Throwback Thursday: IMTS Then and Now

Paul Novak of California-based South Coast Molds was a highlighted shop in IMTS' "We Are" marketing campaign, which solidifies the importance of this niche marketplace. South Coast Mold was featured in MMT's August issue, highlighting its machining strategy.

The Smartforce Student Summit was bustling with activity again this year and had more than 14,000 student visitors.

Hardinge displayed its fully digital five-axis VMC designed for mold and die work.

The machine features X-axis travels of 762 mm (30"), Y-axis travels of 630 mm (24.8") and Z-axis travels of 600 mm (24"). The standard version is equipped with a direct-coupled Big Plus CT40 spindle providing 15,000 rpm and an oil chiller, as well as preparation for through-spindle coolant (with a rotary union).

Moldmakers were onsite to find solutions to their reverse engineering challenges. For example, Geomagic Design X, a reverse engineering software that combines history-based CAD with 3D scan data processing so you can create feature-based, editable solid models compatible with your existing CAD software.

Hexagon Manufacturing Intelligence was one exhibitor catching the eyes of mold builders with its inspection and measurement technology that uses data to help make molds right the first time. Toolmakers, die makers and mold makers rely on 3D measurement to check and verify their equipment before the final article goes into production. Its CAD/CAM software packages offer advanced tooling design capabilities. Molds and dies can be measured using CMMs with a variety of sensor configurations and inspection methods to suit the workpiece’s size, material and form. Portable metrology systems are ideally suited to qualifying jigs and fixtures in situ and checking tooling for damage or wear. Laser scanning solutions can also be used for digitizing and reverse engineering tooling from a finished part.

GROB's G350 five-axis universal machining center was attracting attention. As a trunnion-type, the machine can use shorter tool assemblies to access certain features without risk of the spindle head getting in the way. This improves rigidity. As a horizontal, it provides a great deal of space in the Y axis because the spindle approaches from the side of the workpiece rather than the top. Extra space enables accommodating larger parts. As an added benefit, the spindle retracts, turtle-like, back into the housing during tool changes. This avoids the risk of interference when repositioning the workpiece.

This five-axis universal machining center is ideally suitable for workpieces requiring five-sided machining, with compound angle holes and surfaces with forms and flow profiles and for precision components.

DMG MORI held a press conference to review its current growth and future plans. “Global One” is aimed at the integration of DMG MORI COMPANY LIMITED and DMG MORI AKTIENGESELLSCHAFT to establish a global, integrated machine tool group.

DMG MORI shared the four key elements to its technology cycles, which are essential for its five-axis milling or turn and mill machines for six-sided complete machining. DMG MORI also presented its advantages to the marketplace, including high-quality and individual technological solutions, more than 96 percent spare parts availability, qualified service employees for quick service and support, 24/7 hotline for immediate support with service issues around the clock, highly specialized application engineers to optimize your production processes and 3D software solutions and intelligent software products.

Automation solutions were showcased extensively at the DMG MORI booth, including workpiece handling, pallet handling, tool handling, automation calculation, flexible manufacturing cells and production lines.

The Makino D200Z five-axis vertical machining center offers high quality surface finishes.

This mold component shows the high quality surface finish possible with Makino's simultaneous five-axis machining using its Pro6 control that simplifies machine controls and increases productivity. It is designed to move operators fluidly through machine set up, empower them with easily accessible information and protect them with enhanced safety. The Pro6 accelerates productivity for machine shops and tool, die and mold makers with streamlined screen layouts, operator guidance and latest machine functions.

Big Kaiser releases critical information to determine the appropriate spindle system. Its patented BIG PLUS(R) spindle system provides dual contact between the spindle face and the flange face of BIG-PLUS tooling.

Komet debuts its first 3D-printed line of cutting tools. Using 3D laser sintering technology KOMET is now able to achieve a new level of performance. The HPC design allows more blade stability and more cutting edges per diameter for higher feedrates. The blades can be brazed at a higher helix angle for a smoother cut and the coolant channels can have a complex shape to position them at the optimum location for cooling and chip evacuation.

Ingersoll Cutting Tool's Top On CAT 50, M20 Connection is designed for greater productivity, application flexibility, increased rigidity at greater L:D ratios, overall better milling performance at extended lengths and the connection is well suited to high-feed milling.

Ingersoll Cutting Tools' Typhoon high-speed jet spindles have been developed for use when high RPM is required for small diameter tools on limited RPM machines. The new spindles are for semifinish and finish machining applications such as milling, drilling and grinding. The system utilizes the machine tool’s existing coolant supply, driven by a high pressure pump (minimum 290 PSI) as an energy source to rotate a turbine up to 40,000 RPM. Typhoon is not intended to replace the machine’s spindle, but rather to upgrade the existing machine, providing improved performance, faster machining, better surface quality and extended tool life.

MC Machinery's automation cell featuring an OPS Ingersoll is ideally suited for mold manufacturing. The OPS Ingersoll Eagle V9, one of MC Machinery’s 5-axis milling machines, is making an impression on the mold and die industry. The Eagle V9 combined with the die sinking machine Gantry Eagle 1200 and a MultiChange Flex-Robot can deliver the flexibility needed for shops to meet full capacity.

Single Source Technologies FCS modular clamping system is designed to provide quick, custom setup options for unrestricted access to five workpiece surfaces, enabling moldmakers to spend less time on setups and more time on machining.

Hurco offers its 3D Print Head, an optional, spindle-powered wireless accessory for Hurco VMCs that extrudes plastic PLA filament for 3D printing directly on a CNC machine.

The Additive Manufacturing Conference 2016 returned to the site of its successful debut alongside IMTS 2014. AMC 2016 covered the processes, products and possibilities of additive manufacturing technologies for industrial, end-use part production. The conference included tours of the International Manufacturing Technology Show and multiple professional networking opportunities.

The American Mold Builders Association held its Night at the Ball Park for members during IMTS to see a Chicago White Sox game.

Sumitomo's PCD grades DA2200, DA150, DA200 and DA90 provide the toughness of cemented carbide and wear resistance of diamond. It was specially developed for machining of non-ferrous materials. This grade is available for turning, milling, boring and other demanding machining applications.

The OPM250 is a single process machine which combines laser metal sintering and high speed milling within the same workspace, allowing users to create finished 3D printed molds within a single machine. This additive technology allows not only for improved mold cooling channels and cycle times, but also streamlines mold design, significantly reducing the number of components necessary to create a complete mold. Last week Phoenix Deventures CEO Jeff Christian spoke about his company's success with the technology.

Jeff Christian CEO of Phoenix Deventures has successfully used Sodick's OPM250L machine, which integrates metal 3D printing and traditional machining by alternating between machining and printing within the same workspace. This mold is an example of the work that can be accomplished. This technology can dramatically improve surface finish and virtually eliminate EDM, according to Christian.