American Machinist articles from May 2005

American Machinist archives from May 2005

Decreasing the fuel tax to reduce gas prices.(FROM THE EDITOR)
May 1, 2005... I find it hard to believe that U.S. Energy Secretary Sam Bodman startled a group of energy-company officials and industry representatives when he announced that high energy prices, especially for gasoline and other transportation fuels, are...

Big Three automakers also strike out with some AM readers.(WE'VE GOT MAIL)(Letter to the Editor)
May 1, 2005... Thank you for writing in your March editorial ("Big Three automakers strike out," p. 8) what I've felt for over 20 years. It appears the only way the Big Three will get the message is when they deal with the fact that may never regain the...

TIMTOS 2005 focus is the global economy.(TECHNOLOGY TRENDS)
May 1, 2005... As part of its strategy to become a forerunner in the global economy, Taiwan again hosted its biennial Taipei International Machine Tool Show (TIMTOS). The Taiwan External Trade Development Council (TAITRA) and the Taiwan Association of...

World engine plants gain global automation partner.(TECHNOLOGY TRENDS)
May 1, 2005... The "world engine" will soon be moving from the drawing board to actual production thanks to the signing of a major automotive contract. Mitsubishi Electric Automation Inc., Vernon Hills, Ill., will supply automation products, machine controls,...

Solid PCBN inserts.(CUTTING PRODUCTS)
May 1, 2005... Secomax CBN 100 and CBN 300 solid-PCBN indexable inserts have pin-lock-hole clamping and are for use with M, P, and D-style toolholders. CBN 100 is for light, continuous to moderate interrupted cuts of hardened steels, facing alloys, and...

Variable-helix endmills.(CUTTING PRODUCTS)
May 1, 2005... Tuffcut XR four and five-flute solid-carbide endmills are for heavy rough milling and finishing of almost all metals. The Altima AlTiN-coated endmills come in more than 280 variations including square-end and multiple-corner radii and stub,...

U.S. Cutting Tool Institute billings index.(CUTTING PRODUCTS)
May 1, 2005... U.S. CUTTING TOOL INSTITUTE BILLINGS INDEX Index for January '04-December '04 January $126,819,295 119.2% February $130,560,000 123.0% March $154,823,146 145.4% April $142,985,844 134.7% May ...

Grippers mount without adaptor plates.(TOOLING & WORKHOLDING)
May 1, 2005... DPD series double-wedge parallel grippers come in 12 sizes with strokes from 1/16 to 2 in. and exert grip forces ranging from 12 to 400 lb. Both DPDL long-stroke models and DPDS short-stroke models have patterns for mounting to other...

U.S. firms suffer under tax code.(GOVERNMENT MATTERS)
May 1, 2005... The United States Government is once again playing the patsy when it comes to international trade and tax issues. A recent study by Garrett Vaughn and financed by the Manufacturers Alliance/MAPI, highlights significant tax disadvantages under...

A little more conversation, a lot more action.(MACHINE OF THE MONTH)
May 1, 2005... Hurco, a well-known builder of machining centers, entered the lathe market last fall with the launch of its TM series of slant-bed lathes. The defining feature of these machines is Hurco's Max CNC control, which lets them accept both...

Electrode software.(BITS & BYTES)
May 1, 2005... Work NC-CAD Electrode software for designing, extracting, and machining EDM electrodes reportedly saves users up to 40% in preparation and cutting times. This module is part of WorkNC Version 17. The direct selection of surfaces and 2D...

Software puts shop on the fast track.(BITS & BYTES)
May 1, 2005... Stafford, U.K.-based Rail-Ability accelerates designs of vehicles that lay rails, build platforms, and keep railroads safe using SolidWorks 3D mechanical-design software. It gives the railway-maintenance-equipment maker an edge over competitors...

Maker of nondefective component not liable for machine accident.(LAW & LIABILITY)
May 1, 2005... Shannon Henry worked at a Texas-based Alcoa plant that processes raw aluminum into roll form and then paints it. Scrap aluminum produced by the process is taped onto an electrically powered scrap winder. Alcoa designed and assembled a control...

Productivity gets an extra boost: milling/drilling tools raise the bar on cutting effectiveness.(TOOLING)(Cover Story)
May 1, 2005... Plaudits from users of a series of milling and drilling tools include claims of shaft-milling times cut in half, tool lives extended 53%, machining costs down by more than two-thirds, and productivity levels up almost 100%. Such benefits result...

Labor costs need attention.(RETROSPECTIVE: 50 years ago in AMERICAN MACHINIST)
May 1, 2005... In the May 23, 1955, issue, Editor Burnham Finney pointed out that the urge to increase manufacturing efficiency should be irresistible for companies, since labor costs were on the rise and prices were tending upward. He suggested manufacturers...

Beauty is in the eye of the beholder.(RETROSPECTIVE: 50 years ago in AMERICAN MACHINIST)
May 1, 2005... That issue also reported Henry Ford II was happy to see the Detroit Free Press come back from the auto show with a piece of fabric he fancied. Ford sent it to the design department for analysis. Said the report, in effect: "The material is...

Machine tool builders are put to task.(RETROSPECTIVE: 50 years ago in AMERICAN MACHINIST)
May 1, 2005... Another May 23 item detailed a talk by Rodger J. Emmert, General Motors executive in charge of facilities and process staff, at a recent NMTBA meeting. Emmert said GM put quality at the top of its list (based on opinions gathered from a survey...

Isolating unwanted vibration: isolation systems optimize manufacturing processes.(MACHINE INSTALLATION)
May 1, 2005... Shops often overlook vibration issues when installing machine tools or equipment. However, planning for vibration control, optimally before constructing a new facility or during redesign of an existing one, can save shops a lot of money in the...

Stop babysitting high-speed machines: machine-monitoring modules make unattended high-speed machining reliable.(MACHINING CENTERS)
May 1, 2005... Unexpected factors such as centrifugal force, unbalance, vibration, thermal expansion, and more come into play when machining centers run at high speeds. Compensating for such negative affects typically requires operators plant themselves at...

No high-speed surprises: for the best results, pay attention to the details.(HIGH-SPEED MACHINING)
May 1, 2005... To realize the benefits of high-speed machining (HSM), shops must evaluate and optimize the entire production process: the machine tool, its spindle and tooling systems, and its programming software. Success, according to Steve Ortner,...

System steers shop to precise toolsetting.(CASEBOOKS)
May 1, 2005... Metaldyne's Edon, Ohio, plant manufactures automotive steering knuckles, probably one of the most complex parts on cars. These components present a machining challenge because they require milling, drilling, and boring a variety of holes and...

Laser tracking for the track.(CASEBOOKS)
May 1, 2005... Like all Formula 1 racing teams, the Renault F1 Team develops secret designs that hopefully make their car quicker than the competition. To test these designs, the team sets up cars in a wind-tunnel facility using laser-tracking systems that...

Shop evacuates molding problems.(CASEBOOKS)
May 1, 2005... The Illinois Tool Works (ITW) ITW Filtration of Lake Geneva, Wis., processes polyphenylene sulfide (PPS)-based products, has a lot of out-gassing work, and deals with hard-to-fill parts in its molding operations. To overcome these molding...

Rigid VMC.(SPOTLIGHT: EASTEC)
May 1, 2005... The Vertex 550-5X 5-axis VMC's casting provides a rigid machine structure. Its gear-drive system for A and C rotary axes deliver high-speed radial performance and overall drive-system stiffness. The A trunnion-tilt axis also has ample dual-side...

Inspect assemblies in trays.(SPOTLIGHT: EASTEC)
May 1, 2005... MarVision MS 662 measuring machines provide measurements for large precision parts, high-volume components, and assemblies in trays and pallet lots. They incorporate CCD cameras, TTL lasers, and mechanical touch-probe sensors....

Tooling tackles cast iron.(SPOTLIGHT: EASTEC)
May 1, 2005... Seco-Carboloy's range of PCBN inserts and TK grades machine cast iron materials. Among them are SecoMax CBN300 solid PCBN inserts with pin lock holes for added insert-mounting security. TK grades, such as TK1000 and TK 2000, provide...

Straight or angle grinding.(SPOTLIGHT: EASTEC)
May 1, 2005... SelectG universal grinders perform flexible, precise, small-lot work. For easy changeovers, the machines' wheelheads rotate 90[degrees] to 60[degrees], accommodating either straight or angled wheels. In addition, guides ensure positioning, and...

Software locates bottlenecks.(SPOTLIGHT: EASTEC)
May 1, 2005... Proficy Machine Tool Efficiency (MTE) shop floor intelligence software collects real-time availability, performance, and quality data from machine tools and production systems so companies can understand their shop floors and identify losses in...

Router for batch machining.(SPOTLIGHT: EASTEC)
May 1, 2005... The EcoRaptor router's 40x27.5x9.5-in. work envelope accommodates nested (batch) machining and low-quantity runs of panels, extrusions, electromechanical parts, and aerospace profiles. It comes with a 600-W, 60,000-rpm spindle; 10-tool...

Bandsaws.(SPOTLIGHT: EASTEC)
May 1, 2005... Cosen Saw offers bandsaws with capacities from 8 to 80 in. It manufactures the machines to exact specifications using major namebrand components. Booth 1335 Cosen Saw USA Charlotte cosen.com

Flexible borescopes.(SPOTLIGHT: EASTEC)
May 1, 2005... Hawkeye Blue flexible borescopes come in 0.098425, 0.15748, and 0.23622-in. (2.5, 4, and 6-ram) diameters for looking inside castings, tube assemblies, and welded joints in bent tubes. Additional applications include automotive and diesel-parts...

Large-volume measuring.(SPOTLIGHT: EASTEC)
May 1, 2005... SmartScope Flash 500 metrology systems provide 19.69x17.72x7.87-in. (500x450x200-mm) XYZ travel. Optical assemblies move in the X-axes across angled steel cross beams while parts move in Y-axes on precision servo-driven stages. Both use...

Ballnose-tooling options.(SPOTLIGHT: EASTEC)
May 1, 2005... BallPlus ballnose milling systems reportedly have improved clamping mechanisms and offer more application options. They include cylindrical and conical shanks and five milling inserts. Each shank carries different milling inserts. Clamping and...

No-slip grooving inserts.(SPOTLIGHT: EASTEC)
May 1, 2005... Dovetail clamping systems of Groove 'N Turn inserts prevent slippage or rotation during axial or radial cuts. Built-in stops also prevent movement in pockets during cuts. Available single or double-ended, the inserts come in two submicron-grain...

Portable pump/separator.(SPOTLIGHT: EASTEC)
May 1, 2005... Portable Model #315 pump/separators remove tramp oil and floating chips from coolant for up to 10 machine tool sumps, some as large as 400 gallon. These separators use permanent-oil separation elements plus high-capacity bag filters for...

Grinder with wear-free guideways.(SPOTLIGHT: EASTEC)
May 1, 2005... As an important feature of the Magerle MFP 50 grinder, hydrostatic wrap-around guideways used in the Y-axis are reportedly wear-free and offer rigidity and load capacity, dampen vibration, and provide maximum precision and process reliability....

Rotary-screw compressors.(SPOTLIGHT: EASTEC)
May 1, 2005... A S-T series rotary-screw compressors come in 20 and 25-hp models that feature integral refrigerated dryers and condensate drains. These units also include Kaeser's "split cooling air flow" to improve cooling, reduce noise, and deliver 59 to...

Toolholders dampen vibration.(SPOTLIGHT: EASTEC)
May 1, 2005... Sino-T toolholding systems reportedly provide reliable tool clamping, vibration dampening, and run-out accuracy of 5 [micro]. They incorporate stiff bodies as clamping mediums to provide consistent support across clamping zones. Standard...

HMC provides generous travels.(SPOTLIGHT: EASTEC)
May 1, 2005... EC-300 HMCs sport 20x 18x14-in. travels, twin pallet changers, and built-in tombstone-indexing capabilities. These machines also feature 8,000-rpm, 40-taper spindles with inline, direct-drive systems that attach to the spindles. Haas reports...

EDM hinges on accuracy.(SPOTLIGHT: EASTEC)
May 1, 2005... Accuracy is key in the design of the Robofil 2050TW wire EDM. The machine is thermostablized, and precision glass scales measure down to 0.0019685-in. (0.05 mm) increments. The 2050TW uses two wire spools handling 0.0008 (0.02 mm) to...

Indexer control.(SPOTLIGHT: EASTEC)
May 1, 2005... The all-digital servo control of the 5C indexer features a four-line LCD that lets users view and edit program information. The control stores up to 50 programs with as many as 1,000 steps in each program and indexes at 360[degrees]/sec....

Software interprets 3D shapes.(SPOTLIGHT: EASTEC)
May 1, 2005... Mastercam Art software add-on uses 3D shapes from 2D art. Fast and easy-to-use toolpaths cut artistic and finely detailed surfaces. Additional tools let users perform easy and quick changes, edit, or revert to a previous design. Fully developed...

Module generates machining offsets.(SPOTLIGHT: EASTEC)
May 1, 2005... The GibbsCAM TMS module option targets programming multiple parts fixtured on tombstones. After users orient and position parts on the workholders, the module automatically generates offsets and rotations for optimum machining. Then, the...

Software enhances productivity.(SPOTLIGHT: EASTEC)
May 1, 2005... ShopMill Version 6.4 software has easy, step-by-step, onscreen programming that reportedly reduces programming, tooling, and production times. It works with Siemens' Sinumerik 810D or 840D CNCs running Windows XP. Additional software features...

Parting and grooving tools.(SPOTLIGHT: EASTEC)
May 1, 2005... Combinations of CoroTurn SL adapters and CoroCut SL cutting blades tackle parting and grooving operations. The adapters feature serrated interfaces that combine with different cutting blades. Reportedly, the interfaces control vibration and...

Stable VMC.(SPOTLIGHT: EASTEC)
May 1, 2005... Revo 4020 VMCs feature highly rigid structures with boxed columns for stable precision. Accurate 10,000-rpm spindles are standard for high-speed milling, drilling, and rigid tapping. Machine travels are 40.2x20.1x20.1 in. with rapid traverses...

High-speed machining center.(SPOTLIGHT: EASTEC)
May 1, 2005... The new design of the HSM 400U five-axis high-speed machining center's rotational axes reportedly allows speeds up to 25x faster than conventional rotary tables. The rotation axis goes up to 250 rpm and the swivel axis to 150 rpm with a swivel...

Handling chuck-wrench safety.(PRACTICAL IDEAS)
May 1, 2005... My special chuck-wrench design, incorporating a spring-loaded ejector pin, prevents accidents caused by leaving the wrench in lathe chucks. To accommodate the ejector pin and spring, I drill through and counter bore the center of the wrench....

Drilling table for milling machines.(PRACTICAL IDEAS)
May 1, 2005... A steel plate measuring 3/8 x 18 x 18 in. with a 1 1/4-in. square bar 8-in. long welded to its back and held in a vise works well as a drill table. For any vertical milling machine, this setup provides drilling with more reach and eliminates...

2005 cutting tool charts: find the right cutting tool for milling and turning applications with the most comprehensive, up-to-date data.
May 1, 2005... With the launch of its new website in June, AMERICAN MACHINIST will introduce an interactive version of its industry-specific Cutting Tool Charts. These charts, compiled using information from cutting tool suppliers, focus on milling and...

Manufacturers' directory.(Directory)
May 1, 2005... To help you contact key material handling manufacturers quickly, the following Manufacturers' Directory also contains complete telephone numbers of the main offices. Listings in boldface type indicate the advertisers in this edition. A ...

Products & services directory.(Directory)
May 1, 2005... Here, in alphabetical order, are suppliers of the products, services, and systems. Companies listed in boldface also have an advertisement in this issue. Blue listings were purchased. Check the Advertisers Index for correct page number. ...