Moore Tool (Bridgeport, Connecticut) currently designs, engineers and builds machines in conjunction with its sister company, Producto, in a 200,000-square-foot facility with approximately 200 employees. When the company set out to build a five-axis, high speed machining center for use in the production of critical components, it faced numerous challenges. The machine was intended to serve critical needs of the turbo machinery, mold and die, scroll compressor and medical markets. To help meet the needs of these applications, a control supplier analyzed the machine’s control system in order to optimize the performance of this particular design.

The machine needed to possess capabilities such as high speed (30,000 rpm to 40,000 rpm) cutting capability when milling materials ranging from aluminum to hardened Steel and titanium; dynamic response; good stability and vibration dampening; automation adaptability; a user-friendly Windows working environment; onboard cooling; substantial onboard memory in a CNC without external devices for downloading complex programs; and, above all, high precision.

Moore Tool embodied a “from the ground up” approach to develop its Five-Sided Precision (FSP) line of machining centers. Speed and accuracy were considered when evaluating the needs of working with various materials, as were the differing requirements of production and part accuracy. The requirements of machining aluminum and titanium with high production rates can differ when compared to the intricate contours and features of mold components produced directly in hardened steel. Adding the requirements for efficient graphite machining also produces significant challenges.

The company says the need for a combination of high precision and high material removal rates was evident. The complex contour surface profiling on leading and trailing edges of blades, and especially blisks and IBRs, made a high speed processor essential to maintain acceptable feed rates. The machine configuration, particularly as it relates to the position and configuration of the rotary tables and spindle, would also play an integral role in meeting the needs of Moore Tool’s customers.

The machine’s CNC is an 840D from Siemens (Elk Grove Village, Illinois). To maximize machine performance, Siemens performed a detailed dynamic analysis of the machine, control and servodrive system. This service is called “Mechatronics.” Data gathered during the Mechatronics process are used to optimize the complete machine concept.

In complex blade contour and finishing operations, the CNC provides an aerospace-specific software feature, CompCAD, by which the control’s compressor function smoothes point-to-point programming. The real benefit of the control is realized when processing the part using Non-Rational Uniform B-Splines (NURBS), with which the machine can reach an advanced level of smooth contouring and chatter elimination. This is achieved by using splines in an axis-specific tolerance window. According to the manufacturer, contour violations are thus avoided; the efficiency of acceleration/deceleration curves is increased; and slowdowns/speed-ups at block transitions are virtually eliminated.

According to Moore Tool’s engineers, in programming, the open architecture of the CNC, along with its high speed, user-defined macros and block search capabilities, have made it an “ideal choice” for the FSP300X. They go on to say that the ability of the CNC to handle large programs, which are typical for intricate mold and die applications, without “drip feed” is also noteworthy.

Optional features that are available with the machine include high-frequency spindle options as high as 80,000 rpm; a range of robotic part loaders, all of which are designed and built by Moore Tool, with the control parameters incorporated into the host CNC; a graphite machining package; a laser tool-setter with measurement and compensation standards; and various customized configurations. The machine can be enhanced with Siemens’ Simodrive 611D drive packages.

The Machine Tool Camp 4′x8′ is a light-weight machine. The instructions are detailed but more of a connect-the-dots type deal rather than a tutorial. Metric or imperial is irrelevant here because you would probably order most of your parts from this company.
Pros:
1. Easy to assemble once you have all the parts (Order from them. Its cheaper and easier.)
2. Light-weight so could be moved around, within reason.
Cons:
1. Light-weight causes vibration during use.
2. Light-weight material may deflect (bend or bow) slightly during use.
3. Less precision.
4. Might be hard to cut aluminum frame members to the tolerances listed.
5. I would have liked more of a tutorial in the instructions rather than just connect-the-dots. Instructions need more large pictures.

Cad Cut CNC 4′x8′ Router is a heavy duty machine. It is as close to an industrial machine as you will ever get. The instructions are pretty good with lots of big drawings as well as tutorial. This is a big heavy machine. If you are looking for precision then this is it. I think this one would be easier to do in metric than the other, if you feel you must.
Pros:
1. Very high precision machine.
2. Heavy weight means no vibration during use.
3. This machine is stout! No deflection here. No bending of frame or gantry during use.
Cons:
1. Big heavy machine.
2. You must weld frame. (Any cheap stick-welder will do. Mine costs less than $100. It looks pretty easy to do.)
3. Takes two people to man-handle some of the pieces during assembly.

And now a few words about the big routers in general.
1. You should go to the garage with two yardsticks (meter-sticks?) taped together and see if you really have 6′x11′ clearance somewhere. These machines are really large! You are talking about a permanent fixture that can’t be easily moved. These things are as big as a car!
2. Small motors are better. They can still be powerful but the smaller and more lightweight the better. You don’t want to weigh the gantry down with big heavy motors like I have. It’s a headache.
3. You should consider if you really have the money for one of the large machines. It adds up. Expect to spend $5000+ US before all is said and done.
4. I don’t plan on using Gecko’s for the controllers. I am going to use Rutex because they look like they have more bells and whistles and there is less wiring to be done. In my case, the schematic parts of all the “Plans” are useless. You should consider if you will follow the schematics or not.

CNC machining is a job sits comfortably atop the hierarchy of manufacturing jobs. A skilled machinist can command a very good salary in fact $60,000 a year or more is not uncommon.

As a CNC machinist your job will also be more secure and safe from outsourcing. This is due to the level of skill required to be successful and while simple tasks such as assembly are being outsourced a rapid rate. This is not to say that outsourcing will have no effect in the machineing field, or that your job will never be outsourced because any job white or blue-collar is facing the outsourcing pinch.

Finding a job as a CNC machinist shouldn’t be too hard. Most manufacturing companies have machining departments and there are many shops that specialize in just CNC. Landing one of these jobs will be much easier if you have some machining experience, or if you have a degree from a technical college. If you don’t have a degree from a technical college or any experience I’ll tell you a little trick that will allow you to sneak in the back door, and land that CNC job and even beat out more qualified candidates.

You’re going to want to research perspective companies and find the pay scale for their CNC positions. Once you got a list of prospective companies go apply for an entry-level position at that company. Punch press, sweeping what ever just get in the door.

How will this help you get a CNC job? 90 percent of all manufacturing companies promote from within. They’ll give current employees preferential treatment before hiring an outsider even if the current employee is lacking experience for the open position.

Keys to getting promoted in a to a CNC operator position:

You’ll need a strong work ethic.

Perform well on the job.

Have a good attitude.

Show a willingness to learn and make it known that you want to learn about CNC machines.

And most important be dependable. that means always show up on time, and always volunteered to work overtime if it’s available.

Note these tips for getting ahead only apply to non-union jobs because they promote people based on performance where most union jobs only look at seniority.

I looked at a bunch of designs and decided to try a fairly simple 3 axis machine as my first effort. The idea was to use a Dremel tool for the cutting head and use the machine to engrave aluminum front panels for my guitar amps. As it turned out the machine isn’t accurate or rigid enough for that. A dremel just has too much slop in the bearings for accurate machining. The machine will do a reasonable job machining soft materials like plastic and soft woods, and it does quite a good job of plotting PCBs. I haven’t tried drilling PCBs yet but I’m pretty sure it’ll handle that too.

I found a couple of old Datasouth printer chassis at a computer surplus place and the printhead mechanism supplied the linear bearings and 1/2″ hardened rods for the axes. I used the rods as is for the X and Y axes so they are quite long - about 18″. I discovered after building the machine that the rods will bend under load and the accuracy of the machine suffers as a result. OK for plotting but machining requires very stiff axes.

The rest of the machine is made from 3/8″ and 3/4″ MDF - its easy to work with, quite stiff and very stable. I have a few rough sketches of this machine but its very specific to the Datasouth parts so there’s not much point in reproducing them here.

Here is the X axis taking shape. The black parts are linear bearings (bushings, actually) that were cut off the printhead assemblies.

One of the side supports being drilled. I made a drilling template which helped keep the axis rods parallel. Its extremely important that the axes be accurately positioned and exactly 90 degrees from each other.

The X and Y axes are in place below. Here you can see the 1/4-20 threaded rod I used as leadscrew. Not nearly as smooth or accurate as a machined leadscrew but WAY cheaper. I dispensed with the “floating nut” as used on some other designs and simply embedded a T nut in the carriage of each axis. To keep the less than straight threaded rod from binding the free end rides in a fairly loose bushing. The threaded rod is joined to the stepper motor with a short piece of plastic tubing which serves as a flexible coupler. Small hose clamps keep the plastic tubing from slipping on the motor shaft.

Below - the completed machine doing some test plots on a piece of copper clad board. The brass tube is a crude pen holder. I’ve since made a better one shown below. I use Staedtler super fine tip permanant markers for PCB plotting - the ink is supposed to resist etching solution but I haven’t actually etched a board as yet. With these pens the machine will lay down a trace of about 30 mils on 50 mil centers - its good enough to do 50 mil lead pitch SMT packages. I estimate the accuracy of the machine to be about .005 inches while plotting.

Below is the new penholder. The pen is a friction fit in the white UHMW plastic block. The cast aluminum parts and X shaped springs originally held a SCSI tape drive’s read/write head. This assembly holds the pen vertical and the springs push it lightly against the plotting surface. Non-permanent ink is good for doing test PCB plots since it washes off.

A sample of a PCB plot. This example has pads for an 18 pin SMT package with .050″ lead spacing. Quality is pretty good but as you can see some traces are touching. This can be fixed by adjusting the autorouter to leave more space between tracks.

UHMW plastic was used to make a mount for a Dremel tool. Unfortunately the machine is not rigid enough for machining metal or hard wood - side loads on the X and Y axes cause the metal rods to flex and accuracy goes out the window. I haven’t tried PCB drilling yet but I’m pretty sure it will handle it since the load is mostly vertical.

The stepper controller board I designed. It uses programmable logic devices to implement 3 or 4 phases with half and full stepping. The chips on the left are ULN2003 peripheral drivers which are used in pairs to drive up to 1 amp per phase. The board will drive four stepper motors and interfaces to a PC’s parallel port. I originally designed this board for my CNC foam cutting machine which has four motors.

Sample engraving in aluminum. Most attempts were not this good. The letters are about 3/16″ high

Sample engraving in plastic. More consistent results than metal. These letters are about 3/8″ high.

CNC Software

I tried a bunch of different CNC software packages and while none of them had everything I was looking for the clear winner in bang for the buck was Dak Engineering’s Turbo CNC. Its a DOS program and the interface is pretty crude but it turned out to be the fastest and most accurate for my uses and its only $20 US. It doesn’t have the file import features I wanted so I ended up writing some simple file conversion utilities to so I can plot Gerber files etc. More info on my software page.

I use the freeware version of Cadsoft’s Eagle schematic/layout editor for creating PCB’s. This is a very good software package which includes excellent part libraries and an autorouter. The freeware version will do boards up to about 4″ x 3″ which will handle most small projects. Eagle produces a gerber file which can be converted to GCODE (the “language” of CNC) using my converter. You load the GCODE file into TurboCNC and plot.

I wrote another utility that reads a GCODE file and will do translation and scaling on the coordinates. I found this to be very useful for scaling parts up and down and in particular for setting the Z (up and down) axis coordinates. When plotting for example and the pen is not drawing you want it just off the plotting surface - there’s no point in having it move up any more than necessary. Try plotting a board with Z moves of 1″ and you’ll see what I mean - the plot will take at least 10X longer to complete than it will with minimum Z moves.

In multispindle machining, the longest operation at a given position dictates the time required to make a complex part. Generally, the position dedicated to working on a part's back end takes the longest time, because just one spindle performs different operations.

To overcome this problem, Tornos Technologies US Corp. (Brookfield, CT) has developed the MultiDECO 20/Sd, an eight-spindle machine with two independent, three-axis backworking stations. In essence, according to the company, it's a ten-position machine.

In operation, positions one through six are used to work on the front of the part. Every two indexes, two parts are cut off in positions seven and eight. Those parts are then taken by the two independent pickoff spindles, and presented to as many as five tools per part for backworking. In theory, then, if the longest front-work operation is 10 sec, and the backworking position requires 20 sec, cycle time would still be 10 sec.

Further enhancing productivity and quality are the eight independent motorized spindles. Adjustable spindle speeds range from O to 8000 rpm. The RPM is optimized for each position. The goal with the machine is for parts to come off complete, with no secondary operations required other than inspection and washing, ready for packaging and shipping.

Tornos says that as many as 40 parts/min can be produced on the machine, and it maintains part tolerances of 0.0002" (0.005 mm). Accommodating part diams to 20 mm, the machine can be equipped with a palletizer, or parts may be placed on a conveyor belt. A dedicated bar feeder holds up to 80 bars, and standard tool attachments permit rotary milling, polygon and thread milling, broaching, and cross-drilling operations.

PC based CNC machine tool controllers are starting to become the trend in CNC machining. Retrofitters and OEMs are looking toward the PC as the new machine tool controller platform to accommodate today's need for "high-speed" machining. More and more retrofitters and OEMs are starting to switch from a pre-fabricated controller to a PC based CNC controller for a variety of positive reasons. The most common reasons are described below.

PC based CNC machine tool controllers are less expensive than pre-fabricated controllers. You can replace your existing pre-fabricated control with a PC based controller at a fraction of the cost when compared to replacing your control with another pre-fabricated controller. This cost savings is accomplished because a PC based CNC controller uses a standard Windows based 95, 98, ME, NT or 2000 personal computer, motion control board, digital I/O card and CNC machine tool control software, which are relatively inexpensive components.

If you don't want to build your own PC based CNC machine tool controller, you don't have to. Today, there are several different companies manufacturing various ready-to-go, bolt-on professional PC based CNC controller enclosures. Most of these controller enclosures include all the hardware and software necessary to control your machine including the amps and motors. Users can also purchase separate high-quality hardware and software components and use their own personal computer.

PC based CNC machine tool controllers are easy to install. The idea behind advanced PC based CNC machine tool controllers is to eliminate the need for tracing wires to the PLC or write ladder logic. Rather, the computer becomes the PLC and does the logic thus eliminating the need for PLCs and writing ladder logic. PC based CNC machine tool controller software generally comes equipped with several ready-to-go operator screens to choose from and even customize for ease of use and to get you up and going in minimal time. The software generally allows you to mix and match physical buttons, knobs, gauges, switches, lights and displays with virtual ones.

PC based CNC machine tool controllers are also easy to use. A well designed PC based CNC controller software package generally has the ability for a user to fully customize the control's user interface without being a C++ or VB programmer. For example, the control's user interface is able to be designed by dragging and dropping control objects around the operator screen and then setting each control object's size, caption and functions with fill-in-the-blank or check boxes within Windows. The user interface can be as simple or as feature rich as the operator desires. Control operators are no longer subject to the rigid design of pre-fabricated controllers. PC based CNC machine tool controllers also offer various programming styles such as G code, conversational or CAD to motion.

PC based CNC machine tool controllers are quickly retrofitted. Most companies cannot afford to take months off to get a machine on-line and productive. A good PC based CNC machine tool controller's learning curve is only about 1/5 of the time needed when compared to most controllers that still use PLCs. On average, installation is capable of being done in three days for the most common types of knee mills, bed mills, lathes, lasers, water jets, plasmas and punch presses.

PC based CNC machine tool controllers are capable of stilling running a customer's old G code programs. A state-of-the-art PC based machine tool controller, for example, allows flexibility to run a Fanuc G code program in the morning and then an Allen Bradley in the afternoon. Definable G code and M code tables are generally built into the control to allow configuring the new controller to understand pre-existing programs.

Real time solid modeled or wireframe tool path simulation while the machine is cutting is one of the features a good PC based CNC machine tool controller contains. Being able to perform tool path animation and CNC verification prior to pressing Cycle Start is also an important feature. Simulation provides step-by-step control over each move graphically, moving the light source, solid model rotation and viewing angles.

PC based CNC machine tool controllers are user customizable and are considered an open system. The best software allows screens to be customized without having to be a VB or C++ programmer. Typical Windows-style fill in the blanks and check boxes are used on well-organized screens so that even novice Windows users can drag and drop objects into place and set their properties. More advanced users are able to configure the controller routines to support new processes and new technologies with well-documented software application program interfaces (APIs) made available to all customers as well as source code for ActiveX and DLLs.

All good software supports the ability to integrate third-party applications. PC based CNC machine tool controller software contains, at a minimum, machine maintenance software, remote diagnostics via a modem, self-diagnostics and remote machine tool monitoring via RS232, ActiveX or a Network card. This includes automatic collection of manufacturing data in real time without operator intervention as a standard feature.

PC based CNC machine tool controllers are fast and can easily accommodate today's "high speed" machining requirements. With over 200,000 motion cards shipped to date these cards can achieve 62.5 microsecond servo update times per axis, which result in cutting feedrate velocities of up to 122,000 IPM. Some digital I/O cards can detect a change of state at rates in the 10 KHz range. DSP microprocessors close the servo loop using dual 32 bit micro processors to increase productivity, feedrates, accuracy and cut quality. Multiple events and multiple position motions can happen simultaneously. 3D profiles can even be cutting while the tool is changing. The extra processor on the motion card is not only the best way to close the servo loop with the motors, it is also the fastest method known to date to produce the fastest block-to-block cutting speeds.

With PC based CNC machine tool controllers, maintenance and repair are no longer an issue. Machine operators are now the masters of their own machine. Self-diagnostics are generally a part of every system. When it comes to parts, off-the-shelf Windows 95, 98, ME, NT or 2000 personal computers and brand name hardware purchased from local sources can be used. Are your parts now either so proprietary or hard to find that they do not exist anymore? How long can you be down? PC based CNC machine tool controllers eliminate the need to rely on others. Machine operators can learn how to service, support, maintain and upgrade the complete control and replace any part themselves.

PC based CNC machine tool controllers help eliminate downtime. No more waiting for proprietary parts that can only be obtained through the control's manufacturer. Generally, there is a terminal strip and cable that connects the machine wiring to the computer. All that needs to be done is to unplug the cable from the computer. This will not disturb the wiring to the machine. Next, restore the screens, G codes, M codes and logic files within 10 seconds from a saved backup on a floppy disk. The backup file is also small enough to be emailed. If the problem is the motion or I/O card, either of these can be replaced by anyone without disturbing the wires. If a control breaks, swap out another computer to replace any control for any machine type at anytime.

PC based CNC machine tool controllers are easier and quicker to service. Manufacturers of PC based CNC controller software hire qualified technicians to immediately answer technical questions via phone, fax or email. If application assistance or custom logic is needed, the PC based CNC controller software manufacturer has qualified in-house staff and local reps that can fulfill these needs either on-site or via the internet. Also, most PC based CNC machine tool control software manufacturers do not detach themselves from the hardware boards and takes responsibility for all of the hardware boards they sell.

PC based CNC machine tool controllers allow use of your existing motors and amplifiers. This holds down the cost and labor plus ensures that the motors and amps are sized right for the machine. Good hardware can control existing motors that are: Brush or brushless, AC or DC, servo, stepper, PWM or hydraulic. The amps or drives can be either current driven or velocity type. Spindle drives use current mode or inverters. Feedback can be closed or open loop. Closed loop systems use encoders or resolvers. There are a number of companies that also make digital I/O cards. Touch screens are also available.

Capable of simultaneous 3-tool cutting, C65 features Polygon Generating Capability, 2 Y-axes for turrets, and guide-ways for turrets with slides based on plate-type slide system. Turret slides and counter-spindle slide offer 1 g acceleration rate and rapid traverse rates of 75 and 150 fpm. With 1 5/8 or 21/2 in. bar capacities, machine offers respective max spindle speeds of 6,300 and 5,000 rpm at 20 kW or 26 hp, 100% duty rating and 77 lb-ft torque.


INDEX Corporation introduces its C65 CNC Single Spindle Bar Machine, continuing a 90-year tradition of building successful single-spindle bar automatics featuring a heavy-duty counter-spindle and Y-axis for extended machining flexibility and increased speed.

With optional 42mm (1 5/8inch), or 65mm (2 1/2inch) bar capacity, a maximum spindle speed of 6300, respectively 5000 RPM at 20KW or 26Hp at 100% (60min) duty rating and 105Nm (77ftlbs) torque, the C65 has enough power to do a lot of work in a short time.

Both turret slides and the counter-spindle slide offer a 1g acceleration rate, and rapid traverse rates of 25 and 50m/min (75 and 150 ft/min), adding to the productivity because of its faster motions. These production advantages can often become essential for the survival of a business, particularly for job shops.

According to an Index spokesman, "The new model offers new levels of productivity and flexibility for work done from bar stock. In the past it was either speed or flexibility; with the C- series both goals can be accomplished."

Speed. Three tools are in cut simultaneously almost all the time plus a counter-spindle equipped with the usual Z-axis and X-axis allows the user to complete parts very quickly. Both axes are electronically coupled with the second turret (slave- axes). As a result, the third turret can be working on the part in the counter-spindle while the other two turrets work on the main spindle, so that three tools may be in cut simultaneously. In addition, C65 productivity benefits from higher machining power and higher acceleration and traverse rates.

Flexibility. Two Y-axes for the turrets and a very powerful counter-spindle provide flexibility unmatched by other automatics for machining even complex parts without compromising speed or productivity.

An additional innovation is the Polygon Generating Capability which results from the counter-spindle operating as a polygon generating attachment. The actual polygon generating head is mounted directly on the face of the chuck. No additional equipment is required. The very high rotational inertia and stiffness of the counter- spindle assures vibration-free cuts, as well as long tool life, even on alloy steel.

An innovative highlight of the CS42 is in the design of the guide-ways for the turrets. The slides are not based on the traditional linear system, but on a highly innovative plate-type slide system. The slide surfaces are made of a match between a cast iron plate, and steel strips with ceramic-coated slides. This slide system offers significant advantages over the traditional slide ways: several times greater stiffness, improved dampening characteristics, and it is more compact. The actual axis drive is accomplished by rod-kinematic drive linkages arranged on the rear of the cast iron machine bed.

Despite its large working range, the machine exhibits a compact screw machine size design, requiring little floor space to make sure it fits into every shop that runs screw machines When speed and productivity count, which is the case in a screw machine shop, the C65 will be hard to beat.

ACF Machine, Inc., Union, Missouri, has recently instal led a new Citizen L720 CNC Swiss turning center.

The firm, operating since 1992, specializes in production CNC turning. It started out in Art Fink's garage with a single piece of equipment.

Today, Fink's firm has five employees in a 6,000-sq.-ft. facility with five pieces of CNC equipment. Each piece has a sub-spindle and live tooling.

Above (1-r): ACF's Doug Kappelmann, McClain Machine Tool's Gene Jacobs & ACF's Art Fink.

The new seven-axis Citizen Swiss turning center, purchased through McClain Machine Tool Solutions in St. Louis, features: a 10,000 rpm spindle; 18 tools (seven live); 700 series Mitsubishi Windows controls; bar capacity up to 20mm (3/4"); and a CAVL20 magazine barfeeder.

Fink noted that ACF Machine purchased the new Swiss turning center for the speed, efficiency and quality it offered, and to keep up with the company's growth. He especially likes the unmanned capabilities that it provides and that it is all Servo controlled (no pneumatics or hydraulics).

The company, which is ISO compliant, produces small to large production runs from all standard metals and most plastics in many shapes and configurations. They can also work with customers on parts design and development.

ACF serves a wide range of commercial and industrial customers throughout the mid-America region.

When asked about what accounts for ACF Machine's success and growth Fink stated, "Good customer relationships along with our industry knowledge and expertise." Fink and Shop Manager Doug Kappelmann combine for almost 45 years of manufacturing experience.

In multispindle machining, the longest operation at a given position dictates the time required to make a complex part. Generally, the position dedicated to working on a part's back end takes the longest time, because just one spindle performs different operations.

To overcome this problem, Tornos Technologies US Corp. (Brookfield, CT) has developed the MultiDECO 20/Sd, an eight-spindle machine with two independent, three-axis backworking stations. In essence, according to the company, it's a ten-position machine.

In operation, positions one through six are used to work on the front of the part. Every two indexes, two parts are cut off in positions seven and eight. Those parts are then taken by the two independent pickoff spindles, and presented to as many as five tools per part for backworking. In theory, then, if the longest front-work operation is 10 sec, and the backworking position requires 20 sec, cycle time would still be 10 sec.

Further enhancing productivity and quality are the eight independent motorized spindles. Adjustable spindle speeds range from O to 8000 rpm. The RPM is optimized for each position. The goal with the machine is for parts to come off complete, with no secondary operations required other than inspection and washing, ready for packaging and shipping.

Tornos says that as many as 40 parts/min can be produced on the machine, and it maintains part tolerances of 0.0002" (0.005 mm). Accommodating part diams to 20 mm, the machine can be equipped with a palletizer, or parts may be placed on a conveyor belt. A dedicated bar feeder holds up to 80 bars, and standard tool attachments permit rotary milling, polygon and thread milling, broaching, and cross-drilling operations.

The company recently introduced the Hardpoint 300, a CNC machine that combines turning, drilling, milling and grinding. It is a modular concept machine and can be configured with up to four main spindles and a variety of tooling combinations, depending on user needs. The machine can machine the front and rear faces of a single part; machine a single face on two parts simultaneously; machine the front and rear faces of two parts simultaneously; or machine a single face on four parts simultaneously.

The company says its product represents a flexible and economic machine concept for high-quality, complete machining of small components. The axes is variable, with up to ten possible. The machine offers fully automatic, synchronous complete cutting of complex workpiece geometries, up to a diameter of approximately 3" x 3" (80 mm x 80 mm).

The modular machine concept is said to ensure machining efficiency and flexibility. The various platforms are said to allow several cutting processes to be combined, thereby eliminating the need to operate multiple machines. The company says this reduces floor space requirements and operation costs. The machine incorporates an internal gantry loader. External loaders are also available as is a post-process measuring system.

Based on single-piece frame cast from polymer composite material, Genesis(TM) 130H can be installed and re-located with no special lifting equipment. Direct-drive spindle motors eliminate need for mechanical adjustments, while cam-driven double gripper loader enables part load/unload times of 2 sec. Work area is isolated from machine frame to minimize thermal expansion from contact with hot chips. Stainless steel cutting chamber with steep inclination ensures that chips fall clear of work area.


Rochester, New York, February 16, 2006-- Gleason's new Genesis(TM) 130H CNC Vertical Hobbing Machine features a revolutionary new design that optimizes dry machining, significantly reduces floor space requirements and greatly improves cycle times.

The 130H Hobber is the first in a new family of gear production equipment from Gleason called Genesis(TM). All of the Genesis machines share a common platform: a single-piece frame cast from an advanced polymer composite material, which can be made faster, more accurately and with inherently more rigidity than conventional cast-iron assemblies. This common platform design also ensures a small, compact machine footprint and enables the user to install and re-locate the machine with no special lifting equipment or special foundations.

While the 130H Hobber can accommodate wet cutting processes, it is particularly well-suited for dry machining. The work area is completely isolated from the machine frame to minimize thermal expansion from contact with hot chips, and a stainless steel cutting chamber with steep inclination ensures that chips fall completely clear of the work area.

The 130H Hobber is equipped with an innovative new mechanical cam-driven double gripper loader fully integrated into the machine. As a result, costly non-productive time can be cut to a minimum, with part load/unload times as short as two seconds.

Unlike conventional hobbing machines, the Genesis 130H utilizes a new, patent-pending hob drive system to eliminate complicated mechanical and hydraulic clamping systems. Instead a simple "D-Drive" system enables the spindle to transmit more torque, with less runout, and at the same time accommodate the use of larger diameter hobs for greater performance and longer tool life.

The 130H also features direct-drive spindle motors, which further reduces setup and machining times by eliminating the need for mechanical adjustments and change gears. Higher acceleration/deceleration rates and increased torque, combined with faster axis motions reduce non-cutting time between cycles and increase overall productivity during machining.

Other significant features include:

o An Easy Access Service Module that consolidates hydraulics, lubrication and pneumatics into one location.

o Optional on-board chamfering and deburring capability.

o Availability of the latest SIEMENS or FANUC controls and the latest Gleason software running in a true Windows[R] environment.

o The chip conveyor may be located from either the side or rear of the machine to meet any cell/system arrangement.

Gleason Corporation is a world leader in the development, manufacture and sale of gear production machinery and related equipment. The Company's products are used by customers in automotive, truck, aircraft, agriculture, construction, power tool and marine industries and by a diverse set of customers serving various industrial equipment markets. Gleason has manufacturing operations in Rochester, New York; Rockford, Illinois; Dayton, Ohio; Plymouth, England; Munich and Ludwigsburg, Germany; Bangalore; India, Studen, Switzerland; and Harbin, China and has sales and service offices throughout the North and South America, Europe and in the Asia-Pacific region.

Designed to optimize CNC machining process, VERICUT v6.0 can simulate multiple setups in single session. Collision checking monitors spindle states, enabling program to catch programming errors with spindle and cutting tool usage. With in-process model of simulated workpiece, inspection and process documents accurately reflect state of workpiece at any stage of process. Model Export creates CAD models from in-process cut model generated by simulating NC program.


(Chicago, Illinois - Wednesday, September 6, 2006) - CGTech showed the latest version of VERICUT CNC machine simulation and optimization software at IMTS in booth D-3035. VERICUT 6.0 has many new features designed to increase the ability of CNC manufacturing engineers to analyze and optimize the entire CNC machining process in order to increase manufacturing efficiency.

"Due to global competitive pressures on our customers CGTech is increasingly challenged to simulate more complex processes and more complex machines," said Product Marketing Manager Bill Hasenjaeger. "VERICUT 6.0 ties these complex processes together with the ability to simulate multiple setups in a single simulation session."

VERICUT 6.0 also includes enhanced collision checking that monitors spindle states for milling and turning simulation, enabling VERICUT to catch common programming errors with spindle and cutting tool usage. Additionally, significantly enhanced simulation of complex cutting tool shapes commonly used in production processes shows the NC programmer or manufacturing engineer exactly what will happen when using the tool.

"The result of this work is a tightly unified environment for simulating complex mill/turn multi-function machining centers for production processes," said Hasenjaeger. VERICUT 6.0 leverages the results of simulating these complex processes with the ability to create inspection instructions, CNC inspection programs, and automated process documentation using the simulated workpiece. Because of VERICUT's accurate feature-rich in-process model of the simulated workpiece, the inspection and process documents utilize and accurately reflect the state of the workpiece at any stage of the process.

To ensure VERICUT's simulation is as accurate as possible, CGTech has partnered with many key machine tool builders, control manufactures and CAD/CAM companies. CGTech's Technology Partner Program establishes a cooperative working relationship with a goal of helping mutual manufacturing customers maximize their success and productivity.

"IMTS is a fantastic show for us because not only do we get a chance to meet with many current and future customers, we can meet with most of our partners under one roof. No other show is that productive," said Hasenjaeger.

Some of the new and improved features users will find in VERICUT 6.0 include:

Multiple Setups in a Single Session

With the new Project Tree in VERICUT 6.0, the manufacturing engineer can organize all his NC process steps in one place and the workpeice(s) transition from setup to setup automatically during the simulation. Each setup has its own CNC machine, fixtures, tools, NC programs and simulation settings. The cut stock moves from setup to setup, with automatic orientation. Once a user selects the CNC machine configuration, the stock, fixture and design component information is attached to the machine, ready to simulate the entire set of machining operations.

Simulate Machines with Multiple Synchronized Tools

VERICUT 6.0 now offers the capability to synchronize up to 32 machine "channels" or machines with multiple synchronized CNC controls. VERICUT's virtual machine is organized into multiple sub-systems that can all synchronize together seamlessly.

New Tool Manager Speeds NC Program Optimization

VERICUT's NC program optimization module--OptiPath[R]--is easier to implement thanks to a redesigned Tool Manager. OptiPath tooling data is now stored inside the Tool Manager. This simplifies the implementation by placing all relevant tool information in one place. Creating new tools has also been simplified. The new tool assembly wizard allows the user to create a new milling tool in one simple panel by answering a few questions.

Model Export Enhancements

Model Export creates CAD models from the VERICUT 'in-process' cut model generated by simulating an NC program. The model includes machined features such as holes, fillets, corner radii, pocket floors and walls - exactly as it is cut on the CNC machine. In VERICUT 6.0, Model Export outputs features where possible and also "synthetic features" when individual features are not possible or desirable (such as "scallops" created by a ball endmill).

Create CNC Probe Programs and Inspection Sequences

VERICUT is an ideal place to create probing routines because of the 'in-process' model which is not available anywhere else in the CNC manufacturing process. Rather than having to create additional "manufacturing" CAD geometry that "hopefully" represents the as-cut workpiece, using VERICUT's simulated in-process feature geometry to create the CNC probe program makes on-machine in-process inspection a practical reality. In addition to on-machine probe programming, VERICUT 6.0 allows the creation of customizable inspection reports in HTML or PDF format for use by machine operators or quality control staff.