Emuge Corp. (Northborough, Massachusetts), has expanded its line of Full-Speed taps with ten new styles, each available in 20 different sizes, in both inch and millimeter. "The taps allow exceptionally fast tapping at record speeds on modern CNC equipment," explains Emuge President Peter Matysiak. "Increased speed reduces cycle time while improving thread quality. If tapping time is reduced by 10 minutes per hour at a machine rate of $150, annual savings of $125,000 can be achieved and capacity can be increased by 833 machine hours."

The new taps are designed for freer, faster and more efficient cutting. The taps feature an advanced cutting geometry that reduces friction between the workpiece and the tool, according to the company. High-profile relief angles permit increased tapping speeds, reduced heat and longer tool life. An optimized number and shape of flutes, a shorter thread length, extremely hard surface coatings and coolant-through technology also contribute to the tool's improved performance.

Alan Shepherd, technical director for Emuge, explains that the Full-Speed taps were developed to tap at least two to five times faster than conventional taps. Achieving such performance improvements involves more than simply replacing a conventional tap with one of its newer tools. The tool is only one component (albeit an important one) of a system that includes a modern CNC machine tool with a rigid (synchronized) tapping cycle, a collet-type tap holder and, where applicable, use of a tap with coolant passages to deliver high-pressure coolant directly to the cutting zone.

"With all of the above elements in place, shops accustomed to tapping cast iron at speeds of 60, 70 or even 100 surface feet per minute with conventional taps will find that they can tap at speeds as high as 250 surface feet per minute with our new tools," Mr. Shepherd reports. "In tapping of stainless steels, users can go from 20 surface feet per minute to 80 to 90 surface feet per minute. They can cut cast aluminums at up to 250 surface feet per minute and tap mild steels even faster." The accompanying table compares the cutting speeds of the new taps to conventional taps for a range of materials.

In addition to faster tapping rates, the tools offer longer tool life—two to ten times the life of conventional taps in cast iron, according to Mr. Shepherd. Frequent tap breakage is no longer a common problem for metalworking firms. Mr. Shepherd attributes this to improvements in new machines, synchronized speed and feed controls, improved tap holders and improved taps. Another consideration: Holes are increasingly being drilled and tapped in the same setup on the same CNC machine, so that the tool breakage problems associated with tool positioning errors have virtually disappeared.

Envizage will unveil its new model-making technology, CAP-CARBON, and new range of classroom-friendly Denford micro-CNC machines on Stand 3519 during National Manufacturing Week 2007 at the Melbourne Exhibition & Convention Centre, from May 22 to 25.
Envizage will also demonstrate its Modelmaker laser scanner on its stand, as well as provide information about its roto-moulding service.

A broad range of services are provided by Envizage, including rapid prototyping, model making and low-volume manufacturing. Envizage also supplies designers with software from Autodesk (Maya, Studio, ImageStudio, Motion Builder, Showcase and Sketchbook Pro) and hardware from Hewlett Packard. Envizage also offers accredited training and services/support.

Model making services fall into four categories namely concept, functional, presentation and pre-production. Concept models help a designer see and feel what their idea will look like in the flesh. Functional models are tough and durable to help prove a design, and can include working hinges and latches.

Presentation models are ideal for when a designer has to impress, or needs real accuracy to verify the design for manufacture. Pre-production models are a short run of mouldings, castings in any material, or low volume tooling. This is a highly cost-efficient means of proofing a product before committing to manufacturing it.

Envizage can produce models in materials such as metals, plastics, rubber seals, see-through, and in colour or metallised surfaces. Envizage helped a customer make a life-size ride-on mower with working electrics to show resellers before the national launch.

Envizage also created a lifelike scale replica of a million dollar mining vehicle so that the client could take it to international trade shows.

UK company is renowned for the design and manufacture of precision CNC tube forming machinery - including systems for highly complex car and truck exhaust systemsAcross the world, Preston-based Addison Tube Forming is renowned for the design, supply and manufacture of precision CNC tube forming machinery for numerous industries - including the manufacture of today's highly complex car and truck exhaust systems. Across the Atlantic, sister company, McKee-Addison, of Ohio, USA, produces the widest range of end forming machines and associated tooling, all of which are frequently used in tandem with Addison bending technology.

Indeed, ever since the two companies of Addison Tube Forming and McKee Tool Corporation became one back in 1998, they have provided the only real choice for innovative CNC tube bending, forming and cutting machinery.

* New name - new corporate identity - today, with both Addison and McKee-Addison's tube bending and forming technology ranges now globally recognised across the international automotive, shipbuilding, aerospace, air conditioning, furniture, sports and hospital equipment industries, the company has decided that the time is now right for both organisations to simply trade as AddisonMckee.

* Worldwide expertise - commenting on the decision to adopt a single company name, AddisonMckee's UK export and sales director, Peter Chapman said, 'Since the original merger of Addison and McKee back in the late 1990s, both companies have grown to become acknowledged experts in all aspects of tube forming technology.' He said: 'At Addison, we are technical leaders in both machine design and application experience, whereas McKee can claim similar achievements in the end forming arena.

Coincidentally, we have both developed all-electric models to help eliminate the need for hydraulic systems.' Chapman added: 'Globally recognised as leaders in our field - and with new product developments in the pipeline - we have decided that the time is now right to adopt a single company name.

In short, whether it's tube bending or end forming there's only one name to remember - and that name is AddisonMckee.' * Global image - along with the adoption of a single name across all its operations, a new corporate identity, specially created to clearly establish AddisonMckee as a global brand, has also been produced.

* World class - AddisonMckee's skilled workforce is capable of manufacturing CNC tube bending and end forming machinery and tooling to suit virtually any application.

At its UK plant the company produces a range of over 50 basic hydraulic and electric CNC machines that can bend pipes ranging from the 4mm sizes used in automotive components through to the 273mm tubes used in shipbuilding.

The company manufactures a wide range of end forming equipment, tooling and other associated machinery from its base in the USA.

World-leading tube-bending and end-forming technology specialists, AddisonMckee, of Preston, UK, and Wilmington, USA, have developed a high-performance, lower cost tube bending range aimed specifically at the more basic requirements of the tube bending industry.

Benefiting from AddisonMckee's reputation for quality, precision and reliability, at an exceptionally competitive price, the new Powerbend range combines years of proven design techniques to provide the high levels of accuracy, repeatability, prompt tool change and ease of operation as required by today's manufacturing industries.

High quality solution of international standards

"As the leading innovator and provider of tube bending technology," commented AddisonMckee Sales & Marketing Director, Peter Chapman, "we have been able to use our expertise to provide a high quality solution for those companies who would ideally like to invest in AddisonMckee equipment, but have not always been able to justify the sophisticated capabilities that some of our machines offer. In the new Powerbend range we have created a choice of exceptionally durable models of international standards and revolutionary design, each with the added advantage of an exceptionally attractive price point. From launch, there will be a choice of 50mm, 75mm, 100mm and 125mm diameter capability models."

Impressive capabilities

Hydraulically-powered mandrel tube benders, capable of bending carbon steel tube from 50mm diameter to 125mm diameter, the models in the new Powerbend range offer maximum bend angles and CLR of 180[degrees] and 250mm respectively.

Machine beds and tanks are of one integral assembly. Hydraulic valves and filter are externally mounted for easy access. Electrical connections to the valves are of the plug-in type with position indicators. And the bend head is mounted to the bed on slideways and is adjusted laterally for CLR setting by means of a lead screw.

Main spindle

Mounted on heavy-duty taper roller bearings, the main spindle carries the bend arm. Rotation is by hydraulic cylinder connected to the spindle by chains. The angular position feedback to the servo is by encoder, through instrumentation grade gearing from the main spindle.

Simple to locate bend die

Easily located on the bend arm on double drive keys, the bend die is retained by a single nut if a tool spindle is used or bolted directly to the tooling platform for small CLR bending.

Clamp die mounting slide

The clamp die mounting slide is hydraulically powered with toggle mechanism for maximum gripping pressure and operated in a rise and fall motion to clear the tube on subsequent Y axis feeds. The clamp block moves across the clamp slide by lead screw for CLR adjustment. Clamp tooling is drop-in type with simple height adjustment.

Reaction arm / follower slide

Hydraulically powered and direct acting, the reaction arm carries the follower slide which takes the pressure die and is infinitely variable for speed via valve adjustment. The drop-in pressure die has simple screw adjustment for ease of alignment with the bend die.

Wiper die mounting

A rigid mounting post with three axis adjustment for easy set-up ensures good quality bends and long die life.

Plane of bend unit

On all models, the tube carriage (Y axis) moves along the machine bed on precision low friction bearings. Linear motion is by AC motor drive, with position feedback by absolute encoder. The collet is carriage mounted, with rotary motion (B axis) provided by AC motor, with absolute encoder position feedback for precision and repeatability. The master collet is designed to accept segments for the required tube diameters, clamping is by hydraulic cylinder actuated mechanism.

Mandrel unit

Fitted as standard with hydraulic actuation, the mandrel unit includes one 22mm diameter quick-change rod. Anticipated mandrel retraction is standard for high bend quality. Additional rods and automatic mandrel lubrication are offered as optional extras.

Allen-Bradley control

Programming of all Powerbend models is provided by an Allen-Bradley alphanumeric keypad. The many simple routines and features available include: tool monitoring to prevent collision; inch/imperial data input; 1000 programme storage; maximum 16 bends per programme capability; Y, B, C axis data input and automatic release of tube prior to final bend to prevent follower die / collet collision.

Simple milling-type operations can now be combined within the same cycle as turning on a flat bed manual/CNC lathe following the development by Colchester-Harrison of the latest Alpha 1550 XM. The new machine incorporates a c-axis spindle drive with either a Capto toolpost or an eight position indexing turret that are both able to carry driven tools.
combination manual/CNC lathe, Colchester-Harrison, TS Harrison, Harrison Lathes
Central to the Alpha success has been the combination of control and software interface for turning single components with the added advantage of performing repeat cycles under CNC direct from memory. Now, with the added capability to perform tasks such as pitch circle drilling, tapping, milling, slotting or profiling off-centre line, in the same cycle as turning the component, this provides a totally new opportunity for users, to improve efficiency and quality, especially in the toolroom, workshop or subcontract machine shop.

By providing the capability to turn components and produce other features within the same setting, the Alpha XM concept enables geometric relationships of these features to be maintained to the main datums. Not only does this improve quality, it eliminates the need for resetting the job on other machines, simplifies inspection and reduces jig and fixturing requirements.

The Alpha 1550 XM has a swing over the bed of 554 mm and options of 2 m or 3 m distances between centres. It is powered by a 15 kW spindle motor with c-axis having a maximum speed of 105 revs/min and a resolution of 0.001 degrees. The high torque drive of 152 Nm through an all-electric three speed gearbox enables the correct ratio to be automatically selected from the Fanuc 21iTB control. Speed ranges are 1 to 224 rpm, 1 to 672 rpm and 1 to 2,000 rpm.

The Capto toolpost provides a quick-change, three-way toolpost for turning and milling with internal coolant supply while the optional 360 mm diameter Duplomatic eight-station indexing turret, has four driven tool positions and four fixed tools.

It is the control and manual Guide i software combination that separates the Alpha from other machine types and with the 1550 XM, the off-line programming software AlphaLink is included as part of the machine package. Included is full simulation and toolpath animation available to view in any direction or full 3D model format that can be cut, sectioned or zoomed on the 10.4 inch LCD screen.

Included in the software are rigid tapping and continuous thread cutting cycles as well as constant surface speed, 32 pairs of tool offset and 64K of part program memory with an option to extend this to 128K.

Kimray Inc. in Oklahoma City manufactures control valves and related equipment for oil and gas-producing companies. It reports a 40% to 50% increase in machining efficiency due largely to CNC-based production machines.

The company's turnkey manufacturing facility houses dozens of lathes, grinders, and turning, milling, sawing, and bore-finishing/honing machine tools. Nearly all have CNC systems, including its Emco Maier Emcoturn 420 MC Plus and Hyperturn 665 MC Plus lathes, which sport Siemens Sinumerik 840D CNCs and Simodrive 611D drive packages.

"I can do so much more with the Sinumerik 840D, such as programming and cut-and-paste operations, while the machine is running," reports one of Kimray's lathe operators. "Each screen lets me go into a lot of detail for such tasks as separating mains from subs with part and workpiece programs."

The operator uses the Siemens CNC for axis and spindle movements on both Emco machines. He easily accesses programs and data and transfers it back to the machines (from the company's main host system) as needed.

He also comments that on a typical setup, he "likes the sensitivity — the ability to move the axis a ten-thousandth to a hundred-thousandth at a time." He goes on to say that "the control's program-test feature is useful for new programs. Each tool has its own geometry page and up to four offsets, which makes my job less complicated."

According to Tom Jackson, director of sales-support operations for Emco Maier USA, the company's 420 machine permits simultaneous production of two parts without interruption or collision. The Siemens digital drives produce dynamic performance in both the main spindle and X/Y axes.
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