NCMT to show expanded product range

Two further new agency lines will be in evidence on stand 5229. Italian tool presetters produced by Speroni, Italy, will be on display as well as MetalMAX vibration analysis, which helps to prevent machine tool chatter by avoiding natural frequencies when machining any material. In the case of light alloys, it can push productivity and quality to the boundaries of what is currently available.

In addition, there will be the BIG Daishowa range of high quality Japanese toolholders and cutting tools. New items will include a tapping tool holder that compensates for synchronisation errors; and a modular end mill that offers the economy of interchangeable, indexable-insert front ends with eccentric relief normally found on solid carbide cutters.

The XEBEC range of high-precision, abrasive deburring tools made from aluminium oxide, including two new products, will also be exhibited.

Okamoto IGM-15NC2 grinder

Okamoto's new IGM-15NC2 twin-spindle CNC internal grinder provides versatility, productivity and precision. The benefits of incorporating two spindles on the same machine are numerous. Elimination of multiple chucking not only simplifies set-up and boosts productivity, but also optimises dimensional accuracies.

For example, a workpiece that requires an ID, OD and face grind normally requires the use of two separate grinders. Since no two machines are identical and the workpiece has to be re-chucked, the relative accuracies of the features are lost. This is not the case with the IGM-15NC2 because the workpiece stays fixtured and the spindles needed for the multiple grinds are on the high-precision wheelhead.

Specification includes an ID grinding capacity of 6 mm to 100 mm, maximum grinding stroke of 80 mm and swing over table of 600 mm. Maximum longitudinal travel is 500 mm, while feed rate is up to 10 metres per minute.

The Fanuc 18i-TA 2-axis control with conversational programming has a ‘teach input’ format that reduces the time needed for programming and allows easy operation. The automatic grinding cycle can be interrupted at any time to re-dress the wheel. A feed-hold function allows cycle stop for verification of location and dimensions.

The table rides on high precision linear guideways and is driven by an AC servo motor that enables minimum feed increments as fine as 0.25 micron. Both high-frequency, inverter-controlled spindles have 10,000 and 20,000 rpm speeds as standard. Any combination of 10,000, 15,000, 20,000, 30,000, 40,000 and 60,000 rpm is available as an option. Two-point diamond dressing of the ODs and faces of the grinding wheels is provided.

The workhead, which swivels from -5 to +15 degrees, features cast iron construction and utilises high-precision, double angular contact bearings. Workhead speed, infinitely variable from 100 to 850 rpm, is programmable through the CNC.

Optional accessories include coolant systems with paper filter, magnetic separator, coolant temperature regulator, a variety of chucks and in-process gauging.

Okamoto UPZ-210Li surface grinder

Described as a new style of profile grinder, the UPZ-210Li is a counterpart to optical profile grinding machines, but differs in that it allows the use of coolant. The machine is designed for grinding small, accurate components like mould inserts and high-speed punches for producing integrated circuit contacts. The grinding head can be swivelled ±5 degrees, allowing high precision grinding of vertical-shoulder parts, which was very difficult in the past.

Instead of being hydraulically actuated, the table is driven by two linear motors which are temperature controlled within 0.1°C, achieving up to 300 reciprocations/minute (20 mm table stroke). The high stroke count prevents heat build-up, minimises wheel wear and gives the machine greater accuracy than high rpm systems that remove larger amounts of material with every pass.

An internal, 100X–1,000X CCD camera enables profile measurement and automatic compensation for grinding error. A CAD image can be overlaid on the part to compare dimensional data. This avoids having to remove the workpiece for off-line inspection, as reinserting it can affect wheel and part alignment and compromise grinding accuracy. Reduced part handling also speeds the process.

Speroni MAGIS 400 bench-top tool presetter

This will be the first time that NCMT will have exhibited Speroni tool presetters, having gained the agency only last year. One of the latest models to be introduced is the bench-top model, MAGIS 400. The ergonomically designed system has an integrated calibration master, pneumatic axis locks, X- and Z- axis fine adjustment, a CCD camera and an integral ISO 50 taper spindle. The single-screen control has an optional touch screen to increase the speed of tool measurement.

The machine has a standard X-axis range of 50 to 350 mm and is available in three column sizes with either a 400, 500 or 600 mm travel in the Z-axis. The unit comes as standard with a pneumatic spindle brake that allows the operator to lock the spindle at any point in the 360-degree rotation, guaranteeing correct, stable positioning of the tool prior to measurement and/or presetting.

MAGIS 400 is supplied with an episcopic front ring light system that provides a light source for manual inspection of the tool tip / insert on the screen. A variable adjustment knob facilitates inspection of different types of coated inserts.

Speroni ESPERIA STP44 tool presetter

New also is the ESPERIA STP44 tool presetter, which is of rigid construction for shop floor use. It incorporates a novel taper adaptor and a claw system that accommodates all pull stud designs, allowing changeover for setting the next tool in just eight seconds. Repeatability of positioning is to within half a micron.

As with all Speroni tool presetters, the thermo-balanced structure is made of artificially aged, pearlitic cast iron to ensure the equipment is fully isostatic and will not deform or distort over time or as the temperature changes.

Unlike most presetter designs, the homogeneous structure avoids the drawbacks of systems that use light alloys and/or granite, which have different and unstable reactions to changes in temperature and the environment. There is consequently no need for frequent recalibrations during a shift due to temperature changes.

Both hardware and software are developed and produced in-house by Speroni, whilst peripheral equipment is sourced from the very best suppliers – Schneeberger linear guideways, Heidenhain encoders, Sony camera, etc.

MetalMax vibration analysis

The exclusive UK distributorship for Manufacturing Laboratories Inc’s MetalMAX and Harmonizer diagnostic products, which analyse machine vibration on the shop floor, was awarded to NCMT last year. MACH 2010 will mark the equipment’s first showing in the UK at a national exhibition. The so-called ‘tap testing’ equipment is especially suited to supporting applications engineering and programming when machining titanium and other superalloys.

The patented technologies dramatically increase productivity and reduce tooling costs by identifying for each machining application the spindle speed, feed rate and depth of cut that will maximise metal removal rate, while maintaining accuracy and surface finish. It does this by avoiding vibration and chatter through correct selection of machining parameters so that each unique combination of machine structure, spindle, toolholder and cutter does not resonate at its natural harmonic frequencies.

A ‘tap test’ taking two to four minutes is performed using a hammer to strike the tool, clamped workpiece and any other machine element, either static or moving. Precision vibration sensors and specially developed TXF softw