What We Learned at Westec 2017

Grob’s G550 HMC has a uniquely configured one-sided trunnion that can present the workpiece to a conical ball mill so that the tapered side of this type of cutting tool does the metal removal. The advantage is a smooth surface finish accomplished with large stepovers for productivity. Table tilt (the rotary A axis) provides maneuverability to avoid excess tool length and its effect on tool rigidity. In this case, the tool paths can be complicated--this demo was programmed in five axes with HyperMill from Open Mind Technologies.

Emag is thinking about “E-mobility,” a new term for the trend to electrically powered vehicles. The company was showing an electro-chemical machining (ECM) process for this internal gear, a critical part for power transmission in electric motor applications.

ECM poses many variables that must be precisely controlled, but advantages include flexibility, high precision and a machine with a relatively small footprint.

FlexArm showed its FlexArm tapping units, but the big news is that the company is introducing FlexDrill CNC machines. These are high-speed drilling, milling and tapping machines with either a bridge-type or cantilever-type spindle carrier. The TRD series is designed for a long, narrow bed (10 to 35 feet in the X axis, 2 feet in the Y axis), while the GRD series is designed for a long, wide bed (10 to 30 feet in the X axis, 4 to 6 feet in the Y axis). Both series can be equipped with a three-jaw spindle unit and matching tailstock that enables these machines to process pipe and shafts.

Traditionally, Westec has been a good place to see abrasive waterjet machines, one of the best represented class of machines at this show. Omax used the opportunity to announce its new GlobalMax Jet Machining Centers designed to enable companies to add basic waterjet cutting capabilities. Calling them entry-level might be unfair, given the accuracy and capability of the models. However, ease of operation and affordability are said to be the key characteristics that make these machines attractive to shops around the country and around the world that are new to waterjet cutting.

Making a lot of chips? That’s a good sign. Here’s one way to process them to get the most from recyclers: briquette them. Ruf Briquetting Systems makes equipment that squeezes out reusable coolant and compacts loose chips into briquettes in various sizes and shapes as shown here.

Here’s a nifty way to blow chips and coolant out of workpieces in the machine. It’s a chip and coolant fan from BIG Kaiser. Mountable in a collet chuck and tool holder, the chip fan goes into the machine spindle for a chip and coolant clearing operation. The fan is coolant fed to blast out chips with high-pressure fluid, then spins to blast out any remaining coolant with a strong gust of air from the fan blades.

BIG Kaiser is also a big fan of its Speroni tool setters and inspection machines, such as this Magis 500, shown here checking one of the company’s precision boring heads.

This tombstone for an HMC features cable-free operation of its programmable rotary-axis units for five-axis and 3+2 machining. The version with four units on one side of the tombstone demonstrated independent control of each unit. From KME CNC, the tombstone’s servo-driven rotary units are powered by a rechargeable power cell that rides on top of the tombstone. Wireless communication with the machine’s control unit is based on radio frequency technology to avoid interference from electrical noise in a shop environment. Without wires or cables, the tombstone is free to shuttle in and out on a pallet system.

Invented by a job shop, the Shop Mule from Abacorp is designed to transport stackable plastic tote bins holding workpieces, fixture items and a drop-in tray for cutting tool assemblies. The idea is to delivery everything needed to get a job running and reduce setup time. The cart is narrow so it can maneuver crowded shop aisles or be parked between machines.

Haimer’s Uno 20140 Microset tool presetter helps the user find and focus on the desired cutting edge. The red dots projected by the laser on the tool make it quick and easy to position the optics manually, the company says. Although this model is manually operated, Haimer’s range of presetters also includes fully automatic models.

GibbsCAM 12 from 3D Systems features a new user interface with a flexible, customizable toolbar. The developers say the intent is to streamline programming workflow by making each step intuitive and convenient, which aids both veteran and occasional users. Enhancements to functionality of the CAM software include VoluTurn for applying constant chip load tool paths to turning operations, faster definition of multiple part setups, and easier five-axis machining with clearance checking and collision avoidance.

Connecting machine tools to a computer network for data collection and analysis is the first step to harnessing the power of the Industrial Internet of Things (IIoT). Memex displayed its options for making the hookups to late-model and legacy machines. The Ax760 MTC (lower left in the picture) plugs into the I/O board of legacy machines for MTConnect compatibility. The DNC Adapter (lower right) provides an interface for downloading NC programs to machines with Ethernet, RS-232C or tape readers. Adding communication ports to a control is accomplished with the add-on unit at the top left. The MTC-One (top right) is the company’s newest and most powerful connectivity board. Its Arm Som microprocessor is capable of running Linux, MTConnect adapters, agents and other IIoT software such as Complex Event Processing (CEP) as well as other applications that might be needed to connect to and process data from devices.

In-house drill and tool sharpening can be as automated and productive as you want it to be, says Darex. The XPS-16+ is the company’s four-axis CNC drill grinder and sharpener. The user selects the point style and other variables at the touchscreen panel and the unit is designed to do the rest automatically.

BeAM highlighted its laser metal deposition (LMD) additive manufacturing technology in Autodesk's booth as the result of a partnership between the two companies. BeAM says its machines (which offer build volumes ranging to 1,200 by 800 by 800 mm) are the first to enable full five-axis simultaneous deposition, made possible through the use of PowerMill for programming.

Datron Dynamics' Neo high-speed mill is a compact machine designed for creating precision models, prototypes and metal parts in an office setting to accelerate the engineering workflow. If it looks a bit like a 3D printer, that's intentional—the machine’s small size, multifunction touchscreen and Next software with an app-like interface are intended to appeal to machining beginners.

On-demand manufacturer Proto Labs unveiled a new digital-inspection option made possible through its recently opened metrology lab, whereby part scans are compared to CAD data to generate a color map such as the one seen here. Coupled with this capability is an emphasis on “lean tolerancing”; critical dimensions are limited to 12, to encourage customers to use precise dimensions only where necessary.

Additive manufacturing (AM) equipment had a noticeable presence at this year's Westec, including the RenAM 500 metal 3D printer from Renishaw. Coupled with the company's QuantAM build preparation software and inspection technology, the machine forms part of a complete production system for manufacturing end-use parts in stainless steel, aluminum, cobalt chrome and other metals.

While many exhibitors were touting new machining technologies, TCI Precision Metals emphasized how a simple change from stock material to precision blanks could dramatically improve throughput for production machining. Starting from a near-net-shape blank (center) rather than stock allows shops to skip straight to high-value machining and can improve productivity by as much as 25 percent, the company says.

Ultimaker, a company that got its start selling DIY 3D printer kits, now sees its future in industrial applications including fixturing and end-use parts—hence its presence at Westec. The Ultimaker 3 extrudes two filaments at once (one of which can be a water-soluble support material) and features a built-in camera and Wi-Fi connectivity.