Haas CNC Machining 3 ENG

NUMBER 03
TABLE OF CONTENTS
NUMBER 03
FEATURES
Sinclaire Harding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Progressive Portugal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rocker Science. And the Art of Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydroforming Design Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2
The Multicracker : A Modern Miller’s Tale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TM
CYCLE TIME
Windshear Inc. holds Grand Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
12
Congratulations to Leanders Bros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Haas Automation Europe Celebrates 25 Years of Affordable Technology . . . . . . . . . . 32
Haas supports European Championship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
What a difference a year makes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
THE ANSWER MAN
26
Application Solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
30
CNC MACHINING EUROPE is published by Haas Automation Europe. CNC Machining Europe is distributed free of charge by Haas Automation
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In This Issue
Opportunity Knocks
Someone once said that learning and innovation go hand in hand. “The arrogance of success is
to think that what you did yesterday will be sufficient for tomorrow.” Well, times are changing faster
than ever and with change, comes the opportunity to innovate.
In manufacturing industry in particular the companies that thrive are usually the ones that
continuously and consistently innovate, bringing new and better products to market more quickly than
their competition. This magazine profiles some of those companies and the technology or products
that they develop. Every one of them is a success because it meets the challenges of competitive
manufacturing head-on, even when times are tough (in fact, especially when times are tough).
Our cover story, Florida based Scorpion Performance, is fighting the threat of business migration
to lower cost economies by investing in automation and by engineering smart tooling and fixturing.
Scorpion’s products are pretty good, too!
German company PTW has invented a device for saving energy in the earliest stages of food
and bio-fuel processing. The Multicracker couldn’t be simpler, yet it addresses two of the most
TM
fundamental issues faced by its users: the rising cost of energy and commodity foodstuffs.
As its name suggests, Swedish company Hydroforming Design Light is using water to innovate
the forming process, discovering new and exciting applications every day and winning orders from
around the world.
Portuguese mould maker P J Ferramentas proves that there’s still plenty of room to improve
On The Cover
more traditional engineering disciplines, and UK company Sinclair Harding has resurrected and
updated eighteenth century technology to build beautiful timepieces coveted by royalty.
Innovation is also a priority at Haas Automation: the pursuit of new and better ways to machine
metal is relentless. At its factory in the US, Haas employs a design team of more than 100 engineers in
its quest to make CNC manufacturing technology better, faster and lower cost than it has ever been.
Many companies report that their number one constraint on growth is the inability to hire workers
with the necessary skills. Haas Automation is tackling the shortage in the precision machining
sector at a grass roots level. Its innovative Haas Technical Education Centre (HTEC) program
continues to grow in Europe and around the world, helping to ensure that there’s plenty of creative
talent entering the industry in years to come. In 2000, President Clinton had a message for students
and businesses everywhere, “What you earn depends on what you learn.” Companies can’t
Nothing says “Power and
Performance” like a set of
high-ratio anodized-aluminum
innovate without educated people, so let’s all keep learning. Our shared future depends on it.
Matt Bailey
rocker arms. These are from
Scorpion Performance.
Cover Photo: Richard Berry
CNC MACHINING | Sinclair Harding
In the late 1700’s, English scientist and engineer John Harrison
won the government sponsored Longitude Prize for designing
and building a clock that could be carried at sea aboard a
rolling ship; a project that took him most of his working life to
achieve. For the first time, sailors were able to estimate their
east-west position by the accurate comparison of Greenwich
Meantime (set on the clock) with local time, deductible by
gauging the passage of the sun. Harrison’s original creation is
still kept in the Maritime Museum, Greenwich, which is where
Yorkshire based Sinclair Harding owner and managing director
Robert Bray spent three hours studying its movements, before
building his homage to Harrison’s genius.
Story and photos by Matt Bailey
| www.HaasCNC.com
“Within 5 minutes of using the
Haas control, I was convinced,”
he says. “It was so intuitive
and easy to use. As soon as
the machines were installed
we started transferring part
programs. We thought the
machines would be busy at
least 2 days a week. Little did
we know at the time: They
haven’t stopped since!”
“Our version of the Harrison clock is the Sinclair Harding
H1,” says Bray, “a three quarter size representation which
we started in 1999 and which took five years to develop and
finish. It started with a visit to see the original. The curators
at the museum won’t allow photographs, so the only way to
replicate the workings of the original is to memorise them
long enough to make a sketch.”
jewelers, seem to agree; the company’s order books are in
rude health.
“Every year we exhibit at the big clock and watch making
show in Basel, Switzerland, and every time, we come away
with enough work for the next 12 months.”
The oldest clocks are sundials, first used, according to
Sinclair Harding also hand-build’s intricate skeleton
best estimates, around 5 500 years ago. But, sundials are
Congreve (rolling ball) clocks, elegant long case Grandfather
most reliable, governed by the sun’s predictable trace across
clocks, prettily decorated sun and moon clocks, mesmerising
and Grandmother clocks and less well known but
enigmatically named ‘table regulators’.
“The company was started in 1967 by a man named Mike
Harding and was originally based in Cheltenham,” says Bray.
“My uncle, Brian Kitson, had a passion for clocks and went
to see Harding two weeks before the company was due to
cease trading.” Kitson bought what was left of the company,
which included its most important asset, its reputation, and
not a lot else.
not just the oldest method of telling the time; they’re also the
Earth’s sky. However, they have two significant flaws, the first
is that they are only reliable when the sun shines sufficiently to
cast a shadow. The second is that even when they’re reliable,
they are not precise. Precision, when it comes to telling the
time, is where man has applied his engineering ingenuity.
“We use traditional methods to build our clocks,” says
Bray, “but we also use the best available technology to make
the component parts.”
In the tightly packed, labyrinthine industrial unit that
Little more than a decade later and the staff of the
Sinclair Harding calls home, sit a variety of machine tools,
reputation into something as precious as one of its creations.
they were installed, such as the company’s Haas Mini Mill
resurrected Sinclair Harding have shaped and polished that
Its many clients, including private collectors and prestigious
some ancient and well used, others still as shiny as the day
and Haas OL-1 Office lathe.
CNC MACHINING | “Before we bought the Haas machines we compiled a
industrial revolution. Great leaps in understanding revealed
we’d get everything we really wanted for the money we had
electricity, light, chemistry and gases. Mankind’s curiosity
wish list of functionality,” Bray recalls, “but we didn’t think
available. I guess that’s why it was a wish list!”
After the company’s relocation fell through, the idea
of squeezing even more equipment into its already ‘busy’
workspace seemed ridiculous. But it wasn’t just the size of
the Haas machines that persuaded Bray he’d found what he
was looking for.
“Within 5 minutes of using the Haas control, I was
convinced,” he says. “It was so intuitive and easy to use. As
the secrets of the human body, animal and insect life,
gathered pace, inspired and emboldened by the age of
discovery. By our modern day standards Harrison worked
in an inconceivably primitive workshop, with few mechanical
tools besides basic metal formers and shapers. Yet, he
created a time piece that changed the world and helped
give rise to the largest human migration in history as
Europeans sailed the oceans in search of new lands to
settle and new opportunities.
CNC machines have made the clockmaker’s task faster
soon as the machines were installed we started transferring
and less labour intensive, but traditional craftsmanship – not
least 2 days a week. Little did we know at the time: They
- still accounts for about a 50% of the time taken to make a
part programs. We thought the machines would be busy at
haven’t stopped since!”
Bray bought the Haas Office Lathe as a second machine
dissimilar to the methods used by Harrison, 300 years ago
Sinclair Harding.
“Every last piece, even those you cannot see, is hand
to support his main lathe. “As the workshop is very cramped,
polished,” says Bray. “We also make springs from strips of
MiniMill it was quick and easy to learn and the editable
spring qualities. Our dials are made of Brass, engraved and
it’s the perfect size,” he says. “With the same control as the
QuickCode allowed us to create a series of programs.”
For science and technology, the 18th century was a busy
and exciting time and the many breakthroughs of the period
underpinned and gave impetus to the early days of the
| www.HaasCNC.com
brass, which we hammer out to give them the shape and
filled with wax. We finish them by rubbing the dial with a
concoction of Silver nitrate crystals, salt and cream of tarter
which deposits silver onto the surface. It’s a very old process
and the mixture recipe is a closely guarded secret.”
The hands on the company’s more complex clocks take about 2 days to make. The blanks are wire-cut, then each one is
hand filed to give it a 3D shape, highly polished, then turned an electric blue by heating in a tub of brass filings until the desired
hue is achieved. It’s then quenched to hold the colour.
Sinclair Harding also builds movements for other, well-known manufacturers: beating horological hearts that count the
seconds anonymously for spectators at cricket grounds, passengers in railway stations and passers-by in other public spaces
around the country. “This is an important side to our business,” he says, “but client confidentiality means it’s not something we
typically talk about.”
However, Bray can reveal that he personally designed and made the clock that was presented to the Queen at the opening
of the refurbished St. Pancras train station in November 2007. The shape of the clock reflected the architecture of the famous
engine shed and the dial was a faithful copy of the large clock in the Station, which in turn is a replica of the clock made when
the station was first opened in the 19th century. Bray made the drawings from a photograph of the original clock dial and used
HaasCAM from OneCNC to create the first program. One of the challenges was machining the 3-dimensional filigree around
the outside of the dial. Bray made drawings from photographs of the original dial and used HAASCAM OneCNC to create the
first program.
“We were only making one piece at the time, there being only 1 Queen; from a solid piece of 1mm-thick engraving brass.
The blank is clamped through the centre and on the outside and the first part of the operation is to engrave some of the detail
at different depths to give the part a 3D look. I engraved the pockets and the inside diameter detail, removed the centre, reclamped over the engraved filigree and engraved the outside detail.”
The original machining cycle took a whole day, but the company subsequently won a repeat order, and after much ‘playing
around’, Bray got the time down to about 1 hr 10mins. “Mind you,” he says, “the cycle times are not that important: there’s
always plenty of hand finishing to do while the MiniMill is running.”
CNC MACHINING | s
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ike many toolmakers of its ilk, PJF has diversified
PJF’s advantage is founded on its deep understanding
into other areas and built a strong engineering
of die development. Santos claims that a recent trip to China
over its rivals in the far East, where a great deal of European
have yet to gain the same level of know-how. “This is largely
knowledgebase, giving it a technological advantage
mould work has migrated over recent years.
Since 1995, progressive press tools and dies have formed
to assess the competition revealed that its Far East rivals
because of process complexity,” he explains.
Following the receipt of a customer component drawing,
the core of PJF’s activity. The tools the company produces
PJF develops a ‘strip layout’ using CAD software. This is
material feed and completed component. The company’s
to the development of detailed 3D CAD drawings. These are
are complex but need little or no human intervention between
expertise has attracted a growing number of automotive
first tier customers such as Gestamp, Faurécia, John Deere,
Bombardier, Bosch and more recently, TRW.
“We’ve enjoyed good success in recent years and results
have been positive,” explains company director Pedro Santos.
“We are now very well known in the European automotive
market and our goal is to become an industry ‘reference
point’ for the design and manufacture of tools to form sheet
metal parts.”
submitted for client approval before further discussions lead
again submitted for approval before the designs are finalised
and raw materials can be ordered. Machining, hardening and
assembly follow before the tool is tested using PJF’s in-house
press. The first parts to come off the tool allow the company
to focus on improving tolerances so that dimensional
reports can be submitted that meet customer requirements.
Once the report is accepted, PJF has to prove the same
characteristics on the customer’s press. Only when this
final phase has been successfully negotiated does PJF get
paid. When the customer’s plant is in Europe, it’s difficult for
overseas companies to provide such a high level of service
and commitment.
CNC MACHINING | “The Haas machines represent a very
competitive price-to-specification ratio,”
says Mr Santos. “All of our Haas machines
have performed very well and so whenever
we think about a new investment in
machining, we now always think Haas.”
“China has the ability to manufacture simple tools,
but not tools for complex processes such as deep drawing,”
says Mr Santos. “In time this will change, of course,
but until then hopefully we can take steps to ensure we
remain competitive.”
Technology is a significant and common differentiator
when it comes to negating the labour cost advantage
enjoyed by competitors in low wage economies. A couple
of years ago, PJF began a project to refurbish its ageing
machining capacity. After seeing CNC Haas machine tools
at an exhibition and meeting with the Portuguese distributor,
machines have performed very well and so whenever we
think about a new investment in machining, we now always
think Haas.”
The company uses its Haas machines to manufacture
components for from tool steels. The fixtures used are mainly
press systems and magnetic plates, typically holding multiple
parts, which are frequently left to run unattended overnight or
at weekends. The advantage gained in cycle times, however,
is difficult to estimate, as Mr Santos explains.
“It’s very different from part to part,” he says. “We don’t
the company bought and installed a Haas TL-1 CNC/manual
machine two parts alike; every part has a different definition
toolroom mill, a VF-7B vertical machining centre and, most
estimated production time with the actual time achieved, and
toolroom lathe. This was followed soon after by a TM-1
so we don’t measure cycle times. Instead we compare the
recently, a VM-2 vertical machining centre.
also the time taken on different machines. The performance
“The Haas machines represent a very competitive
price-to-specification ratio,” says Mr Santos. “All of our Haas
10 | www.HaasCNC.com
of Haas machines in these terms is excellent.”
All of the Haas machines are programmed by PJF
shop floor operators. There is no CAD/CAM department
at the company: the result of a decision several years ago
to optimise its resources and train operators in the latest
programming skills. Currently PJF has five operators trained
work. We are certified to ISO 9001:2000 and we were the first
company in Portugal to obtain the accreditation with regard to
the design and manufacture of stamping and cutting tools.”
Linear tolerances on PJF’s machined components
to work with Haas machine, with a further two to be fully
are typically 0.05mm with 0.02mm usually required for
The Haas machines have certainly been kept busy in
“On some parts, such as stamping punches and dies,
trained and ready by the summer of 2008.
positioning. Surface finish is also critical.
the short time since installation. Regular customers typically
the finishing is very important,” confirms Mr Santos. “Just like
develops up to 12 progression tools a year for each client.
smooth finish to avoid friction in the sheet metal forming
order between 6-8 tools to fulfil a particular project, while PJF
The company manufactures progression tools up to 3m in
length and also undertakes ongoing reconditioning and tool
modification programmes.
In addition, Santos reveals that the company is actively
pursuing opportunities to manufacture transfer tools, which
use robots to move large fabricated parts, such as car
chassis components, between various pressing operations.
on moulds for plastic injection processes we need a very
process. Today polishing has no part in our production
process: the component has to come off the Haas machines
in a finished condition.”
Quality is just one of the differentiating factors that PJF is
hoping will help retain and win business in what is sure to be
a period of change.
“Change is the new paradigm for my generation,” says
All of these activities demand high quality levels of the
Mr Santos, son of the founder. “If we don’t evolve we won’t
“Our company deals in quality,” says Mr Santos. “At PJF
PT Ferramentas, Lda
machined parts that constitute PJF’s tools.
quality is never an accident; it always results from intelligent
survive so we are constantly challenging ourselves.”
www.pjf.pt
CNC MACHINING | 11
Rocker Science.
12 | www.HaasCNC.com
And the art of
Automation
CNC
| 13
Story and photos
byMACHINING
Richard Berry
Step out of the South Florida sunshine into a cool white building. ¶
Pass a display of newly manufactured medical instruments in the lobby, and continue
down a spotless glass-walled corridor toward a doorway marked “R&D Lab.” ¶
You might assume you’ve entered one of the region’s top medical research facilities. ¶
And then you’re startled by the bark of a 500-horsepower engine roaring to life on a
dynamometer nearby. ¶
This is not your typical manufacturing shop.
14 | www.HaasCNC.com
S
corpion Performance of Fort Lauderdale, Florida,
more power from an engine is to swap out the standard OEM
performance racing industry – and they produce them
less than $300. Scorpion’s products are well designed, well
manufactures aftermarket automotive parts for the
with a passion. They have to; there’s a world of competition
out there. There’s also a serious sense of conviction in
founder Robert Stopanio’s voice when he emphasizes: “We
rockers with higher-performance sets, which often retail for
made and expertly marketed. Business is great.
Scorpion has been steadily increasing its production for
face manufacturing competition from everywhere today,
years. And in 2007, the 45-worker, 3-shift shop manufactured
news is, we’re winning!”
network of approximately 100 distributors and private
especially from Asia.” Then he smiles and says, “The good
It’s a familiar story. As more manufacturing work goes
overseas in search of cheaper labor, companies throughout
North America are feeling the competition – including
Scorpion. After thoroughly analyzing his situation, Stopanio
set a clear, head-on course of action for the company.
“Equipment is available the world over, and aluminum is
the same commodity everywhere,” he explains, “but Asian
nearly a half-million rocker arms, which sold through a
labels. The growing company is now poised at a productivity
“tipping point,” and Stopanio is determined to shake up the
industry. It won’t be the first time this clever entrepreneur has
made waves.
In the Beginning
Stopanio first developed a passion for engines and
manufacturers have that one enormous advantage over us:
speed in his teens, while working at the local Miami-
our own ‘strong suit’: automation.”
custom builder, souping up big marine engines for offshore
inexpensive labor. We decided to fight that advantage with
Scorpion’s signature products are high-performance
rocker arms – bolt-on replacements for the pivoting levers
that sit in the cylinder heads atop most internal combustion
engines, opening and closing the valves. Speed enthusiasts
know that one of the easiest and least expensive ways to get
Hollywood Speedway. He soon began moonlighting as a
racing enthusiasts. He became known for doing things right,
and exceeding the expectations of his customers. Stopanio
and Blue Thunder Engines, the cutting-edge company he
established, quickly gained fame in offshore racing circles
around the world.
Scorpion’s products are well designed, well made
and expertly marketed. Business is great.
That marine racing environment, where millisecond
to the assembly area. There, steel trunnion seats, pins and
mechanical tinkering, is what shaped Stopanio’s future. It also
labor-intensive or machine-intensive, depending on how you
success was often the result of both scientific analysis and
proved the value of analytical research and development.
“In racing, if you follow the leaders, you’ll always be behind
them,” Stopanio observes. “You have to do research and
development in order to stay ahead.” It’s a firm belief that he’s
carried over into manufacturing.
Stopanio’s in-house manufacturing began when he
discovered there were very few reliable sources for the rocker
arms his demanding engines required, so he researched the
problem and developed a way to make his own. Recognizing
this as yet another unique opportunity, Stopanio launched
Scorpion Performance in 1999. He brought over the team
of engine builders and engineers he’d groomed at Blue
Thunder, and began another determined race to contribute
to the automotive performance industry with products “Made
in America, and Proud of it.”
Smart Machine Details
Scorpion’s rocker arms start out as cut-to-length
extrusions of 7000-series aluminum. They’re milled on
six sides, drilled in two axes, CMM inspected, de-burred,
mirror-polished, anodized and laser-etched before going
16 | www.HaasCNC.com
rollers are pressed in automatically. It’s work that’s either
approach it. Stopanio uses automated machines to do as
much of the work as possible.
On the shop floor, Scorpion engineer Billy Allen shows
how they do it. He points to a large, wire safety-cage
containing three 5-axis Haas VF-2SS Super Speed vertical
machining centers flanked by various tooling stations he
designed and integrated. A bright yellow FANUC M-16
robotic arm, floor-mounted in the center, serves the entire
cell. Allen says the integration between the FANUC arm and
the Haas controls was quite straightforward. “We do all the
engineering in-house,” he explains, noting that the robots
arrive as bare arms with actuators. “The interface electronics,
the solenoid valves, the special tooling, and all the stuff on
top, we design ourselves.” It’s a reliable production system
that works around the clock.
A lot happens during each of the machines’ 3-minute
cycles. First, extruded aluminum bars, loaded in quantity
through a wide slot in the cage, are cut to length by a gravity-
fed, servo-controlled chop saw. Next, the robot grabs the
freshly cut piece and loads it into the first VF-2SS. Blurring
through a full 340-degree arc, the yellow arm dives into one
machine, and then another, transferring the evolving rocker arm through a range of shaping, boring
and probing operations. Finally, the robot holds each machined part over a de-burring polisher, before
dropping it onto a conveyor that carries the completed piece to a collection station outside the cage.
If done manually, the eight-step process would require the same five pieces of equipment, but an
additional four operators – and a lot more time. “We still have earlier hand-loaded configurations in
operation,” notes Allen. “They work well, and add to our production. You can actually see our evolution
throughout the shop. We started out with Haas VF-4s fitted with simple, efficient, multi-part fixtures. We
then moved to 4-axis Super Speed VF-4s with high-speed tool changers, and used more complex pinindexed fixturing. Now, with the latest automated cells, we’re running three generations of production
on the floor. Every time we come up with a new idea,” he adds, “things just get faster!”
The newest robotic cell produces one complete rocker every minute. “Speed is important,” Allen
contends, “but the really creative part is designing a cell that will work flawlessly – 24 hours a day.”
CNC MACHINING | 17
“Every time we come
up with a new idea,”
he adds, “things just
get faster!”
18 | www.HaasCNC.com
Their Own Destiny
Robotic technologies are obviously the key element
in Scorpion’s battle to compete with low-wage factories.
“But it comes down to more than just integrating a robot,”
says Stopanio. “Through our R&D efforts, we’ve perfected
good product designs, and developed a lot of smart
tooling and fixtures for these fast Haas machines. And, of
course, we control our own destiny by doing as much as
possible in-house.”
When Scorpion was first getting started, the shop batched
100 parts at a time, and sent them out for anodizing. But
Today, the company anodizes all their own products, as
well as a wide variety of precision parts for other manufacturers
– including the demanding optical- and medical-instrument
industries. Scorpion is preparing to automate the critical
chemical processes with robotic installations similar to their
successful machining cells. Again, instead of depending on
the robot manufacturers to integrate their equipment into
Scorpion’s existing production lines, Stopanio has put his
street-smart engineers to work designing complete, self-
contained robotic cells around Haas machines. “Once again,”
he stresses, “it’s a matter of controlling our own destiny.
“When a private-label client calls us at nine in the
they soon became frustrated with the inevitable variations in
morning and says he needs a set of specific-ratio rockers
– parts left too long in the acid bath would develop blown-out
us. By 4:30 that afternoon, we’re shipping it out in a custom-
the returned units. More than just appearance was at stake
holes. Later, during assembly, press-fit bearings would fall
right through the oversized IDs, and an entire week’s work
would have to be scrapped.
As a result, the shop was forced to develop in-house
with a custom color and logo on them, it’s no problem for
designed box,” Stopanio notes.
No Limiting Factors
“Our only limitation here is space,” says Stopanio. “We
finishing and anodizing capabilities to hold the tolerances
have 30,000 square feet, but our machines are installed out
the number-one thing you have to focus on is quality,” says
the problem, Stopanio is having an additional 80,000-sq-
they demanded. “When you’re making small, precision parts,
Stopanio. The episode marks the beginning of a “control your
own destiny” creed that has since become a major part of
Scorpion’s business philosophy.
to the back door, and there’s just no more room.” To solve
ft manufacturing facility, comprising three buildings, built
in Ocala, Florida. He already has machines and robotic
equipment in storage, anticipating the big move-in, and he’s
CNC MACHINING | 19
planning for ISO certification to further enhance Scorpion’s production capability. As you might expect, the new facility will be fully
automated, using Scorpion’s latest generation of ideas.
“We’ve got the system down so well that we can make a product, turn it around quickly and fully compete with companies in Asia,”
Stopanio states. “Now comes the expansion; there’s no limits. We’ll probably have 90 Haas machines in our second location.”
“Everybody thought Rob was crazy when he started this venture,” remembers Scorpion’s Vice President of Marketing, Moe Rustam.
“They said: ‘The Asian manufactures are going to kill you!’ But Rob’s vision was greater than all that.
“I suppose that’s a lot like Haas making machines in California and selling them in China. People just find it hard to believe. But when
you’ve got a good quality product, and you do a good job with automated manufacturing – and you stand behind your name – you’re
going to be successful.”
Scorpion Performance
www.scorpionperformance.com
20 | www.HaasCNC.com
SIDEBAR
Rocker Arms 101
A rocker arm is the pivoting “seesaw” link found between an
High-performance rocker arms come in significantly higher
engine’s camshaft and each of its valves. These simple levers
ratios: up to 2-to-1 for NASCAR engines. By simply bolting on
valves to open and close at precisely the right time.
7 to 10 percent, allowing the engine to breathe better, and thus
translate rotary camshaft “data” into linear motion, causing the
Designing the rocker arm so its pivot point (fulcrum) is closer
to one end than the other creates a mechanical advantage, which
is defined as the ratio between the two fulcrum-to-tip distances.
Most standard small-block engines use rocker arms designed
a set of higher-ratio rockers, it’s possible to increase valve lift by
produce more power. Specially designed high-lift camshafts can
do the same thing, but they’re more expensive to manufacture,
and much more difficult to install.
In reality, many people who swap out rocker arms have already
with about a 1.5-to-1 ratio. In other words, each arm moves its
changed the camshaft, valves and springs in their engine. For
lobe lift.
a very important one.
corresponding valve 1.5 times the distance of the camshaft’s
these enthusiasts, the rockers are just one part of the puzzle – but
CNC MACHINING | 21
An innovative Swedish company is deploying newly developed,
patented production methods to ‘reinvent’ the hydroforming
process. Today, the company claims to offer its customers the most
cost effective production of hydroformed components in the world,
with Haas CNC machine tools playing a vital role.
Hydroforming
Design Light
Story and photos by Matt Bailey
22 | www.HaasCNC.com
Hydroforming is a cost effective process for shaping
Readers can be forgiven for thinking this is a story about
malleable metals into lightweight, structurally stiff workpieces.
a machine building company. Yes, Hydroforming Design
working material into a die. The process allows complex
hydroforming machines, but right now the company is busy
It uses water at high pressure to press room-temperature
shapes to be formed that would be difficult or impossible
with conventional solid die stamping. Parts produced by
hydroforming can also be made with a higher stiffness-toweight ratio and at a lower unit cost than traditional stamped
or stamped and welded parts.
The hydroforming process has been around a long
time, and today is one of the fastest growing metalforming
technologies. Famous hydroforming applications of decades
past include such diverse items as helmets for the British
Light AB manufactures and assembles its own, high value
generating the bulk of its revenue by subcontracting its
innovative processes.
“At the moment we are definitely a subcontract company,”
confirms Mr Palmcrantz, “however, we already have
customers who want to buy our machines, so maybe in
a couple of years we could explore this potential revenue
stream fully, but not yet.”
So why hydroform in the first place? Well, water in
Army in World War I and kitchen tap spouts in the 1950s.
the right quantities and at the correct pressure can be
Hydroforming Design Light (HDL) AB, has developed
example. As a process, hydroforming stretches material
solutions to bring the process up-to-date and cost-effective
as stamping and deep drawing, and results in a more cost
However, a Vansbro-based Swedish company called
very powerful. Consider the effects of water erosion, for
patented machine construction and patented tooling
more evenly than conventional forming techniques such
for modern manufacturing.
effective construction with lower weight – sometimes as
“In the past hydroforming has been more or less
exclusive to industries manufacturing very large volumes
[automotive, for example] or sectors with high investment
capital availability [such as aerospace],” says Managing
Director Alvar Palmcrantz. “This will now change. Our
patented machine construction has, with all factors equal,
an investment cost that is a fraction of what can be found
available on the market today.”
much as 50% lower. In comparison with traditional methods,
other hydroforming benefits include the ability to draw
deeper sections, tooling at less than half the cost of other
techniques, less material spring back, higher precision on
detail and better surface quality.
Hydroforming Design Light offers three principle variations
of the hydroforming process: Tube hydroforming starts with a
tube placed in a tool that is then filled with fluid at pressures
“One of the impressive factors about the Haas is that
we can machine steel dies as quickly as aluminium
dies, which we make occasionally for lower volume
orders. That said, many of the cavities we machine are
extremely complex and it is not unusual for some dies
to stay on the Haas for a full day or even two.”
around 4000 bar until the pipe deforms into the recesses
complex and it is not unusual for
and furniture components are suited to this method. Sheet
full day or even two.”
of the tool. Automotive structures, exhaust parts, handles
hydroforming is where sheet material sits on top of a tool and
is deflected into the tool profile using high-pressure hydraulic
some dies to stay on the Haas for a
Before parts reach the Haas
fluid. Many vehicle panels are produced this way. Finally, so
machine, which is fitted with a TR
by laser welding into the tool. Containers such as fuel and oil
ZCorporation Spectrum Z510 machine to generate rapid
called ‘pillow’ hydroforming ‘inflates’ two metal sheets joined
tanks are manufactured in this manner.
Of course, one thing that all of these processes have
in common is the need for accurate dies, the production
210 trunnion table, Hydroforming Design Light uses a
3D prints of high definition, full-colour prototypes from
CAD models.
“We make 95% of our mistakes at the modelling stage,”
of which until recently HDL trusted to local subcontract
says Mr Palmcrantz, “which means we scrap less material
“We bought the Haas VF5 CNC vertical spindle machining
Today, Hydroforming Design Light’s main customer is
machine shops.
and save a lot of time.”
centre from the local Haas Factory Outlet, a division of
Volvo Truck. And while it’s fair to say that automotive and
states Mr Palmcrantz. “In the long run, when we have more
potential for this innovative process is vast. The company is
Edstroms, primarily to manufacture our tools and dies,”
Haas machines, we will have enough capacity to undertake
at least 50-60% of our tooling requirements in-house. A plant
growing as quickly as this needs the capability to produce its
own tools.”
Although a relatively young company, its turnover already
stands at more than €1.5 million. However, at the end of
commercial vehicles are the mainstay of the business, the
currently working on a diverse range of customer projects
that include ski-poles, heat exchanger/water cooler parts,
telecommunications components, refrigerator doors and
aircraft seat frames. All will benefit from tremendous weight
and material savings without any sacrifice to strength.
“In another application we manufactured hexagonal
2008, HDL says this will be as much as four times higher.
framework tubes for radio masts,” explains Mr Palmcrantz.
companies supplying industrial components to European
calculated that for a 30m high mast, our version would weigh
The company is a member of the Hydroscand family of
customers since 1969. Group turnover is approximately 100
million euros, a statistic that has grown at least 20% every
year over the past five years.
“We also bought the Haas machine because we want
to be very quick to service our customers,” continues Mr
“The design increased component stiffness by 40%. We
89kg compared with 1400kg using traditionally manufactured
parts.With this method the customer could use stainless steel,
which although is 4-5 times more expensive than galvanised
steel for instance, would still be far cheaper overall.
“Material thickness has nothing to do with component
Palmcrantz. “One of the impressive factors about the Haas
stiffness,” he concludes; “shape is far more influential. There
dies, which we make occasionally for lower volume orders.
the imagination of the component designer.”
is that we can machine steel dies as quickly as aluminium
That said, many of the cavities we machine are extremely
are really very few limitations to hydroforming, perhaps just
CNC MACHINING | 25
M
ulticracker :
TM
A Modern Miller’s Tale
Story and photos
by Matt Bailey
Rising energy costs and increased competition for finite resources:
These fundamental issues are increasing the potential for conflict in our
global society. We must all, it seems, endeavour to do more with less.
German engineering company and Haas CNC machine tool customer
PTW Technologies GmbH has developed a machine that not only reduces
energy consumption but also simultaneously expedites fuel production
and aids in food processing.
26 | www.HaasCNC.com
In
1978, after the first global oil shock, American
author Maurice Berkeley Green published a
book entitled Eating Oil, documenting how food
production in the western nations had come to be entirely
and excessively dependent on oil. In the intervening 30
years, and despite Green’s warning, that dependence
has increased rather than declined.
Currently world oil and liquid fuel consumption are
predicted to increase by almost 900,000 barrels per day
through 2008 and by 1.4 million barrels per day in 2009.
In 2005 Western European governments were already
predicting an inflation rate of 5% a year on food prices for the
traditional grinding or crushing methods and can ‘crack’ up
to 40 metric tons of grain per hour.
PTW joint CEO Martin Rothmann explains how the
Multicracker came into being.
“We were contracted by an Austrian producer of bio-
fuel,” he recalls, “they were at the time using a 300hp
hammer mill to grind corn prior to turning it into ethanol
alcohol and were seeking a more efficient grinding
technology.”
Obviously any type of fuel production only makes
next decade. At that time oil was around $60 a barrel; in June
sense if the energy required for production is less than the
suffice to say, today even affluent, Western nations can no
the better – for the producer and for the environment.
2008 West Texas Intermediate reached $145 a barrel. So
longer depend on cheap energy and plentiful, bargain priced
commodities. There are simply more people competing for
limited resources in the global marketplace.
In this global context - and in answer to one client’s
challenge - PTW Technologies GmbH based near Frankfurt,
Germany invented a radically new, simple and yet highly
efficient machine to grind or ‘crack’ grains, seeds, nuts
and just about any crushable raw material that can be fed
through the hopper. PTW christened their invention the
Multicracker and it uses substantially less energy than
energy in the finished product. The bigger the difference,
“Our client needed a machine that would use less
energy but be at least as productive as their old hammer
mill.” PTW decided to approach the ancient problem of
milling grain from a totally new direction. Rothmann
continues, “In 2003 we built a functional prototype to test
the ‘cracking’ process we had developed. We were still
unsure if our idea would work on an industrial scale, but
the client tested our machine and it worked like a charm!”
At that point PTW knew they were onto something with
global potential.
CNC MACHINING | 27
“The Multicracker cutting discs are rough turned on
our Haas SL30 lathe then we use our Haas EC300
Horizonal Machining Centre to finish the discs. The
EC300 is also used to make most of the remaining
parts for the Multicracker: bearing boxes, base
plates, spindles – we make about 90% of the machine
in house.”
The Heart of the Machine
So, what’s the secret behind the patented technology that
makes the Multicracker so revolutionary? Martin Rothmann
sums it up in one word: “Scissors” he says. “Normally a hammer
mill works with a dull, heavy head that breaks the grains by
falling on them, so you need a lot of energy to constantly lift the
hammer. However with sharp scissors you need less energy
because cutting is more energy efficient than crushing.”
Pairs of intermeshed, rotating disks inset with hard, sharp
ceramic teeth are the heart of the Multicracker. The cracking
disks are lightweight and powered by twin 18.5 kW Siemens
electric motors through a belt driven transmission system.
The distance between the disks is variable to allow precise
regulation of the size of the ground output and the entire
machine is centrally regulated with Siemen’s proven S7-300
control system.
Rothmann elaborates further: “Another advantage over
hammer milling is the uniform output of the Multicracker.
We even offer machines with twin pairs of cracking disks for
multi-stage grinding.” PTW reckons the basic Multicracker
uses as little as 1 kW of electricity per ton of raw material
processed, saving up to 80% in energy costs compared with
conventional methods.
From Prototype to In-House
Series Production
Once PTW had perfected the Multicracker it became
obvious they had a machine with worldwide sales potential.
After patenting the core technology, PTW faced the challenge
of manufacturing and marketing the Multicracker in series.
PTW’s core business had always involved producing high
quality parts for industry so the decision was made to produce
28 | www.HaasCNC.com
CEO Rothmann tells us, “We once used very
expensive machines from a competitor but now
when we make the same parts with the Haas
machine they are just as accurate and they cost us
30% less to produce.”
the Multicracker in-house utilizing their Haas dominated
machine shop. Rothmann explains: “The Multicracker cutting
discs are rough turned on our Haas SL30 lathe then we use
our Haas EC300 Horizontal Machining Centre to finish the
discs. The EC300 is also used to make most of the remaining
parts for the Multicracker: bearing boxes, base plates, spindles
– we make about 90% of the machine in house.”
The advantages of in-house production are substantial,
both for PTW and for their customers. Rothmann sums it up,
“We make special machines for special customers. The basic
Multicracker is adapted to the exact application specs of each
client and we immediately produce the machine ourselves,
shortening delivery time and reducing costs.”
PTW once used machine tools from another source before
turning to Haas. “We are very satisfied with Haas machines
parts on it in the last two years. Our ROI on that machine alone
is fantastic!”
The World Gets ‘Cracking’
With the demand for Multicrackers rising as energy
prices increase, Rothmann’s newest concern is automating
production and moving into new markets. “We don’t sell
many Multicrackers in the United States right now,” says Herr
Rothmann. “Energy prices are very low in the USA compared
to, say, Morocco, where they pay €0.75 per Kilowatt Hour.
One of our Moroccan customers saves €40,000 per month on
electricity with his Multicracker!” But the times are changing
and with $4 per gallon gasoline, US industry is also looking to
alternate and more efficient energy sources.
One emerging market that Martin Rothmann is very keen
and with the Haas service concept.” CEO Rothmann tells us,
on is Africa, where there is an enormous shortfall of basic
but now when we make the same parts with the Haas
the Multicracker can play a vital role in helping people in
“We once used very expensive machines from a competitor
machine they are just as accurate and they cost us 30% less
to produce.”
PTW now owns five Haas machines and is looking to
food and energy costs are particularly high. He believes that
developing countries make the most of their resources and
help them to feed themselves.
The greatest challenge of the 21st century is undoubtedly
purchase more in the future. “We bought a Haas TM1 Toolroom
how to do more with less: More food for more people from
received a contract for high speed drilling. We created an
problem is the Multicracker, a new machine that helps solve a
Mill to train employees but three weeks after it arrived we
automatic feed for the machine and have made over 700,000
less space using less energy. PTW’s answer to this daunting
global problem one small grain at a time.
CNC MACHINING | 29
CNCMACHINING
cycle Time
Windshear Inc. holds
Grand Opening
America’s Windshear Inc. celebrated the opening of the world’s most
advanced automotive wind tunnel on July 18th. The event, which drew
nearly 300 attendees, marked the opening of the first commercially
available, full-scale, single-belt, 180-mph rolling-road wind tunnel in
the world.
Windshear uses a Single-Belt FlatTrac Rolling-Road system
from MTS Systems. The road is a continuous steel belt running
beneath the vehicle to simulate the road beneath a racecar
traveling on a speedway. This provides the most accurate
aerodynamic road simulation possible in the automotive
industry, and greatly advances capabilities for motorsport
organizations, as well as automotive manufacturers.
Jacobs Technology, the advanced-technology arm of
Jacobs Engineering, operates the Windshear facility. Jacobs
Technology specializes in design, construction and operation
Representatives from global automotive manufacturers,
motorsports teams and local government joined Windshear
employees for the ceremony. Local dignitaries and the press
were on hand to welcome Windshear to the community. The
high-tech facility was completed just 15 months after breaking
ground in April 2007.
Windshear welcomed its first customer, a Formula 1 team,
in June 2008, and is 95 percent booked for the remainder of
the year. Demand for test slots into 2009 remains strong.
“We are very pleased with the progress made on opening
of wind tunnels for automotive, aerospace and defense
industries throughout the world. Other Jacobs Engineering
facilities include NASA Ames Research Center, NASA
Langley Research Center, a cold-climate wind tunnel for
Hyundai Motor Company and the Crosswind Facility for GE
Aircraft Engines.
For more information about Windshear, please visit
www.windshearinc.com.
About Windshear
Windshear Inc., headquartered in Concord, N.C., operates
the wind tunnel to customers,” said Peter Zierhut, business
the only commercially available full-scale, single-belt, rolling-
repeatable data previously only available to a select few
level motorsports organizations and auto manufacturers.
manager, Windshear. “Our facility offers highly accurate,
Formula 1 teams, and previously not available anywhere in
North America.”
30 | www.HaasCNC.com
road wind tunnel in the world. The firm’s clients include top-
Windshear is an independently operated entity of Haas
Automation Inc.
Congratulations to
Leanders Bros
FIA Top Methanol Funny Car European Champions for 2008!
The Leanders Bros drag racing team – Sponsored by US
machine tool builder Haas Automation Inc - is the 2008 European
Champion after speeding to victory in this year’s contest with the
help of its innovative, Haas machined slipper clutch.
certain that they were the 2008 European Champions. Leanders
eventually finished top of the leader board with 335 points; 20
points clear of the runner-up.
Using a Haas EC400 horizontal machining centre, the team
The FIA European Championship consists of five races that
has made 10 versions of its slipper clutch this year - two of these
winners of the championship in 2006 and with a good showing
evaluate its design and performance - used a further five. One of
are held at different venues throughout Europe. As previous
in 2007, Leanders Bros knew what they were facing in order to
grasp this victory in 2008.
The Sweden based team took its first win in the second race,
held in Finland, and crossed the line with a time that equaled
the European record of 5.694 seconds. A superior performance
meant a win in Sweden and the fastest race time at the Germany
designs they have used themselves, and other teams - to help
these teams ran in the “Pro Modified” classification and, although
it missed out on a European record by 1/100th of a second, the
car recorded the fastest final speed at 383 km/h.
So, what’s next for the European champions?
“The team is already preparing for next season’s European
meeting. Santa Pod, England hosted the final races of the
Championship,” says Ulf, “ and we are also hoping to participate
end of the first qualifying stage. “This was caused by the force
to make this dream a reality, the team needs to find additional
season, but unfortunately the blower belt on the car broke at the
of 1 000hp taking it’s toll on a car that, due to bad weather, was
forced to undertake the race in a slower and more controllable
speed than the 5.60 seconds it was built to run at,” says driver
Ulf Leanders. This breakage gave the team an agonising wait
for the other competitors to complete their races before it was
in races in the USA throughout the Autumn and Spring.” However,
sponsors. “We believe we have the car to compete at the highest
level in the USA. We also have a very innovative clutch which we
will continue to develop and ultimately commercialise and make
available to other teams around the world.”
CNC MACHINING | 31
CNCMACHINING
cycle Time
Haas Automation Celebrates 25 Years of
Affordable Technology
In 1983, Gene Haas founded Haas Automation, Inc., to
manufacture the industry’s first fully automatic programmable
collet indexer. Designed to increase production in Gene’s own
machine shop, the Haas 5C indexer was an instant success,
and over the next 4 years, the product line expanded to include
a wide selection of fully programmable rotary tables, indexers
and machine tool accessories.
In 1988, Haas Automation achieved another industry
milestone by introducing the first American-built vertical
Southern California, and distributed
through a worldwide network of
more than 120 Haas Factory
Outlets. Each HFO has complete
showroom facilities, factory-trained
service personal, extensive spare-parts
inventories and fully stocked service vehicles to provide
the industry’s best service and support.
From the start, Haas Automation has provided reliable,
machining center (VMC) to sell for less than $50,000 – a price
affordable machine tool solutions – at published prices – to
price of $49,900, and quickly became the industry benchmark
relying on volume sales rather than per-unit profit to build the
unheard of at the time. The Haas VF-1 sold for a published
for affordable CNC technology.
Today, 25 years later, Haas Automation is the world’s
leading manufacturer of CNC machine tools – building,
selling and shipping more machines per month than any
other single builder in the Western World. All Haas products
are manufactured in the
company’s
1-million-
square-foot facility in
job shops and contract manufacturers around the world,
company. Extensive use of lean manufacturing methods and
just-in-time production practices allows the Haas Automation
to produce high-precision CNC products while maintaining
exacting quality and value-based pricing.
At present, there are more
than 90,000 Haas CNC
machines and 55,000
Haas rotary products in
use around the world. In
2008, the company will
build more than 14,000
machines, with around
60 percent of them
going to international
markets.
32 | www.HaasCNC.com
CNCMACHINING
cycle Time
Haas Supports
European Championship
Participants at the prestigious
“Modern manufacturing is an exciting, high-tech and lucrative
Euroskills 2008 in Rotterdam, Holland
industry. At Euroskills, talented young people challenged
Haas CNC lathes and vertical machining
available. I speak on behalf of everyone at Haas when I say we
(September) competed using the latest
centres. The machines were supplied
and supported by the company’s European
headquarters in Zaventem, Belgium, and gave
themselves and got their hands on the very best technology
were very proud to be part of it.”
The CNC machining category at Euroskills 2008 was won
students the opportunity to operate state-of-the art CNC machines,
by David den Hartigh from the Netherlands (pictured) who
companies.
awarded Silver.
as used by more than 50,000 of the world’s leading manufacturing
Haas Automation enjoys a well-documented reputation for
encouraging and nurturing careers in precision engineering,
thanks in large part to its worldwide network of modern, purpose
built HTEC’s (Haas Technical Education Centres). As well as
featuring Haas CNC machine tools, HTEC’s are also supported by
some of the biggest and best-known names in precision tooling,
CAM teaching software, CAD and workholding solutions.
At EMO 2007 - Europe’s largest manufacturing trade fair -
Haas Europe Managing Director Mr. Peter Hall announced the
company’s goal of 200 HTEC’s in Europe within the next 5-7 years,
each one conforming to the high-standards already established
in more than 600 similar facilities in North America and Canada.
“European manufacturing companies know only too well
that one of the most serious problems with doing business on
our high-cost continent is the critical shortage of manufacturing
technologists, including skilled CNC machine operators and
technicians,” says Mr. Hall. “The intention is that HTEC’s will serve
as incubators of local economic growth, provide the inventors,
technologists and entrepreneurs of tomorrow and give young
people opportunities for exciting and productive careers.”
Mr. Hall is equally enthusiastic about the potential of the
biennial Euroskills competition and is keen that Haas Automation
Europe does all it can to help such high profile and worthwhile
grassroots events.
collected the Gold medal. Nico Kleer from Luxembourg was
CNCMACHINING
cycle Time
It’s been just over a year since Haas Automation
launched the HTEC (Haas Technical Education
Haas Technical Education Center
Centre) program in Europe and the acclaimed
teaching initiative is already proving that inspired ideas work irrespective
Haas Technical Education Center
of different languages and unhindered by national borders.
What a difference
A Year Makes
Story and photos by Matt Bailey
34 | www.HaasCNC.com
Vrij Technisch Instituut St-Lucas, Belgium
precision engineering industry with CNC machining skills;
skills that Mr. Hall personally considers to be the cornerstone
of advanced manufacturing industry.
“I believe that one of the major reasons for the shortage
is that we fail to attract young people to study and make a
career in CNC technology,” he says. “We’ve found that many
schools use antiquated machine shops equipment and that
as a result the students do not learn the skills needed by their
local industry. We feel that without modern CNC machines and
modern CNC technology, and without up-to-date continuous
training, teachers find it difficult to motivate young people
to choose a career in what is actually a very exciting, very
Announced at EMO 2007, the European HTEC program is
on target to achieve its first-year goals with a total of 9 official
advanced sector.”
As well as providing CNC machine tools and CNC
Haas CNC teaching facilities open at the time of writing and
simulators, Haas also helps schools to renovate and
Russia, Belarus, Sweden and Portugal. In 2009 the company
found that when they’re taught in clean, high-tech and well-
another 9 planned to open before the end of 2008, including
will oversee at least another 30-35 HTEC’s in Europe – in
several countries including Ukraine, Spain, Lithuania, Belgium,
Bulgaria, Romania, Hungary and France - each of which will
be founded and managed by local Haas distributors (known
as Haas Factory Outlets – HFO’s).
“The HTEC program is like a snowball gathering
momentum,” says Haas Europe Managing Mr. Peter Hall.
“When an HTEC opens in a particular country it captures the
imagination of similar schools and colleges, inspiring those
institutions to follow the same path.”
The European HTEC program was launched to counter
modernise classrooms and workshops. The company has
equipped educational facilities, young people – as well as
their parents and local employers – soon change their view
of manufacturing.
“Investing in a facility shows students that today’s
manufacturing is a high-tech business full of exciting and wellpaid opportunities. We also provide an HTEC facility set-up
and a student motivation package, which includes apparel,
visual displays, and reading and learning materials – all of
which go towards to creating a great-looking and inspiring
place to study.”
Together with its program partners - KELLER, MasterCam,
what Haas regards as one of the greatest threats to
Esprit, Renishaw, Sandvik Coromant, Schunk, Blaser, Urma
shortage of talented and motivated young people entering
within 5 years.
sustainable economic development on the continent: the
and Chick - Haas plans to open 200 HTEC’s across Europe
CNC MACHINING | 35
CNCMACHINING
the ANSWER MaN
We had an operator accidentally hit the
wrong key and all of the programs except
O00000 are gone.
Sincerely,
Ben
Dear Haas,
Dear Ben:
I need some information on how to
lock
programs
and
parameters
on
machines so we don’t have different
operators changing programs and machine
parameters all the time.
Sincerely,
Michael
Unfortunately, there is no “undo” function
for when this happens. However, the
Dear Richard:
Yes, there is an easy way to duplicate a
program on the Haas control. Simply press
List Program, cursor to Device and select
Memory. Then cursor to the right and select
the program to be copied, and then press
Dear Michael:
The best and most secure way to protect
programs and parameters on a Haas
machine is with the memory lock keyswitch
option. This can be purchased from your
local HFO and installed in the field. You
can also use Settings 7 and 8 to protect
the programs and parameters, but these
settings are easily changed.
enter. Now, key in the letter O followed by
a new program number, and then press
the F2 key to duplicate the program. The
duplicate program will be listed in the
directory with the new number. (On older
controls, there’s a similar method using the
F1 key.)
Haas Applications
•••
Haas Applications
•••
Haas control does prompt the operator to
be sure that this isn’t done by accident.
We recommend regular backups of the
programs in your machine to prevent
total loss of programs. As with any other
computer system, it’s a good idea to back
up your files to an external device for safe
keeping. On newer Haas machines with a
built-in USB port, this can be done easily
using a USB memory stick. On older
machines, files can be backed up to floppy
disk or via RS-232. If your machine has the
Ethernet option, you can back up your files
over the network.
Haas Applications
•••
Dear Haas,
Dear Haas,
With the G73 high-speed peck cycle,
I have to machine a part that is very
what setting needs to be changed if I
simple way to duplicate a program in
hole? Right now, the drill is only moving a
similar to one I did last week. Is there a
require the drill to retract 0.100” in the
memory so that I can save my original
really small amount, and chips are packing
and modify the duplicate program for my
up in the flutes. I could use G83, but I don’t
new part?
Sincerely,
Richard
want the tool to come completely out of
the hole while it is drilling.
Dear Haas,
Is there a way for the user to recover
programs after they have been erased?
36 | www.HaasCNC.com
Sincerely,
Jeremy
Dear Jeremy:
Dear Jacob:
You can control the retract amount in
SSV stands for Spindle Speed Variation.
the G73 peck-drilling cycle by changing
SSV varies the spindle speed during
Setting 22. Setting 22 is the canned-cycle
delta Z; this setting specifies the distance
the Z axis retracts to clear or break chips
during a G73 canned cycle.
Haas Applications
•••
Dear Haas,
My new Haas VMC has a side-mount
tool changer with 24+1 tool capability. How
turning to prevent vibration from building, or
cancel vibration by changing its frequency.
Dear Haas,
How do I set up a dead stop in my SL-30?
Can I use a bar feeder for a dead stop?
Sincerely,
Desmond
Fabricate a tube that attaches to the
without having to change the numbers in
the center plate to attach the dead stop
go straight to the machine.
Sincerely,
Jack
hole pattern available when you remove
there. This tube can have an adjustment
rod at the back for use with jobs of different
lengths.
It is not recommended to use a bar feeder
as a dead stop, because the pushrod
Dear Jack:
CAM systems with Mill Tool Table
Assignments allow tool libraries that exceed
the number of tool numbers and pockets
available on the machine. Haas machines
with side-mount tool changers allow tool
numbers up to T200 in a program. To set
your machine for this, use Setting 90 to set
a tool-number range – from the number
of pockets in the tool changer up to the
maximum of 200. With Setting 90 set to
200, the control will display 200 tool length
offsets, and increase the tool numbers
available in the tool-pocket table to 200.
Programmers can use CAM libraries up
will rub on the workpiece as it rotates.
The pushrod does not rotate with the
workpiece. If you want to use the pushrod
as a stop, we recommend that you program
the pushrod to reference position, load the
part and then retract the pushrod after the
chuck closes. The V axis is used to control
the pushrod. Moving the pushrod away
from the rotating workpiece will prevent the
workpiece from rubbing and damaging the
stationary pushrod.
Haas Applications
•••
Dear Haas,
tool data. (For tool numbers with 4 digits,
through the Settings I saw something
see the Advanced Tool Management
section in the Operator’s Manual.)
Haas Applications
and off during the cycle.
amount specified by Setting 165, and with
a duty cycle determined by Setting 166. An
M39 in the program turns off SSV. A program
stop command such as M30 or pressing
RESET will also turn SSV mode off.
Here’s an example: When turning a long
shaft, it may have a tendency to chatter
as the diameter gets smaller, because the
diameter of the workpiece is significantly
smaller relative to the length being turned.
By giving Setting 165 a value of 50 and
Setting 166 a value of 30, a programmed
rpm of 1000 would vary from 950 to 1050
rpm, and cycle through that range every
three seconds.
SSV can be used while OD or ID turning; it
is not available while threading or tapping.
M38 SSV ON
M39 SSV OFF
Setting 165 SSV Variation (in rpm) this is
to 200 tools, and post programs without
having to manually edit the G-code for the
M-codes are used to turn this feature on
the spindle speed continuously by an
Dear Desmond:
face of the chuck throat. Use the three-
an editor? I would like to have the program
spindle speed as defined by two Settings;
Programming an M38 command varies
can I use my tool numbers from the CAM
tool library, which consists of 150 tools,
This feature lets the operator vary the
I have an SL-20, and while I was paging
how much we want to vary the rpm.
Setting 166 SSV Cycle (scale is 0.1
second) 30 is 3 seconds.
Haas Applications
called SSV. What is it and how do I use it?
Sincerely,
Jacob
•••
CNC MACHINING | 37
Haas Automation, Inc.
Haas Automation Europe
Haas Automation Asia
2800 Sturgis Road •
Oxnard • California 93030
Tel: +1 (805) 278 1800
Fax: +1 (805) 278 2255
Toll Free: 800 331 6746
www.HaasCNC.com
Mercuriusstraat 28 • B-1930
Zaventem • Belgium
Tel: +32 (2) 522 99 05
Fax: +32 (2) 523 08 55
[email protected]
www.HaasCNC.com
No. 96 Yi Wei Road • Building 67
Waigaoqiao Free Trade Zone
Shanghai, 200131. P.R.C.
Tel: +86 (21) 3861 6666
Fax: +86 (21) 3861 6799
[email protected] I www.HaasCNC.com
EN_11/2008