THIS WEEK IN MACHINERY: Hobbing, Hybrid Multitasking, Deep Hole Drilling and More

New products from Gleason, Mazak, Methods Machine Tools, Okuma and UNISIG.

Gleason Horizontal Hobbing Machines

(Image courtesy of Gleason.)

(Image courtesy of Gleason.)

Gleason Corporation has introduced the P90CD and P90iC horizontal hobbing machines.

Based on the P90 hobbing machine, the new P90CD hobbing machine with integrated chamfering/deburring module has been designed for disc-type workpieces, like automotive pinions and short shafts.

The P90CD features an integrated CNC chamfering/deburring station which works in parallel to the cutting process. The P90CD can hob parts up to a diameter of 60 mm and module 3 mm; larger diameters are available on request. Cycle times are as short as 10 seconds for planetary pinions. The chamfering/deburring station includes an auto-meshing feature which avoids tooth-on-tooth cut workpieces and chamfering tools for consistent cycle times and to avoid damage to workpieces.

The new P90iC hobbing machine with integrated chamfering/deburring Unit was specifically designed for the hobbing and quality chamfering/deburring of geared shafts, but can be used for disc-type workpieces as well.

The P90iC features an integrated chamfering/deburring unit which eliminates burrs and creates even and precise chamfers. The P90iC handles any workpiece up to a diameter of 100 mm and module 3 mm; larger diameters and modules are available on request.

The P90iC can be used for one or two-cut processes for finish hobbing or to create a quality base for subsequent hard-finishing operations.  The two-cut process in particular is executed in a single setup (cutting-chamfering/deburring-cutting) and eliminates secondary burrs and residue on the gear flanks. This process is designed to aid subsequent hard-finishing processes, protecting the tool life of finishing and dressing tools, especially if a honing process is applied.

Direct-driven hob head options are available for both machines.

For more information, visit the Gleason website.

Mazak Hybrid Multitasking Machine

(Image courtesy of Mazak.)

(Image courtesy of Mazak.)

The new Mazak VC-500 AM hybrid multi-tasking machine combines full 5-axis capability and additive technology. This new machine will make its world debut at IMTS 2016. The VC-500 AM brings together Mazak’s multi-tasking machine experience with fiber laser technology, additive knowledge and Kentucky Mazak iSMART Factory manufacturing operations.

Designed for manufacturers who require optimum part finish and high accuracy, the VC-500 AM machine builds part features to near net shape up to ten times faster than other comparable systems without wasting expensive material and losing time by subtracting large amounts of metal from a solid material using normal multitasking machining technology.

Constructed on a 5-axis platform, the new VC-500 AM accommodates a wide range of part sizes and shapes, making it suitable for educational institutions and research and development facilities as well. The VC-500 AM can machine parts up to 19.7″ in diameter, 12″ in height and up to 440 lbs. The additive cladding head can work in the same machining area, depending on the application and location of the features of the part.

The new VC-500 AM offers users geometric freedom vis a vis direct metal deposition, which allows for both additive and subtractive machining capabilities in a single setup. The laser cladding heads of the VC-500 AM reside side-by-side with the subtractive machining spindle.

During operation, the VC-500 AM uses fiber laser heat to melt the chosen metal powder that will be used to the grow near-net-shape 3D forms. The cladding head applies the molten material layer by layer, all of which solidify as the desired part surface or features grows. The laser cladding head can also be used to coat chosen sections of the part with metal, allowing the machine to repair worn or damaged high-value components.

Part of the company’s SMOOTH TECHNOLOGY platform, the Mazak MAZATROL SmoothX CNC allows operators to generate programs for highly complex parts production. It has several advanced functions that are designed to ensure the shortest possible machining cycle times, especially in fine increment programs for simultaneous 5-axis operations and free-form die-mold machining.

Ergonomics also play an important role in the functionality of the MAZATROL SmoothX CNC. A large 19″ display presents all of the critical machine data within a single page view, while the tilt control panel allows for optimum positioning based on operator height. An SD card allows the CNC to store up to 32GB of data.

For more information, visit the Mazak website.

Methods Machine Tools Vertical Machining Center

(Image courtesy of Methods Machine Tools.)

(Image courtesy of Methods Machine Tools.)

Methods Machine Tools, Inc. has expanded its FEELER line to include the FEELER HV-1100V, a high performance vertical machining center.

The newest of the FEELER HV line, the HV-1100V features a dedicated trunnion, 4+1 axis configuration and a 13.8” (350 mm) rotary table. The trunnion is solidly built Autocam with roller cam technology, and offers a 16” (406 mm) by 14” (356 mm) work envelope. The tilting A-axis has a full +/- 120 degree of motion.

The FEELER HV-1100V’s reinforced cross-ribbed column structure and no counter-balance weight design is designed to improve torsional torque resistance and reduce low frequency resonance for optimal stability. This design is intended to reduce peck-drilling vibration and prevent oscillation normally caused by a counter-balance weight. The new FEELER design also improves movement stability on the Z-axis and delivers 30 percent increased rigidity.

The FEELER HV-1100V offers an X-Axis travel of 33.5″ (850 mm), a Y-Axis travel of 19.3” (490 mm) and a Z-Axis travel of 20.7″ (5250 mm).  Speed vibration control is ensured by a high-rigidity spindle that increases metal removal rates by over 30 percent and improves machining accuracy and tool life. A maximum spindle speed of 12,000 RPM on 30 HP direct drive, 40 taper spindle is standard.

The HV-1100V also features a 30 tool magazine swing arm, and an automatic tool changer with a tool-to-tool time of 1 second/60Hz. A fast chip removing system with chip conveyor, automatic lubrication system, dust-proof electrical cabinet and Methods’ safety package are all standard on the HV-1100V. A FANUC 0iMFControl with 4th Axis prep and a 10.4” color LCD is also standard and available in a swiveling control box for ergonomics and convenience.

For more information, visit the Methods Machine Tools website.

Okuma Horizontal Lathe

(Image courtesy of Okuma.)

(Image courtesy of Okuma.)

The LB3000 EX-II is Okuma’s premier 1-saddle lathe. It’s available with milling function and Y-axis capabilities and features an optional extended bed length that is 30 percent longer on the L, M and MY models.

The LB-EX platform is designed for speed, accuracy and reliability which enable a variety of configurations and allows the machine to be used for many industries, including oil and gas. AT IMTS 2016, this machine will be shown cutting a gear ring.

Built with Okuma’s box slant-bed design, the LB provides rigidity and thermal stability, which are especially important when used in facilities with uncontrolled environmental conditions.

This 2-axis CNC lathe is the largest horizontal lathe in Okuma’s Affordable Excellence collection of machines and is equipped with Okuma’s high-power, high-torque PREX motor, delivering machining for heavy to high-speed cutting.

This machine provides the capacity to turn and mill pipe-type products with a through-hole diameter that can accommodate larger work pieces. It’s also available in two bed lengths. The spindle design allows flexibility of feeds and speeds to cut workpieces of a variety of materials and yields excellent surface finish and impressive metal removal rates.

For more information, visit the Okuma website.

UNISIG Deep Hole Drilling

(Image courtesy of UNISIG.)

(Image courtesy of UNISIG.)

At IMTS 2016, UNISIG will display its line of deep hole drilling solutions. Experts will be on hand to consult with attendees on how best to incorporate deep hole drilling into their operations. UNISIG will highlight two of its systems: a high-performance gundrilling machine and an automation-ready rifling machine, as well as examples of complex deep hole drilled workpieces.

UNISIG’s UNE 12-2 gundrilling machine is designed to help any shop bring in gundrilling processes with a low overall investment. It features components and engineering to deliver more exact gundrilled holes at an increased rate than machines retrofitted to perform gundrilling operations.

The UNE 12-2 is rated to gundrill diameters measuring up to 0.50 inches and depths up to 30 inches. Its vector-driven variable speed spindles rotate at rates that reach 12,000 rpm. UNE machines’ modular design allows for express delivery of a variety of machine configurations for the rapid addition of deep hole drilling to a manufacturer’s production line.

The R-2A rifling machine will also be on display. It is used for the final process of rifle barrel blank manufacturing and completes a rifle cell. With a servo-motor-driven headstock and glass scale, the R-2A machine provides control over the barrel blank manufacturing process and manufactures calibers ranging from .17 to .50.

Workpieces requiring a wide range of deep hole drilling applications will also be on hand, showcasing what is possible with a variety of deep hole drilling methods and equipment.

These will include a complex mold base that was manufactured with a combination of deep hole drilling and machining processes that significantly reduced the number of setups. An additional display will include a variety of workpieces with on- and off-center deep holes.

For more information, visit the UNISIG website.

Follow @ENGcom_machine on Twitter.