laser wrinkle rings swiss machine bells and whistles s swiss-style lathe continues to evolve adding...

Laser cutting on the Tsugami S205-II with IMG 400LS Laser Cutting System combines six-axis Swiss machining with laser cutting

on one machine for machining medical parts and other extremely small parts with delicate features.

June 2015 | AdvancedManufacturing.org 71

SwiSS Machining

Laser Wrinkle Rings Swiss Machine Bells and Whistles

Jim LorinczSenior Editor

Products target improved cycle time,

safety, machining performance Swiss-style or not, CNC automatic lathes have carved

out an impressive record machining precision engi-

neered parts for a wide variety of industries includ-

ing medical, aerospace, electronics, hydraulics, and

automotive. The Swiss-style lathe continues to evolve adding

new functions to maximize efficiency in machining complex parts

complete. By now the ability to bring multiple tools into the cut

has found general acceptance as well as recognition of the chal-

lenge that it poses to programming skills. The Swiss machine

technology bar continues to be raised higher with the addition

most recently of on-machine laser cutting, added to other recent

advances including full B-axis capability and quick and easy

changeover to machining with or without guide bushing.

Programming and setup have all but eliminated long change-

over times so typical of older cam-operated screw machines.

Machine CNC controls and third-party software from Partmaker,

Esprit/DP Technology, and Mastercam/CNC Software have

streamlined programming with 3D modeling and simulation for

72 AdvancedManufacturing.org | June 2015

maximizing productivity-enhancing processes like

angular drilling (B-axis), deep-hole drilling, milling,

tapping, thread whirling, and hobbing. There’s still

something in cycle time to be gained by pressing

one’s nose to the machine window while tweaking

a program, though, and cycle time, especially in

longer run jobs, is still the name of the game.

Laser Cutting On Swiss Machines

The newest addition to Swiss machines is

on-machine laser cutting which can perform

extremely fine feature cuts in thin tubing and

small cylindrical parts, like those typically found

in the medical device industry for stents. Rem

Sales, the exclusive North American importer of

precision Tsugami machine tools, has introduced

the Tsugami S205-II with IMG 400LS Laser

Cutting System which combines six-axis Swiss

machining with laser cutting on one machine. The

SwiSS Machining

Fine shapes on parts like stents including diamond patterns, windows,

J-slots, fine holes from 0.005 to 0.010" (0.13–0.25-mm) diameter, and even

spirals are laser cut using the Marubeni Citizen-Cincom Inc. Laser System

L2000 on the L20E Swiss machine.


advantage for small parts manufacturers is that it replaces

two machines with one, eliminates the need for multiple

part setups, and significantly reduces part production time.

While originally designed to speed production of small, cy-

lindrical parts for the medical industry,

the Swiss Laser combination machine

has potential applications for other

industries that manufacture similar-

sized parts.

Marubeni Citizen-Cincom Inc.

(Allendale, NJ) has introduced its

air-cooled Laser System L2000 for

Cincom machines on the L20E Swiss

machine, machining an endless array of

geometric shapes on tubing or creating

tubing from solid stock. Shapes include

diamond patterns on stents, windows,

J-slots, 360 fine holes from 0.005 to

0.010"(0.13–0.25-mm) diameter, and

even spirals to create a flex in micro

tubing. The L2000 laser system fea-

tures a 400W IPG Photonics fiber laser

with 10 µm delivery fiber producing kerf

widths down to 20 µm. A CCD- inte-

grated camera allows optical viewing

and alignment.

Converting Swiss to

Non-Swiss Is Easy, Fast

The Traub TNL series of Swiss-style

machines is available in both sliding

headstock and fixed headstock CNC

automatic lathe versions, with and

without guide bushings. “The Traub TNL

series machines can be changed from

Swiss to non-Swiss in as little as 15 min-

utes, using the guide bush only when

necessary for medical and automotive

or other long parts,” said Hans Koschig,

Index Corp. (Noblesville, IN). “Swiss

machines are at their best for machining

parts with a large length-diameter-ratio.

There are just a few steps to convert

the Traub TNL series lathes from sliding

headstock to fixed headstock turning

and back again. The extremely long Z

travel distance of the headstock ensures proper positioning of

the main spindle. The powerful main spindle is equipped with

a C axis as standard which delivers high torque to achieve

large cutting volumes,” said Koschig.

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The Traub TNL18-7B machine features a vertical bed de-

sign, seven linear axes and an extra B axis. “The additional

B axis in the upper tool carrier can pivot 100° for machin-

ing highly complex parts. Complicated contour elements

that require additional operations such

as milling, drilling, lateral drilling, or

threading can be machined at any

angular position,” said Koschig. The

advantage of being able to convert

from Swiss machining with the guide

bushing to a non-Swiss machine

means that small precision parts can

be machined closer to the headstock

without using ground bar. The larger

remnant produced in Swiss machining

with the guide bush is eliminated. Also,

said Koschig, the guide bushing must

be adjusted with the right surface

pressure from the bush to the bar to

achieve consistent machining results.

It isn’t unusual for the Traub TNL18

being used to machine micro-parts

from difficult to machine materials like

titanium and special steel alloys.

CNC Automatic Lathes Built

to Handle Exotic Materials

CNC automatic lathes like the

Cyclone series of machines from Ga-

nesh Machinery (Chatsworth, CA) are

designed for machining small precision

parts made from exotic materials. They

depend on a strong and rigid machine

with sufficient available tooling to

improve cycle time when machining

Inconel, titanium, and exotic steel for

industries including medical, aero-

space, and transportation, defense,

and energy markets.

“Even for small precision parts the

basis for a strong machine starts with

strong spindles with larger bearings

and heavy castings,” said Kamal

Grewal. “From there we strengthen all

of the elements that affect the rigidity

of the machine at the interface of the

cutter and the workpiece so the right tooling can be utilized

to achieve the optimum metal removal rate.”

Cyclone CS-32, Cyclone NCY-32, and the Cyclone

GTS-32 machines feature five large Ø110-mm bearings in

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SwiSS Machining


the 32-mm spindles and 10-hp (7.4-kW) spindle

motors for efficient metal removal to reduce cycle

times. “Ample tooling provides for the ability to

machine complex workpiece; or to have multiple

parts set up on the machine at one time for fast

changeover,” said Grewal. All the machines in

the Cyclone series use automatic bar loaders for

sustained lights-out production. High-speed NSK

spindles up to 80,000 rpm are available to meet

the needs for small milling and drilling tools. The

seven-axis Cyclone 32-CS can run barstock up

to 1 3/8" (35 mm) at 6000 rpm, and has a full-

featured 6000-rpm subspindle for simultaneous

machining. The four-axis Cyclone NCY-32 has

18-tool stations with seven live tools and all of the

other CS-32 features, but is intended for jobs that

do not require a subspindle. The six-axis Cyclone

GTS-32 gang-tooled CNC lathe can also run

barstock up to 1 3/8" (35 mm) at 6000 rpm, and

has a full-featured 6000-rpm subspindle for simultaneous

machining in the beltless integral motor-spindles.

Machines that Complement Swiss-Style Machining

Multiprocess production centers from Willemin-Macodel

(Hawthorne, NY) complement Swiss-style machines, espe-

cially for precision workpieces that require more milling than

turning, according to President Alain Guerdat. “The six–

eight axis 508MT [mill-turn] fits in nicely into Swiss shops

for machining medical, dental, and aerospace parts from

42-mm bar with 42,000-rpm spindle and up to 72 tools

optional,” said Guerdat. The compact 508MT (mill-turn) fits

into a 6 × 8' (1.8–2.4-m) footprint and can be equipped

with barfeeder and automatic load/unload capability making

it a flexible production center. Features include a high-per-

formance motor spindle with HSK-E40 toolholder/taper and

wide angular movement from −15 to +100°. XYZ travels are

450 × 200 × 425 mm.

The 508MT is capable of low-speed roughing operations

with high chip removal rate, high-speed finishing operations,

and the ability to machine materials that are difficult-to-

machine like stainless steels, titanium and alloys, and cobalt

chrome. High-pressure coolant through the center is op-

tional. Synchronized milling/turning on A-axis spindle/divider

and counter spindle. A multiposition back-working turret has

three working positions as counter spindle, self-centering

vise, and fixed or rotating tailstock for milling and turning.

Cyclone series CNC automatic lathes from Ganesh Machinery

(Chatsworth, CA) are designed for machining small precision

parts made from exotic materials like this part.

SwiSS Machining


Peripherals include tool breakage detection with a mechan-

ical detector for tools up to 0.3-mm diameter and tool length

and diameter measured by laser or sensor. Part measurement

is accomplished by a sensor mounted on the toolholder.

Innovative Products Are

Knuckle-Buster Proof

The intRlox Mini Nut for Swiss

automatic machine tool applications

from Rego-Fix Tool Corp. (Indianapolis,

IN) has an anti-slip locking design that

is engineered to prevent the locking

wrench from slipping off the nut during

assembly and disassembly. Milled slots

on the outside diameter of the nut mate

with corresponding features of the

wrench to prevent slippage during the

tightening and loosening processes.

Benefits include improved operator

safety and prevention of damage to

other tools. The intRlox design includes

a special surface treatment to enhance

clamping forces and extend the life of

the nut by protecting against corro-

sion. The intRlox can replace any brand

of older-style mini-nuts. It is currently

available in ER 11, 16 and ER 20 sizes

in standard versions and ER 16 and 20

for coolant versions.

Rego-Fix has expanded its retrofit

reCool coolant-through low-mainte-

nance system to static toolholders on

Swiss automatic machines following

hard on successful introduction of

reCool for live tooling on CNC lathes. In

as little as two minutes, the new static

reCool system converts a standard

Swiss tooling collet locking nut into a

coolant-style nut that employs the new

Rego-Fix intRlox anti-slip nut design.

Changing tooling involves simply loos-

ening and removing the locking nut and

supply piping.

Implementing and changing

through-tool coolant in the restricted

confines of a Swiss automatic machine

has traditionally required working with coolant plumbing

passing through the back of the machine tool block. reCool

eliminates the need to work behind the tool block and

thereby reduces setup and tool changing time. By sending

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coolant flow directly to the cutting edge, through-coolant

operation benefits tool life and expedites chip removal and

is more effective in getting coolant to the cutting edge than

spray pipes or nozzles.

Thread Whirling Toolholder Handles Most Profile Shapes

Exsys Tool Inc. (San Antonio, FL) has introduced a thread

whirling toolholder that mounts to one of the rotary tool

stations on single-spindle Swiss screw machines. It is an

inexpensive alternative to dedicated thread whirling machines

for processing micro-components with long, slender thread

profiles such as medical bone screws, dental implants and

aerospace fasteners. The ring-shaped toolholder has an

adjustable range of 0–15° to accommodate most profile

shapes. It employs a maximum input and output of 6000 rpm

and maximum torque output of 13 N•m for thread milling

rough stock at extremely high speeds.

Because of its open interface, the Exsys toolholder ac-

commodates cutting tool inserts from different suppliers. The

inserts, however, must be identical and evenly spaced for the

thread whirling process. The cutting edges of these inserts

face the toolholder’s opening and rotate around the bar stock

to cut an external thread. The machine’s Z-axis longitudinally

feeds the toolholder at high speeds, while the bar stock

rotates at slow speeds via C-axis control. Each insert then

takes its cut of the material as the toolholder whirls around

the bar stock.

Micro-Turning Tool System Designed

with High-Precision µm-Finish

Horn USA Inc. (Franklin, TN) offers carbide inserts from

the S274 system for micro turning with high-precision. The

“µ-Finish” inserts are specially designed to machine ex-

tremely small precision parts and are intended to reduce

production costs related to downtime and increase process

reliability with maximum precision.

Precision grinding processes applied to the “µ-Finish”

inserts guarantee a repeatable center height of ±0.0025

mm. Each cutting edge is inspected under 200× magnifica-

tion as an additional quality control measure. This attention

to detail ensures that once the tool has been set up, no

further height adjustments are required when replacing a

worn insert.

The micro-grain carbide structure and specially

designed geometries are well suited for machining steels,

stainless steel, and brass. A new coating type AC25

developed for micro turning, grooving, and parting-off

applications resists wear and build-up of material on

cutting edges.

QUICK RELEASE BALL-LOCK

PINS.

Fairlane Products quick release fasteners and accessories in inch and metric sizes. The pins have a wide range of uses in fastening, locating and alignment applications and come in a variety of diameters, lengths and materials. Also available are wire rope lanyard assemblies. Call or go online to find a distributor in your area.

Fairlane Products, Inc.33792 Doreka DriveFraser, MI 48026(586) 294-6100FAX (586) 294-6822800-548-2935fairlaneproducts.com

FRL-067A 3.375x4.875.indd 1 3/20/14 1:44 PM

SwiSS Machining

?Exsys Tool Inc.800-397-9748 / www.exsys-tool.com

Ganesh Machinery 888-542-6374 / www.ganeshmachinery.com

Horn USA Inc.888-818-4676 / www.hornusa.com

Index Corp.317-770-6300 / www.indextraub.com

Marubeni Citizen Cincom Inc.201-818-0100 / www.marucit.com

Rego-Fix Corp.317-870-5959 / www.rego-fix.com

Tsugami/Rem Sales LLC860-687-3400 / www.remsales.com

Willemin-Macodel Inc.914-345-3504 / www.willemin-macodel.com

laser wrinkle rings swiss machine bells and whistles s swiss-style lathe continues to evolve adding...

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