MACHINING

VOLUME1

NUMBER1

1/1997

Cover StoryPatrick Racing

FeaturesAmerican Performance

Gyroplane Precision

Industry News

New Options

1

Patrick RacingCOVER STORYCOVER STORY

Nigel Patrick served a rather speedy apprenticeship inthe profession of drag racing. In 1977 he begancollecting his first Christmas-tree reaction times, and

by 1978 he’d made a quantum leap to the top of the ProStreet class, dominating the field three years running. Heearned number-one plates from two sanctioning bodies, andquickly upped the ante by entering the rarefied atmosphere ofFunny Bike competition, building and racing turbo,nitro-injected, and blown alcohol-injected E.T. eaters.

American-Made Speedsters

THE MASTHEAD:CNC Machining is published by Haas Automation Inc., 2800 Sturgis Road, Oxnard, CA 93030-8933. (805) 278-2800, Fax (805) 278-2255.Postmaster: Invalid mailing addresses should be returned to Haas Automation, 2800 Sturgis Road, Oxnard, CA 93030-8933 postage guaranteedby Haas Automation. CNC Machining is distributed free of charge by Haas Automation Inc., and its authorized dealerships, agents and distributors.CNC Machining accepts no advertising or reimbursement for this magazine. All contents of CNC Machining are Copyright © 1997 and may notbe reproduced without written permission from Haas Automation Inc. CNC Machining is distributed through a worldwide network of Haas AutomationDistributors, and by individual subscription request. Contact Haas Automation headquarters via mail or fax to be added to subscription list. Published quarterly. © Haas Automation, Inc. & CNC Machining Magazine names. Designed and Printed in the U.S.A. www.HaasCNC.com

VOLUME1 SPRING1997

NUMBER1

A.P.E.Motors

RotaryAirforce

TechTopics

NewProducts

IndustryNews

Haas’ #13 VF-1 StillRuns Like New

Fixed FocusDid You Know?Tooling Tips

Patrick Racing –American-MadeSpeedsters

Gyroplane Flies withthe Haas VF-3

Machining CenterNew Features

Haas’ New HomeHaas Spins a Web

MACHINING

In this issue of

Continue on page 2

by Paul GarsonCoverStory1

4

6

9

14

20

32

His efforts were finally rewardedin 1984 with an MDRA NationalChampionship in Funny Bikes, andthe AMA Drag Bike NationalChampionship in Top Fuel, a seriousdrag race double-header. A year later,Nigel opened the doors of his newhigh-performance facility, Patrick Racingin Fountain Valley, California. Onceoperating in earnest, he channeled hisconsiderable talents into research anddevelopment, focusing on cylinderheads and normally aspirated engines.

Acknowledged worldwide as anexpert in high-performance cylinderheads and precision engine building,Nigel utilizes an air flow bench andSuperflow engine dynamometer in hisworkshop. In addition, and perhapsmore importantly, Nigel invested in aHaas VF-0 Vertical Machining Center,and TekSoft CAD/CAM design soft-ware for his PC. This setup enablesNigel to literally sculpt billet cylinderheads from blocks of raw aluminumstock. His high-performance enginesare in use by many street performanceriders and race teams, some who aredirect competitors.

Nigel’s CNC-machined heads forHarley-Davidson Twins are cut fromsolid, 8.5” square, 25-pound blocksof aircraft-quality 6061 T6 aluminum.Patrick’s cylinder heads are morerobust and precision cut than theirstock counterparts, and much moreaesthetically pleasing. Nigel’s successwith these heads is due to his bal-anced desire for both their looks andthe punch that they deliver.

Machining his way down fromthe 25-pound block to the completed10-pound unit involves some fairlycomplicated processes. “As it turnsout,” Nigel says,“ it actually involvessome five different moving axes, some-thing I wouldn’t be able to do withoutthe Haas rotary table.”

Nigel utilizes a fully-integratedHaas TRT-310 tilting rotary table –giving him access to various compli-cated angles on the part, and enablinghim to form the many intricate shapesand contours of the heads with asingle setup.

“Actually,” Nigel says, “it’s reallya high-tech way to manufacture thesehigh-performance heads. Each oneis a perfect clone of the original,because of the super-tight tolerancesthe Haas holds. I can maintain a0.0001 of an inch accuracy eachand every day.”

When the process is over, eachperfect,10.5-pound billet head hasbeen through five different setups onthe Haas VMC, and has a machinedsurface accuracy of 0.0002”. Allmajor machine work has been com-pleted, including the finished external

shape, the receptacles for the valveguides and seats, and all the tappingand drilling to hold the rocker boxes,intake manifold and exhaust pipes.

Nigel is able to machine 30heads at a time before moving on tothe cutting of valve seats, and theflow-dynamic porting that gives theseheads that extra performance boostthat Harley riders are after.

To date, Patrick Engineering’sproduct line includes billet heads forboth Harley-Davidson Big Twins andSportster models (1984 to present).In response to overwhelming customerdemand he offers all cylinder headsin eight different bolt hole patterns,with even more variations on the way.

In the past two years, businesshas been so successful that Nigelneeded to purchase another CNCmachine just to keep up with the orders.

In December 1995, when shop-ping for a new machine, he onlycared to look through one catalog.This time, he purchased a Haasmodel VF-4 with a larger xyz envelopeto accommodate the odd shape of thebillet heads. The VF-4 gives him a littlemore working room, and speeds up

production enough to make the extracost worth the investment.

Although his original Haas VF-0is still in daily use churning out perfectcopies of the Patrick performanceheads, it continues to provide close-tolerance finishes as good as the firstday it was used.

Nigel Patrick’s success has beenbuilt on solid design, and the ability toprovide that little-bit-extra that customerssometimes don’t expect. “I’m proud ofthe extra-heavy-duty heads I’m able toproduce on the Haas machine,” saysNigel. “They’re about a pound heavierthan the stock units, mostly because ofthe extra material around the combus-tion chamber... of course, they’re alsomuch stronger, since they’re made ofaircraft 6061 T6.”

“You know, I’m also proud ofthe fact that I’m one of the only after-market manufacturers of this qualityof performance parts using anAmerican-made CNC mill,” saidNigel.“ The Haas machines haveserved me well, and I’m glad theparts I make for American bikes aremade in the USA on an American-made CNC machine.”

“I’m proud of

the extra-heavy-

duty heads I’m

able to produce

on the Haas

machine.”

“...Each head is

a perfect clone of

the original,...”

A.P.E. Motors

54

American Performance Engineering (APE) of Burbank,California, makes parts for some of the fastest motorcyclesin the world, including a 1000-hp bike that does 0-234mph in just over six seconds.

Haas’ #13 VF-1 Still Runs Like New

It started out as a Japanese-madeKawasaki. But, before long, almostevery part had been replaced by abeefed-up custom-made part. Now, it’sactually an American-made bike.

In 1989, APE was a job shopweaning itself off aerospace work bydeveloping a line of high-performancemotorcycle parts. Most of these partsare machined out of aluminum, andinvolve drilling holes or milling pocketsand profiles. Since the parts are usedas covers and plates, it’s importantthey have a smooth finish. In addition,some parts, such as cam sprockets,are milled out of light steel.

APE initially farmed out work tolocal job shops equipped with CNCmills. But as these shops became busyin the late 80s, it became increasinglydifficult to get parts made fast enoughto satisfy customers, without cost-pro-hibitive rush charges. So, APE lookedinto buying its own CNC mill.

“We had to buy our own CNCmill,” says Jay Esbach, president ofAPE. “We didn’t have a choice. If wedidn’t deliver on time and at the rightprice, our distributors would buy fromour competitors – and we’d be out ofbusiness,” Esbach said.

In 1989, Haas Automation beganmanufacturing machining centers tocompete with the low-cost offshorebrands. Back then most people thoughtthe reason not to buy a Haas was,even if they built a machining centerthat worked, there was no guaranty itwould last past the warranty. Of course,they were all wrong, and that attitudehas changed now.

“I never would have bought a first-year machining center,” said Esbach,“but I knew Gene Haas. He said he’dstand by his machines, so we boughta Haas VF-1, serial number 00013,and a 5C collet indexer. We’re stillusing it, and it’s still cutting parts justlike new,” notes Esbach.

The Haas VF-1 has travels of20” x 16” x 20” (xyz), direct drivewith a toothed-drivebelt, and 10-hpspindle that delivers up to 7,500 rpm.It has a wide, cast-iron base thatprovides dependable cutting torqueand superior rigidity.

“The VF-1 did two-months-worth ofwork in two days. So we were able toexpand our product line, and offer moreparts. Plus, the VF-1 helped us with ourcorporate identity. We could engraveour trademark monkey on most of ourparts. That has helped us in Japan,where they won’t buy our parts withoutour trademark monkey,” adds Esbach.

One of the biggest differencesbetween machining centers is found intheir controls. Some are easy to useand program; some aren’t. According

to Ben Esbach, who programs theVF-1, the Haas control is easy.

The control of the VF-1 is made byHaas. It’s a 32-bit Fanuc™ compatiblecontrol that executes 500 blocks persecond of programming. (The only dif-ference between old and new VF-1’s is

that program execution speed is nowup to 1,000 blocks per second.) It fea-tures a number of Haas OneTouch™features, including OneTouch™ Power-up, which turns the power on, homesall axes, picks the number 1 tool andloads it into the spindle – so themachine is ready to make chips.

“I like the way it’s easy to set thework coordinate system offsets. Youindicate a hold, touch a button andthe offsets are loaded automatically.Those are the G50 codes, which are

Continue on page 8

by Bob Thomas

"We build aircraft and, ofcourse, everything we build has gotto be right on the money. It’s got to beright; somebody’s life is depending onit,” said Shane Seitz, manufacturingmanager of Rotary Air Force.

At the beginning of 1994, thecompany decided to upgrade theirmanual machining operations toCNC. The objective was to increaseproductivity and quality, whiledecreasing cycle times and the time ittakes to complete prototypes. A dozenmachining centers were evaluatedover a four month period. In July 1995,the company purchased a Haas VF-3machining center.

The VF-3 weighs 12,500 lbs.and has travels of 40” x 20” x 25”(xyz). It has a 15-hp motor, geared-head, heavy-duty water-cooled spindle,speeds up to 10,000 rpm, and a20-pocket electronic tool changer. Thehigh-speed, dual 32-bit Fanuc™ com-patible control is also built by Haas.

“We were a manual machineshop transferring all our machiningoperations to CNC,” Seitz said. “The VF-3 has a nice control that’sreally simple to use. You know thecontrol is simple when the guys you’retraining pick up on it fast,” he said.“The VF-3 has all the power andspindle rpm we need, and it gives usthe most bang for the buck.”

Advanced OneTouch™ featureson the Haas-built control save trainingand production time. For example,Haas OneTouch™ power-up turns thepower on, homes all axes, picks upthe #1 tool and loads it into thespindle, so the machine is ready tomake chips. Tool-length setup storesoffsets for 50 different tools (newVF-3’s store 100 offsets), and can beprogrammed with either radius ordiameter, whichever the operator ismost familiar with. Work coordinateoffsets are loaded automatically withone button after touching-off the part.OneTouch ™ tool offset sets tool-length offsets with one button, andanother button loads the next toolautomatically for offset measurement.

Prototype Production: From Months to Weeks

“I can draw an air foil with ourCAM system, and send the programvia DNC to the VF-3 for testing in lessthan a day,” Seitz said. “We canprove the program in single-blockmode and edit right on the machine’s

control. Once we get the first part out,we don’t have any QC problems withtolerances that don’t fit. There’s nodeviation from one part to the next,”he said.

The company has found the tool-load monitor, tool-life managementand single-block modes critical toproving out parts without crashingtools. The tool-load monitor keepstrack of spindle load for each tool,and warns when the load exceeds anoperator-defined safety margin. Sowhen the tool load alarms are set totight tolerances, the machine shutsdown before a tool crash occurs. Thetool-life management system keepstrack of how long a tool is in the feedmode. When tool time exceeds

operator-defined parameters an alarmcomes on, virtually eliminating dam-age to the part from a dull tool.Single-block mode allows one line ofcode to be run at a time. The operatorpushes a button to execute each lineof code.

Formerly, prototyping requireddrawing a profile and sending it to avendor. From the drawing the vendorgenerated a CNC program, thenmade the cut. If there were additionalchanges to the prototype part, thewhole process had to be repeateduntil the part was correct.

“Now, 5,000 lines of code canbe generated and machined in justfive hours. CNC programs are sent tothe Haas for proofing and editing,”Seitz said. “Short programs and basicediting are done right at the mill. Itbrought our prototype-to-productiontime down from months to weeks.”

Smooth Surface Finish

“The most critical component onthe gyroplane is the hub bar thatholds the main rotor blades. It wasredesigned this summer,” Seitz said.“The tolerance is 0.0005-inch andthe surface finish must be smooth.Many of our components require asmooth surface finish, so we use double point or single point mills at9,500 rpm to turn out surface finisheslike glass. The hub bars look likemirrors, with surface finishes of 0.3micrometers. That’s proof the VF-3’sspindle and fixture are super rigid,”Seitz said.

The VF-3’s accuracy of ±0.0002-inch is attributed to heavy castingsthat reduce vibration, and ball screwsmounted at both ends to reducethermal growth. Wide-stance castingsand a liquid-cooled spindle furtherenhance rigidity.

Made of solid 6061 T6Aluminum, the hub bar is 211⁄2” longby 3” by 11⁄2”. Its sides are flat, butat angles. Viewed from the side,it’s machined into a very flat V with15-degree slopes on each side, anda flat center section. The hub bar

Rotary Airforce

76

Rotary Air Force, of Saskatchewan, Canada, hasmanufactured Gyroplanes since 1970. A Gyroplane isan experimental, ultra-light aircraft with its lift and drive

provided by a free-wheeling rotor system. Technically, it’s nota helicopter, as the craft requires a minimum of 50 feet for arunway. Gyroplane kits are sold in the U.S. for use in cropdusting, cattle control and pleasure.

Gyroplanes Fly with the Haas VF-3

Continue on page 8

by Bob Thomas

“We can prove the

program in single

block mode and

edit right on the

machine’s control.”

Fixed Focusdetermines the rotor-blade angle. Thisangle is partially determined bymachining, then the hub bar is put intoa pressure jig and bent to the exactconing angle.These angles must bewithin ±0.001-inch tolerance to clearthe rotor head components. “The finaloperation is boring holes in the end ofthe hub bar,” Seitz said. “Since a spe-cial fixture stands the 211⁄2” bar onend for this operation, we needed thelong z travel the Haas VF-3 provides.”

Rotor Molds

Rotary Airforce just put its firstaluminum mold into production. It’s acompression mold for the 163-inch-long fiberglass rotor blade. Machinedin sections out of aluminum, it has atolerance of ±0.001-inch This is thefirst time the company’s been able tomachine molds out of solid aluminumblocks. The blocks are assembledtogether to form an aluminum moldthat can be heated and cooled.

“Tolerances are super criticalwhen you’re machining a mold inpieces,” said Seitz. “The tolerance onthe rotor mold is 0.001-inch, becauseonce the rotor is made it has to behand finished.”

“Spindle speed and feed overridefeatures on the control allow us to varythe speeds and feeds at any timeduring machining operations,” he said.

“The VF-3 is very fast. I can feedtools up to 300 inches per minuteand rapid at 710 inches per minute,with smooth tool changes. We likethe VF-3,” Seitz said. “It proved tobe a profitable investment.”

98

really simple to do. The offsets arereally easy to enter on that machine.You touch the tool to the part, press abutton and the coordinates are saved,”Ben Esbach said.

“Another feature that saves timeis the editor. It’s easy to use, andquick. For example, to get to the bot-tom of a program, push a button andyou’re there instantly. The Fanuc™control on our other machine takes awhile to scroll through the program,”reports Ben Esbach.

The Haas control has a numberof features that ease programming

and reduce errors, such as the abilityto change between Yaznac™ andFanuc™ settings. And, a built-in safetyfeature stops the program from runningif the wrong tool is called up. Thiscommand can be disabled, if youwant to take a chance.

“Most of the work we doon the mill is cosmetic – mak-ing parts that look good onthe motorcycle. We putgrooves on them, mill outfancy-shaped pockets andinscribe our name. The Haasmill makes a great engravingmachine. Our logo, a mon-key holding a little APE sign,is programmed on our CAMsystem, and engraved on theparts,” he adds.

Hole locations on partscan be pretty important; they oftenhave to line up with fixtures. In thecase of APE’s parts, the holes oftenmust match holes on a motorcycleengine casting.

“We drill holes in the parts, thenhave to fit the parts into another fixture.They fit every time,” says Ben Esback.“The graphics on the control show thepart being cut, and also let you knowwhether you’ve got your work zerocoordinates set,” he said. “OneTouch™power-up saves us time.On our otherCNC you have to load the X and Z

coordinates in the morningto let the machine knowwhere it is.”

The Haas control alsohas built-in online help,which helps with program-ming. For example, enterthe coordinates to programa circle or radii, and thecontrol will write the G-code for you. It’s almostlike having a CAM systemin the control.

“My CPA says he cantell when I bought each

CNC machine,” adds Esbach,“because we increased our sales andprofits after every purchase. In fact, wegrew 1,000% in seven years. We’refinding it difficult to keep up with theorders again, so we’re going to buy acouple more Haas machines.”

RotaryAirforceAPEMotors

The Ball Bar Test – It's the Only Way

Industry people in-the-know have beenaware for years that Haas Automation Inc.puts every machine they build through arigorous ball-bar test before shipping.Although most machine-tool manufacturersshy away from taking the time to doublecheck their machines with the intensity thatHaas does, most will at least check some ofthe machine's geometry with a laser system.

Unfortunately, old-style laser inspectioncan only check a single axis at a time; and,at that, it can only check the straight-lineaccuracy of that axis.

Haas uses the more stringent ball-bartest, checking not only linear accuracy, butalso the overall machine geometry. The ball-bar test is a tell-all examination that ultimatelyinsures the three-dimensional squareness and

absolute accuracy of each Haas machine.The test is done with a bar that can out-

put micron (0.0000393") changes in length.

It is attached to both the spindle and a fixedpoint on the table. The machine is then putthrough a series of circular moves in the X/Yplane, and half-circle moves in the X/Z and

Y/Z planes.Encoder data from the bar is fed into a

computer, which outputs a chart of themachine’s accuracy. Any deviations insquareness or length show up as distortedcircles and are very easy for a technicianto spot.

Because of their rigorous attention todetail and insistence on producing only qual-ity machine tools, Haas sends the results ofthis ball-bar test, as well as numerous otherdetailed inspection check lists, along witheach machine. They see it as assurance totheir customers that the machine they receiveis accurate, properly aligned and ready tomake chips.

From Haas' standpoint, it's the only wayto do things.

TECH TOPICSTECH TOPICS

CHATSWORTH, CA – In past years such complex jobs as per-formance head-porting required skilled craftsmen to painstakinglysculpt the ports by hand – a process thatcould take days. The new 5-axis horizontalfrom Haas Automation accomplishes thesame job in just a few hours. In today’scompetitive world, that’s the differencebetween winning and coming in second.

Based on Haas’ shop-provenHS-1R horizontal machining center(24” x 20” x 22” travels), the HS-1R 5AXcomes standard with a 15” x 40” extend-ed table, an HRT-210 (8.27” platter)rotary table, and full 5-axis control. Twodifferent A-frame support blocks – plainbearing or needle bearing – are availableas options, as well as a 20” x 20” tablefor added flexibility.

Built of heavily-ribbed, American-made iron castings, this machine utilizesHaas’ exclusive anti-flex, torque-tubedesign for superior rigidity. A 15-hp motordrives the high-capacity spindle to 7,500 rpm through an oil-cooled,2-speed gearbox. The 24-pocket tool changer is fully-enclosed to

protect tool tapers from chips and coolant, and an automatic chipauger senses loads to prevent jamming. High-speed, brushless

servo motors provide rapids up to 710ipm to further reduce cycle times, anda 22-hp, 10,000-rpm spindle is avail-able as an option.

Driving the HS-1R 5AX is thehighly-refined, user-friendly Haas CNCcontrol. The 5-axis software has beenfine-tuned for high speed to meet thechallenge of processing large, complexfiles, such as those associated withcylinder-head machining. Memory isexpandable to 8 megs, and a high-speed RS-422 port (115,200 bps)may be added for even more speedand versatility.

The HS-1R 5AX is a versatile,high-performance machine perfectlysuited for cylinder-head porting,manifold work and other compoundmachining operations. With a starting

price less than $149,000, the HS-1R 5AX is less expensive thanany competing machine.

Continued from page 5 Continued from page 6

The Haas CNC Controlprogram starts again, the spindlewill be restored to the statecommanded in the program.

• When tapping, you do not needto turn the spindle on with M03 orM04. The control starts the spindleitself prior to each cycle and it will,in fact, be faster if you do not turnon the spindle, as the control muststop it again anyway.

• The action taken by the controlwhen the operator presses Reset iscontrolled by several settings. Theseare: 31 to reset the program pointerto start of program, 56 to reset todefault G codes, and 88 to resetoverrides to 100%.

• This control can turn itself off in wayscontrolled by settings. These settingsare: 1 to turn off after machine isidle for nn minutes, and 2 to turn offwhen M30 is executed. In addition,for safety reasons, the control willturn itself off if an overvoltage oroverheat condition is detected forlonger than four minutes.

• There are, in fact, so many settingswhich give the user powerful com-mand over this control that usersshould read the entire settings sec-tion of the manual to get an idea ofwhat is possible.

• It is possible to control a Haasrotary table using the serial port andmacros from our control or ANYFanuc-compatible control. An exam-ple set of macros is available fromthe Haas applications department.

• If you are having occasional errorswhen using RS-232 communica-tions, X-modem is a standard

communications mode which ismuch more reliable when a fewerrors occur. Our control supportsthis, as do almost all softwarecommunication packages for PCs.

• You can turn the Mill's tool carouselwithout changing tools by usingM39 and Tnn. This can be usedto recover from some unusual con-ditions. However, it will also tellthe control you have a differenttool in the spindle, which may notbe the case.

• A tool overload condition, asdefined by the Tool Load Monitordisplay (Curnt Cmds, page down),can result in one of four actions bythe control. They are controlled bysetting 84 and can be: Alarm – togenerate an alarm when overloadoccurs; Feed Hold – to stop withFeed Hold when overload occurs;Beep – to sound audible alarmwhen overload occurs; or Pause –to temporarily Feed Hold the controlwhen overload occurs.

• Setting 85 is one of the most pow-erful settings in this control. Whenit is set to the accuracy required bythe user, the machine can be pro-grammed at any feed rate up tothe maximum without the errors

ever getting above that setting. Thecontrol will ONLY slow at cornersWHEN IT IS NEEDED. This settingactually defeats all of the years ofdiscussion by competitors needingmultiple block lookahead.

• This control actually does lookahead for block interpretation up to20 blocks. This is NOT NEEDEDfor high speed operation. It isinstead used to insure that DNCprogram input is never starved,and to allow cutter compensationto have non-XY moves insertedwhile cutter compensation is on.

• The feed rate which is entered inyour program can be misinterpret-ed if you do not use a decimalpoint. BUT setting number 77 canbe used to change how the controlinterprets the feed rate WHENTHEIR IS NO DECIMAL POINT.The values in this setting can selectthe Fanuc default, to assume integervalues, or to place the decimal ina selected position.

Look to future issues of CNCMachining for more tips and tricks to help with your everydayuse of the Haas control.

1110

• When in Edit or Mem mode, youcan select another program quicklyby simply entering the Onnnn pro-gram name you want and pressing“cursor down”.

• You can output several programs atonce to the serial port by typing allthe program names together on theinput line and pressing “send”.

• When you send files to the floppy,you must put the highlighted cursoron the program you are saving or onthe “ALL”. Also, the name entered onthe input line is the floppy file name.

• If you have the rigid tapping option,you can verify the exact spindlespeed by checking the second pageof Diagnostic data.

• When you receive (input) a programfrom the floppy disk, it is always a“receive all”. That is, there must bean Onnnn program name in thefloppy files. The name you enter onthe input line is the file name.

• Program files on a floppy still muststart and end with a %, like RS-232.

• You can select an axis for joggingby entering that axis name on theinput line and pressing the Handle/Jog button. This works for the normalX, Y, Z, and A axes, and the B, C,U, and V auxiliary axes.

• Searching for something in aprogram can be done in eitherMem or Edit mode by entering theaddress code (A,B,C etc.), or theaddress code and value (A1.23),and pressing the down or up cursorbutton. If you enter just the addresscode and no value, the search willstop at the next use of that letter,regardless of value.

• It is not necessary to turn off coolant,stop the spindle, or move the z-axisprior to a tool change. The controlhandles those tasks and, in fact, itwill be faster because the control willoverlap some of these operations (dothem all at the same time).

• The Help display has all the G andM codes listed. To get to themquickly, press the Help button andthen the C button.

• There is an alarm History whichshows the previous 100 alarms.You can get this display by pressingthe Right cursor button. Press Rightcursor again to select the normalalarm display.

• You can move a block of lines fromone program to another by defininga block with the F1 and F2 buttons,then selecting another program andcopying them to the second pro-gram by pressing Insert. Thereis a reminder of this at the bottomof the screen when you go to thesecond program.

• You can turn off a block definitionby pressing the Undo button. Thisreturns the cursor display functionsto normal.

• You can write the Macro variablesto RS-232 or floppy by pressingProg List and then selecting themacro variable display page (pagedown from Curnt Cmds). You canalso load the macro variables backin this same way.

• The coolant pump can be turned onor off manually any time a programis running. This will override whatthe program commands until theprogram commands on or off. Thisalso applies to the chip conveyor.

• The spigot position can be changedmanually any time a program isrunning. This will override what theprogram commands until anotherspigot position is commanded(H code is programmed or coolantis turned on).

• The Jogging speeds of 100, 10,1.0 and 0.1 inches per second canbe adjusted by the feed rate over-ride buttons. This gives an additional10% to 200% control.

• You can stop or start the spindleanytime you are at a single-blockstop or a feed-hold. When the

by: Kurt Zierhut

Did You Know That...

TECH TOPICSTECH TOPICS

Tooling Tips

Indexable-insert milling cutters are

mechanically simple toolholders

that can be expected to provide

long and reliable service. Problems

that arise usually result from a conflict

between cutter design and applica-

tion, or a lack of proper maintenance.

Application: Cutter Pitch

One of the key considerationsregarding cutter application isproper cutter pitch. Workpiecematerial considerations,machine-tool horsepower, andmetal removal rates can alsohelp determine proper cutterpitch. Relatively soft materials,like aluminum and low carbonsteel, produce chips which aredifficult to curl, so coarse cutterpitch can be beneficial. Butmilling operations involvingmaterials like gray cast iron,which produce a powderychip, can actually benefit fromthe use of fine pitch cutters.

Adequate machine-toolhorsepower can permit feedingmedium and fine pitch cuttersat their proper chip loads of.008 to .010 ipt; sufficienthorsepower can also enablemetal removal rates to beincreased with medium andfine-pitch cutters.

Wear in the chip gullets of thecutter is normal, but one of the mostcommon indicators of milling cuttermisapplication is extraordinary wear.A way to combat gullet wear is toswitch to a cutter with a coarser pitchthat provides a larger chip gullet foreasier chip evacuation. An alternatewear-reduction method, if you'reunable to reduce pitch, is to lowerthe cutter feed rate (inch per tooth).A change to a cutter with high-shearangle geometry can also reduceexcessive wear, because the high-shear inserts will kick chips up andout of the cutting area.

If the cutter is worn excessively inareas other than the chip gullet, look

for interference points on the fixtureor workpiece, where chips may bebuilding up.

Application: Cutter Geometry

Tailoring cutter geometry to theoperation at hand is another criticalcomponent of proper cutter applica-tion. Workpiece materialconsiderations again play a role, asdouble-positive or high-shear geometrycutters are good choices for millingsofter materials. If the part beingmachined does not require milling toa square shoulder, use of a lead-angle cutter will produce a thinnerand therefore more easily-curled chip.

When milling gray castiron, on the other hand, adouble-negative geometryis ideal, and permits the useof a maximum number ofcutting edges.

Chip-formation consider-ations make lead-angle cuttersnecessary when milling high-temperature alloys.

The size and horse-power of the machine toolwill help determine whatcutter geometry can be used.Positive and high-sheargeometries lend themselvesto lower horsepowermachines, while negativegeometries require higherhorsepower machines.

Finally, the configurationof the workpiece, and itsfixturing, can dictate thechoice of cutter geometry.Specifically, thin-walled

1312

Tooling Tips and Techniques From the Application Experts at Kennametal Inc.

Basic Milling Cutter Application and Maintenance

parts, or weaker fixturing, require freer-cutting geometries, like double positiveor shear-angle cutters.

Maintenance: Long, and Short-Term

After application considerations,cutter maintenance is the way to assurelong and reliable service. Maintenancecan be broken down into daily stepsand long-term routines.

On a daily or shift-by-shift basis, alogical time for maintenance is whenindexing inserts. After removing theinserts, blow out and wipe out all pocketsto remove chips or fine particles. On theinserts themselves, remove any built-upedges before indexing, so that the insertand wedge seats properly.

Take this opportunity to replace anydamaged or badly worn hardware,make sure all nests and inserts are prop-erly seated, then tighten all screws to the

proper torque specifications.Before mounting the cutter, check

cutter bore, keyways and mounting facesfor dirt or burrs. Double-check all boltswhen mounting the cutter to the spindle.

Long-term maintenance, performedon a weekly or monthly basis, alsoinvolves close inspection of the cutters fordamaged hardware, excessive wear, orother irregularities that may have beenmissed during daily care. This is the timeto make sure that screws and slidingcontact surfaces have sufficient high-pressure, high-temperature lubricants.

Simple, consistent maintenance,along with correct cutter application,can help you mill consistently and pro-ductively over the long term.

For more expert cutting tool applica-tion advice, including answers to yourspecific application questions, call theexperts at Kennametal ApplicationSupport at 1-800-835-3668.

Left: Examples of course pitch (left) and finepitch milling cutters. Coarse pitch cutters workwell in materials that produce soft, difficult-to-curl chips, like aluminum and low-carbon steel.Fine pitch cutters can be productively appliedon workpiece materials that produce a powderychip, such as grey cast iron.

Right: Ongoing inspection and maintenance ofcutter hardware is critical to the productivity,accuracy, and safety of milling operations.Insert-holding nests and wedges are subject tohigh pressures and continual abrasion, andshould be replaced before excessive wearcauses problems.

“The size and horse-

power of the

machine tool will

help determine what

cutter geometry can

be used. Positive

and high-shear

geometries lend

themselves to lower

horsepower

machines, while

negative geometries

require higher horse-

power machines.”

TECH TOPICSTECH TOPICS

The Machining Center

VMC with Extra-Long 120" X-Travel, Only From Haas

Designed for extra-long parts, such as wing sparsand molds, the Haas VF-10 Vertical Machining Centerfeatures travels of 120" x 32" x 30". Built of heavily-ribbed,American-made iron castings for structural integrity andrigidity, this C-frame VMC utilizes triangulated, wide-stance construction to damp vibration and prevent flex.The result is accuracy of ±0.0002 inch and repeatabilityof ±0.0001 inch. For more precise positioning, linear(glass) scales are available as an option.

The VF-10 is available with a 40-taper or 50-taperspindle, and a 15-hp motor drives the water-cooled spindleto speeds of 7,500 rpm through a two-speed gearbox.A 20-pocket automatic tool changer comes standard,with a 32-pocket changer available as an option. Bothchangers are fully-enclosed to protect tool tapers from chipsand coolant, and feature tool-to-tool change times ofapproximately 5 seconds.

The optional 50-taper spindle is driven by a 30-hpmotor that delivers 450 ft-lbs of torque for heavy materialremoval and true high-torque power.

New, Compact HRT-160-SP Rotary Table

The compact design of the new Haas HRT-160-SPallows fitting of multiple units to multi-spindle machiningcenters with a spindle distance of 11” (or more), as wellas to single-spindle machining centers. To increase produc-tivity and efficiency, more than one HRT-160-SP can be

14 15

NEW PRODUCTSNEW PRODUCTS

run on single-spindle VMC’s to machine multiple parts withfewer tool changes.

Designed with a narrow footprint specifically for usewith multi-spindle mills and pallet systems, the HRT-160-SPaccommodates parts on a 6.3” (160 mm) platter. Therotary table's six standard T-slots easily accommodatesix-inch chucks. The table mounts in the horizontal position,and allows feeding of parts through a 1.5" diameter thru-hole to a depth of approximately six-inches from the faceof the platter.

Rotary tables decrease cycle times by providingversatility and flexibility in workpiece positioning. Forexample, a rotary table can rotate a part into positionfor each machining operation, eliminating the need torefixture, and the extra handling required for repositioning.

The HRT-160-SP provides true simultaneous 4th-axiscutting (A axis is fully interpolated with xyz axes) whenmounted on Haas vertical or horizontal machining centers.Mounted on non-Haas machines, the HRT-160-SP allowsnon-interpolated rotation (semi 4th-axis) by using anM-function to initiate positioning.

Accuracy and reliability of the rotary table areguaranteed by such features as a 0.5-hp DC servo motorwith 63:1 worm gear ratio, a hardened and CNC-groundworm shaft with pre-loaded angular contact bearings, anda hardened precision-ground table. Backlash is reducedthrough use of a CNC-hobbed "deep-tooth engagement"worm gear. The HRT-160-SP provides accuracy of ±15arc seconds with repeatability of 10 arc seconds. Resolutionis 0.001 degrees and maximum feed rate is 80 degreesper second.

Tilting Rotary Table for 5-Axis Machining

The T5C 2-axis tilting rotary table provides five-axispositioning with 360 degrees of rotation and 240degrees of tilt for machining operations. The tilting rotarytable decreases cycle times by providing versatility andflexibility in workpiece positioning.

When mounted on Haas VMC’s or horizontals, theT5C provides fully-interpolated, true-simultaneous 4th- and5th-axis positioning (A and B axes of the rotary table arefully interpolated with x,y,z axes of the machining center).On other machining centers the T5C allows non-interpo-lated rotation and tilt, with positioning triggered by an M-function to the rotary table’s control box.

Rotation speed is variable up to 200 degrees per

second and tilt speed is variable up to 60 degrees persecond. The T5C handles small parts with a 5C colletwith air collet closer, or five-inch, 3-jaw chuck. Maximumcombined fixture and workpiece weight is 30 lbs.

The T5C incorporates thelatest design concepts forlong life, high reliabilityand accuracy.Rotary axisaccuracyis ±45arc seconds,with repeatabilityof 10 arc secondsand resolution of 0.001 degrees.

The accuracy and reliability of the tilting rotary tableis guaranteed by such features as a hardened and CNC-ground worm shaft with pre-loaded angular-contact bear-ings, and a hardened, precision-ground platter. Backlashis reduced through the use of a CNC-hobbed ”deep-toothengagement“ worm gear.

Applied Technology the Rotary Way

Haas Automation has released their new 32-pagerotary catalog and application guide for 1996-’97. Thisfull-color brochure opens with a bit of Haas history, thendetails the ongoing development of the most popularrotary tables in the world.

Throughout the remaining pages, each series ofindexers and tables gets its own section, complete withdimension drawings, specifications and exampleapplications. The back of the brochure lists a host ofaccessories and available optionsfor the entire line ofrotary products.

Increasing pro-ductivity is the nameof the game, andHaas plays it well.Get your hands onwhat has beendescribed as the mostwell thought out bookcovering the industry'sbest conceived, designed,and built rotary products.

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Y

Z

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The Latest CNC Machines from Haas

Two New Precision Lathes, withProgrammable Tailstocks, Are Big Hits withHaas Customers

The compact HL-2 and large-stance HL-4 slant-bed CNC lathes withprogrammable tailstocks have gaineda serious following among Haas cus-tomers. The HL-2 features a 10” x 20”

work envelope with 20”swing, and the HL-4 has a14.25” x 34” work enve-lope with 25” swing. BothCNC lathes feature simpledesigns and rugged con-struction to assure uptimereliability and economicaloperation for competitiveperformance.

A programmablehydraulic tailstock provideshigh accuracy positioning by

reducing part flexing. The cast-iron,programmable tailstock, with wide-spaced linear guides, provides a super-stable base. Motion is controlled by

the NC program or, in manual mode,by the operator.

The HL-2 weighs 8,000 lbs. andthe HL-4 weighs 11,000 lbs.; bothfeature a unique torque-tube, cast-ironbase for torsional rigidity. Oversizedguides, with an unusually wide stance,enhance rigidity and stability for heavy-duty cutting. The slant-bed design facil-itates chip flow into the reservoir.

The HL-2 CNC lathe featuresa 15-hp drive,providingspindle speeds of50 to 3,750 rpm,and an automatic10-station tool turret.The HL-4 CNClathe features a30-hp drive, pro-viding spindlespeeds of 30 to3,500 rpm, andan automatic 12-station tool changer.The Haas-built controlfeatures dual, high-speed 32-

bit processors, and is Fanuc™ com-patible. Located for easy part setupand tool loading, the control hasunique Haas OneTouch™ features,such as power-up, which combine tofurther enhance productivity.

Haas Horizontal Now Features Larger Travels

The Haas HS-1 is a traveling-column, 4th-axis horizontal machiningcenter. This low-cost, high-production horizontal features new heavy-duty castings and larger travels of 24” x 20” x 22” (xyz).

Weighing in at over 13,000 lbs, the HS-1's heavy-duty ironcastings are fully ribbed for structural integrity and rigidity. Accuracyis ±0.0002 inch and repeatability is ±0.0001 inch. A 15-hpmotor, with two-speed gearbox, drives the oil-cooled spindle tospeeds of 7,500 rpm, and easily performs heavy-duty cutting operations. A standard 24-pocket (40-taper) automatic tool changeris fully-enclosed to protect tool tapers from chips and coolant.

Two New Haas VMC’s Feature Extra-Long Travels

The Haas VF-7 VMC, with 84" x 32" x 30" (xyz) travels, andthe VF-9 VMC, with 84" x 40" x 30" (xyz) travels, provide the largesttravels available on C-frame vertical machining centers. TheVF-7 andVF-9 provide economical solutions for large, square-format parts,such as engine blocks and mold bases.

These new Haas VMC’s utilize heavy-duty, cast-iron A-frameconstruction for structural integrity and rigidity. Accuracy is ±0.0002inch and repeatability is ±0.0001 inch. Linear (glass) scales areavailable as an option.

Large Y-axis VMC Provides Moldmakerswith a Competitive Advantage

The all-new Haas VF-8 VMC, with travels of 64" x 40" x 30"(xyz), provides the longest Y-axis travel available on a C-frame vertical machining center. Previously, expensive gantry mills requir-ing lots of floor space would have been necessary to machine suchlarge parts as molds and sheet-metal tooling. The VF-8 is an eco-nomical solution for such large, square-format parts.

Weighing over 24,000 lbs, the VF-8 utilizes heavy-duty, cast-iron A-frame construction for structural integrity and rigidity. Themachine provides accuracy of ±0.0002 inch and repeatability of±0.0001 inch. A 15-hp motor, with two-speed gearbox, drives thewater-cooled spindle to speeds of 7,500 rpm (a 22-hp, 10,000

rpm spindle is available as an option). A standard 20-pocket(40-taper) automatic tool changer is fully enclosed toprotect tool tapers from chips and coolant. Tool-to-toolchanges are approximately 5 seconds.

The Machining CenterNEW PRODUCTSNEW PRODUCTS

32-Tool Option for VMC’s

Set up 32 tools and runmultiple jobs, or a family of parts,for just-in-time manufacturing. Theall-new Haas 32-pocket toolchanger utilizes a 2-pin geneva

motion for fast, random tool selection. The tool changer automati-cally travels the shortest distance to the next selected tool.

Built with the same technology as the time-proven 20-pockettool changer, the new 32-tool option features the unique Haassinusoidal-motion arm to accelerate and decelerate shuttle move-ment with only two moving parts. Thisprovides smooth tool changes andreliable, long-life operation. Each ofthe 32 tool pockets features a slidingcover to prevent chips from enteringand sticking on the tool tapers.

With this expanded tool optioncomplicated parts and operations,like in-process inspection and lights-out manufacturing, are mucheasier to program. Haas suggests using the 32-pocket toolchanger for back-up tooling, in conjunction with macros to moveto the secondary tool, when utilizing tool-life management.

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New Automatic Parts Catcher and Tool Presetter for Haas CNC Lathes

The new Haas Automatic Parts Catcheris a labor-saving feature which frees theoperator to perform other tasks while theCNC lathe with bar feeder runs unattended.Adjustable for part length and diameter, thepneumatically-powered APC swings into posi-tion to catch parts as they are completed.

The Haas Tool Presetter is a compact,manually-operated arm which swings intoposition to set tool offsets. The Tool Presetteris permanently mounted on the spindle hous-ing, with all wiring enclosed to protectagainst damage from chips and coolant.

Haas’ line of compact, slant-bed CNClathes features unique torque-tube, cast-ironbases for torsional rigidity. Oversized guides,with an unusually wide stance, enhancerigidity and stability for heavy-duty cuttingand competitive performance. The CNClathes feature a 10" x 20" or 14.25" x 34"

work envelope, a 20" or 25" swing, and areavailable with programmable tailstocks.

The HL-1 and 2 feature 15-hp drives with spindle speeds of 50 to 3,750 rpm.The HL-3 and 4 feature 30-hp drives with spindle speeds of 30 to 3,500 rpm. AnAutomatic Tool Turret is available with 10 or 12 pockets. The Haas-built, Fanuc™compatible, dual 32-bit control is located for easy part setup and tool loading.Unique Haas OneTouch™ features increase productivity, such as OneTouch™ ToolOffset and OneTouch™ Power-Up sequences.

Multi-Function Jog Handle with Remote Control Features

Most machines use the jog handle to move the axes around.On Haas machines the jog handle can also be used in other modesto cursor through the program for faster editing, or scan through off-sets, parameters, etc. When running a program in single block, thehandle can be used to step through a program. Mold makers willfind this an exceptional feature, since you can step through 100blocks of code with one rotation of the handle. A new feature for theJog Handle allows it to override spindle and feedrate commands.Speeds and feeds can be variedin 1% increments from 0to 999% for the utmostin control.

Remote JogHandle option – Speedsetups and get a closer look at your work, while movingthrough all three axes with our Remote Jog Handle.

1918

Chip Auger

Tried, true and machine-shop proven. Eliminatechip handling chores by utilizing a compact, built-inautomatic chip auger. Chips are compressed andwrung of coolant, and discharged at a 24” height.Or, you can employ Haas’ traditional chip conveyorto discharge chips into a standard 55 gallon drum.

New Features

50-Taper Spindle Option for VMC’s

The new Haas 50-taper spindle is built withthe same rigid, dependable technology utilizedin the shop-proven 40-taper spindle. Take heaviercuts with larger diameter, longer length tools. Theall-new Haas 50-taper spindle is driven by a30-hp motor that produces 450 ft. lbs. of torque,and winds up to 5000 rpm. The spindle, whichis driven through a 2-speed, liquid-cooled,geared head, is mounted in a super-rigid head-stock that provides 38” of z-axis clearance, andmoves on super-precise 40mm ballscrews.

Lathe Gearbox

The shop-proven Haas HL-3 andHL-4 CNC lathes are now availablewith a performance-enhancing 2-speed gearbox. The smooth andpowerful transmission provides extrapower and smooth finishes for low-speed, high-torque cutting operations.

The gearbox option supplies750 ft. lbs. of spindle torque at a low400 rpm – this is for serious metalremoval. The Haas Lathe gearboxoption is designed for applicationsthat require the removal of more material, at higher rates, from larger-than-usual parts.

NEW PRODUCTSNEW PRODUCTS

Industry News

2120

By March, 1997, Haas Automation will be fully operational in theirnew manufacturing facility in Oxnard, California. The new 415,000 sq. ft.facility is located on an 86-acre industrial site south of the 101 Freeway, anda few miles from the Pacific Ocean.

This new facility will house one of the largest, most modern machine-toolmanufacturing facilities in the U.S. Utilizing flexible manufacturing systems(FMS) for “lights out” operation, it will be the most automated machiningfacility in the western United States. The completion of this new facilityenables Haas to locate all its manufacturing operations under one roof.Daily operations will be further streamlined through improved organizationand a major investment in new equipment. Haas is investing an additional$10 million in new manufacturing equipment on top of the estimated $20million price tag for the new plant.

”The major reason Haas in investing as much as we are,“ said DenisDupuis, Haas‘ general mangaer, ”is so we can continue doing what we’vealways done – increase our productivity and efficiency, while manufacturingeven better products at even lower prices.“

As for the decision to move to Oxnard, the major reasons seem to bethe overall quality of life, and the cooperation Haas has receivedfrom the city. ”We‘ve been impressed with the City’s stream-lined permit process,“ said President Gene Haas. ”It‘smade the process of moving our operations thatmuch easier.“ In addition to the 415,000 sq. ft.facility, Haas plans to build an industrial com-plex on the remaining 40 acres of land. ”Futureexpansion is already part of the plan,“ Haas said.

The new facility’s one-year construction periodwill generate approximately $9 million, andemploy more than 100 people. When the moveis complete, the expected impact to the community will be over $30 million,and more than 500 people will be employed.

Haas‘ non-stop sales increase, which began in 1989, is attributed toits quality products, innovative designs, reliability and fair prices. The com-pany increased its sales 566 percent during the period of 1989 through1994, when sales reached $89 million. In 1995 sales increased 90 per-cent to $168 million, and in 1996 sales increased again to $230 million.

Haas’ new 415,000 sq. ft. facility in Ventura County, scheduled to open in March, 1997.

Haas’ New Home Web Page puts the “C” into Convenience

As record-breaking numbers surf thepipeline of the world wide web, and corporate participation on the informationsuperhighway grows, Haas Automation catches the wave with their new web site. To find Haas on the web, point your browserto http://www.HaasCNC.com.

Featuring colorful graphics and neatlydesigned pages, the Haas web site is wellorganized and easy to view. Click on ourProduct Center for information on all CNCmachines and rotary products. Here, producticons link to short editorial descriptions ofeach product line, and to scrolling chats forspecifications. Color images of most machinesshow the depth and variety of the Haas line.

Other areas within HaasCNC.com are: aCompany Profile section detailing the Haas his-tory; a Sales department featuring an on-line

survey; a Service Center that‘s still under devel-opment; and a Dealer Network with interactivemap that lets you pinpoint any area of theworld for distributor information, and provideslinks to Haas distributor home pages. Visitorsshould also take note of our easy-to-use e-mailsection, and custom literature-request form.

Although this web site is one of the metalworking industry’s most complete andwell thought out, Haas has big plans forfuture expansion. “We feel this site is a reallygood start,“ said Peter Zierhut, HaasMarketing Manager. ”But the future will holdsome very useful expansions to the currentareas, and a lot of interactive capabilities forour visitors.“

”We foresee a day when distributorswill be able to access drawings for servicepurposes in a matter of seconds; and our

customers will be able to seek service help,on line, 24-hours a day. A graphical database will house photos of each of ourmachines, and have video clips of themachines in action. There also will be a specification chart for each machine, as wellas the cross-reference chart we currentlyemploy,“ Zierhut said. ”I figure that, fairlysoon, our distributors will be able to placeorders on-line through an interactive form.“

If you‘re into metalworking, go toHaasCNC.com and experience all the webhas to offer. While you‘re there, be sure tobookmark the site, because if I know anythingabout Haas Automation, the site is sure to bean ever-evolving area of the world wide web.

HaasCNC.com – A place to watch thefuture unfold, and get some useful informationat the same time.

Competition is fierce in car racing, and no one wantsto come in second. Race teams are forced to find newways of squeezing out performance to stay on top.

Hendrick Motorsports of Harrisburg, North Carolina,is one of the largest, most sophisticated and successful racing operations in the world. Hendrick is a leadingforce in NASCAR racing, and has been winning racessince 1984. During the ‘96 season, Hendrick driversTerry Labonte (5) and Jeff Gordon (24) finished first and second place respectively in Winston Cup points.

Hendrick needed flexible machine tools for highly specialized work, but wanted affordable, reliablemachines with lots of features. To meet these needs theyteamed up with Haas Automation for the 1996 and'97 Winston Cup racing seasons.

The Haas 5-axis HMC allows Hendrick to performcomplex jobs like finish-porting, with high speed andaccuracy, while the Haas VF-4 VMC and HL-4 CNClathe fit the bill for less complex parts.

"We are pleased to have Haas as a sponsor,” saidRandy Dorton, Director of Engine Development for

Hendrick Motorsports.“After thoroughly

researching themachine-tool

industry, wefound Haas

was the number-one choice for

the CNC equip-ment we were looking

for. We need to produce morequality, high-tolerance parts, so we can

continue winning races and capturing championships.At Hendrick Motorsports, we want to continue as aleading force in NASCAR racing. By teaming up withHaas Automation, we feel we've positioned ourselveswith the ability to manufacture super-high-quality parts –something that's necessary to build high-speed preci-sion engines and reliable race cars."

Haas Sponsors Hendrick Motorsports NASCAR Racing Effort

At Haas, we don’t think CNC technology that’s affordable, wellbuilt, precise and operator-friendlyis too much to ask for...

It’s everything.