributing Editors
82
staying sharp
26 Managers Desk Managing a shop in the normal times between crises. Machine Technology Importance of tool presetting.
Kip Hanson (520) 548-7328 khanson@jwr.com Susan Woods (224) 225-6120 susanw@jwr.com
90
Electronic Media Editor

Dennis Spaeth (847) 714-0176 dspaeth@jwr.com
104 A Site for More Eyes CTE Web site grows traffic, expands video, product and machine shop content.
28
Art Director
IMTS 2012 preview

Refer to the following sections to preview highlights of the metalcutting technology scheduled for exhibition at IMTS 2012. 116 Show Preview
34 Workholding Defining chucks used for turning. 42 Shop Operations Threading on the manual lathe. Ask the Grinding Doc Understanding the real cause of grinding burn.
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Circulation
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on the cover:
128 Chicago Guide 134 Tooling and Workholding 158 Machine Tools and Accessories 184 Metalworking Products
Corporate Staff
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Cover design by Gina Moore.
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Jacqueline D. Roberts (847) 714-0181
(Contents continued on page 10)

6 | AUGUST 2012 | CTE
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www.doosaninfracore.com/machinetools Corporate Ofce & Engineering Center: 19A Chapin Road Pine Brook, NJ 07058 Tel: 973-618-2500 Midwestern Technical Center: 1701 F Howard Street Elk Grove Village, IL 60007 Tel: 847-437-1010
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contents
departments
12 16 22 Lead Angle Industry News New Product Focus
Cutting and grinding, cover to cover www.ctemag.com

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200 Productive Times 202 Marketplace 206 People & Companies 212 Advertisers Index 216 Look-Ahead
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On the Web at www.ctemag.com

A guide to whats new on CTEPlus
Smartphone benets You can use your smartphoneand a free application available at get. neoreader.comto scan the quick response (QR) matrix bar code images below and instantly access the respective reports on ctemag.com. You can also access the reports by entering the URLs listed on your Web browser. High-speed milling A video compilation from RobbJack Corp., Lincoln, Calif., demonstrates a variety of high-speed milling operations. cteplus.delivr.com/1h9me Adept adapter question Dr. Jeffrey Badger fields a question from a shop truing its diamond wheels offline, then remounting them onto the nontapered spindle without using an adapter. The shop is wondering whether its tight wheel tolerances negate the need for an adapter. cteplus.delivr.com/1hvdm Automotive resistance The fourth installment of our Automotive Motion series about the origins of the automobile industry recalls the backlash faced by the earliest motorists. cteplus.delivr.com/1ghgu
Central/South
Bill Klingler (847) 714-0186 bklingler@jwr.com
Worldwide Germany, Austria, Switzerland

Uwe Riemeyer, Sabine Galensa +49 202 271 69 0 riemeyer@intermediapartners.de
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By Alan Rooks, Editorial Director
he recent brouhaha over the Chinesemade opening-ceremony uniforms for the U.S. Olympic team was very entertaining. U.S. legislators denounced Ralph Lauren Corp., headquartered in New York, for outsourcing the uniform manufacturing, with Senate Majority Leader Harry Reid suggesting the offending uniforms be put in a pile and burned. The outraged politicians seem to have read a recent report that an overwhelming majority of people from all political stripes said they support Buy America policies that would mandate taxpayer money be spent only on goods made in the U.S. Nearly 90 percent of Republicans and independents and 91 percent of Democrats said they support the policies, according to a survey by The Alliance for American Manufacturing and the United Steelworkers. Ironically, these policies wouldnt apply to the U.S. Olympic team, which is privately funded. However, the legislators have conveniently forgotten that it was, and is, U.S. government policy to allow free trade with China. With the enthusiastic support of U.S. multinational companies, the U.S. has watched China undercut U.S. manufacturers for years. Ralph Laurens decision to outsource the uniforms was certainly a bad PR move, but it was a good bottom-line decision. The whole affair reminded me of a scene from the great movie Casablanca. Humphrey Bogarts character, Rick, is asking Captain Renault, the local gendarme, why his club is being shut down. Im shocked, shocked to find that gambling is going on in here, says the captain, just as a club employee hands Renault his cut from the clubs casino. Like Renault, U.S. legislators are shocked, shocked to find U.S. companies manufacturing in China, even as they fill their campaign coffers with contributions from companies that profit from it. The uniform flap does, however, serve to highlight the return of the Made in America debate. Despite the U.S. being completely enmeshed in the global economic system, during times of economic distress we return to this argument. Ironically, uniform-gate occurred at a time when U.S. manufacturing is growing much faster than the rest of the economy. Low labor costs, a low U.S. dollar and a reevaluation of outsourcing have spurred
Made (or not) in the U.S.A.
creation of more U.S. manufacturing jobs. A recent MIT survey stated 14 percent of U.S. manufacturers have plans to bring production back to the U.S. from abroad. However, with more foreign companies manufacturing in the U.S., its getting harder to say what a Made in U.S.A. product really is. Japanese companies have built cars in the U.S. for years, and, in terms of labor and parts, their American content rivals that of cars made by U.S. companies, which outsource large portions of their cars content. And all-American GM makes as much money from its Chinese operations as it does in the U.S. The aerospace industry is just as confusing. Boeing sends much of its parts manufacturing to other countries in an effort to get companies in those countries to buy its planes, which Boeing then assembles in the U.S. Meanwhile, its archrival, France-based Airbus, is building an assembly plant in Mobile, Ala., in large part to build political support when it bids on U.S. defense business. And a Chinese company wants to buy bankrupt Hawker Beechcraft Corp., the Kansas-based private aircraft maker. Its clear that the days when most products used in the U.S. were made in the U.S. by U.S. companies staffed by U.S. workers are over. Take the metalworking industry. If you attend IMTS 2012, youll once again see companies from all over the world selling cutting tools, machines and accessories. Most of the foreign companies have extensive U.S. operations, employing thousands of Americans to sell their wares to U.S. companies and machine shops. Some, like DMG/Mori Seiki USA and Mazak, are building or expanding U.S. manufacturing operations. Plus, consider that U.S. manufacturers are growing, in large part, by increasing their exports, not by selling more products in the U.S. Any investment, be it U.S. or foreign, in U.S. manufacturing is good for American workers. If the prognosticators are right, U.S. manufacturing still has a good future. Who knows? Maybe a U.S. company will be making uniforms for some other countrys Olympic team. CTE
industry news

Green technologies to power innovation
When you work as a futurist, like Dr. Patrick Dixon, you have to spend a lot of time in the present looking at lots of different information. I live in a very virtual world, said the London-based Dixon. Although trained as a physician, he works as a futurista business consultant who specializes in global change strategies. Being a futurist requires neither a crystal ball nor tea leaves. Instead, Dixon, the author of 15 books on management and trends, said, Im constantly sampling humanitys stream of consciousness. In his quest to stay ahead of the curve, Dixon taps into traditional and social media, including the Financial Times, New Scientist magazine, Twitter.com, YouTube.com and LinkedIn.com. Along the way, he explores hot topics such as environmental sustainability and the drive for business innovation. Dixon credits another crucial source of informaFuturist Dr. Patrick Dixon predicts major progress in green tion that helps shape his technologies will occur. views: the companies with which he works. I lecture or consult in on airplane wings to nanotechnology many different nations and to many dif- that reduces friction inside car engines. ferent industries every year. In each case, Many of the most exciting innovations I work with people who are creating the are invisible, Dixon said. future, people on the front edge of inMoreover, the way that innovation novation. They give a perspective that is occurs is shifting. In the past, corporate much sharper than what you would get innovation teams used to lock themfrom other sources. selves away until they were ready to So what does the future hold? apply for a patent. Now, according to Dixon predicts major progress in Dixon, many of the biggest innovations green technologies will occur. This mo- are happening more openly. ment in history is one of extraordinary Companies such as Hewlett-Packard, opportunities, he said, because concern GlaxoSmithKline and IBM are using about the environment is driving gov- open-innovation tools, sometimes givernment policy and consumer demand. ing a problem to several universities to Consumers expect their companies crack or even turning to social media. to produce products that are greener but Many of the worlds greatest challenges not more expensive, Dixon said. And are too complicated to be solved by any theyre getting those products, because one companys research department, innovation can deliver both. he said.
Dixons latest book, Sustainagility: How Innovation and Agility Will Save the World (2010, Kogan Page Ltd.), details dozens of ways companies have found to become greener. Even the most profit-focused companies have realized that the fastest way to grow is to look after the environment, he said. Reducing global warming saves money. Thats why the green tech revolution is advancing so fast. New fuel-conserving inventions are springing up everywhere, from winglets
Global warming may indeed bring challenges humanity has never before faced. Yet companies that are nimble and entrepreneurial can take advantage of upheaval. The world can change faster than the time it takes for you to organize a board meeting, so you have to plan ahead. In crisis there is opportunity, Dixon said. Thats the lesson of history. Some of the greatest fortunes have been made at times of economic meltdown or war or chaos. Companies need leadership teams that are able to make a big leap. In facing the future, the real key to success is agility, Dixon said. Its always having plan C, because plan B is not enough. Every sensible leader has at least two backup strategies. Donna Guinivan, marketing communications manager, Trelleborg Group AB, Sweden
PCD
tools compete with monocrystalline tools
Monocrystalline, or natural, diamond cutting tools are widely applied when making precision parts, such as optical lenses, because they can impart ultrafine surface finishes and achieve exceptionally high profile accuracy. However, monocrystalline diamond costs two to five times more than other tool materials, such as sintered PCD and carbide. For decades, chemical vapor deposition has been used for depositing polycrystalline diamond (called CVD diamond or PCVD) film from 2m to 500m thick on cutting tools, such as carbide ones with less than 6 percent cobalt content. Then, nearly 2 decades ago, Norton Diamond Film, then a unit of SaintGobain Abrasives Co., Worcester, Mass., became one of the first companies to grow CVD diamond film to about 1mm thick. (The companys operations have since been merged into other SaintGobain units.) When comparing mechanical properties (see Table 1 on page 18), CVD diamond is much harder and stronger than sintered PCD, tungsten carbide, silicon nitride and silicon carbide, but not much different from natural diamond.
However, the technology breakthrough didnt transform into market success because of the high cost to produce the CVD diamond thick film and fabricate a cutting tool. The secret of cutting with diamond is to use a diamond tools hard face and direction to cut a workpieces weak faces and directions. To make tools more capable of doing this, the hard and weak crystallographic planes of CVD diamond thick film are grown together to make it a stronger cutting tool material. However, accurately grinding that material into the required shape significantly increases manufacturing difficulty and cost. Because the price of natural diamond has been rising quickly over the last several years, toolmakers began looking for practical and economical technologies to produce CVD diamond thick plate and fabricate tools. Strong industrial demand gave birth to a new generation of DC arc plasma reactors, which can cost-effectively grow CVD diamond up to 100mm in diameter and 2mm thick. Looking at the materials chemical composition, CVD diamond is 99.999 percent pure carbon and more pure than natural diamond because CVD diamond is made in a controlled-lab environment. Therefore, lab-grown diamonds generally make higher quality cutting tools. Nonetheless, high internal stress is often observed inside CVD diamond because of its rapid growth. This is one of the properties that prevents CVD diamond from being effectively grown into thick plate and makes it difficult to grind. The newly developed DC arc
plasma reactor by Simple Technology Inc., Henderson, Nev., effectively reduces the residual stresses inside diamond and consequently improves grinding results. To make matters worse, CVD diamond has its crystallographic planes randomly oriented inside its structure, and different planes have different hard-
ness levels and strengths. Even within the same crystallographic plane, strength varies from direction to direction. As it is being ground from one direction, the wear resistance from each diamond grain is different, and the diamond grinding wheel may not be able to cut a plane in one grain thats oriented in its hard direction. As a result, grinding CVD
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A DC arc plasma reactor can grow CVD diamond up to 100mm in diameter and 2mm thick.
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ctemag.com | 17
industry news
diamond thick plate becomes a manufacturing headache. The difficulty was overcome with the development of new diamond grinding wheels by Simple Technology in the last 2 years that employ a unique bond that enables grinding CVD diamond thick plate accurately and with fine surface finishes. The recipe for making the grinding wheel is proprietary, but the technology breakthrough enables CVD diamond cutting tools to be economically produced. The quality of CVD diamond tools has also evolved. Lab tests at the Custom Craft Lens Service Inc., a leading lens manufacturer located in Las Vegas, show that a new CVD diamond tool from Simple Technology for making precision lenses has a surface waviness of 0.37m on the cutting edge, which is the same surface quality as a monocrystalline diamond tool. Since summer 2011, when the new CVD diamond tools became available from Simple Technology, Custom Craft
CVD diamond Knoop hardness (GPa) Youngs modulus (GPa) Thermal conductivity (W/mK) Density (gm/cm3) Natural diamond 50 to 100 Sintered PCD 50 to 75 Tungsten carbide (6% cobalt) 18 Silicon nitride 16 Silicon carbide 20
85 to 100
1,180
1,050
800
600
310
400
600 to 1,600 (in plane) >2,000 (perpendicular)
1,000 to 2,000
500
100
40
135
3.51
3.51
4.1
1.5
3.2
3.2
L.K. Bigelow, Journal De Physique IV, Colloque C7, supplement to Journal de Physique 111, Volume 3, November 1993
Table 1. Properties of CVD diamond compared to other materials.
has been applying them on an Optoform lathe to manufacture lenses. According to the company, a CVD diamond tool cuts as many lenses as a monocrystalline diamond tool before tool relapping is required and costs 30 percent less. Diamond tool manufacturer K&Y Diamond Ltd., St.-Laurent, Quebec,
also tested the new CVD diamond tools in its labs and in Germany for more than 6 months. According to K&Y Diamond, the new generation of CVD diamond tools matches the results from monocrystalline diamond tools when cutting optical lenses. The company is examining cutting CVD diamond plate
with lasers as an alternative to cutting it with diamond grinding wheels. The low tool cost for CVD diamond is partially a result of the transition from microwave plasma reactors to DC arc plasma reactors, which enable more rapid production of much larger CVD diamond thick plate in each reactor run. Z.Y. John Wang, Ph.D., Department of Mechanical Engineering, University of Nevada, Las Vegas; William T. Wang, Simple Technology Inc., Henderson, Nev.; and Y.H. Dong and L.H. Dong, Institute of Marine Materials Science and Engineering, Shanghai Maritime University, China

for such goods, indeed better than expected. But a detailed reading of the numbers offers a less optimistic view. Total orders increased $2.32 billion. Defense orders went up $865 million, accounting for 37 percent of the total increase. But defense was set for a rebound after a sharp contraction in April. Meanwhile, machinery orders went up
$1.263 billion, accounting for another 54 percent of the total increase. But much of the increase in machinery orders was for turbines, which were also expected to rebound after a weak April. What happened to machinery outside of turbines? Core capital goods went up $1.024 billion, which was less than the machinery number, meaning
Cutting tool sales rise in May
The total billings index for membercompanies of the United States Cutting Tool Institute increased in May compared to April, rising 8.8 percent. May had the second highest index percentage for 2012, with only March posting a higher one. Compared to May 2011, the index was up 16.5 percent in May 2012. In addition, total billings in dollars for May 2012 climbed 15.25 percent compared to the previous May. For more information about USCTI, call (216) 241-7333 or visit www.uscti. com.
YOUR PROBLEM IS NOT UNIQUE.

At least not to us. Ritens technical support group has nearly 200 years in combined machine tool experience. Weve worked closely with hundreds of customers to perform minor miracles on under-performing manual and CNC lathes and grinders. We can: Repair and rebuild tailstocks, headstocks, live quills and spindles Do custom upgrades on older machines to increase capacity, speed and accuracy Custom engineer workholding products Detect and resolve bearing problems Provide on-site field service on installed equipment Do test runouts and metallurgical certifications Dont think that your problem is unique. After 75 years, Riten has been there, done that, and is ready to help you. Give us a call at 1-800-338-0027.
Total Billings Index

(The index uses 2007 annual data, which equals 100 percent, as its baseline.) 2010 May April March February January December 87.9% 2011 105.9% 103.1% 114.9% 93.2% 94.2% 108.0% 2012 122.4% 113.6% 126.7% 120.9% 115.1%
The USCTI collected the above data from member-companies.
Durable goods demand mixed in May
On the surface, the May durable goods report from the U.S. Department of Commerce suggests robust demand
Solutions, not excuses
www.riten.com
ctemag.com | 19
industry news
that some of the increase in machinery was for parts, which are not included in capital goods. The conclusion is that, outside of turbines, demand for core capital goods was a bit soggy. May numbers were not as strong as the headlines suggest, but the month was probably not that bad either. Demand for capital equipment appears to be creeping higher. This just means manufacturing activity is more in line with overall GDP growth, which is positive but muted. This is in contrast to the first quarter, when manufacturing surged. Clearly, the slowdown in overseas demandprimarily in Europe and Chinais the culprit. U.S. business capital spending will still grow this year, but not as strongly as in 2011. Highlights of the report include: n Durable goods orders increased by $2.32 billion (1.1 percent) after falling $8.6 billion over March and April. n Expectations were for a modest decline stemming from weak aircraft orders. Instead, total aircraft orders grew $696 million (5.5 percent). n The major positives besides aircraft were motor vehicle orders (0.5 percent); electrical equipment, appliances and components (1.1 percent); and machinery orders (4.1 percent). The major negatives were metals declined 0.8 percent, and computers and electronic products slipped 0.9 percent. Paul Edelstein, director of financial economics, IHS Global Insight
The following letter is in response to Susan Woods article Avoiding Holding Penalties about toolholders for endmills in the July issue.
I enjoyed reading your article. One trick thats not well known for improving a slightly worn endmill holder is to grind a flat 180 from the Weldon flat on the endmill shank to bridge the wear spot and achieve three-point contact. The tool will hold better and be basically like a new toolholder. Just dont grind a CTE large flat widthwise. GARY SCHMIDT M.A. FORD Manufacturing Co. Inc. DAVENPORT, IOWA
correction
An incorrect torque specication was provided for Makinos a51nx and a61nx horizontal machining centers in the sidebar article on page 70 about cutting iron with 40-taper machines within the Pedal to the Metal article about high-speed/ high-performance milling in the July issue. The correct torque is up to 223 ft.-lbs. Cutting Tool Engineering regrets the error.
FOR OVER 50 YEARS, PROUDLY MANUFACTURING CUTTING TOOLS IN CLEMSON, SC
When a drill leaves my area, it has to be 100% and I make sure of that. I make sure these drills are exactly what our customers need to get the job done.
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www.gfii.com 800.348.2885
new product focus
Suppliers can send press releases about new metalworking products to Cutting Tool Engineering, 40 Skokie Blvd., Ste. 450, Northbrook, IL 60062; or by e-mail to alanr@jwr.com.
.
Quickmill says its Annihilator series of gantry machining centers have a simple gantry design that enables quick installation, enhanced rigidity and faster speeds. A FaNUC or Siemens control is available. The machines are for producing large parts, enabling shops to increase their range of services, according to the company. Quickmill www.quickmill.com
- . Nextec Laser Metrology LLC says its WIZprobe

noncontact laser-scanning sensor significantly reduces component inspection time. The sensors large dynamic range enables collecting thousands of data points quickly and accurately, the company reports. It can measure a variety of materials at varying angles and surface finishes, including shiny surfaces. The sensor automatically performs self-calibration via real-time, closed-loop adaptive control. Nextec Laser Metrology LLC www.nextec-wiz.com
. Walter Surface Technologies Internationals Enduro-Flex flap disc has a backing that can be trimmed to extend product life. This also imparts a more consistent surface finish and removes more metal, according to the company. A 5" 40-grit disc removes up to 2,500 g of material during its lifespan. Walter Surface Technologies International www.walter.com
. Kistlers Type 9129A is a three-component,

modular cutting force measurement system for turret lathes. It measures forces up to 8 kN when turning IDs and ODs. The systems dynamometer has four integral, threecomponent force sensors, the outputs of which are sent to its corresponding nine-way flange socket. To minimize temperature errors, the force sensors are mounted with electrical ground isolation under high preload conditions between the cover plate and two lateral base plates. Kistler www.kistler.com
machine shop managers than any other magazine in the metal, metalworking and machinery market.*
15,551 machine shop managers subscribe to CTE
2 July 201 www.c
| Issue | Vol. 64 om
CUTTING TOOL ENGINEERING reaches more
temag.c
December 2011 BPA Circulation Statement
October Editorial Focuses: Parts Design; EDMing; Reaming; Testing & Measurement. Ad Close: September 4, 2012.
require milling peed ce High-s erforman -p a high ng system ni machi s
Advertise in CTE the magazine machine shop managers subscribe to!

2:18 PM
ills n endm shop n lding all for ho the sm s collets g for vs. ER n Deburrin duct review lders ck ho training working pro C elo Sid tal m CN 2 6/18/1 Plus: benefits fro lder and me lho ing big g tool, too Reap Cuttin
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See the 1910 Packard on display at CTEs 2012 IMTS booth, #W-1900.
new product focus

. The Luxxor
portable video camera from Gradient Lens Corp. attaches to any Hawkeye rigid or flexible borescope, as well as most other brands. The camera allows users to view internal visual-inspection images on portable or benchtop video monitors or on a computer. Video footage and still images can then be viewed, saved, documented and e-mailed. The resolution on the " color CCD is 768494 pixels. Gradient Lens Corp. www.gradientlens.com/lpc
. South Bend Lathe Co.s Model SB1024F variable-speed milling

machine has a Fagor 3-axis digital readout for table positioning. The machine features a longitudinal power feed, adjustable halogen work light, hardened and ground table surface, chromed steel quill and Meehanite body castings. The X-axis and Y-axis lead-screw nuts are double-bronzed for ultrasmooth movement with minimal backlash, according to the company. South Bend Lathe Co. www.southbendlathe.com
- . Rockford Systems Inc. offers a roll-up lead-screw protection device for lathes. The safety device protects the operator by preventing him from contacting moving machine parts and keeping clothes from becoming entangled with those parts. Two self-rolling/unrolling units consist of a tear- and oil-resistant band attached to aluminum and pressed-steel brackets, which secure to and travel with the lathe carriage. The device is available in various band widths and lengths. Rockford Systems Inc. www.rockfordsystems.com . The ProHold 4" double-acting, two-station hydraulic vise from Planet Products Corp. is for production workholding applications. It provides a full bidirectional, hydraulic, 1.75" stroke with up to 6,000 lbs. of clamping and unclamping force. Each station clamps independently of the other, allowing various size parts to be fixtured in the same machining operation. Planet Products Corp. www.planet-products.com
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ctemag.com | 25
managers desk
staying sharp
By Keith Jennings
Managing in the middle
fter reflecting on a few of my recent if no one is screaming about something, visions of management incidents and assessing whether pointlessly surfing the Internet or going home early I handled them correctly or maybe crashed to hang with guests can creep onto the scene and be a and burned, it crossed my mind that management distraction from utilizing that very valuable middle of shop fire drills is like a set of bookends. The time. drama of unexpected incidents, machine breakdowns As Ive instructed my hard-working shop guys, or employee problems that require a manager to just because youre frantically running around, stop everything and immediately handle is hopefully sweating and seeking a crisis to manage doesnt interspersed with periods of relative calm. necessarily mean youre being productive. Some As president of a small company, the fire-drill management gurus claim that scenario indicates other situations I typically encounter include having to problems. Perhaps if your management acumen was make decisions other supervisors do not have the better, those incidents would be less frequent. But, authority to make or arent when youre transitioning comfortable making. So, established company Effective management during calm an my involvement is required, from a crisis-driven, quickperiods is still as important regardless of what I have turnaround environment scheduled. Between these to a more organized and as crisis management. bookend crises, hopefully, predictable one, that you have time to get some mindset is difficult to break. tasks accomplished in a nonemergency manner. Plus, some people like the adrenaline rush of a crisis Effective management during calm periods is still situation. So, while Ive not yet rid our company of as important as crisis management even though its senseless, distracting events, this summer has been tempting to take advantage of the time and not be as more defined by fighting the temptation to be lazy aggressively involved with certain issues. when there isnt a crisis. Ive had my share of annoying matters to deal with Thankfully, I have not allowed myself to slip into recently, including some discussed in previous columns. such a situation too frequently, but its hard at times. Like clockwork, my June vacation was disrupted by After all, when the shop is quiet and seems to be work problems, which I still had to resolve when I running smoothly, isnt it OK to disappear and enjoy returned. It didnt stop there, with equipment problems a margarita? Every now and again, yes it is, assuming and similar issues consuming my time. your shop has enough people who can handle matters Then, when things calmed down after a hectic in your absence. several days, I found myself having to resist the However, if you fail to take advantage of the periods temptation to postpone or ignore working on of calm between the bookend predicaments, youre nonurgent projects. Then in July, we had out-of-town likely missing a great opportunity to truly organize guests visit, spent time with our daughters while your shop, fix what needs fixing, meet with important they were home from college for the summer and clients or read more about those new CNC machines celebrated the Fourth of July. All of this combined you want to buy. Dont forget to manage in the middle. made it tempting to forego other duties that werent A future fire may be averted because you did. CTE emergencieseven though it was an ideal time to tackle some of them. About the Author: Keith Jennings is president of Crow After all, fire drills are tiring and if the shop is Corp., Tomball, Texas, a family-owned company focusing on functioning OK, a quiet day of writing, organizing machining, metal fabrication and metal stamping. Contact or strategizing can be a welcome endeavor. However, him at kjennings@jwr.com.
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machine technology
staying sharp
Importance of tool presetting

By Dr. Scott Smith, University of North Carolina at Charlotte
To most machine tool users, the meaning of endmill presetting is actually closer to endmill length measuring. The endmill
is mounted in the toolholder, with the tool length approximately correct. The gage length of the tool is then measured in a presetting station or by a touch-off procedure in the machine tool. The difference between the actual tool length
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The basic principle of Skiving / Roller Burnishing is the skiving tool (a modified floating reamer) produces a geometrically true round bore, which is a prerequisite for successful roller burnishing. To date, this process has proven to be the fastest method of ID finishing of seamless or DOM tubing, with average rates of metal removal from 100 to 150 IPM. Total stock removal in one pass as much as .375 on diameter. It is common to produce ID hole sizes to within .0005 on diameter & 6-10 RMS finish. Float reaming or skive tooling is becoming increasingly popular where customers are needing to increase cycle times & eliminate timely hone operations. The basic principle behind this tooling is the tool body holds a floating cutter magazine with two cartridges & inserts that oppose one another & have diametrical adjustment of .080 .118 depending on the tool diameter. These tools are designed to follow the parts existing hole & give you uniformed size, finish, & wall thickness as well as produce a geometrically true round bore. These tools are capable of opening up existing bores 1/8 or less on diameter & drill depths exceeding 100 times diameter.
Figure 1. Shaft collars mounted on endmills permit repeatable tool-length setting with a tight tolerance.
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and the tool length used when the NC program was prepared is entered in the CNC as a tool length offset. The control uses the offset to adjust the NC program to correctly position the tool tip. The U.S. standard for overall length tolerance for endmills is specified in ANSI B94.19-1985. For all endmills except those for heavy-duty use, such as roughing, the overall length tolerance is 0.062", about 116". Many users control the installed tool length with a substantially worse tolerance than that. From the point of view of NC programming, the tool is a cylinder and absolutely rigid. If the cylinder length differs from the length that was used during programming, it is a simple matter to adjust the Z-axis position of the machine and place the tool tip in the geometrically correct position. If the geometry of the intersection of the cylinder and workpiece were all that mattered, this strategy would work. However, the length of the tool
Controlling tool length is important, and, fortunately, there are some simple procedures to set the tool length repeatedly with a tolerance at least an order of magnitude better than the ANSI standard. Soraluce Aduse - IMTSa halfpageisland-test3.pdf One strategy isCTE to shaft collar
(Figure 1). Prior to the mating of the tool and holder, the collar is clamped on the endmill. When the endmill is inserted into the holder, the collar provides a stop for the axial position of the tool.
1 7/13/2012 4:00:52 PM
(continued on page 32)
BlueSwarf
C
CM
MY
CY
CMY
BlueSwarf
Figure 2. A shaft collar on an endmill, aligned with a witness mark on the toolholder, provides a repeatable cutting-edge position and improves balance.
affects much more than the geometry. The cutting performance of the machine-and-tool combination strongly depends on tool length (see my June 2009 and March 2010 columns). Tools set at the wrong length can easily cause chatter. Random procedures in tool length setting lead to random machining performance.
ctemag.com | 29
machine technology
(continued from page 29)
staying sharp
With the collar in place, the tool length is held constant for all types of holder styles, including shrink fit, collet and hydraulic. In shrink-fit holders, the collar should be left in place until the holder is cool. In collets or hydraulic holders, the collar should be left in place until the collet is tightened or until the hydraulic clamping is achieved. The collar can also be used to
accurately position the flutes and improve balance repeatability. A cutting edge can be aligned with the slit in the collar (like a gun sight), and then the slit can be aligned with a witness mark on the toolholder (see Figure 2 on page 29). This sets the teeth in the same angular position with respect to the holder every time the tool is changed. The position of the shaft collar on an endmill can be set, for example, using a Stop-Loc device (Figure 3). The sliding stop on the Stop-Loc is set to the desired length of the tool minus the thickness of the collar. The tool tip is placed against the sliding stop, and the collar is attached to the endmill at the end of the device. The collar is held in position with a screw clamp. The collar then provides a stop for the tool when it is inserted in the holder. After the tool is inserted, but before cutting, the collar is removed. Experiments have shown that most operators can use this procedure to quickly and reliably set the tool CTE length with a tolerance of 0.004".
About the Author: Dr. Scott Smith is a professor and chair of the Department of Mechanical Engineering at the William States Lee College of Engineering, University of North Carolina at Charlotte, specializing in machine tool structural dynamics. Contact him via e-mail at kssmith@ uncc.edu.
Stop-Loc
Figure 3. A Stop-Loc device is used to set the position of the shaft collar on an endmill.
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workholding
staying sharp
Defining chucks used for turning

By Joe Mason, United Machining
For turning applications, there are many types of workholders. One is the chuck, a universal holding device capable of OD or ID clamping. It can be manually, pneumatically, hydraulically or electrically actuated. Lathe chucks are mounted horizontally, vertically (facing up) or inverted (facing down). The chuck is bolted to a machine-mounted adapter plate. A drawtube is connected from the rear of the chuck, and the CNC or operator actuates the drawtube to clamp and unclamp the chuck. Workholding components, sometimes called top tooling, are mounted to the chuck face. (Top tooling components are sometimes, but not always, jaws.) The workpiece is placed in the center of
Figures 1 and 2. A 3-jaw OD chuck (left), and a 3-jaw ID chuck.
the tooling, the drawbar is actuated and the part is clamped in a defined manner based on the type of chuck being used. The jaws (or another type of top tooling) slide to and from the chuck centerline. There can be two to eight jaws, depending on part shape, configuration and clamping area available. Figure 1 is a typical 3-jaw OD chuck. When using a 3-jaw ID chuck (Figure 2), the part ID may or may not have been ma-
Figure 3. A part being held between centers.
chined prior to setup. All chucking operations require a specifically designed process, because to function correctly the jaw diameter must closely match the part diameter. Figure 3 shows a part being held between centers that was previously machined on the ends. This allows the part to be completely turned in a single
operation, which is common for finish turning and hard turning applications, such as turning shafts with tight tolerances from end to end. Turning between centers with face drivers requires a chuck, a driver mounted in the chuck and an opposing center for stability. As with most workholders, specific chucking solutions for unique cutting requirements are custom-designed. For example, Jade Tool Inc., Traverse City, Mich., has been designing and building custom chucks for more than 20 years.
Among other products, the company has developed pin chucks for roughing and finishing. The following examples are custom chucks designed by Jade Tool. A pin chuck (Figure 4) pulls the part
against the stop face (end stop) and has jaws that rock side to side to ensure secure six-point contact on the part, even if it is out of round. A collet chuck (Figure 5) can be an
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ctemag.com | 35
workholding
ID or OD gripping chuck. It grips with either a pullback action to help pull the part against the end stop or a static grip for thinner parts that may be distorted by the pullback action. A diaphragm chuck (Figure 6) can also be an ID or OD gripping chuck. It is normally used for finish machining, grinding or inspection. Because of its low-profile jaws and built-in chip slots, it can also be used for milling. Jade Tool also offers a soft-touch chuck (Figure 7), which can be an ID or OD gripping chuck as well. This chuck, which uses jaws, centers and supports a part around its entire ID or OD and has a patented design to hold thin-wall parts without distorting them. Thin-wall parts are a growing challenge because they are being used more frequently in automotive components to reduce weight. How a part is clamped is directly related to the print that defines the parts most important features and how those erations is necessary. The part print defines the locating scheme and subsequent chucking requirement. The parts geometrical tolerances on the finishing print will complete the workholding plan. It is extremely important to understand Figures 6 and 7. A diaphragm chuck (left), and a soft-touch the required tolerances, chuck. especially when finishing part features in multiple operations or features are related. Cast or forged round parts should have setups. CTE a machine start dimension taken from the primary datums. If primary datums About the Author: Joe are not designated, then a review of the Mason is cost estimator part finish requirements determines the and process engineer for required initial and subsequent finish United Machining Inc., Sterling Heights, Mich. workholding. In most circumstances where the parts He has worked in the OD, ID and ends require finishing, turn- metalworking industry ing consists of roughing and finishing. But since 1978. Contact him at cncgcode@ sometimes only one of these turning op- earthlink.net.
staying sharp
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shop operations
staying sharp
Threading on the manual lathe

By Tom Lipton
Screws and screw threads hold millions of things together. Nearly as many types and forms of threads exist as there are products that use threaded fasteners and connections. Equally, there is much confusion and misuse of threads in general among those who arent gearheads. From the machinists point of view, cutting threads is a satisfying experience. When youre done, hopefully, you have two parts that mate together with a level of precision and smoothness not found in run-of-the-mill, hardware-grade fasteners. I have always enjoyed cutting threads on the manual lathe and have learned a few tricks over the years. Align your threading tool against a freshly faced end or against the side of the chuck. The little arrow-shaped alignment
cepts inserts. The inserts are precisely ground and easily changed. One insert cuts dozens of thread pitches. I learned how to thread on the lathe using the compound infeed method. Contrary to popular belief, the compound set doesnt have to be at half the thread angle. By using whats called modified-flank infeed and changing this angle, you help alleviate threading problems All images: T. Lipton in difficult-to-cut materials. Align your threading tool against a freshly faced end or Another advantage to against the side of the chuck. threading with the comtools you see are a pain and are only good pound is you dont have to keep track of for gaging hand-ground tool bits. the dial position. The cross-feed dial is al If you do a lot of threading on a ways zeroed after each pass, so you have manual lathe, invest in a tool that ac- less to remember, such as whether the
last pass was at 0.030" or 0.050". The main disadvantage is your Z-axis position changes as you feed in. This is usually not a problem on external threads, but it can be on internal threads that end against a shoulder. Try the following strategies when you are ending threads and the part designer has not specified a thread. When I want to do something with the groove that gets cut at the end of the thread, I usually use the threading tool and traverse a small relief at the end. It saves a tool change and looks OK. If I want a nicer look, I switch to a radius tool. Just be sure the relief is a little smaller than the threads minor diameter so the mating part will thread all the way to the shoulder.
member, its easy to pull a rope; its really hard to push one. When you have a choice, fine threads are easier to cut and need fewer passes than coarse ones. The shallower depth on difficult-to-cut materials might save your bacon. For quick and easy day-to-day
threading gages, I keep a complete set of nuts on rings in my toolbox for fitting threads. One ring holds coarse threads and the other holds fine ones. When you thread, be sure to run the nut the full length of the threads. When left to their own devices, machinists tend to cut threads tighter than necessary.
Keep a complete set of nuts on rings, with one ring for coarse threads and the other for fine threads.
Use a large DOC on your first pass during threading. The point is small; in the first couple of passes, the area of the tool tip engagement is also small. Taper your DOC as you get deeper. On the last pass, feed straight in with the cross-feed at a light 0.001" spring cut. This cuts on both tool flanks and removes chatter and tool marks from the thread. I can never remember which line on the threading dial to use with which thread pitch. If youre lucky, it will be marked. When in doubt, just use the same number or line each time. Always use the same number when cutting multiple-start threads. Do internal threading from the inside out with left-hand tools. You will get less chatter and see whats happening down the bore. You will need left-hand threading tools, running the lathe in reverse. Rectemag.com | 43
shop operations
Mating materials in threaded connections are important. If you must use the same material for male and female threads, do yourself a favor and put a few molecules of thread lubricant or antiseize on them before you crank them together. If you do happen to get male and female threads wedged together in an inti-
staying sharp
mate embrace, a simple trick to separate them is to quickly warm the female portion to 100 F or so, using a propane torch. A quick shot of penetrating lube before you twist might save the work. When measuring threads, a dedicated thread micrometer is handy and quick to use at the machine. But for
A thread file is ideal for straightening the annoying half thread fade at the beginning and end of an external thread.
the highest accuracy, use the three-wire thread measuring method. This method is more accurate because the wires present a true parallel surface for measuring. If its good enough for the gage makers, its good enough for me. A piece of modeling clay or window glazing putty can help hold pesky thread measuring wires. Better yet, buy a set of the plastic holders that fit the micrometer spindle. Thread files actually work. They are great for straightening the annoying half thread fade at the beginning and end of CTE an external thread.
About the Author: Tom Lipton is a career metalworker who has worked at various job shops that produce parts for the consumer product development, laboratory equipment, medical services and custom machinery design industries. He has received six U.S. patents and lives in Alamo, Calif. Liptons column is adapted from information in his book Metalworking Sink or Swim: Tips and Tricks for Machinists, Welders, and Fabricators, published by Industrial Press Inc., New York. The publisher can be reached by calling (888) 528-7852 or visiting www.industrialpress. com. By indicating the code CTE-2012 when ordering, CTE readers will receive a 20 percent discount off the books list price of $44.95.
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staying sharp
ask the grinding doc
Dear Doc: I creep-feed grind slots in hardened steel and am constantly battling burn. Some days I can crank up the feed rate and grind without burn, but other times burn occurs even at a low feed rate. Why?
The real cause of burn
The Doc Replies: My customers think grinding faster is the primary cause of burn. Therefore, I first have them test for burn and chart burn severity vs. specific material-removal rate (SMRR). The SMRR is calculated by the following equations, both of which give results in mm2/sec. DOC (mm) feed (mm/min.) 60, or 10.75 DOC (in.) feed (ipm). If you keep all other grinding conditions constant, burn should increase as you increase the SMRR. However, other factors play an even more important role than
J. Badger
Higher SMRRs are not always the cause of burn.
SMRR, and if these arent chosen correctly youll get results like those shown in the figure above, taken from a company flute-
grinding HSS, which shows the severity of burn from acid cooking. Acid cooking is a process whereby the workpiece is boiled
By Dr. Jerey Badger
in hydrochloric acid to show the severity of residual tensile stresses. Why are the results all over the place? The biggest cause of burn is not an SMRR thats too high. Instead, its caused by dull dressing, a timid grit-penetration depth (i.e., not grinding aggressively) or bad cooling when creep-feed grinding. If you have oneor allof these conditions, youll burn the workpiece regardless of the SMRR. The theoretical surface temperature vs. SMRR for creep-feed grinding at a 1mm depth and increasing feed rates can be calculated using The Grinders Toolbox, a program I use to predict grinding temperatures. For a given set of dressing and grinding conditions, temperatures rise with an increasing SMRR. Thats fine and reasonable, but if you have dull dressing, a timid grit-penetration depth and bad cooling, youre going to experience burn at a much lower SMRR. (To see a chart illustrating SMRR for different grinding scenarios, see the online version of this article at ctemag.com. Under the shortCUTS menu, click on Grinding Doc.) Lets say your burn threshold is 600 C. If you dress aggressively and choose an aggressive grit-penetration depth, you can grind about as fast as you want and not burn. But if you dont dress right or if your speeds and feeds are timid or your cooling is poor, be prepared for burn at low SMRRs. Dear Doc: I ID grind tungsten carbide with 240-mesh electroplated diamond wheels. When I first use a wheel, the first few parts have a poor surface finish and chatter marks before good parts are produced. Is there a way around this? The Doc Replies: I recently visited a company that had the same issue. To overcome it, the operator mounts the wheel and then uses a dial gage, a piece of wood and a mallet to tap the wheel as close to true as possiblewithin 0.001" and preferably less. He then grinds several IDs undersize and allows the wheel to break in. This knocks off the high,
rogue grits. Once the wheel is broken in, he reruns those parts to size while proCTE ducing the others.
About the Author: Dr. Jeffrey Badger is an
independent grinding consultant. His Web site is www.TheGrindingDoc.com. Hell be giving a Rollomatic-hosted grinding course about grinding tungsten carbide Nov. 6-8 in Mundelein, Ill., near Chicago.
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ctemag.com | 49
Archives MNATP, Collection Meillassoux
Mixed Message
CTEs 2012 Salary Survey reveals how much various metalworking professionals are making.
.S. manufacturing has been on a roller coaster ride over the past 4 yearsgoing way down during the Great Recession, rising and then recently dipping again. Some sectors have rebounded nicely while others have struggled. Salaries in the metalworking industry reflect that scenario. Some metalworkers have seen salaries rise, others have seen them drop. But nearly everyone has seen benefits decline, perhaps reflecting companies desire to control costs in an uncertain business environment, according to Cutting Tool Engineerings Seventh Biennial Salary Survey.
cover story
The top moneymakers, as usual, are corporate managers. They averaged $102,563, which is down $12,877, or 11.2 percent, from 2010. Other positions that registered a decline are plant management and engineering supervisorthe second and third highest paid positions, respectively. Plant managements pay dropped $3,685, or 4.7 percent, to $74,281 on average, and earnings for engineering supervisors dipped $676, or 0.9 percent, to $72,880. Design engineers were the biggest gainers, increasing $6,287, or 11.2 percent,
from 2010 to make $62,568 on average in 2012. Manual machinists received the smallest increase. Their pay went up $697, or 1.8 percent, to $38,294. The benefits picture is a different story. Basically, all positions saw an across-the-board reduction in benefits: health insurance, dental insurance, profit sharing/401(k), paid training/continuing education and use of a company car. As the cost of health insurance continues to spiral upward into the stratosphere, only the majority for two positions receives that benefit: CNC machinist at 56.1 percent (down from 71.6 percent in 2010) and corporate management at 63.0 percent (down from 79.3 percent). In 2010, most positions topped 50 percent for health insurance. For dental insurance, the majority for only one positioncorporate management at 58.2 percentreceives it when the majority for most positions received that insurance as a benefit in 2010. However, 26.7 percent more corporate managers had their teeth covered in 2010. Even as metalcutting equipment and software continues to advance technologically, less than 50 percent in all positions receive paid training/continuing education. CNC machinists have the highest percentage for this benefit in
2012 at 42.3 percentdown from 71.3 percent in 2010. Most programmers, shop supervisors, plant managers and corporate managers also used to receive paid training, according to the previous survey. Similar to the 2010 survey, CTE used e-mail to collect survey data from owners and managers of parts manufacturing companies who subscribe to the magazine. The e-mail directed them to a Web-based survey that requested average annual salaries and benefits for themselves and their employees. CTE sent 9,963 e-mails, which didnt ask participants to identify themselves in the survey unless they wanted to enter a drawing for an incentive prize. We received 189 completed responses. The average salary was calculated according to the arithmetic mean. For example, if four recipients indicated their programmers earn average annual salaries, even when receiving an hourly wage, of $46,000, $59,000, $51,000 and $53,000, the mean would equal $52,250. The benefit percentages were calculated by dividing the total number of positive replies for a specific benefit by the CTE total number of respondents. Special thanks to Dennis Spaeth, electronic media editor, for survey coordination.
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National Average
gained
$160,000 $140,000 $120,000 $100,000 $80,000
in 2010, corporate managers in the South make the most compared to other regions, earning $131,497 on average in 2012. Thats an increase of $1,695, or 1.3 percent. A corporate manager in the Midwest earns the least vs. that position in other regions, at $94,483.
$102,563 $38,294 $45,615 $51,462 $52,736 $59,653 $62,568 $64,353 $59,449 $72,880 $74,281
MM: Manual Machinist CNC: CNC Machinist P: Programmer TD: Tool & Die Maker TME: Tool/Manufacturing Engineer DE: Design Engineer PE: Project Engineer SS: Shop Supervisor ES: Engineering Supervisor PM: Plant Management CM: Corporate Management
$60,000 $40,000 $20,000
MM CNC
TD TME DE
PE
SS
ES
PM
CM
Region
EAST
( ME, NH, VT, NY, PA, DE, MA, RI, CT, NJ, MD, WV )
Region
SOUTH ( TX, AR, LA, MS, AL, FL, TN, KY, VA, NC, SC, GA )
$160,000 $140,000 $120,000 $100,000 $80,000
$160,000 $140,000 $120,000 $100,000 $80,000
$104,069
$37,992
$46,085
$41,346
$62,500
$80,000
$73,750
$65,000
$59,545
$68,333
$34,460
$42,186
$50,111
$54,724
$65,750
$66,408
$63,500
$59,224
$72,400
$40,000 $20,000
$68,667
$40,000 $20,000
MM CNC
TD TME DE
PE
SS
ES
PM
CM
MM CNC
TD TME DE
PE
SS
ES
PM
$69,769
$60,000
$60,000
CM
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$131,497
Region
MIDWEST
( OH, IL, IN, MI, WI, MO, IA, MN, OK, KS, NE )
$160,000 $140,000 $120,000 $100,000 $80,000
$40,000 $20,000
MM CNC
$38,714
$46,600
$51,823
$52,432
TD TME DE
$60,662
$57,467
PE
$67,125
SS
$61,483
ES
$75,955
PM CM
Region
MOUNTAIN
( MT, ID, WY, CO, NM, AZ, UT, ND, SD )
$160,000 $140,000 $120,000 Insufficient data Insufficient data $100,000 $80,000 $37,125 $44,508 $62,400 $42,880 $37,667 $60,000 $40,000 $20,000
$77,180
$67,333
MM CNC
TD TME DE
PE
SS
ES
PM CM
Region
$160,000 $140,000 $120,000
WEST
( WA, OR, CA, NV, HI, AK )
$80,000
Insufficient data
$100,000
$41,075
$45,979
$56,594
$50,392
$50,000
$84,217
$46,000
$54,658
$40,000 $20,000
MM CNC
TD TME DE
PE
SS
ES
PM CM
m the
biggest percentage decrease in salary based on the national average. With an average salary of $102,563, they earn 11.2 percent, or $12,877, less than 2 years ago. That position at companies with more than 100 employees registered a decrease in pay of $16,870, or 10.0 percent.
$77,500
$60,000
$102,105
$119,152
$61,500
$64,000
$94,483
$60,000
ctemag.com | 53
Company Size
$160,000 $140,000 $120,000 $100,000 $80,000 $37,253 $44,926
1-19 EMPLOYEES
m mc at a company with more than 100 employees continues to be a more lucrative position, paying $47,083 on average, than one at a smaller company. A manual machinist at a company with 20 to 99 employees earns $39,077, and one at a company with one to 19 employees receives $37,253.
$56,847 $71,444 $72,165 $98,255
$48,703
$52,727
$57,803
$59,112
$40,000 $20,000
MM CNC
TD TME DE
$65,875 PE
$60,000
SS
ES
PM CM
Company Size
$160,000 $140,000 $120,000 $100,000 $80,000
20-99 EMPLOYEES
Company Size
$160,000 $140,000 $120,000 $100,000 $80,000 $102,916
100+ EMPLOYEES
$40,000 $20,000
$40,000 $20,000
MM CNC
TD TME DE
PE
SS
ES
PM CM
$47,083
MM CNC
$47,907
$59,233
$59,587
TD TME DE
$63,500
$69,429
$57,333
PE
$73,571
SS
$76,500
ES
PM CM
$89,500
$150,857
$39,077
$46,904
$55,152
$49,333
$59,909
$63,640
$65,833
$61,086
$72,688
$74,271
$60,000
$60,000
Company Type
$160,000 $140,000 $120,000 $100,000 $80,000
$37,824 $45,622 $49,533
JOB SHOP
$40,000 $20,000
MM CNC
$50,500
TD TME DE
$60,788
$68,367
$66,667
PE
$59,220
SS
$72,062
ES
PM CM
Company Type
$160,000 $140,000 $120,000 $100,000 $80,000
$40,283 $48,673
TOOL, MOLD & DIE SHOP
$55,375
$53,484
$57,500
$60,706
$70,800
$71,050
$69,333
$88,429
$74,533
$88,333
$40,000 $20,000
MM CNC
TD TME DE
PE
SS
ES
PM CM
Company Type
$160,000 $140,000 $120,000 $100,000 $80,000
SUPPLIER OF METALWORKING PRODUCTS
$40,000 $20,000
MM CNC
TD TME DE
PE
SS
ES
PM CM
Company Type
$160,000 $140,000 $120,000 $100,000 $80,000
$34,325 $44,029
GENERAL MANUFACTURER
$40,000 $20,000
$50,040
$53,132
$53,400
$47,833
$43,000
$48,675
$75,000
$91,160
$60,000
$114,644
$44,154
$43,361
$55,500
$51,000
$61,143
$56,833
$59,667
$56,956
$74,600
$60,000
$97,729
$60,000
$71,760
$93,290
$60,000
MM CNC
TD TME DE
PE
SS
ES
PM CM
MICRO TOOLS
ctemag.com | 55
Company Type
$160,000 $140,000 $120,000 $100,000 $80,000
OTHER
m at "other"
manufacturing facilities that dont qualify as a job shop, supplier of metalworking products, tool, mold and die shop or general manufacturer make the most when evaluating company type, averaging $125,562. However, manual machinists at those companies earn the least.
$125,562
$33,929
$46,818
$57,486
$60,492
$67,000
$96,634
$75,000
$57,100
$74,500
$70,727
$60,000 $40,000 $20,000
MM CNC
TD TME DE
PE
SS
ES
PM CM
Benefit
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%
HEALTH INSURANCE
Benefit
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%
DENTAL INSURANCE
29.6%
37.6%
25.9%
15.9%
13.2%
13.2%
10.6%
31.7%
11.1%
31.2% PM
44.4%
56.1%
37.6%
24.3%
19.0%
18.0%
13.2%
46.6%
15.3%
40.2%
63.0%
MM CNC
TD TME DE
PE
SS
ES
PM
CM
MM CNC
TD TME DE
PE
SS
ES
CM
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58.2%
Benefit
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%
PRECISION CNC GRINDING MACHINES

PROFIT SHARING
PEEL/OD FLUTE CHAMFER PROFILE GRINDING FILTERS
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31.7%
37.0%
23.8%
15.9%
12.7%
13.2%
34.4%
10.6%
29.1%
57.7%
Machine Grinder - Cycle Times:

3 Flute1/2 Spiral Tap: 47s 3 Flute 3/8 Centerdrill: 41s 4 Flutes 3/8 Endmill: 59s 1/2 Tap w/ Gunnose: 54s
MM CNC
TD
TME
DE
9.0% PE
SS
ES
PM
CM
Benefit
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%
ROTARY TRANSFER SERIES

PAID TRAINING
AEROSPACE
31.2%
42.3%
26.5%
14.3%
10.1%
11.6%
25.4%
23.3%
39.2%
6.9%
MM CNC
TD
TME
DE
PE
SS
7.4%
PEEL GRINDING SERIES
AUTOMOTIVE
ES
PM
CM
Benefit
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%
COMPANY VEHICLE
FLUTE GRINDING SERIES
CUTTING TOOLS
15.9% PM
MM CNC
TD TME DE
PE
SS
ES
CM
59.3%
% 1.1%
2.6%
1.6%
2.1%
0.5%
1.1%
2.1%
9.5%
1.6%
MEDICAL DEVICES
m (59.3 percent) continue to receive a company vehicle as a benet. The second highest percentage is 15.9 percent for plant managers. All other percentages are in the single digits, with only 0.5 percent of tool and die makers receiving the perk of a company vehicle.
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ctemag.com | 57
New Life for Old Iron

Retrofitting is an effective and economical option to make new money with old machine tools.
By Alan Richter, Editor
C.V. Tools six 1980s-vintage lathes were experiencing a combined 10 hours of downtime a week because of obsolete controls. The controls were difficult to repair and the wires were deteriorating. The shop thought about replacing the three Cincinnati Milacron and three Mazak turning workhorses with new machines, but the units were well-maintained and took mostly light cuts, noted Kenneth Mattson, plant manager for C.V. Tool Co. Inc., Fitchburg, Mass., a manufacturer of hardware for various industries, including steam turbine, nuclear and aerospace. The shop typically cuts bronze, 400 series stainless, Ni-resist cast iron and mild steel. Because the NC lathes were mechanically sound, retrofitting them with new controls, electrical systems and drive motors on the two axes made sense. Retrofitting the machines would prevent removing them from the shop and incurring rigging costs, so C.V. Tool decided to retrofit, Mattson explained. The shop looked at several machine tool retrofitters, including one that wanted to move the machines to its facility to scrape ways and perform other rebuilding work. C.V. Tool ultimately chose AHS Machinery Service & Sales Inc., Tylersport, Pa., whose bid was only for retrofitting and therefore did not require moving the machines. Like others interviewed for this article, C.V. Tool found real value in retrofitting, provided that the machines being retrofit met specific criteria. Mattson described AHS President Robert Sorensen as being the most realistic about the process, understanding that the fairly straightforward turning, boring and facing operations C.V. Tool performs on the lathes didnt require all the bells and whistles that a new version of the machines old control would provide. Instead, Sorensen recommended a DynaPath CNC for the six machines, saving about $30,000 per
Machines in Motion
A Pratt & Whitney Wolverine milling machine that Machines in Motion retrofit cuts hardened steel.
For more information about the benets of retrotting a machine with a new control, view a video presentation from Machines in Motion Inc. on www. ctemag.com by scanning the QR matrix bar code on your smartphone (app available at get.neoreader.com) or entering the following URL into your Web browser: cteplus.delivr.com/1hvdh.
Learn more about machine tool retrofitting
machine compared to the new-version option. After discussing the pros and cons, the shops operators and maintenance personnel agreed with Sorensen. Although the machines may be large, the retrofit price doesnt have to be. The one thing a lot of people dont understand is the cost of the retrofit has very little to do with the size of the machine, Sorensen said. The CNC doesnt know or care how big the machine is. A small machine with a complex toolchanger might cost more to retrofit than a very large horizontal boring mill with manual tool operation. Theres very little
New Life for Old Iron (continued)

PLC operation to contend with there. To minimize production disruptions, AHS retrofit the six machines one at a time over the course of a year, with each taking about a week and a half to complete. AHS did most of the engineering and design work while the machines were still in service. The machines tools that werent getting retrofit were running around
the clock [to maintain production], Mattson said.
Meet the New Control Except for some minor changes to the program format, such as positioning characters differently, programming stayed the same after the retrofits, according to Tony Botti, NC programmer at C.V. Tool. The existing programs required some tweaking to run correctly, he added, but then ran right off the bat.
Although change can be intimidatingespecially after running the same control on the same machine for more than a quarter of a centurythe operators found the new DynaPath CNCs were user-friendly and significantly more reliable than the old ones, Botti said. After a couple days of working with the control, they were able to increase their setup speed. In addition, the DynaPath is efficient, requiring fewer buttons to push and screens to navigate through compared to the old CNC. Each screen can do quite a few operations vs. having a bunch of knobs and buttons like the old control did, Botti said. Operators are able to do their work quite quickly. The retrofits also streamlined the equipment, eliminating a stand with a computer and monitor on it, an electrical cabinet and a lot of wiring from each machine. The original computer and monitor measured about 4' high 2' wide 1' deep, and the cabinet was about 5' high 3' wide 3' deep, Mattson pointed out. Each retrofit machine has a control pendant that measures 2' high 2' wide 6' deep and hangs in front of the machine. It opened up everything, he said. Even the airflow is better because a couple of these machines are in corners. The increased space enables setting
Retrofitting often involves removing electrical clutter, such as this rats nest of wiring in a machines electrical cabinet.
fixtures and other tooling closer to the machine, enhancing operator efficiency, Botti added. One thing that didnt change is the speeds and feeds for the machines. Downtime is what were saving on now, Mattson said.
Retrofit Benefits A retrofit is going to give you first and foremost reliability and repairability, AHS Sorensen said. When some of these old controls fail, you cant find the parts for them or, if you do, it takes a long time. He added that customers often inquire about putting bigger motors on a machine to boost cutting speeds, but thats a mechanical function rather than an electronic one. Besides, getting a machine to cut at 1,000 ipm isnt the challenge. The problem is the machine wasnt built to operate at those speeds. Youre going to have excessive wear at least and you might have more serious problems with heat buildup, he said. I tend not to promise improvements in cycle times. Other benefits retrofitting provides include the ability to monitor machine conditions, such as tool load and oil and bearing temperatures, that the old control might not have offered. The control can then be somewhat interactive and
change the feed rate based on tool load, Sorensen explained. A retrofit can also provide new control features, such as the ability to write and edit programs at the machine, graphically plot on the control screen what the part is going to look like and enable conversational programming. According to Sorensen, those features enable an operator with fewer skills than a machinist to run the machine. Nonetheless, a retrofit will not radi-
cally alter a machines capabilities. If I was building a new machine today, I could take full advantage of the CNC, Sorensen said. On a retrofit, unless we add sensors and some hardware, the new control is limited to doing the same machining operations the old control was doing. It just does them in a more user-friendly manner.
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International Tool Machines
ctemag.com | 61
New Life for Old Iron (continued from page 61)

in Motion Inc., agreed that ease of programming is a significant retrofit benefit. The Chino Hills, Calif., company retrofits machines with Centroid CNCs, which come standard with the Intercon conversational part programming language. Its essentially a fill-in-the-blank processor where youre going to pull up a canned cycle for making a rectangular pocket, for example, he said. Then only
questions that pertain to defining that rectangular pocket appear on the screen. Laursen noted the requirements and expectations for a retrofit vary by customer. For the most part, every machine we do is a one-off, and every customer we interface with is a one-off, he said, adding that the list of machines the company retrofits includes lasers, waterjets, grinders, lathes, mills, punch presses and spe-
International Tool Machines
Before-and-after photos of a peel and plunge grinder International Tool Machines retrofit.
cialty machines. For example, Laursen noted reducing cycle time is important for a production shop, possibly requiring a retrofit to include an upgrade to AC brushless motors to increase cutting speed. An aerospace manufacturer, however, might be primarily concerned with improving machine accuracy and may want to add linear encoders and scales. A typical job shop may just want to make a machine it was struggling with easier to use. A lot of times, they are just sick and tired of dealing with floppy drives and RS-232 (a standard for communication
contributors
AHS Machinery Service & Sales Inc. (215) 257-0571 www.ahsmachine.com C.V. Tool Co. Inc. (978) 353-7901 www.cvtool.com International Tool Machines (386) 446-0500 www.itm.com Machines in Motion Inc. (877) 733-5500 www.cncmachinesinmotion.com
AHS Machinery Service & Sales
These images show the control and electrical system originally in a machine (left), the equipment retrofit by AHS Machinery with standard industrial hardware (middle) and the old hardware and wiring AHS removed from the machine.
between devices) and want to upgrade to Windows or something thats familiar and easy to use, Laursen said. Michael Kelley, mechanical engineer for International Tool Machines, Palm Coast, Fla., emphasized how the companys retrofits extend the life of the CNC grinding machines ITM builds, which can be 25-plus years old. The strategy tends to
be economical as the retrofit machine runs almost like a new machine, he said, noting a retrofit is usually 30 to 60 percent of the cost of a comparable new grinder. Many customers find a high return on investment when an old machine is retrofit. ITM also says each retrofit is unique and can include replacing the CNC and any worn or brittle wires, upgrading soft-
ware, updating the mechanical assembly and reconfiguring drives and motor spindles. ITM tests all the existing electrical components in the electrical cabinet and replaces any that are not compatible with the new control system, Kelley said. A retrofit will cost less than half the price of a comparable new machine, according to Laursen, and the more
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New Life for Old Iron (continued)

expensive the machine, the smaller the percentage a retrofit will cost. It could be just 10 percent of what a new machine costs, he said.
Retrofit Candidates AHS Sorensen noted the best machines to retrofit are mechanically sound, U.S.-built, NC and CNC machines from the 1970s and 80s. They were built to last a lifetime. Many of those machines, which might have cost $300,000 to $500,000 new, became available when large U.S. factories closed and the machines sold for scrap value, he added. These machines can still be found at liquidation auctions and offer a great opportunity to purchase good iron at a low price, Sorensen said. Many of my customers have done that, factoring the cost of an immediate retrofit into the purchase price. C.V. Tools Mattson pointed out that newer machines are often made with very light metal and dont have the du-
Machines in Motion
Machines in Motion retrofit this Cincinnati Milacron Sabre vertical mill with a new Centroid control.
rability to justify retrofitting. You can run them for 3, 4, 5 years, but then you are almost going to have to throw them away, he said. Although converting an old manual machine to CNC is possible, it generally is not the best avenue to take because of the cost. If youre going to spend the
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For more information, visit Resources, click on Article Archive and enter the keyword retrot.
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sure everything else is in top condition, Sorensen said. That would require a rebuild or remanufacture. ITMs Kelley noted retrofitting a CNC machine is almost always more suitable than converting a manual one from the perspective of reducing cycle time and enhancing repeatability, and the decision largely depends on what the user wants to accomplish with a CNC machine. Its not unusual for an end user to believe adding a CNC will be a cure all for a machine, especially one purchased used from a seller who swore it was in perfect condition, according to Machines in Motions Laursen. They think theyll have a brand-new machine when Im done and rarely is that the case. In contrast, a machine a shop is using is a better candidate because the shop knows what its capable of. Its the level of expectation, Laursen said. They dont have false hopes that its going to suddenly jump up and dance around like it never did before. Because, as Sorensen previously noted, a CNC doesnt care how big the machine is, many users suffer sticker shock when inquiring about retrofitting Bridgeport-style knee millsa common smaller machine. I dont even quote them anymore because people get insulted when I tell them what it is going to cost, he said. The truth is the price of the hardware is the price of the hardware. It doesnt matter that its going on a machine that doesnt cost as much as the CNC does. Therefore, retrofitters tend to focus on bigger machines. I just got a contract for two large Pratt & Whitney lathes, Laursen said. Im looking forward to getting those done.
Better Shop Around Its possible for end users to save money by doing retrofits themselves in-house, but its not advisable because they may not know enough about the electrical aspects of a machine, according to ITMs Kelley. The manufacturer would have the proper tools, parts and knowledge of the installation, he said. Kelley added that its best to consult the OEM as it has the drawings of the electrical and mechanical layouts. Otherwise, target a company that has experience working with the control being retrofit. Expect delays if you dont go to an expert, Kelley said. Targeting a retrofitter with a good track record is sound advice because anyone can buy the electronics and claim to be able to do a retrofitor at least start it. Weve done a lot of cleanup jobs, AHS Sorensen said. Machines in Motions Laursen suggests contacting the retrofit control manufacturer for recommendations when considering a specific retrofit service company and talking to other customers to get a sense of a retrofitters work. That should include inquiring about replacement of wiring, relays and encoders. We usually replace all the electronics because thats the heart and soul of a precision machine, he said. I suggest buying all new elecCTE tronics when reliability is critical.
About the Author: Alan Richter is editor of CTE. He joined the publication in 2000. Contact him at (847) 714-0175 or alanr@jwr.com.
ctemag.com | 67
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A HORN groove milling tool creates square, linear grooves. The same tool was used to bore mill the largest bore (including the face), groove mill the two grooves on that diameter and bore mill a smaller diameter from the bottom up.
Grooving Slotting
While it may have different names, groove milling can be an effective way to perform slotting and slitting.
As we all know, industry terms mean different things to different people. This is the case with groove milling. Words and terms are intermixed and overplayed no matter how you look at it, said Duane Drape, national sales manager for HORN USA Inc., Franklin, Tenn. The difference between groove milling and slot milling or slitting or anything along that line is hard to define.
By Susan Woods, Contributing Editor

CoroMill indexable-insert groove mills. Michael Trimble, product manager for Vargus USA, Janesville, Wis., said groove milling tools to us are slotting tools that can run at higher speeds and feed rates than traditional slotting tools, such as Woodruff cutters.
William Durow, applications and development project coordinator for Sandvik Coromant Co., Fair Lawn, N.J., agreed that groove milling is basically slotting and slitting. It depends on who you talk to, what industry they are in and, frankly, who they were taught by. But groove milling and slotting are fundamentally the same thing, he said. Sandvik Coromant offers a full line of
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When Grooving Met Slotting (continued)

a lathe or groove milling. If you can produce the groove on a lathe, you do it, said Matthew Schmitz, national product manager GRIP products for Iscar Metals Inc., Arlington, Texas, which offers groove mills as part of its TANG, GRIP, CHAMSLIT and MULTI-MASTER products. In nearly every case, it will take more time to generate that same groove on a mill than a lathe. Schmitz also noted that if the groove has a shape other than parallel sidewalls, the task becomes difficult on a mill and will likely require a special tool, which adds cost. There are only a handful of reasons to use a mill for a groove rather than a lathe, he said. These include the shape or size of a workpiece, machine capability or capacity in a given shop, to gain chip control, to eliminate an additional setup and to control workpiece feature tolerances without the concern of an additional setup. Also, because groove turning uses a single-point tool, Schmitz feels it is more accurate.
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Drape doesnt necessarily agree that groove turning is more accurateit is definitely application specificbut said with groove milling you have a rotating tool so you will get more of a scalloped-type finish.
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Notable Inserts Groove milling tools are available as solid carbide, with a replaceable head (or insert) that screws on the end of the shank or with indexable inserts that fit into pockets on the tool body. We offer solid and insertable based on a diametric requirement, Drape said. When groove milling a small ID, an insertable tool might not fit. We typically switch to insertable at 10mm in diameter and up, he said. As the diameter increases, the cost of solid-carbide tools gets progressively larger, which is where inserts come in. The problem you can potentially run into with an insertable tool is there is a fine line where the accuracy of an insertable cannot be as good as a solid, Draped added. Because you have replaceable components, you cant maintain the same accuracy.
When the diameter is large enough, Vargus Trimble indicated that indexableinsert groove mills are more economical. Say a solid-carbide tool costs $150 vs. $150 for a tool body and $25 for a replaceable head (insert) with three or six teeth. If the solid-carbide tool produces 1,000 grooves and the insertable tool produces 1,000 grooves, the solid-carbide tool will cost more over the long run because the user has to pay for a completely new tool once its worn. (Vargus doesnt recommend resharpening.) For the insertable tool, he only has to pay $25 for each replacement head. Vargus offers Groovex solid-carbide and indexable-insert groove milling tools. Whether solid or insertable, groove mills create simple linear and circumferential groovesa square bottom or halfround groove such as for internal circlip or O-ring grooves. Insertable tools are more flexible in terms of grades and geometries because the head or inserts can be changed. These tools are used for angled grooving, chamfering, parting off and generating gear teeth profiles, Woodruff keyways and T-slots, just to name a few applications. Add threading to the list. Thread milling is nothing more than helical grooving, Drape said. A thread is a groove that commonly has 60, 55 or 30 included sidewalls. It is a constant groove that is moving up a component. You have to use different-shaped tools but the process is the same.
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Vargus USAs Groovex GM Slot groove milling tools are available for creating groove widths from 1.2mm to 4mm and up to 3.25mm deep.
Making a Slit Slitting cutters are applied to create narrow, square grooves up to a couple inches deep. It is all relevant to the size of the groove, but it is usually deeper than the width of what you are grooving, Drape said. Iscar differentiates slitting and slotting cutters by noting slitting cutters are blade-type cutters that accept inserts that resemble parting or grooving inserts most commonly applied when turning. Slotting cutters are also blade-type cutters, but they hold inserts that resemble those typically found in milling cutters. According to Iscar, slitting cutters are generally used when the width of the groove is less than ", while slotting cutters are for making wider grooves. However, there can be some overlap.
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ctemag.com | 75
When Grooving Met Slotting (continued)

Because the slitting cutter is such as expensive toolyou have to mount many expensive insertsyou use it only when you absolutely need to, Schmitz said. But for a long, deep groove that runs the length of a shaft, it might be more economical to use a slitting cutter [rather than a slotting cutter]. For example, a 6"-dia. slitting cutter that accepts 12 single-edge inserts requires $168 worth of inserts at $14 each. If the cutter body is $800, it would cost almost $1,000 just to set up the tool. Using a cost per edge to keep the comparison relative, a slotting insert with four cutting edges for a 6"-dia. slotting cutter costs about $4.30 per edge 16 inserts, or $68.80. The cutter body costs about $1,500. While the initial cost is greater, each insert index for the slotting cutter is $100 less compared to the slitting cutter, according to Schmitz.
Iscar
Iscars CHAMSLIT groove milling tool is an economical slitting tool but is used only for making shallow grooves, according to Iscar. It can produce a groove up to about 1/8" deep and from 0.047" to 0.158" wide. It can produce internal and external grooves.
But, in this example, the slotting cutter has half-effective teeth. In other words, there are only eight effective cutting edges (opposed inserts), which is 20 percent less effective than the comparable slitting cutter. And the slotting cutter generally requires a reduced chip load compared to a relative slitting cutter. So you always have to weigh the advantages and disadvantages of slitting and slotting to see which cutter will fit your environment best, Schmitz said. The tooling cost of the slitting cutter may be more in the long run, but some will easily justify the cost with its performance. Others will slow down the machine performance and keep the economics in the overall tooling cost.
Get out the Chips Chip evacuation is a concern in any metalcutting operation, but it is critical when grooving because chips are more prone to being trapped inside a groove and being recut. However, several tool design factors can aid chip evacuation when grooving. Groove milling is an interrupted cutting operation, so the chips typically break into manageable sizes. Groove turning can
produce long, stringy chips. A staggered-tooth, or half-effective, cutter design helps break chips. In the case of our slotting cutters, we have opposing, or half-effective, cutters, Schmitz said. So if you have 10 inserts in the cutter, only five are effective. One insert cuts the top side of the groove while the insert behind it cuts the bottom (or opposing) wall, which helps with chipbreaking. It also produces a narrower chip than what would be produced with a single wide insert, enhancing chip evacuation. Generally, a cutting edge on a slotting cutter is oriented at 90 to the slot wall. The angle of the cut sends the chip into the sidewall. Iscars tools feature the cutting edge orientated at a different angle. It is not 90 to the slot, said Hassan Naraimhan, national product manager for indexable milling cutters at Iscar. It could be 70 or 60, so that deflects the chip from the slot surface so it doesnt damage it. The angle actually draws the chip away from the slot wall. Also, most groove mills have through-
Sandvik Coromant
Sandvik Coromants CoroMill 327 is for grooving small holes or creating circlips or O-ring grooves. Geometries are also available for thread milling. The 327 goes down to 9.7mm (0.382") in diameter and provides a limited DOC.
coolant capability for chip flushing. Milling deep grooves can also be challenging. As the depth of the groove increases, your cutter diameter needs to
grow exponentially, Schmitz said. So if the groove depth is increased by 1", the diameter of your cutter will increase
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When Grooving Met Slotting (continued from page 77)
at least another 2" in diameter or more. Sandvik Coromants Durow noted that heat-resistant superalloys, such as Inconel, create a lot of heat during machining. When you cut a deep, narrow groove, there is no place for the heat to go so it goes back into the cutter, which will inevitably give you poor and unpredictable tool life, he said. You will need to take multiple shallow cutsat least 15 to 25 percent the diameter of the cutter for each passuntil you reach the desired depth. This will help prevent some of the heat going into the tool.
Tricks of the Trade Feed rate control plays an important role in grooving. Feed rates are largely dependent on the width of the slot and tool, Schmitz said. If you have a very narrow slot, you need to consider the strength and rigidity of the tool required for the groove. When using circular interpolation to perform groove milling, feed rates are decreased when cutting IDs and increased
HORN USA
A HORN 58mm (2.284") groove milling tool creates a square, linear groove in 4140 alloy steel. General speeds for this type of application would be 400 to 500 sfm with a medium chip thickness of 0.03mm to 0.1mm (0.0012" to 0.0039").
when cutting ODs, according to Durow. Your programming has to be a bit different when grooving internally vs. externally, he said. People need to remember
to program on the centerline of the tool. They must understand the danger of chip thinning and program accordingly so they do not underfeed or overfeed their tools.
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For an internal groove in a hole, the programmed feed rate is often that of the feed rate at the center of the hole. The feed rate calculated at the periphery is different and the result is often an excessive feed rate for the cutter. The feed rate, then, should be decreased to allow for the difference. As for external grooves, it is just the opposite. Again, the feed rate calculated at the periphery is different but the result is often too low of a feed rate for the cutter. The feed rate should be increased to allow for the difference. Iscars Schmitz noted one tooth should be engaged at all times when groove milling. You always want the spindle under load, and that applies to any milling operation, he said. If you have a period where the spindle is not under load, you could experience spindle whip (typically accompanied with a hammering sound during the cut), damage the spindle and cause tool failure. Therefore, if you have a shallow groove, it would be in your best interest to have a fine-pitch cutter so you always have the cutter under load. One final recommendation from HORN is to enter the groove with a ramp angle of 45 to 180 to achieve the maximum DOC. A radial entry of the milling cutter creates a long contact angle, which leads to vibration. The fastest method to get to the groove depth is to take the tool directly to the groove depth. Drape said. But you inherently put chatter into the workpiece if you do that. So we recommend that from the time you make your first
contact with the workpiece to the point where you get to full depth, you should have traveled a minimum of 90 of the workpiece diameter. If you are still getting chatter because of other factors, such as weak fixturing or long tool pro-
jection, take 180 or even 360 to reach full depth. You actually reduce the workpiece pressure and that can help eliminate chatter. CTE
About the Author: Susan Woods is a contributing editor for CTE. Contact her at (224) 225-6120 or susanw@jwr.com.
www.ctemag.com
For more information, visit Resources, click on Article Archive and select the Grooving category.
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Viva Vending!
Fastenal
A shop employee retrieves an item from one of Fastenals vending machines.
Vending machines can help manage tool and supply usage and keep costs in check.
By Yesenia Salcedo, Senior Editor
alk into any parts manufacturing facility, big or small, and you are likely to find a toolcrib that helps keep all the tools organized in one placemost of the time. Many cribs have a manager or a staff that manually dispense tools and supplies. That approach is changing, however, with the growth of automated inventory control management systems, including industrial tool and supply vending machines. While point-of-use vending machines are not new to the metalworking industrytheyve been around about 20 yearstheir manufacturers as well as toolmakers and distributors have noticed a surge in their popularity. But will vending machines someday be more common than toolcribs? One company seems to think so.
A few years ago, Fastenal Co., an industrial products distributor, didnt even have a vending machine program. Fastforward to April 2012, when the Winona, Minn.-based company announced more than 10,000 of its FAST Solutions vending machines had been installed globally. To put our vending growth into perspective, by March 2010 we had installed a total of 892 machines and just 2 years later that number was 9,798, said Russ Rubie, vice president of Fastenals FAST Solutions division, which was created in 2008. He anticipates the company will have installed a total of about 29,000 machines by the end of 2013. Fastenal has installed its machines which are manufactured by a partner in almost every U.S. state, as well as in Canada, Mexico, Europe and Asia.
Pam Ray, supply programs manager for Iscar Metals Inc., Arlington, Texas, said the toolmaker also casts a big spotlight on vending. The company began to notice growth in 2007, so it started making a vending system called Matrix4, which comes with proprietary management software. Seco Tools Inc., Troy Mich., is another toolmaker bullish on vending. This is growing crazy fast; were having a hard time keeping up with the demand, said Magnus Tillman, business solutions program manager at Seco. Vending machines are used to control inventory on the shop floor, which leads to cost savings and those savings help attract customers. Seco offers SecoPoint machines with configurable Smart Drawer technology, which dispense and accept returns of
Viva Vending! (continued)

items, according to Tillman. Karl Almquist, business services manager at toolmaker Sandvik Coromant Co., Fair Lawn, N.J., said its hard to tell how much of the increased interest in vending solutions stems from an internal need by end users and how much is from promotion of vending systems and their capabilities by integrators (companies that purchase day-to-day items on behalf of a manufacturer), distributors, tool manufacturers and vending machine
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companies. A lot of integrators, distributors and tooling companies have set goals for installation of vending equipment to increase sales of the products they sell, he said. In any case, Sandvik Coromant offers AutoTAS software, which interfaces with many vending systems, to manage tool inventory. Whatever the reasons, theres growing demand. What it comes down to, according to Fastenals Rubie, is part manufacturers want more accountability as well as a way to eliminate excess tooling and MRO inventory.
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Sandvik Coromants AutoTAS softwares logistical functionality includes item catalogs, stock control, purchasing and statistics. The software interfaces with Sandvik Coromant enterprise resource planning software, tool catalogs, log-in systems, vending equipment and vertical storage systems.
Saving Time and Money Managing a manual toolcrib can be time-consuming and unrestricted access sometimes leads to theft and hoarding. With vending machines, workers access items via codes or electronic cards. Software records usage by operator, and data on tool usage is displayed and stored for analysis. Something magical happens when you have to identify yourself and enter how many items you are taking out of the systemyou become more accountable and more responsible for the items you take, Secos Tillman said. Sandvik Coromants Almquist estimates 20 to 40 percent of tool inventory is out of control at any shop, based on information from Sandvik. Almquist also said, on average, 15 percent of scheduled jobs are stopped because of lack of tooling, 20 percent of an operators time is spent looking for tools and up to 40 percent of a supervisors time is spent dealing with tooling issues, such as ordering tools. Taking control of your inventory will save time and money, he said. Based on experience with its own customers, Latrobe, Pa.-based toolmaker Kennametal Inc. estimates a vending unit can: n reduce tool consumption 10 to 30 percent, n cut inventory 30 to 75 percent, n slash administrative costs 50 to 90 percent, n shrink machine downtime 10 to 60 percent, and n trim tool transaction costs 30 to 60 percent. Kennametal offers its ToolBOSS inventory management solution.
One of the key benefits of point-of-use systems is reduction of inventory and associated carrying costs. Its not unheard of for a parts manufacturer to keep 2 to 3 months of inventory for certain items, and maybe even keep items in inventory that dont move at all, said Secos Tillman. Our goal is to control inventory levels so only 2 to 3 weeks of inventory is in the vending machines. This means the inventory is turning faster and less money is tied up in inventory.
Power of Software Vending machines do more than just control inventoryequally as important is the data their software generates. Controls and reporting are a major part of the value proposition, according to Fastenals Rubie. Depending on the sophistication of the system, you can
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Precision Efficiency Versatility

do more than just track what employee took out what tools for a certain job, he said. With Fastenals software, for example, you can set controls so that employees only have access to specific products and amounts needed for the job. He added that Fastenals system can also track usage by individual employees as well as by department, job number, cost center, location and other user-defined criteria. Also, users can program vending machine software to trigger a reorder notification when the inventory on items falls below a certain level, allowing more product to be automatically ordered when a certain level is reached, before the supply runs out. So now when the employee goes to get a tool, its thereits not out of stock, and you dont have to place a rush order
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Seco Tools SecoPoint vending machines with Smart Drawer technology in use at Avon Gear and Engineering Co., Shelby Township, Mich.
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if youre on deadline and facing a fine for missing it, said Eric Mason, sales and service manager for Automated Inventory Solutions, which manufactures databased, inventory-management vending
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include coil (candy-style) machines, drawer systems and locker systems, which all come in various sizes and congurations. All require a power source and most require an Internet or network connection for the management software. Typically, vending machines can be congured based on the number of items a customer needs to have dispensed. Getting an item from a point-ofuse vending machine is easy. Typically, machines have a touch screen or keyboard for user identication. Some require entering a user name and password, swiping a card or badge reader or a combination of these options to log in. Sounds simple enough, but its not as easy as just dropping a machine on the oor, according to Karl Almquist of Sandvik Coromant. Its a project. Even if you want a simple system, you will need to consider the fair amount of data loading and training required, whether you do it yourself or pay whoever you got the machine from to provide those services. Sandvik Coromant provides its AutoTAS software for free to users, but there are fees for installation and report writing and annual service charges for technical support and upgrades. Its not unusual for a shop to have thousands of SKUs. Each SKU needs to be
entered into the system, Almquist said. If you have 100 employees using the system, they all have to be set up. All of the locations for all the tools have to be dened. That can be time-consuming. Theres no right or wrong way when it comes to stocking these machines. Ultimately, you can put whatever you want in thereas long as the customer wants to control the supply of that item, according to Larry Harper of CribMaster. However, the must-stock inventory, according to Magnus Tillman of Seco Tools, are expensive, high-usage and missioncritical items. It could be a 10-cent screw, but if its critical for running that halfmillion dollar machine, then its important for the customer to control that item, he said. Items typically kept in vending machines include spare parts, lubricants, abrasives, gages, carbide inserts and other cutting tools, grinding wheels, hand toolsand anything for MRO. Also, safety equipment like glasses, aprons and gloves are commonly vended. According to Iscars Pam Ray, one of its customers began controlling the number of work gloves each employee could take out during a certain period. The shop paid for a vending machine in 6 months with the savings from purchasing fewer gloves. Y. Salcedo
machines in its Kearneysville, W.Va. plant. Vending machine software generates multiple reports. Canned reports include usage by operator and cost center. Reports also analyze the frequency of tool purchases and the costs of those tools. Custom reports can track virtually any other parameter. Software-generated reports are really the key to tool management, said Larry Harper, president of CribMaster, Marietta, Ga., which manufactures and sells a suite of vending machines and offers leasing through third-party leasing companies.
Sandvik Coromant
The machine itself can cost from $5,000 for a basic coil machine to $25,000 to $35,000 for basic drawer machines to hundreds of thousands of dollars for more sophisticated systems, depending on size and level of customization. Two basic cost structures are available. One is to purchase the machine outright from the manufacturer or distributor. In addition to the up-front cost, this approach generally comes with limited service, but it also gives shops more freedom to use whatever brands of tools and distributors they want. If a shop buys a vending machine outright, it pays the up-front cost, but is more likely to strike a consignment deal with the distributor, where shops dont pay for tools until they use them, further reducing
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Green lights on drawers in vending cabinets help the user first identify the drawer and then the compartment of the item being vended.
ng
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ctemag.com | 87
at I
Paying the Price The convenience of vending machines comes at a price, but that price varies for each shop based on the machine selected and the deal made with the supplier or distributor.
MT
S!

inventory costs for the shop. Another option is to have a vending machine installed as part of a service agreement with an industrial distributor, whereby the distributor provides the machine at little or no cost in exchange for the shop meeting a specific spending requirement or as long as the shop already consumes a qualifying amount of products. The most obvious benefit is that theres no capital expense for the machine. Certain distributors, like Fastenal, provide tool and supply replenishment services as well as consignment plans. Iscar offers a plan for shops to own the machines when they purchase more of its tools. If a shop selects a no-machine-cost deal, it doesnt need to shell out an initial investment. Although whatever company supplies the machine chosen isnt likely to limit the shops purchases from other distributors outright, if the shop agrees to give that company a certain part of its business, it may be limiting itself because it will be less able to purchase tools and supplies from other distributors.
Iscar Metals
Iscars Matrix4 drawer vending machine.
Any type of arrangement optimally has to be a good business decision for all parties, Sandvik Coromants Almquist said. But you need to do your homework. You have to look at your long-term goals, the flexibility in your shops purchasing department and consider ongoing costs, such as yearly maintenance on vending machine hardware and software updates, IT work, if required, and dataentry costs. For many shops, the best solution is
to work with the toolmaker or distributor that supplies the biggest portion of the shops tools and supplies, according to Iscars Ray. The best scenario is where a distributor supplies the vending machine as an enhancement service, she said. You want the vending solution to come from the company you are buying your products from instead of getting it from a vending system manufacturer or through third-party vendors. You want that local support there. Your distributor knows the products and knows your business. Part manufacturers of all sizes can benefit from some type of vending system. Typically, a small shop, one with three to five CNC machines, does not have
the volume to justify a full cabinet-sized vending machine, but they could definitely use a smaller pod-sized one like Secos SupplyPod, according to Tillman. Medium-sized manufacturers might require two or three point-of-use vending areas, with vending machines for different tools for different jobs at each location. A larger manufacturer might have four or more point-of-use areas with a group of large vending machines at each location. Large machines can dispense from 250 to 400 items. The typical cabinet is 140"35"35". As for that old shop staple, the toolcrib, it isnt going away anytime soon. Vending machines are definitely not a complete replacement for toolcribs, Ray said. Automated Inventory Solutions Mason agreed. Vending machines arent going to be able to handle everything, he said. Some items are always going to be controlled in a toolcrib, such as very large drills or cutting tools that cannot be vended. Still, vending machines will continue
to make their way into job shops of all sizes. Vending is getting bigger and bigger in the market, Ray said. Part manufacturers are just looking for a solutiona way to take that uncertainty of
inventory out of their process. Vending machines allow manufacturers to focus all of their time making products for their customers instead of spending time on CTE inventory management.
About the Author: Yesenia Salcedo is senior editor of CTE. Contact her at (847) 714-0177 or ysalcedo@jwr.com.
www.ctemag.com
For more information, visit Resources, click on Article Archive and select the Tool Management category.
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ctemag.com | 89
Multi Grind
All images: Minnesota Grinding
John Glatczak of Minnesota Grinding programs one of the shops Studer S40 grinding machines.
Minnesota shop succeeds by being good at many different By Robin Yale Bergstrom, RYB Communications part-grinding methods.
Minnesota Grinding has grown a lot in its 53 years in business. It was founded by two partners in 1959 as a small tool grinding shop in a garage behind a White Castle restaurant in Minneapolis. In 1961, the partners built a 6,000-sq.-ft. facility in Minneapolis and began to add employees. That facility was expanded several times until it became landlocked at 23,000 sq. ft. In 2005, Minnesota Grinding moved into its current 43,000-sq.-ft. facility with high bays, overhead cranes for handling large pieces and 35 employees working three shifts, 5 days a week. As you might expect, business is very goodbut it took some work to get there. We gradually expanded into centerless, cylindrical and thread grinding, said David Schranck, human resources manager and information technology manager (and manager of the intangibles) at Minnesota Grinding.
In the 1980s and early 1990s we added horizontal machining capabilities, but being a job shop we found it difficult to compete with high-volume, production-type operations, Schranck said. We realized our greatest strengths were in precision grinding and advising customers on how they could modify parts or manufacturing processes to achieve a better end product, often at a lower cost. Eventually, we added machines for flat grinding, honing and lapping. In 1995, the company began focusing on precision grinding. It eliminated much of its machining capacity and continued to add grindersmostly CNC machines. By 2005, Minnesota Grinding had outgrown its building and moved into its current Crystal, Minn., plant. The company offers centerless, cylindrical and thread grinding, lapping, honing, double-disc grinding, Blanchard and surface grinding, and some CNC turning and Swiss-style machining. Industries served
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Multi Grind (continued)

include medical, automotive, aerospace, food processing and roofing. We could be centerless grinding bar stock, and a few hours later the same machine could be grinding pins for hard drives, Schranck said. We may be repairing a large roller for a roofing customer in one department, while thread grinding titanium bone screws in another. We like to be challenged. We pride ourselves on doing work right the first time, on time and with impeccable quality.
Workhorse Grinders The grinder brand of choice is Studer from United Grinding Technologies Inc., Miamisburg, Ohio, said Harlen Gibbs, operations manager at Minnesota Grinding. Theyre real workhorses, Gibbs said. The company has four Studers: an
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Operations Manager Harlen Gibbs with Minnesota Grindings new Studer S33 grinder.
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S20, two S40s and a new S33. The companys first Studer, the S20, was purchased in 1988. We found the rigidity of the Studers is key to our precision and repeatability requirements, and the service weve received from UGT, the technical supportwhether its helping with a programming issue or just fixing or adjusting the machinehas been remarkable, Gibbs said. The shops S20 has been running every work day for 24 years. Minnesota Grindings Studer grinders achieve tolerances of 0.0001" to 0.0004" and impart surface finishes
from 8in. Ra to 16in. Ra. Gibbs said the machines can tackle just about any workpiece material, including aluminum, titanium, Hastelloy, stainless steel, Inconel, carbide and plastic. We just had a job that was made of rhenium, an exotic, expensive material, Gibbs said. Not the kind of stuff that leaps out at you from the periodic table. The part was an aerospace coupler that required ID, OD and thread grinding. Before the shop decided to buy the S33, Minnesota Grinding looked at other, less-expensive grinders, but they were less rigid and lacked the service and support track record UGT provides, according to Schranck. The S33 has the latest generation of high-frequency, internal grinding spindles that have maximum speeds of 120,000 rpm, allowing the grinding of
the wheelhead to do different kinds of features, such as ID grinding. In the past, we probably quoted jobs based on running a part on multiple machines, Gibbs said. The new Studer, with its Fanuc 0i-TD control, allows us to do a job with multiple diameters and multiple faces and shoulders in one setup in a single machine versus using multiple manual machines. This makes us more productive, more competitive and more cost effective. Also, the S33 will
open up other market opportunities because the machine is much more precise, faster and more flexible than any other cylindrical CNC grinder.
Flexibility and Growth Joel Schoening, grinding technician and lead man at Minnesota Grinding, runs through a common part-grinding scenario: The part, with nine diameters, is a 16"-long shaft, and we grind the entire shaft in two operations. I chuck on
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The S33 grinds a 16"-long shaft that requires nine different diameters.
very small bores, according to UGT. The basic wheelhead on the S33 can be indexed at 0 or 30 for straight and angular plunge grinding. A universal turret wheelhead swivels manually or automatically, permitting OD, ID and face grinding in a single setup. The machine features a Hirth coupling B-axis with a 1 indexing that repeats within 0.08 arcseconds. This permits extremely accurate ID-to-OD runout and concentricity. Also, the S33 has a shoulder probe and a B-axis that automatically rotates
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ctemag.com | 93
Joel Schoening, grinding technician and lead man, checks the shoulder probe on the new Studer S33.

one end and grind six diameters from the shoulder to the end. Then I flip the shaft and grind the other shoulder and the three remaining diameters. The diameters are from 1.5" to 0.750" and gradually step down. There are bearing journals on each side that are about 1" in diameter. There is a keyway on one end. These parts have a print tolerance of 0.0005" runout, Schoening said. Weve run these same shafts on other machines and achieved 0.0003" from diameter to diameter, giving us a Cpk of 1.394. On our new S33 we are holding 0.000050" from diameter to diameter, giving us a Cpk of 3.0134. When Schoening initially ran this part on the S33 and checked it with his tenths indicator, the needle didnt even move. I had another operator check the part and he said my indicator must be broken. Then we checked it with a 20 millionths indicator, turning the part slowly, and found it to have 0.000050" runout.
Matt Wilkie adjusts the shops Studer S20 grinder. Purchased in 1988 to run one shift, it now runs three shifts a day, 5 days a week. The machine still holds tolerances as tight as 0.0001".

According to Schranck, there are about 12 grinding shops in the immediate vicinity, but Minnesota Grinding offers the most flexibility. The majority of these shops offer only a few types of grinding services, he said. Because we do so many different types of grinding we have far more flexibility when it comes to accepting a wide variety of different jobs. Gibbs said, If it uses grit and takes off material, were probably in it.
Tough Times During the Great Recession, hours were cut at the company, but there werent any layoffs. We all took it on the chin, Schranck said. We went from the low point in the economic cycle, where we were running our shop just 32 hours a week, to where we were back running
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The Studer S40 grinding area. Note the flow of coolant and the angle of the wheel.
The nine diameters on this shaft are from 1.5" to 0.750". The diameters gradually step down.
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40 or more hours a week. We then expanded our second shift, and in 2011we added a third shift. Most recently, the company added several grinding and honing machines and retrofit several other machines. There are also plans to purchase another Studer this year in response to growing demand. With such growth comes a need for more skilled workers. Gibbs said its best to hire a machinist who doesnt know
grinding. As long as the machinist has basic metalworking skills and inspection skills, grinding can be taught. Schranck said the company has its own custom-designed skills test. Weve used this assessment for the last 15 years on everyone who comes through the door looking for a job, he said. Its not difficult, but covers a variety of topics, including reading the most rudimentary drawing, questions about gaging, a few math problems and some things that
ctemag.com | 97
Harlen Gibbs and part of the Minnesota Grinding staff.
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reveal their attention to detail. You find out very quickly who the detail-oriented, technical people are. The test is part of the screening process. Schranck said: If they tell me they have experience, I give them an application and the assessment, put them in a room and close the door. Nine times out of 10 theyll go through the application and assessment, but the 10th person just walks out the door, leaving the pencil and papers behind. This separates the talkers from the doers. If an applicant does well on the assessment, an interview follows. It includes a verbal introduction to the companys technology and operations. Very few applicants walk in with a skill set that fits what we do, Schranck said. So we explore their experience in depth to determine what skills would be applicable in our shop. Because of the proprietary work the company handles, prospective employees arent allowed to see much of what goes on at the shop. In fact, many of our
In fact, many of our customers would like to tour our shop, but we have a closed-door policy because we have so many condentiality agreements.
customers would like to tour our shop, but we have a closed-door policy because we have so many confidentiality agreements, Schranck said. Gibbs noted many prospective customers will e-mail a part drawing and want to start discussing the best ways to make the partbut thats not quite how Minnesota Grinding works. Our philosophy, which differs from a lot of shops, is not to just take a print and make the part to the print, Gibbs said. We really discuss what the customer needs and wants out of that part. We look thoroughly at design and process, and we make sugges-
tions about other possible ways for us to grind the part, offering the customer options other than what they may have been thinking about. In some cases we go back to them and say, If you did this differently, we could make you a better part and at lower cost, he continued. We just dont make things to print. CTE
About the Author: Robin Yale Bergstrom is principal and editorial director at RYB Communications, Hebron, Ky. He can be reached at (859) 6899551 or www.rybcom. com. For more information about United Grinding Technologies Inc., call (937) 8471253 or visit www.grinding.com.
www.ctemag.com
For more information, visit "Resources, click on Article Archive and select the Grinding category.
ctemag.com | 99
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Booth N-6951
All images: CTEPlus
CTE Web site grows traffic and expands video, product and machine shop content. By Dennis Spaeth, Electronic Media Editor
More people are getting more information via the Internet, and Cutting Tool Engineering is clearly a part of that trend. Sustaining double-digit growth over the past 5 years, CTEs Web siteCTEplus at ctemag.comnow attracts about 21,000 unique visitors and about 48,000 total visitors each month, according to AWStats, a Web site analysis tool. (The AWStats unique visitor count resets each month, so a unique visitor who visits in January, for example, would also be a unique visitor in February.) Another measurement tool shows ctemag.com traffic growing from year
104 | AUGUST 2012 | CTE
A Site for More Eyes

to year. Google Analytics uses a different methodology than AWStats, measuring the total number of unique visitors across an entire year. That means, for example, a user visiting in January would not be counted again in February. Google Analytics showed that CTEs Web site reached a total of more than 106,000 unique visitors during 2011, 36 percent more than in 2010. Through May, ctemag. com reached nearly 55,000 unique visitors, outpacing 2011 by about 21 percent compared to the same period a year earlier, according to Google Analytics. With those kinds of numbers, its prob-
The CTEplus home page, which features a new video player at the top of the page under Video Reports, offers access to almost every part of the site, including Industry Reports, Daily Industry News and Product News.
ably safe to assume that nearly everyone reading this has been to the CTE Web site within the past year. But just in case you havent, or youre not aware of some of the recent changes, heres a quick, userfriendly guide to whats new and different at ctemag.com.
Video Reports Featured at the top of the home page is a YouTube player set to stream industry-related video reports through a playlist set up on our YouTube channel, CTEplus. While our Video Reports have been featured on the home page for some
S AT U E E S TH O O B IMTS 340 # E-3
A Site for More Eyes (continued)

time nowvia a slideshow linked to a player on another page of our sitethe new video player, which made its debut in June, plays video reports on the home page. To begin watching videos, simply click the play button. If you prefer watching larger videos, hover over the full-screen option in the lower righthand corner of the player, then click and watch a full-screen version. Hit the escape button on your keyboard at any time to reduce the video player and return to the home page. You can pause or stop the player whenever youre done viewing. Among the more than 160 videos available on the site is a series of reports produced in conjunction with Dr. Jeffrey Badger, a grinding consultant who authors CTEs Ask the Grinding Doc column. There are 31 episodes available on CTEplus, with more to come. The Grinding Doc video series tackles questions Badger has received from shops throughout the world. Each epi-
g g - .
CTEplus now offers opt-in e-mail newsletter subscribers the option of selecting specific categories of content for which they would like to receive e-mails. This allows you to target the content you receive and make sure you stay up to date on the latest technology and news in your area of expertise. To select the categories that interest you, click the Email Newsletter Signup located at the bottom of the shortCUTS column on the home page.
The new video player on CTEplus enables visitors to watch video without leaving the home page. If you want a closer look, just hover over the lower, right-hand corner of the video player until you see full screen pop up, then click. The video will fill your screen.
sode runs 3 to 5 minutes and covers one question, to which Badger generally recommends a solution. Other video reports produced by CTEplus focus on new products and technologies, such as the 3- to 5-minute
video vignettes filmed at trade shows. These reports focus on a new machine or process being demonstrated on the exhibit floor. CTEplus interviews a company representative, who takes the audience through a product demonstration. The idea behind these reports is simple: To ask the questions you would ask if you were at the trade show talking
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CHICAGO, IL - MCCORMICK PLACE
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106 | AUGUST 2012 | CTE
HEAD STRONG
Product news briefs, such as this one from Carmex Precision Tools, include a brief article based on a news release from the company, a product photo and company contact information.
to company reps, and to explain how the product or process works. Look for more such reports to be shot during IMTS 2012. (See sidebar on page 112.) Also, when CTE editors write about a new process or technique, they often obtain video footage from the companies they interview. CTEplus uses that video footage, which usually demonstrates an aspect of the process at the heart of the
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ctemag.com | 107
STARTEC XP-P REVOLUTIONARY FLUTE GRINDING OF SOLID CARBIDE & HIGH SPEED STEEL ROUND TOOLS
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story, in much the same way CTE uses photos and charts in the magazine. ply not room for all of them. About 4 years ago, CTEplus created an area for all product news briefs that CTE editors deem relevant to the industry. The Product News database now contains more than 1,500 reports that offer information about each product or service, along with a photo and the companys contact information. There are several ways to search for
Product News As you might imagine, CTE fields a large number of news releases about new or improved products from companies throughout the industry. While CTE publishes product announcements in each issue of the magazine, theres sim-
product information: n Product Search field. Use the keyword search field in the upper lefthand corner of the site (below the CTEplus logo) to conduct a quick product news search from anywhere on the site. n Product Search page. Use the Reports menu in the CTEplus navigation bar across the top of the site to visit the Product Search page. There
As the column name implies, the shortCUTS found on the left-hand side of CTEplus is a convenient way to browse product and article content on one topic all within one search results page.
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The Machine Shop Directory of shops and the services they offer was introduced in 2011. The search page offers a number of criteria to narrow the search from among the more than 500 shops included in the database.
ctemag.com | 109
ADVERTORIAL
IMTS2012 What will you discover? Show Highlights:
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The change toward more hardened components as well as the recovery in the automotive industry has created a strong growth in hard part turning over the last couple of years. Sandvik Coromant brings application knowledge and a range of unique and highly competitive CBN products to IMTS this year. The product assortment will include new edge geometries and unique grades to support operations in hard part turning.
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Energy:
Sandvik Coromants constant focus on R&D and customer development has allowed it to meet the increasing global demands in the energy sector. To help visitors discover how to achieve good chip control and trouble free production in the energy industry, reliable and productive machining solutions for a variety of different components will be highlighted in this area.
Gear milling:
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Aerospace:
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Discovery Express is a schedule of short seminars with topics ranging from innovative application techniques and new tools, to important ideas on enhancing efciency and protability. Green Light Machining: Machining Economics and Optimization On average, machines only cut chips around 30% of the time. That means 70% of the time your machines are sitting idle, costing you money. Attend Green Light Machining and learn how the latest production techniques and technologies, like quick-change tooling, and high pressure coolant can help reduce setup and tool change times, and boost your profitable machine uptime. Milling: Chip Thinning The Golden Rule in CNC milling is thick to thin - you want to avoid thick chips on exit, which leads to edge failure and poor tool life. This seminar covers the latest innovative application and programming tips to help you maximize performance through optimized chip generation. Improving Performance in Tapping Tap performance is directly related to the size and condition of the drilled hole. Learn more about key factors to consider for improving your tapping operations, hole quality and cost per hole. High Pressure Coolant Considerations Discover how to go beyond traditional flood coolant for heat removal. Learn how high pressure coolant can affect how chips are formed and broken, resulting in decreased tool wear, fewer machine stoppages, shorter machining times and better component quality - especially in hard to machine materials. Double Productivity in Hard Part Turning Hard part turning is a popular costeffective alternative to grinding. Learn how to make the process more efficient, stable and productive with CBN-tipped Xcel inserts and SafeLok technology to secure your process and extend your tool life. Drilling: See the Whole Picture Materials, tolerances, surfaces, chip evacuation, tool holding, applications... many variables go into a successful drilling operation. Learn more about how to select the right tool and maximize the drilling process to ensure the highest quality and a lowest cost per hole. Milling: Programming Methods Having the right tool is only part of the equation - how you use it can make the difference between profitable machining and wasted time and material. Get a better understanding of the latest tool path and advance milling programming strategies that can improve your cutting tool performance and overall machining productivity. Silent Tools: Solution to Long Overhangs Tools with long overhangs are becoming more common in all kinds of applications, including milling, turning and deep hole boring. Learn how to more effectively reduce vibration with dampened tools while staying productive and maintaining close tolerances. Silent Tools: Productivity Booster for Unstable Milling Get tips on how to increase your cutting productivity by reducing vibration in long reach milling operations using Silent Tools dampened milling adapters. Learn how these tools help deliver greater surface finish, process security and can boost productivity by up to 300%. Sustainable Manufacturing Learn how reduce, reuse and recycle can be applied to your machining processes and what the future of sustainable manufacturing will look like. Hear about new materials and how new smaller, custom components will require even more integration of part design with manufacturing technology.
Learning Opportunities At IMTS2012

IMTS 2012 Conferences:
Doug Evans Grade Development Specialist
Optimization of Process and Tool Selection in Hard Part Turning Operations
Aaron Habeck Marketing Project Manager
The Influence of Drill Design on Performance and Hole Quality in Drilling Operations
Michael Verkamp Director of Business Services
The Shift in Manufacturing towards Value-Added Services
Please visit: www.sandvik.coromant.com for more information.
To see the Discovery Express schedule and book your sessions today, visit: http://www.sandvik.coromant.com/discovery
Search the CTEplus article archive by selecting the Articles option under the Reports menu in the main navigation bar at the top of the site. The Article Archives search page offers a number of criteria to narrow your search.
A Site for More Eyes (continued from page 109)

you can search by keyword or product category. Use the drop-down menu to select one of the more than 40 product categories. shortCUTS search. Select from among the 20 or so categories listed in the gold-colored column along the left side of the page. By clicking on a category such as Cutting Tools, for example, the shortCUTS search delivers five product news items and five feature articles associated with that category. Search results for each of the options are listed in the chronological order they were posted to the site, with the most recent items at the top.
Buyers Guide Last year, CTE added a new section to
CTEplus on location at IMTS 2012

CTE, W Cutting Tool Engineering, will be shooting video reports with machine shops and manufacturers on the exhibit hall oor during IMTS 2012, which will be held Sept. 10 to 15 at McCormick Place in Chicago. If youre going to the show and think your shop has a unique story to tell, send an e-mail to reserve a time slot during the CTEplus Shop Day at the CTE booth (W-1900). The goal for CTEplus Shop Day, which will take place during regular show hours Tuesday, Sept. 11, is to learn more about some of the people and machine shops that receive the magazine each month. Among the questions well be asking: n How long has your shop been in business? n How many people does it employ? n What services does your shop offer? n And, most importantly, what makes your shop unique? If youre interested in reserving a 3- to 5-minute on-camera interview at our booth, e-mail CTEplus Electronic Media Editor Dennis Spaeth at dspaeth@jwr.com. In addition, manufacturers that would like to schedule a new product or technology video shoot at their booth during IMTS 2012 show hours can contact CTEplus at (847) 714-0176 or their sales representative. Though the nal video reports are from 3 to 5 minutes (and sometimes longer), the shoot itself requires about 30 minutes to complete. D. Spaeth
112 | AUGUST 2012 | CTE
its annual Buyers Guide: A directory of more than 500 machine shops and the services they provide. As with the manufacturer and distributor information published in the guide each November, CTEplus posted the shop information to the guides online counterparta database searchable by manufacturer, distributor and, now, machine shop. [Editors Note: If you would like your machine shop included in the 2013 CTE Buyers Guide, contact Julie Distenfield at julied@jwr.com to find out how.] To use the Machine Shop Directory, conduct a search by keyword, service category, territory served, location or a combination of these. If you know a portion of the name of the company you want to contact, type the name into the Company Name field and click the search button. For example, if youre trying to locate any company that offers cylindrical grinding services and is located in, say, New Jersey, use the Service Category menu to select Grinding, then the subcategory Cylindrical. Next, select the Anywhere button under Territory Served, then choose New Jersey using the state menu under Company Located In. Clicking the search button produces one result: Drew Peterson Inc. in Whippany, N.J. The search for distributors is nearly identical, offering a search by Company Name, Product Category (rather than Service Category), Territory Served and Company Located In. The Manufacturers Directory offers a search by Company Name and by a Product Category menu that contains more than 190 main categories and numerous subcategories.
Behind every great tool theres a great idea

The tool:
MicroKom BluFlexTM precision boring system with Bluetooth technology
The idea:
Using Bluetooth technology to transmit tool data to a portable display unit.
Why its great:

Safe and easy reading of the tool position on oversized display in mm or inch. Magnetic display unit can be positioned anywhere within eld of view. Same adjustment key and display unit can be used for multiple heads.
Industry Reports Whether youre looking for an article from CTE or simply want to browse through our Daily Industry News headlines, visit the home page at ctemag.com. Access to specific articles in the current issue is available at the top of the home page under Industry Reports. If youre more interested in locating an article from among the 2,000 or so stored in our Article Archives, use the Reports menu to select Articles. From the Article Archive search page, you can search by keyword, date, topical category, author or a combination of these. The Daily Industry News section, lo-
Learn more about this and other great ideas.

Go to www.komet.com/greatideas or scan this QR code.
www.komet.com 800-656-6381
ctemag.com | 113

cated a little farther down the home page, offers a convenient listing of daily headlines that link to news items from a wide range of news sites, including information posted on CTEplus.
Subscription Forms A growing number of CTE magazine readers are subscribing on CTEplus. Site visitors can sign up for a new subscription, renew an existing subscription or submit a change of address. Since adding the option to receive either a digital or print version of the magazine a couple of years ago, more than 6,500 magazine subscribers now receive the digital edition. Other Resources In addition, the CTEplus navigation bar includes an Events link, which takes you to a listing of industry meetings and trade shows, and a Resources menu that offers a few other tools, including: n an Association Directory searchable by name, n a searchable Abbreviations section
To access the online subscription forms for CTE magazine, use the Subscribe menu in the main navigation bar and select the appropriate option (right). Visitors can fill out a new subscription form, complete a renewal form or submit a change of address. You can request the print edition or the digital edition (left).
that provides the full term for common abbreviations used throughout the industry, and n a glossary of terms that provides definitions for industry jargon you may want to look up. Finally, if you have any questions about CTEplus or the magazine, click on the Contacts tab on the home page. Youll find information on how to contact the
CTE staff or leave a general message. C TE

About the Author: Dennis Spaeth is electronic media editor for CTE and manages CTEplus. He can be reached at (847) 7140176 or dspaeth@jwr. com.
High Performance Taps

The new and improved Applix range of taps from Union Butterfield out performs the competition by up to 50%!
Standard HSS Tap Union Butterfield Applix Tap Productivity Up to 3 times more holes threaded than standard taps Machining time Cut machining time by up to half Go deeper DIN overall lengths allow for greater threading depths compared to competitors ANSI standard taps Versatile Multi-application design for use in a wide range of materials
MIN SEC
Applix - The obvious choice whe

www.precisiondormer.com USA: (800) 877-3745 CANADA: (888) 336-7637
n Tap life is on the clock!
114 | AUGUST 2012 | CTE
CTX gamma 2000 TC
Weve got a vision for your part, and its something you never imagined. With superior technology, progressive techniques and a little creative problem solving, you can have the speed, accuracy and efciency to make the competition sweat. Its possible with the widest breadth and depth of machine technology in the world.
Machining is believing.
September 10-15 | Chicago Visit us at booth #S-8900
www.dmgmoriseikiusa.com
855-364-6674
Really Big Show
imts preview
All IMTS images: AMT
IMTS 2012 is expected to draw from 85,000 to 90,000 people at Chicagos McCormick Place.
IMTS, the premier U.S. metalworking show, is expected to be one of largest ever.
The 29th edition of the International Manufacturing Technology Show is on track to rank among the top five largest IMTS events, according to its sponsor, AMT - The Association For Manufacturing Technology. The trade show will cover close to 1.2 million sq. ft. of exhibit space, displaying wares from more than 1,800 exhibitors. The show will be held at Chicagos McCormick Place Sept. 10-15. CTE has coverage of 190 of the products that will be on display at IMTS 2012, including tooling and workholding products, machine tools and accessories and metalworking products (see pages 134 to 198).
116 | AUGUST 2012 | CTE
IMTS is expected to host 85,000 to 90,000 manufacturing industry professionals from more than 119 countries, who get a chance to view 15,000 new machine tools, controls, cutting tools, software, components and manufacturing systems and processes, according to AMT. They also gain valuable ideas and insights from the worlds leading equipment producers. Attendees come to look, learn, buy and network. IMTS hours vary from building to building. The Lakeside Center (East) and West Building hours are 9 a.m. to 5 p.m. daily; the North and South Building hours are 10 a.m. to 6 p.m. daily.
Partnership with IANA IMTS has partnered with Germanybased trade fair organizer Deutsche Messe AG to co-locate the first-ever Industrial Automation North America show with IMTS. IANA will showcase products and solutions for production automation, complementing IMTS focus on manufacturing technology and metalworking. We are thrilled to reinforce the international nature of IMTS by having one of manufacturings premier trade show organizers join with us, said Peter Eelman, vice president of exhibitions and communications for AMT. This is a major step in expanding and strengthening the range
Fully
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Visit us at IMTS Booth W-1700
Remarkable increase in performance:

Competition Tigertec Silver WPP10S
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See the product video: Scan the QR code or go to http://goo.gl/frwc2
WALTER NORTH AMERICA Walter USA, LLC N22W23855 RidgeView Pkwy W Waukesha, WI 53188, USA 800-945-5554 service.us@walter-tools.com www.walter-tools.com/us Walter Canada N22W23855 RidgeView Pkwy W Waukesha, WI 53188, USA 800-945-5554 service.ca@walter-tools.com www.youtube.com/waltertools Walter Tools S.A. de C.V. Boulevard Louis Donaldo Colosio 2255 2do Piso, Colonia San Patricio 25204 Saltillo, Coahuila, Mexico +52 (844) 450-3500 service.mx@walter-tools.com www.facebook.com/waltertools
Really Big Show (continued)

of solutions available to IMTS visitors. IMTS offers several educational opportunities in conjunction with the show, returning to its roots. In the early years, IMTS was actually an educational event and only turned into a buying/selling forum after World War II, Eelman explained. Along with the IMTS 2012 Conference, the show is colocating six conference programs: The IMTS 2012 Conference (Sept. 10-14) focuses on five topic tracks with 72 industry-specific sessions. The conference focuses on materials, manufacturing technology, alternative manufacturing processes, quality/metrology and plant operations. IANA Global Automation & Manufacturing Summit (Sept. 12-13) is a collaboration between CFE Media and Hannover Fairs International, presenting a 2-day, senior-level conference. Key topics in global automation and manufacturing will be highlighted, including enterprise asset management, process optimization, energy management and sustainable manufacturing. Case studies on how plants have automated for profitability, improved performance of existing assets and reduced maintenance costs will be presented. The conference is located in McCormick Places East Building. The International Society of Automation (ISA) will team with Hannover Fairs International to bring 1-day training and educational workshops for all attendees at IANA and IMTS (Sept. 13-14).

118 | AUGUST 2012 | CTE
The Motion, Drives & Automation Conference (Sept. 10-11) will present two conference tracks, Motion Control in Automation and Hydraulics and Pneumatics in Automation. EHS Todays Americas Safest Companies Conference (Sept. 11-12) includes keynote speakers, panel discussions and 18 sessions across three industry tracks. TRAM Aerospace Conference, or Trends in Advanced Machining, Manufacturing and Materials (Sept. 12-13), explores issues in the aerospace industry. Midwest Clean Tech 2012 takes place Sept. 12 and focuses on clean technology based on energy efficiency, reduction of waste and pollution and other means.
Machine Components/Cleaning/Environmental focuses on the parts required to monitor and service machines in a safe and environmentally responsible manner. Metal Cutting focuses on innovations in equipment to cut metal, including machining centers, turning centers and other machine tools.
Metal Forming & Fabricating/Laser targets metal forming, fabrication, waterjet and laser-based machining. Welding, metal treating and marking equipment are also included. Quality Assurance features metrology equipment and systems and equipment that checks machine accuracy.
H.B. CARBIDE COMPANY
What a carbide company should be!
IMTS Pavilions The show theme for IMTS 2012 is Be There, which AMT says is a call to action for industrial decision makers to get ideas and find answers to manufacturing problems and challenges. To help guide visitors, IMTS is organized into 10 pavilions:
Abrasive Machining/Sawing/ Finishing features technology for tight-tolerance and precision surface finish applications, including grinding, sawing and cutoff machines and finishing technologies. Controls & CAD-CAM focuses on automation and software that can optimize plant operations and cost efficiency. EDM focuses on CNC wire and sinker EDMs, which are typically used in making tool, mold and die and specialty components. Gear Generation focuses on gear cutting, forming and finishing, as well as broaching, shaping and slotting. IANA-Industrial Automation North America focuses on all areas of industrial automation. Industry-specific conferences and workshops are part of this pavilion.
For over a quarter century, HB Carbide has manufactured high-quality tungsten carbide, made-to-print preform blanks, extruded rod, and wear parts. We are recognized in the marketplace for our attention to detail for the following: Special preform blanks Cut-to-length rod Competitive lead times Quick quote response Proven Customer Service
Tel: 800-459-8521 Fax: 800-459-8547
info.star-su.com/hb-imts
ctemag.com | 119

Tooling & Workholding Systems focuses on cutting tools and workholding solutions that help shops reduce setup and machining time.
Emerging Technology Center The IMTS Emerging Technology Center will feature a Local Motors rally fighter car being built live on the exhibit floor. Local Motors, Chandler, Ariz., is a collaborative manufacturing firm and its car designs come from an open-source design community. Other ETC presentations focus on additive manufacturing; MTConnect, the open-source communications and interconnectivity standard for manufacturing equipment and devices; and MTInsight, a customized manufacturing business intelligence system. The additive manufacturing section focuses on how the technology can reduce the time between design and production and eliminate certain processes associated with traditional machining,
IMTS attendees will once again have the opportunity to examine new approaches to manufacturing at the Emerging Technology Center.
such as tooling. MTConnect is an interconnectivity and communications standard that helps link, monitor and analyze manufacturing equipment. MTInsight is a business intelligence tool for manufacturing. With a growing cache of apps, the goal of MTInsight is
to create new data and insight into the manufacturing process. ETC visitors can try the MTInsight demo.
Manufacturing Presentations The AMT Manufacturing Stage, a new feature at IMTS, will be located on the Grand Concourse. The stage will feature
Precision Tools
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2012
120 | AUGUST 2012 | CTE

manufacturing experts talking with visitors about various manufacturing topics. Speakers include AMT President Doug Woods and Local Motors President Jay Rogers. Also, the Reshoring Initiatives Harry Moser will share reshoring stories, focusing on total cost of ownership. Begun at IMTS 2008, the Advanced Manufacturing Center this year features a Boeing Fuel Cell Demonstrator Aircraft and a Lotus Formula 1 racecar. The FCDA is the worlds first manned aircraft powered by fuel cells. It is part of Boeings effort to
IMTS attendees, such as these at Heidenhains exhibit, come to the show to look, learn, buy and network.
122 | AUGUST 2012 | CTE
North Building - Hall N

Abrasive Machining/ Sawing/ Finishing Gear Generation
East Building - Hall E

Controls & CAD-CAM
EDM
IANA
Metal Forming & Fabricating/Laser
IANA - Industrial Automation North America Machine Components/ Cleaning/ Environmental
South Building - Hall S
Quality Assurance
West Building - Hall W

Tooling & Workholding Systems
IMTS 2012
IMTS 2012. The Pavilion structure helps you compare equipment, capabilities, process, serviceeverything you need to know. And its all conveniently organized in the McCormick Place exhibit halls.
Show organizers have arranged the trade show into industryspecific pavilions. The pavilions for the 2012 event are Tooling & Workholding (Hall W), Metal Cutting (Hall S), Abrasive Machining/ Sawing/Finishing (Hall N), Gear Generation (Hall N), Metal Forming & Fabricating/Laser (Hall N), Controls & CAD-CAM (Hall E), EDM (Hall E), IANA Industrial Automation North America (Hall E), Machine Components/ Cleaning/Environmental (Hall E) and Quality Assurance (Hall E). In addition, the Emerging Technology Center is in Hall N and the NIMS Student Skills Center is in Hall C of the North Building.
develop environmentally friendly technologies for aerospace applications by reducing aircraft emissions. The Lotus Formula 1 racecar, powered by Renault as part of a technical partnership with Boeing Research and Technology, can accelerate from 0 to 160 kph and decelerate back to 0 in less than 4 seconds. The Lotus featured at IMTS replicates the car that will be driven by Kimi Raikkonen in the 2012 F1 Race of the Americas in Austin, Texas. The AMC also will feature the Virtalis Virtual Reality Theater, which focuses on the relationship between design, manufacture and data in virtual reality. For more information and to register, visit IMTS.com.
igh Helix H 40 & 6 Flut e 5
MIUM Carb ide PRE
Stub to Extra Long Lengths Available Progressive Geometry AlTiN Coating
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Besides playing black jack, numerous applications exist for industrial automation. IMTS attendees can learn more about them at the first Industrial Automation North America show, which is co-located with IMTS 2012.
Same Day Shipping From:
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ctemag.com | 123
CTE booth at IMTS offers rare sighting of antique car

i i
and want to see an American classic, stop by the CTE and MICROmanufacturing booth at IMTS, where a mint-condition 1910 Packard Model 30, seven-passenger touring car will be displayed. These cars were built between 1907 and 1912 and this is one of 17 of this body style and model known to exist today. Packard is said to have made a number of automotive design innovations, including the modern steering wheel, the rst production 12-cylinder engine and automotive air-conditioning. The booth also will feature multiple video displays of the history of U.S. automobile manufacturing. Visit CTE and MICROCTE will have a 1910 Packard touring car on display at its booth at IMTS. manufacturing at booth W-1900.
Foam
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Uncle Earls Hand Healing Soap Strong cleaning agents without abrasives Hydrating compounds put liquid into your skin Foam cleans without added water 100% natural ingredients
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888.249.4855 ZebraSkimmers.com
124 | AUGUST 2012 | CTE
WHEN NUMBERS MATTER: 6 NEW JOBS. 2 MONTHS TO FULFILL. 1 a51nx HMC.
Making the parts that really matter takes a horizontal machining center that delivers what matters most: faster cycle times, greater reliability and higher-quality results. Which is why a Makino HMC is the only real choice for the production parts that matter most. See the a51nx at work. Book a personal demonstration at IMTS 2012, booth S-8700. makino.com/IMTS
2012 Makino
slice of
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311
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Bring Coating Expertise In-house User-friendly Operation Short Technical Learning Curve Offer Rush Orders Flexible production schedule Reduced Operating Costs
See Us at IMTS booth W-1680
Your Very Own PVD Coating Profit Center

New business opportunity - be production-ready within a week with your very own PVD Coating Profit Center. You can now be competitive while providing your customers with the State of the Art coatings as well as ALL of the Standard coatings like AlTiN. With Platits full line of PI machines, you will be able to integrate coating into your manufacturing process to ensure an independent, stable and innovative competive edge.
...side of support
Tomorrows Technology Today
WORLD CLASS SUPPORT! Remote Diagnostics On-Location Troubleshooting Parts Replacement Phone / Web / Email
Experience Our US Support Center - www.platitusa.com/support Platit offers world class support for the US/North America region including the Online Help-Desk System, On-Location Troubleshooting, Remote Diagnostics and Live-Phone Support from our centrally located US location. Starting your own in-house PVD Coating Profit Center in North America is now worry-free as we are with you every step of the way 1-855-4-PLATIT
T (847) 680-5270 F (847) 680-5271 E pvdcoating@platitusa.com W www.platit.com
PCT CARBIDE Chicago Challenge

3D H/V SERIES
Solid Micro-Grain Carbide End Mills
Coated Ball Nose End Mills for Materials to 55HRC
Overview of crowd at North Avenue Beach, with skyline in the background.
H/V Coating for improved lubrication and high hardness Special cutting edge design provides high rigidity Tight diameter (0,-0.001mm) and shank (H5) tolerances improve accuracy and tool life Flute design promotes efficient chip evacuation
H/V (High Velocity Series)
3D - METRIC Part No. HV 10700 HV 20500 HV 20700 HV 20800 HV 30700 HV 40700 HV 50110 HV 60110
* USD
Flutes 2 2 2 2 2 2 2 2
D 1.0 2.0 2.0 2.0 3.0 4.0 5.0 6.0
R 0.5 1.0 1.0 1.0 1.5 2.0 2.5 3.0
I 2.0 4.0 4.0 4.0 3.0 8.0 10.0 12.0
L 70.0 50.0 70.0 80.0 70.0 70.0 110.0 110.0
d 6.0 6.0 6.0 6.0 6.0 6.0 8.0 8.0
Price* $33.63 $28.03 $28.63 $31.17 $28.83 $28.83 $40.58 $42.77
All Chicago images: City of Chicago, Department of Cultural Affairs and Special Events
Fun Chicago facts

n The nations rst skyscraper, the
www.pctcarbide.com Phone: 888-398-9449

2011 PCT CARBIDE
10-story, steel-framed Home Insurance Building, was built in 1884 at LaSalle and Adams streets and demolished in 1931. n Residents were threatened by waterborne illnesses from sewage owing into Lake Michigan, so the city reversed the Chicago River in 1900 to make it ow toward the Mississippi River. n Historic Route 66 begins at Grant Park on Adams Street in front of the Art
Institute of Chicago. n The rst self-sustaining nuclear chain reaction, ushering in the atomic age, took place at the University of Chicago in 1942. n The 1,451' Willis Tower, completed in 1974, is the tallest building in North America. n Chicago is the birthplace of mail-order retailing (Sears and Montgomery Ward), the car radio (Motorola) and the TV remote control (Zenith).
128 | AUGUST 2012 | CTE
A guide to a few must-do activities while in Chicago for IMTS.

Chicago was only 46 years old in 1883 when Mark Twain wrote, It is hopeless for the occasional visitor to try to keep up with Chicago. She outgrows his prophecies faster than he can make them. By that time, Chicago had grown more than 100-fold, from a small trading post at the mouth of the Chicago River into one of the nations largest cities. During the next 20 years, it would quadruple in population as it repeatedly reinvented itself, according to Choose Chicago (www. choosechicago.com), Chicagos newly formed tourism bureau. Today, Chicago is a global city, a thriving center of international trade and commerce and a place where many organizations host their trade shows. As involving as IMTS is, youre bound to have some free time while in Chicago, which you can spend either appreciating the citys architecture or finding the nearest place to order a delicious deep dish pizza. Following is a brief guide to CTEs hometown:
Precision
At Any Speed!
Featuring The Best Track Record In The Industry
Tours, Must-See Sights Shoreline Sightseeing. Experience one of Chicagos popular architecture cruises. Shoreline Sightseeing offers daily boat cruises down the Chicago River and out into Lake Michigan, offering visitors and residents alike a unique vantage point to enjoy the city and its iconic skyline. Go to www.shorelinesightseeing.com. Guided Building Tours. The Chicago Cultural Center guided building tours take you to see the worlds largest Tiffany glass dome and other architectural gems in the Peoples Palace on a free guided tour of this Beaux Arts landmark building. Tours are offered every Wednesday, Friday and Saturday at 1:15 p.m., and depart from the Chicago Cultural Centers Randolph Street lobby. Millennium Park. Situated on 24.5
Precision Better than 0.00002 (1/2) repeatability Speed 12,000 rpm Totally sealed, no metal-to-metal moving parts Sizes from 3 to 18 diameter Interchangeable top jaws Custom designed diaphragm chucks available 4400 Austin Blvd. / P.O. Box 550 Island Park, NY 11558-0550 (516) 431-1112 Fax (516) 431-1928 Toll-Free 1-800-810-2482
Come visit us at IMTS 2012, Booth #1251
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ctemag.com | 129
The new standard for roughing applications
Visit us on booth #W1464
: Premium cutting edge, more innovative shank.
: The patented safety belt for your cutting tools.
Productivity + 30 % Tool life + 200 % Process reliability 100 % Runout accuracy < 3 m Spindle Liners Steel & Urethane License partners Sandvik Coromant, Kennametal, Walter, Emuge Draw Tubes /Widia, Bars / Nuts Franken, HAM, Data Flute, Helical More Chuck Adaptors www.haimer-usa.com/usa/safelock.php
Spindle Stops Part Ejectors

Haimer USA, LLC | 134 E. Hill Street | Villa Park, IL 60181 | USA | Phone +1-630-833-1500 | haimer@haimer-usa.com | www.haimer-usa.com
Spindle Liners Steel & Urethane Draw Tubes / Bars / Nuts Chuck Adaptors Spindle Stops Tool Holders Shrinking Technology Part Ejectors
Balancing Machines Measuring Instruments Tool Management
Anz_SafeLock_7.125x4.875"IMTS.indd 1
11.07.12 10:09
Lathe Spindle LIners

The best quality CNC Lathe Spindle Liners in the industry with the quickest deliveries.
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CNC Lathe Accessories

Spindle Liners (Reduction Tubes) Spindle Liner Racks Coolant Collector extensions Top Load Sport Bar Supports Spindle Extensions Draw Tubes / Bars / Nuts Spindle Stops Part Ejectors
Support Bars longer than the Lathe spindle.
All JF Berns Company equipment is designed & manufactured in the USA!
Call 513-851-4600 or Visit us at: WWW.JFBERNS.COM Email: INFO@JFBERNS.COM
130 | AUGUST 2012 | CTE
Chicago Challenge (continued)

acres of public green space in the heart of downtown, Millennium Park features the now-famous Cloud Gate, or Bean, sculpture, gardens, fountains and walking paths along the citys lakefront. Navy Pier. With more than 8 million annual visitors, Navy Pier is the Midwests top tourist attraction. Take in skyline views on the Ferris wheel, enjoy a Chicago Shakespeare Theater play or watch a 3-D Imax movie. SkyDeck. Step out into space on SkyDeck Chicagos The Ledge, 1,350' above the ground. The Ledge offers a unique vantage point of the surrounding cityscape in a glass box protruding from the 103rd floor. Its located at the Willis Tower (formerly the Sears Tower). Chicago Cultural Center, the nations first free municipal cultural center, is one of the citys 10 most popular attractions and is said to be one of the most comprehensive arts showcases in the U.S.
Shop Till you Drop Chicago is a leading shopping and
fashion destination. From major department stores to chic designer boutiques, the city boasts a vibrant retail scene. Today, the city is home to more than 250 Chicago-based fashion designers and 400 independently owned boutiques. Magnificent Mile. A Chicago shopping spree typically starts at the Mag Mile along North Michigan Avenue, stretching from the Chicago River to Oak Street. Its the destination for department store giants Neiman Marcus, Saks Fifth Avenue, Nordstrom and Bloomingdales, alongside hundreds of specialty shops and boutiques such as Crate & Barrel, the Apple Store, the Disney Store, American Girl Place, Niketown, Tiffany & Co. and Ralph Lauren. State Street. Often called That Great Street, State Street is in the heart of the Loop. One of the citys first major retail outlets, the flagship Marshall Fields State Street store (now Macys) has been a Chicago icon for more than 150 years. The store is an architectural gem, offering 10 selling floors of ready-to-wear clothes, collections by Chicago-based designers
and fine home lines. Another shopping destination on State Street is the former Carson Pirie Scott building, which now houses Target.
Food Favorites No visit to Chicago is complete without trying its two most famous foods: Chicago-style hot dogs and Chicago-style deep dish pizza. Chicago Pizza. When eating Chicagostyle pizza, youre best advised to use a knife and fork. The deep dish delicacy was reportedly invented in 1943 at the still standing and always crowded Pizzeria Uno, 29 E. Ohio St. A Chicago pizza is about 2" thick and arrives in a heavy black pan. Chicago has many other deep dish pizza restaurants, including Edwardos, Ginos East, Giordanos, Leonas, Home Run Inn and Lou Malnatisall of which have several Chicago locations. Chicago Hot Dogs. The tube steak made its first recorded appearance in Chicago at the 1893 Worlds Columbian Exposition, but the true Chicago-style dog was invented 40 years later by push cart
ctemag.com | 131
Chicago Challenge (continued)

vendors during the Great Depression. For a nickel, a hard-pressed Chicagoan could get practically a full meal: a hot dog with a salad on topspecifically, yellow mustard, bright green relish, onions, tomato wedges, a pickle spear, sport peppers and a dash of celery salt, bulging from a steamed poppy seed bun. Thats what youll get if you order a hot dog with everything or the works at one of hundreds of Chicago hot dog stands, some of which have attained iconic status. These include Superdawg, 6363 N. Milwaukee Ave.; Wieners Circle, 2622 N. Clark St.; and Hot Dougs, 3324 N. California Ave.
Get Moving After you indulge in one of those Chicago favorites and want to work off some calories, the 18-mile path along Lake Michigan is popular for cyclists and runners. Along the way, there are 33 beaches plus tennis courts, athletic fields and one of the eight Chicago Park District golf courses. In-line skating, miniature golf,
Navy Piers Ferris wheel is a replica of the first Ferris wheel, introduced at the 1893 Worlds Fair in Chicago.
bowling and other recreational activities are readily available. For additional information, including local customs and transportation guides and maps, visit the Chicago Office of Tourism and Cultures Web site at CTE www.choosechicago.com.
Editors Note: All the information in this guide is courtesy of Choose Chicago, an organization created recently by combining the Chicago Convention and Tourism Bureau and the tourism portion of Chicago Office of Tourism and Culture.
MODEL R-4600
3-JAW O.D. AND I.D.
FOR TURNING OR STATIONARY WORKHOLDING APPLICATIONS One chuck will grip I.D. and O.D. with no change to the mechanism required. Pull back action in both modes Completely sealed Drawbar operated or with built-in air or hydraulic cylinder 6 to 1 average mechanical advantage Minimum loss of gripping power due to centrifugal force Jaw travel of 0.250" each jaw with 1.5" stroke actuator Positive pull-back action Holding power ratio of 5.4:1. Completely sealed Service
SEND A DETAILED PART PRINT FOR AN IMMEDIATE QUOTATION
STACE ALLEN CHUCKS, INC. 2250 W. Minnesota St. Indianapolis, IN 46221 Telephone (317) 632-2401 Fax (317) 637-7563
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LET US SOLVE YOUR CHUCKING PROBLEMS!

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132 | AUGUST 2012 | CTE
workholding power chucks engineered solutions oil country chucks set-tru scroll chucks universal scroll chucks heavy duty chucks 12-jaw hydraulic chucks specialty chucks indexable carbide negative and positive turning inserts threading inserts grooving milling drills solid carbide drills hss and cobalt drills dies taps reamers annular cutters manual plus cnc lathes oil country lathes experts technology research partnership e-store customer service ingenuity and much more...
toolmex your industrial solutions provider
www.toolmex.com +1-508-653-8897 Local 800-992-4866 US Toll Free
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tooling and workholding
. R&J Tool offers a patented process for resharpening carbide and ceramic indexable inserts for milling and turning. The company sharpens the tools by selectively grinding material to produce a new cutting edge. The process does not reduce an inserts IC or locating surfaces. According to the company, the process takes into account unique geometries, edge preps and coating combinations for specific applications. R&J Tool Booth: W-1846.
. The Smart Damper

from BIG Kaiser Precision Tooling Inc. is a through-coolant, dynamic damping system that reportedly eliminates vibration and reduces chatter when deep-hole finish boring and extendedreach facemilling. This translates to finer surface finishes and higher metalremoval rates. Models are available for the companys boring tools with KAB4 to KAB6 connectors and shell mills with a 1"-dia. pilot. BIG Kaiser Precision Tooling Inc. Booth: W-1600.
. Schunk
Inc.s Tendo E compact hydraulic toolholder is suitable for milling, drilling and reaming. The toolholder can safely transfer torque up to 384 ft.-lbs. at a 20mm clamping diameter, the company reports. Runout is less than 0.0001" at 2.5 diameters. Common spindle connections are available, including HSK A63, SK 40, BT 40, CAT 40 and CAT 50. Schunk Inc. Booth: W-2000.
. Seco Tools TK1001

and TK2001 insert grades reduce the number of grades needed when turning cast iron. TK1001 is for finishing gray cast iron up to semistable conditions, nodular cast iron under stable conditions and steels hardened to 40 to 45 HRC. TK2001 is for turning nodular and gray cast iron in difficult applications, including heavy interrupted cutting. TK-grade inserts are available in 211 new geometries. Seco Tools Booth: W-1564.
. LMC Workholding offers

Chandox SE Series Super Thin chucks. The steel chucks are suitable for holding parts for gaging and metrology applications. A user directly rotates the chuck knob for gripping and loosening a part without the need for a handle. Jaws are reversible to grip various sizes more conveniently, the company reports. LMC Workholding Booth: W-1314.
. Star SU LLC
offers custom carbide drills and reamers, including single-pass port cavity tools, which allow complete cavity machining, reduce cycle times and hold industry tolerances for size and finish. Its Super Round tool produces extremely round holes within microns, reams holes with interrupted cuts and imparts fine finishes for spool-bore applications, according to the company. Star SU LLC Booths: N-6924, W-1385.
134 | AUGUST 2012 | CTE
Celebrating our 100th Year

2012 marks Scully Jones 100th year of continuous service to the manufacturing sector as a company that began with quality in mind and continues to this day. We look forward to the next century of business with the same sense of quality and pride in what we manufacture as we did in 1912 . Most complete line of Floating Holders in the Industry! Scully Jones/Seibert (SJS) offers direct replacement for all Tapping & Reaming Systems, Tap Adapters, Collets, and Special Machine Drilling products. We can provide cross-reference information by fax or phone to convert T.M. Smith, Collis, Glenzer, Zeigler, Bilz part numbers to SJS numbers.
SAFE-TORQUE TAP DRIVERS Designed for use in machines with reversing spindles. These tap drivers come equipped with feed compensating springs and be used for lead screw tapping.
HYDRAULIC CHUCKS Scully Jones/Seibert manufactures a complete line of standard chucks, along with special built to customer specifications. All standard and special chucks are repairable in most cases.
AUTOMATIC RECESSING TOOLS Ideal for cutting circular oil grooves, retaining ring grooves, reliefs, and chambers inside existing holes. In addition, using these tools, virtually any machine can counterbore, face, and backface.
Email: Scullytools@gmail.com | 1901 S. Rockwell Avenue, Chicago, IL 60608 phone 800.752.8665 | fax 773.247.6088 Website: www.scullyjones.comsee our catalog online.
tooling and workholding products GO MULTI-V!

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- . Allen
Benjamin Inc.s high-performance, colorcoded taps made of HSSE premium steel are engineered for specific applications. Each of the six color ringsblack, white, yellow, green, blue and redindicate an application-specific tap geometry and design criteria based on the characteristics and hardness range of various workpiece materials. Available tap styles include spiral point, spiral flute, form and straight-flute die cast. Taps for threading cast iron are also available. Allen Benjamin Inc. Booth: W-2474.
Toll Free: 800-665-6734 Fax: 866-308-7471 info@magaforusa.com www.magaforusa.com
IMPROVED performance FEWER tool changes LONGER tool life
. Kurt Manufacturing Co.s Model 3400V Versatile Lock vise has a 6" jaw opening and 0.0005" clamping repeatability. The vise prevents parts from lifting under heavy clamping loads, and the pull-type jaw clamping design reduces deflection, the company reports. The 3400V has a one-piece vise body and stationary jaw machined from 80,000-psi ductile iron, which enhances strength and reduces vibration. Its available in standard and reverse manual and hydraulic models. Kurt Manufacturing Co. Booth: W-2423.
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Keyway, hex, spline, hexalobe, CNC push and strip broaching tools Custom broaching solutions
Call or e-mail for catalog today!
Toll Free: 800-247-2024 Fax: 413-863-2714
info@hassay-savage.com www.hassay-savage.com
. Simonds International says saws applied with its SineWave technology cut workhardening material, such as tool steel and stainless steel, 30 to 40 percent faster than traditional bandsawing. The technology uses a unique rocking motion that forces each tooth of a bimetal blade to penetrate the workpiece and impart a fine surface finish. The blade grows in width, creating a self-feeding action that improves productivity, the company reports. Simonds International Booth: N-6672.
. Command Tooling
Systems LLC has introduced driven tools for Swiss-style machines. The tools were developed in cooperation with local medical manufacturers and Commands parent company, EWS Tool Technologies. The tools have a labyrinth seal, which shields internal components from contaminants during machining. The housings are made of high-strength alloy steel and the solid shafts are made of tool steel. Runout is reportedly better than 2.5m. Command Tooling Systems LLC Booth: W-2528.
136 | AUGUST 2012 | CTE
. Standard solid-carbide
and carbide-tipped Thin Saws from Gaylee Saws are available in diameters from " to 4". The company produces solid-carbide saws with a tolerance of 0.0005"/-0.0000" on thickness and 0.005"/-0.000" on OD. Saws with tighter tolerances can be ordered as specials. The solid-carbide saws last 100 times longer than HSS ones, according to the company. Gaylee Saws Booth: W-2474.
. Advanced
Machine & Engineering Co. designs and builds Amrok dedicated manual fixtures for horizontal and vertical machining centers, as well as other CNC machines. According to the company, the fixtures reduce machine setup and cycle times, improve operator safety, reduce workpiece handling and improve tolerances because a single fixture is used instead of multiple ones. Advanced Machine & Engineering Co. Booth: W-2405.
PVD Coating Systems

Supplying Advanced PVD Coating Systems all over the world
Product Lineups
Arc
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AIP Technology chnolog provides Smooth Surfa Surface coatings with High High Deposition osition Rate
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UBMS Technology provides High Adhesive DLC Film for wear ea parts and other coatings
Specialty

Hybrid (AIP+UBMS) S) sys system In-Line Coating system ste PVD Coater for Piston ton Rings
Models els
. North American Tool Corp. produces special taps in inch and metric sizes. The taps vary from standard designs based on their shank and drive dimensions, thread form and geometry, number of pitches (threads per inch) and other variables. The taps are available in HSS, HSSE premium steel, carbide and other materials. Coated taps are available. North American Tool Corp. Booth: W-2474.
. BIG Kaiser
Precision Tooling Inc.s 310 EWD digital boring head shows absolute setting accuracy on a built-in digital display. The measurement system displays linear movement of the tool carrier in both directions during diameter adjustment of 0.00005". The boring heads use existing 310 EWN insert holders to allow the maximum boring range per head and are compatible with special insert holders, the company reports. BIG Kaiser Precision Tooling Inc. Booth: W-1600.
series W guarantee... We t High Stability with Highly Efficient Production!! P
AIP-S
URL Email
www.kobelco.co.jp/pvd/en/ www. w kobelco.co.jp/pvd/en/ / pvd@kobelco.com

Visit us at Booth
W-1151
ctemag.com | 137
tooling and workholding products
Come see why this is the best collet nut system for your CNC tooling!
. Hardinge Inc. has made more than 200,000 custom workholding designs for turning, milling, grinding, welding, assembling and positioning. A custom product can increase part accuracy, eliminate secondary operations, add flexibility to a machine, enable automation integration and minimize bulky fixturing, according to the company. It can also reduce job setup, changeover time and operator handling. Users often select specials for gripping odd shapes and delicate materials and to avoid part scratching and slippage. Hardinge Inc. Booth: S-8148.
. Walter USA LLC

offers an array of cutting tools, including Tiger-tec Silver inserts for turning, Titex X-treme Inox solid-carbide drills and Valenite indexable milling cutters. The inserts resist plastic deformation and crater and flank wear, and reduce machining times, according to the company. In addition to three insert grades, four geometries are available: ones for facing and light cutting, medium machining, general machining and roughing. Walter USA LLC Booth: W-1700.
IMTS BOOTH W-2185

Visit: www.t-toolusa.com
.
Abtex Corp.s ceramic filament brushes are mounted in the companys proprietary, molded, composite material. Ceramic fiber has a hard, durable grain that exposes sharp cutting edges as it wears. The application-specific brushes cut fast to reduce cycle times and provide long tool life, the company reports. Abtex also tests parts in its lab to determine the appropriate abrasive filament product. Abtex Corp. Booth: N-7138.
T-Tool USA LLC 2850 Glades Circle, Suite 11 Weston, FL 33327 Phone: 954-358-6071 Toll Free USA: 855-358-8665
. The Lightnin Rod from R&R Tool Inc. helps inexperienced machine operators correctly load parts. Through internal test situation analysis, operators using the device are trained quicker and are able to produce a more reliable product than those not using it, the company reports. Placing the material in the machine and watching for the Lightnin Rods blue light to remain lit during tightening ensures accuracy within 0.0002". R&R Tool Inc. Booth: W-1497.
138 | AUGUST 2012 | CTE
aqua micro drills are Made from Ultra Micro Grain Carbide Nachis Patented Aqua Coating (Multi layer TiALN + Special lubrication film) End mill type shank for precise and accurate drilling 7 x D Effective DRILLING flute length USA Stock item in diameter range (0.2~1.99mm)
nachi america inc.

headquarters & main warehouse 715 pushville road, greenwood, indiana 46143 U.S.A
toll pree phone:1-888-340-8665 Fax: 1-888-383-8665 URl: WWW.NACHIAMERICA.COM
. Rego-Fix Tool Corp.s

dual-contact Rego Plus toolholders are compatible with all BIG Plus spindles and include a line of ER and powRgrip toolholders. According to the company, these toolholders reduce TIR, improve tool rigidity, increase surface finish quality and improve part accuracy. The holders are licensed by BIG Daishowa. Rego-Fix Tool Corp. Booth: W-2364.
. Heimatec Inc. has introduced complete lines of tooling, each designed for specific brands of turning machines. Those include ones from Haas, Okuma, Mazak, Spinner, Miyano and Nakamura. Full-specification literature by machine brand is available. Heimatec Inc. Booth: W-1986.
. SaintGobain Abrasives Inc.s Norton Paradigm diamond and CBN grinding wheels are for grinding the flutes of carbide and HSS tools. The wheels have a bond that provides exceptionally fast cycle times and a low cost per part, the company reports. The wheels high grain retention and uniform structure provide a high G ratio, up to 2.5 times longer wheel life and a 30 percent higher material-removal rate, according to Saint-Gobain. Saint-Gobain Abrasives Inc. Booth: N-7051.
HYDRA-GRIP
Arbors and Chucks...
For accuracy you just can't get with conventional workholding.
Equalized hydraulic pressure expands or compresses uniformly from geometric centerline, compensating for "in-tolerance" piece part variation such as size, taper, "bell-mouth" or "out-of-round."
Telephone 586 977-9000
Fax 586 977-9190
Website: www.agdavis.com
140 | AUGUST 2012 | CTE
E-mail: agdavis@agdavis.com
IMTS watertower ad.indd 1
6/13/12 9:52 AM
- . The Rekord DZBF series taps from Emuge Corp. provide chip-breaking capabilities to eliminate the formation of long, continuous chips common when threading carbon steels, alloy steels and austenitic stainless steels. In combination, the cutting face geometry and spiral flute form affect chip flow, chip curl and chip length. This results in short, controllable chips, which eliminate flute clogging, according to the company. Emuge Corp. Booth: W-1536.
er . Jergens Inc. has added ER collets to its Fixture Pro 5-axis, quickchange workholding system for holding rods and other round workpieces. The base of the ER collet mounts to the systems risers and pallets. The system offers quick-change capabilities for complete part-to-part changeover in less than 60 seconds, the company reports. Collets are available for ER 11, ER 16, ER 20, ER 25 and ER 32. Jergens Inc. Booth: W-2312.
- . The ROTA NCR 6-jaw chuck from Schunk Inc. features a a central chuck piston, which supports three inner pendulums evenly arranged at a 120 angle. Each pendulum works in conjunction with three pairs of base jaws, resulting in six-point contact. The chuck clamps deformable rings, housings and thin-walled workpieces while providing maximum clamping force, according to the company. Diameters up to 1,200mm are available. Schunk Inc. Booth: W-2000.
Now offering Special Carbide & PCD Tools for machining composites...
Producing & stocking NAS compliant cutting tools for the aircraft industry.
Drills, Core Drills & Reamers with Straight Shanks or Adapted Shanks Stepped and Piloted Drills, Core Drills & Reamers Rivet Shavers & Nutplate Drills Specializing in HSS, Cobalt, Carbide and PCD made-to-order items from 3/32 to 1/2 up to 12" long for all industries
better.
Grind
Grinding Fluid Filtration
Diamond & CBN Wheel Truer
Producing & stocking carbide tipped port contour cutters for the fluid power industry.
MS-MC-SAE-Rosan cavities Inch & metric sizes Specializing in short-run & made-to-order items Simple to complex profiles Send us the part print & well design the tool Wetmore Tool & Engineering 5091 G Street, PO Box 637, Chino, CA 91710 Toll Free 800.708.3713 Local 909.364.1000 Fax 909.364.2333 www.hpwetmore.com
Wheel Truing and Dressing Machines Grinding Fluid Filtration Systems Carbide Rod Cut-Off Machines Drill and Tool Grinders PCD Tool Grinders Check out the machines in action from your smart phone! www.rushmachinery.com
Join us at IMTS Booth N7233
WETMORE Tool & Engineering
Supplying Cutting Tools to All Industries for Over 50 Years! ISO certified
WETMORE
(800) 929-3070 mail@rushmachinery.com Rushville, NY USA

ctemag.com | 141
Machinery
.
DocMagnets new permanentelectromagnetic chuck is for hard milling applications. The magnetic material, which does not contain rareearth magnets, reportedly facilitates demagnetization, making it easier to remove hardened steel workpieces from the chucks steel surface. Each pole delivers more than 1,500 lbs. of clamping force. Workholders are available in any size in 4" width or length increments. DocMagnet Booth: W-1092.
. Lovejoy Tool Co. Inc. makes milling specials from less than 1" to more than 55" in diameter. The company can make custom tools for machining cast iron, heatresistant superalloys, steel, stainless steel, aluminum and composites. The latest CAD/CAM and manufacturing technologies are used in the toolmaking process, according to the company. Lovejoy Tool Co. Inc. Booth: W-2214.
. Walter USA LLCs

Prototyp Protodyn HSC solid-carbide thread former is suitable for use in all formable materials, such as steel, stainless steel and aluminum with less than 12 percent silicon. The micrograin carbide substrate, which has a multilayer TiCN coating, enhances toughness and wear resistance, the company reports. The tools h6 shank tolerance enables use in shrink-fit toolholders. Walter USA LLC Booth: W-1700.
Cut Your Grinding Costs by 2/3!
The price of MCT 5000 is $108,000 The price of MCT 500 is $68,000
Available Models: MCT 6000 MCT 5000
Manufacturing and regrinding: Polycrystalline Tools, Inserts, End Mills, Reamers, Drill Bits, Burrs and more.
Tel: 714-952-4622 Fax: 951-808-0973 Made in the U.S.A.
MCT 500
Samatic 6 axis CNC Tool and Cutter Grinder is the most flexible and cost effective grinding machine with autoloader or manual loader available.
Machine Control Technology

210 South Crouse Drive, Corona, CA 92879 E-mail: MachineControlTech@sbcglobal.net
142 | AUGUST 2012 | CTE
Integrate deburring into machining cycles.
Most machining operations generate burrs that are removed in a separate deburring department after the primary machinery operation. We will show you how to integrate the deburring process into your machine tool cycles by using Osborn brushes. Once your part comes out of the machine, its nished. No burrs. For 125 years, Osborn has been the global leader in surface treatment and nishing solutions. Metalworking companies around the world rely on our experienced engineers and application technicians to solve their problems. When you start with Osborn, you nish rst.
Finish. First.
Osborn Sells Solutions

The Global Leader in Surface Treatment Solutions and Finishing Tools
Abrasives ATB Power Brushes Chemical Products Load Runners Machines & Equipment Maintenance Brushes Polishing Buffs Polishing Compounds Punched/Staple-Set Brushes Road-Sweeping Brushes Strip Brushes Wide-Face Rollers Wire Power Brushes
Osborn Tel: 800-720-3358 +1-216-361-1900 Web: vehicles.osborn.com Email: info@osborn.com
2012 Osborn
Printed in U.S.A.
LIT12003
W5M2012-4
Brushing and Finishing Solutions for Motor-Driven Vehicles

Finish. First.
For more information, visit: metalworking.osborn.com Email: info@osborn.com 800-720-3358 1-216-361-1900

2012 Osborn
Superior Solutions
Finish. First.

NE 2m W m
Deburring
2mm
(.079)
MICROCOFA
VEX-S
Drill and Chamfering

5mm - 10mm
(.197 - .394)
. The Turbo 10 from Seco Tools is for square-shoulder milling from roughing to finishing. The cutter is also suitable for slotting, contouring, helical interpolation and ramping. Diameter range is from 0.625" to 4", and the maximum cutting depth is 0.354". The cutter has a coated, prehardened body with two different pitch configurations for meeting tight tolerances and providing high reliability, the company reports. Mounting types include cylindrical, Weldon, arbor and Combimaster. Seco Tools Booth: W-1564.
. The PreciFlex from Exsys Tool Inc. is a modular toolholder system for lathe tooling changeovers. It has a single base holder and multiple tooling adapters that utilize the ER collet pocket. It allows interchanging of tooling adapters between fixed and rotary base holders. Repeatability is within 5m. Exsys Tool Inc. Booth: W-1664.
SOLO
Back Spotfacing
. Lexair Inc. says its Production Dynamic Full Bore collet chuck increases the through-hole capacity of lathe spindles 25 to 30 percent by using a self-contained mechanical-grip/airrelease actuation system. This allows use of a lathes full spindle-bore capacity. The chucks design eliminates the drawtube needed in hydraulic chucks, creating the additional capacity. Its available in eight sizes for stock diameters from 0.25" to 5.5". Lexair Inc. Booth: W-1322. . The SafeLock from Haimer USA LLC is a tool clamping system that provides integrated pullout protection for round tools. In combination with corresponding carbide drive pins in the toolholder (shrink fit, collet or hydraulic chuck), spiral-ground grooves in the tool shank prevent the tool from twisting or being pulled out of the holder during extreme machining. This enables a doubling of metal-removal rates by increasing cutting depths and feed rates, the company reports. Haimer USA LLC Booth: W-1464.
(513) 860-9900
www.HeuleTool.com IMTS W-1352
144 | AUGUST 2012 | CTE
.
Fixtureworks offers manual clamps from Imao, OK-Vise and Mitee-Bite. The clamps provide quick and secure fastening of parts for repetitive machining operations and enable easy loading and unloading of workpieces, according to the company. Clamping forces range from 2 to 2,200 lbs. Configurations include swing, pull, snap, hook, toe and side. The heat-treated alloy steel clamps have a black-oxide finish. Fixtureworks Booth: W-1686.
- . Techniks CoolBLAST
toolholders have coolant paths that direct coolant to the tool tip. Benefits include faster feeds and speeds, enhanced chip evacuation and longer tool life, according to the company. Shrink-fit and endmill holders are available. In addition, facemill arbors have a CoolBLAST arbor screw that provides a coolant path when used with through-coolant facemills. Techniks Booth: W-1732.
ctemag.com | 145
. TMX power chucks

are available from Toolmex Industrial Solutions. One suitable application is holding aluminum automotive wheels, where face clampingan alternative to traditional axial clampingimproves concentricity and minimizes deformation of thin-wall parts during machining, according to the company. The chucks reportedly combine high clamping forces, maximum precision and minimal effort. Toolmex Industrial Solutions Booth: W-2275.
. Nampower
. The CoroMill abrasive nylon disc brushes from Brush 176 from Sandvik Coromant Co. is an Research Manufacturing Co. Inc. contain indexable-insert, full-profile hob for ceramic and silicon-carbide filament to roughing, semifinishing and finishing deburr parts while imparting fine surface gears. It can more than double tool life finishes. The discs are made with a and reduce cutting time by 50 percent fiber-reinforced thermoplastic base that compared to conventional HSS hobs, results in less vibration, according to the according to the company. The milling company. The brushes come in two styles: tool covers gear profile sizes from module dot for general-purpose deburring and 4 to 6 and is custom made for profiles surface finishing, and turbine for medium with, for example, addendum modification and heavy deburring. and protuberance. Brush Research Manufacturing Co. Inc. Sandvik Coromant Co. CTE Advent 3.375x3.75 BW Ad_Layout 1 10/18/11 2:27 PM Page 1 Booth: N-7263. Booth: W-1500.
CLAMPS. FIXTURING ACCESSORIES. MACHINE TOOL COMPONENTS.
The
Specializing in Solid and Replaceable Thread and Form Mill Tooling
Specialists
Thread Milling
Fixtureworks is your source for Fairlane Products rest pads, grippers, Swivots and quick release ball lock pins. Imao clamps and set-up accessories; Kipp handles, spring plungers, knobs and hand wheels; OK-Vise clamps; Mitee-Bite low-prole edge clamps; and Speedloc mounting systems from Modern Industries.
It is the primary goal of Advent Tool & Manufacturing, Inc. to be the customer needs driven, preferred, world class manufacturer / supplier of the finest quality thread milling / form milling / specialty milling systems and solutions, to the machining,metalworking and manufacturing industry, for the next millennium.
call toll-free
888.794.8687 www.fixtureworks.net
146 | AUGUST 2012 | CTE
FXW-066 3.25x4.625.indd 1 6/25/12 1:54 PM
www.advent-threadmill.com
or visit our website at
1.800.THREAD4
When We Say LIVE TOOLING We Mean It!
Heimatec, a name you may not knowbut you soon will. Great reputations have a way of spreading. A leading German supplier of live tooling, Heimatec offers a wide assortment of tools for CNC lathes and machining centers, plus the U-TEC quick change system, angle heads, multi-spindle drilling heads, specialty tools and more. Application engineering, dealer and end user training from our Chicago headquarters, plus a nationwide network of quality machine tool reps and dealers to serve you. NEWLITERATURE DOWNLOADS ON LIVE TOOLING FOR BRAND-SPECIFIC MACHINES OKUMA, MAZAK, HAAS, NAKAMURA AND MORE!
VISIT US AT IMTS BOOTH W-1986

16 E. Piper Lane Suite 121 Prospect Heights, IL 60070 847-749-0633 info@heimatecinc.com www.heimatecinc.com Preben Hansen, President
. Ingersoll Cutting Tools says its Pro-Trio ballnose contour roughing endmills have three effective flutes and accept double-sided inserts. The tools are suitable for copy, channel and deep-pocket milling. Sidecutting insert stations enhance flexibility when side milling, according to the company. The dovetail clamping system ensures insert stability. Ingersoll Cutting Tools Booth: W-1822.
. HyperAccurate microdrill holders from Genevieve Swiss Industries Inc. are for Swiss-style machines and precision lathes. The holders have a prehardened shank and precision nut for enhanced concentricity. Collet sizes are from 0.5mm to 5.8mm. Genevieve Swiss Industries Inc. Booth: W-1592.
. Kennametal Inc. says its KM4X spindle connection provides three times the bending moment-resistant capacity compared to other systems. The spindle connections high clamping force and controlledinterference levels result in a robust connection, high stiffness and restrained bending moment for improved performance when machining titanium, according to the company. This enables higher cutting speeds and feeds. Kennametal Inc. Booth: W-1522.
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. Iscar Tool Advisor software from Iscar Metals Inc. is for selecting cutting tools based on cutting conditions, machine power, metalremoval rate and cutting time. Users can enter two to six mandatory fields for quick results or complete more detailed fields, including ones specifying machine parameters, tool diameters and tool grades. The software provides the three best tool options but can display up to 25 tool recommendations per application search. Iscar Metals Inc. Booth: W-1800.
. Microscope microtools from Vargus USA are for high-performance threading, boring and grooving bores as small as 1.0mm. The line includes a range of single-ended inserts and toolholders with an easy-touse clamping system, according to the company. Vargus USA Booth: W-2245.
. Tools coated
with Zenith coatings from Tool-Flo Manufacturing Inc. are effective for dry machining stainless steel, cast iron, carbon steel, titanium and hightemperature alloys hardened up to 68 HRC. The coatings have an optimal thickness and offer high adhesion and enhanced wear resistance, according to the company. Tool-Flo Manufacturing Inc. Booth: W-2346.
- . Nexus Tools ShrinkMILL system uses shrink-fit technology to maximize the connection between a facemill arbor and the tool. The shrink-fit connection reduces runout and vibration, permits high feed rates, extends insert life and enables fine surface finishes, according to the company. The shrink-fit process heats the facemill, which expands the bore to receive the arbor, and the bore shrinks around the arbor as the tool cools. Nexus Tool Booth: W-1732.
- . Norton
Quantum X creep-feed grinding wheels from Saint-Gobain Abrasives Inc. feature the companys pore-induced construction, Quantum ceramic abrasive and latest bond technology. The wheels reduce grinding cycle times up to 50 percent while using at least 20 percent less power, according to the company. They are available in blank stock in type-01 straight wheel in six sizes from 16"1"5" to 20"5"8". Saint-Gobain Abrasives Inc. Booth: N-7051.
. Royal Products says its standard special live centers are standard products that accommodate about 90 percent of what were previously considered application-specific requirements. Each center incorporates the companys Roto-Shield technology to deflect coolant, protect bearings and extend operating life up to 300 percent. Royal Products Booth: W-1622.
. Paltech PH 5000grade turning inserts from Palbit by Toolmex Industrial Solutions incorporate a new medium-temperature CVD coating process that combines Ti(C,N) and aluminum oxide. The coating provides enhanced adhesion, toughness and wear properties through microstructural optimizations and post-coating treatments, the company reports. Five new inserts are available, which are for turning steel and cast iron. Toolmex Industrial Solutions Booth: W-2275.
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. Iljin USA
Inc. says its PCD provides long tool life, enhanced thermal and chemical stability, and extreme wear and abrasion resistance. Grades are available with grain sizes from less than 1m to 40m with diamond volumes from 40 to 95 percent. PCD tools are suitable for cutting tungsten carbide, ceramics, aluminum silicon, copper alloys and advanced composites. Iljin USA Inc. Booth: W-1868.
. Darex LLC says its improved XPS-16 CNC drill bit sharpener sharpens any 2-flute HSS, cobalt or carbide SAE bit, and metric twist bits from 3mm to 16mm in diameter. It sharpens any angle from 118 to 150. It stores up to 50 drill files and allows users to choose no-split, X-split, R-split and splitonly operations. The new model is 20 percent faster than the previous version, according to the company. Darex LLC Booth: W-2180.
. WIDIAs M270 and M370 series of inserts are for high-feed milling. Three M270 grades are available: TN2505 for good wear resistance when cutting materials as hard as 60 HRC, TN6540 for enhanced toughness and TN6525 for toughness and wear resistance when dry machining steel. The M370 inserts are double-sided, have six cutting edges and enhance performance and reliability when milling steel and cast iron, according to the company. WIDIA Booth: W-1452.
- .
UDCB diamond-coated endmills from U.S. Union Tool Inc. are for milling solidcarbide molds and parts. The tools can cut features and shapes that previously had to be ground or EDMed, according to the company. The ballnose endmills are available from 0.20mm to 6.0mm in diameter and are suitable for operations from roughing through finishing. U.S. Union Tool Inc. Booth: W-2108.
- . M.A. Ford Manufacturing Co. Inc.s TuffCut XT series 278 endmill is a new 5-flute version of its XR high-performance endmill. The tool has enhanced corner protection, a whisper blend between the OD and neck, and a proprietary carbide substrate coated with ALtima Blaze. The endmill provides 20 percent higher feed rates compared to competing tools and reduces harmonic vibration and imparts finer finishes, according to the company. M.A. Ford Manufacturing Co. Inc. Booth: W-2457.
. Brush
Research Manufacturing Co. Inc.s FlexHone diamond tools are for deburring, edge blending and surface finishing hard materials, such as carbide, ceramic and aerospace-grade alloy steels. The tools resin-bond diamond crystals have high friability, creating self-sharpening edges. Standard sizes are from 4mm to 20mm in three different mesh sizes. Specials can be ordered. Brush Research Manufacturing Co. Inc. Booth: N-7263.
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. The
SmartBore system from Rigibore Inc. is a cutting-edge adjuster with DRO for boring tools or cartridges. It enables an operator to manually make micron-level accuracy adjustments while a tool is in the machine spindle. Adjustment data is wirelessly transmitted for remote display. The minimum bore diameter is 16mm. Rigibore Inc. Booth: W-1280.
- . The CoroDrill 870 from Sandvik Coromant Co. is an exchangeable-tip drill for the intermediate hole-tolerance area of IT9 to IT10. A secure interface between the drill body and tip ensures reliability and precision, while the quick tip-change procedure helps to maximize active machining time, according to the company. Standard lengths are from 3 to 5 diameters deep. Diameter range is from 12mm to 20.99mm. Sandvik Coromant Co. Booth: W-1500.
. Sumitomo Electric Carbide Inc.s SN2000K- and SN2100Kgrade ceramic inserts are for rough milling and turning cast iron. SN2000K is for high-speed turning and finishing and promotes long tool life and wear resistance through its hardness and toughness. SN2100K provides high shock and impact resistance and is suitable for roughing gray cast iron, according to the company. Sumitomo Electric Carbide Inc. Booth: W-2422.
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. The RT100 HF drill from Guhring Inc. provides a high penetration rate when drilling nickel-base alloys. The point geometry helps dissipate heat, and the tool has a double-margin flute for enhanced stability in the cut, according to the company. It is coated with nano-Si, a silicon-based PVD coating that is 57 percent harder than TiAlNbased coatings, the company reports. Guhring Inc. Booth: W-2322.
. TT7005- and
TT7015-grade Black-Rush inserts from Ingersoll Cutting Tools are for turning cast iron. The bond between the coating and substrate enhances chip resistance, the company reports. After the inserts are coated, a surface treatment is applied that reduces friction, cutting force and built-up edge. This enables stable and consistent tool life and the ability to impart fine finishes. Ingersoll Cutting Tools Booth: W-1822.
- . Precision Cutting
Tools Inc. says its AXC series drills have a triple-margin design for high-penetration capability and accuracy. Designed for cutting aluminum, the tools 15 internal coolant design enhances chip evacuation and controls the temperature at the tool/ workpiece interface, the company reports. The spiral-fluted, right-hand cutting drills are from 3.0mm to 20mm in diameter, with models for producing holes 3 to 30 diameters deep. Precision Cutting Tools Inc. Booth: W-2164.
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ctemag.com | 153
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. Tiny Vise edge clamps from Carr Lane Manufacturing Co. grip the sides of a workpiece so the top is accessible for machining. The clamps are suitable for fixturing small parts and available from a miniature #8-32 thread to a 1"-8 thread with 2,500 lbs. of clamping force. Force is applied by positive screw action when turning a hex wrench. Carr Lane Manufacturing Co. Booth: W-1663.
. Rigibore Inc.s Active Edge boring tools wirelessly and automatically adjust the cutting edge with micron-level accuracy. Adjustment can be performed remotely while a tool is in the machines spindle or carousel, eliminating operator intervention. No spindle modification is required. Up to eight cutting edges can be precisely compensated without touching the boring tool, according to the company. Rigibore Inc. Booth: W-1280.
. LMT Fettes Xchange modular tap combines a solid-carbide cutting head and steel shank. The head is screwed onto the shank and replaced when worn. The tap is for threading cast materials, such as iron, brass and highsilicon aluminum. The through-coolant taps are available in M8 to M18 sizes. LMT Fette Booth: W-2464.
. J&M Machine Inc.s Four Steps to Improved Tooling Performance technology includes the use of high-torque retention knobs and machining practices that can extend tool life 30 percent. According to the company, the retention knobs prevent premature failure and decreased tool life when properly installed. The company provides installation instructions. J&M Machine Inc. Booth: W-2179.
. Lenzkes Clamping offers Multi-Quick 60 and 106 clamps. Both have a double-stepless adjustable range and high clamping pressure via low torque. The MQ 60 clamps are for smaller machines, and the MQ 106 clamps provide extra reach and enhanced adjustability through an integrated sliding plate with a stepless, horizontally adjustable fixing set. Lenzkes Clamping Booth: W-1880.
. Vargus USA offers 14D carbide inserts for producing API round buttress threads. The line for the oil and gas industry includes a comprehensive variety of standard tools, the company reports. Specials can be ordered based on customer specifications for distinct applications. Vargus USA Booth: W-2246.
154 | AUGUST 2012 | CTE
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. Velocity Products offers a new line of tooling specifically for Okuma lathes. Also available is a patentpending K column modular clamping and machining system for difficultto-machine workpieces on horizontal machining centers. This through-feed, tombstone-style workholder brings barfeed technology to all brands and sizes of HMCs, according to the company. Velocity Products Booth: S-9410.
. Elliott carbide roll burnishing tools from Monaghan Tooling Group can impart mirror-like finishes on ODs, IDs, faces, tapers and spherical surfaces, according to the company. The square- or cylindrical-shank tools are for use on all turning centers. They are available with four standard roll radii: 0.032", 0.062", 0.093" and 0.125". Monaghan Tooling Group Booth: W-1286.
. NTK Cutting Tools SX7-grade SiAlON ceramic inserts are for machining nickel-base alloys used in the aerospace industry. The inserts provide enhanced flank- and notch-wear resistance, according to the company. The inserts can turn at speeds from 600 to 1,500 sfm and feeds from 0.008 to 0.014 ipr. NTK Cutting Tools Booth: W-1163.
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156 | AUGUST 2012 | CTE
. Carmex Precision Tools LLCs DMT 3-in-1 multipurpose tool drills, threads and chamfers in a single operation. The company also offers a variety of thread mills, ranging from tiny tools to large ID and OD thread mills, and recently introduced a series for Swissstyle machines. According to Carmex, its Helical Advantage design boosts productivity, imparts finer finishes and extends tool life. Carmex Precision Tools LLC Booth: W-1180.
, . Pioneer N.A.
offers lines of chucks, collets, indexers and rotary tables, drills, reamers, tap drivers and related attachments, and tool-presetting equipment. The company, which reports it has sold more than 30,000 chucks since 1985, offers air chucks 2.5" to 10" in diameter that can be run at 6,000 rpm and have 0.00006" repeatability. Its diaphragm chucks have diameters from 3" to 6" and a maximum operating speed of 12,000 rpm. Pioneer N.A. Booth: W-1192.
. The SJL
chucks from SMW Autoblok Corp. can be switched from a 2+2+2 equalizing chuck for clamping raw materials to a 6-jaw, self-centering chuck for clamping machined diameters. In equalizing mode, the chuck clamps parts with sets of two jaws equalizing as pairs. In 6-jaw mode, the chuck is suitable for boring top jaws and clamping thin-wall workpieces that require equal wall thickness. Diameters from 220mm to 1,250mm are available. SMW Autoblok Corp. Booth: W-1400.
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ctemag.com | 157
machine tools and accessories
. Rollomatic Inc.s LaserSmart laser cutting/ablation machine is for producing PCD, PCBN and other superhard cutting tools, which have traditionally been produced via spark erosion and polish grinding processes. Laser cutting creates a superfine cutting edge and surface finish, and laser ablation allows tool geometry optimization, according to the company. Rollomatic Inc. Booth: N-7200.
.
Doosan Infracore Machine Tools NHM5000 HMC accepts workpieces up to 33.5"43.3". The machines one-piece casting provides a rigid base for the table and column, and the bed is made of finegrain Meehanite to dampen vibration and dissipate heat. A 25-hp, two-geared motor powers the 6,000-rpm spindle, which produces 704 ft.-lbs. of low-end torque. A refrigerated cooling system maintains a constant spindle temperature, regardless of ambient temperature or cutting conditions. Doosan Infracore Machine Tools Booth: S-8100.
. Amada
Machine Tools America Inc.s S-10 mill/ turn machine has two turrets, with eight or 12 stations each, and one main spindle. A choice of gantry part loading, bar feeding or manual loading is available. The optional subspindle and reversing vise offer alternative ways to work both ends of a part in one loading. In coordination with the C-axis, each turret is independently capable of simultaneous 3-axis motion. Amada Machine Tools America Inc. Booth: S-8986.
. Star SU LLCs PTG-6L 5-axis tool and cutter grinder is for producing, sharpening and reconditioning various cutting tools. The grinder has a six-station wheel pack, an integrated linear motor and direct-drive rotary technology. It also features a traveling tool platform for CNC steady resting and workholder adjustment, a NUM Flexium controller and automatic wheel-sticking capabilities for unmanned operation. Star SU LLC Booths: N-6924, W-1385.
. The VL 5i turning
machine from EMAG LLC can machine workpieces up to 250mm in diameter in a single clamping. In addition to a 28kW spindle that provides 300 newton-meters of torque, the machine has an automation system with a revolving belt that contains drag frames. The distance between the loading and machining positions is 550mm, which enables short idle times, according to the company. EMAG LLC Booth: N-6846.
. MAG
IAS LLCs 6-axis FTR AutoDrill combines a horizontal boring mill chassis and the companys extended-reach ram with a gimbal head for milling and drilling composites and composite-sandwich structures. Boeing will use the first one at its South Carolina plant for producing 787 fuselage barrels, beginning in the second quarter of 2013. It will be equipped with MAGs minimum-quantity-cryogenic tool cooling technology. The machine utilizes a Fischer 20-hp, 24,000-rpm spindle equipped with an HSK-50A tool interface. MAG IAS LLC Booth: S-8519.
158 | AUGUST 2012 | CTE
Featured at Booth W-1654
www.tungaloyamerica.com 3726 N. Ventura Dr. Arlington Heights, IL 60004 ph: 888-554-8394 fax: 888 -554-8392
. Scotchman Industries
Inc.s advanced feed system, coupled with a Scotchman circular cold saw, can turn a semiautomatic machine into a fully automatic production machine. According to the company, the advanced feed system allows companies to increase productivity, decrease setup time, reduce operator error and eliminate waste. With an optional material clamp, it can be used as a programmable stop system or an automatic programmable push-feed system. Scotchman Industries Inc. Booth: N-6417.
. The QXD200 machine from Vollmer of America Corp. is for finishing PCD tools. The machine combines rotary erosion and fluting with a polishing wheel to impart a mirror finish in a single setup. The machine has six programmable axes and a six-position toolchanger. Offline simulation creates a 3-D model that can be incorporated into other software packages for tool geometry verification. Vollmer of America Corp. Booth: N-6751.
. Agathon Machine Tools Inc.s DOM Semi 4-axis grinding center is for periphery grinding of ISOstandard indexable inserts. The grinder has an infeed axis with a linear motor, a polymer concrete base for enhanced vibration damping and an enclosed grinding area to keep moving axes and the handling system dry. Automatic handling of each workpiece occurs during grinding via an integrated pick-and-place, linear handling system. Agathon Machine Tools Inc. Booth: N-6951.
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CNC honing system from Sunnen Products Co. combines a 60" stroke and 20-hp spindle for honing bores up to 12" in diameter or larger. The machines synchronized servo axes eliminate the flattening of the crosshatch angle thats typically inherent at the stroke-reversal points when honing. The operator has the option to virtually eliminate crosshatch if required. The standard spindle speed is 0 to 300 rpm, with options of 0 to 600 rpm and 0 to 1,200 rpm. Sunnen Products Co. Booth: N-7400.
304 Winston Creek Parkway, Lakeland, FL 33810 863/688-0071 Fax: 863/682-6233 www.rockford-ettco.com
160 | AUGUST 2012 | CTE
. Femco Inc.s Model HL35DMSY CNC lathe has a C-axis, Y-axis, subspindle and Durga 23-station, twindisk turret. The turret provides 12 tools for OD turning and 11 tools for ID turning. All ID tool stations can be equipped with radial and axial power-driven tools. The main spindle has a 10" hydraulic chuck and a 25-hp, 4,000-rpm spindle with 2.95" bar capacity. The subspindle is equipped with an 8" hydraulic chuck and a 20-hp, 5,000-rpm spindle. Femco Inc. Booth: S-8021.
.
The UMC-750 universal machining center from Haas Automation Inc. is for simultaneous 5-axis machining and 5-sided (3+2) machining with a dual-axis trunnion table. The 40-taper machine is equipped with an 8,100-rpm, inline, direct-drive spindle and comes with a 40+1-tool side-mount toolchanger. An optional 12,000-rpm spindle is available. Both spindles yield 90 ft.-lbs. of cutting torque. Haas Automation Inc. Booth: S-8119.
/ . Index
Corp.s R300 turn/mill center has two independent 5-axis subsystems, each with a motorized milling spindle and an assigned work spindle. The machine can simultaneously machine complex parts, short bars up to 102mm and chucked parts up to 315mm in diameter. The machine is targeted at applications where larger chucked parts require a large amount of milling and drilling. Options include grinding with a grinding point or an external wheel up to 150mm. IndeX Corp. Booth: S-8450.
. The Model 528XW from Rollomatic Inc. is a 5-axis CNC tool grinder with a six-station wheel changer. The machine is particularly well suited for grinding specialty cutting tools and modifying, regrinding and production grinding rotary cutting tools, according to the company. The wheel changer, which has a repetitive concentricity of less than 2m, can replace wheel packs at the same time the automatic loader places a blank into the machine without increasing cycle time. Rollomatic Inc. Booth: N-7200.
ctemag.com | 161
. The Model AG400L wire EDM from Sodick Inc. features advanced linear motor-driven technology. According to the company, the machine is ideal for small to medium-size parts and molds that require tight tolerances and fine surface finishes. The company offers a 10-year positioning accuracy guarantee for all its wire EDMs. Sodick Inc. Booth: E-5102.
.
FOBAs M-Series laser marking workstations are available in two sizes and with three models each. The laser markers are expandable to five axes, height-adjustable and have a control panel that can be mounted on the right or left side of the workstation. The companys Intelligent Mark Positioning technology automatically detects workpieces and their positions and aligns the mark accordingly. FOBA Booth: N-6534.
- . LNS Americas Fox WS series oil-mist collectors are airfiltration systems that eliminate oil mist and smoke. Five models with capacities from 170 to 1,250 cfm are suitable for all machine types and machining processes using water-soluble, synthetic or neat-oil coolants. The Fox WM series is available in 2,500-, 5,000- and 7,500-cfm models. LNS America Booth: S-8586.
. Siemens Industry Inc.s Sinumerik 828D Basic T addresses the needs of shop floor turning machines. It combines CNC, PLC, operator panel and axis control for five axes/spindles, including live tooling. Therefore, milling and drilling on a turning machinefor face and peripheral surfacingare possible. The 828D Basic M is for milling machines. Even in complex moldmaking operations, it enables mirror surface finishes and reduced machining times, according to the company. Siemens Industry Inc. Booth: E-5010.
162 | AUGUST 2012 | CTE
.
Mitsui Seiki USA Inc.s HU100A-5XL HMC is for heavier applications that require a rigid and accurate machine. Users can choose axis travels from 1,300mm to 2,500mm; four, five or six axes of continuous motion; and a rotary table, trunnion table or table-on-table. Fixed spindles from 6,000 rpm and high-speed spindles up to 20,000 rpm are available. The company also offers quill-type spindles for precision boring with short tools. Mitsui Seiki USA Inc. Booth: S-8319.
. The
RZ 60, a gear grinding machine from Reishauer Corp., incorporates two spindles. This enables grinding on one spindle while the workpiece on the second spindle is changed and synchronized with the grinding wheel threads. At maximum speed, the grinding and workpiece spindle positions are controlled with the companys Precision-Drive electronic gearbox. This also enables multiple-start grinding wheels for making planetary pinions. Reishauer Corp. Booth: N-7018.
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.
Kitamura Machinerys MycenterHX800iLTGA HMC offers a work size of 59.1"59.1", clamping power of 30,710 lbs., pallet size of 31.50"31.50" and X-, Y- and Z-axis stroke of 55"49.21"52.16". The 68,200-lb. machine comes standard with a 35-hp, 12,000-rpm, two-step-geared, dual-contact spindle that delivers 280.3 ft.-lbs. of maximum torque. The multiplestep, energy-efficient spindle saves 40 to 50 percent kWh of energy. Kitamura Machinery Booth: S-9148.
. Hennig
Inc. manufactures vertical-wall covers to protect the ways and CNC feedback devices of horizontal machining centers from hot chips and coolant. Based on available space, the covers can be designed with telescoping steel boxes, stainless steel or fabric aprons, bellows with steel plate protection (lamellas) or the companys aluminum FlexProtect system. Hennig Inc. Booth: E-5714.
. The Mitsubishi MV wire EDM from MC Machinery Systems Inc. features a noncontact cylindrical drive using a linear shaft motor, an improved power supply and automatic threading. The machines round magnetic shaft creates a noncontact design with 360 of magnetic flux. This design reportedly delivers no wear, no cogging and no backlash, which enhances energy efficiency, accuracy and speed. MC Machinery Systems Inc. Booth: N-6825.
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. The Flexible Pallet Container 3000 automation system from Fastems LLC is an alternative to pallet pool technology, providing end users and machine builders a flexible manufacturing system installed in a container. The FPC 3000 handles 800mm and 1,000mm pallets and uses a low-profile, dual-rail, guided, pallet-change vehicle instead of a crane-style pallet changer. The system accommodates loads up to 3,000 kg, heights up to 1,800mm and diameters up to 1,600mm. Fastems LLC Booth: S-9148.
Booth Numbers: W-2180 & N-7209

164 | AUGUST 2012 | CTE
Visit us at IMTS
. IQMS RTStation
is a touch-screen user interface for a shop floor work center. Powered by Android technology, the device displays machine monitoring details, such as part counts, cycle speeds and other machine processes, in real time on a 7" screen. It provides machine downtime information, prints work orders, logs rejects for production reporting, allows for operator clocking in/out and displays job setup information. IQMS Booth: E-3259.
. AccuteX EDMs EZ-53SA 3-axis CNC wire EDM has an automatic wire threader and Windows-based CE control. The machines X, Y and Z work envelope measures 19.7"11.8"7.1". All consumable items that fit on the companys other EDMs are compatible with the machine. Optional 4th-axis indexing capability is available. AccuteX EDM Booth: E-5225.
- . SB
Machine Tools distributes the JapanTek 5X-410 machining center. The machine has a 120 (90 15) tilting spindle head to achieve five-face machining. The machine offers four machining capabilities: 5-axis machining with the standard two-pallet automatic pallet changer, five-face machining with APC, horizontal machining with APC, and vertical machining with APC. A 30-hp main motor, 60-tool magazine with automatic toolchanger and throughspindle coolant are standard. SB Machine Tools Booth: S-9463.
, .
Rattunde Corp.s ACS + CFMcurve integrates a sawing machine and machining center. The ACS cold saw utilizes a sawing algorithm with servomotor-controlled feed to continuously adjust critical sawing parameters during each cut. This reduces sawing times, improves surface finish and extends blade life, according to the company. The CFMcurve simultaneously machines each workpiece end using 12 independent servo-controlled axes. Operations include threading, boring, profile turning and grooving. Rattunde Corp. Booth: N-6737.
166 | AUGUST 2012 | CTE
. The Tongtai
TMT-2000 from Absolute Machine Tools Inc. is an 8-axis multitask turning center cast from Meehanite iron. The machines monoblock, 75 slant bed reportedly enhances rigidity and chip flow and improves operator ergonomics. The perpendicular Y-axis leads to simplified programming, according to the company. Rapid traverse rates are 1,181 ipm for the X-axis, 590 ipm for the Y- axis and 1,417 ipm for the Z-axis. Absolute Machine Tools Inc. Booth: S-8536.
. OPEN-XS from Prima Electro North America LLC is a modular system that can be applied as a CNC or general-motion control. It controls the servodrives and input/output modules distributed on a digital fieldbus and the analog or Pulse&Direction axes. The control unit is based on a PC platform and can be supplied in a stand-alone configuration or integrated with a monitor or the companys compact control panel. Prima Electro North America LLC Booth: E-5139.
ARNO Special Offer
. The Drill 300 EDM from GF AgieCharmilles employs electrodes from 0.012" to 0.12" in diameter to drill various workpiece materials, including Inconel, titanium, steel and carbide. The EDM has a Z-axis travel of 17.72" and a 45 tilting head to drill angled holes. The 6-axis configuration enables drilling round and shaped cooling holes, for example, in aerospace blades and vanes. The indexing table allows holemaking in a circular pattern. GF AgieCharmilles Booth: S-8754.
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ARNO SA System
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Enshu USA Corp.s GE series HMCs have refrigerated and temperaturecontrolled (1 C) spindles, ballscrews and servomotor mounts. Two machines have 40-taper spindles: the 400mm-pallet GE460H and 500mm-pallet GE480H. Their 29.5-hp, 15,000-rpm spindles are paired with rapid-traverse rates of 3,543 ipm. The 500mm-pallet GE580H and 630mm-pallet GE590H have 50-taper, 40-hp, 10,000-rpm spindles. Enshu USA Corp. Booth: S-8774.
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ctemag.com | 167
. The
Matsuura LX-160 from Methods Machine Tools Inc. is a two-pallet, 5-axis VMC with a top spindle speed of 46,000 rpm. The X-, Y- and Z-axis travels are 19.7", 9.8" and 11.8", respectively. The rotation center of the tilting B-axis is lowered below the pallet surface to reduce the movement of each axis during simultaneous 5-axis machining, shortening cycle times. The machine has a 6.3"7.9" work envelope. Methods Machine Tools Inc. Booth: S-9119.
- . IBAG North
Americas Micro Line compact spindles fit Swiss-style machines with 16mm- to 33mm-dia. spindles, speeds to 120,000 rpm and power to 390w. Right-hand spindles are also available for enhanced flexibility. IBAG North America Booth: E-5167.
. Known as Punch Master, the Model 1500 CNC profile grinder from Unison Corp. has a polymer case base to absorb vibration during grinding. Polymer bases have a low thermal expansion coefficient, providing low sensitivity to temperature fluctuations. The machine is for grinding round and nonround OD shapes, peel grinding and contouring. The grinder is equipped with Yaskawa AC digital servomotors and drive amplifiers. Unison Corp. Booth: N-6648.
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See us at IMTS Booth
# W-1163
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SPARK PLUGS (USA), INC.
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NTK Cutting Tools

Division of NGK Spark Plugs USA 46929 Magellan Drive, Wixom, MI 48393, U.S.A. Phone: 248-668-0100 Fax: 248-668-0200 Toll Free: 866-900-9800
www.ntkcuttingtools.com
. Heidenhain
Corp. offers its TNC 640 milling control with an optional turning control for multitask machining. The user enters all programming steps in plain language, the company reports. The control has a specially prepared keyboard surface and screen frame to eliminate fingerprints. An optimized user interface improves function presentation and clearly displays status information. Heidenhain Corp. Booth: E-5224.
. The Cyclone
52 BY2 turn/mill lathe from Ganesh Machinery Inc. enables working on the fronts and backs of parts. The 9-axis machine offers a 2" bar capacity and has a 15-hp main spindle and subspindle, and 35 tool positions with 18 driven tools, 12 of which are for the B-axis. Ganesh Machinery Inc. Booth: S-9371.
. NUM Corp. says its

Flexium CNC kernel, with a soft PLC, provides scalability for specialized machine tool builders. This allows OEMs to use the same control system across a range of machine designs. It can be applied economically to small machines with up to five axes and spindles, for example, or large machines with up to 200 axes, the company reports. NUM Corp. Booth: E-5135.
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Torque of up to 900 Nm ( 20 mm) Permanent run-out and repeat accuracy of less than 0.003 mm (0.0001) Increases tool life of up to 40 %, which results in huge savings Be a Part of the Experience. Visit us at IMTS Booth W-2000.
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. The 255 CL centerless

cylindrical grinder from Agathon Machine Tools Inc. grinds workpieces from 0.5mm to 30mm in diameter and plunge lengths up to 125mm. The grinding and control spindles form equivalent NC axes that are freely programmable, the company reports. The grinding and regulating wheels are supported unilaterally and can be mounted from the front. Agathon Machine Tools Inc. Booth: N-6951.
. Romi Machine Tools Ltd.s GL 170G is a gang-tooled CNC turning center. It comes with a hightorque, 15-hp motor; an A2-5 spindle nose with 2 bar capacity; and a 60 slant bed that provides easy access to tooling and workpieces, according to the company. Its worktable has three T-slots for tool positioning. Toolholders for the machine can accommodate through-coolant and driven tools. Romi Machine Tools Ltd. Booth: S-8792.
.
Milltronics Manufacturing Co. Inc.s VM3224 VMC has a 38"24" table and X-, Y- and Z-axis travels of 32", 24" and 26", respectively. The machine comes standard with the Milltronics 8200 CNC, linear roller ways, dual-arm 24-pocket toolchanger, six-spigot flood coolant, 180-gal. coolant capacity and chip auger. Machining accuracy is enhanced with 38mm ballscrews that are stretched and anchored with triplex bearings on each end, the company reports. Milltronics Manufacturing Co. Inc. Booth: S-8329.
. BLM Group USAs EM80 is an integrated CNC end machining center for cutting, chamfering, facing, boring, threading and profiling tubes. The machine comes with a 4,000kg capacity bundle loader. A conveyor brings parts toward a two-position chute where they are dropped in the appropriate bin. The machine handles lengths from 2,500mm to 120,000mm, tube diameters from 10mm to 80mm with wall thicknesses from 0.8mm to 12mm and solid bars from 10mm to 60mm. BLM Group USA Booth: E-4694.
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. The
FTC-1320V traveling-column VMC from Chevalier Machinery Inc. enables highspeed drilling, tapping and milling. The 6,614-lb. machine has a 25.6"14.4" table and X-, Y- and Z-axis travels of 19.7", 12.6" and 9.8", respectively. The spindle center to column is 15.6". To increase rigidity during machining, the machines base is a one-piece casting with a slope design equipped with a large-volume coolant flow for enhanced chip removal. Chevalier Machinery Inc. Booth: S-9066.
. Behringer
Saws Inc.s HBM800ALU is an automatic bandsaw for cutting aluminum and other nonferrous materials. After loading stock, the machine manages the entire sawing process and displays real-time cutting data on the operator terminal. The saw handles round workpieces up to 31.4" in diameter and squares up to 31.4"31.4". The saws narrow kerf (0.042") minimizes material usage. Behringer Saws Inc. Booth: N-6859.
- . Marubeni
Citizen-Cincom Inc.s M432VIII Swiss-style lathe has a B-axis with rotary tools on the gang tool post and a third Y-axis on the back tool post. The B-axis locates on the slant axis in reference to the Y-axis direction. When drilling angular holes on a conventional machine, an adjustable angle spindle is needed. A B-axis incorporating rotary tools can change the angle continuously, allowing multiple angular holes to be drilled in a single setup, according to the company. Marubeni Citizen-Cincom Inc. Booth: S-9419.
. The
Rhino bar feeder from Lexair Inc. supports and feeds bar stock through a lathe for production machining. The bar feeder handles material from 0.125" to 3" in diameter and up to 12' long. The singletube, muzzle-loading design feeds round, hexagonal, square and asymmetric stock. The units hydrodynamic oil cushion eliminates bar whip and dampens vibration and noise, according to the company. Lexair Inc. Booth: W-1322.
.
Makino Inc.s D300 5-axis VMC is for small, complex, 3-D contouring typically seen in aerospace, medical, high-end job shop and die and mold applications. The machines worktable has a work area diameter of 300mm, accommodating workpieces up to 450mm 270mm and 120 kg in weight. The X-, Y- and Z-axis travels are 300mm, 500mm and 350mm, respectively. The machine provides a top feed rate of 60,000 mm/min. and comes standard with a 15,000-rpm HSK-A63 spindle. Makino Inc. Booth: S-8700.
Our quality product line includes:

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.
Kaufman Manufacturing Co.s rotary transfer machines can reportedly be changed over to a new part in 35 minutes or less. According to the company, highvolume transfer systems can replace three or more existing machine tools while reducing floor space and extending tool life. Kaufman Manufacturing Co. Booth: S-8012.
1760 Tuttle Avenue Dayton, OH 45403 800.732.4565 - toll free 937.259.9241 - fax
174 | AUGUST 2012 | CTE
sales@monaghantooling.com www.monaghantooling.com
. The Slant Turn

Nexus 600M from Mazak Corp. is for turning large parts. It employs a headstock with a 14.75"-dia. bore mounted on a 60-hp, 500-rpm turning spindle, which generates up to 5,162 ft.-lbs. of torque for heavy cutting. The spindle is also used as a C-axis, capable of indexing at 0.001 increments. For convenient tool management, the machine uses a 12-position drum turret for tool indexing. The machine is also equipped with a 10hp, 4,000-rpm milling spindle. Mazak Corp. Booth: S-8300.
& . The BTH-130.R24 horizontal

boring and milling machine from Toshiba Machine Co. America has a 2,000mm 2,400mm table, a maximum swing diameter of 3,200mm and can hold workpieces weighing up to 20 metric tons. The double-pinion, B-axis drive mechanism provides stable table indexing, according to the company. Four 50-taper spindle options are available, with a maximum speed of 4,000 rpm. Toshiba Machine Co. America Booth: S-9436.
. United Grinding Technologies

Inc.s Studer S41 CNC universal cylindrical grinder has a Granitan S103 machine bed, which reportedly provides rigidity and thermal stability. The longitudinal and cross slides and the swivel axis for the wheelhead feature electric direct drives, which swiftly and precisely move to the working position, according to the company. The guide ways of the longitudinal and cross slides are molded directly into the machine. United Grinding Technologies Inc. Booth: N-6800.
. The
Value Master F400VM VMC from Hyundai WIA Machine Corp. has X-, Y- and Z-axis travels of 31", 18" and 20", respectively. Standard features include a 30-tool swing-arm toolchanger, through-spindle coolant, BIG Plus tooling and rigid tapping. To eliminate thermal growth during machining, all axes are driven by doublenut ballscrews, according to the company. All ballscrews are connected directly to the servomotors without gears or belts, eliminating backlash. The machine can be configured with an 8,000- or 12,000-rpm spindle. Hyundai WIA Machine Corp. Booth: S-8948.
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ctemag.com | 175
.
Nagel Precision Inc. offers the ECO H horizontal honing machine for lowproduction runs. The machine has three servodrives, and a 3-hp, 4,000-rpm servomotor drives the honing spindle and controls the stroking. The ballscrews reach stroking speeds higher than 25 m/min. and have a maximum travel range of 250mm. The machine can hone bores up to 40mm and can store multiple part programs. Nagel Precision Inc. Booth: N-7040.
. Datron Dynamics Inc. offers the Datron C5 high-speed milling machine for simultaneous 5-axis machining. The machine accommodates parts up to 100mm in diameter and has a 48,000-rpm spindle, 22-station toolchanger, integrated tool-length measurement and Heidenhain linear scales. It has a 1-sq.-ft. footprint and fits through a standard 36" door. Datron Dynamics Inc. Booth: N-6049.
. The
Nakamura-Tome WY-250L multitask turning center from Methods Machine Tools Inc. has two turrets, each with a 3.93" Y-axis. Standard functions include a spindle speed override switch, a program number search, C-axis synchronization and helical interpolation. The machine provides rapid-traverse speeds of 1,181 ipm and 1,574 ipm in the X-axis and Z-axis, respectively. Multiple tools can cut simultaneously. Methods Machine Tools Inc. Booth: S-9119.
Ohio Carbide, LLC

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176 | AUGUST 2012 | CTE
. Doosan Infracore Machine Tools Lynx 220LMSA turning center can machine parts up to 9.45" in diameter and 20.0" long. The machine has live tooling and a subspindle to cut complex geometries. The 20-hp AC spindle motor has maximum torque of 93.6 ft.-lbs. Linear-motion guide ways enable rapid-traverse rates of 1,181 ipm for the X-axis and 1,417 ipm for the Z-axis. Ballscrews are centered between the guide ways and directly mounted to the AC servomotors to eliminate backlash from intermediate gears or belts. Doosan Infracore Machine Tools Booth: S-8100.
Visit us at IMTS 2012 North Building, Booth 6846
September 10-15, 2012 Chicago, Illinois
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- .
The CncGcoder HD Super hand-held CNC G-code programming tool from RBR Machine Tools features a 3.5", bright-color, LCD touch screen thats easy to read in any shop environment, according to the company. The model has eight times the internal storage, two times the processing speed and twice the battery capacity as the companys previous HD models. The programming tool is for backing up, editing and transferring G-code programs. RBR Machine Tools Booth: S-9163.
. The TNC 640

milling control from Heidenhain Corp. is available with optional turning capability to perform multitask machining. With the control, a user enters all programming steps in plain language. The new optimized user interface provides greater transparency during programming, presents functions better and displays status information more clearly, according to the company. Heidenhain Corp. Booth: E-5224.
. ANCAs MX5 CNC tool grinder has a 26kW spindle and two wheel packs for grinding carbide and HSS tools up to 5/8" in diameter. The grinding wheel and spindle are supported in the machine by a casting called the bisymmetrical gantry. Evenly straddling the tool center line, the spindle gantry minimizes the effects of thermal growth and provides rigidity, according to the company. ANCA Booth: N-7414.
. The VL 2 P from
EMAG LLC is a vertical pickup, two-spindle turning machine. While one workpiece is being machined, the second spindle automatically loads itself using the pickup method. This means the next workpiece is immediately ready for machining, resulting in short chip-to-chip times, the company reports. The machine processes workpieces up to 100mm in diameter. EMAG LLC Booth: N-6846.
. KMT Waterjet Systems Inc. offers NEOLine 40i and Streamline PRO2 series waterjet pumps. The NEOLine 40i pump has a 55,000psi operating pressure and low-profile cabinetry for easy access to pump controls and components. The 60- and 125-hp, 90,000-psi Streamline PRO2 pumps provide significant advances in uptime, according to the company. KMT Waterjet Systems Inc. Booth: N-6150.
. Maintenance Service Corp. provides targeted repairs to remedy machine tool problems, such as ones caused by the damaged machine components in the photograph, when customers wait too long for preemptive repairs. According to the company, it provides solutions to mechanical accuracy and reliability problems through its baselining procedures. The company is the North American service arm of German machine builder Schiess Brighton GmbH. Maintenance Service Corp. Booth: S-8275.
178 | AUGUST 2012 | CTE
S AT U E E S TH O O B IMTS 340 # E-3
.
GROB Systems Inc.s G550T HMC allows 5-axis simultaneous machining, with the table operating in A and B axes, as well as turning at up to 800 rpm. This enables production of parts that require turning and milling, such as machine wheels and housings, in one setup. The table has a maximum rotation of 240 in the A-axis and 360 in the B-axis. The machines horizontal spindle design provides access to all workpiece faces, including the insides of hollow parts. GROB Systems Inc. Booth: S-9490.
.
The Tripod 700S Powerflex from ICON Technologies is a modular, 6-axis parallel kinematics machine. PKM technology means that motions in the X, Y and Z axes are performed by three parallel axes, combining the flexibility and envelope of a robot with the accuracy and stiffness of a traditional machine tool. The work envelope is 800mm 800mm 400mm. The machine comes with a 40or 80-pocket toolchanger. ICON Technologies Booth: S-8348.
- . Fuji Machine America Corp.s CSD-300R twin-turret, twin-spindle lathe is equipped with live tools and can turn, drill and mill in one setup. The machines hydraulic clamping robot can load/unload parts up to 7.87" long 4" in diameter. The spindles are equipped with 15/20-hp, high-output motors. The turret speed is 0.26 sec./index. Fuji Machine America Corp. Booth: S-9059.
. The 30i-B/31i-B5 CNC from FANUC FA America is for highspeed, simultaneous 5-axis machining. According to the company, the control significantly reduces cycle times while improving part accuracy and quality. Execution of common instructions is more than 2.5 times faster than the previous generation. With the hand-held operators unit iPendant for CNC, the control achieves improved operability, according to the company. FANUC FA America Booth: S-8919.
- . The Tsugami B0326 6-axis Swiss-type lathe for producing parts less than 32mm in diameter is available from REM Sales LLC. The machine can be converted from direct-drive, guide-bushing, bar-fed operation to non-guide-bushing operation when fitted with an optional chucker kit. It has a dual-path FANUC 32i-B CNC, which reportedly reduces cycle time by permitting simultaneous operation on the main and sub spindles. REM Sales LLC Booth: S-9410.
- . MP Systems V2 highpressure coolant system for CNC machine tools is for general-purpose machining and has a compact design. The system houses its internal components within a sheet-metal frame body that fits under a standard-height bar feeder. Casters enable the pump to be moved. A heat exchanger is optional. MP Systems Booth: S-9410.
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Finally, Cutting Tool Hardware that Cuts the Fat.

High-precision, reliable cutting tool hardware without inated costs and wasted time thats The Maple Difference. With over 30 years experience as a leading manufacturer of common cutting tool hardware, Maple Industries, Inc. knows how to cut the fat: All products are machined to exacting tolerances Complete traceability production/inspection Just-In-Time delivery avoids costly downtime and delays Cost-efcient manufacturing guarantees competitive pricing
. Berger LLC
provides 4- to 7-axis robotic systems for grinding and polishing. The company offers a basic program for programming robots, which is adaptable to customer requirements. Workpieces can be loaded with different magazine systems, such as chain, sliding and rotary table magazines. Berger LLC Booth: N-7259.
Lock Pins Shim Seats Chipbreakers Cam Pins Clamps Screws

ISO-9001
55309 Lyon Industrial Dr. New hudson, MI 48165 Phone: 248.446.9560 Toll Free: 800.537.5447 Fax: 248.446.9864 www.maple-ind.com
. Hermle Machine Co.s C 22 5-axis machining center is constructed on a mineral cast base utilizing the companys patented modified gantry design. The machine has X-, Y- and Z-axis travels of 450mm, 600mm and 330mm, respectively. Standard spindle speed is 15,000 rpm (18,000-, 30,000and 42,000-rpm spindles are optional). Hermle Machine Co. Booth: W-1536.
ctemag.com | 181
. The JUSTAR grinding center from Erwin Junker Machinery Inc. can produce completed parts in one setup. The company reports that the flexible grinder has an automatic wheel changer, a unique coolant nozzle system, an intelligent measuring system and an integrated dressing system. Erwin Junker Machinery Inc. Booth: N-6840.
. Flow International Corp.s Mach 4 waterjet cutting machine can be expanded up to 48 in length to increase the cutting area as needed. The machine offers roller pinion motion to reportedly increase cutting speed. Included is the companys Dynamic XD technology with Dynamic Waterjet software for providing tapers and stream-lag compensation with 3-D bevel cutting. Flow International Corp. Booth: N-6217.
- . Rosler Metal
Finishings R-SF line of mini-drag finishing machines reportedly provide 40 times the grinding power compared to rotary vibrators while eliminating impingement between delicate workpieces. The machines have hydraulic carousel assemblies to allow vertical movement for versatile processing and up to four rotating work stations, each with independent drives. The units feature a protective cabin with Plexiglas doors. Rosler Metal Finishing Booth: N-7432.
.
The Mycenter-HX800iLTGA HMC from Kitamura Machinery has a work envelope of 59.1" in diameter 59.1" and a pallet size of 31.50"31.50". The X-, Y- and Z-axis strokes are 55", 49.21" and 52.16", respectively. The clamping power of 30,710 lbs. and a table-load capacity of 4,400 lbs. allow machining of large workpieces and complex fixturing, according to the company. The machine comes standard with a 35-hp, 12,000rpm, two-step-geared, dual-contact spindle. Kitamura Machinery Booth: S-9148.
182 | AUGUST 2012 | CTE
Your One Stop for Cutting Tools

HIGH PERFORMANCE MACHINING PRODUCTION MACHINING SPECIAL APPLICATIONS MAINTENANCE
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customerservices@morsecuttingtools.com www.morsecuttingtools.com
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Morse CTE Full Pg Ad_June 2012.indd 1
6/26/12 10:56 AM
metalworking products
. CNC Software Inc.

says its Mastercam X6 CAM software can create accurate, fully associative stock models. According to the company, a precise machining stock model provides numerous benefits, including viewing and verifying work as it progresses, performing stock model comparisons and easily choosing existing stock for rest machining. The CAM software enables users to create stock models at any point in the machining process. CNC Software Inc. Booth: E-3340.
. Earth-Chain
Inc.s sPINner machine deburrs batches of small parts made of nonmagnetic materials, such as titanium, aluminum and brass. Parts are automatically demagnetized at the end of the deburring cycle, so residual magnetism is reportedly not an issue. The machine removes light burrs and whiskers without changing part dimensions or adding ferrous material to part surfaces. The stainless steel pin media can access threads, slots, crossholes and blind-holes. Earth-Chain Inc. Booth: W-1732.
. igus Inc. developed

a compact cable carrier system that can turn through 3,000 in minimal space. The TwisterBand TB30 guides energy, data and media with little wear. At high rotating speeds, the cable carrier stays close to the axis. Applications for the slim, circular chain system are mainly in robotics, test jigs and lifting and assembly equipment. igus Inc. Booth: E-5610.
. CGTechs Version 7.2 of its Vericut CNC machine simulation, verification and optimization software includes enhancements to the user interface to simplify common user actions. The software eliminates manual prove-out of NC programs and reduces scrap and rework, according to the company. A new feature optimizes a program from a saved simulation. Users can adjust and re-optimize without rerunning the simulation. CGTech Booth: E-3346.
. Nikon
Metrology Inc. says its LC15Dx digital laser scanner is an alternative to a tactile probe for many coordinate measuring machine applications, including molds, small turbine blades and medical devices. The LC15Dx achieves a probing accuracy of 2.5m and a multiple-stylus test accuracy of 6m in tests comparable to EN/10360-2 and -5. A thermal stabilizer inside the scanner body eliminates the uncertainty and delay caused when scanning before operating temperature is reached, according to the company. Nikon Metrology Inc. Booth: E-5371.
. The VSM/ SIKO valve seat inspection system from Euro-Tech Corp. is for measuring cylinder heads in automobiles, small engines, off-road vehicles, motorcycles and diesel engines. The VSM is a manual gage and uses mandrels armed with inductive built-in transducers. The VSM consists of a mandrel, joint coupling, hollow shaft and driving component. Euro-Tech Corp. Booth: W-2453.
184 | AUGUST 2012 | CTE
Expand your horizons

3M 2012. All Rights Reserved. 3M is a trademark of 3M.
Winterthur Technologies is now part of 3M

Winterthur Technologies Group is a leading global supplier of industrial abrasives and equipment. Its Winterthur, Wendt and SlipNaxos brands are used worldwide in the cutting tool, automotive, aerospace, oil and gas, medical, glass and steel industries. Together, 3M and Winterthur offer you todays most innovative portfolio of advanced abrasive technologies to help you achieve the next level of manufacturing precision and productivity.
See us at IMTS 2012 Booth N-7063
We invite you to learn more by visiting us at the 2012 International Manufacturing Technology Show (IMTS) in Chicago, September 1015.
. The QC20-W
ball bar from Renishaw features a company-developed linear sensor and Bluetooth wireless technology, allowing testing in closed-door manufacturing settings, where access for wiring can raise safety and procedural issues. The device enables testing in three orthogonal planes through a single reference point. A single hardware setup means quicker testing and the ability to produce a representative volumetric measurement of positioning accuracy. Renishaw Booths: E-5530, N-650.
. Beta LaserMikes
BenchMike tabletop laser measurement device does not touch a part, eliminating part distortion and operator influence that can impact measurements. The instrument can measure diameters, multiple ODs, TIR, taper and part position. Four models are available, providing a measurement range from 0.001" to 2.0". Linearity is as low as 0.000020". Beta LaserMike Booth: E-5326.
. MobileCollect from
MicroRidge Systems Inc. wirelessly collects measurements from hand-held gages using mobile modules that attach to the gage or fixture and then send those measurements to a PC. The technology is ideal for applications with heavy radio frequencies, significant machinery, robots and electrical noise, the company reports. Transmitter and receiver options fit individual gaging and measurement collection requirements. MicroRidge Systems Inc. Booth: E-5552.
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186 | AUGUST 2012 | CTE
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Let us make it perfectly clear!
. CribMaster
says its ProStock carousel dispensing system provides flexible sizes, on-site reconfigurability and high capacity in a small footprint. It keeps the necessary production tooling next to the machine and automates replenishment with direct communication to distributors. The unit measures 82" tall 34" wide 34.75" deep and weighs 625 lbs. unstocked. CribMaster Booth: W-1446.
.
Hommel-Etamic America Corp.s F435 and F455 systems automatically measure geometric tolerances, surface roughness and straightness in one setup. According to the company, an advanced probe permits roughness and waviness inspections along with form and position tolerance measurements via a simple adjustment on the rotary control, significantly enhancing productivity. The system is for workpieces up to 430mm in diameter and weighing up to 40 kg. Hommel-Etamic America Corp. Booth: E-5545.
. The Darwin
centrifugal mist collectors from Losma Inc. offer throughputs from 353 to 1,767 cfm. The collectors are reportedly suitable for all types of machine tools. During operation, centrifugal force pushes oil mists through an annular filter medium. Collected oil is then sent back to the machine through a drainage pipe. Three designs are available for air that contains soluble mists and heavy particulate, soluble mists, and neat soluble mists and vapors. Losma Inc. Booth: E-5718.
Did You Know There is a DEUBLIN Coolant Union Replacement for All Machine Tool Brands?
DEUBLIN is the world leader in coolant unions for CNC machine tool applications. With a full range of options including bearing-supported and bearingless, closed-seal or Pop-Off, our patented AutoSense designs, controlled leakage, & multi-passage options.
For more information contact DEUBLIN at info@deublin.com or (847) 689-8600 Request a FREE Machine Tool Catalog at www.deublin.com/MachineToolCatalog or scan the QR code.
ctemag.com | 187
Universal Grinding metalworking products Corporation

Grinding Services:
l l l l l l l l l l
Blanchard Centerless Bar & Tube Double Disk Gun Grinding Hypro Lapping I.D. & O.D. Prole Surface TG&P or DG&P Time Saver
. Rollon USAs Acturatorline

actuators are available in belt- and screw-driven models. The actuators are for a variety of OEM machinery applications, including robotic handling systems, conveyors and packaging machines, semiconductor equipment, lab automation and life sciences platforms, machine tools and machine accessories, and part-transfer and assembly lines. Rollon USA Booth: E-4351.
888-825-2707
Fax: 216-631-5589
sales@universalgrinding.com www.universalgrinding.com
. Spring Technologies Inc.s NCIMUL 8.9 software is for simulating, verifying, optimizing and reviewing CNC machining programs. Three-dimensional graphics help users avoid machine crashes while algorithms and embedded, process-based know-how optimize cutting conditions. To verify part programs, the software investigates and corrects coding errors, simulates to locate and correct motion errors and validates the program. Spring Technologies Inc. Booth: E-3267.
D500 HPG
DillonManufacturing Inc.
. Incertecs capabilities
include precious, semiprecious and alloy metal plating; metalizing plastics; custom masking; and advanced testing methods. The company serves the aerospace, medical, military, automotive and electronics industries. Its processes use advanced recycling and water treatment systems. Incertec Booth: N-6270.
, .
Firetrace International offers automatic fire detection and suppression systems for CNC machines and EDMs. The systems are for extinguishing machine fires sparked by oil-based metalworking fluids, coolants and lubricants. The systems are compatible with most extinguishing agents, including nontoxic, nonconductive and noncorrosive ones. The agents leave no residue on machines or workpieces and will not contaminate lubricating oils or fluids, the company reports. Firetrace International Booth: E-5387.
NO ORDINARY CHUCK GREASE

D500 HPG Chuck Grease formula is special engineered for your applications and budget.
DILLONMFG.COM or call 800-428-1133
Dillon Manufacturing Inc. 2115 Progress Drive, Springeld, OH 45505
188 | AUGUST 2012 | CTE
. MunchMan hinged steel belt conveyors from Jorgensen Conveyors Inc. transport heavy chip loads generated during machining. They employ a stocked conveyor arrangement at the lower curve and through the incline and system chip discharge. As the chips go through the transition at the lower curve, they are sucked in and pinched between two moving belts through the incline and discharge area. Chips are effectively compressed and trapped until forced off the discharge end of the conveyor. Jorgensen Conveyors Inc Booth: E-5724.
. LQ MechatronikSysteme GmbHs A-TEC motor starter for control cabinets can be integrated into existing wiring schemes and machine layouts. This is because of its clear input, output and software interfaces, according to the company. To install it, users must have an ASi-bus or ASi-gateway for overall control. In this way, the power and data reach the motor starter module via the standard input interface. The ASi communications interface is housed inside the module mounting. LQ Mechatronik-Systeme GmbH Booth: E-4020.
rogramming .
Version 2013 of PartMaker software from PartMaker Inc. is for programming CNC mills, lathes, wire EDMs, turn/mill machines and Swiss-style machines. The software has a revamped surface machining module for simultaneous 3-, 4- and 5-axis milling. The module enables use of the Vortex area-clearance strategy to gain the maximum benefit from a solid-carbide tool, in particular using the full flute length as the cutting surface, according to the company. PartMaker Inc. Booth: E-3222.
. Tapeswitch
Corp.s safety switch mats, used to guard machines, provide millions of actuations at any point and are fail-safe protected. The safety mat is a simple, normally open switch. When a specified minimum weight is applied to the safety mat, the switch closes and a stop signal is sent to the guarded machine. Standard actuation forces range from 22 lbs. (100 nominal) to 66 lbs. (300 nominal). Custom products can be ordered. Tapeswitch Corp. Booth: E-5814.
. Gusset magnets from Strong Hand Tools align, locate and hold steel gussets, base plates and steel panels against a steel frame or substructure when assembling, tacking and welding. Four rare-earth disc magnets embedded in the faceplate hold steel panels with direct, even clamping pressure. Three positioning pins on the faceplate act as a guide for quick alignment and positioning of the gusset magnet. Strong Hand Tools Booth: N-6276.
lift module. Kardex Remstar LLCs Shuttle XP vertical lift module delivers parts to the operator at an ergonomic height. The system is comprised of two large sections of racking with an extractor that runs up the center to store trays in the racking and deliver them to an access opening at the operators request. Maximum tray capacity is 1,598 lbs. (246,550 lbs. per system). Kardex Remstar LLC Booth: W-1617.
190 | AUGUST 2012 | CTE
. Mahr Federal Inc.s MarSurf M 400 skidless surface gage has motorized probe-height adjustment that automatically zeros the probe in seconds. It features a magnetic, breakaway probe mounting system, which protects sensitive probes from accidental damage and facilitates fast probe changes. Mahr Federal Inc. Booth: E-5242.
. Marposs Corp.s Mida

VOS optical touch probe system is for use on large 3- and 5-axis machining centers. The system consists of a receiver with integrated interface and a transmitter unit that is compatible with Mida touchtrigger probes. Mida VOS permits up to four transmitter/probe units to be used in an application with only one receiver, enabling multiple-channel operation. Marposs Corp. Booth: E-5519.
2560-4087_CTE-0812_7X2.375.ai 1 6/20/2012 11:18:26 AM
. Creative CNC LLCs Metaflux Gleitmetall is a lubricant for machine tools. It contains titanium, which reduces vibration noise and prevents seizing, wear and corrosion, but doesnt contain nickel or copper so there is no possibility of electrolyte formation, according to the company. The lubricant is abrasion-resistant, nonflaking and temperature-resistant from -180 to 1,350 C. Creative CNC LLC Booth: E-4195.
CM
MY
CY
CMY
2012_04_12_IF__D_quer_178 x 60mm_Layout 1 12.04.12 22:04 Seite 1
Visit us at IMTS Booth #E-5344
perspective even at components with small radii and steep flanks independent of size, shape or surface finish
from every
The InfiniteFocus product group offers high resolution cutting edge measurement. Users measure surface roughness including form of components. The robust technology of Focus-Variation enables the use in both research and production.
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. Jorgensen Conveyors Inc.s MunchMan hinged steel belt conveyors handle heavy chip loads, including large stringy chips and balls of chips. The conveyors employ a stacked arrangement at the lower curve and through the incline and chip discharge to compress, or munch, the chips and reduce material handling costs, the company reports. The company can design a conveyor to fit most CNC lathes and machining centers. Jorgensen Conveyors Inc. Booth: E-5724.
. Certified Comparator Products CC-V Video Contour Projector incorporates large-field-ofview optics into a horizontal benchtop comparator to enhance versatility. The comparator has a digital zoom camera and advanced image processing for automatic operation. Certified Comparator Products Booth: E-5602.
. The HPF-100
(Hydrostatic Paper Filter) and HPF-500 coolant filtration systems from Mayfran International reportedly utilize a unique side-sealing method to prevent chip and particulate bypass. The automatic systems provide a clean and continuous supply of coolant to a machine tool without downtime, according to the company. Mayfran International Booth: E-5072.
. Helukabel USA Inc.s JZ 603 and JZ 603-CY control cables are oil-resistant, flame-retardant and suitable for medium mechanical stresses with free movements in dry, damp or wet indoor environments. The control cables have received five global certifications: UL (U.S.), HAR (Europe), CSA (Canada), CCC (China) and GOST-R (Russia). Helukabel USA Inc. Booth: E-4256.
.
ParleVision PGC Plus software from Parlec Inc. shows how users can manage tool data in a shop environment. The company also offers new tools and technologies for MTConnect, high-speed machining, submicron tool inspection, RFID data transfer and CAM integration. Parlec Inc. Booth: W-2300.
. GTI
Spindle Technology offers the iPad vibration analysis system with VibePro and VibeTrend apps. VibePro collects and analyzes machine vibration signals, allowing a user to take readings and leverage the iPad platform. VibeTrend stores and graphs overall RMS vibration amplitude levels for condition-based maintenance. Users can view vibration amplitude levels in acceleration (g) and velocity (ips) through a free DropBox account. GTI Spindle Technology Booth: N-7317.
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Get a grip on surface finishing costs.

IMTS Booth #N-7432
Whether its tool and die cast parts or structural steel and stampings, todays metalworking industry is highly competitive. You need better results for less. Rosler offers the industrys widest range of shot blasting and mass finishing equipment. Our integrated system solutions provide precise, repeatable processes for the lowest costper-piece. Its time to get a grip. Call Rosler today.
Visit www.rosler.us or call 269-441-3000.
.
Calculated Industries Model 4087 Machinist Calc Pro is an advanced machining math calculator. Model 4089 is an international version that defaults to metric drill and thread sizes. Both versions allow users to choose the default setting as U.S./imperial or metric. Functions include right-triangle and trigonometric solutions, bolt-pattern hole layouts, drill and thread size tables, wire size measurements and machining parameters. Calculated Industries Booth: E-5413.
. Master
Magnetics Inc. offers a retractable and flexible magnet for retrieving metal parts from hard-to-access tight spaces, such as engine compartments, behind heavy equipment and down drains. The tool, which uses a neodymium magnet, has shielded sides so it wont be attracted to metal surroundings until activated. The 23"-long shaft can snake through confined areas and holds its shape, the company reports. Master Magnetics Inc. Booth: W-2088.
. The Cognitens WLS400A from Hexagon Metrology is a 3-D optical measurement product that can transform a robot into a metrology device. The light-based system accurately measures large components, analyzes early root causes of potential assembly problems and lowers scrap costs during assembly ramp-up, according to the company. The system uses digital stereovision technology to generate accurate 3-D data in vibration-prone shop environments. Hexagon Metrology Booth: E-5202.
. Jorgensen Conveyors Inc.s Wedgewire drag flight scraper conveyor separates chips and fines from coolant, enabling clean coolant to pass through the conveyor into a machines coolant tank. Chips and fines fall to the bottom of the conveyor or are brushed off the top of the filter cell. The conveyor can filter particles as small as 150m. Jorgensen Conveyors Inc. Booth: E-5724.
. IMC Supplys industrial vending system connects to the Internet to automatically collect data. The online reporting suite covers product replenishment, usage, on-hand inventory and receipts. It holds up to 60 different SKUs. Users can run multiple units with one computing station. There are no software upgrade charges for the system, the company reports. IMC Supply Booth: W-1165.
.
The QVI SNAP from RAM Optical Instrumentation is a benchtop digital measuring machine. It can measure any 2-D part placed within its field of view, according to the company. It features a large-depth-of-field telecentric lens system, megapixel camera with digital zoom and Measure-X 2-D metrology software. RAM Optical Instrumentation Booth: E-5602.
194 | AUGUST 2012 | CTE
Machining Solutions for Mission Critical Metallics
CUT TITANIUM LIKE BUTTER!

Stellram 7792VX high feed milling cutters can increase metal removal rates up to 5 times, substantially reducing part costs. Cutting forces directed axially into the spindle, reducing spindle wear, improving machining stability Productive machining on older equipment Face milling, pocketing, slotting, and plunging
Titanium ATI 425 ATI 6-4 ATI 5553 ATI 1023
See us in Booth W-1546
Call today: 1.800.232.1200. Or visit our websites for more technical information. Websites: ATIstellram.com ATImetals.com email: usa@stellram.com
ATI Allegheny Ludlum ATI Allvac ATI Engineered Products ATI Ladish ATI Wah Chang 2012 ATI. All rights reserved. Starburst, Stellram and ATI 425 are registered trademarks of ATI afliated companies. TM-trademark of ATI afliated companies. US Patents # 7,806,634 B2; 7,600,952 B2; 7,220,083 B2 European Patents # EP 1 689 548 B1; EP 1 897 643 B1
. Platit Inc.
says its PVD coating machines, such as the 311, enable a company to bring coating expertise in-house and become a coating profit center by offering standard coatings, such as AlTiN. The environmentally friendly machines optimize coating properties, have a short technical learning curve and minimize tool damage via reduced handling, according to the company. Platit Inc. Booth: W-1680.
. Grinding fluids from oelheld U.S. include special additives from the companys laboratories to reportedly increase versatility and quality. New formulated solutions enhance accuracy and cooling when high-speed grinding, the company reports. oelheld U.S. Booth: N-6668.
.
Osborn International offers refined TYencapsulated stringer bead brushes. According to the company, it developed the brushes in conjunction with offshore pipeline companies to quickly and effectively clean J-weld joints. The narrow-face, aggressive knots used to make the TY-encapsulated wheel brushes have been refined with improved elastomers and are reportedly ideal for cleaning stringer bead welds. Osborn International Booth: N-7436.
.
To make it easier to determine appropriate speeds and feeds, CGC Tools Inc. says it modified its speeds and feeds calculator to select the workpiece material first. Then, users choose the milling method, DOC, tool and tool diameter. The calculator has a reset button to determine the speeds and feeds for as many tools as desired. CGC Tools Inc. Booth: W-1948.
. With Fastenals FAST Solutions program, a users local Fastenal store provides the vending machines, keeps them filled via an automated ordering system and only charges for dispensed items. This means there is no capital expense, inventory carrying costs or labor required to manage inventory and refill the machines, which offer Web-based reporting capabilities. Compact, point-of-use units dispense individual inserts and round tools, and allpurpose cutting tool and MRO machines are available. Fastenal Booth: W-1154.
. Sanborn Technologies
centrifugal filtration systems remove swarf, sludge and tramp oil from metalworking fluids. The equipment is suitable for use at machine tools, in central systems and at end-of-pipe plant waste streams. The product line includes the new LiquaPac HS2, which produces dry solids because of its unique bowl design and high rotational speeds. Sanborn Technologies Booth: N-7538.
196 | AUGUST 2012 | CTE
Reliability begins with a cup of coffee.

Relationships are built by taking the time to sit down with you, and discovering what keeps you awake at night.
Colonial isnt typical in the SPINDLE INDUSTRY establishing customer relationships

that are a perfect fit providing spindle systems to international companies looking for experience and reliability. The solutions we provide deliver the highest quality in the world at a reliable Lowest Cost Per Piece, GUARANTEED! An industry first. What do you take in your coffee?
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.
FORCAMs Factory Framework manufacturing execution system software is a shop-floor management technology that provides resultsoriented performance measurement and benchmarking. It connects, collects and standardizes real-time data from heterogeneous machine controls. The software then delivers Web-based reports on the operating conditions of machines and systems. FORCAM Booth: E-4481.
. JobPack
Inc.s Master Scheduler software provides a closed-loop production scheduling system that enables dynamic response to changes in work orders and resource availability. The software automatically schedules production jobs to maximize available machine capacity, personnel and other resources based on delivery dates. JobPack Inc. Booth: E-3240.
. Magnetic Products Inc.s beltless magnetic conveyors are for controlling ferrous metal materials, such as stampings, chips, fasteners and scrap. To move material, permanent magnets are conveyed below a nonmagnetic stainless steel slider bed. The liquid-tight, sealed conveyor housing can be submerged in machine coolant reservoir tanks, the company reports. Magnetic Products Inc. Booth: E-5804.
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198 | AUGUST 2012 | CTE
I will succeed every time I compete against you. Ive directed my team to see and compare the worlds newest manufacturing technology solutions in person. They have the budget and the power to buy. Theyll meet with the best minds in the business. Educational sessions will enhance their knowledge. Decisions will be made. Orders will be placed. We will begin taking deliveries. You will be hard-pressed to keep up. Some call this continuous improvement. We call it survival of the ttest.
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productive times
Advancing cellular manufacturing

Many manufacturers are struggling to reduce inventory, increase customer service levels and decrease lead timesall while remaining profitable. However, addressing one goal often contradicts another. Manufacturers often employ cellular manufacturing to address those goals by minimizing work in process, decreasing setup times and removing waste from the machining system. Typically, dedicated work cells efficiently produce a family of parts, but they may not have the flexibility to quickly respond to customer needs and market changes. Latrobe, Pa.based Kennametal Inc., a manufacturer of tooling, engineered components and advanced materials, faced this conundrum at its toolholder production facility in Solon, Ohio. Recently, a challenge came from Kennametal management to create a work
Methods Machine Tools
Kennametal uses Nakamura-Tome Super NTX mill/turn machines with robotic material handling from Methods Machine Tools to produce toolholder blanks at its Solon, Ohio, facility.
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200 | AUGUST 2012 | CTE
flow that decreased lead times, reduced costs and increased customer service levels across a large offering of products. In addition, management wanted to reduce the manufacturing footprint and procure a system that delivered value. These were very demanding goals, said Jim Stanko, engineering manager at Kennametal. We started by challenging our machine tool partners to propose a solution that would allow us to achieve these goals. Kennametals original plan entailed purchasing six to eight mill/turn machines. The first set of four mill/turn machines would produce a semifinished product called a blank. Stanko said, A blank is typically a club of metal with either a KM, HSK or steep-taper back end. We planned to manufacture them in economical lot sizes with at least 50 to 100 pieces per run. The finished blanks would then be stored in a supermarket by blank style, with each blank style servicing approximately 30 to 40 different line items in the companys catalog. The second set of mill/turn machines
END USER:
Kennametal Inc. (800) 446-7738 www.kennametal.com
CHALLENGE: Reduce lead times, manufacturing footprint and costs when making toolholders. SOLUTION: Work cells employing advanced multitask machine tools.
SOLUTION PROVIDER: Methods Machine Tools Inc. (877) 668-4262 www.methodsmachine.com
would primarily serve to create the frontend features of the part, such as a TG/ER collect chuck, endmill adapter or shell mill adapter. The operator would simply pull the required number of blanks from the supermarket for the order, which might range from one piece to 20 pieces. The machine would then be set up to produce the required items and quickly changed to run the next job.
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productive times
Machine tool supplier Methods shuts down is to change pallets. By havMachine Tools Inc., Sudbury, Mass., ing a large tool chain along with the palchallenged the original plan. Methods let hives, the setup time between orders proposed using just four mill/turn sys- is externalized and does not create additems instead of the six or eight mill/turn tional downtime. systems we had originally planned to buy. Stanko said: We call the entire The proposal was highly productive and system from Methods Machine Tools our advanced manufacturing cell. It economical, Stanko said. Methods recommended producing the has allowed us to decrease lead times blanks with Nakamura Tome Super NTX for operations prior to heat treat from mill/turn machines with robotic material up to 14 days to a matter of hours. handling. The machine has its tool spin- Many times we have been contacted dle on the upper side and two turrets on by one of our customers experiencing the lower side. With its B-axis automatic toolchanger capability, including the unique configuration of two lower turrets, the Super NTX allows three tools to cut simultaneously. By using the two lower turrets during the tool change, idle time is reduced. The Super NTX also has an integrated recipe management system. This allows the operator to program and save a new style of blank by specifying the Methods Machine Tools diameter, length and end conMatsuura Cublex-42 and Cublex-25 mill/turn nection for the blank so it can machines from Methods Machine Tools produce the be recalled later. front ends on Kennametals toolholder blanks. Once the systems are set up, they run minimally attended. Through the use of a vision system and an emergency need. We can now literlaser measurement, the robotic material ally walk over to the supermarket, pull a handling system ensures the proper raw blank, set the blank in a fixture, schedmaterials are being presented to the ma- ule the part to run next and have the part chine. One operator services two systems, ready for heat treat in less than 1 hour. performing quality audits, feeding mate- This would have been impossible in the rials and removing finished blanks. past, he noted. Kennametal then uses a Matsuura The advanced manufacturing cell also Cublex-42 mill/turn machine and a significantly reduced Kennametals cost. Cublex-25 mill/turn machine to make Prior to implementing it, Kennametal the finished blanks into parts. The Cublex had 14 operators and 12 machine tools. multiprocess technology provides 5-axis Now, Kennametal only needs one operamilling, vertical and horizontal turning tor per shift and uses four mill/turn machines, while more than doubling the and optional grinding. Each of Kennametals Cublex machines production rate. has an attached pallet hive and at least It was a matter of Methods knowing 180 tools in the tool chain. Within the which technology would work best for pallet hive is a series of fixtures, which our operation, Stanko said. He added allow the operator to set up orders for that the advanced manufacturing cell Methods developed allows the plant to KM, HSK and steep-taper products. Its been a big time saver. While one remain competitive on toolholders, mainorder is being run, multiple other orders tain high service levels, greatly reduce lead are loaded, queued and scheduled to run, times and thrive in a high-mix, low-volStanko said. The only time the machine ume environment.
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To place a marketplace ad in CTE,,. call 847-498-9100

202 | AUGUST 2012 | CTE
New grinder boosts production capacity

ZPS-Frzovac Nstroje a.s., a manufacturer of HSS milling tools, was looking to boost its market share and better equip a new training and education center at its headquarters in Zln, Czech Republic. The center allows the companys employees, as well as experts and students from technical-vocational schools and technical universities, to become acquainted with new manufacturing technology. The company accomplished both goals with the installation of a new high-speed grinding machine, Lean Selection speed, from Erwin Junker Maschinenfabrik GmbH, Nordrach, Germany. Equipped with two grinding spindles and employing CBN or diamond grinding wheels, the machine combines fast grinding times and an automated loading system. ZPS uses the grinder for production runs and training demonstrations.
In 2012, ZPS estimates it will produce more than 300,000 milling cutters on the Lean Selection speed grinder and additional capacity is available on the machine if needed.
The new machine replaced several conventional cylindrical grinding machines at ZPS, providing a higher rate of machine availability, higher part quality and higher output, according to the company. Founded in the 1930s, ZPS has been manufacturing HSS milling cutters since the 1950s. Today, the company is the
END USER:
ZPS-Frzovac Nstroje a.s. +420-576-777-510 www.zps-fn.com
CHALLENGE: Increase capacity when producing milling cutters. SOLUTION: A two-spindle, automated, highspeed grinder.
SOLUTION PROVIDER: Erwin Junker Machinery Inc. (847) 488-0406 www.junker-usa.com
largest milling cutter manufacturer in the Czech Republic and employs about 120 people. In 2011, the company exported approximately 70 percent of its tools, with half going to Germany. In recent years, ZPS has increased its
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Goodrichs Interiors (Cargo Systems) business unit in Jamestown, ND seeks experienced professionals like you to join our growing team. Our Manufacturing and Operations teams support Complete Cargo Handling Systems for Wide-Body Aircraft. From Electrical Control Systems to Mechanical/Components System and Power Drive Systems, each of our employees makes a signicant contribution to our business and clients. Explore opportunities available for: Project Manager, Engineering Machinists Supply Chain Team Leader III Mechanical Engineer NC Programming Team Leader Quality Manager Apply online at www.goodrich.com/careers and search for positions in Jamestown, ND. GOODRICH IS AN EQUAL OPPORTUNITY EMPLOYER COMMITTED TO ADVANCING DIVERSITY IN THE WORKPLACE. EOE D/M/F/V
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ctemag.com | 203
5/7/12 3:54 PM
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Junker
The Lean Selection speed machine grinds cylindrical, stepped and tapered ODs, as well as the cutting edge, in a single clamping.
export volume but its capacity for rough and finish grinding of milling cutters was limited. The new Junker machine, which supplies all the machines that follow it in the production line, provides the company with the capacity it needs. In 2012, ZPS estimates it will produce more than 300,000 milling cutters on the Lean Selection speed grinder and additional capacity is available on the machine if needed. The Lean Selection speed grinding machine is equipped with a high-resolution B-axis. Each of the two 12,000rpm grinding spindles has 12kVA drive power. The machine also features a glass
To place a marketplace ad in
call 847-498-9100
204 | AUGUST 2012 | CTE
Junker
An automation system for the Lean Selection speed machine includes Junkers Jurogot loading cell.
BURR MonsteR
urrs
scale on the X-axis, a FanUc 0i control, Junkers Juwop programming system and a tailstock with microfine adjustment. With peripheral speeds of up to 140 m/sec., rough and finish grinding can be performed efficiently at high metal-removal rates using the Junker Quickpoint grinding method, according to Junker. With the Quickpoint method, the grinding wheel creates the final dimension on the outer contour of the milling cutter and removes the entire grinding allowance in one longitudinal pass. Grinding between male or female centers results in high accuracy, Junker reports. In addition to tool grinding, the machine can grind parts such as gearbox components and camshafts. At ZPS, an automation system for the Lean Selection speed machine includes Junkers Jurogot automated loading cell. A robot loads the parts through an opening in the machine hood. The machine grinds cylindrical, stepped and tapered ODs, as well as the cutting edge, in one clamping. In addition, a diameter gage on the grinding table provides automatic dimension correction. ZPS is particularly pleased with the machines uptime. With batch sizes of 50 to 2,000 tools, ZPS Lean Selection speed requires two changeovers per day, on average. A three-point mounting interface on the grinding spindle and workpiece spindle simplifies this task. ZPS is reportedly pleased with the start-up process, grindCTE ing quality and on-site customer service.
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people & companies

p
n Carbide Tool Services Inc., Anoka, Minn., added Nick Nagy to its sales team. Nagy will be responsible for the Midwest territory and key technical applications. CTS repairs and regrinds cutting tools. n Metalworking fluid supplier Cimcool Fluid Technology, Cincinnati, announced Jerry Byers, manager of R&D, is the new president of the Society of Tribologists and Lubrication Engineers for 2012-2013. Byers joined STLE in 1977 and will be celebrating 40 years with Cimcool. n Machine tool builder Drake Manufacturing Services Co., Warren, Ohio, promoted Jill Palumbo to
Jill Palumbo
Jeremy Halford
Chris Haltom
Derriest Alexander
mechanical engineering manager. Palumbo, who joined Drake in 1997, will supervise the design of mechanical and electromechanical systems and manage design and project engineering teams in the mechanical engineering department. n Distributor IBC-IndustrialSupplyPlus Inc., East Granby, Conn., appointed Ron Nuez president in addition
to his role as COO. In his dual role, Nuez will continue to oversee sales, management, daily operations and finances, and will provide the strategic vision and direction for the company. n Toolmaker Kennametal Inc., Latrobe, Pa., announced that Chairman, President and CEO Carlos Cardoso was elected chairman of the board of trustees of the Manufacturers Alliance
Customers storm Methods open house
On June 13 and 14, machine tool supplier Methods Machine Tools Inc. hosted its Metal Storm 2012 open house at the companys headquarters and Northeast Regional Technology Center in Sudbury, Mass. The event drew 1,500 attendees from 450 companies. The event featured more than 50 machines under power, including Matsuura 5-axis vertical and horizontal machining centers, Nakamura multitask turning centers, KIWA-Japan HMCs and VMCs, Feeler milling and turning centers, and FANUC VMCs and EDMs. According to Bryon Deysher, president and CEO of Methods, such events are better for the company than a trade show. Our customers are here talking with us, he said. They have access to the management team, and theyre not walking next door to a competitors booth. At the open house, we have quality time with our customers in a more intimate and relaxed atmosphere, which is critical for relationship building. Deysher felt the timing for Metal Storm was ideal because many customers were making decisions about new machine investments. More contracts (to make parts) seemed to be coming up, he said. I talked to a customer who was waiting to buy two or three Feeler machines because he has a $50 million contract to build sniper rifles. We wanted to take care of opportunities like that now rather than have people defer decisions to IMTS in September. During the 2 days preceding the open house, Methods conducted training for its sales staff. Having our sales team in from all over the country for 2 days of training was vital, Deysher said. They could see nearly every machine model we represent under power. It was also a great opportunity for them to network with each other. On the day following the event, Methods hosted 70 Massachusetts vocational-technology school students, providing demos, tours and discussions about job opportunities in manufacturing. We have to develop the next workforce and show them its an attractive career. We need young, highly skilled labor ready to embrace new technologies, Deysher said. Metalworkers are no longer guys in dirty overalls standing in front of drill presses.
206 | AUGUST 2012 | CTE
Methods Machine Tools
Methods Machine Tools drew 1,500 people to its June open house.
One of the topics frequently discussed at Metal Storm was the use of more job shop automation. As business comes back from China and Mexico, even smaller job shops are looking at ways of running lights-out overnight and on weekends, said Jamie Hanson, director of corporate development for Methods. As a result, these shops are considering solutions such as a manufacturing cell demonstrated at Metal Storm. It consists of a rail-mounted FANUC 6-axis robot servicing a KIWA VMC, Feeler turning center, FANUC EDM and Zeiss coordinate measuring machine. The cell has automated changing of chucks on the lathe and fixtures on the mill, as well as automatic part loading/ unloading. Technical seminars were conducted throughout the event, including one titled Production on Demand, Methods term for an automated machining cell for small-lot production and quick retrieval and setup of previously run jobs. Alan Rooks
for Productivity and Innovation, an Arlington, Va.-based business research and executive education organization. Cardoso will serve a 2-year term. In other company news, Kennametal appointed Lorrie Paul Crum vice president, corporate relations. Mayfran International Inc., Cleveland, appointed Jeremy Halford president, Americas. Halford will be responsible for operations in North and South America. Mayfran manufactures scrap and coolant management and material handling equipment. CNC machine tool builder MultiCam Inc., Dallas, announced Chris Haltom joined the company as North American sales manager. MultiCam also appointed Derriest Alexander 5-axis router product manager to oversee the new product line. Lastly, the company named Lance George south central sales manager. REM Sales LLC, Windsor, Conn., appointed Ron Gainer regional sales manager. Gainer will support Tsugami distributors in the Northeastern U.S. REM Sales is the exclusive North American importer of Tsugami machine tools. Riten Industries Inc., Fort Mill, S.C., appointed Thomas Spratt to manage the sales and distribution of its workholders in the Eastern U.S. Spratt will have key-account responsibility and oversee the activities of Ritens network of representatives and distributors. Sandvik AB, Sandviken, Sweden, appointed Pr Altan head of external communications. Also, Emil Nilsson was appointed executive vice president and CFO of the Sandvik Group and a member of group executive management. The Sandvik Group serves the metalcutting, mining and construction and materials industries. Toolmaker Sandvik Coromant Corp., Fair Lawn, N.J., appointed Ester Codina marketing and communications manager, market area Americas. In her new role, Codina will develop a communications plan to help the market area achieve its sales and growth goals. Sapient Automation, Hatfield, Pa., named Tim Harrison Midwest sales director. The company provides automated storage and retrieval
Ron Gainer
Thomas Spratt
Ester Codina
Mark Parillo
systems. n Star SU LLC, Hoffman Estates, Ill., named Mark Parillo director of marketing. Parillo has almost 2 decades of automotive and industrial marketing experience. Star SU offers machine tools and cutting tools. n Wall Colmonoy Corp. hired two new executive employees at its Detroit headquarters. Ed Kanters is CFO and Cindy Vario is corporate human
resources manager. Wall Colmonoy manufactures nickel alloys for coating and brazing.
p
n CGTech, Irvine, Calif., and DP Technology, Camarillo, Calif., announced the availability of the ESPRIT-to-VERICUT interface. The interface launches VERICUT NC
Machine debuts highlight of DMG/Mori Seiki USA Innovation Days
DMG/Mori Seiki USAs annual 3-day Innovation Days event at the companys headquarters in Hoffman Estates, Ill., concluded on May 10 with strong attendance and a diverse schedule of seminars. During the event, the company demonstrated 36 machines and introduced more than a dozen machines to the U.S. market, including the Milltap DMG/Mori Seiki USA 700, DMU 65 monoBLOCK and DMG/Mori Seiki USA demonstrated 36 machines DMF 260/11. and introduced more than a dozen machines to the The Milltap 700 is JapanU.S. market at its iDays event. based Mori Seikis first joint corporate development project with its partner, Germany-based DMG. The vertical milling and boring center is supported by a Siemens 840D solutionline control and provides high-speed machining and quick tool changes within a compact footprint, according to DMG/Mori Seiki USA. Rigid construction further contributes to machining complex geometries with optimal surface finishes. The DMU 65 monoBLOCK 5-axis universal milling machine has a range of applications and was used in five different demonstrations, cutting materials ranging from aluminum to carbon steel. The DMF 260/11 travelling-column machine has a unique configuration, with an extended X-axis of 43.3", according to the company. Cutting demonstrations highlighted the machines heavy roughing capabilities and ability to perform simultaneous 5-axis milling. Technical seminars included expanding production, shop floor networking and communication, manufacturing in America, gear milling and online learning. Innovation Days 2012 also coincided with the launch of the DMG/Mori Seiki University 50 Series Education On Demand (EOD) training class. The EOD platform features a new interface and simplified course navigation. DMG/Mori Seiki also hosted more than 100 students on a tour of the facility and exhibition.
ctemag.com | 207
people & companies

verification, machine simulation and optimization software from within ESPRIT 2012 CAM software. CGTech also announced a partnership with Zoller Inc., Ann Arbor, Mich., a presetting and measuring machine manufacturer. The Zoller vision system provides a direct link between the presetter and VERICUT. Erie, Pa.-based Eriez Hydroflow added to its services engineering and technical support for industrial customers planning to install filter units or filtration systems. This support includes system recommendations and design, layout, installation and start-up services. In other news, 2012 marks the 65th year of partnership between Eriez and sales representative company DominionCarolina, High Point, N.C. Eriez provides technology for magnetic, vibratory and inspection applications. Gibbs and Associates, Moorpark, Calif., announced that GibbsCAM customer Blue Chip Engineering, a job shop in Ramsey, Minn., engineered and machined a mobile sculpture to be awarded as part of a Buckminster Fuller Challenge international prize. Gibbs and Associates develops GibbsCAM software for programming CNC machine tools. Machine tool builder Hardinge Inc. announced that more than 750 people attended its machine technology show in Elmira, N.Y. Turning, milling, grinding, automation, rotary and workholding applications were demonstrated. Kistler, Novi, Mich., announced the official opening of its new North America Technical Center in Novi. Kistler supplies sensors, systems and instrumentation for automotive development. Losma USA purchased a new 16,000-sq.-ft. facility, which is more than twice the size of its previous plant. Located in Sparta, N.J., the new plant will help Losma streamline its U.S. assembly process and increase inventory. Losma manufactures air and coolant filtration systems. Machine Toolworks Inc., a distributor of machine tools in Oregon, Washington, northern Idaho and western Canada, moved its headquarters to a larger 10,000-sq.-ft. facility in Seattle. The new facility
IMCO
IMCOs Matt Osburn and Steve Avers join the engineering students of South Dakota School of Mines & Technology and their racecar. Clockwise, starting with left front: Ashley Locke, Eric Lee, Matt Murphy, Osburn, Alex Kotten, Jordan Krell, Evan Hoglund, Avers, and Callen Schmalz.
IMCO gives students tools, advice on racecar development project

plastic and titanium. We rounded up a bunch of tools for working with those materials, Osburn said, valuing the first shipment at more than $10,000. The assortment included Streaker M20 endmills for cutting aluminum, M904 endmills for general-purpose machining, M525 endmills for titanium and hard steels, FR10 routers and prototype tools for cutting CFRP. IMCO also contributed when a special need arose. We needed a really big tool we couldnt get locally, said Evan Hoglund, the team member responsible for all machining. IMCO didnt have a tool that size, so Hoglund described what he needed to do and Osburn selected an IMCO tool that would do the job. IMCO offered the team more than just toolsthey also offered advice. The team members didnt have any formal machining training, so throughout the project the students consulted IMCO on speeds and feeds and techniques. In the end, the relationship paid off. At the 120-team competition in May, Hardrocker Racing took 11th place in design, fifth in autocross and fourth in skidpad. For more information on the project, visit www.hardrockerracing.com and www. camp-sdmines.com.
When a team of engineering students asked several cutting tool manufacturers for tools to help build a racecar for a contest, IMCO Carbide Tool Inc., Perrysburg, Ohio, was eager to assist. With the tools provided by the company, the South Dakota School of Mines & Technologys Hardrocker Racing Team was able to design and build a racecar and enter it in the Formula SAE competition at Michigan International Speedway. Typically, student teams cant afford all the required cutting tools. Looking for a sponsor, engineering student Jordan Krell e-mailed information about the project to several toolmakers. When Krells e-mail reached Matt Osburn, the IMCO vice president and technical director was intrigued. Were always looking for new ways to test and prove our endmill designs, he said. I thought, That sounds kind of cool. The companys main goal was to encourage future engineers. We need those people because they strengthen our manufacturing base and that strengthens our country, Osburn said. When IMCO expressed interest, the students informed Osburn they work with aluminum, steel, carbon fiber-reinforced
208 | AUGUST 2012 | CTE
features a new technology learning center and display area. n Machine tool builder Mazak Corp. is expanding its manufacturing plant in Florence, Ky. This expansion will increase potential production capacity to 200 machines per month. The company is also bolstering its customer service and support offerings with expansions to its National Technology Center & Center for Multi-Tasking and Manufacturing Excellence, and its North American Parts Center. Combined, the three expansions will add more than 200,000 sq. ft. to Mazaks Kentucky manufacturing campus, increasing total floor space to 800,000 sq. ft. n Industrial distributor MSC Industrial Direct Co. Inc. plans to invest more than $31 million in a new, 180,000-sq.-ft. building in Davidson, N.C., creating 400 jobs by 2017. Plans call for creating a co-headquarters with MSCs existing office in Melville, N.Y. n Coating supplier Oerlikon Balzers Coating USA Inc., Schaumburg, Ill., announced the expansion of its Rock
Hill, S.C., operation. The Rock Hill coating center will add new processing equipment and support services. n Machine tool builder Okuma America Corp., Charlotte, N.C., and its distributor Hartwig Inc. held an employee appreciation cookout to celebrate a successful first half of the year at Hartwigs Okuma Tech Center in Houston. More than 60 guests attended. The Okuma Tech Center serves as a showroom for Okuma CNC machine tools. n Oliver of Adrian is celebrating its 100th anniversary in 2013. Based in Adrian, Mich., the company offers drill sharpening equipment. n Precision Aerospace Components Inc., Staten Island, N.Y., acquired the assets of Fastener Distribution and Marketing Co. FDMC is the parent company of Aero-Missile Components (AMC), Bensalem, Pa., which provides fasteners and other components to the military and aerospace industries, and Creative Assembly Systems (CAS), Groveport, Ohio, which provides fasteners, tooling and other products
to the transportation and housing infrastructure markets. Precision Aerospace also provides fasteners and components to the military and aerospace industries. n Computer-aided engineering software developer Third Wave Systems Inc., Minneapolis, has been selected to participate in the Department of Energys $54 million Innovative Manufacturing Initiative. Third Waves project is a 3-year initiative focused on developing technologies that will empower U.S. manufacturers to evaluate the effects of design changes and various materials, anticipate part quality and manufacturing costs prior to implementation, and produce lower-waste, lower-cost manufacturing programs. n Workholding provider Zagar Inc., Cleveland, announced a new partnership with Precihole Machine Tool Ltd., Thane, India. Zagar will exclusively import the complete line of Precihole deep-hole drilling, honing, skiving and burnishing machines for North America. CTE
Mazak Corp. hosts Midwest open house
Mazak Corp. hosted an open house at its Midwest Technology Center in Schaumburg, Ill., to highlight the facilitys recent 18,000-sq.-ft. expansion. The event took place June 26-28 and drew more than 800 people. The expansion of the center included a 124-seat auditorium and two training rooms that allow Mazak to host more events with its technology partners as well as free classes and seminars for customers. The extra space will also be used for showcasing turnkey projects and test cuts. Such additions give Mazak customers more opportunity to process components from various materials, including polymers, steel, aluminum and high-temperature alloys, using the latest machine tool technology, the company stated. The Florence, Ky.-based machine tool builder exhibited 20 Mazak machine tools, including the Nexus Compact vertical machining center for making medical parts, the Variaxis i-700 multitask machine for processing long workpieces in single setups and the Quick Turn Nexus 250 MSY turning center, which includes a second spindle and offers turning, milling and Y-axis capabilities in a single setup. The open house featured presentations on topics such as reshoring, automation, spindle utilization and training. In his presentation, Harry Moser, president of the Reshoring Initiative, pointed out that up to 25 percent of offshored jobs might return to the U.S. if manufacturers were to use total cost instead of cost per part to calculate manufacturing costs. Most companies make sourcing decisions based on price alone, resulting in a 20 to 30 percent miscalculation of actual offshoring costs, he said.
Y. Salcedo
An open house at Mazaks Midwest Technology Center highlighted the facilitys recent 18,000-sq.-ft. expansion.
The Midwest Technology Center is one of eight regional Mazak Technology Centers across North America. George Yamane, marketing manager for Mazak, stressed that the companys centers, as well as the capital cost of expansions, are part of its investment in customer service. Yesenia Salcedo
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Look-Ahead (continued from page 216)

error when documenting measurements. The system has an accuracy of 0.0005" for inspecting a part that fits in a 5" to 6" cube, Scotton noted, and system size can be scaled up or down to suit the application. The question is always going to be whats the accuracy required by the customer, he said. That impacts the cost as well because for better accuracy you have to buy higher resolution cameras. He noted the systems price range is from about $15,000 to $70,000. As of press time, three systems are in place at part manufacturers. Scotton indicated that one of those companies is Oxford Performance Materials, Windsor, Conn., which makes industrial and biomedical parts and biomedical raw materials and is partnering with CCAT to help enhance the technology because they really fell in love with it. For more information, contact Connecticut Center for Advanced Technology Inc., East Hartford, Conn., at (860) 291-8832 or www.ccat.us. In contrast to cutting through materials with abrasive waterjets, abrasive waterjet milling uses high-energy fluid jets to produce complex, freeform surface features on parts by controlling the jet penetration depth. However, waterjet milling relies on craftsmanship, or a trial-and-error approach, in which users need to do significant development work to identify optimal operating parameters followed by extensive partquality analysis, according to Dragos Axinte, a professor of manufacturing engineering at the U.K.-based University of Nottingham. To improve process capability, the universitys Machining and Condition Monitoring Research Team is leading a European project to develop a self-learning control system, called ConforM2-Jet. Self-learning methodologies are increasingly used to search for optimal solutions of complex systems when experimental data is available, Axinte said. The self-learning ability of the ConforM2-Jet controller will increase the robustness and efficiency of high-energy, fluid-jet milling
University of Nottingham
Using the ConforM2-Jet control, a freeform surface on a Ti6Al4V workpiece is efficiently abrasive waterjet milled without human intervention.
University of Nottingham
production systems. At the end of the project, we will have produced the software and a control system to completely automate abrasive waterjet milling and hence take it out of the craftsmanship remit. Axinte explained that the controller is highly accurate because it uses calibrated mathematical models of the materialremoval and process-monitoring techniques that allow corrections during waterjet milling without human intervention. The models are used to develop the predictive controller, which is supported with CAM software developed to generate the theoretical jet-plume path for a particular part. The jet path is then transferred to the self-adaptive model, which also receives real-time sensorial information that indicates the status of the abraded footprint, or depth of removed material. An acoustic emission sensor mounted on the workpiece monitors the input jet energy that erodes the surface to help
calculate the area of the abraded waterjet footprint, Axinte added. Based on this information, the selfadaptive module makes the necessary adjustments to key process variables, such as jet feed speed, he said, thus, bringing the abrasive waterjet milling process to the required performance level. The researchers have only applied garnet abrasive in the waterjet, but Axinte noted the universal system allows the use of other abrasives, such as aluminum oxide and silicon oxide, when processing harder materials, such as engineered ceramics. The ConforM2-Jet consortium plans to license or commercialize the system. For more information, contact the University of Nottingham at +44 115-951CTE 4013 or www.nottingham.ac.uk.
About the Author: Alan Richter is editor of CTE. He joined the publication in 2000. Contact him at (847) 714-0175 or alanr@jwr. com.
ctemag.com | 211
ad index
ADVERTISER NAME PAGE # CONTACT NAME CONTACT PHONE 152 Customer Service 978-567-8867 2L Inc. 3M Abrasive Systems Div. 185 Customer Contact Center 866-279-1288 ext. 1687 Abtex Corp. 142 Mark Fultz 315-536-7403 Advent Tool & Mfg. Inc. 146 Jim Hartford 800-THREAD-4 102 Roland Merk 203-730-8741 Agathon Machine Tools 140 Jim Sobol 586-977-9000 A.G. Davis/AA Gage 191 Astrid Krenn Alicona Corp. Allied Machine and Eng. Corp. 4-5 James Alpeter 800-321-5537 AMAMCO Tool 103 Andrew Gilpin 800-833-2239 167 Bruce Welz 800-943-4426 Arno Rouse USA LLC Bal-Tec 112 Patricia Johnson 800-322-5832 J.F. Berns Co. 130 Joe Berns Jr. 513-851-4600 BIG Kaiser Precision Tooling Inc. 65 Tim Stapula 888-TOOL-PRO Bilz Tool Co. Inc. 38 Tim Fara 800-227-5460 53 Donna Strozeski 800-752-8035 Briney Tooling Systems Brush Research Mfg. Co. Inc. 85 Michael Miller 323-261-2193 BTA Heller Inc. 28 Mark Solich 248-597-0346 191 Jennifer Goedde 775-445-6234 Calculated Industries Carbide Tool Services Inc. 98 Patrick Hjelm 800-243-9577 69 Sales 888-628-5030 Carmex Precision Tools LLC Carr Lane Mfg. Co. 35 Judy Camp 314-646-1850 97 Jim Dillon 734-591-1041 CDP Diamond Products Ceratizit USA Inc. 157 Robert Bokram 586-759-2280 CNC Software Inc. 105 Ben Mund 800-228-2877 179 Ben Mund 800-228-2877 CNC Software Inc. Cogsdill Tool Products Inc. 120 David Lopes 803-438-4000 197 Kim Dethomasis 519-253-2461 Colonial Tool Group Inc. Control Gaging Inc./Product Control Technologies 96 Dave Hayes 734-668-6750 Criterion Machine Works 118 Bob Wahlstrom 800-854-7441 164 Matthew Bernard 800-547-0222 Darex Corp. LLC Datum Point Tool Inc. 118 Dan Janness 248-588-8588 Davenport Machine, div. of Brinkman Products Inc. 66 Donna Foley 800-344-5748 Deublin Co. 187 847-689-8600 Diamond Alternatives LLC 167 Gene Swatek 734-755-1505 Dijet 173 Jeanne Mound 800-743-4538 188 Joseph P. Shouvlin 800-428-1133 Dillon Mfg. Inc. 43 Joseph P. Shouvlin 800-428-1133 Dillon Mfg. Inc. DMG/Mori Seiki USA Inc. 115 Customer Support 877-275-6674 Doosan Infracore Machine Tools 8-9 John Ross 973-618-2500 68 Dave Bartholomew 805-388-6000 DP Technology 186 Dyana Morton 586-716-5151 Ebbco Inc. 67 Matt Ehmling 713-462-4944 Edge Industrial Supply Efficient Manufacturing Technologies 87 Frank Holubek 954-907-7796 Eltool Corp. 76 Ed Crotty 877-435-8665 EMAG L.L.C. 177 Amanda Brandemihl 248-442-6719 Erasteel 41 Pauline Carel 800-365-1152 Eriez Magnetics 39 Dan Zimmerman 888-300-ERIEZ (3743) Fastenal 78-79 877-507-7555 Filter Technology LLC 93 Randal J. Armstrong 734-272-4784 Fixtureworks 146 Justin Gordon 888-794-8687 M.A. Ford Mfg. Co. Inc. 101 Judy Brauer 800-553-8024 G II Solutions Inc. 170 Curtis Brown 800-948-5478 Gagemaker Inc. 86 Mary Jo Burt 713-472-7360 34 Scott Laprade 413-562-4800 Genevieve Swiss Industries Inc. GKI Inc. 153 Karen Brady 888-GKI-TOOL Goodrich Corp. 203 Priscilla Martinez 719-550-4445 77 Kevin Cranker 866-888-9600 Gorilla Mill Gradient Lens Corporation 81 Doug Kindred 800-536-0790 Greenfield Industries 21 Haley Mitchell 706-650-4379 Greenfield Industries 155 Haley Mitchell 706-650-4379 Greenleaf Corp. 94-95 Bill Greenleaf 800-458-1850 Griggs Steel 182 Mark Mullen 800-521-1410 GTI SpindleTechnology Inc. 56 Mark Kennedy 603-669-5993 Guhring Inc. 32 Customer Service 800-776-6170 Haimer USA LLC 130 Brendt Holden 630-833-1500 HAINBUCH America Corp. 74 Jurgen Bettray 800-281-5734 212 | AUGUST 2012 | CTE CONTACT E-MAIL / WEB SITE contact@2Linc.com / www.2Linc.com superabrasives@mmm.com / www.3m.com/abrasives mark@abtex.com / www.abtex.com jim@advent-threadmill.com / www.advent-threadmill.com rmerk@agathonusa.com / www.agathon.com jsobol@agdavis.com / www.agdavis-aagage.com astrid.krenn@alicona.com / www.alicona.com info@alliedmachine.com / www.alliedmachine.com andrew.gilpin@amamcotool.com / www.amamcotool.com bwelz@arno-rouse.com / www.arno-rouse.com baltec@usa.net / www.precisionballs.com joe@jfberns.com / www.jfberns.com bigkaiser@bigkaiser.com / www.bigkaiser.com tfara@bilzusa.com / www.bilzusa.com dstrozeski@geminigroup.net / www.brineytooling.com sales@brushresearch.com / www.brushresearch.com msollich@btahellerinc.com / www.btahellerinc.com jenniferg@calculated.com / www.calculated.com costsavings@carbidetool.com / www.carbidetool.com sales@carmexusa.com / www.carmexusa.com info@carrlane.com / www.carrlane.com jimd@cdpdiamond.com / www.cdpdiamond.com robert.bokram@ceratizit.com / www.ceratizit.com info@mastercam.com / www.mastercam.com info@mastercam.com / www.mastercam.com cogsdill@cogsdill.com / www.cogsdill.com kdethomasis@colonialtool.com / www.colonialtool.com dhayes@controlgaging.com / www.controlgaging.com bobw@criterionmachineworks.com / www.criterionmachineworks.com mattb@darex.com / www.darex.com datumpt@aol.com / www.radstartool.com info@davenportmachine.com / www.davenportmachine.com www.deublin.com eswatek@yahoo.com / www.diamondalternatives.net jmound@dijetusa.com / www.dijetusa.com sales4@dillonmfg.com / www.dillonmfg.com sales4@dillonmfg.com / www.dillonmfg.com info@dmgmoriseikiusa.com / www.dmgmoriseikiusa.com john.ross@doosan.com / www.doosaninfracore.com/machinetools dave.bartholomew@dptechnology.com / www.dptechnology.com dyana.morton@ebbcoinc.com / www.ebbcoinc.com mattehmling@gmail.com / www.edgeindustrialsupply.com emtcorp@bellsouth.net / www.werkzeugschleifen.de ecrotty@eltool.com / www.eltool.com abrandemihl@emag.com / www.emag.com pauline.carel@eramet-erasteel.com / www.erasteel.com eriez@eriez.com / www.eriez.com websales@fastenal.com / www.fastenal.com rarmstrong@filtertechno.com / www.filtertechno.com jgordon@fixtureworks.net / www.fixtureworks.net sales@maford.com / www.maford.com info@giisolutions.com / www.giisolutions.com maryjo.burt@gagemaker.com / www.gagemaker.com slaprade@genswiss.com / www.genswiss.com service@gkitool.com / www.gkitool.com priscilla.martinez@goodrich.com / www.goodrich.com/careers kcranker@gorillamill.net / www.gorillamill.net info@gradientlens.com / www.gradientlens.com haley.mitchell@gfii.com / www.gfii.com haley.mitchell@gfii.com / www.gfii.com billgreenleaf@greenleafcorporation.com / www.greenleafcorporation.com mmullen@msn.com / www.highspeedsteel.com mkennedy@gtispindle.com / www.gtispindle.com sales@guhring.com / www.guhring.com brendt.holden@haimer-usa.com / www.haimer-usa.com sales@hainbuch.com / www.hainbuch.com
ADVERTISER NAME Hassay Savage Co. heimatec Inc. Heule Tool Corp. HORN USA Inc. IMC Supply IMTS 2012 - Intl. Mfg. Technology Show Ingersoll Cutting Tools International Tool Machines Co. Iscar Metals Inc. ITI Tooling Co. Inc. J&M Machine Inc. J.M. Sales - USA Jorgensen Conveyors Inc. Erwin Junker Machinery Inc. J.W. Done Co. Kanefusa Corp. Kennametal Inc. Keo Cutters KMT Waterjet Systems Kobe Steel Ltd. Kobe Steel Ltd. Koma Precision Inc. Komet of America Inc. Korloy America Inc. Kyocera Industrial Ceramics Corp. Kyocera Micro Tools LMT Onsrud Cutter LP Machine Control Technology MachineTools.com Inc. Makino Inc. MAPAL Inc. MAPAL Inc. Maple Industries Inc. Mastercut Tool Corp. Methods Machine Tools Inc. Micro 100 Tool Corp. Mikron Corp. Monroe Mil-Tec Inc. Miraclean Mitee-Bite Products LLC Mitsubishi Materials U.S.A. Corp. Monaghan Advanced Tooling Technology Monster Tool Co. Monster Tool Co. Morse Cutting Tools MP Systems MSC Industrial Supply Co. Myers Precision Grinding Company Inc. Nachi America (Cutting Tools) New Tech Cutting Tools Inc. Northfield Precision NTK Cutting Tools oelheld U.S. Inc. Ohio Carbide LLC Okuma Machinery Inc. Osborn OSG Tap & Die Inc. PCT CARBIDE Pibomulti North America PIONEER N.A. Planet Products Co. Platit Inc. PRAB Practical Machinist Precision Cutting Tools Inc. Precision Dormer
PAGE # CONTACT NAME CONTACT PHONE 136 William Fletcher 413-863-9371 147 Preben Hansen 847-749-0633 144 Kara A. Schuler 513-860-9900 70-71 Duane Drape 888-818-HORN 153 Craig Clausel 901-345-6001 199 Jessica Aybar 703-827-5288 30-31 Reception 866-690-1859 57 Peter Chen 386-446-0500 Cover 2, 1 Customer Service 877-BY-ISCAR 161 Leigh Bickham 201-934-6333 40 Andy Rowley 800-322-7750 145 Joe Mazzenga 248-321-6170 175 John D'Amico 262-242-3089 80 Sales 847-488-0406 54 Michael Kapgan 510-784-0667 25 Saki Terada 81-587-95-7221 Cover 4 Osny Fabricio 724-539-5000 52 Tom Hensel 586-771-2050 99 Robert Pedrazas 620-856-6239 84 Suzuki Saeko 81-3-5739-6761 137 Suzuki Saeko 81-3-5739-6761 121 Mary Buffum 860-627-7059 113 Bob Davila 847-923-8400 149 Jimmy Kim 888-711-0001 46-47 Mark Gardiner 828-698-4137 55 Mark Thum 714-428-3711 36 Jennifer Neubauer 800-234-1560 142 Sam Yu 714-952-4622 204 785-965-2659 125 Mark Rentschler 800-552-3288 20 Mary Gilbert 810-364-8020 109 Mary Gilbert 810-364-8020 181 Patricia Kuschell 800-537-5447 122 Aimy Shaluly 727-726-5336 13 Jamie Hanson 978-443-5388 131 Randy Nedrow 800-421-8065 61 Hans Liechti 203-261-3100 88 John Forrest 800-564-5832 152 Brian Sutton 716-763-4343 200 Andy Arsenault 603-539-4538 45 Ron Lawson 800-523-0800 174 Scott Monaghan 800-732-4565 123 Josh Lynberg 888-CARBIDE 205 Josh Lynberg 888-CARBIDE 183 Rick Rennie 800-255-1701 100 Jeanette D'Errico 860-687-3436 7 Bruno Gruaz 800-521-9520 49 Michelle Okuley 216-587-3737 139 Butch Wisner 317-530-1040 186 Aaron Fike 800-227-9876 129 Paul DeFeo 516-431-1112 169 Shintaro Nabeshima 248-668-0100 24 Philipp Storr 847-531-8501 176 John D. 216-543-9041 91 Julie Murphy 704-504-6324 143 Jeff Naymak 800-720-3358 62-63 Drew Strauchen 630-790-5168 128 Nino D'Andrea 416-398-9446 107 Gregg Mitchell 248-377-8170 48 Mr. N. Kiriyama 847-593-6000 157 Tony Avellaano/Dan Howard 513-984-5544 126-127 Bo Torp 847-680-5270 163 Chris Gibbs 800-968-7722 181 14-15 Louie Covarrubias 800-334-9373 114 Alex Traianopoulos 800-877-3745
CONTACT E-MAIL / WEB SITE billfletcher4@gmail.com / www.hassay-savage.com www.heimatecinc.com k.schuler@heuletool.com / www.heuletool.com sales@hornusa.com / www.hornusa.com info@imcsupply.com / www.imcsupply.com jaybar@amtonline.org / www.imts.com info@ingersoll-imc.com / www.ingersoll-imc.com grind@itmfl.com / www.itmfl.com information@iscarmetals.com / www.iscarmetals.com leigh@indexingtechnologies.com / www.ititooling.com arowley@jmmachineinc.com / www.jmmachineinc.com jamazzenga@jbo-usa.com / www.jmsales-usa.com info@jorgensenconveyors.com / www.jorgensenconveyors.com info@junker-usa.com / www.junker-usa.com mkapgan@jwdone.com / www.jwdone.com s-terade@kanefusa.co.jp, sales-ex@kanefusa.co.jp / www.kanefusa.net osny.fabricio@kennametal.com / www.kennametal.com thomas.hensel@keocutters.com / www.keocutters.com bob.pedrazas@kmtwaterjet.com / www.kmtwaterjet.com suzuki.saeko@kobelco.com / www.kobelco.co.jp/english suzuki.saeko@kobelco.com / www.kobelco.co.jp/english mbuffum@komaprecision.com / www.komaprecision.com marketing@komet.com / www.komet.com korloyamerica@korloy.com / www.korloyamerica.com mark.gardiner@kyocera.com / www.kyocera.com/ceratip mark.thum@kyocera.com / www.kyoceramicrotools.com jneubauer@onsrud.com / www.onsrud.com machinecontroltech@sbcglobal.net / www.machinecontroltechnology.com info@machinetools.com / www.machinetools.com mark.rentschler@makino.com / www.makino.com mary.gilbert@us.mapal.com / www.mapal.us mary.gilbert@us.mapal.com / www.mapal.us pkuschell@maple-ind.com / www.maple-ind.com aimys@mastercuttool.com / www.mastercuttool.com sales@methodsmachine.com / www.methodsmachine.com info@micro100.com / www.micro100.com hans.liechti@mikron.com / www.mikron.com/tool-us john@toolalliance.com / www.miltecusa.com soundwaves@miraclean.com / www.miraclean.com andy@miteebite.com / www.miteebite.com marketingservices@mmus.com / www.mitsubishicarbide.com smonaghan@monaghaninc.com / www.monaghaninc.com sales@monstertool.com / www.monstertool.com sales@monstertool.com / www.monstertool.com rrennie@morsecuttingtools.com / www.morsecuttingtools.com www.mp-systems.net gruazb@mscdirect.com / www.mscdirect.com mokuley@myersprecision.com / www.myersprecision.com bwisner@nachiamerica.com / www.nachi.com aaron@swiftcarb.com / www.swiftcarb.com info@northfield.com / www.northfield.com snabeshima@ntktech.com / www.ntkcuttingtools.com us@oelheld.com / www.oelheld.com service@ohiocarbide.com / www.ohiocarbide.com jmurphy@okuma.com / www.okuma.com jnaymak@osborn.com / www.osborn.com drew.strauchen@osgtool.com / www.osgtool.com contact@pctcarbide.com / www.pctcarbide.com info@pibomulti-na.com / www.pibomulti-na.com sales@gohpi.com / www.pioneerna.com www.planetproducts.com b.torp@platit.dk / www.platit.com chris.gibbs@prab.com / www.prab.com www.practicalmachinist.com marketing@pctcutters.com / www.pctcutters.com alex.traianopoulos@precisiondormer.com / www.precisiondormer.com ctemag.com | 213
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ADVERTISER NAME Radiac Abrasives Inc. Rigibore Inc. Riten Industries Inc. Rockford Ettco Procunier Rollomatic Inc. rose plastic USA LP Rosedale Products Inc. Rsler Metal Finishing Rush Machinery Saint-Gobain Abrasives Sanborn Technologies Sandvik Coromant Co. Sandvik Coromant Co. Sandvik Coromant Co. Schunk Inc. Scully Jones Corp. Seco Tools Inc. SGS Tool Co. SIC Marking USA Slater Tools Soraluce America Inc. Stace-Allen Chucks Inc. Star SU LLC Star SU LLC Star SU LLC Stellram/ATI Engineered Products Stellram/ATI Engineered Products Stor-Loc Sumitomo Electric Carbide Inc. Technifor Inc. THINBIT TMFM LLC Tool-Flo Mfg. Inc. Tool-Flo Mfg. Inc. Toolmex Corporation Transor Filter System Tru Tech Systems T-Tool USA LLC Tungaloy America Inc. Tungco Inc. Tungsten Toolworks Unison Corp. United Grinding Technologies Inc. Universal Grinding Corp. USCTI US Shop Tools Vargus USA Walter USA Inc. Wetmore Tool & Engineering YG-1 Tool Co. Ltd. Zebra Skimmers Corp. Zoller Inc. PAGE # CONTACT NAME 108 Marianne Dodakian 165 Kipp Hoscheit 19 Mitchell Kirby 160 Larry Bull 106 Eric Schwarzenbach 64 David Windmueller 198 Dan Morosky 193 Kaitlin Braithwaite 141 Bill Freese 33 Abby Marschke 189 Steve Friedman Cover 3 Bjrn Roodzant 23A Bjrn Roodzant 110-111 Bjrn Roodzant 171 Veronika Gaertner 135 Krai Rajakumar 215 Customer Service 75 Susan Biskopski 156 Laurie Barcaskey 168 29 132 Phillip Grimes 17 119 92 27 April Jackson 195 April Jackson 201 Mike Ryan 11 Paul Ratzki 44 Susan Doyle 73 Lenore Perry 168 Jim Hartford 170 Doug McLaughlin 198 Doug McLaughlin 133 Sharon Bronaugh 148 Irvin Kaage 59 Tim Wheeler 138 Marc Wijtenburg 159 Ryan Cox 60 Cliff Nance 18 John Forrest 89 Dave Swider 51 Christy Lincoln 188 Monica LaKota 151A 42 Greg Stoddard 83 Scott Golden 117 Mark Hemmerling 141 Phil Kurtz 2 Al Zaitoon 124 Steve Davidian 37 Christoph Zoller CONTACT PHONE 866-723-4223 262-363-3922 800-338-0027 863-688-0071 866-713-6398 724-938-8530 800-821-5373 269-441-3638 800-929-3070 800-551-4413 508-660-9150 800-SANDVIK 800-SANDVIK 800-SANDVIK 919-767-2010 773-247-5900 800-832-8326 330-686-5622 412-487-1165 586-465-5000 815-315-9261 317-632-2401 847-649-1450 847-649-1450 847-649-1450 800-232-1200 800-232-1200 800-STOR-LOC 847-635-0044 704-525-5230 888-THINBIT 877-SPLINE-5 800-345-2815 800-345-2815 508-653-8897 800-354-3040 877-TRU-TECH 954-358-6071 888-554-8394 270-825-0000 800-564-5832 248-544-9500 937-847-1253 216-631-9410 216-241-7333 800-448-3144 800-828-8765 800-945-5554 800-708-3713 800-765-8665 440-349-0141 734-332-4851 CONTACT E-MAIL / WEB SITE mdodakian@radiac.com / www.radiac.com mail@rigiboreinc.com / www.rigiboreinc.com info@riten.com / www.riten.com lbull@rockford-ettco.com / www.rockford-ettco.com solutions@rollomaticusa.com / www.rollomaticusa.com davew@rose-plastic.com / www.rose-plastic.com filters@rosedaleproducts.com / www.rosedaleproducts.com kbraithwaite@rosler.us / www.rosler.us mail@rushmachinery.com / www.rushmachinery.com contactnorton@saint-gobain.com / www.saint-gobain.com steven.friedman@sanborntechnologies.com / www.sanborntechnologies.com bjorn.roodzant@sandvik.com / www.sandvik.coromant.com/us bjorn.roodzant@sandvik.com / www.sandvik.coromant.com/us bjorn.roodzant@sandvik.com / www.sandvik.coromant.com/us veronika.gaertner@us.schunk.com / www.schunk.com knraj15@aol.com / www.scullyjones.com marketing.us@secotools.com / www.secotools.com biskopskis@sgstool.com / www.sgstool.com lbarcaskey@sicmarkingusa.com / www.sicmarking.com direct@slatertools.com / www.slatertools.com sales@soraluce-america.com / www.soraluce-america.com info@stace-allen.com / www.stace-allen.com sales@star-su.com / www.star-su.com sales@star-su.com / www.star-su.com sales@star-su.com / www.star-su.com ajackson@stellram.com / www.atistellram.com ajackson@stellram.com / www.atistellram.com sales@storloc.com / www.storloc.com p_ratzki@sumicarbide.com / www.sumicarbide.com sdoyle@usa.technifor.com / www.technifor.us thinbit@kaisertool.com / www.thinbit.com jim@advent-threadmill.com / www.tmfmllc.com dmclaughlin@toolflo.com / www.toolflo.com dmclaughlin@toolflo.com / www.toolflo.com sharon.bronaugh@toolmex.com / www.toolmex.com info@transorfilter.com / www.transorfilter.com sales@trutechsystems.com / www.trutechsystems.com marc@t-toolusa.com / www.t-toolusa.com rcox@tungaloyamerica.com / www.tungaloyamerica.com cliffnance@mac.com / www.tungco.com john@toolalliance.com / www.tungstentoolworks.com dswider@unisoncorp.com / www.unisoncorp.com christy.lincoln@grinding.com / www.grinding.com monica@universalgrinding.com / www.universalgrinding.com uscti@uscti.com / www.uscti.com greg@usshoptools.com / www.usshoptools.com sales@vargususa.com / www.vargususa.com service.us@walter-tools.com / www.walter-tools.com/us info@hpwetmore.com / www.hpwetmore.com nancyhan@yg1usa.com / www.yg1usa.com zebraskimmers@yahoo.com / www.zebraskimmers.com sales@zoller-usa.com / www.zoller-usa.com
The Advertisers Index is provided as a courtesy to advertisers. Every effort is made to avoid errors, but should one occur, CTE is not responsible.
Reviewed by the Engineering Index. Cutting Tool Engineering (ISSN:0011-4189) is published monthly. Copyright 2012 by CTE Publications Inc., 40 Skokie Blvd., Suite 450, Northbrook, IL 60062-1698. All rights re served. Periodicals postage paid at Northbrook, IL 60062 and additional mailing offices. Circulated in the U.S.A. to qualified individuals concerned with the material-cutting function in industry. For others, subscriptions are $65 per year in the U.S.A.; $95 in Canada. Other foreign subscriptions are $115 per year; overseas delivery via airmail, $175. Editorial and advertising offices: 40 Skokie Blvd., Suite 450, Northbrook, IL 60062-1698. Phone (847) 498-9100; Fax (847) 559-4444. This magazine is protected under U.S. and international copyright laws. Before reproducing anything from this publication, call the Copyright lications makes every effort to ensure that the processes described in Cutting Tool Engineering conform to sound machining practices. Neither the authors nor the Clearance Center Inc. at (978) 750-8400. CTE Pub publisher can be held responsible for injuries sustained while followingprocedures described herein. Postmaster: Send address changes to Cutting Tool Engineering, P.O. Box 2747, Orlando, FL 32802-2747. Canada Post: Publications Mail Agreement #40065725. Canada Returns to be sent to 2835 Kew Dr., Windsor, ON N8T 3B7. Produced in the U.S.A.
Experienced. Trusted. Insightful
214 | AUGUST 2012 | CTE
look-ahead
tis mont
Cutting Tool Engineering covers: n An economical structured-light scanner for inspecting parts; and A self-learning control to automate abrasive waterjet milling.
By Alan Richter, Editor
Noncontact, light-based metrology systems are nothing new. But their price tags can be restrictive for smaller part manufacturers, which often become confused when trying to understand what technology to acquire and how to implement it, according to Tom Scotton, director, model and simulation for Connecticut Center for Advanced Technology Inc. CCAT promotes partnerships between industry, academia and government to create a collaborative framework for addressing economic challenges and increasing competitive advantages. In addition, when visiting small manufacturers to help them minimize cycle times, CCAT personnel would often notice parts stacked up in the metrology room waiting to be inspected, Scotton explained. Thats when we realized that allowing them to make parts faster only exacerbates the bottleneck problem in the metrology room, he said. To overcome these issues, CCAT developed, with the companys Modeling and Simulation Applications Engineer Nasir Mannan as the technical brains, an automated quality inspection structured-light scanner, Scotton noted. According to Scotton, the scanner is an economical turnkey system that enables a small manufacturer to begin inspecting parts efficiently within a couple of hours after installation instead of the typically long implementation process for a complex, conventional system. The scanner is also suitable for reverse engineering. He explained that the line-of-sight inspection system uses two off-the-shelf digital cameras to gather data and a high-brightness projector, similar to
216 | AUGUST 2012 | CTE
terns, typically stripes, onto the object being inspected. From each viewpoint, software automatically converts the series of striped patterns into a 3-D definition of the objects surface, and then each 3-D viewpoint is aligned and merged into the complete 3-D model of the part. A single- or dual-head turntable axis holding the part indexes that part to capture data from various vantage points. Software algorithms then turn the collected informationthe various light patternsinto a 3-D representation of the object for inspection purposes. In addition to a turntable axis, a machine tool can index the part during the inspection process. CCAT inspected parts in a Hurco CCAT 5-axis milling machine at its CCATs structured-light scanner uses two digital cameras Advanced Manufacturing to gather data and a projector to display a series Center with a wireless interof patterns, typically stripes, onto the object being face using a scanner mounted inspected. on a tripod with lockable wheels, Scotton explained. We basically machine a part on the Hurco, open the door, roll our scanning head up to the machine and communicate wirelessly with the machines controller, he said, noting the inspection system tells the machine to index the part to various locations. Then we capture the data and do the inspection [on the machine]. The technology CCAT could be applied on a numCCAT inspected parts in a Hurco 5-axis milling machine ber of different machines. with a wireless communication interface using a Scotton pointed out that structured-light scanner mounted on a tripod with lockable wheels. the system automatically generates inspection reports, what might be used for a PowerPoint eliminating the potential for human (continued on page 211) presentation, to project a series of pat-
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2012 Kennametal Inc. l All rights reserved. l A-12-02818-EN

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August 2012 | Vol. 64 | Issue 8 www.ctemag.

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Get Non-stop Performance from our World-leading Cutting Tools.

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By Alan Rooks, Editorial Director

Made (or not) in the U.S.A.

Green technologies to power innovation

tools compete with monocrystalline tools

Multiple Diameter Carbide Drills and Reamers

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System technology from one source

600 to 1,600 (in plane) >2,000 (perpendicular)

Table 1. Properties of CVD diamond compared to other materials.

18 | AUGUST 2012 | CTE

Cutting tool sales rise in May

YOUR PROBLEM IS NOT UNIQUE.

Total Billings Index

The USCTI collected the above data from member-companies.

Durable goods demand mixed in May

Solutions, not excuses

20 | AUGUST 2012 | CTE

FOR OVER 50 YEARS, PROUDLY MANUFACTURING CUTTING TOOLS IN CLEMSON, SC

Manufacturing Team Lead, Clemson, SC Plant

new product focus

- . Nextec Laser Metrology LLC says its WIZprobe

. Kistlers Type 9129A is a three-component,