Machining and EDM Innovations to Look for at IMTS
MoldMaking Technology previews some of the EDM and machining products and exhibitors applicable to mold builders that will be featured at IMTS 2022.
Edited by
Chris Pasion
Managing Editor, Modern Machine Shop | Production Machining
Photo Credit: MC Machinery (top left) GF Machining Solutions (bottom left) Sodick (top right) and Hurco Companies (bottom right).
Innovations will be abundant at IMTS 2022, which takes place at McCormick Place in Chicago, Illinois, from September 12-17. Professionals from all over the industry will be present to showcase their new products and services, and attendees will get a glimpse of the future of manufacturing as they peruse the show floor.
To prepare you for the event and help familiarize you with some of the products and exhibitors that will be present, MoldMaking Technology has compiled our product coverage below. Click on the company name to be taken to the full product post and learn about what you can expect to see at IMTS.
This installment features machining and EDM innovations, but be sure to keep an eye on MMT’s website for more exhibitors and products to be featured in the lead-up to the event.
CNC Mill/Drill/Tap Centers Feature High-Speed, High-Torque and High-Volume Machining
Absolute Machine Tools offers the Seiki KT Series CNC mill/drill/tap centers in six affordable models with three distinct spindle configurations to meet any mold builder’s needs, all within a small footprint.
The standard spindle configuration is a 0-15,000 rpm, 28-hp peak/6.5-hp continuous direct-drive spindle. An optional 0-10,000 rpm direct-drive, high-torque (120 Nm/88.5'/lbs) 28-hp peak/11.3-hp continuous spindle is said to provide 40 taper milling performance. Finally, an optional, high-speed 0-24,000 rpm, 35-hp peak/5-hp continuous direct-drive spindle is available for applications such as mold detail machining. All three spindles offer BBT-30 dual contact spindle taper and rigid tapping speeds up to 6,000 prm, the company says.
Bridge-Type VMC is Built for Cutting Performance, Accuracy for Mold & Die Applications
DN Solutions (formerly Doosan Machine Tools) introduces and demonstrates the BVM 5700, the latest member of its family of vertical machining centers (VMCs), at IMTS 2022 booth ##338900. The BVM 5700 is a massive machine, the company says, weighing 17,000 lbs with a structure built for cutting performance and accuracy. With its bridge-type construction, and single-direction moving table, DN Solutions notes that customers can handle heavier parts and cut with increased rigidity. Its design and sheer mass also reportedly provide excellent dampening characteristics that offer high-quality 3D machining surface finishes for mold and die applications where precision surface finish is demanded. The BVM 5700 shines in production prototype environments.
Fast Wire EDMs Exhibit Removal of 3D-Printed Metal Parts From Large Build Plates
EDM Network exhibits its newest, mid-sized Fast Wire EDM machine, EDMMax656W, developed for the laser powder bed fusion (LPBF) 3D metal printed market. The Fast Wire EDM was designed to quickly remove 3D-printed metal parts from the larger build plates — 625 x 625 mm in size. More recently, EDM Network notes that small molds are also being 3D printed to be used in this type of application.
The Fast Wire EDMs are not flush dependent, meaning that, unlike typical brass wire EDMs, printed parts can be randomly positioned on the build plates when cut. Cutting can also be performed approximately three to four times faster in these interrupted flush conditions with no wire breaks. The use of molybdenum wire and paper filters reduces the average cost to operate to about $1.00/hour.
High-Speed VMC Offers More Intuitive Machining, Surfacing
Expand Machinery debuts the Genmill VFM-2416 five-axis (4+1) this year at IMTS booth #338048. As a high-speed machining system with 2,700 block look-ahead for precise part tolerances — the highest in the industry, the company says — in addition to faster control, moldmakers are able to benefit from more intuitive 3D surface machining and better finishes.
In addition to the general benefits of a full five-axis machine — reduced setups, shorter tooling, improved quality, faster throughputs and the ability to machine more complex workpieces — the Genmill VFM-2416 features a 100-mm zero backlash roller cam tilting rotary table with 360° rotary motion and a swing angle of -20° to +120°. Constant preload on the roller cam is said to ensure the table stiffness necessary for precision machining at any angle. Additionally the Genmill VFM-2416 offers enough extra table space for a work vice so the workpiece can be machined to meet the needs for the tilt/rotary table mounting surface in one operation.
Wire EDM Machine Enhanced With High Precision, Intelligent Interface, Service Support
GF Machining Solutions highlights advances in EDM technology, service, support, automation and tooling, all of which is designed to help shops solve their manufacturing challenges through complete solutions and holistic support. Moreover, in booth #338376, System 3R is showcasing tooling solutions to reduce setup time and automation solutions to maximize machining hours.
Integrated problem-solving solutions include the new Cut X 500 and Cut P 350 Pro wire-cutting EDM machines for precision part generation. To maximize machine-tool value and competitive readiness, GF Machining’s subscription-based Success Packs are said to feature comprehensive customer support as well as digital services that add connectivity for remote machine monitoring and troubleshooting no matter the location. Rounding out the lineup of live demonstrations will be an automated cell featuring a Mill 400 U and Form P 350 with a Fanuc robot. There will also be a System 3R WorkPartner 1+ modular pallet system connected to a GF Machining Solutions Laser P 400 U laser texturing machine.
Five-Axis Machine Demos Challenging Aerospace, Medical and Mold Applications
GROB Systems Inc. demonstrates a range of five-axis machining applications on its compact G350 Generation 2 Universal Machining Center at IMTS 2022. At its shared booth with YG-1 Tool Co. (booth #431400), GROB says attendees will be able to see how the company meets and exceeds the demands of aerospace, medical and die/mold machining. Personnel will also be on hand to answer specific customer application questions.
GROB machining centers are made in the U.S. at its Ohio-based, 400,000-square-foot GROB Systems production facility, and can include advanced automation solutions for increased productivity. The GROB G350 on display at IMTS includes a dynamic rotary table with a 200 rpm B-axis with infinite rotation, and a maximum rotation of 360° in the A-axis. The G350 Generation 2 is equipped with a Siemens 840D sl control, 16k rpm spindle, 117-tool holding capacity and an HSK-A63 tool interface. The GROB G350 features a pyramid fixture holding three parts at once — one each for an aerospace, medical and mold part.
Moldmaking Applications Supported by CNC Controller With Fully Integrated Process Monitoring
At IMTS 2022, Heidenhain unveils the novel TNC7. The CNC control supports users from initial design to final machining, from one-off jobs to serial production, and from simple slots to complex contours. According to the company, the control platform also enables machine manufacturers to adapt the user interface to their machines and offers dynamic development potential for greater functionality. Its single, most important feature, however, is the set of reliable processes that it provides builders for moldmaking applications.
For example, the TNC7 is said to be the first CNC control on the market to provide the users with fully integrated process monitoring. Based on one or more reference machining operations, the TNC7 can reliably detect process deviations and can immediately respond appropriately. Thus, a broken tool or indexable insert will not cause secondary damage.
Three-Axis Machining Center Aids Mold Builders With Reduced Cycle Times, Improved Surface Finish
The VMX30Di three-axis machining center from Hurco Companies takes CNC machining to the next level with the delivery of speed, performance and precision to any machining application, according to the company. With a 15,000 rpm spindle and Big-Plus CAT40 spindle taper, the VMXDi performance series has been designed to help job shops focusing on batch production or mold and die work be more productive and profitable.
VMX30Di features a 40"x 20" table, and a table load of 3,000 lbs. Equipped with a direct-drive spindle, the VMXDi series (XYZ travels: 30" x 20" x 24") is said to offer a high-quality surface finish, quieter spindle, reduced heat transfer and less head growth. It also provides reduced chip-to-chip time and faster spindle acceleration and deceleration. Its most important function for mold builders, however, is the VMX30Di’s ability to create accurate geometry that will require as little polishing as possible, Hurco says.
Heavy-Duty, Precise Five-Axis Machining Manages Multiple Projects, Fixtures in One Setup
Hwacheon Machinery America showcases the D2-5AX, designed for heavy-duty, precise five-axis machining typically seen in mold and die, aerospace and general machining applications. New to this product is enhanced machine strength, a rigid structure and automation options with an automatic workpiece changer. It is also equipped with Hwacheon’s own software package, including a scheduling system, so that production teams can manage multiple projects, increasing productivity.
With a machine weight of 10 tons, the D2-5AX is said to ensure minimal vibration and thermal growth stability in production environments. For high accuracy and precision, Hwacheon says the D2 5AX is built with the highest quality components which achieve AC/DC values of 0.7 G. The D2-5AX has a range of spindle options beginning with its standard 50 hp high-torque spindle of 12,000 rpm (up to 24,000 rpm). Moreover, temperature sensors on the spindle and the machine bed measure and compensate for thermal factors.
Five-Axis Machining Center With Integrated CAM Software Overcomes Skills Gap
Jingdiao North America announces the GRA200 five-axis machining center designed to machine complex, tight-tolerance parts — including molds — for industries ranging from die and mold, aerospace, medical, energy or automotive. Highlighted in particular is the company’s Surfmill CAM software, which has been integrated to overcome the skills gap in places such as the toolroom.
In addition to providing a given set of directions for the machine, the company’s own integrated CAM system offers several features to aid the operator in navigating the GRA200. Prior to producing the NC code, for example, Surfmill is said to verify the program won’t crash during operation; an alert system has been included in the case a crash is imminent. To reduce machine downtime, an Auto-Alignment feature aligns the workpiece in the X, Y and Z axes. Surfmill is also able to compensate for tool length —measuring the length, in addition to the radius — and an On Machine Measurement feature uses a Renishaw probe to determine the critical dimensions of the workpiece and whether it’s within tolerance, providing a 3D image of the cut prior to removal.
Flexible Five-Axis Machine Ideal for Lights-Out Manufacturing
Kitamura Machinery, a premier manufacturer of precision horizontal, vertical and five-axis machining centers reveals an all new, all-in-one automation solution for its MedCenter5AX five-axis simultaneous vertical machining center (VMC) at IMTS 2022, booth #339133, South Hall. Demonstrating the core qualities for lights-out production the MedCenter5AX will feature a newly designed and field expandable 24-station automatic pallet changer with a high-performance, 120 tool ATC — all in a compact footprint, incorporating an unmanned machining development process for a multitasking machining environment that maximizes uptime.
Kitamura’s versatile MedCenter5AX is said to an ultra-high precision, five-axis machining center that offers unparalleled accuracy and speed for expanded machining capability in the machining of highly complex, small to medium, multisided parts in one setup. The machine’s stiffness, flexibility and cutting capability make it an optimal choice for manufacturing precision parts for the medical, aerospace and telecommunications industries, the company notes.
EDM, Precision Milling Technologies Highlight High-Precision Features for the Moldmaking Industry
MC Machinery, a subsidiary of the Mitsubishi Corp., showcases its latest EDM and precision milling technology, including wire and sinker EDMs, machining centers and automation, at IMTS booth #338129.
Newly featured sinker EDMs include the Mitsubishi SV12P and SG12 and Gantry Eagle 800. The former features mAIsmart IDPM3 (Intelligent Digital Power Master Control), which uses a state-of-the-art sensor to monitor the total amount of electrode contact area within the workpiece, so the system can automatically changes power conditions based on real-time measurement feedback to produce the most efficient burn. This results in up to 40% less electrode wear and up to 30% reduction in machining time for moldmakers.
Five-Axis Machining Center Accommodates Small Workpieces
IMTS 2022 visitors can see Mitsui Seiki’s PJ 303X five-axis machining center in action in booth #338700, demonstrating its maximum precision and versatility in processing of workpieces up to 230 mm tall and 280 mm in diameter (9" x 11"), and 20 kg (44 lbs) in weight. Typical applications cover an extensive range of critical parts such as lens molds, medical products, EDM electrodes and fuel cell components.
A key feature Mitsui Seiki highlights is that the PJ303X is designed to accurately machine smaller parts — including molds — rather than large, critical components. Its X-, Y-, and Z-axis travels are 300 mm, 325 mm and 200 mm (11.8", 12.8", 7.9") respectively. A-axis rotation is +40º to -100º, and the C-axis rotates a full 360º. High-speed linear motors move the X-, Y- and Z-axes, while the rotary axes employ direct-drive motors. Rapid traverse speed for the X-, Y- and Z-axes is 20 m/min (66 ft/min).
High-Precision Grinders Capture Optimal Mold Surface Finishes
According to Okamoto Corp., surface grinding the mating portions of a mold is a fundamental step for a high level of accuracy and smooth, flat surface finish. The ACC-SA1 series MDI-controlled saddle-type surface and ACC-32·80CHiQ surface double column grinder in particular are said to be ideal for a moldmaking shop.
ACC-32·80CHiQ is designed for high-precision grinding of large components —including molds 40" x 40" and up — to meet demanding mold and die base applications. Its ultra-rigid double column design and construction stands up to prolonged heavy-duty grinding conditions, Okamoto says, and its Double-V Way construction provides continued peak accuracy. It also enables aconsistent high degree of flatness across the entire workpiece surface. Exclusive Okamoto iQ Software simplifies data input. Auto dress with compensation for unattended grinding and shift plunge for faster material removal rates are additional features. Table size is 32" W x 80” L, with a maximum pass width of 40" and maximum distance under standard wheel of 23.5". Larger capacity models are available.
Rotating Wire, Step Cutting Features Cut EDM Wire Consumption, Optimize Cutting Conditions
With the addition of the patented iGroove function, Sodick says it has quite literally put a new spin on the capabilities of wire EDMs. Featured in three of Sodick’s existing wire EDM lines (ALN, ALP, ALC), the addition of the iGroove and Stepcut functions reportedly show improved results in accuracy and surface quality while simultaneously reducing wire consumption — this machine lineup is especially suited for thick workpieces (60 mm or greater). With the cost of consumables on the rise, this model evolution also helps reduce the frequency of resupplying.
The iGroove function rotates the wire from the top to the bottom of the workpiece, ensuring the entire surface of the wire is used during the cut, and eliminating the need for taper compensation due to wire wear. This twisting mechanism creates a consistent, fresh electrode surface from the top of the workpiece to the bottom, Sodick notes, and, as a byproduct, the wire feed speed can also be slowed down. This leads to reduced wire usage without drawbacks such as excessive electrode damage — initial trials are said to have shown a 25% reduction in wire consumption on any given workpiece, with additional savings seen on cuts that require multiple skim cuts. Wire speeds are sourced from the built-in ALN conditions.
Vertical Machining Center Connects the User to the Control
The VMCsi, powered by the Siemens Sinumerik One control, is said to be the most powerful vertical machining center (VMC) offered by TRAK Machine Tools – Southwestern Industries Inc. yet, and is on display at IMTS 2022.
The company says it has been crafted to connect the user to the control. A wide, 19" touchscreen interface, integrated field descriptions, instructive animations and high-quality graphics are said to make the control easy to learn for users of any background. Probing can be readily mastered, in addition to advanced tool management, four-axis simultaneous machining and dozens more advanced capabilities. The heavy machine tool construction provides mass for heavy cuts with solid Meehanite-ribbed casting for vibration absorption and rigidity.
Gundrilling Flexibility for Medical Applications
UNISIG showcases its extreme depth-to-diameter hole drilling technologies — an important benefit for moldmakers, the company says — including the ability to create holes with high precision. UNISIG’s UNE6 Series small-diameter gundrilling machines, for example, are said to excel at drilling deep holes in demanding materials, including high-strength titanium and surgical-grade stainless steel, as well as achieve improved concentricity through tool and workpiece counter rotation.
At the show, UNISIG will highlight medical production on the UNE6-2i that features two independent high-speed spindles for production of 10" or 30" maximum part lengths and available integrated automation onboard. The machine's high accuracy enables it to drill hole diameters from 0.03-0.25" (0.8-6 mm) and depth-to-diameter ratios from 20:1 to more than 100:1 in workpieces up to 11 lb (5 kg). With a total drilling speed of 28,000 rpm and a 3,000 psi (207 bar) flow-based coolant system, UNISIG says the UNE6-2i combines exceptional process control with an intuitive smart control interface.
Cylindrical Grinder Shows Off High Precision
United Grinding North America features the Studer S131r cylindrical ID-radius grinding machine for the toughest ID grinding operations where maximum precision is paramount.
The Studer S131r is said to excel in general grinding applications and the production of complex workpieces made from extremely hard materials, along with hydraulic components such as axial pump pistons, guide plates and housings from hardened steel, cast iron and copper. The machine also handles single-clamping production of complex workpieces with tapers between 20º and 90º.