Industries Information

More compact and inexpensive than traditional milling machines, a machine with the same strength, power, and accuracy to cut high-performance alloys is priced at only US$6,800

Tormach, innovator of CNC technology, has introduced of its PCNC 1100 CNC, the most affordable 3-axis milling machine on the market. With a base price of only US$6,800, the PCNC 1100 CNC mill represents an entirely new class of machinery, more compact and inexpensive than traditional mills, with the same strength, power, and accuracy to cut high-performance alloys.

Tormach coins the term, ‘Personal CNC’, to describe the product, drawing parallels in cost, size, and ease of use of the personal computer compared to its bulky, room-sized predecessors.

Three years in development, the design of the agile PCNC 1100 combines reliable cast-iron construction with the best of CNC technology to create a simple and robust platform with ample options for user-installed upgrades.

The mill weighs 1130 lb and is equipped with a 1.5HP - well suited for short run and prototyping applications as well as secondary operations.

‘Tormach’s PCNC release is really the advent of a revolution in CNC which will make the technology far more accessible and far simpler to use,’ said Tormach CEO, Greg Jackson.

‘Where 3D printers have allowed companies to make prototype replicas in house, this new generation of CNC will enable companies to affordably produce both working prototypes and initial production parts.
Further reading

CNC is easy to use for smaller machine shops
Easy-to-use, PC-based CNC machine control software brings the benefits of precise computerized cutting to individual craftsmen and small to medium-sized businesses

Low cost toolholders offer quick changeover
To reduce the high cost of tooling - a barrier to truly affordable CNC machining - a range of low cost, quick-change toolholders has been introduced

Five-axis machine drills and routs aluminium
An advanced 5-axis profile machine centre will be shown at MACH 2008 and is capable of drilling, routing, tapping, cutting and notching in aluminium and steel

Unlike 3D printers, where the material is limited to plastics, materials used in Personal CNC technology are basically anything that can be cut with a tool.’ With a modern bed mill style frame and iron construction, the machine is fully capable of cutting iron, steel, titanium, and even chromium alloys such as 300 or 400 series stainless.

Details of the mill include a 4500 rev/min variable-speed spindle, dovetail ways and ground ballscrews, with a 15-point lubrication system and full-bellows covers.

The standard 33.5in x 9.5in table and 17in vertical clearance provides a work envelope suitable to the majority of small or medium parts.

Available upgrades include fourth axis, 20,000 rev/min spindle, integrated stand, and a quick-change tooling system.

All machines are designed by Tormach engineers and built with USA-manufactured electronics, and are sold and supported directly by Tormach LLC.

* About Tormach - the people at Tormach are dedicated to delivering tools, accessories, and components of unprecedented value in the world of CNCand motion control.

Whether customers are involved in R and D, education, short run production, or simply entrepreneurs with new ideas, Tormach products allow them to make what they need easier, quicker, and more affordably.

http://www.manufacturingtalk.com/news/tys/tys101.html 

Mould and toolmaker has acquired high-speed and high-performance 5-axis milling machines to increase its productivity and maintain ia competitive advantage

Market-leading Manchester, UK-based mould tool and die specialist Hanson Thorpe Precision toolmakers has recently invested in 2 new Mikron milling machines from GF AgieCharmilles. The machines - a high-speed (HSM 300) and a high-performance 5-axis (UCP 600) were installed at the company’s facility in August 2006 and November 2006 respectively.

Both machines are being used to increase Hanson Thorpe’s productivity and maintain its competitive advantage in the tough, demanding and global mould tool and die sector.

* Hanson Thorpe - Hanson Thorpe was established 1991 by directors Des Thorpe and Stuart Hanson.

The company operates from a 11,000 sq foot facility in Middleton, Manchester and it specialises in the design and manufacture of small to medium-size plastic injection, compression and die cast mould tools up to about 1.5 tonnes.

The company also provides a comprehensive mould tool repair and modification service.

The tools manufactured by Hanson Thorpe are used in and across a diverse range of sectors which include - medical devices, automotive, packaging etc.
Further reading

Graphite electrodes milled at high speeds
Designed specially for high-speed maching of graphite, a machining centre is built on a polymer concrete base, providing the best damping properties and exceptional stability

Die-sinking EDMs offer higher accuracy
Die-sinking EDMs have, as standard, quality glass scales, which continuously measure and correct axis positions, ensuring that all components are in the required range of accuracy

Wire EDM improves subcontractor services
EDM subcontractor has purchased a wire EDM to improve its manufacturing services and improve turnaround times and achieve tight customer delivery deadlines

In addition to the tool making side of its business - the company has also diversified its operations by aggressively targeting high-growth and high added value sectors (e g, the medical sector) - and is now also manufacturing complex high-precision medical components (rasps, implants etc) for a growing number of customers.

Hanson Thorpe is a big player in the mould tool and die sector - and the company has an international reputation for the quality of its products and services - and is at the cutting edge of mould tool design and manufacture (multi-impression, twin-shot, 3D-formed tools, etc).

Only a few months ago the company won the prestigious ‘Best toolmaker of the Year’ award - part of The Plastic Industry Awards 2006.

Hanson Thorpe employs 24 people at its facility of which two are CAD/CAM design engineers and 17 are employed on the machine shop floor.

The company has made (and continues to make) prudent and strategic investment in advanced machine tool technologies - and the two recent Mikron machine tool purchases are evidence of the company’s forward thinking approach.

Said Stuart Hanson, director at Hanson Thorpe: ‘We are always on the lookout for new technologies to improve our business performance.

Investments that improve our quality, help reduce lead times and make us even more cost competitive are always of interest to us.’ * About the UCP 600 - the Mikron UCP 600 is a high-performance 5-axis machining centre.

The machine provides Hanson Thorpe with 5-face and simultaneous 5-axis machining capability which it employs to the full in the manufacture of complex high precision parts for the medical sector.

The machine (as is the case with 5-axis milling technology) helps the company significantly reduce time and resources spent on job set ups and fixturing - and enables Hanson Thorpe to economically manufacture complex parts (in one hit) that are required in low/medium volume.

The UCP 600 is a universal machining centre that delivers high-performance.

Irrespective of whether the requirement is high and precise material removal and/or super fine finishing - the machine can deliver.

Since its installation in November the UCP 600 has been put through its paces machining a variety of components from a equally diverse range of materials - titanium, exotics, aluminium, stainless steels, etc.

The UCP 600 has a 16kW 20,000 rev/min spindle and X, Y, Z travels of 530 x 450 x 450mm.

The machine has rapid rates of 22m/min and a (30-position/optional 58-position) automatic tool changer (ATC).

The UCP 600’s rotary tilting table (280mm x 400mm) can handle a maximum table load of 200kg and has tilting capability of +122/-100 deg and rotation speed of 30 rev/min and tilt speed of 20 rev/min.

Continued Hanson: ‘If you’re involved in and serious about medical component manufacture you need 5-axis machining capability at your finger tips.

It’s just not economically viable trying to manufacture complex, high precision components without it.’ * About the HSM 300 - GraphiteMaster - the Mikron 3-axis HSM 300 GraphiteMaster services Hanson Thorpe’s EDM manufacturing cell - and is dedicated (as its name suggests) to the manufacture of graphite electrodes.

The machine is equipped with a high-frequency spindle (6kW 30,000 rev/min HSK 40) and has acceleration of 17m/s2 on X, Y and Z-axes powered by the Heidenhain iTNC 530 control).

The HSM 300 has a generous tool changer (18 standard - 27 optional) for extra versatility - and the machine’s dust extraction system ensures that the workpiece, working area and tool changer remain dust and particle free.

Said Hanson: ‘We manufacture electrodes exclusively from graphite.

We use graphite because of its high performance and low wear characteristics.

The electrodes we design and manufacture are complex and intricate.

We often use very small cutters (down to 0.4mm diameter diamond coated) to give us the results we need.

As far as we’re concerned the HSM 300 gives us the best in class performance.’.

* EDM capability - in addition to its milling technology Hanson Thorpe has invested heavily in EDM.

The company’s EDM capability is formidable and consists of: four die-sink machines; one wire cut machine and one hole driller supplied by market-leading EDM manufacturer - Charmilles.

Hanson Thorpe’s EDM cell is serviced by the new HSM 300 GraphiteMaster and an older Bostomatic high-speed machining centre.

The spark erosion machines themselves have built-in automation, i e, electrode holders and workpiece palletisation, which means the company (and its customers) benefit from unattended operations and reduced lead times.

This cell also features a dedicated CMM which allows fast, efficient and direct data transfer of electrode measurement to the EDM machines’ control systems and to further ensure higher productivity and avoid manufacturing delays - Hanson Thorpe holds extensive consignment stock of cut, pre-drilled, tapped graphite electrodes which ensure smooth and continuous production.

http://www.manufacturingtalk.com/news/agi/agi156.html 

Accuride has produced optimised 3D models of its ‘off the shelf’ ball bearing slides to make the design process simpler and quicker

Accuride International has launched a new service that will save product designers and engineers significant time when creating 3D CAD drawings that incorporate the company’s most popular products. Creating 3D models of telescopic slides can take a significant amount of time to complete. To make the process much simpler, quicker and to help reduce the possibility of mistakes being made, Accuride has produced optimised 3D models of its ‘off the shelf’ products that can be downloaded via its website.

This article was originally published on Engineeringtalk on 22 May 2007 at 8.00am (UK)
Related stories

More slides available off the shelf
Accuride International has extended its off-the-shelf product range into what is now believed to be the largest of its kind in Europe

Slides are ideal for access and positioning
The versatile design of the 9300 series, along with a choice of features and mounting options, makes these slides ideal for access and positioning in a variety of heavy duty applications

Accuride telescopic slides are built into many everyday products to provide access and movement, for example to open and close drawers or slide out shelves.

The slides are used across a broad range of industries particularly in the automotive, domestic, industrial, furniture, IT and telecoms sectors.

Accuride’s 3D drawings have been optimised for fit, form and function to make them easy for product designers to use and to keep the file size relatively small for downloading.

The dimensional features most important for integrating a telescopic slide into a larger drawing have been retained and unnecessary information stripped out.

Because the 3D images can be downloaded and integrated into larger drawings within minutes, designers can evaluate different telescopic slide products to optimise their designs.

The 3D models can be downloaded in IGES format free from the company’s website.

Metric linear actuators feature guide tubes of chrome plated precision steel, with gun metal follower nuts and plastic end caps

JW Winco has expanded the scope of its portfolio with a range of metric linear actuators with left and right hand threads. The actuators feature guide tubes of chrome plated precision steel, with gun metal follower nuts and plastic end caps. The tubes are also available in stainless steel. Tubes come in a variety of diameters, and travel lengths from 120 to 350mm.

The actuators may be ordered with only one shaft end protruding, or with the shaft ends protruding at both ends.

The PMM slide from Micromech can be mounted in horizontal or vertical direction and the specially designed U-shaped ball cage made of brass eliminates creeping of the cage

The PMM compact slide from Micromech has consistent high running motion accuracy, which results in unsurpassed reliability. Thanks to the innovative design combined with a fine adjustment (pre-loading is by selection on ball diameter), these slides are showing an extremely low friction resistance, smooth running qualities and long operation lifetime.

This article was originally published on Engineeringtalk on 4 June 2007 at 8.00am (UK)
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Low-profile bearing offers high precision
The FMB turntable bearing is designed to provide high-performance circular motions in as small a package as possible

Designed for rapid and precise movements the slides have stainless steel table bodies, coming in three sizes with stroke lengths of 5 to 70mm.

Ultra-compact and lightweight the bodies are made from stainless steel type 1.4034 and hardness 54-57 Hrc.

The PMM slide can be mounted in horizontal or vertical direction and the specially designed U-shaped ball cage made of brass eliminates creeping of the cage, which is limited in travel by the use of inside screws.

The slide-top and centre rails are of equal lengths and mounting surfaces are fine machined by precision grinding.

All the flanks of the slide are ground parallel to the guide-ways and so can serve as reference faces.

The slide-top and centre rail are provided with tapped attachment holes drilled to a standard pitch configuration.

These ultra compact miniature slides weigh from 2 to 70g and are aimed at meeting the demand from scientific, pharmaceutical and research establishments.

The Miniscale optical encoder integrated into Schneeberger’s miniature recirculating linear motion guides has a resolution of 1um with a repeatability of +/-2um

Schneeberger’s miniature recirculating linear motion guides are now available with a directly integrated optical encoder to combine load carrying, precision alignment and position feedback functions in one convenient package. The Miniscale system is available in the UK from Basingstoke based LG Motion.

This article was originally published on Engineeringtalk on 4 June 2007 at 8.00am (UK)
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Distribution deal covers SMAC range
A new agreement allows LG Motion to sell and support the SMAC range, with its proprietary linear motor technology that allows programmable control of speed, position, and force

Website has more on automation and control
New site will be continually updated to provide an important resource for automation and control system professionals throughout Europe

The upper surface of the Miniscale guideway includes a durable, micro-etched scale which is read and interpolated by a very small reading head mounted on the moving carriage.

Cabling is completed with a flexible printed circuit board with length to match the travel range.

With a direct TTL-level quadrature output, the Miniscale’s resolution is 1um with a repeatability of +/-2um.
Further reading

XSlide bearing is inherently self cleaning
The new XSlide linear positioning stageis aimed at medium-precision applications in production, test and research applications where price and performance are important selection criteria

Tables cut the cost of positioning systems
Modular positioning tables provide extremely cost effective manual and motorised positioning solutions for medium precision manufacturing and research applications

Overall accuracy is with +/-3um up to 30mm of travel and +/-10um up to 300mm travel.

The Miniscale is available in four standard rail widths of 7, 9, 12 and 15mm with matching carriages for dynamic load capacity to 3680N.

For dynamic loads up to 4750N and improved offset load capability, four wide rails with increased bearing distribution are available in widths of 14, 18, 24 and 42mm.

Maximum rail lengths are 760 to 960mm with longer versions available upon request.

Schneeberger has developed the Miniscale bearing system to meet the increased acceleration and high speed performance required by linear motor drives.

The low-friction, two-row, miniature recirculating ball and rail motion guide technology ensures quiet running with excellent smoothness that is well suited to scanning or high-speed incremental moves.

The integral measuring system, optimally placed closer to the load, ensures the best precision for backlash-free positioning systems, removing the accumulated ‘lost motion’ errors that are apparent in rotary encoder systems.

Contoured front plates ensure that rails are wiped clean during use and provision for in-situ lubrication is included.

Special environment, clean room and vacuum-compatible versions are also available.

The system offers reduced engineering and assembly times, as well as simplified parts ordering and inventory management.

It is suited to applications in electronics and semiconductor manufacturing, biotechnology and medical equipment, MEMS and metrology systems.

Danaher Motion’s standard range of Thomson ball screws offers precision of between 12um on a length of 300mm

Danaher Motion has released a new generation of Thomson ball screws featuring a complete redesign of the ball recirculation mechanism of the nuts. The resultant advantages are even less wear, further reduced torque variation, and a reduction in noise generation. The innovative diverter systems will first be fitted in ball screws with rolled screws and a screw lead ranging from 5 to 10mm.

This article was originally published on Engineeringtalk on 8 June 2007 at 8.00am (UK)
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Slotless motors reduce inertia
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All additional models offered by Danaher Motion will also be converted to the new diverter system over time.

Thomson ball screws consist of a lead screw and cylindrical or flange nut.

They have always been characterised by good rigidity, little clearance and quiet operation, allowing for high levels of positioning accuracy.

Some of these characteristics are further enhanced by the new diverter system that is fitted in the nut to ensure simple ball returns.

This in turn increases positioning precision and economic viability still further.

The standard range offers precision of between 12um on a length of 300mm.

All ball screws are designed for ambient temperatures of between -20C and 120C.

Temperatures of no more than 140C are also permitted for intermittent operations.

The corresponding nut units can be preloaded to reduce clearance or produce no clearance at all.

Every Thomson screw can be supplied with customised final machining.

Customers can also order screws with an annealed end for final machining in-house.

At the heart of the TwinBin system is a double bin that has two compartments arranged vertically one above the other and separated by a slide

Hurst Green Plastics produced the TwinBin fastener management system, reducing wastage of fasteners and other small parts in the aerospace, defence and other industries, but was faced with the problem of producing a versatile and cost-effective rack to accommodate the TwinBins. The original arrangement, based on welded steel racks custom fabricated for each order, had many limitations.

This article was originally published on Engineeringtalk on 20 June 2007 at 8.00am (UK)
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Rail system aids transport of heavy equipment
SCM Materials Handling system for transporting heavy, expensive equipment makes extensive use of the Rexroth 45mm wide ball rail system

Online tool eases automation specification
Once the main information has been input then the Easy-2-Combine system auto-calculates the moment of inertia and will work out the size of the drives required

These are, however, completely eliminated in a new design developed in conjunction with ADM Automation, which is based on aluminium extrusions and accessories from the extensive Bosch Rexroth MGE range of basic mechanical elements.

At the heart of the TwinBin system is a double bin that has two compartments arranged vertically one above the other and separated by a slide.

This allows the bin to be loaded with products that the operator accesses from the lower compartment until it is empty.

Then, by simply withdrawing the slide, the lower compartment can be replenished.

This ensures that the older stock is used first rather than mixed with newer items.
Further reading

Aluminium profiles aid diabetic screening
Rexroth’s MGE modular profile assembly system is applicable to enclosures, special and series machinery and ESD-capable systems

Motion system improves on robotic options
A preconfigured Cartesian Motion Systemhas provided Applied Cooling Technolog with a safe, convenient and cost-effective solution for loading cooling fins into its innovative finning machines

Building system enables flexible manufacturing
Producing ergonomic workstations and efficient materials transfer systems for use in modern lean manufacturing installations is fast, easy and inexpensive with the latest range of MPS products

The empty upper compartments clearly identify bins where stock needs to be added.

The TwinBin system is a Kan Ban solution that adheres to Six Sigma principles.

It not only helps to eliminate stock-outs which interrupt production, but also greatly reduces the risk of spilling or contaminating parts, issues which are particularly important in industries like aerospace and defence.
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TwinBins are housed in racks which, according to customer requirements, can be supplied to accommodate any number of bins.

When the system was first launched, these racks were fabricated from sheet steel and were produced on an order-by-order basis.

‘That gave us a problem’, said Stephen Clarke, Managing Director of Hurst Green Plastics.

‘We could have the bins ready for delivery in just a few days, but it was taking six to eight weeks to get the frames made’.

‘We even tried putting frames into stock to get round this, but that didn’t help with specials, and we also had problems when customers wanted a particular colour of paint finish’.

These were not the only shortcomings of the fabricated steel frames.

They were also heavy and bulky which made them difficult to stock and to transport to site, particularly for the export orders that form a significant part of Hurst Green Plastics’ business.

In addition, the frames were difficult and costly to modify if the end user’s requirements changed.

To find a solution to these problems, Hurst Green Plastics enlisted the aid of ADM Automation, a company with wide experience of designing and fabricating structures for industrial applications.

After carefully analysing the requirements, ADM Automation proposed a solution based on MGE aluminium extrusions from Bosch Rexroth.

Bosch Rexroth has an enormous range of extrusions to choose from, which makes it easy to find exactly the right product.

Secondly, Bosch Rexroth offers a full range of accessories.

‘Finally, as you would expect from a company with the reputation of Bosch Rexroth, quality is beyond reproach’ Clarke said.

‘The new racking concept developed by ADM Automation incorporates three sizes of MGE extrusions together with coupling components from the MGE range’.

‘Where a specialist component required for the application has been designed by ADM, it has been secured to the structure with standard fasteners from the MGE range’.

‘This arrangement means that the racking can be fabricated quickly and, as customers are invariably prepared to accept the natural aluminium finish without painting, the delivery bottleneck that had been so troublesome with the steel racks is eliminated completely’.

‘Further, the new racks are much lighter than their steel predecessors and they have been designed by ADM so that they can be supplied as flat packs, which dramatically reduces shipping costs’.

‘The new racking system also benefits from versatility, allowing customised racks in special configurations to be offered quickly and cost-effectively’.

‘Recent examples have included an L-shaped assembly and a rack the form of a cube, both of which were configured to make best use of the limited space available on the end user’s site’.

‘Finally, the use of aluminium extrusion rather than welded construction for the racks makes them easy to extend and modify’.

‘In particular, because the bins are retained by slide nuts, drilled fixing holes are not necessary’.

‘As a result, when a bin is moved no unsightly holes with potentially sharp edges are left behind’.

‘All of these benefits are provided without any significant cost penalty’.

‘Although the basic materials used in the aluminium frames are more expensive than those used in the old steel frames, the cost of fabrication is reduced and the cost of painting is eliminated entirely’.

‘These savings easily compensate for the small extra expenditure on materials’.

‘Our TwinBin system was well received in the market from day one, but there’s no doubt that the new racking system, based on Bosch Rexroth products, has made it even more attractive to our customers’ Clarke said.

‘And, of course, it’s solved a lot of problems for us’.

‘We no longer have to worry about deliveries and paint colours’.

‘Aluminium extrusion may seem like a very simple product but, as we’ve discovered, it’s got a lot to offer and it can provide really big benefits’.

The hard anodised profile of the PDU2 and its corrosion-resistant internal components help it survive regular cleaning

Hygiene-conscious manufacturers can now make substantial cost-savings on the labour-intensive process of conveyor belt cleaning. Primarily aimed at the food-processing sector, the Keith Handy Design’s mobile Jet System not only automates the task but also enables mesh belt conveyors of different sizes and dimensions to be served by a single unit.

This article was originally published on Engineeringtalk on 20 June 2007 at 8.00am (UK)
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This makes Jet System a highly a cost-effective investment for small manufacturers.

Providing both structural support for the machine and linear movement of the steam generation head is a HepcoMotion PDU2 Profile Driven Unit.

This robust product combines proven belt technology, advanced materials engineering and Hepco’s expertise in aluminium profile design.
Further reading

Guidance technology improved
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Backup edge trimmer guards against downtime
A purpose-built edge trimmer from HepcoMotion is protecting a major paper manufacturer against costly downtime on its automated systems

It comprises a slotted profile into which fits a drive belt and carriage.

This arrangement effectively seals the unit and creates the clean profile that proved so attractive to Keith Handy when he was specifying a linear system for Jet System.

‘I expected to design the linear system myself but PDU2 fits the bill perfectly and is available off the shelf’, Keith Handy explains.

‘It’s neat, lightweight, compact and allows the span of movement to be adjusted within a smooth profile’.

As the PDU2 is driven by a small, comparatively low-powered stepper motor its low friction characteristic was also considered to be important.

The Herculane wheels that are central to the design of the PDU2 run virtually friction free on the inside surface of the profile and also provide stable support for the carriage plate.

The Jet System uses steam as its power source for cleaning.

Steam generation has developed significantly over recent years.

It is a modern, environmentally sensitive technology that uses no chemicals and minimal water compared to conventional methods.

Furthermore, steam sanitises as it works, breaking down debris and killing bacteria on contact.

‘The hard anodised profile of the PDU2 and its corrosion-resistant internal components were important factors for these relatively hostile conditions’, Keith Handy continues.

‘And with increasing demand for power wash versions of Jet System for the US market the corrosion resistance of the PDU2 is especially important’.

Metric linear actuators are now available with two separate threaded shafts

Metric linear actuators are now available from JW Winco with two separate threaded shafts. The actuators feature guide tubes of chrome plated precision steel, with metal follower nuts and plastic end caps. The tubes are also available in stainless steel. Tubes come in a variety of diameters, and travel lengths up to 1150mm.

The actuators may be ordered with one shaft right hand thread and one shaft left hand thread, both shafts right hand thread, or both left hand thread.