DEEP HOLE DRILLING INSERTS,LATHE MACHINE CUTTING TOOLS,CARBIDE INSERTS

DEEP HOLE DRILLING INSERTS,LATHE MACHINE CUTTING TOOLS,CARBIDE INSERTS,We offer round, square, radius, and diamond shaped carbide inserts and cutters.

Sandvik

Toolholder with Single Base Holder and Adapters with ER Collect Pocket

The Preci-Flex tooling system is designed to be a fast, accurate and cost-effective solution for turning machine tooling change-overs. According to the company, the modular system is the first tooling system on the market with a single-base holder and multiple tooling adapters that use the ER collet pocket. The system’s conical and flat face planar interface allows the use of either an adapter or a standard ER collet and enables collets, endmill holders, expanding collet chucks and shrink fit tooling to be mounted on a single-base holder.

Available in a range of sizes, the tooling system provides unsurpassed productivity and reliability, RCMX Insert with every toolholder offering repeatability within 5 microns, the company says. The system CCGT Insert also virtually eliminates machine downtime and allows tooling adapters to be interchanged between fixed and rotary base holders for fast, economical machining.

EXSYS Tool Inc.


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Opening Our Doors for Manufacturing Day

Earlier this month, we hosted nearly 80 students from two local high schools for Manufacturing Day. Held on the first Friday in October, Manufacturing Day allows students to see first-hand the reality of modern-day Coated Inserts manufacturing careers.

After an introduction to BIG KAISER and short video explaining the differences of modern-day manufacturing and manufacturing of years past, students were divided into groups for more in-depth discussions on tooling, workholding, tool measuring systems and the repair room.

The tooling station highlighted the variety of tool holders, boring tools, cutting tools and angle heads BIG KAISER offers. Students learned the importance of each product, as well as when each is appropriate to be used.

The importance of proper workholding the methods to stabilize a workpiece and the workholding products to do so were shared with the students. Different types of chucks and a demonstration of clamping knobs and pallets and their significance in multi-axis systems rounded out the discussion.
Milling inserts
During the discussion on measuring instruments, students learned that tool presetters are invaluable for keeping the machine running and increasing tool life while obtaining precise and repeatable measurements. A few students had the opportunity to try to make an adjustment on a SPERONI ESSENTIA.

In the repair room, students got to see a completely disassembled angle head and learned the culprit for most angle head repairs is coolant-related. Our repair technicians shared the process for cleaning, reassembling and testing the angle head before being returned to the customer.

Finally, to test the students’ knowledge of their visit to BIG KAISER, they participated in a rousing game of Kahoot! Prizes were awarded to the winners.

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The Carbide Inserts Blog: https://andyclaren.exblog.jp/

Desktop 3D Scanner Captures Part Shapes

NextEngine’s desktop scanning unit is about the size of a cereal box. It controls the AutoPositioner roundtable to automate part indexing for scanning multiple views.

From points to part: the left photo shows a part to be scanned. The middle image shows a 3D mesh model generated from multiple scans aligned and blended in the system’s basic software. The right image shows the geometry as fully rendered in 3D CAD with parametric information.

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Scan it. Cut it. That’s the approach many shops would like to take. A new desktop laser scanning system promises to make that a practical reality at low cost. The system allows 3D objects to be digitized so that surface data can be used to create part geometry for toolpath generation. The NextEngine Desktop 3D Scanner from NextEngine Inc. (Santa Monica, California) uses a set of laser “eyes,” digital camera technology and image sensors to capture scan data from multiple, triangulated views. The system’s special software assembles and manipulates the data to create a 3D model suitable for use in a CAM system.

Scanning systems for reverse engineering have been available for years. What sets this new system apart from existing systems is that it is priced and packaged like a consumer electronics product. The hardware consists of a scanning unit (about the size of a cereal box) and a turntable that automates part positioning for scanning. The user interface software, ScanStudio Core, operates the scanner and the turntable. It is priced at $2,495. Two software options, ScanStudio Pro and RapidWorks, provide further capabilities and are priced in the same range.

For the machine shop, desktop scanning is a benefit when the machining process starts with a part—a prototype, a pattern, a model or a free-form “organic” shape carved in the studio or found in nature. CNC machines are designed to produce parts as the end product. The physical object cut from metal is the output. But CNC machines also require input, the numerical part program that gives the proper commands. Digital laser scanning helps bridge the gap from “start part” to end part by providing the “art” (shape geometry) in the middle. According to developers, the desktop scanner makes 3D scanning technology available to virtually any machine shop.

The scanning unit uses arrays of low-power lasers that sweep across an object while 3-megapixel cameras capture scanned data. Multiple sweeps and multiple positionings of the object are usually required to gather a complete 3D scan. The various passes can be displayed and merged in the PC software. Objects with matte white surfaces are easiest to scan; objects with shiny black surfaces are more difficult. The latter may require a powder dusting to reduce reflectiveness.

Objects the size of a soda can or smaller can be scanned in the “macro Surface Milling Inserts mode,” while objects as large as a shoebox can be scanned in the “wide mode.” The roundtable can be used to index smaller objects automatically for multiple scans. Large objects may have to be repositioned by hand. Developers say that, theoretically, there is no limit to the size of the object because any number of scans can be stitched together. Parts fitting within the "wide mode" can be scanned and aligned with one click. Scans from larger parts are semi-automatically aligned with “virtual beads” that the software can use to locate and connect common points in the scanned data for merging. Regardless of the merging process, blending and trimming overlaps is automated, thus speeding what might otherwise be a tedious process.

Scan data can be used to create file formats in three categories—mesh, surface and solid—that WNMG Insert correspond to the level of software acquired by the user. For example, the standard software that comes with the system is adequate for STL formats that can be exported to a CAM system for basic machining. Most shops will be interested in the surface or solid file capabilities because they provide geometry comparable to the models shops often use as input to CAM.


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Using Cameras to Align Tools and Spindles on Swiss

Misalignment can cause machining misfires. For Swiss-type lathes, it is important that tools on the gang slide are aligned with the main spindle’s centerline and backworking tools are aligned with the subspindle’s centerline to ensure accuracy and prevent breakage of tools such as small boring bars. Similarly, the main and subspindle centerlines must be aligned with each other for accurate part pickoff operations.

Ben York, president of Swiss Turn Solutions, a consulting company that offers the Theory 168 line of machine tool accessories, says a common way to check alignment is to use interapid- or coaxial-type dial indicators installed in spindles. For example, installing an indicator in a subspindle to probe a rotating turned bar in the main spindle is one way to align both spindles with each other. However, Mr. York explains that there can be issues using these devices to perform such alignments. In some cases, he says an indicator simply might not fit in a Swiss-type’s VBMT Insert guide bushing or general workzone. If it does fit, the distance that the indicator sticks out of the spindle typically causes alignment error. Plus, a transfer measurement from the main spindle to the subspindle to the tools is typically required for aligning tools with the main spindle, which can lead to error stacking.

Mr. York says his company developed a non-contact camera system that offers a more precise and repeatable way to determine not only the current state of spindle and tool alignment, but also the amount of misalignment to correct it. The Perfect Zero Swiss system uses cameras that are installed in the main and subspindles to enable the user to view tools under magnification to determine their actual position when they are moved to the theoretical spindle centerline position. The system’s Carbide Turning Inserts software then determines how much the tool must be moved to bring it to the actual centerline position.

To perform tool alignment with the main spindle, the user installs an 50× magnification camera in the guide bushing and plugs the camera into the system’s dedicated computer with Perfect Zero software via a USB port. A 5-minute calibration cycle that uses a supplied target as a reference point enables the software to determine and record the location of the spindle centerline. Next, each tool is driven to the spindle centerline and a magnified image of the tool is shown on the computer screen. Crosshairs on the screen represent the spindle centerline, and the distance that the tool center point (for drills) or insert edge (for boring bars) is away from the centerline can be seen. The gang slide is then manually moved to align the tool with the spindle centerline. The software, in combination with machine position, calculates the difference, which the user inputs into the control.

Guide-bushing cameras are available in diameters as small as 10 mm. A more general shank-type camera can be installed in a subspindle to perform similar alignment of backworking tools to the subspindle centerline as well as aligning main and subspindle centerlines. The latter is important to ensure proper subspindle part pickoff from the main spindle for subsequent backworking operations. Mr. York cites a shop that was experiencing a problem with small parts being scratched when the subspindle picked them off the main spindle. This shop tried using a dial indicator installed in the main spindle, but the device could not align the spindles as accurately as needed. However, a Perfect Zero camera installed in the guide bushing could be positioned 0.1 inch away from a target installed in the subspindle (essentially where the part would be picked) and proper alignment was attained.

Mr. York says the system is valuable even for very accurate Swiss-types as it can detect positioning error because of tool runout or variability when small tools are installed in collet-style toolholders. It achieves position repeatability of 0.0002 inch and can be used for tools as small as 0.005 inch in diameter. The system includes a guide-bushing camera, a shank-type subspindle camera, a dedicated laptop computer with Perfect Zero software, various visual calibration targets and a portable service cart. The subspindle camera is a universal model and can be used in lathes as well as mills to determine work coordinates, especially for small parts and parts made from delicate materials. It also can be used on a 3D printer to determine the position of a substrate onto which another material will be printed.


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