On Manufacturing/April 2016

Cost-Effective Paint Atomizer

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Here’s a compelling argument for the optimized EcoBell3 atomizer from Dürr for applying electrostatic coatings: According to Dr. Hans Schumacher, director of the Dürr Application Technology Div., the new turbine that drives the flexible bell disk/shaping air ring system can operate with approximately 40 percent less air than previous setups thanks to the optimized vanes and nozzles deployed. (There are two turbines, which are selectable based on application parameters.) So in cases when the application calls for paint flow rates up to 600 milliliters and turbine speeds of 50,000 rpm—which accounts for about 90 percent of the operations at that level of paint flow—the compressed air savings of 40 percent is achieved. Says Schumacher, “The high-efficiency solution that incorporates this technology makes it possible to cut compressed air and spare parts costs by approximately $1,680/year, while the highest efficiency solution can achieve an annual savings of up to $2,240 for each robot. When one considers the fact that our customers operate up to 100 atomizers along each painting and coating line, the savings potential becomes all the more apparent, and the cost of upgrading is fully recuperated in just one year.”

It is also worth noting that the EcoBell3 turbines are nickel coated, which protects the assemblies from electrical corrosion, extending service life.
durr.com


Multifunctional Platform for Precision Machining

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The people from Cranfield Precision, part of Fives, point out that conventional machine tool platforms use stacked linear axes as the primary motion control system. So their TTG machine platform—which lends itself to multiple machine configurations and processes, including OD grinding, ID grinding, profile grinding, milling, polishing, hard turning, and metrology—is non-conventional. That’s because it coordinates two rotary axes and a short linear axes in a “twin turret” design, such that they are able to produce relative motion—both position and angle—between the tool and workpiece over a swept working area.

Thanks to two rotary, highly damped hydrostatic bearings, the machine base is stiffer than is typically the case. And because of the twin-turret design that allows a simple, non-contacting labyrinth seal, there is good thermal stability because it prevents the thermal distortions that can be caused by the heat generated from constantly changing the coolant return path as the grinding wheel carriage moves along the linear axis.

There are two sizes, the TTG for parts up to Ø 100 mm and the TTG400 for components up to Ø 400 mm.
fivesgroup.com


Compact Drill/Tap and Drill/Mill Centers

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Haas Automation has developed two small-footprint machines that lend themselves to lean production operations, the DT-2 Drill/Tap Center and the DM-2 Drill/Mill Center. The DT-2 is a BT30 taper machine that features a 15,000-rpm inline direct-drive spindle (option: 20,000 rpm) and a high-speed 20+1 side-mounted tool changer. The DM-2 is a 40-taper machine with a 15,000-rpm inline direct-drive spindle and a high-speed 18 +1 side-mounted tool changer. But then the machines become spec-wise the same. That is, they both have a 28" x 16" x 15.5" work cube and a 34" x 15" T-slot table. The spindle on both machines features a 15-hp vector drive system that produces 46 lb-ft of cutting torque. Both provide cutting feed rates of 1,200 ipm and 2,400 ipm rapids. Both allow high-speed rigid tapping to 5,000 rpm. Both have steeply sloped internal sheet metal for efficient chip removal and a 45-gallon flood coolant system. Both have 1-MB program memory and a 15" color LCD monitor. And both 
are built by Haas in the U.S.
haascnc.com