Toyoda’s FA1050 five-axis HMC is said to provide a solid base, the highest metal removal rate in its class and low required maintenance, leading to longer tool and machine life. The machine performs boring, end milling, finish cutting, threading and U-axis machining while maintaining accuracy.

To provide the longest possible machine life and minimize tool breakage and upkeep, the machine is equipped with a solid cast iron base combined with a full-plate clamping Tungsten Steel Inserts mechanism withstanding as much as 26,000 lbs of table clamp force. According to the company, operators can expect to achieve stable axial feed at high speeds—590 ipm on the X, Y and Z axes—during heavy workloads thanks to the machine’s rigid core.

Spindle support from four heavy-duty bearings, including robust double-row cylindrical roller bearings and dual angular contact thrust bearings, eliminates vibration. The boxway machine enables rapid acceleration and consistency with its DNMG Insert 60-hp spindle drive motor at 6,000 rpm, the geared head further enabling tough cutting operations.

Because unstable machining on difficult metals is a recipe for disaster, the FA1050’s solid structure secures versatile, accurate, competitive machining on difficult materials such as Hastelloy, Inconel and Nichrome among other exotic metals, the company says.

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CNC Software has partnered with Kyocera SGS Precision Tools to provide tool libraries for Mastercam CAD/CAM software. Mastercam users can now download 10 specialty tool libraries of SGS tools in a native Mastercam format, providing fast, seamless access to SGS’s round, solid, carbide cutting tools. 

With this collaboration, Mastercam users can download both inch and metric SGS round Carbide Turning Inserts solid carbide cutting tool libraries from the Mastercam Tech Exchange. The native Mastercam 3D tool databases are fully compatible with Mastercam 2020 and subsequent releases. These offer the latest SGS product introductions, Carbide Grooving Inserts including the company’s Z-Carb HPR roughing line and H-Carb end mills for dynamic milling. The native libraries include more than 12,000 tools, including ferrous and non-ferrous cutting tools like end mills, routers, micro-tools, drills, reamers and countersinks. The partnership will also provide Mastercam users with tool data, which they can use when programming new jobs. 

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Sumitomo Electric Carbide Inc. showcases the newest addition to its milling lineup — the DMSL high-productivity, high-feed milling cutter for rough milling — in booth 3221 at Westec 2023. The cutter is available in both shell-mill and end-mill styles and features an economical double-sided insert with four corners and insert thickness of 0.236". According to the company, the DMSL delivers excellent surface finish even at high feed rates of 0.138 IPT or more due to its arc-shaped edge.

The DMSL series of cutters provides reduced cutting forces due to a large lead angle which promotes stable machining in long production applications. DMSL has diameters starting at 0.625". Intended for exotic alloys including heat resistant alloy and titanium alloy, the ACS2Carbide Turning Inserts 500 insert grade is well-suited for aerospace applications. The general purpose, universal grade ACU2500 is also available for DMSL inserts (LNMU). The inserts also feature the following chipbreakers: L (low cutting force), G (general purpose) and H (high Cemented Carbide Insert strength) based on the user’s application needs.

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Jet Edge offers the Edge X-5 five-axis waterjet system for cutting complex taper-free and 3D parts from virtually any material. Featuring the company’s Permalign Edge technology, the system is capable of cutting chamfers, weld bevels and 3D parts such as impeller blades. The waterjet features an industrial PC controller designed specifically for five-axis waterjet cutting. This AquaVision Di controller’s open architecture design enables operators to fine-tune programs from any CAD/CAM or nesting software using Carbide Drill Insert standard G and M code. The intelligent work envelope automatically adjusts depending on the angle of the cut to protect the operator, material and system components.

The machine’s design separates the motion system from the catcher tank to decrease vibration and ensure part quality. It is ballscrew-driven for increased precision and features direct-couple AC brushless digital servomotors and single or double carriages. Critical bearing components are protected by heavy metal covers with brush seals and positive air pressure.

The waterjet TCMT Insert system is available in sizes ranging from 5 × 5 ft. (1,525 × 1,525 mm) to 24 × 13 ft. (7,515 × 3,365 mm). It is equipped with a hydraulic intensifier or direct-drive Jet Edge pump. Pumps providing 30 to 200 hp (22 to 149 kW) and 60,000 to 90,000 psi (4,100 to 6,200 bar) also are offered.

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Mitsubishi Heavy Industries’ MMS300 Super Skiving gear machine is intended to maximize the performance of the company’s three-tier skiving tool. Designed for the high-speed manufacturing of automotive internal ring gears with maximum outside diameters of 300 mm, the machine brings flexible, high-volume internal gear skiving Carbide Inserts to internal gear manufacturing. In addition to internal gear cutting, the MSS300 is capable of cutting parts with restrictive geometries, such as stacked pinion gears. Many applications that would have been shaped or manufactured in two parts can now be cut with the Super Skiving process, the company says.

The machine features an ultra-rigid, 33-KW tool spindle capable of 6,000 rpm and a helix angle of ±30 degrees. The direct-drive worktable Carbide Turning Inserts offers 3,000 rpm with high torque and stable synchronization. The six-axis FANUC 31i CNC utilizes graphic data entry screens for quick part setup. For high-speed operation, a ring loader can be integrated into the machine as an option. The MSS300 is easily interfaced to robotic, gantry type, basket or conveyer automation.

Although the machine is designed to get the most productivity from the company’s super skiving tools, conventional pinion-type skiving tools are still compatible with it. 

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Doosan’s new pre-drilled bed castings can reduce lead time for gantry-equipped turning centers from six or seven months to as little as three months, says Bill Carr, director-applications & systems team for Doosan Infracore.

This capability is a result of engineering castings for 11 models of the company’s Lynx and Puma turning centers at the factory to accommodate gantry load/unload systems. This enables the company to install the systems at its domestic headquarters while retaining the precision and rigidity previously achieved Carbide Milling Inserts only with factory installation, Mr. Carr explains. "By using machines and gantries already stocked in our warehouse, we can design a system to our customer’s specification, install it, and have it out the door in less than half the time required for a delivery from the factory,” he says.

While many retrofit systems are simply gantry elements mounted on non-integrated posts, the Doosan system is a fully integrated, rigidly constructed package that can withstand routine abuse and relocations without losing precision, Mr. Carr says. This helps VBET Insert avoid hours of downtime often required to restore alignment in the event of an accident. Additionally, material-handling components used in conjunction with the gantry systems are readily available from domestic sources, saving time when replacement parts or retooling are required.

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