AS THE WORLD TURNS (Part Two)

MID-SIZED LATHE IN MULTIPLE CONFIGURATIONS
Romi Machine Tools Ltd. (Erlanger, KY), offers its C620 CNC lathes. Swing over the bed is 620 mm or 24.4 in A2-8 in spindle is standard. The C620 is designed for maximum flexibility in configuring the machine to customer needs ? offering a variety of headstocks, bed lengths, turrets, tooling and operating choices. The control is a Siemens Sinumerik 802 sl with 10.4 in LCD monitor. Both manual and hydraulic tailstocks are available.

For chucking work, customers will usually opt for the one-meter version, which offers a smaller footprint, and the two-meter bed length for shaft work. Customers requiring heavy low-end torque will want the geared headstock. Parts requiring higher rpm and better finishes will be better served with the V-belt, direct drive headstock. Both bed lengths are available with live tooling options.

The C620 can be equipped with an electrically driven disk type turret with VDI-40 tooling or a servo driven WTO tool turret allowing machining with static and live tools. A 4-station electrically driven vertical axis turret is also available, as is a 3-position quick-change toolholder. The geared headstock version can be equipped with a hydraulic indexing system with 72 positions allowing milling and drilling operations. With the direct drive headstock, an optional disc brake system allows milling and drilling operations in 360 different angular positions. Rigid tapping operations can be accomplished due to the no-play feature of the transmission.

A C620 Combination Lathe equipped with the optional Manual Machining Package offers three machining modes depending on operator skill levels:
? Manual Mode. The operator machines the part as a conventional lathe using the control apron. Parallel turning, taper turning, radius turning, drilling and grooving can all be performed in manual mode.
? Cycles Mode. This is a semi-automatic mode. The machinist fills in the conversational screens on the control for feed, speed and cycle data and approaches the part manually using the control apron. He then performs the machining cycle by pressing the cycle start button. Machining operations in this mode are drilling, tapping, grooving, cutoff, threading, and rough and finish turning.
? Teach Mode. In this mode, the operator, while machining the first part, saves the machining process step-by-step into memory. The control converts these machining processes into a program that can be run automatically on subsequent parts. Manual operations and cycles operations can be saved together into the same program and stored in the CNC memory or flash card. www.romiusa.com

ECONOMIC SWISS TURNING
Rem Sales (Windsor, CT), a division of Morris Group, Inc., is the exclusive North American importer of the full line of Tsugami Precision Swiss CNC machine tools. Two 20 mm models, the S205 and S206, are designed to provide Swiss technology users the flexibility and capability to meet a wide range of needs at an affordable price.

"This exciting 'S' platform allows our customers a full range of capabilities and enhanced productivity, which will help them differentiate from their competitors," states Scott Anthony, national sales manager of Rem Sales. "These machines are a natural evolution, as many have embraced the concept of flexibility as demonstrated by the successful introduction of the 'Super SwissTurn' SS Series a few years ago. The new S205 and S206 models feature a modular tool zone similar found in the SS Series, but offer a lighter frame and faster spindle speed, setting the bar high for the 20 mm Swiss turn market."

Both machines are suited for the production of complex parts. Live tools for cross and face operations are found on the main and sub spindle. A two-path control permits true simultaneous operation of the main and sub spindle, dramatically reducing cycle times. The modular and roomy tool zone allows driven tools to be moved from main to sub spindle and from face to cross positions with ease by the operator, minimizing down time between different jobs.

The S206 has the same capabilities of the S205 plus back-working Y axis movement. An easy-to-use Fanuc 31-iA control is standard on both models, which also can accommodate an optional "chucker kit" that allows the machine to be run as a Swiss turn or fixed headstock lathe. The fixed headstock configuration can use unground bar stock, eliminating costly bar remnants and improving part concentricity. www.remsales.com

TOOLROOM LATHES
South Bend Lathe Co. (Bellingham, WA) has 14 in x 40 in EVS Toolroom Lathes that feature a 3 V-way bed constructed of precision ground Meehanite cast iron, Allen Bradley electrical controls and Japanese-made Yaskawa inverter, and Japanese spindle bearings. A tailstock barrel moves 6 in without moving the tailstock, and an adjustable feed-rod clutch system prevents crash damage. On-the-fly feed-direction controls make it easy to move carriage back-and-forth during operation. The SB1012 features a 5 hp, 220V, 3-phase, 60 Hz motor and the SB1013 features a 5 hp, 440V, 3-phase, 60 Hz motor. Both machines carry one-year warranties. www.southbendlathe.com

SUPER PRECISION, HIGH‐PERFORMANCE
Hardinge offers the T‐42 Super‐Precision® and High‐Performance Turning Centers as replacements for the previous Conquest 42, Conquest T‐42, Quest 42 and RS Precision and Super‐Precision® machines. These new T-Series turning centers are the new benchmark in high‐precision, high‐performance turning. This new machine is designed for two-axis high-precision machining or complex multi‐tasking operations that require a high level of precision, delicate part handling and parts made complete in a single setup. High‐Performance and Super‐Precision® high productivity packages are available to choose from with features that include but are not limited to: Live Tooling with C axis, Sub Spindle, Y axis, Main Spindle Parts Catcher, and Sub Spindle Parts Catcher, designed for removing delicate high precision parts with critical surface finish requirements without damage to the part. www.hardinge.com

MULTISPINDLE PRODUCTION OPERATIONS
Multispindle Production Center
The ZPS America (Indianapolis, IN) 642 CNC multispindle production center uses a double Siemens 840 D CNV. The rigid European-built machine offers up to 72 CNC axes and can perform nearly any metal cutting operation on precision parts from drilling and tapping to milling, hobbing, spline gears and broaching. This line offers very high processing flexibility and fast changeover with the ability to drop a variety of complex precision parts complete as either a bar-fed or chucker operation. Across the spindles, a wide variety of precision metal-cutting operations can be accomplished very quickly and without handling.

The machine's flexibility is provided through its standard features: 6 independent AC-driven CNC horizontal spindles, 6 independent compound slides (X and Z), 6 independent tool carriers with driven tools, 5 backworking tools (3 driven), and a wide range of standard pre-settable VDI tooling for quick changeover to increase flexibility. Since the cutoff slide is an additional, separate slide, it reduces the backworking cycle time that is usually a limitation of multis.

The patented state-of-the-art-designed spindle drive system is the key to the machine's precision, thermal stability, and high reliability. According to tests performed at a technical university in Europe, this spindle drive system proved to be superior to other multispindle drive systems due to its mechanical precision and genuine simplicity.

Each of the machine's six spindles is linked by a composite shaft to its own motor into the spindle drum, which employs a precise Hirth coupling. This makes it unnecessary to reverse-index the drum at the end of each 360 deg cycle, connect, and disconnect the motors to the spindles with each indexing, cool the drum to dissipate the heat generated by the spindles, or to supply power to the spindles through rotating, slip-ring connectors. This saves time, energy and cost and adds precision as well as reliability. This system also allows for the strongest and most adjustable clamping power in the industry. You may set your spindle drives to the part or rpm you need. Therefore, you have actually three machines in one. You only have to change the standard drives, all of which can be done in a single day. This offers from 10 mm to 52 mm with optimal speeds and feeds.

The mechanical rigidity and thermal stability are the reason for the built-in accuracy of the machine. Therefore, the use of refrigerant is not needed, which is what makes this machine so interesting to users. Using the built-in mechanical compensation allows for a new dimension of accuracy in CNC multispindle machines. Because hydraulics and refrigeration are eliminated in the spindle drum, the machine has a significantly higher uptime, has greater thermal stability, and as a result provides higher precision and efficiency than other CNC multispindles on the market.

This innovative, patented technical solution allows the independent control of the speed of each spindle and the power of each AC spindle motor according to the requirements of specific machining operations performed by each customer. The machine is provided complete with all options and includes capabilities that make it effective on today's precision machining floors: quick changeover; simple, intuitive programming; single-point presettable driven tooling; and teaching software as well as a standard CAM programming software.

A range of optional equipment includes a CNC pick-up spindle with up to five tools (three driven) for backworking, attachments for radial and axial drilling and milling operations from cut-off slide, parts conveyor, bar stock feeding and high-pressure tool coolant system. Also, four real Y axis, with up to 185 mm stroke, attach three standard toolholders for driven tools.

6-Spindle Lathe Offers Speed and Accuracy
ZPS offers its cam-driven 6-spindle automatic lathe with 67 mm bar capacity. The rigid, European-built machine is designed for continuous or series production of precision turned parts. Solid base casting ensures maximum rigidity and stability. The machine includes six frontal slides with up to 110 working strokes, and six cross slides plus four compound slides with clamping, and bar stop in the 6th station. An independent cam controls each slide. Stroke is adjustable on the rocker arm of the corresponding drive. Machines in the range are provided with different spindle speed ranges (200 to 3200 rpm), depending on material type and size.

Through the Hirth Coupling with the spindle drum being fine bored in the casting positioning errors are eliminated. The maltese cross smoothes precise indexing to increases the accuracy and longevity of the machine tool. Four safety clutches prevent the slides from overloading. Spindle drum locking is accomplished by a Hirth coupling for ultimate concentricity, repeatability and precision. A bar stock guide is standard, and the machine can also include automatic bar loaders and bar magazines for long, unattended operation. Spindles are driven by Simodrive Siemens variable speed motors and the machines are controlled through a Siemens S7.

To accomplish nearly any operation, the machines can be provided with a wide range of optional equipment, including NC drive of the pick-up spindle, bar stock feeding and clamping in the fourth station, attachments for high-speed drilling, reaming, tapping and broaching, and multi-spindle drilling heads on the frontal slides.

8-Spindle Lathe for Multiple Operations
ZPS offers its cam-driven 8-spindle automatic lathe with 32- or 42-mm bar capacity. The rigid, European-built machine is designed for continuous or series production of precision turned parts. Solid base casting ensures maximum rigidity and stability. The machine includes eight frontal slides with up to 110 working strokes, and eight cross slides plus four compound slides with clamping, and bar stop in the 8th station. An independent cam controls each slide. Stroke is adjustable on the rocker arm of the corresponding drive. Machines in the range are provided with different spindle speed ranges, depending on material type and size.

Four safety clutches prevent the slides from overloading. Spindle drum locking is accomplished by a triad of rims with spur gearing. A bar stock guide is standard, and the machine can also include automatic bar loaders and bar magazines for long, unattended operation. Spindles are driven by Simodrive Siemens variable speed motors and the machines are controlled through a Siemens S7.

To accomplish nearly any operation, the machines can be provided with a wide range of optional equipment, including NC drive of the pick-up spindle, bar stock feeding and clamping in the fourth station, attachments for high-speed drilling, reaming, tapping and broaching, and multi-spindle drilling heads on the frontal slides.

Multifunction Center Replaces Transfer Machines
An 8-spindle 867 CNC multispindle production center from ZPS can accommodate stock to 72 mm diameter. Provided with a double Siemens 840 D CNC control, the European-built machine offers up to 72 CNC axes and can perform nearly any metalcutting operation on precision parts from drilling and tapping to milling, spline gears, broaching and hobbing. With a cast iron base and total weight of more than 30,000 lb, the 867 is extremely rigid. Combined with the highest spindle torque in the industry (191 nm), the stable 867 can handle difficult materials with great precision.

"This multispindle offers high-precision CNC production capability with its 16+1 tool carriers to a range of part sizes that until now have been processed on transfer machines," said Olaf Tessarzyk, managing partner and president of ZPS America. The CNC Multi line offers very high processing flexibility and fast changeover with the ability to drop a variety of complex precision parts complete as either a bar-fed or chucker operation.

The machine's versatility is provided through its standard features: 8 independent AC-driven CNC horizontal spindles, 8 independent compound slides (X and Z), 8 independent tool carriers with 8 12000-rpm driven tools, 5 backworking tools (3 driven), and a wide range of standard presettable VDI tooling for quick changeover to increase flexibility. However, it is the patented state-of-the-art designed spindle drive system that sets these machines apart. It is the key to the machine's precision, thermal stability, and high reliability. According to tests performed at a technical university in Europe, the spindle drive system proved to be superior to other multispindle drive systems due to its mechanical precision and genuine simplicity.

Each of the machine's eight spindles is linked by a composite shaft to its own motor into the spindle drum, which employs a precise Hirth coupling. This makes it unnecessary to reverse-index the drum at the end of each 360 deg cycle, connect, and disconnect the motors to the spindles with each indexing and cool the drum to dissipate the heat generated by the spindle motors. The result is greater precision and reliability across high duty cycles. Spindle indexing takes only one second, not only saving time, but reducing energy and cost. This system also allows for the strongest and most adjustable clamping power in the industry.

The mechanical rigidity and thermal stability are the reason for the built-in accuracy of the machine. Therefore, the use of refrigerant is not needed, which is what makes this machine so interesting to users. Even without spindle compensation this machine tops the precision of its competitors. Using the built-in mechanical compensation allows for a new dimension of accuracy in CNC multispindle machines. Because hydraulics and refrigeration are eliminated in the spindle drum, the machine has a significantly higher uptime, has greater thermal stability, and as a result provides higher precision and efficiency than other CNC multispindles on the market.

This innovative, patented technical solution allows the independent control of the speed of each spindle and the power of each AC spindle motor according to the requirements of specific machining operations performed by each customer. The machine is provided complete with all options and includes capabilities that make it effective on today's precision machining floors: quick changeover; simple, intuitive programming; single-point pre-settable driven tooling; and teaching software as well as a standard CAM programming software.

A range of optional equipment includes a CNC pick-up spindle with up to 5 tools (3 driven) for backworking, attachments for radial and axial drilling and milling operations from cut-off slide, parts handling gripper or ejection slide, parts conveyor, bar stock feeding and high-pressure tool coolant system.

Production "Swings" With Precision
ZPS offers the Manurhin Swiss-style CNC series that covers a range from 13 mm to 32 mm bar diameter. The rigid, European-built machine is designed for continuous or series production of precision turned parts. Solid base casting ensures maximum rigidity and stability. The Swiss style turning centers provide outstanding accuracy and quality surface finish conditions for precision parts. The machines are equipped with the GE Fanuc control systems and drives that are capable of handling up to 11 controlled axes.

The specially developed programming software, Swing Plus, simplifies the programming so the programmer takes in consideration only the X, Y and Z axes during programming, just as on typical two-axis CNC lathes. Swing Plus offers user-friendly programming specially adapted for simultaneous operations. Each machining operation is individually programmed in ISO code with graphic interface and tool library. SWING Plus generates the part program by taking into consideration the machine kinematics and machine requirements. The Swing Plus, integrated in the Fanuc 18i controls or programmed off line, ensures the full benefit from Swing's performance.

It's possible to machine a part with up to 4 tools cutting simultaneously. The sliding headstock provides up to 250 mm stroke that enables part machining in succession at one collet clamping as well as the machining of long parts with small diameter. There are 23 tool stations, and 14 stations can be driven, so the machine can finish the most complex parts that are otherwise machined in several operations. The use of two identical spindles increases machining capacity in rear slide operations and enables evacuation of long parts (110 mm to 250 mm) through the subspindle.

The extraordinarily rigid structure of the cast steel machine base provides optimum machining conditions. Right from machine set up to production, Manurhin's ergonomics and accessibility increase productivity. Three live spindles may be fitted on the rear tool rack for cross drilling and tapping as well as milling with the Y-axis. Three live spindles also enable high-speed drilling, polygon turning or thread and slot-milling. Two axial and three transversal live spindles may be fitted on the rear machining unit in order to work via the subspindle.

To accomplish nearly any operation the machines can be provided with a wide range of optional equipment, including NC drive of the pick-up spindle, bar stock feeding and clamping, attachments for high-speed drilling, reaming, tapping and broaching, and multi-spindle drilling heads on the frontal slides. www.zpsamerica.com

IDEAL FOR AEROSPACE AND OIL FIELD
The YV-600A by You Ji is a highly flexible vertical turning center that is ideal for the aerospace, oil field, and other industries turning medium-sized work pieces. Absolute Machine Tools, Inc. (Lorain, OH) offers this compact system, which features a 6-station hex turret that ensures little to no tool interference. The VTC is designed for standalone applications or easy integration into production lines. It comes in mirror-image right and left-hand versions, allowing shops to place machines side by side in a work cell. Such an arrangement boosts productivity by giving shops two spindles in essentially the same space as one horizontal turning center. This also lets one operator run both machines.

Solid machine construction is key to the YV-600A performance. The 34,000 lb VTC's rigid vertical column and base are Meehanite castings, heavily ribbed for reduced thermal distortion and vibration dampening. The You Ji YV-600A has the precision and repeatability to deliver even the tightest tolerances. Its X and Z axis linear guideways are completely enclosed, and a forced lubrication system ensures high precision. The high-speed linear way system enables rapid traverse rates of 787 ipm. Box ways are also available. The VTC's precision Class 3 ballscrews are driven directly by the servo motors, eliminating belts or gears for high precision.

The spindle construction is a heavy-duty design incorporating high precision double roller bearings and 45 deg angular contact thrust bearings. The spindle also is protected from coolant contamination. The NN type spindle bearings are used to withstand high centrifugal loads and spindle loads. The 30 hp, high-torque Fanuc "P" series double-wound spindle motor coupled with the two-speed ZF gear box provides the same power output as a Fanuc 50 hp single with the two-speed gear box. The "P" series motor delivers power for heavy duty machining and high speed for fine finishing. The spindle produces nearly 3,000 ft-lb of cutting torque for heavy cutting.

A live tool turret is available as an option. Chip control is excellent as chips and coolant wash directly into the standard chip conveyor. An optional chip wash system forces any chips from the machining area into the conveyor. Other standard features include a three jaw, 24-in hydraulic chuck with cylinder and one set of soft jaws and six boring and turning tool holders. A Fanuc OiT-C CNC with manual guide conversational programming is also standard. Absolute can engineer turnkey systems with fixtures and full automation. www.absolutemachine.com