Northeast Manufacturing News March 2017 : Page 1

NORTHEAST Serving Since 2005 Connecticut, Delaware, District of Columbia, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, Vermont & West Virginia M ANUFACTURING N EWS Boston Centerless Receives Nadcap Accreditation Feature Editorial Quality Control & Measurement Full Measurement Automation and Integration Vol. 13 No. 3 March 2017 See Online DIGITAL EDITIONS at www.mfgnewsweb.com Turn-Mill Center for Flexible Production The vertically arranged machine bed and other smart design features result in a spacious work area, with 660 mm of turning length now available. A second lower turret makes the machine more productive. Boston Centerless announced that it has received Nadcap accreditation for Nondestructive Testing. The accredita-tion applies to Ultrasonic Testing (UT) services. Boston Centerless is now on the Qualified Manufacturers List (QML) of Nadcap accredited suppliers. “Receiving Nadcap accreditation is an important milestone for Boston Centerless,” said Steven Tamasi, CEO of Boston Centerless. “We have made a significant investment in state-of-the-art testing equipment for our Material Validation Center, which performs Nondestructive Testing on bar materi-als. Nadcap, along with our ISO 9001 Continued on Page 78 Alicona is expanding its range of production-integrated measurement solutions. See Page 10 Additive Manufacturing 3-D Printing Technology Uses Traditional Manufacturing Materials Programmable Tooling is a hybrid process designed for low volume production. See Page 26 INDEX has developed a new genera-tion of its G200 turn-mill center. The new compact machine offers significantly higher performance -potentially up to 30% greater productivity -in the same Continued on Page 78 Investments in Fiber Laser Technology Boost Productivity Miller Metal and BCL Manufactur-ing have both purchased TRUMPF fiber laser machines from Mid Atlantic Ma-chinery to enhance their productivity. TruLaser 5030 Fiber Miller Metal purchased a TruLaser 5030 fiber with an integrated 8 kW solid-state laser. “This productive ma-chine will assist Miller Metal by short-ening its production time with higher cutting speeds and minimal down-time,” said a company spokesperson. Features include an automatic nozzle changer, smart collision prevention, dot-matrix coding, a single cutting head Continued on Page 78 Sciaky to Deliver Large, Industrial-Scale Metal 3-D Printer to Airbus Applying Technology Verifying Dimensional Accuracy of Complex Components Highly complex quick-couplers require tight tolerances. See Page 40 Education/Training Enhanced GibbsCAM 2016 Education Editions GibbsCAM 2016 Classroom and Student Editions now have free access to GibbsCAM VoluMill. Sciaky EBAM 110 System Sciaky, Inc., a subsidiary of Phillips Service Industries, Inc. (PSI) and provider of metal additive manufacturing (AM) solutions, has announced that Airbus will take delivery of a state-of-the-art electron Continued on Page 28 Emuge Introduces Tool Reconditioning in U.S. Facility Emuge Corp. has introduced tool grinding and reconditioning services based out of the company’s North American headquarters in West Boyl-ston, MA. A new state-of-the-art manu-facturing facility at Emuge Corp. is now equipped with the latest technology high precision CNC grinding machines Continued on Page 76 See Page 48 Material Handling Vision System Improves Bin Picking Triangulation method improves resolution. See Page 60 Subscription Changes: To make name, address subscription changes contact: • Phone: 800-375-8488 • Fax: 817-488-7813 • E-mail: info@mfgnewsweb.com • www.mfgnewsweb.com CHANGE SERVICE REQUESTED Gross Publications, Inc. NORTHEAST MANUFACTURING NEWS P.O. Box 847 Grapevine, Texas 76099-0847 U.S.A. DALLAS, TX PERMIT 4245 Advertiser Index Page 55 PRSRT STD U.S. POSTAGE PAID

Turn-Mill Center For Flexible Production

INDEX has developed a new generation of its G200 turn-mill center. The new compact machine offers significantly higher performance - potentially up to 30% greater productivity - in the same footprint as the earlier generation. The machine redesign has increased the maximum turning length to 660 mm, and has resulted in a higher performance milling spindle, expanded live tool complement and an Xpanel with i4.0 readiness. The new machine offers flexibility and high-speed machining of both bar stock and chucked parts complete in one set-up.

The machine bed is arranged vertically, making the machine stand higher, but extending in the work area, thus permitting the second lower tool carrier to increase machine productivity. “Reducing cycle times by 30% compared to the first G200 generation is well within the bounds of possibility with appropriate workpieces,” said an INDEX spokesperson.

The fluid-cooled main and counter spindles are designed identically and feature a bar capacity of 65 mm (max.Chuck diameter 165 mm). Motorized spindles allow productive turning machining with a power of 31.5/32 kW (100%/40% duty cycle), a torque of 125/170 Nm and a maximum speed of 6,000 RPM.

The G200 has three tool carriers so tools can be assigned to almost any machining type on the main and counter spindles independently. This means greater flexibility for the programmer in organizing the machining steps.

Due to the large work area, it is possible to work with three turrets simultaneously on the main spindle or counter spindle without them interfering with each other. One example: the lower right turret with an angular tool can machine the inside of a workpiece clamped in the main spindle, while the other lower turret and upper tool carrier machine the outside. The same is also possible on the counter spindle. This increases the possibility to use three cutting edges simultaneously, and in some cases even four tools.

The two 14 - tool turrets are arranged in mirror image, each with an independent Y-axis (+/- 45 mm). All tool stations can be equipped with live tools. Tools with internal coolant supply (up to 80 bar) can be used as well.

A special feature is the upper tool carrier, which has an additional Y-axis (+/- 65 mm) and a 360° swiveling Baxis. It is designed on one side to provide an added 14 tool positions and has a milling spindle on the rear. Its drive delivers speeds up to 7,200 RPM (power 22 kW, torque 52 Nm at 25% duty cycle).

The upper turret head can be swung into a horizontal position about the Baxis and then moved into the work area up to a position of 30 mm below the spindle center. In this position, the turret can machine towards the main or counter spindle, or even simultaneously, depending on the application. This position is often used to perform face machining with straight tools.

A feature of the lower tool carriers is the parking positions. The turrets are designed to move to the left or right to a position that is outside of the work area, avoiding risk of collision. This allows the other tool carrier to work freely over the entire turning length. Also, the 845 mm slide travel of the upper tool carrier is dimensioned in the Z-axis so that the tool covers the complete turning length of 660 mm without having to rotate the B-axis by 180°.

The INDEX Xpanel i4.0 ready control concept of the new INDEX G200 generation focuses on productivity and ease of use. Numerous control elements of the machine operating panel have been integrated into the screen, where they can be operated directly on the 18. 5” touchscreen with visual support. The remaining keys on the machine control panel are provided with LED backlighting for a better user dialog. The operating panel provides the option to display the control screen in a second view. Using this second page, Xpanel i4.0 ready can, for example, display the INDEX Virtual Machine (VM) simulation directly on the machine (optional).

The operator can quickly switch between the control screen and the Onboard Virtual Machine and use the simulation either independently or coupled with the current machine operation. In Crash Stop Mode, if a virtual collision is detected, the running workpiece program is stopped before the actual crash, preventing any damage. In RealTime Mode, the machining process can be observed in real time simultaneously on the machine control panel.

Another new feature is the openness of Xpanel i4.0 for information technology (IT) extensions. The VPC box (industrial PC, optional) can be used also for any other type of customer application. With such a directly networked control, any information and application can be retrieved from the company and operated on the machine.

For more information contact:
INDEX Corporation
14700 North Pointe Blvd.
Noblesville, IN 46060
317-770-6300
sales@index-usa.com
www.indextraub.com

N. NY
Britton Machinery Sales
330 Castlebar Rd.
Rochester, NY 14610
585-924-9335
www.brittonmachinery.com

W.PA
Marcus Machinery
106 Bellefield Court
Gibsonia, PA 15044
412-862-0803
info@marcusmachinery.com
www.marcusmachinery.com

MA, CT, RI, ME, NH, VT
High Performance Machinery
313 South Main St.
Orange, MA 01364
978-204-6501
hpm@mass.rr.com
www.highperformancemachinery.com

MD, E. PA, NJ, NY (Long Island, NYC), DE
Single Source Technologies, Inc.
2 Hagerty Blvd., Suite 300
West Chester, PA 19382
610-430-3670
www.singlesource.com

Read the full article at http://www.virtualonlineeditions.com/article/Turn-Mill+Center+For+Flexible+Production/2728125/388776/article.html.

Sciaky To Deliver Large, Industrial-Scale Metal 3-D Printer To Airbus

Sciaky, Inc., a subsidiary of Phillips Service Industries, Inc. (PSI) and provider of metal additive manufacturing (AM) solutions, has announced that Airbus will take delivery of a state-of-the-art electron beam additive manufacturing (EBAM) 110 System. The aircraft manufacturer will utilize Sciaky’s industrial-scale metal 3-D printing system to produce large structural parts made of titanium.

Sciaky’s EBAM process combines computer-aided design (CAD), AM processing principles and an electron beam heat source. Starting with a 3-D model from a CAD program, Sciaky’s fully articulated moving electron beam gun deposits metal via wire feedstock, layer by layer, until the part reaches near-net shape. From there, the nearnet shape part requires heat treatment and post-production machining. In the end, there is minimal material waste.

Sciaky brings quality and control together in one step with IRISS - the Interlayer Real-time Imaging and Sensing System. “IRISS is the only real-time monitoring and control system in the metal 3-D printing market that can sense and digitally self-adjust metal deposition with precision and repeatability,” said a company spokesperson. “This closed-loop control is the primary reason that Sciaky’s EBAM 3-D printing process delivers consistent part geometry, mechanical properties, microstructure and metal chemistry, from the first part to the last.”

EBAM utilizes wire feedstock, which can accommodate a wide variety of metals and refractory alloys such as titanium, tantalum, niobium, tungsten, Inconel and stainless steels. Sciaky’s EBAM 110 System has a work envelope of 70” (1,778 mm) x 47” (1,194 mm) x 63” (1,600 mm).

“Sciaky is very proud to partner with a world-class innovator like Airbus,” said Bob Phillips, Vice President of Marketing for Sciaky, Inc. “We all know that metal 3-D printing technology is going to revolutionize manufacturing in the aerospace industry, and Sciaky is committed to being at the forefront of this movement.”

Sciaky’s lineup of EBAM systems can produce parts ranging from 8” (203 mm) to 19’ (5.79 meters) in length. Gross deposition rates range from 7 to 20 lbs. (3. 18 to 9.07 kg) of metal per hour.

For more information contact:
Sciaky, Inc.
4915 W. 67th St.
Chicago, IL 60638-6493
877-450-2518
708-594-3800
www.sciaky.com

Airbus
www.airbus.com

Read the full article at http://www.virtualonlineeditions.com/article/Sciaky+To+Deliver+Large%2C+Industrial-Scale+Metal+3-D+Printer+To+Airbus/2728127/388776/article.html.

Boston Centerless Receives Nadcap Accreditation

Boston Centerless announced that it has received Nadcap accreditation for Nondestructive Testing. The accreditation applies to Ultrasonic Testing (UT) services. Boston Centerless is now on the Qualified Manufacturers List (QML) of Nadcap accredited suppliers.

“Receiving Nadcap accreditation is an important milestone for Boston Centerless,” said Steven Tamasi, CEO of Boston Centerless. “We have made a significant investment in state-of-theart testing equipment for our Material Validation Center, which performs Nondestructive Testing on bar materials. Nadcap, along with our ISO 9001 and AS9100 certifications, will help us better support our aerospace and defense sector customers with a wider range of service capabilities.”

Nadcap is an industry-managed approach to conformity assessment that brings together technical experts from both industry and government to establish requirements for accreditation, accredit suppliers and define operational program requirements throughout the aerospace and defense industries.

“The accreditation underscores Boston Centerless’ commitment to the highest quality standards and processes in order to provide customers with superior products and services,” said the spokesperson. The Nadcap program is administered by Performance Review Institute.

For more information contact:
Boston Centerless
11 Presidential Way
Woburn, MA 01801
781-994-5000
www.bostoncenterless.com

Read the full article at http://www.virtualonlineeditions.com/article/Boston+Centerless+Receives+Nadcap+Accreditation/2728130/388776/article.html.

Investments In Fiber Laser Technology Boost Productivity

Miller Metal and BCL Manufacturing have both purchased TRUMPF fiber laser machines from Mid Atlantic Machinery to enhance their productivity.

TruLaser 5030 Fiber

Miller Metal purchased a TruLaser 5030 fiber with an integrated 8 kW solid-state laser. “This productive machine will assist Miller Metal by shortening its production time with higher cutting speeds and minimal downtime,” said a company spokesperson. Features include an automatic nozzle changer, smart collision prevention, dot-matrix coding, a single cutting head and a shared laser network.

“Unlike other machines in its class, the high-powered 8 kW solid-state laser allows the TruLaser 5030 fiber to easily cut medium and thick materials with reliability and precision,” said the spokesperson. “This is the laser of choice due to new features such as BrightLine, Pierce- Line, LensLine and CoolLine technology. The TruLaser 5030 fiber is able to produce high-caliber cuts on a wide range of materials and thicknesses.”

TruLaser 3030 Fiber

BCL Manufacturing invested in TRUMPF’s TruLaser 3030 fiber with LiftMaster Compact. The 3030 fiber is designed for cutting sheet metal parts with reliability and flexibility. “BCL will be able to shorten its production time with higher cutting speeds and minimal downtime due to new features such as an automatic 18-nozzle changer, a universal cutting head and QR code marking abilities,” said the spokesperson. “With features such as BrightLine, PierceLine and CoolLine technology, the TruLaser 3030 fiber is able to produce high-caliber cuts on a wide range of materials and thicknesses.”

The TruLaser 3030 fiber’s integrated TruDisk laser provides up to 6 kW of solid-state laser power. The laser enables the TruLaser 3030 fiber to process nonferrous reflective materials, including copper (up to 0.4”) and brass (up to 0. 4”). This machine can cut up to 1” in mild steel, 0.8” in stainless steel and 0.8” in aluminum.

For more information contact:
TRUMPF Inc.
Farmington Industrial Park
111 Hyde Rd.
Farmington, CT 06032
860-255-6000
info@us.trumpf.com
www.us.trumpf.com

Mid Atlantic Machinery
6332 Flank Drive
Harrisburg, PA 17112
717-541-1633
www.midatlanticmachinery.com

Miller Metal
16356 Sussex Hwy
Bridgeville, DE 19933
302-337-2291
www.millermetal.com

BCL Manufacturing Company
161 Bello Dr
Windber, PA 15963
814-467-8225
www.bclmanufacturing.com

Read the full article at http://www.virtualonlineeditions.com/article/Investments+In+Fiber+Laser+Technology+Boost+Productivity/2728131/388776/article.html.

Emuge Introduces Tool Reconditioning In U.S. Facility

Emuge Corp. has introduced tool grinding and reconditioning services based out of the company’s North American headquarters in West Boylston, MA. A new state-of-the-art manufacturing facility at Emuge Corp. is now equipped with the latest technology high precision CNC grinding machines and inspection equipment, providing tool reconditioning for U.S. and Canadian customers for Emuge taps, drills and end mills, in addition to other brands of carbide drills and end mills.

“Reconditioning Emuge tools by Emuge makes sense,” said Bob Hellinger, President of Emuge Corp. “Emuge has the knowledge and manufacturing expertise to refurbish an Emuge tool to its original condition and specification, providing maximum performance levels, predictable operation and longer life than any other method.”

Emuge reconditioning services offer complete inspection and evaluation of all tools received. Reconditioning services include complete regrinding to the original geometry of Emuge taps, drills and end mills, as well as other brands of drills and end mills. Reconditioning services also include corner radius, Weldon flats and other modifications to standard end mills, and PVD coatings through a state-of-the-art coating system. All reground tools are delivered with a detailed report on services rendered.

For more information contact:
Bob Hellinger
President
Emuge Corporation
1800 Century Drive
West Boylston, MA 01583
800-323-3013
bob.hellinger@emuge.com
www.emuge.com

Read the full article at http://www.virtualonlineeditions.com/article/Emuge+Introduces+Tool+Reconditioning+In+U.S.+Facility/2728133/388776/article.html.

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