VOLUME1 NUMBER3

FALL97

Haas Automation, Metalcrafters and Pathfinder Explore Mars

Features A New Set of Chisels Machining Complex Models The ABCs of Probing New Products VR-11 Zip Drive Capability

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VOLUME1

FALL1997

In this issue of
EditorialStory 1
n the last edition of CNC Machining I discussed changing technology and its effect on business and the work force. The article touched on the rising standard of living resulting from technology, and the higher skill levels required to make our new technologies productive. The discussions that ensued from that editorial centered on the work force, with the number one question being: Where can I find these higher skilled people? In the search for an adequate response to this question, the words of John F. Kennedy kept coming to mind. He said, Our progress as a nation can be no swifter than our progress in education. I keep feeling that JFK was right, but history has proven him wrong. Both the level and standard of education of the average citizen in the U.S. has declined horrendously in the past 30 years. All statistics point to a public school system that barely teaches minimum basic education. This is by U.S. standards, which are among the lowest of all industrialized nations. Yet, we continue to advance at an alarming rate through technological innovation. How is this happening? But, I digress. The answer to the number one question, Where do I find qualified people? You dont find them, you grow them. But, you dont have time to find basically good people with unemployment levels at 4.5% there is not much to choose from and train them to handle all the new technology you are introducing. And if you did, once trained, they would just go elsewhere for a few cents an hour more. All that investment would be wasted. These are the responses I hear from everyone I talk to in the machine tool business. So, what are you to do? Haas has been suffering through the same labor problems and theyve been exacerbated by our tremendous

EDITORIAL

NUMBER3

The Work Force of Tomorrow

By Denis Dupuis, General Manager, Haas Automation, Inc.

IndustryNews

2
The Work force of Tomorrow

growth. Over the past couple years, I have spent some time working with a few gentlemen in the Los Angeles area on exactly this problem. Bill Lavoie and

At the same time, we have worked with David Goodreau (Chairman of the Small Business Association) and Barry E. Stern,

ShopFocus

6
Haas World Tour, Website Update

TechTips

A New Set of Chisels Machining Complex Models ................pg 8 Simplifying Turning of Stainless Steel ................................................pg 14

ShopFocus

Grow Your Productivity With a System for Insert Selection ............pg 22

12

The ABCs of Probing........................pg 24

Focus on Mold Making ......................pg 12

NewProducts

30

Haas Pushes the Envelope with Larger Machines and New Capabilities

On the Cover
Mars: an artist's rendering of Mars landscape, Pathfinder and Sojourner, courtesy NASA/JPL/Caltech. Metalcrafters, of Simi Valley California, used Haas CNC machines to fabricate parts for the Pathfinder. See page 16 for complete story.
Sojourner, Mars Rover, and spacecraft design and images copyright 1996-97, California Institute of Technology. All rights reserved. Further reproductions prohibited.

page

THE MASTHEAD: CNC Machining is published by Haas Automation, Inc., 2800 Sturgis Road, Oxnard, CA 93030 805-278-1800, Fax 805-278-6364. Postmaster: Return invalid addresses to Haas Automation, 2800 Sturgis Road, Oxnard, CA 93030-8933 postage guaranteed. CNC Machining is distributed free of charge by Haas Automation, Inc., and its authorized distributors. CNC Machining accepts no advertising or reimbursement for this magazine. All contents of CNC Machining are Copyright 1997 and may not be reproduced without written permission from Haas Automation, Inc. CNC Machining is distributed through a worldwide network of Haas Automation Distributors, and by individual subscription request. Contact Haas Automation headquarters via mail or fax to be added to subscription list. Published quarterly. Haas Automation, Inc. & CNC Machining Magazine names. Designed and Printed in the U.S.A. www.HaasCNC.com

Ron Smetzer (of local community colleges) helped us sign up with Californias apprenticeship program some years ago. We initially entered six of our employees in the program, which consisted of full-time work during the day and machinist classes at night. The program varies from two to four years, depending on the needs of the student. Unfortunately, the state program only supported training on manual machines far below the level of training we needed. We were looking for CNC machinists and programmers, the state program was far behind the technology in aspects of training requirements. Haas Sean Tillett (Machine Shop Manager Turning) worked with Lavoie, Smetzer and state representatives to upgrade the program in an attempt to raise it to the level we needed. The program has been a fruitful, albeit long-term, project.

Ph. D., who are proposing reforms focusing on the last two years of high school education in California. They believe the Adult Education system is well positioned to take on the task and should play an important role in implementing these reforms. They are currently compiling the statistics necessary to further a reform package and hope to make some headway in the near future. While this is a local story, there are groups in every state attempting similar school system reform. I believe we, as employers, must take an active role in helping these associations improve the secondary school system, so it generates the basic level of knowledge we need to meet our labor demands today and in the future. It has long been known that European countries hold a sizable lead over the U.S. when it comes to apprenticeship programs. However,
Continued on page 32

NEWS
INDUSTRY NEWS

Haas European Vacation

Haas Web Site Redesigned

Over the past six weeks, Haas Automations popular web site has been undergoing a transformation of sorts. The marketing department has been very busy designing a new and improved Haas Home Page filled with even more useful information. Every area of HaasCNC.com has undergone some level of evolution, said Peter Zierhut, Marketing Manager at Haas Automation. By looking at each area individually, and building upon an already successful program, we have actually doubled the content of our web site. The backbone of the Haas page is the machines, and that hasnt changed. They are still the stars of the show. But everything was open to improvement, Zierhut explained. For example, the machine areas each grew considerably, with the addition of new machines to the specifications data base, drawings and specifications of overall machine dimensions, and a listing of available options for each of the three major CNC machine lines. The Dealer Network area has also been completely redesigned, and is now navigated via a series of detailed maps and pop-up distributor listings. In addition, theyve added the following new areas to the Haas web site: A New Technology area featuring the latest features, options and CNC technology from Haas Automation; a Quality Assurance area detailing Haas systematic testing procedures and their 98% Up-Time Guarantee; a Promotions area spotlighting the latest promotions and factory-direct incentives; a News section where visitors can read the latest news releases about Haas and Haas products; an Employment area featuring Haas employment opportunities; and a CNC Machining area where readers get a taste of Haas quarterly magazine and can sign up for a subscription. The new Haas web site should be up and running by the time you read this, so go and surf your way to HaasCNC.com.

HANNOVER, GERMANY By the time you read this, Haas Automation will Haas management. This should result have participated for the first time in a tiny little trade show in Europe called EMO in increased coverage in the internaHannover 97. For those of you who dont know, EMO is the largest international tional press, and increased product trade fair for metalworking in the world. In other words, nearly 2,000 exhibitors recognition throughout the world. from 37 countries filled 19 halls and 148,414 square meters of stand space to As Haas continues to grow at a present The Whole World of Metalworking to more than 160,000 visitors from break-neck pace, it becomes increas56 countries. ingly important to expand their Phew! Now that weve gotten that cleared up, what EMO Hannover was to international customer base. EMO Haas was an opportunity to showcase high-quality, American-made, affordable Hannover the biggest trade show in machine tools to the rest of the world. Haas descended on the show with an the world was another step toward impressive line-up of high-tech machines. Key among them was the new VR-11 fivebecoming the best selling machine axis profiling VMC with 120 x 40 x 30 travels. This versatile machine has tool in the world. already captured the attention of the aerospace world with its high capabilities and affordable price. Also on display were the new HL-6 lathe, an HL-2 lathe, VF-2 and VF-4 vertical machining centers and an HS-1RP horizontal machining center. Haas exhibited their products in conjunction with their European distributor Mikron, which markets Haas CNC products under the Mikron name (as their VCE-series verticals, HCE-series horizontals and TCE-series lathes) in continental Europe. EMO was an opportunity to see the manufacturer behind the Mikron machines, and see what makes Haas the best selling machine tools in America. EMO Hannover also provided Haas an opportunity to court the international trade press. Journalists from leading international publications visited the booth and met with Project engineer Thomas Velasquez with the VR-11 just prior to shipping to EMO Hannover.

Lathe Promotion Ends October 31st

The very popular Haas Lathe promotion, started in September, offers a package of high-productivity options at no charge. This special, which ends October 31, 1997, includes a combo-package of Haas most popular Lathe options a $7,780 value installed at no cost to the end-user. The options included in this special factory incentive are: Haas QuikCode Programming Option, a 3.5 Floppy Disk Drive, a $3,000 Tool Presetter and the very popular Rigid Tapping Option. This promotion is available for all Haas CNC lathes, except the new HL-5 and HL-6, which, instead, carry a special introductory price. If a new turning center is in your future, be sure to call your Haas distributor for complete details on this special promotion before it ends.

Haas Opens First Overseas Office in Beijing, Hires Region Manager for North Asia
In order to increase overseas sales and provide better service to international customers, Haas Automation, Inc., has opened their first-ever overseas office in Beijing, China. This office will be headed up by Haas new Regional Manager for North Asia, Owen Chen, a Chinese national with extensive experience in the machine-tool industry. Our goal is to expand our worldwide market for Haas machine tools, and provide the same kind of service in China that has made Haas the best-selling machine tool in America, said Al Nodarse, Director of Sales for Haas Automation. We plan to establish more distributors to better serve the region, and set up a Haas Service Center to provide after2
CNC MACHINING

sales support. We feel Owen Chen has the experience and reputation to help us achieve these objectives, Nodarse said. Chen has a BA in International Business from Beijing International Business and Economics University, and an MBA in International Business from University of San Francisco. Concurrent with his studies at USF, Chen worked at the Lever Corporation (a trading company) in San Francisco dealing with chemicals and pharmaceuticals. In 1989, Chen returned to Beijing, where he joined the German machine tool manufacturer Maho (now DMG) as their first representative in China. In this position he was responsible for all sales, marketing,

administration and service in China. After building a solid reputation and successful sales record with Maho, Chen joined the Cosa Lieberman Group to manage the Agie EDM Machine line in China and Hong Kong. Chen worked for Cosa until 1997, when he joined Haas Automation, Inc., as Regional Manager for North Asia.

Haas World Tour

Trade shows are an important way to build name-brand awareness and demonstrate your product to the masses. For Haas Automation, 1997 has been a banner year, with direct participation in 12 major shows around the world, and dealer participation in many more. Haas will participate in even more shows during 1998, with added emphasis on the international market. If you havent had the opportunity to visit one of these shows, there are still a few stops left on the Haas World Tour. In October, Haas will be showcasing products at two APEX shows, one in Dallas (14 -16) and another in Cleveland (21-23). Haas will also showcase products at PRI in Columbus, Ohio December 5-7. Be sure to mark your calendars!

Haas Automation, Inc., Beijing Representative Office Friendship Hotel, Room 20538 3 Baishiqiao Road, Beijing 100873, China Phone: 011-86-10-68498888 Ext. 20538; Fax: 011-86-10-68499491

GET $7,780 IN FREE OPTIONS

FALL 1997

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PROTEC T YOUR
t Haas, we build machine tools that deliver on our aggressive policy to protect your bottom line. Its all part of the package when you buy a Haas CNC machine. We do this by focusing on your needs, and applying the following three Haas rules of economical ownership:

Economical to buy

Haas machines are designed and priced to give you more features and benefits for your dollar than any other machine in their class. We know the challenges of todays manufacturing environment demand that you get more than you pay for. At Haas we deliver true value by including standard features on our machines that other builders believe are options.

Economical to own
Ownership of a feature-packed, highly-reliable, value-priced machine tool has its own rewards. First, Haas CNC machines have the industrys most user-friendly control, featuring a host of Haas-only productivity enhancers youll find nowhere else. Haas machines are also easy to operate, maintain and service. Designing this ease-of-use into our machines from the initial concept is part of the Haas economic philosophy. And, to top things off, Haas machines command one of the industrys highest resale values just try to find a used Haas for sale.

Economical to operate
Haas machines are designed to deliver reliable operation day-in and day-out. We know your bottom line depends on making chips, thats why Haas is the only machine tool manufacturer that provides a 98% Up-Time Guarantee. Your Haas machine will perform, or Haas will pay for your down-time.

Haas Automation, Inc. 2800 Sturgis Road Oxnard, CA 93030

800-331-6746
WWW.HAASCNC.COM

BOTTOM LINE.
HAAS VMCs, HMCs, CNC LATHES AND ROTARY PRODUCTS PROTECTING YOUR BOTTOM LINE.

MADE IN THE USA

Creative Applications
SHOP FOCUS

.R. Beall is not your ordinary machinist. He doesnt buy a CNC machine to do a particular job, or produce a specific part. Rather, he buys the machine as a tool, and designs things utilizing the machines capabilities.
By Scott Rathburn

A New Set of Chisels

But, J & J Beall, Inc., of Newark, Ohio, is not your ordinary machine shop, either. Its not filled with chips of steel and aluminum, or barrels of coolant. Rather, its filled with chips of wood and sawdust, and racks of lumber. Which is understandable, since J & J Beall, Inc., is a woodworking shop, and J.R. Beall does his machining out of wood. Im a craftsman, Beall said. The machine is just a set of chisels to me. I dont know exactly what Im going to carve with those chisels, but once Ive got the machine, I can familiarize myself with it and do all sorts of things. Basically, Im a woodworker, but Im also a mechanic and designer. I always buy a machine first, then figure out what Im going to do with it later. Its a different approach, but Im able to make products that nobody else is able to make, Beall said.

One of Bealls sets of chisels is a Haas VF-0 vertical machining center with 20 x 16 x 20 (xyz) travels. I believe in using whatever technology is available to do whatever can be done, Beall said. The Haas gives me an enormous advantage over other woodworkers. I can do things those other guys cant even dream of doing. Now, wood is not a material usually associated with a CNC machining center. But, according to Beall, its actually harder to work with wood than metal. There are a lot of difficulties in working with wood, he said. Wood changes its shape constantly due to moisture variations. And its more abrasive, because it sucks all kinds of abrasives up from the soil into its cell structure. Its full of grit, so bits and tools dont last as long. Some woods will just destroy a tool immediately; high-speed steels have a very short life. But using tantung bits and the right speeds and feeds, Beall explained, its possible to get incredible results. You cant imagine what a beautiful job you get in wood with a flycutter, if you run it at the right speed and feed it slow. Its a perfect finish right off the machine, he said. Theres no sanding; all I do is buff it.

I use a flycutter thats maybe 3 or 4 inches in diameter, and run it at 5,000 or 6,000 rpm, so theres lots of surface speed. It works really nicely. Of course, you have to use the

right kind of woods, he said. I use ebony, and exotics like rosewood, boxwood and bubinga. Some of the things Beall makes with his Haas are fancy, multi-faceted, fluted bowls, and geometric carvings out of blocks of wood. Using circular interpolation along the z axis, he makes swooping cuts to create circular patterns, and even leaf designs. He has even machined an entire chess set out of wood, with each ten-sided piece meticulously machined using a cutter only 0.030 high. Some pieces, like the Queen, feature spiral twists created by using a Haas 4thaxis rotary table. The small cutter and 4th-axis allow me to create realfancy complex shapes, Beall said. But all this fancy stuff is just what Beall does to show off. The rest of the time hes busy manufacturing products and inventing things. From time to time I make something like those bowls

just to show people it can be done. But Im an inventor, he said. I have a bunch of patents for woodworking tools. One of Bealls patented products is a wood threading tool. Now, when most people think of wood threading they probably think of broom handles, but thats as far as they go. But wood threading has been around for hundreds of years, Beall states. In fact, hes written a book on it. For someone whos interested, and has some creativity, theres a variety of projects that use wooden threads. In fact, I put furniture together that way. According to Beall, threading devices previously available just werent suitable for production threading. They used a little fixed bit that you cranked around a dowel to cut the thread. But the bit would get dull quickly, almost immediately in fact. So he decided to design his own threading tool. The tool I make uses a router and a carbide bit, he said. You can thread with it for weeks and months on end without it getting dull. You can really do production threading. One of the key components of Bealls wood threader is a plastic insert that guides the dowel during threading. This insert has an internal thread one inch in diameter with a #6 thread pitch. (Beall offers kits in 1-6, 3 4-6, 58-7, and 12-8.) Each thread size uses a Delrin insert with very course internal threads, he said. Tapping this insert would be difficult because of its coarseness, and because the beginning thread must be precisely oriented. Beall explained. The thread is much coarser than you

can buy a tap for, so we would have had to get special taps made. Rather than invest in custom taps, Beall looked to injection molding to produce the threaded inserts, but the molds were very expensive $25,000 to $75,000. Youd pay as much for a set of molds, as you would for a CNC machine, he said. Despite the cost, however, Beall had a set of molds made and began producing the inserts out of ABS. Unfortunately, injection molding couldnt hold the tolerance he needed for the part, so he sought a better method. Beall found he could achieve the accuracy he needed by machining the inserts out of Delrin on his Haas VF-0 vertical machining center. Using helical interpolation and a single-point cutter we can do the internal threading very accurately, and we can use the same cutter for all of our threading kits. The Haas produces a lot nicer part, and Im able to bring the process in-house where I have control of it, Beall said. The machine has paid for itself, easily, several times over. Through the use of a Haas VF-0 vertical machining center, J.R. Beall is able to maintain the accuracy he needs to meet the demand for his patented wood threader. As an added benefit, hes able to create some impressive works of art and have a little fun in the process.

Photographs by Judith Beall

J.R. Beall: 614-345-5045

PC Modeling PC PC
TECH TIPS

-based solid modeling CAD systems are in the news today. When properly implemented, they offer speed and capability at a fraction of the price of workstationbased solids. The new breed of solid modelers is having the greatest impact on small- to medium-sized machine shops because they can now afford to own the software necessary to directly import their customers solid models for machining.

These solid modeling systems are affordable now because they are built on modular engines from third-party suppliers. Instead of reinventing the wheel, CAD developers today assemble modules of code upon mathematical foundations called engines, or kernels. In this country, the most-used solid modeling kernels are Parasolids from EDS Unigraphics and ACIS by Spatial Technology.

3D

GEOMETRY AND THE PC

out with the blueprint and straightedge

Once a model has been completed, there still remains the greater challenge of machining the parts, molds or dies. Rounded lines and ergonomic shapes increase marketability, but the designer needs feedback from the manufacturing side to keep costs down. After the part is imported into the CAM system, and as the tooling is being developed, the customer will continue to work with the machine shop to refine design. Its really the modeling capability of the NC software that cuts time from the design-tomanufacture process, and dollars from the resulting products Cost of Goods figure.

Machining Complex Models

By Larry Diehl, Surfware, USA

The Following is an overview of CAD modeling: defining geometry

A good way to begin is to understand three ways CAD systems define 3D geometry: Wire frame models are simple stick model representations of a solid. Wire frame modelers that only save the stick model do not work with the true mathematical surface data, but may be able to produce shaded images, though not reliably. These cant produce accurate 3D tool paths because surface information is not stored in the data file. continuous surface is defined with mathematics. Even though it was constructed of many individual entities joined or linked together, it is now defined as a single complex shape. Solid modelers also have the ability to represent simple surfaces. However, a solid modeler also saves the information about how the various surfaces meet, which allows for Boolean operations such as addition or subtraction of volumes. A solid model is created by using cubes, cylinders, cones, spheres or extrusions of shapes. It is a fully enclosed model and has volume. Solids can be added, subtracted or intersected with one another to create the desired finished part. Entire edges of a part can be easily rounded with one command. In the same way, intersecting surfaces can be filleted. All edges are automatically trimmed as the model is constructed. Solid modeling, however, is unable to handle complex surfaces well, especially filleting. The technology to machine surfaces directly from solids is still lacking because it takes tens of thousands

Creating the model is only the first step in developing a customers new part. In order to bring the part to production, a versatile CAM system is needed to import the model and convert the surfaces for machining.

Surface modelers create true mathematical models of the surface of an object. The object may be represented graphically as a wire frame structure, but in this case, the entire

CNC MACHINING

FALL 1997

WWW.HAASCNC.COM

Machining Complex Models

of Boolean operations to create tool paths from solid geometry. Since the math that generates tool paths works on surfaces, and not directly on solid models, a CAM system still needs to be based on strong underlying surfacing mathematics.

(From page 9)

Heres Something You Dont See... EVER.

for machining. In real life however, an NC programmers biggest headache comes from trying to import files into a CAM system thats incompatible with the customers part file. Of course, if the solid modeler outputs IGES and most do then a CAM system that reads IGES accurately can open and machine the model. An excellent IGES translator delivers valuable flexibility in reading files from most design systems. A solid model can be represented in IGES as trimmed surfaces (IGES 144 entities). For machining, it is unnecessary to stitch together these surfaced faces because they have already been trimmed to one another. The volume data which the original solid model contained is lost when the data is converted into the IGES surfaces format. This is no cause for alarm, however, because volume data is not used in machining. For example, to machine a die cavity that produces an auto fender, only the skin of the fender is machined, not the volume that would be represented were it a solid object. Some CAD vendors interpret entities in a slightly different way than is defined by the IGES standard. Some create entities that are not compliant with any of the standard IGES entities. These variations on IGES standards are sometimes called flavors. To translate from a wide variety of CAD systems, an IGES translator must be user-configurable to accommodate different flavors.

see it now
No matter how models are created, you can visualize them better if your NC software has a fast, interactive graphical display. Wire frame representations of surface models can be quickly rotated to see the entire model, then stopped at any point, and rendered in seconds. Display and manipulation of a shaded surface model is now possible on a PC with CAM software that has been written to support Open GL, the 3D Graphics Library defined by Silicon Graphics. This option works best with a high-end GL graphics card. In this country Parasolids and ACIS are the most frequently -licensed kernels for CAD solid modelers. The Parasolids kernel is from EDS-Unigraphics, the developer of a high-end workstation-based CAD modeler. ACIS is from Spatial Technologies, a company that hopes to promote its engine as the standard for 3D data exchange, a lofty goal with so many proprietary solid and surface modelers already in the marketplace. A versatile CAM system can import files from every CAD system out there, whether a surface or solid modeler, as well as from digitizers and rapid prototyping systems. A direct translator can flawlessly import solid models into a CAM system and convert them to surfaces

Custom Business Leasing Designed to Fit Your Needs.

At CNC Associates we know your industry, but we dont know your particular business needs. Thats why we dont limit your choice of lease options, as our competitors do. Instead, we structure repayment plans that fit your needs, rather than the needs of the average customer. Here are some lease structures weve designed for current customers:
v A 60-, 72-, or 84-month lease, with 2 payments in advance and a $1.00 buyout v A 60-, 72-, or 84-month lease, with a 10% purchase option v A 60-, 72-, or 84-month lease, with no payments for 30, 60, or 90 days after delivery of the equipment A 60-, 72-, or 84-month lease, with no advance payments and no payments for 30, 60, or 90 days A 60-, 72-, or 84-month lease, with low payments for the first 6 12 months, v and payments gradually increasing throughout the remainder of the lease First payment of 7.5% of invoice in advance, 7.5% interest for the term of the lease, 7.5% purchase option One or two regularly skipped monthly payments each year throughout the term of the lease A 36-month lease with low payments and fair-market-value purchase option (may be financed, should you choose to purchase the machine after the 36th month)

Wire Frame Model Wire frame models are simple stick models which do not work with the true mathematical surface data.

Surface Modelers create true mathematical models of an object's surface, defining it as a single complex shape. Solid Modelers create fully enclosed models with volume and information regarding how the objects intersect.

These are just some examples of how we work with you to structure a lease plan that meets your needs. Interest rates are competitive, so give us a call. Well help you purchase the fine HAAS products you need to make your business grow.

Finished Prototype

In the next issue of CNC Machining, part two of this series will discuss various machining features and methods. About the author: Larry Diehl initially developed Surfcam in the 1980's. He continues to program daily as Surfwares chief soft developer and oversees Surfcam product development.

CNC ASSOCIATES, INC.

2800 Sturgis Road Oxnard, California 93030 Tel. 805-278-0303 Fax 805-485-0803

10

CNC MACHINING

FALL 1997

Focus On Mold Making

SHOP FOCUS

Global Tool & Engineering uses Haas vertical machining centers to speed up the manufacturing process for injection molds. From roughing and finishing molds, to high-speed machining of
Photo: James Martin

graphite electrodes, Haas VMCs have helped Global move from startup in 1994 to sales of $6 million in 1996.
FROM STARTUP TO $6 MILLION IN TWO YEARS
Brad Berkley, Globals 27-yearold CEO, and Scott Wahl, executive vice-president, recognized that mak ing injection molds (called tooling in the mold industry) is one of the most time-consuming and critical stage of getting a product to market. To speed up the process, they founded Global Tool & Engineering in October 1994. Initially, Scott Wahl and I put our know-how and contacts to work, Berkley said. We sub-contracted tooling to meet the fast turn-around times demanded by our customers. We would sell a mold package, have it built, have it sampled, and have the quality control done. Then wed tie it all together and call it Global Tool & Engineering. By the end of the first year our sales had reached $2.3 million and we had seven employees. We saved our money from the first year and started up the factory. To satisfy the increasing demand their innovative

Global's CEO Brad Berkley

Photo: James Martin

Erasing Lead Times Yields Big Success

G
12

etting products to market before the competition and before they become obsolete can be the difference between success and failure of a major product line. Nowhere is this more important than in the handheld electronics and communications industries. These companies exist solely because of their products. Accordingly,

they have accelerated the time-to-market paradigm. Global Tool & Engineering, Inc., of Carrollton, Texas, is one of the leading companies helping these industries get products to market quickly. Global manufactures quick turn-around

plastic-injection molds, and their innovative approach has decreased lead times by more than 50%. Needless to say, this has fueled explosive growth for Global.
FALL 1997

approach created, job, and one that is compatible with Global started buying the customers CAD system. In most their own equipment and situations, CNC programs are created manufacturing molds inoffline using Mastercam. house. Today, they have Global uses the Haas VMCs to 70 employees, and rough- and finish-cut mold cavities, have facilities in cores, and insert pockets, as well as Carrollton, Texas, and to machine EDM electrodes. Materials St. Paul, Minnesota. routinely machined are aluminum, By 1996, Globals H13 & S7 tool steel, 420 stainless sales had grown to $6 and graphite. million. Foremost among Globals machine tools are several Haas vertical machining centers (VMCs) two VF-1s, two VF-2s and a VF-3 as well as two Agie CNC EDMs with16-electrode changers. The company utilizes Selective Laser Sintering Machines for rapid prototyping, and has plasticinjection-molding machines to prove tooling and make short production runs. The Haas VMCs are a A graphite EDM electrode after machining. Photo: James Martin big part of our success, Berkley explained. They allow very aggressive THE TROUBLE WITH GRAPHITE machining rates and provide the tight tolerances and high repeatability we There are a number of difficulties need for machining molds. Because associated with graphite,explains they require very little training and are Jerry Bichsel, Globals tool-room maneasy to operate, theyve made it easy ager. Graphite is brittle, so you have for us to staff-up. Recognizing the conto use high spindle speeds to prevent tribution Haas machines were making chipping. With the Haas VMC's, to their growth, Global purchased five weve been able to machine many of Haas VMCs in a ten-month period. our electrodes at 300 ipm. Global uses the latest CAD software to These high-speed cutting capabildesign tooling, including Pro-E, ities, along with liquid-cooled, 15-hp ProMold, SDRC Ideas and CADKEY. spindles providing 10,000 rpm, They select the best program for the allow Global to shorten their moldContinued on page 28

CNC MACHINING

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13

Turning Tips
TECH TIPS TECH TIPS
The good news is that modern toolholders and specific stainless steel inserts are available to make your stainless steel work easier. The new generation of inserts provides higher positive rakes, new coatings and better matches for heavy roughing, medium roughing and finishing operations. With the right tooling, you can effectively apply proven turning principles and techniques to facilitate stainless steel turning and manage the most difficult cuts.

For Stainless
and higher temperatures, causing a tendency toward smearing and work-hardening of the surface. These characteristics are typical of all grades of austenitic stainless steel. Obviously, the hardness of workpiece material affects the life of cutting tools. Stainless steel is deformation-hardened when it is colddrawn. The deformation-hardened layer on incoming mill stock is considerably thicker in austenitic stainless steel than in carbon steel. Even bar stock that has been straightened is cold-drawn to some extent, with surface hardness values of HB300 or more. The inside of the material may be half as hard as the surface, but its on the surface where the cutting takes place.

Figure 1

anticipate the challenges

Anticipate work-hardened surfaces. Make deeper cuts and set feed rates that ensure entry of the cutting edge past the hardened zone. Another problem is heat. Stainless steel has much lower thermal conductivity, and higher ductility than conventional steel. Therefore, it requires considerable energy to cut a chip, and thus generates more heat. Since stainless is unable to dissipate heat quickly, the workpiece, especially the cutting area, gets very hot. The chip forming process implies that a fresh metal interface is continually produced and forced, at very high pressure and temperature, along the tool material. Since heat from the cutting zone is not removed with the chips, the higher cutting temperatures increase the tendency for tool wear and plastic deformation, especially when interruptions are encountered. Excessively hard cutting action in most stainless steel workpieces generates various types of very hard, continuous chips. To break these continuous chips into smaller, less abrasive and more manageable sizes, select an insert with high positive rake and aggressive chipbreaking designs. Sandvik has recently added more insert choices to their stainless steel M-line. These newer inserts were developed specifically for stainless steel, with positive rake angles and strong geometries. Lets look at some recent insert advances and how they facilitate turning of stainless steel workpieces.

rules of thumb:
Here are some rules of thumb based on our own experience in thousands of stainless steel turning applications: 1. Use state-of-the-art inserts. The new ones can improve material removal by as much as 30%. 2. Match the insert to the application. Youll get better finishes and longer tool life. 3. Learn to visually diagnose and remedy symptoms of premature edge failure. 4. Ensure that your shims are in good shape. 5. Use some proven techniques for the more demanding cuts. Lets first look at what makes stainless steel a tougher material to turn than conventional steel. Then, well explore each of the five Rules of Thumb separately.

Simplifying Turning of Stainless Steel

By Mike Castner, Sandvik Coromant

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oday, turning of stainless steel represents about 24% of all metal turning, and that proportion is rising. Various stainless steel grades present a challenge to all machining operations. Thats because they have characteristics that yield more friction, heat and chip control problems than most common steels and cast irons.
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turning stainless steel

Turning stainless steels is not necessarily difficult, but it can be demanding. Their higher alloy content generally equates to more difficult and costly turning processes. Ingredients added to improve corrosion resistance and tensile strength, especially nickel and molybdenum, often work against machinability. This is because they deform in a plastic manner. As a result, tools are subjected to more friction, higher cutting forces

state-of-the-art inserts
New developments in state-of-the-art inserts for stainless steel turning are: improved coatings, stronger substrates, higher positive rakes and improved chipbreaking geometries. It is very important to choose the correct grade/geometry combination, and match it correctly to your application. Fortunately, the carbide substrates and PVD/CVD coatings are already matched to the geometries utilized in the most common applications. New, advanced coating techniques provide better chemical barriers to isolate the workpiece surface. These new coatings help reduce friction and built-up edge (BUE). Developments in insert geometry and higher positive rakes take productivity one step higher (Fig. 1). The benefits are freer cutting action, as well as longer edge life. A positive rake means more

Figure 1 above: Cross-sectional view of Sandvik Coromant's inserts for stainless steel turning in finishing (MF) and roughing (MR) shows higher positive rakes and improved geometries. The newer M inserts ensure continuous cutting and smoother chip flow, smaller variations in cutting forces, lower temperatures, and less deformation-hardening of the material.

continuous cutting, smoother chip flow, lower cutting forces, lower temperatures and less deformation-hardening of the material. A sharp edge means softer cutting action with lower cutting forces. This, in turn, means less deformation of the workpiece material, decreasing the likelihood of burr formation. A positive sharp cutting edge, combined with a correctly balanced open chipContinued on page 32

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Metalcrafters on Mars
By Scott Rathburn

magine this, youre playing a round of 18 in Pasadena, California. Its the final hole and you check the tee-box monument for particulars. Its a tricky Par 4. Unfortunately, the hole is located in the center of a green only seven inches in diameter... more than 1360 miles away, in Houston, Texas.

Though this scenario sounds impossible, it is exactly the situation faced by the navigation team of the Mars Pathfinder mission. For their game of interplanetary golf, Earth was the tee box, the yardage was 309,081,764 miles and the hole was a 15-mile diameter spot above the atmosphere of Mars on July 4, 1997. The navigation team planned the voyage as a Par 4, with only four trajectory corrections between Earth and Mars. They did, however, reserve the option for a fifth stroke within the final 24 hours in case of a bad game. The final stroke was unnecessary, though, as the navigation team successfully made par and landed the pathfinder in the hole on July 4, 1997.

Artists Rendering Courtesy of NASA/JPL/Caltech

A E R O S P A C E

U P D A T E

A E R O S P A C E

U P D A T E

A E R O S P A C E

U P D A T E

Haas Helps Take Former Sheetmetal Shop to Mars

wo years ago they were just another batch of parts for the machine shop. Sure, the blueprints were from NASAs Jet Propulsion Laboratory, but Norm MacKenzie thought nothing of it. He had done numerous jobs for JPL during his 25 years as a machinist.

Norm MacKenzie machined this part for the guidance system of the Mars Pathfinder.

On July 4, 1997, however, MacKenzie proudly became a part of American history when NASAs Mars Pathfinder module landed on the surface of the distant red planet. You could say he was partially responsible for the success of the mission. For, deep within the intricate confines of the Pathfinder module, those same parts he machined two years ago held the electronics for the main guidance system that led the Pathfinder successfully to Mars. At the start they were just another set of parts, MacKenzie explained. But the more we got into it, and started talking to the engineers, we realized they were going to Mars, and it was going to take seven months to get there. The culmination was watching the landing on television. Ill be honest with you, I was a little nervous. I wanted to make sure the Pathfinder landed. That was a big thrill when I watched that. But it started as just another job. It may have been just another job, but it was a job that Metalcrafters of Simi Valley, California, couldnt have

taken on a few years ago. It took the About five years ago, addition of CNC machining centers Metalcrafters realized they could create and a skilled machinist Norm more of a seamless operation going MacKenzie to take them to Mars. from sheetmetal to machining to For the past 22 years welding by bringing their machining Metalcrafters has made their mark on processes in-house. It would give them the world by manumore control over facturing close-tollead times and qualerance, precision At the start they were just ity, and allow them sheetmetal encloto better serve another set of parts, sures for a variety their customers. of industries from Unfortunately, their NASA to Disney. old equipment MacKenzie explained. For most of those didnt have the 22 years, But the more we got into capability or capacMetalcrafters didnt ity to meet their have much of a growing machining it, and started talking to machine shop to needs. They pursupport their sheetchased their first the engineers, we realized vertical machining metal business. What we had, center to meet the basically, was a increasing demand. they were going to Mars. couple knee mills It quickly with controls, said became apparent Scott Stewart, Metalcrafters General the VMC could machine parts faster Manager. We machined out of necesand more accurately than the old knee sity doing only what we had to and mills. We kept the knee mills, Stewart sent out the rest. said, but it was kind of like having a

new Cadillac and an old Chevy nobody wanted to run the old machines. They could cut three-times as fast on the VMC. The success they found with the VMC got Metalcrafters management thinking. We realized that, not only could we support our sheetmetal operation, but maybe we could make money at machining as well, Stewart said. At that time, however, their only machinist worked part-time and had limited training. If the machine shop was going to be profitable, they needed a full-time, skilled operator to run the machines. Thats when they hired Norm MacKenzie. Originally from Scotland, MacKenzie has been cutting chips for more than 25 years. Despite 21 years in the States, his Scottish brogue is still quite evident. As far as hes concerned, though, hes an American through and through. MacKenzie took over the helm of Metalcrafters machine shop four years ago. Since then, theyve added a new machining center almost every year. The last two machines added were a VF-2 VMC (30 x 16 x 20 travels) and a VF-6 VMC (64 x 32 x 30 travels)

MacKenzies parts with electronics and sensors installed. *

from Haas Automation, Inc. Weve bought about a mill per year, which has been a very reasonable growth rate, Stewart said. Whenever we add machines we look at adding two things capacity and capability. We look at adding capacity, so we can get more work out the

This intricate part held an array of directional sensors.

door. We look at adding capability, so we can take on more difficult jobs. Our goal was never to be a machine shop, but thats basically what happened. The work was there, and we had the capability and the capacity. Weve gone from machining out of necessity, to building a more seamless operation with the sheetmetal shop, to doing 65-70 percent straight machining jobs. If we were just supporting the sheetmetal shop and not taking in all this outside work, we could probably still get by with one, maybe two, VMCs. But some of the same customers buying sheetmetal are buying machined parts also. Its like onestop shopping. Disney is probably a classic example, Stewart said. If they cant get their sheetmetal and machining at the same place (a lot of their stuff gets both, then gets welded) theyll go someplace else. When they want to put a ride together they arent always willing to wait. They need their parts, and they need them now. Youve got to be able to deliver the finished package.

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MacKenzie agreed. A lot of companies are doing that now Lockheed, McDonnell-Douglas, Rockwell as a way to maintain quality control, he said. Increased demand for machined parts prompted Metalcrafters to invest in additional CNC equipment. They chose a Haas VF-2 vertical machining center to expand their capacity. We needed a machine to get more work out of here, Stewart said. We heard a lot of good things about the Haas machines, so we looked into them. We liked what we saw, and bought

Thats what makes the Haas so easy to run. We do a lot of multiple fixturing, and the Haas lets you load multiple fixture offsets and multiple tool offsets quickly and easily. On our other machines youve got to physically punch the number in, which increases the chance of mistakes. With the Haas, you just punch one button to enter the offset, then another to go to the next tool. The Haas also has better performance the tool changer, point-to-point with the turret, spindle orientation these things are all faster, which saves a lot of time. Weve been able to reduce cycle times

The Mars Pathfinder Sojourner. (NASA/JPL/Caltech) *

one. It was a reasonably priced machine that was going to help us increase our capacity. With all his machinists busy making parts on the other machines, the task of setting up the first job on the Haas fell to Stewart. I was surprised how easy the control was, its very self-explanatory, Stewart remarked. Within half an hour I guessed my way through the control and set up the job. You can basically look at the control and understand it, especially if youve been on another machine. Id say its more userfriendly than any other control. The keyboard is so simple, the way its designed, MacKenzie added, everything has its own little section.

quite a bit with the Haas. And its very accurate, I can hold two-tenths all day. MacKenzie goes on to say, One of the biggest things about the Haas machines is their versatility. We machine ductile-iron castings, 15-5 stainless, P21 stainless, 4130 steel, then we go to the different aluminum alloys. We run all sorts of materials. With the Haas, I dont have any problems running aluminum then changing over to steel. A lot of machines cant do that. According to Stewart, Metalcrafters is always looking to increase their plants capacity and capability. The VF-2 allowed them to increase their capacity and pump more parts out the door. But as jobs

rolled in with larger production runs and bigger parts, they needed to expand their capabilities by adding a larger machine. They chose a Haas VF-6 with 64 x 32 x 30 travels, and their investment soon paid off. We had a job for Disney that was too large to cut on our other machines, Stewart explained. It was a heat-treated casting of ductile iron that was 20 inches tall. Every surface had to be machined, and we had to drill and tap holes, including blind holes at the bottom of the part that could only be reached from the top. The VF-6 was the only machine we had that would cut it, and cut it right. Bigger parts, however, are not the only reason for having a bigger machine. Sure, there are times when a bigger machine is the only way to cut the part. But longer travels can also help you be more efficient, by allowing multiple set-ups so you can get finished parts off the machine. Travels are very important with multiple fixturing, Stewart said. Thats where the VF-6 has been really good. Some people look at travels and think Well, my part is small, it will fit in a small travel. But with small travels youre limited to performing one machining operation at a time, or cutting one side of a part. More travel can help you be more efficient by allowing multiple fixtures and operations. The set-up may take a little longer, but the customer is getting finished parts in a couple days instead of weeks. Now, Im servicing the customer. One customer who needed parts quickly was NASAs Jet Propulsion Laboratory. We had done a few sheetmetal jobs for JPL in the past a little thing here, a little thing there. Then all of a sudden a job pops up where they need it, and they need it now. They realized we were doing machining and gave us this aluminum panel to do. We didnt even know what it was for, you couldnt tell. Then they gave us another panel, then four more. It wasnt until later that we found out everything was going into the

The Mars Pathfinder module with the Sojourner. (NASA/JPL/Caltech) * * Photographs & Renderings Courtesy of NASA/JPL/Caltech . Sojourner, Mars Rover, and spacecraft design and images copyright 1996-97, California Institute of Technology. All rights reserved. Further reproductions prohibited.

Pathfinder, Stewart said. They needed parts fast, and we made it happen. N o rm MacKenzies extensive experience and the versatile capabilities of the Haas machines are the key ingredients that made the JPL jobs happen. Typically, JPL would send a blueprint to Metalcrafters. MacKenzie would look over the blueprint and start machining the part usually writing the program right at the control. Since these were R&D parts, MacKenzie would often discover things that werent right. So, working hand in hand with the engineers, he would make changes until he had a finished part. Then hed ship the part to JPL, where the engineers would test it, make more changes, red-line the blueprints and send them back. Theyd make changes and Id just make another part for them, MacKenzie said, and another, and another, until even-

tually we came up with the final part. One of the most challenging JPL jobs, MacKenzie noted, was a small part designed to hold an array of six directional sensors for the main guidance system of the Mars Pathfinder module. Starting with a 9 x 9 x 3 block of 7075 aluminum, he machined an intricate web of pockets, ribs, holes and mounting tabs designed to secure the sensors for their 309-million-mile journey. It was a challenge because there were so many different angles and pockets in it, MacKenzie said. Ive made a lot of fancy parts, but this was a little different, because of what it was, where it was going and what it was doing. MacKenzie opted to program the part directly at the Haas control rather than use a CAD/CAM program. For me it was faster that way. I didnt have the luxury of sitting and waiting

for the program, he said. A lot of the part was very flimsy, with thin walls, so I had to be real careful and do a little bit at a time through MDI (manual data input). I couldnt afford to get 70% into the part and lose it. MacKenzie used the Haas VF-2 with multiple fixtures to make three of the parts at a time, just in case he made a mistake. There was a lot of work involved, and I couldnt afford to lose the part. The hard work payed off, though, when the Pathfinder successfully bounced to a stop on the surface of Mars. His parts had done their job and become a part of history. Its a thrill to see it up there, MacKenzie explained, a little part of me up there. I dont know where Mars is, but I know its up there, and Ive got a part up there, albeit thats just a tiny part, but Ive got a little part up there.
Metalcrafters:805-581-2971.

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Tooling Tips
TECH TIPS TECH TIPS
In fact, just the opposite is true. With todays understanding of the sophisticated factors and forces at work in a successful insert application, it is clear that tomorrows magic bullet will be an extremely productive solution for a very specific set of machining conditions. Putting such a solution to work successfully will require an in-depth understanding of the complex interactions of the seven critical components that unite to produce an optimized cutting system. This article will provide an overview of those system elements.

How To Grow Your Productivity With A Systems Approach To Insert Selection: Part I in a Series

the elements
Every successful cutting tool application represents a combination of: 1) a substrate, 2) one or more coatings in most, but not all, cases, 3) a chipbreaker, or top form geometry, 4) a specific edge preparation, 5) a specific style and nose radius, 6) a toolholder and 7) a cutting fluid. A quick glance at any manufacturers catalog will clearly demonstrate that the potential combinations of these elements run into the thousands, if not the millions. Finding a way to make sense out of such a variety of choices is the major challenge facing both cutting tool producers and cutting tool consumers in the coming years. Materialbased color codes, and selection procedures built on them, are a step in the right direction, but only a first step. As insert systems become more and more application specific, new selection paradigms must be created to guide consumer choices. Regardless of the shape these may take, they must necessarily be grounded in a thorough understanding of the individual role of each of the seven elements and their interactions in the cut.

By Karl Katbi, Product Manager, Valenite, Inc.

or the last decade or so, the cutting tool industry has been on a quest for simplicity in its turning and milling insert offerings, consumed by the search for a mythical universal grade or two that could be matched with a few chipbreakers to handle virtually any job that came through the door. Whats been learned from that exercise is that there is no single magic bullet that will deliver optimum productivity in every machining application.
CNC MACHINING

the substrate
In a coated insert, the substrate is the foundation for the cutting system,

but it never actually comes into contact with the workpiece. This fact permits cutting tool manufacturers to tailor substrate properties over a much broader range than was possible when the uncoated substrate was the cutting tool. Nearly all substrates are made from tungsten carbide (WC), which is still the only material available with the combination and hardness and toughness required to handle a broad range of cutting applications. Other materials, such as ceramics and cermets, provide a useful complement to WC at the high speed end of the application range, but these are rarely used with coatings. The first substrates were simply traditional straight WC grades which were coated to improve their performance. Some of these combinations proved so useful they are still in production today. Improved processing capabilities led to the production of enriched substrates in which the cobalt content of a layer near the surface is significantly enhanced while the formation of cubic carbides is prevented. This provides substantially more edge strength than a straight-grade substrate and is widely applied in inserts intended for roughing and interrupted cutting applications, as well as on some hard-to-machine materials. A more recent development is the family of fine grain substrates in which the size of individual WC grains is controlled. These are primarily used in insert systems designed for machining very tough materials, such as aerospace and high-temperature alloys. Finally, substrate performance can be enhanced by selectively adding other types of carbide to the straight WC mixture. The most common alloys consist of WC plus titanium carbide (TiC), tantalum carbide (TaC), vanadium carbide (VC) and niobium carbide (NbC), or some mixture of

A selection of inserts from Valenite

them. Each of these additional carbide materials produces specific properties which are useful in a range of common applications.

coatings
There are two factors to be considered in evaluating insert coatings: the material or materials used, and the process by which they are applied. Both impact insert system performance. The coating itself acts as the interface between the workpiece and the cutting tool. Depending on the application, coatings can provide wear resistance, abrasive and crater resistance, built-up-edge resistance, chemical resistance or a simple reduction in friction, which lowers cutting temperatures. The most commonly used coating materials and the properties they provide are: TiC - abrasive, flank, and nose wear resistance TiCn - abrasive and some crater wear resistance TiN - some crater resistance, friction reduction and a diffusion barrier Al203 - crater and wear resistance, plus abrasive wear resistance at

high cutting temperatures Al2O3/ZrO2 - best crater resistance, but softer than Al203 There are four major coating technologies used in the cutting tool industry today. These are differentiated primarily by the temperature at which they operate. This is important, because the temperature at which the coating is applied directly impacts the performance of substrate properties. The most common coating technology is Chemical Vapor Deposition, or CVD, which operates at a temperature of roughly 1,000 C. Nearly as common is Physical Vapor Deposition, or PVD, which operates at the other end of the temperature spectrum in the 400 C range. Between these two extremes are two other emerging coating processes which promise to enhance insert system performance. Plasma Assisted Chemical Vapor Deposition, or PCVD, is well accepted in Europe and is being explored in North America. PCVD operates in the 600 C range. Finally, Medium Temperature Chemical Vapor Deposition, or MTCVD, is an emerging and promising technology that operates in the 800 C range. The key factor to bear in mind is, that the properties of both the coating
Continued on page 29
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The ABCs of Probing

TECH TIPS TECH TIPS

Could your machining application benefit from touch probing? In this article an industry expert provides you with the tools you need to make an informed decision.
Marposs Mida T-series probe in a turning machine application.

two kinds of probes

Q. Broadly speaking, what are touch probes used for? A. Touch probing systems are used to help provide process control on a wide range of CNC machine tools including CNC lathes, vertical and horizontal machining centers and grinders. Probing applications typically fall into two broad categories: spindle or turret probing, and tool probing. Spindle or turret probing systems consist of a spindle or turret mounted touch probe with stylus, a transmission system and a machine/ control interface. These systems are used for setting up the machining cycle; for in-process part inspection with feedback for automatic tool compensation; and, sometimes, for onmachine final part inspection. In machining-center setup applications, a spindle-probe system will locate the part at specified data points and provide automatic input of work coordinate positions. During part changeovers, probing makes it possible to take one fixture and setup off the machine, put another one on, and get quick validation to start machining. Benefits usually include a substantial reduction in set-up time and increases in machine-tool productivity or overall throughput. For in-process applications, the spindle or turret probing system measures critical machined dimensions to make sure they conform to original specifications. Most often, the inspection is combined with data feedback for automatic tool compensation. This provides process control that is especially cost-effective in turning operations. Sometimes, measurement of particular dimensions serves to provide final part inspection right on the machine. Tool-probing systems consist of

a table-mounted touch probe and stylus, an adjustable probe holder and a machine/control interface. These systems have two primary functions. One function is to check tool diameter and length, which can save setup time by eliminating the need for off-machine tool presetting. The second function is to check for broken tools, which can prevent possible damage to the tool, the part and the machine and consequent breakdowns in production. Actually, broken tool detection is an incidental offshoot of the toollength measurement. The probe checks the tool length against a programmed error margin say ten thousandths. If the error is greater than this, the tool registers as broken and is replaced.

fixturing matters
Q. In what way is fixturing important to probing? A. You often hear quite to the contrary that with probing, you dont have to spend money on hightech fixturing with high precision. Instead, you can use a low-cost holding system, find the part in the fixture, set your work coordinates automatically and be off and running. If you put on a new part thats not located in exactly the same place, you can simply re-establish the coordinates and go to work again. Fixturing is no more or no less important with probing than it is without it. With probing, however, it should be possible to reduce the cost of fixturing. The designer must under-

T
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he use of touch probes on machine tools is growing as more and more shops learn how to use them to reduce setup time and improve productivity. Yet, some shops are overlooking the value of touch probes or are under utilizing this technology. To explore this and other issues relating to touch probing, author Edward Marchitto has chosen a Q and A format. Marchitto is a systems engineer with Marposs, one of the leading international firms in the design of high-production/high-speed in-line contact gauging systems.
CNC MACHINING

Marposs Mida T-series probe used on a horizontal machining center.

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have lent themselves well to indicators, but it is easier to program the probe and record data when hitting flat or cylindrical surfaces. To sum up, fixturing used in conjunction with probing may not have to be as precise as before, in terms of repeatable location of the part, but it has to be carefully designed for proper accessibility to a locating reference point.

positions are then recorded, and the program proceeds to the next block of code.

BUILT TO LAST

dont forget training

Q. How important is instruction, or training, to successful customer use of a probing system? A. Extremely important. Marposs strongly encourages probe users to invest up-front in training but the training need not be exhaustive. The most important things to learn about probing are the fundamentals of calibration, and how to program the probing cycles supplied with our system. Marposs, along with Haas distributors, has a program in place to train its customers in these skills. The program also offers training in programming the Pro-Mac control option. With respect to this training, it may be helpful to clarify some issues. In the first place, the probing cycles are themselves macros. They are complete and fully documented for the user. Training for the probing cycles does not require prior knowledge of macros. However, training in macro programming requires a strong NC background. This is because macros are control-resident programs which incorporate a lot of CNC fundamentals. It must be remembered, however, that training is only the first step to successful probing. Other skills will only be mastered through experience.

what you need

Q. Are Haas machines capable of incorporating probing with the simple addition of some software? A. Along with the software, you need a The Marposs Mida touch probe is used to set up a diesel fuel pump Pro-Mac control body for re-machining on a vertical machining center. option. The Pro-Mac stand that the probe itself can be option provides advanced programused to accurately locate the part. ming capabilities for controlling all His own primary goal is simply to the motions of the probe and cutter hold the part securely on its proper path. It allows you to use variables datum surfaces. The workholding and mathematic and trigonometric design must be such that it gives the functions, as well as logical and conprobe proper access to the locating ditional statements. reference points. Both the spindle-probe and toolTo meet this goal, the fixturing probe systems require sufficient must reflect particular design considprogram memory, or storage. The erations. For example, if an NC proMida standard package uses gram needs to set up a Z-axis zero 100 feet of memory for both spindlepoint in a work-coordinate system, probe and tool-probe macros. the probe has to be able to touch G31 is the fundamental CNC that surface with a part in the fixture. code for probing and is used extenThis is not a new idea. Many sively in all probe applications. fixtures are designed with a feature During motion caused by a G31 specifically used for location purposes. command, axis targets and a feed Often a sphere, or tooling ball, is rate are programmed, and the probe used. A designer should know, howsignal is monitored to sense contact. ever, that spheres are more difficult to When contact is detected, the probe than cubes. Tooling balls may machine stops axis motion. The axis

what holds shops back

Q. We all know of shops that are well run and progressive, with bright operators who could undoubtedly learn to run a probing cycle. In many of these shops, there remains a big resistance to get into probing. Why do you think this is? A. A number of concerns hold people back, but some are simply
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his is a Haas aluminum-bronze worm gear before the teeth are cut its a key part of our rotary tables. The gear blank is mounted to the spindle before the teeth are cut. Then, each unit is hand-trammed while in-position to a runout of less than .0001 of-an-inch. By mounting the worm gear blank to the spindle before cutting the teeth, were able to maintain superior overall concentricity. Each gear is then hand mated to one of our ultra-precision worms to produce a highly-accurate worm gear set for dependable, precise operation. Each and every part machined by Haas at our state-of-the-art facility gets this much attention. Its the only way we know to ensure that weve built a superior rotary table that will provide you with years of dependable service.

Contact us for complete details about our full line of rotary tables and indexers including dual, triple and quad-head models. Haas Automation, Inc. 2800 Sturgis Road, Oxnard, CA 93030 800-331-6746 fax 805-278-2240

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Continued:
The ABCs of Probing
(Continued from page 26)

How to Grow Your Productivity With a Systems Approach to Insert Selection: Part I in a Series (Continued from page 23)

not valid. For instance, many potential users have a real fear of probe breakage, even though probes are designed to resist damage from crashes and have software designed to prevent many mistakes. Another major concern is maintenance how often must you calibrate the probe? For the right answer to that question the probe user first needs to understand the importance of calibration. Machine tool probes, such as the Marposs Mida probe, are highly repeatable microswitches and will perform flawlessly regardless of operator skills. A probe, however, has no knowledge of its own about positioning. It uses the machines positioning capability and must therefore be calibrated to a surface of known location and size. Offsets relating stylus centerline to spindle centerline and machine position are then stored and considered each time a measurement cycle is run. An understanding of the importance of calibration, together with part-toler-

ance requirements, will determine the frequency of calibration. I have seen successful applications where calibration was performed once per part, and others where it was performed only once per month. Marposs recommends that beginning probe users, however, calibrate at least once a week. As process knowledge and experience with a particular probe and machine tool system increase, the ultimate frequency of calibration can be established. With a tool probe, a set of routines is needed to calibrate the probe for measurements of tool length and diameter. The probe is therefore calibrated to a tool of known length and diameter. The frequency of calibration should be determined in the same way as with the spindle probe.

summing up
Anyone contemplating the use of a probe should understand that the basic philosophy and concepts of on-machine

probing are not difficult. Moreover, training in running the probe cycles will strengthen operator confidence through hands-on machine demonstrations and user application development. This means that the probes potential will depend almost entirely on the compatibility of your manufacturing process. All manufacturers can profitably consider machine probing as a tool for enhancing existing processes, or for improving the design of new processes. In many cases, the use of a probe will save setup time and costs, eliminate operations or allow machines to run unattended for longer periods. Most impressively, probes used for process control will often result in dramatically improved process capability. If you wish to purchase a Marposs spindle or toolholding probe from your Haas distributor, request part numbers WPRO-M for spindle probes, and part numbers TPRO-M for tool probes. Marposs 888-627-7677

and the substrate are changed by the application process. The same coating applied to the same substrate by different processes may provide very different performances in the cut.

be possible without effective Top Form Geometries on the inserts.

edge preparation
In the past, most manufacturers offered only one or two standard edge preparations, or hones, for any particular insert size and geometry. Today, however, it is recognized that the hone is really determined by the application for which the insert system is intended. An insert system intended for high-speed finishing of steel has very different edge preparation requirements than one to be used

chipbreakers or top form geometries

With todays sophisticated insert shapes, the term chipbreaker no longer describes the contribution of this element to the insert systems. Top Form Geometry is a more precise term for the very complex shape seen on the cutting surface of a modern insert. While chip control is still a major

In general, a large nose radius provides better surface finish. These geometric factors, in conjunction with the toolholder, determine the effective lead angle. This in turn impacts cutting force and the resultant heat and wear which shorten tool life.

toolholder
In turning, the toolholder is the primary determinant of lead and rake angle, both of which can influence chip thickness, horsepower requirements, cutting forces and tool life. In milling, the critical toolholder-related factors are radial and axial rake, which have the same impacts found in turning applications.

cutting fluids
This is one of the most overlooked factors in the performance of any metalcutting application. Recent testing has shown that the choice of cutting fluid can have substantial impact on both insert life and cutting system performance, especially on hard-to-machine materials like stainless steels and high-temperature alloys.

Focus on Mold Making

making times considerably. Typically, operators will machine a roughing electrode and immediately put it to use in the EDM machine. Then, while the roughing electrode is burning, theyll machine the finishing electrode. Normally, machining the finishing electrode would take longer than the EDM roughing operation. However, the Haas VMCs allow Global to complete the finishing electrode before the roughing operation is done providing justin-time manufacturing, and reducing lead times. Machining graphite EDM electrodes poses other problems as well. Graphite creates a very fine dust when its machined, Bichsel said, which gets into everything. So, we use flood coolant to eliminate the dust problem. We can pro-

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gram the coolant nozzles position with the Haas P-Cool option, so we dont have to stop the VMC and manually reposition coolant nozzles.

HANDLING LARGE PROGRAMS AND GETTING SMOOTH SURFACE FINISHES

Another factor in machining molds is the necessity of processing large CNC programs. These files must be downloaded to the CNC control fast, and executed quickly, to eliminate cutter hesitation while the control waits for the next block of data. The Haas 4 MB of expanded memory allows large program files to be fully loaded into the CNC control, and the 1000-block-per-minute processing speed eliminates cutter hesitattion. This keeps dwell marks from spoiling

an otherwise smooth surface finish. A smooth surface finish off the machine reduces manual bench work, Bichsel said. Because of the spindle speeds we can maintain, the surface finish from the Haas is very good. The blends we get on complex surfaces have reduced our bench work by as much as 80 percent. The Haas has handled everything weve thrown at it, including unattended operation, Bichsel said. We load the automatic tool changer with all the tools for a particular job, upload a long-running program into memory and push the cyclestart button. They make money for us with the lights out. Thats why theyll pay for themselves in less than two years.
Contact Global at 972-241-4300.

in summary
Laboratory testing and field experience have clearly demonstrated that the very subtle interaction of the seven elements of an insert cutting system can have extremely large impacts on application performance. The quest for a universal insert material and chipbreaker combination is a dead end. The direction for the future is in matching insert cutting systems more and more specifically to workpiece materials and cutting operations. In the next installment of this series we will examine substrate and possibly coating materials and their contribution to insert system performance in more detail.

function, the Top Form Geometry also serves to reduce cutting forces. Lower forces mean less heat, deformation and friction, which enhances tool life and often improves workpiece size control and finish. Perhaps the best example of this is the use of chipbreakers on milling inserts. Generally speaking, milling chips tend to break themselves, but the other benefits of a well-engineered Top Form Geometry are easily seen in reduced horsepower requirements and better parts. Many of todays highspeed milling applications on relatively low-horsepower machines would not

for roughing, even though both may share the same basic geometry. Ceramic and cermet materials also require edge preparation in the form of a T-Land geometry. Testing shows that very subtle variation in the width and angle of the T-Land can have substantial impact on tool life.

style and nose radius

Here, at least, conventional wisdom still prevails. Selecting a style with the greatest included angle will provide the strongest possible insert for the application.

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Haas CNC Lathes

New Products & Features

Haas Introduces Vector Spindle Drives
Productivity Enhancement Option

Haas Automatic Pallet Changer

Standard 20-hp* motor

Haas Automation recently Faster spindle acceleration/decel. announced the addition of a Vector Improved chip-to-chip time Spindle Drive option for all their High-speed rigid tapping VMCs, HMCs and CNC lathes. Reduced cycle times The Haas vector drive option Closed-loop system with encoder employs a true, closed-loop vector to Precise rpm control deliver peak performance and pre Better tool life and finish cise speed control under any load Constant chip load (up to the limits of the drive). The Increased maximum torque and range vector drive provides the absolute Higher speeds and feeds best performance throughout the full Increased feed per revolution range of standard spindle speeds, Precise speed control as well as increased maximum Designed and manufactured by Haas torque and a broader torque range. The Haas vector drive option *20 hp peak provides faster acceleration and deceleration, faster spindle orientation and a simplified interface directly to the control. See Productivity Enhancement Option adjacent for added benefits. The vector spindle drive option is currently available for all Haas VMCs, CNC lathes and HMCs, except those with 30-hp motors or high torque options. The vector drive option is standard with the Haas 50-taper spindle.

L-6

The new Haas HL-5 and HL-6 CNC lathes are now rolling off the assembly line, and production is ramping up to full capacity. These large capacity machines have drawn lots of attention since their debut in March, and the first production models have already hit the road as part of the Haas World Tour of trade shows.

A VR-11 is prepared for shipping to Hannover, Germany for the worlds largest trade show.

Five-Axis Profiling VMC from Haas Automation

Haas Automations new VR-11 fiveaxis profiling vertical machining center provides a cost-effective solution for large 5-axis machining operations. Providing an impressive 32-degrees of spindle rotation on the A and B axes, this unique machine is perfect for such industries as aerospace, and mold & die, where undercuts and contouring are the norm. Based on Haas shop-proven VMC design, the new VR-11 offers a large work envelope of 120 x 40 x 30 (xyz). A high-torque, 20-hp spindle provides up to 7,500 rpm, and features a vector spindle drive for the absolute best performance throughout the entire rpm range. Brushless servo motors ensure high-speed contouring capabilities, and yield quick rapids to reduce cycle times. The 5-axis spindle features a fullyenclosed gimbal design to protect gears from chips and coolant, and a 32-pocket (40-taper) automatic tool changer swings out of the enclosure for unobstructed

Zip Drive Option Available for Haas CNC Machines

The latest, high-capacity memory device for computers is now available as an option for Haas CNC machining centers and CNC lathes. The new Zip drive option provides unlimited program storage and high-speed data-transfer rates 100 megs at a time. Just plug and play. The Haas Zip drive option includes everything you need to add a Zip to your Haas CNC machine, including control interface, parallel-port Zip drive, power supply and connecting cables. Use the Zip to transfer entire program directories, back up important jobs or even DNC large files. Included software allows you to switch the drive between your Haas and your PC. Or, if you prefer, buy a second Zip for the PC and just move disks from drive to drive. This versatile option is available for all new Haas CNC machines. Please check with you distributor for information regarding retrofit compatibility and field installation. Zip is a registered trademark of Iomega Corporation

H
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L-1&2 BB

Big-bore lathes are quickly gaining popularity among shops needing compact machines with larger capacities. Haas has stepped into the fray with their new HL-1BB and HL-2BB Big-Bore CNC lathes. These versatile machines combine the power and capacity of a larger machine 30-hp spindle, 10" chuck and 2.5" barfeed capacity with the small footprint of a compact machine.

machining. Numerous options are available for the VR-11, including a 10,000 rpm spindle for high-speed machining, and linear scales to further enhance accuracy. Optional through-spindle coolant improves tool life, and an automatic chip conveyor reduces idle time by removing chips from the enclosure. Driving the VR-11 is the highly-refined and user-friendly Haas CNC control. Designed and built in-house, this control features dual, high-speed 32-bit processors, and program execution speeds up to 1000 blocks/second. The 5-axis software has been fine-tuned to meet the challenge of processing large, complex files,and memory is expandable to 8 megabytes. The Haas CNC control is both Fanuc and Yasnac compatible, and exclusive OneTouch features boost productivity by reducing complex tasks to the push of a single button. The new VR-11 5-axis profiling VMC from Haas Automation true simultaneous, large-envelope, 5-axis machining at an affordable price.

roductivity is the name of the game, and Haas Automations new Automatic Pallet Changer is an effective way to give your productivity

a boost. Available as a factory-installed option on new VF-3 vertical machining centers, these turnkey systems are simple

to operate and require minimal training. Seamless operation is provided through the Haas CNC control, and air and power are provided by the VMC. The first VF-3 APCs rolled off the line in August and are on their way to customers.

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Continued
The Work Force of Tomorrow
(Continued from page 1)

The Back Page

EDITORIAL
achieve trouble-free and safe operation you should do the following: Change the oil regularly, rotate the tires, flush the cooling system and change the coolant, replace the air filter and fan belts, oh, and dont forget the shock absorbers. Rest assured, this is sound advice; and, followed with some devotion, it will serve you well.

things are not what they used to be on the other side of the pond. During a recent visit to Mikron Machine Tools in Europe, they took great pride in showing me their apprentice shop and introducing me to apprentices. Investments in our future, they told me. It is a wise investment, but weve had to cut back because of budget limitations. Roger Stevens, Chairman of the Stevens Engineering Group, expressed a similar sentiment on my last visit to England. He was ruing the fact that the U.K.s apprenticeship programs were slowly dissipating. What was once the model for apprenticeship programs worldwide, is now drawing a decreasing investment and less interest from both employers and apprentices. Apprenticeship programs are all well and good, you say, but if I invest in this level of training, Im just going to lose those Ive trained to someone else. I have heard this

more times than I care to admit, and each time Im reminded of Henry Peter Brougham who said, Education makes people easy to lead, but difficult to drive; easy to govern, but impossible to enslave. Maybe we need to look at our management approach if we expect to lose people who are trained. Maybe we should learn what our employees are looking for, before we lose them. Not all employees are looking for a couple of cents more an hour. Maybe we should ask them. While I have asked more questions than Ive answered in this column, hopefully Ive provoked some thought. I am sure there are local training or apprenticeship programs in your community. You should look into them. If we dont invest in tomorrow, today; when tomorrow comes, and there is no one to fill our needs, we have only ourselves to blame. Tomorrow comes every day.

To

Preventive Maintenance as an Investment

If you want your car to be reliable, you do the little things to maintain its overall integrity, right? We all learn this lesson eventually. Some of us have learned from experience that preventive maintenance pays back big dividends. Some have learned by gentle reminder; others, however, have learned only after a lesson from the school of hard knocks. The prevent, maintain and be sure school of common sense relates to all machines, no matter what their design or application. Logic is all thats required to make the leap from your car to your CNC machine. Preventive maintenance is good for the machine, your investment and your bottom line. Say it any way you want a machines reliability, length of usefulness and accuracy are linked directly to the attention and maintenance schedule thats been bestowed on the particular equipment. More and more users of CNC equipment are realizing the pivotal role preventive maintenance plays in realizing an efficient production schedule. Rest assured, this area is becoming as important as scheduling and quality considerations, especially in light of growing requirements for ISO 9001 certification, as well as other industrial quality standards. From a practical standpoint, its good business to follow a regimented maintenance schedule. As part of the modern machine shops overall strategy for accuracy, as well as peak productivity, CNC machine maintenance is finally taking its place near the top of the list of importance. Daily, weekly, monthly, bi-yearly and annual routine maintenance is simple for anyone to do, and takes very little time. When compared to costly down-time and repair bills, its as if youre being paid to do it. Come to think of it, that is in effect whats happening. When you follow the recommended maintenance schedule, you are being paid, by yourself, a pretty good wage for the time and effort being invested. Besides the obvious benefits for the long-term usage of the machine, regular maintenance will quite often expose larger potential problems before they cause major trauma. By checking coolant levels, oil levels, cleaning chips from way covers and wiping chips from spindle bores, you are also making some valuable routine observations. When you wipe, clean, change, check and polish, you have to look at what youre doing. Often, you will spot something that might not look quite correct like a slight spot of abnormal wear from a missing fastener simply because youre poking around the machine to do your maintenance. Its at these times that daily and weekly routines seem most valuable. Rest assured, they are, because catching something before it breaks is worth 100-times its value in a repair bill. Consider for a moment all the things invariably tied to the unexpected breakdown. First, your production schedule goes south. Then, you have to shift priorities and jobs around to meet deadlines. Eventually, you miss deadlines. Unfortunately, your customers dont care about your breakdown, they just want their parts. Later, though you dont know it, a really great (can you say big profit?) long-run job went to your competitor... he seemed more reliable. So, go find the Maintenance Schedule section in your Haas Service Manual you know, the one that came with your machine? Youll probably be surprised how simple Haas machines are to maintain on a routine basis. They were designed that way. The daily service check list for your Haas should take no more than a few minutes. The weekly routine, maybe 20 minutes hardly a burden when you consider the pay back. Your shop will be cleaner, the operators will be more aware of their equipment, your Haas will perform at peak output and last even longer. Through preventive maintenance, surprise service calls will become the exception, not the rule.

Simplifying Turning of Stainless Steel

breaker, is usually the best solution for turning stainless steel.

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selection made easier

Tool selection guides, like Sandviks CoroKey, offer users information on which grade and geometry combination will work best in every application finishing (F), medium machining (M) and roughing (R). Sandvik marks this information directly on the inserts for easy identification. The inserts are also shipped in a box with cutting data for that particular insert printed on the label. The cutting data is at best conservative, and should be taken only as the starting point. We strongly recommend the following: push the inserts to the limit. Think parts per edge, rather than insert cost. In that manner, youll maximize productivity all the time.

less steel, select an insert with the correct nose radius. The nose radius is a key factor in insert strength for roughing, and surface texture in finishing. A nose radius of 364ths or larger is usually the best choice for stainless steel turning. In rough turning, the maximum metal removal rate is obtained with a combination of high feed and moderate cutting speed. Machine power is sometimes the limiting factor, and in such cases, the cutting speed should be lowered accordingly. Generally, in finishing, setting the feed no higher than one-third of the nose radius will provide good surface texture and accuracy. Often, this smoother, easier turning means you can get by with a lower power machining center.

tool wear doctor

Having covered whats new in inserts, lets take a look at tool wear. Some edge-wear patterns are normal, while others are symptomatic of improper application, incorrect machine settings or inappropriate

nose radius
Whether youre doing heavy roughing, medium roughing or finishing on stain-

turning techniques. Youll be further along if you diagnose and correct these first signs of trouble, and apply some innovative cutting techniques to minimize them. Remember, tool wear in and of itself is not a negative process. Tools will always wear. Its not a question of if, but when, how much and what type of tool wear will occur. When a tool cutting edge has performed a considerable amount of metal cutting within a reasonable time, wear is very acceptable. It becomes negative when premature breakdown or tool fracture occurs, causing excessive stoppages for edge changes. To control excessive stoppages, push the insert to the limit for 15 minutes, and at that point index the edge. This practical 15-minute rule of thumb will ensure you get more parts per edge with fewer indexing stoppages. It makes no economic sense to try to push the edge beyond that time. Productivity should be your primary concern, not saving a few cents on the remaining edge life.

A Message From
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Make Reliability A Non-Issue.

Get a Haas.