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NCMT, which offers fully engineered solutions for metal-cutting applications, will exhibit a variety of grinders, tool holders and cutting tools on Stand 5229 at Mach 2010.

The company will showcase Big Daishowa’s range of tool holders and cutting tools.

New items will include a tapping tool holder that compensates for synchronisation errors and a modular endmill that offers the economy of interchangeable, indexable-insert front ends with the eccentric relief normally found on solid-carbide cutters.

The Xebec range of high-precision, abrasive deburring tools made from aluminium oxide, including two new products, will also be exhibited.

Okamoto’s new IGM-15NC2 twin-spindle CNC internal grinder, which will be unveiled at Mach 2010, is claimed to provide versatility, productivity and precision.

Incorporating two spindles on the same machine is said to provide the user with a number of benefits.

The elimination of multiple chucking simplifies setup and enhances productivity, as well as optimising dimensional accuracies.

For example, a workpiece that requires an ID, OD and face grind normally requires the use of two separate grinders.

As no two machines are identical and the workpiece has to be re-chucked, the relative accuracies of the features are lost.

With the IGM-15NC2, however, the workpiece stays fixtured and the spindles needed for the multiple grinds are on the high-precision wheel head.

Specification includes an ID grinding capacity of between 6mm and 100mm, a maximum grinding stroke of 80mm and a swing-over table of 600mm.

The maximum longitudinal travel is 500mm, while the feed rate is up to 10m/min.

The Fanuc 18i-TA two-axis control with conversational programming has a ‘teach input’ format that reduces the time needed for programming and facilitates operation.

The automatic grinding cycle can be interrupted at any time to redress the wheel.

A feed-hold function enables cycle stop for the verification of location and dimensions.

The table rides on high-precision linear guideways and is driven by an AC servomotor that enables minimum-feed increments as fine as 0.25 micron.

Both high-frequency, inverter-controlled spindles have 10,000rev/min and 20,000rev/min speeds as standard.

Any combination of 10,000rev/min, 15,000rev/min, 20,000rev/min, 30,000rev/min, 40,000rev/min and 60,000rev/min is available as an option.

The two-point diamond dressing of the ODs and faces of the grinding wheels is provided.

The workhead, which swivels from -5deg to +15deg, features a cast-iron construction and utilises high-precision double angular contact bearings.

Workhead speed, infinitely variable from 100rev/min to 850rev/min, is programmable through the CNC.

Optional accessories include coolant systems with paper filters, magnetic separators, coolant temperature regulators, a variety of chucks and in-process gauging.

The Okamoto UPZ-210Li surface grinder is a counterpart to optical profile grinding machines, but differs in that it allows the use of coolant.

The machine is designed for grinding small, accurate components such as mould inserts and high-speed punches for producing integrated-circuit contacts.

The grinding head can be swivelled +/-5deg, allowing the high-precision grinding of vertical-shoulder parts.

Instead of being hydraulically actuated, the table is driven by two linear motors, which are temperature controlled within 0.1C, achieving up to 300 reciprocations per minute (20mm table stroke).

The high stroke count prevents heat build-up, minimises wheel wear and gives the machine greater accuracy than high-revolutions-per-minute systems that remove larger amounts of material with every pass.

An internal, 100-1,000X charge-coupled-device camera enables profile measurement and automatic compensation for grinding error.

A computer-aided-design image can be overlaid on the part to compare dimensional data.

This avoids having to remove the workpiece for offline inspection, as reinserting it can affect wheel and part alignment and compromise grinding accuracy.

Reduced part handling also speeds up the process.

Big’s FCM Fullcut endmill range for slot and square-shoulder milling has been expanded recently with the addition of FCR versions capable of multifunctional metal cutting, including ramping, helical milling, shoulder milling and peck drilling.

Ramping is becoming increasingly important in the die/mould and aerospace sectors as the technique allows the higher speeds and precise interpolation capabilities of modern machining centres to be exploited, reducing cycle times and the number of cutters needed.

Both the FCM and FCR tooling types are now available with interchangeable threaded extensions at the front end, so users can economise on the number of BBT, HSK or Capto back-end tooling they need to buy.

The back ends and the new front-end extensions both use the Big-Plus face-and-taper contact system for rigid, accurately concentric clamping.

Fullcut mills combine the economy of indexable inserts with the eccentric relief of the cutting edge, normally found on solid-carbide cutters.

This improves the toughness of the edge without reducing its sharpness, which results from having a high positive rake angle in both the radial and axial directions.

Further advantages include reduced noise in operation as well as low cutting resistance, so the tool is both productive and accurate when used on less rigid milling machines and machining centres, according to NCMT.

Six FCR insert grades are available for the machining of almost any material, from highly alloyed steels to aluminium.

The secure clamping of inserts is provided by the patented, high-tensile-steel Alpha Screw system, which also provides maximum support under the insert.

Dry cutting is normally recommended, although through-holes are provided for applications where a built-up edge dictates the use of soluble oil coolant.

A new Big adapter for synchronous tapping will be launched at Mach 2010.

The Mega Synchro tap holder compensates for synchronisation errors during rigid tapping by reducing the thrust load to both the tap and the workpiece by up to 90 per cent, improving thread quality and tap life.

The error compensation is facilitated by a novel mechanism that absorbs the pitch difference between the tap and the synchronous spindle.

The Mega Synchro is capable of supplying coolant through slits to the tap periphery as well as through the tool.

Its design allows the tap holder to be isolated from the axial pressure of the coolant.

The holder is available in a variety of lengths and spindle interfaces, including BBT, HSK and Capto.

Tool bodies in 41 varieties and 172 standard tap adapters offer a range of configurations.

A new range of ceramic fibre-mounted points will be also be shown at Mach 2010.

An alternative to existing aluminium oxide, the ceramic material does not crack, chip or clog, resulting in an improved surface finish.

They can be used with high-speed, pneumatically driven hand tools at speeds of up to 30,000rev/min or 60,000rev/min, depending on the type.

Cutting edges are continually exposed over the entire surface thanks to self-sharpening alumina fibre rods measuring 10 microns in diameter.

The tools work on any material from aluminium to stainless steel and on metals hardened to 57HRc.

Burrs with a base thickness up to 0.2mm may be removed, while fine-edge breaking and chamfering are further applications.

NCMT will showcase Xebec’s A13 alumina cutting fibre, a more flexible type that allows tools to be made having softer bristles for deburring delicate materials such as aluminium alloys and even plastics, without scratching the surface.

Unlike nylon brushes, the fibres do not deform, so they reliably deburr and improve the surface finish on finer detailed and precision parts.

A second version is available, also intended for use in the spindle of static machine tools rather than handheld ones.

The tools are suitable for deburring small bores down to 0.3mm in diameter and grooves as small as 0.5mm in width.

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