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SPRING’98

COVERSTORY AircraftAircraft EngineeringEngineering fliesflies intointo productionproduction withwith HaasHaas

FEATURES SwiftSwift EngineeringEngineering goesgoes fasterfaster withwith sciencescience

YourYour CAD/CAMCAD/CAM questionsquestions answeredanswered

PrecisionPrecision BilletBillet crankscranks upup productivityproductivity withwith HaasHaas CNCCNC machinesmachines 1 VOLUME2 SPRING1998 2

[[In this issue of] ] [ [Product Release] ] 3 NUMBER5 In this issue Product Update 4

5 Who says size 6 7 doesn’t matter? 8 CoverStory 9

10 Aircraft Engineering Takes Flight HEN it comes to machining The VF-11’s standard 20-hp motor At the heart of the VF-11 is the 16 big parts, size really does drives a 40-taper spindle to 7,500 highly-refined and user-friendly Haas W matter. The ability to rpm through a vibration-isolated, two- CNC control. Built around the operator, 11 machine a long, wide part without speed gearbox. For high-torque cutting this control is constantly being improved 12 refixturing is a sure way to increase a 30-hp, 50-taper spindle is to ensure optimum performance. productivity and reduce cycle times. optional, and a 10,000-rpm spindle Featuring dual, high-speed 32-bit 13 ProductUpdate Designed for machining extra-long is available for high-speed work. A processors, and program execution and extra-wide parts, such as wing spars 20-pocket automatic tool changer speeds up to 1,000 blocks per second, FeatureStory 14 Size Matters ...... 1 and molds, the new Haas VF-11 Vertical comes standard on the VF-11, and a the Haas control is fully FANUC™ and Machining Center features travels of 32-pocket tool changer is optional. YASNAC™ compatible. This, along The New VF-5 ...... 32 15 Swift Engineering Uses 120" x 40" x 30" (xyz). Built of heavily- Both changers feature tool-to-tool with unique Haas OneTouch™ features, Science To Go Faster 12 Soon-To-Be Machines ...... 32 ribbed, American-made iron castings for change times of approximately such as OneTouch™ power-up and 16 structural integrity and rigidity, this 5-seconds, and are fully-enclosed to OneTouch™ tool offset, combine to IndustryNews C-frame VMC utilizes triangulated, protect tool tapers from chips and establish the Haas control as the 17 wide-stance construction to damp coolant. A load-sensing chip conveyor industry’s benchmark for productivity Expansion in ’98 ...... 2 vibration and prevent flex. For extremely removes chips from the enclosure to and ease-of-use. 18 precise positioning, linear (glass) scales reduce idle time, and automatically Haas World Tour ...... 2 are available as an option. reverses should a jam occur. 19 Trade Show Calendar ...... 2 ApplicationStories 20 RacingReport 21 Precision Billet Haas Sets Pace at Daytona ...... 3 Goes Brushless 6 22 Haas Sponsors Open-Wheel Racing ...... 3 23 Speedway Engineering ShopTalk Shifts Into High Gear 11 24 How Much CAM Do You Need? ...... 22 25 How To Select A Cutting Fluid ...... 28 26

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28 THE MASTHEAD: CNC Machining is published by Haas Automation, Inc., 2800 Sturgis Road, Oxnard, CA On the Cover 93030 • 805-278-1800, Fax 805-278-6364. Postmaster: Return invalid addresses to 29 Haas Automation, 2800 Sturgis Road, Oxnard, CA 93030-8933 postage guaranteed. When you’re pulling 6 G’s or travelling at CNC Machining is distributed free of charge by Haas Automation, Inc., and its authorized twice the speed of sound, the last thing you 30 distributors. CNC Machining accepts no advertising or reimbursement for this magazine. want to worry about is the quality of the All contents of CNC Machining are Copyright © 1998 and may not be reproduced parts holding your plane together. This without written permission from Haas Automation, Inc. CNC Machining is distributed month’s cover story tells how Aircraft 31 through a worldwide network of Haas Automation Distributors, and by individual Engineering Corp. of Paramount, CA, is subscription request. Contact Haas Automation headquarters via mail or fax to be added helping eliminate that worry on both the 32 to subscription list. Published quarterly. © Haas Automation, Inc. & CNC Machining military and commercial fronts. Magazine names. Designed and Printed in the U.S.A. www.HaasCNC.com Photo courtesy Comstock 800-225-2727 33 CNC MACHINING • SPRING 1998 WWW.HAASCNC.COM 34 1 2

34 5 [ [Industry News] ] [ ] 6 News Racing Report7 8 9 10 11 Expansion Underway in Oxnard Racing Report 12 13 T has been less than a year since the existing production lines and increase Dale Wins But Hendrick return visits by the Haas-sponsored “Having the best and most 14 grand opening of Haas’ new machine shop capabilities, as well as Motorsports Leads Pack Hendrick Motorsports team. The advanced equipment is a prerequisite in 15 Hendrick trio of Chevrolet Monte racing,” said John Anderson, PacWest’s 16 420,000-square-foot facility in house one months worth of finished ASCAR’s 50th season opened I 17 Oxnard, and already it’s time to expand. machine stock to improve shipments to Carlos carry the “HAAS CNC” sticker Vice President of Race Operations. “The February 15 with the roar of 18 directly in front of the rear wheels on addition of the Haas CNC equipment With sales hitting another record high in customers. The first of two planned new engines and a flock of 19 N either side of the cars. will be a great asset to the PacWest 1997, and ’98 shaping up to be more expansions, Haas II is scheduled for four-door Fords (Taurus) slamming doors 20 of the same, the fastest growing machine completion by mid year. design and technical team. The benefits 21 and scrubbing rubber to grab the PacWest CART: PacWest’s of being able to design and manufacture 22 tool builder in America is set for another At present, Haas is shipping more Daytona 500 crown before 185,000 Mercedes powered Reynards will growth spurt. than 500 CNC machines per month out ‘in-house’ are immeasurable.” 23 standing and screaming spectators. carry the Haas logo in ‘98 24 For the 1998 season, PacWest will Excavation has already begun for of the current facility, with a maximum The crowd favorite and eventual 25 continue with the same successful racing another 200,000-square-foot building capacity of 600 machines. The addition winner Dale Earnhardt finally broke his Haas has joined PacWest Racing 26 platform used in 1997, running a Reynard adjoining the existing facility. This new of Haas II will increase the overall capacity 20-year curse taking his first Daytona Group as a Technology Partner/ 27 chassis powered by the advanced 28 addition will enable Haas to expand its to about 800 machines per month. 500 checkered flag and earning a Sponsor in support of PacWest’s ongoing FedEx Championship Series Mercedes-Benz engine on Firestone tires. 29 hand-slapping row of congratulations 30 competition. Haas will supply PacWest from the NASCAR pit crews. An untold PacWest Wire: 31 1998 Haas World Tour Goes to Chicago with two CNC vertical mills, two 32 number of fans, machinists and Haas “Big Mo” Mauricio Gugelmin took dignitaries also rooted for the Haas- lathes, and technical support. The 33 AST year, the biggest to see most, if not all, of Haas logo will appear on the to the track with two minutes left in the 34 sponsored Hendrick Motorsports team final session of Spring Training at show on the Haas the Haas product line as they returned to defend their Reynard/Mercedes-Benz cars driven world tour was EMO hard at work cutting by Mauricio Gugelmin (#17) and Homestead, Florida, and ran a series L remarkable 1-2-3 finish at last of fast laps culminating in the best lap Hannover in Germany. This parts – including the Mark Blundell (#18) that PacWest cam- year’s running. of the session. year – though there are latest new machines. The pack accelerated to speed as paigns in the FedEx Championship, as some international venues – The Haas Automa- well as the PacWest entries in the PPG “We weren’t here to qualify,” the starter gave the green flag to Terry commented Mauricio, “But it was nice the largest show is closer to tion booth will be located Labonte in the Haas-sponsored Dayton Indy Lights Championship. home at IMTS 98 in in the Metal Cutting “Haas is thrilled with the opportu- to show we do a quick time when we Hendrick Motorsports Kellogg’s need to.” With the top runners lapping Chicago. Pavilion in the South Hall Monte Carlo (#5). nity to partner with PacWest Racing IMTS (International in space #8232. This Defending NASCAR Winston Cup Group,” said Gene Haas. Manufacturing Technology huge Pavilion will feature champion Jeff Gordon (Hendrick “The design capabilities Show) is the largest metal cutting machines, Motorsports DuPont Monte Carlo #24) of the PacWest engi- industrial exhibition in the machining centers, turn- then began his incredible run up to the neering and Americas. Scheduled for ing centers, milling, front from the rear of the pack to even- technical staff September 9–16, 1998, this biennial display will be more than $350 million boring, and drilling machines, as well as tually take over the lead on lap 59, and the show is held in the nation’s largest worth of metalworking equipment, jig boring/milling equipment and much, showing the rest of the 43-car field precision exhibition complex: the East, North and materials, accessories, controls and much more. what to expect in ’98. of Haas South buildings of McCormick Place in component parts. Attendee information is available at Gordon maintained the lead (with Chicago, Illinois. The entire show covers Of course, Haas will be at the the IMTS toll-free number 800-322-IMTS a break at lap 107 when Hendrick an area equal to 32 football fields, or show in force with enough machinery to or check the current IMTS information on teammate Labonte took over for two about 1.3 million square feet. On fill its 10,000-square-foot booth. Expect the Internet at http://www.imts.org. laps) for a total of 54 of the 200 scheduled trips around the celebrated Trade Show Calendar Florida track. Gordon’s challenge finally CNC machine tools will 10 mph faster than last year, he April 18-25 EMAQH Buenos Aires, Argentina faltered when he dropped a piston in finished the session just 0.164 seconds the final few laps, sending him back to produce a winning combination. April 21-23 Greater Cleveland Machine Tool Show Cleveland, OH behind overall fast time. “Big Mo” a sputtering 16th-position finish behind PacWest will provide the ideal April 22-27 SIMTOS ’98 Seoul, Korea ended up third overall and said, teammates Labonte in 12th, and Ricky laboratory to showcase the Haas April 27-May 1 MACH ’98 Birmingham, UK product line.” “The car and the new Mercedes Craven (running the Hendrick #50 Bud engine have a lot of potential.” May 5-9 Die & Mould China ’98 Shanghai, P.R. China PacWest is recognized by the Monte Carlo) in 14th. Blundell’s track time was cut short May 19-21 EASTEC W. Springfield, MA racing community as one of CART’s most Keep an eye on the winner’s due to some minor problems, but he May 26-29 AIEE Sydney, Australia circle at the upcoming NASCAR races competitive teams. In 1997, the team claimed four victories and three pole posi- said he ran some productive laps in Sept. 9-16 IMTS IMTS Chicago, Chicago, ILIL and you’ll probably see quite a few tions with a total of 18 “Top 10” finishes. the morning. Continued on page 30

CNC MACHINING • SPRING 1998 WWW.HAASCNC.COM PowerUser control enhancements The Haas control now employs dual, 32-bit Motorola processors thatLarge turret coupling feature 1 MB of high-speed cache memory on a 40 MHz chip. This To achieve fast indexing and superior Ongoing enhancement provides program execution speeds up to 600 blocks/secreliability, we employ an 8-inch-diameter (1000 blocks/sec optional). The dedicated Haas design provides moreface coupling on our turret to provide stability and higher throughput than today’s fastest PC-based systems, allindexing repeatability within without the worry of crashing or locking up. In addition, you can now3 arc-seconds. Since the upgrade the memory on our control to 16 MB of static RAM that retainsturret is servo-controlled, memory changes instantly and permanently. it will index to the next tool in 1 second, or the design opposite tool in 2 seconds. The smartest jog handle you’ve ever seen Advancements... The jog handle on the Haas control can be used to edit programs, override spindle speeds and feedrates, single-block-scroll through Using the same closed-loop20-hp technologyvector asspindle our brushless drive servo programs, and so much more that you’ll wonder how HaasValue motors, this Haas-designed vector drive optimizes the slip angle you ever got along without it. between the rotor and stator of the spindle motor to double low-speed Ongoing engineering and design torque and acceleration, resulting in the fastest and most powerful spindle output ever. advancements with no price increases! How can we do it? At Haas, we have two simple guidelines for engineering: Anti-flex torque-tube (1) Make the machines better, and base casting (2) Get better at making machines. Our engineers understand the economic rewards these two principles provide for our customers. Considerable effort and resources The specially designed Haas torque-tube are invested to continuously upgrade base casting yields superior rigidity and provides the most anti- our machines, while improving the flexing, vibration-damping overall manufacturing process. properties of any base design. It’s so stable, in fact, Simply put: We make the that the machine will cut investment, you get the benefits. accurately with one leveling bolt removed, and it doesn’t require any special foundation for installation. Change Everything HAAS AUTOMATION,Inc 2800 Sturgis Road Oxnard, CA 93030 800-331-6746 But Our Prices. www.HaasCNC.com 1

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Precision Billet Cranks Up 4

5 Proof in Production for 2D parts and Geopath Productivity With Haas Brushless Axis 6 “Where most job shops specialize for advanced 3D parts, such in quantities of less than 100 parts or as brake handles. Story and photos so, we make lots of up to 10,000 “The Haas control is 7 Motor Machining Centers. by preston gratiot pieces, so every second of cycle time very powerful with a lot of is critical,” said Gary Hickman, features, such as 100 tool 8 president of Precision Billet. “We know offsets and 26 work coordi- ou’re flying down a rocky ski run and the trees there’s a big difference with Haas nates, a floppy drive, text 9 brushless servo motors because we still editor and graphics. It’s are just a greenish blur framing the perilous have one machining center with brush faster and makes it easier to 10 servo motors and set the same job up get parts into production,” 11 path ahead. This is not the time to worry about on both types of machining centers to said Hickman. “For exam- make a comparison.” ple, the Haas control allows 12 Y The comparison of brushless the operator to view the your components, and the fact that there is no verses brush servo motors was made cycle times for each tool by 13 snow on the ground is of little consolation. If you with a component called an aluminum selecting the tool life display backstop (cable hanger). Typically, screen. The display shows 14 miss the next apex, you’re likely in for the biggest Precision Billet machines 1,000 back- the total cycle time, feed stops in a normal production run. Five time and number of uses. “face-plant” of your life, and insurance doesn’t 15 tool changes are required to machine By subtracting feed time 1 cover this kind of downhill dementia... This is no the backstop, including a /2" from total cycle time, we 16 1 endmill, #2 center drill, /8" drill, can determine the time spent Precision Billet designs, manufactures and markets a proprietary line time for cheap bicycle parts! of mountain bike components. keyway saw and a 45° endmill. cutting air. We use these 17 “We set both machines up to run figures to reduce excess Precision Billet is a high-end job high-tech components for the highly includes operator-serviceable front the backstop,” said Hickman. “The moves and are able to cut 18 shop and manufacturer of the competitive mountain bike business. and rear derailleurs, handle bar Haas machining center with brushless cycle times by as much as ProShift’s derailleur systems are completely user serviceable with replacement parts available. Very important features for rough & tumble mountain bike enthusiasts. specialized, high-performance The company designs, manufactures shifters, brake levers, brakes, hubs servo motors finished 1,000 parts in 30-percent. Plus, tool life 19 cycling components that you can and markets a proprietary line of and adapter clamps. In addition, as 16 hours. The machining center with calculations can easily be depend on in this fast-paced world of mountain bike and bicycle motocross a job shop, Precision Billet also DC servo motors required 20 hours. made by estimating the number of time it took our previous machines to 20 gonzo biking. (BMX) components under the brand makes parts, including pulleys, frame The high-speed rapids and cutting uses for each tool and inputting an load two tool offsets.” Precision Billet, true to the sport, names ProShift and Atomic Industries. and suspension components, for other feed rates of the brushless servo alarm number for each tool.” 21 Latest in Lathes recently shifted gears, took a calculated The machined-billet product line bicycle manufacturers. motors proved their worth by saving With the Haas control, work chance and replaced several of its older one-half day of production time.” offsets can be set in the CNC part Precision Billet previously owned 22 machining centers with three new Haas program and the offsets can be a 1983 vintage CNC lathe. When Group Ganging Automation VF-0 brushless servo motor verified on the control. To do this, the repeatability problems became 23 machining centers. This single production Because many of the parts operator runs the program from the apparent, a Haas HL-2 CNC lathe change sent productivity rates climbing machined by Precision Billet are small control’s graphics page. If a wrong was purchased. Continued productivity 24 by more than 25-percent. extrusions or other odd shapes, Chick number has been keyed in or a and growth in the marketplace ➞ Bolstered by this success, the vices are employed to increase decimal put in the wrong place it will 25 shop soon replaced another aging throughput by grouping multiple parts be immediately visible. 26 piece of equipment with a new Haas in a single cut program. According to “By verifying part programs on HL-2 CNC lathe. Payback was Hickman, the multiple-piece vices do the control before proving them on 27 reached in just nine months, again a much better holding job while the machine, we avoid scrap parts with an impressive gain in production reducing manual operator time in and tool breakage,” said Hickman. 28 efficiency. And so, as the company running large part orders. “And the Haas control is fast. We continues to grow, so grows the can load ten tool offsets in the same Controls and Cycle Time 29 number of Haas machines on the shop floor. . . Precision Billet has just Another feature of the Haas 30 added an additional HL-1 lathe to its machining centers that Hickman Gary Hickman at the control of the Haas lathe. mechanical workforce. appreciates is the control. Precision Precision Billet has reduced programming time 31 Precision Billet, situated in Santee, Billet utilizes several CAM programs for substantially with several control features unique to the Three of Precision Billet’s Haas VF-0s with brushless motors. Haas lathe, such as G81, G83 and G84 canned drilling California, fabricates a wide array of offline programming, such as EZ Mill cycles identical to those found on mill controls. 32

33 CNC MACHINING • SPRING 1998 WWW.HAASCNC.COM

34 soon had Hickman on the phone ordering another HL-1 lathe. “We found that lathe controls had not progressed as much as machining center controls,” said Hickman. “But the Haas lathe was surprisingly easy to operate. Setting tool offsets is easy and turret indexing is quick and precise. We saw a Computer-designed and machined out of 6061 T-6 aluminum, the Protwist Shifters replace factory plastic. demonstration of the lathe cutting steel and were convinced to buy it. “Mostly, we turn brass or ease of tool offsetting and Haas’ aluminum,” said Hickman. “With the unique turret tool holders. We have Haas lathe, we can hold 0.0002", tool holders set up for specific jobs. You’re unique. That’s why we ask YOU to design your financing plan for the even when we start it stone cold in All we have to do is install a new the morning. We can put in a fresh holder in the turret. Repeatability is HAAS equipment you need. Here are some structures our bar and the diameter will be within a high enough that offsets can be preset customers have helped us design. tolerance of plus or minus 0.0002".” for that specific job,” said Hickman. Precision Billet has reduced lathe programming time substantially with Tell us how to design a financing package to fit YOUR needs. several control features unique to the Production+Payback = Success Haas lathe. For example, G81, G83 “During the past 12 months we and G84 canned drilling cycles are have quadrupled our growth rate. We Conventional financing from 24 months Leases with fair market value purchase options identical to those found on mill controls. can make 500 rear derailleurs a week, • • And the Haas lathe control can be instead of 500 a month. Payback on No advance payments; the first payment is Leases with 1 or 2 regularly skipped monthly programmed in either FANUC™ or the VF-0s has been less than a year,” • • YASNAC™ mode, the latter most said Hickman. “Plus, we have more deferred for 30-90 days and a $1 buyout payments each year commonly used at Precision Billet. time to design, prototype and make Cycle times have decreased new products. Haas’ speed, accuracy Leases from 24 months, with 2 advance Leases for up to 60 months with really low even more because the new HL-1 has • • and ease of setup have allowed us to payments and a $1 buyout payments for the first 6-12 months. AC drives with 710-ipm rapids. increase our throughput. And the faster “Typical lathe cycle times are 50 we make parts the faster we get paid.” percent faster because of faster rapids • Leases with 10% purchase options • A 6-month rental program for those short-term and turret indexing, as well as higher Precision Billet contracts you used to have to pass on. feeds and speeds. Setup times have 9437 Wheatlands Ct., #A also decreased by 50 percent due to Santee, CA 92071 619-448-4508

Product photos courtesy Precision Billet The Precision Billet crew can load ten tool offsets on the Haas VF-0s in the same time it took to load two tool offsets CNC ASSOCIATES, INC. in the previous machines. 2800 Sturgis Road Oxnard, California 93030 CNC MACHINING • SPRING 1998 Tel. 805-278-0303 • Fax 805-485-0803 1

2 Speedway Engineering 3 CNC lathes feeding one mill. Outside of 4 Story axles, everything we do needs a by clint crowell secondary operation in a machining 5 Photos center. We need holes, grooves, Shifts Into High Gear by gerard burkhart slots, tapping, you name it, we’ve 6 got to do it. We were always backed up. We couldn’t sell any 7 more parts, because we couldn’t he people at Speedway Engineering eat, drink and oval-track racing,” Sapper began as he make any more.” 8 explained how they discovered their Speedway Engineering breathe racing. The walls of the front lobby are niche. “As the sport of stock car racing needed a machining center. They 9 evolved, the speeds increased, so we already had a small gear-driven covered with framed pictures of cars and drivers manufactured purpose-built cars. By mill that gave them good service, 10 creating competitive cars, we created so they knew they wanted to stay with a running Speedway Engineering parts to reach the Paul Douglas, shop foreman and CNC programmer, likes the programming ease and flexibility of the Haas control. T a parts market for ourselves.” transmission-driven unit. “We liked the 11 But building cars was a time Haas VF-4 when we saw it, because it have also allowed them to reduce setups. programs. Because the Haas program- winner’s circle. People like NASCAR Winston Cup greats 12 consuming and labor intensive process. was American made, had the right com- Using a Haas 5C rotary indexer – the ming is so efficient, Landy said, they After looking at the numbers, they realized bination of power and flexibility and was first product ever manufactured by Haas initially didn’t plan on getting a Rusty Wallace, Darrel Waltrip, Robert Yates and Bill Elliott. . . 13 it took them four weeks to build a car they easy to operate. The service behind the – Speedway is able to machine all four CAD/CAM system. They ended up could sell for $8,000, but only half a day machine was also a big consideration.” sides of the large center castings for their needing one, however, to program their Speedway parts were on the Winston Cup car that won the 14 to build a quick-change rear end they Since bringing the VF-4 on-line a rear end assemblies in one operation. other CNC machines. Brickyard 400 last year. . . Richard “The King” Petty won his could sell for $1,500. They stopped year and ten months ago, Speedway’s Before getting the Haas, Speedway Sapper sent Douglas and Landy for 15 building cars and focused on parts. production has jumped tremendously. was only able to run four drive plates operator training at the local Haas last national championship with a Speedway Engineering Today, Speedway manufactures They were able to increase sales more at a time on their smaller mill. But with distributor, and three days later, they 16 quick-change rear ends based on than 30% last year – without adding a the VF-4, they’re able to run 20 pieces could run the machine. “We sent them chassis... Bobby Labonte took the pole at this year’s custom-made aluminum castings; full- single person. To meet increased at once – a production increase of before the VF-4 was delivered to the 17 Daytona 500 with Speedway parts... the list goes on. floating rear ends based on 9" Ford demand since then, however, Speedway 500%. They set it up on the machine floor,” said Sapper, “so they were SVO housings; anti-sway bars; front has added a machinist and staggered and three and a half hours later all the familiar with it and could jump in and 18 hubs; drive flanges; axles and other shifts to keep the VMC running 13 hours plates are done. run it when it arrived. As soon as power Speedway Engineering is the life’s Ken Sapper, who had been with miscellaneous parts for teams racing in the a day. Machinist Joe Landy said, “The was run to the machine, the Haas 19 dream of one skilled welder and machin- Deiny almost since the beginning, Winston Cup, Busch Grand Nationals, “I’m not a Haas salesman; I’m a ‘Next Tool’ button and other little touches service guys were out here leveling it ist named Frank Deiny; a man who had became president of the 11 person, Craftsman Truck, NASCAR touring division user,” commented Sapper, “so I don’t make setup a breeze. With our other mill and setting it up. Everything was very 20 a passion for auto racing and the Sylmar, California company when Deiny and the Winston late model series. know all the jargon. I can tell you it flies you have to do 12 things to change a well coordinated.” courage to follow his vision. The family- through aluminum and is a good, rigid tool. With the Haas it’s just one button.” Up until July of ’97, Speedway 21 owned small business has been making machine. Our scrap rate is phenome- Shop foreman and CNC Engineering produced their entire prod- premium quality driveline components for nally low. We are cutting 8620 forged programmer Paul Douglas added, “The uct line without the use of a CAD/CAM 22 auto racing since 1964. Throughout the steel and 4140 heat-treated forgings; the Haas will run a four-hour job without us system: Everything was programmed on years, growing demand for Speedway machine doesn’t make the floor jump, so even looking at it, allowing us time to the Haas control and the files were 23 parts has steadily increased revenues. it must be doing okay. And we are work with the other machines. stored on floppy disks. To speed With the recent addition of a Haas VF-4 holding tolerances of ±0.002", because “I also like the fact that the control is program changes and development of 24 vertical machining center to their shop if everything doesn’t run true on our built around the machinist,” Douglas new products, however, the Haas is now arsenal, they have broken the million assemblies, at 200 mph it’s going to continued. “The 32-bit processors and hard-wired to a PC equipped with a 25 dollar mark in yearly revenues. shake the driver’s teeth out.” memory capacity give us the ability to CAD/CAM system. 26 Like thousands of small manufacturing Setups at Speedway vary greatly. program the control to help out and Today, Speedway Engineering has shops around the world, Speedway is Some jobs run a few hours, while other create shortcuts. The programming ease shifted into high gear to meet the 27 testament that loyalty, persistence and the times they run the same job all week. and flexibility of the control, as far as increasing demand for their products. pursuit of excellence – along with sound And when the machine is open, they use manual input is concerned, are very The Haas VF-4 is enabling them to reach 28 business decisions – bring success. it to do “one-off” jobs. The size of the helpful and user friendly.” a new level of productivity to enter new It began with Deiny working the night VF-4’s table (52" x 18") allows them to At Speedway, jobs are program- markets and expand their product line. 29 shift at his full-time job, so he could work set up as many as three separate jobs on med right at the control panel using They are now racing toward their next on race cars during the day. He eventu- photo courtesy Interstate Batteries the table with tools hung. This lets them Haas’ QuikCode, which combines the million dollar benchmark. . . and their Speedway Engineering parts helped Bobby Labonte take the pole at this year’s Daytona 500. 30 ally earned enough money as a welder skip around and stay ahead with produc- power and flexibility of G-code with next Haas machining center. building roll cages to buy a lathe, then a tragically passed away from cancer in “Our products became so popular tion. The repeatability of the Haas has descriptive English sentences. Both Landy, 31 grinder. In 1967 he opened his shop the late 80s. “We began building parts over the years, we couldn’t keep up with been a great asset in these cases. The who is relatively new to machining, and Speedway Engineering Sylmar, CA 818-362-5865 and never looked back. for modified cars like the ’57 Chevy for demand,” said Sapper. “We had two large table size and long z-axis travel the more experienced Douglas write the e-mail: [email protected] 32

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This process is only one of the 5 many test procedures a race car is goesgoes thethe subjected to before a full-size model 6 is assembled on the Swift production floor. 7 Swift Recognized as a world-class Swift designer and builder of highly 8 successful race cars, Swift is currently constructing entries for two of the most 9 hotly contested international auto racing series: the CART FedEx 10 Championship and KOOL/Formula 11 Atlantic. Designs are tested for aerodynamic efficiency in a state-of- 12 the-art wind tunnel of Swift’s own By using a precise scale model sized at 45-percent of the full-size car, Swift uses its wind tunnel to check the aerodynamic design. One of only four of its type in forces generated by different body panel modifications. the world, this tunnel is just one of the account for changes in downforce in thin enough to replicate the part to 13 tools Swift uses to maintain the edge the nature of 20-pound increments.” scale, yet still support the forces 14 necessary to outpace the competition Swift’s wind tunnel evaluation exerted on the part. in the ever changing arena of models are usually 45-percent versions “Our experience is that if we 15 international auto racing. of the 100-percent file, explains Cross. make the tooling right, we will be able Staying on the cutting edge “So when we test in the tunnel, we are to make the parts right,” Cross contin- 16 requires the harmonious blend of tech- testing an exact replica of the car. This ues, “parts that will fit and perform as CheckeredCheckered nologies to produce a winning piece of is because the source information used designed. So we spend a lot of time 17 machinery. Swift achieves the absolute to make the scale molds and body- making sure we get the tooling right. accuracy and repeatability necessary work for the wind tunnel model came We are committed to the process and 18 through the use of computerized off the same computer file as the depend on the reliability this CNC- modeling methods and the precision full-scale model.” produced repeatability gives us.” 19 machining capabilities of CNC For instance, the engineering file On Track Performance FlagFlag machines from Haas Automation, Inc. on bodywork in the computer provides 20 the surface contour information Indeed, Swift’s meticulous 21

Photo by Michael C. Brown to the CNC milling machines, computer-assisted control of composite “which is best described,” says body panel development and chassis Cross, “as almost literally the design was proven by the company’s 22 Story and photos by preston gratiot paint surface.” out-of-the-box win at its first race with the This same file is used to Newman/Haas Racing Swift 007.i at 23 create a tool on the CNC the 1997 PPG CART World Series machine to make the mold used opener in Miami, Florida. With little 24 ownsizing is one of the big catchwords in industry to lay up the composite parts for more than a year having passed since the full-size or scale model for the designer sketched the first, rough 25 testing. Same file, but a different rendering, this virgin victory illustrates the today, but Swift Engineering Inc. is taking this science 26 Body components use latest carbon fiber technology. scale, just by reducing the speci- value of design-to-production control. fied end size of the parts. Team drivers Michael Andretti and to a new level by designing full-size cars and then 27 d Alex Cross, Executive Vice While most of the body parts Christian Fittipaldi have high hopes for President of Swift Engineering Inc., puts used in both the scale and full-size the California-built racer. And while using a computer program to shrink them down to 45-percent 28 it this way, “Our use of modeling in models are carbon composite parts developmental problems are expected, conjunction with the Haas VF-8 machin- laid up and cured in the autoclave the latest version of the car, the Swift 29 of their original size. These cars are then suspended above an ing center and HL-2 CNC lathe allows (a pressurized oven used to cure the 009.c, is living up to team hopes and us design-to-production accountability. It parts), some parts, such as the wings dreams. Changes in the new car 30 oversized belt-sander and blasted with winds of up to provides the capability to redesign the and canards for the scale model, have include significant advancements in various body panels of the cars on the to be machined out of solid aluminum both the aerodynamics and suspen- 31 140 mph... all in the name of science and technology. computer and accurately machine them billet on the Haas VF-8, because the sion, along with a redesigned – a major plus when we have to carbon composites cannot be made six-speed gearbox. ➠ 32

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Andretti noted that while racing drive formula (open wheeled) race start building a company capable of car feels, the aerodynamic test results 5 with his previous manufacturer, the cars quite well, their real expertise lay producing machines to compete in the will be inaccurate. team was provided with only one behind the scenes, with Brun as the rarefied world of big-time racing. To remove this unwanted layer of 6 aerodynamic development piece designer and Cross as the organizer So Swift shut down production dirty air, a moving ground plane is during the entire racing year. Thanks and front man. Swift Engineering was and relocated to a new 60,000- approximated by employing an over- 7 to Swift’s on-site wind tunnel and their formed with winning in mind. square-foot facility in the hills sized belt not unlike those found on a “design-to-production” capabilities, As with most new companies, overlooking San Clemente, California. belt sander. Only this belt is 94-inches 8 the team will be testing and incorpo- Swift was short on funds but It was here that Swift began construc- wide and 38-feet long! In addition, a rating new designs throughout the brimming with enthusiasm. If they tion of a new state-of-the-art wind vacuum is used at the leading edge of 9 season. “This program is not going to were going to sell cars, they first had tunnel facility, a facility that, when used this belt to suck away the existing sit still,” he said. We’re going to be to prove that their cars could win in conjunction with the programmable boundary-layer that has formed as the 10 putting new pieces on the car all the races. So with a new Swift DB1 accuracy of Haas CNC machines, air is blown through the tunnel itself. 11 time.” /Formula Ford in tow, the crew drove would revolutionize race car design. Another vacuum system is As it is, the Swift 007.i – in this to the Formula Ford Championships in incorporated to hold the belt flat to the A Light in the Tunnel 12 case, the name Swift has nothing to Atlanta. base as it rolls under the test car. This do with birds, speed or newt-like “We had one shot,” says Cross. To be a leading contender in the is necessary because the cars generate 13 creatures but was chosen by Cross “Our car either performed well in that international automotive engineering so much negative pressure underneath because of the historical race car, race or we hitchhiked home, broke game, Swift was going to need the car that they literally suck the 14 “The Swift” – was the first American- and defeated.” The car, driven by frequent access to a world-class wind “ground” up towards them. Cross made Indy Car chassis to win a race another new partner in the fledgling tunnel, preferably a high-tech wind explains that this massive aerodynamic since the season opener in 1983, business, R.K. Smith, took the tunnel designed to evaluate downforce is so powerful that if a Swift 15 when Gordon Johncock drove the checkered flag, and the rest, as they automotive aerodynamics. However, 009.c running at 230 mph could run 16 Wildcat to victory. say, is history. access to most of these wind tunnels on an inverted, upside-down track, it The win meant competitors Swift machines and taps uprights for their CART chassis using Haas HRT-210 rotary table on a VF-8. (located in Europe) is monopolized by would defy gravity and continue Win on Sunday, Sell on Monday? 17 began placing orders for dupes of Big Bucks and Luck the Formula One teams, and time running as if rightside-up due to the Swift is looking to the 19-race their winning entry. As Cross says, and eventually served to provide the would only be available on a massive aerodynamic downforces gen- 18 ’98 FedEx CART series (formerly the nobody wants to drive a loser, “The Indy Car program, aside financial resources and contacts in the sporadic basis. erated by the body and wing designs! PPG CART series) to further establish especially on the race track. “We from being one of the premier racing world marketplace that would make This prompted Swift to consider Contracted time in the Swift 19 its reputation as a builder of winning had orders, with deposits, before the venues in the world, is part of our plan Swift an international entity. building their own tunnel in the States – tunnel is a costly and secret affair, but race cars. This reputation stretches engine had a chance to cool down,” to establish our company as a leader His family name well known a costly venture, but one that would the results are worth the expense. The 20 back to 1983 when Cross, Paul remembers Cross with a smile. in technological development and throughout the world, young Hiro promise easy access and, as an cost of this advanced facility – in the White and Dave Brun, a flight test Of course the new Swift 009.c engineering,” says Cross. “If you can Matsushita wanted to be a profes- added bonus, income from stateside vicinity of $6 million – is currently 21 isn’t expected to build a winning race car in one of the sional race driver. He advanced tunnel time rentals. being repaid through extensive use sell in the hundreds most competitive racing series in the quickly, and in 1991, he became the This advanced technology by numerous Formula One and 22 (Swift is scheduled world, you are obviously capable of first Japanese driver to qualify for the demands a moving ground-plane to NASCAR teams and the Big Three to build six 009.c doing a lot of other things.” Indianapolis 500. It was also the accurately plot the downforce and automakers, all of which are lined up 23 chassis this year), This plan includes eventually same year Matsushita International, aerodynamic forces of a vehicle driving to use the advanced facility. Cross but it does carry a working with the major auto makers including Hiro’s real estate business, through seemingly motionless air. says they could have built a more 24 $425,000+ list and other manufacturers of technolog- bought Swift Engineering. Not an easy task if the only way economical tunnel, but then they price...not counting ical devices all over the world. This now set the executive lineup you can approximate the effects of a probably wouldn’t have as many 25 spares. This means However the road to this goal at Swift to include: Hiro Matsushita, vehicle at speed is to accelerate the air teams waiting in line to book time on it. 26 that while Swift demands dedication, quality and a President and Chairman of Swift around it. If the “ground” under the car Operated as a separate division Engineering will lot of luck. Engineering; David Bruns, Technical in the wind tunnel isn’t moving at the under the Swift Engineering banner by 27 probably make The young company survived the Director and Vice President of same speed as the surrounding air, the noted aeronautical engineer Doug some money manu- early years on the racing successes of Engineering; Jim Chapman, Vice Presi- ground will form what is known as a Smyth, the Swift Aero building is as 28 facturing additional the Formula Ford cars. Then in 1987, dent of Manufacturing and Alex Cross, “boundary-layer” of slower air on any secure as a top secret government customer cars, Swift produced its first Formula Atlantic Executive Vice President, Operations. surface that is moving past it. (Note: operation. “Customers demand this, as 29 the “Selling on car, the Swift DB4. It was also in 1987 From this point on, the Swift This is why you can never drive fast advanced technology is the racer’s Swift’s latest Formula Atlantic racer, the 008.a. Monday” will be that a young Japanese driver entered Engineering team started moving enough to “blow” the dust off your car.) edge, and this science of aerody- 30 centered on selling the scene determined to make a name towards its long-range goals in earnest. This ground-to-air interaction also namic weaponry is as closely engineer from McDonald Douglas the company name as a respected in America’s Formula Ford series. But in order to make the jump to the includes the ground under the car, guarded as any advanced defense 31 decided to enter the world of race engineering/design force of the likes of This young driver soon hooked up big leagues, Swift had to stop building and since this doesn’t reflect the real- project,” said Cross. car construction. While they could Porsche Design or Lotus Engineering. with Alex Cross as his driving mentor the so-called amateur race cars and world parameters a speeding race Continued on page 31 32

33 CNC MACHINING • SPRING 1998 WWW.HAASCNC.COM 34 [Feature] “Get“Get MeMe aa Contract and I’ll Buy a Machine to Do It!” Photo USAF John K. McDowell

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ack before the onslaught of big time AEC was one of the shops to If AEC wanted to increase their percentage of For added flexibility, most of AEC’s Haas 5 successfully survive the ensuing lean production machining, it was obvious they machines are equipped with high-torque mergers, buyouts and corporate down- years, and thus was able to capitalize would need to invest in more – and faster – 10,000-rpm spindles, expanded memory, 6 on the next aerospace boom: equipment. probe-ready packages, 1,000 block/second commercial aircraft. An improving According to Kenney, “Speed doesn’t processors, and 4th- and 5th-axis controls. 7 sizing, the cart often came before the economy, combined with aging buy you much in tooling, because you’re “We have them all set up so we can do any- B planes reaching the end of their talking one part. By the time you get the bugs thing with them,” Kenney said. “We learned a 8 operational life saw airlines once worked out so you can run it up to high rpm, long time ago that it’s cheaper to buy features horse with regard to procuring aerospace con- again investing in new fleets. you’re done.” But production parts are usually now, than try to retrofit them later.” 9 Unfortunately, most of the machined in large batches, so high speed and Kenney reflected that, “With some of the commercial aircraft being built were reduced cycle times are required to keep the other manufacturers, you can’t get delivery on 10 tracts. Shops would bid jobs for the major based on existing designs, so there price per part competitive. “We knew we big, heavy machines for 14-16 months. We 11 was little call for new tooling. couldn’t run the parts fast enough on our old couldn’t wait. You have to machine parts There was, however, a demand for machines,” Kenney said, “they just wouldn’t cut when the orders are there, or you lose out. manufacturers without necessarily having the 12 production airframe parts and new it. It was obvious we had to do something.” We knew how long it would take us to run the tooling. With the number of suppliers AEC looked at a lot of different manu- parts on our existing equipment, and we 13 machinery on hand to make the parts. Only seriously reduced by the previous facturers before deciding to invest in Haas knew we had to do it faster if we wanted to slump, there were now more con- CNC machines. Price, availability, high be in a competitive position in the market- 14 tracts than suppliers to fill them. speed and service after eliminating the competition and securing AEC decided to take advantage were some of 15 of this tremendous potential by diver- the key factors sifying their operation and in their decision. 16 the job would they purchase the equipment manufacturing production airframe “We knew we parts to supplement their tooling. were going to add 17 necessary to fulfill the contract. According to Kenney, this idea had some machines,” been kicked around for years, Kenney explained, 18 although AEC initially tried to stay out “and I didn’t want In today’s world, things are different. As capacity and capability to do the work. No of production work. “A lot of to be dependent on Hal Purdy sets up a Haas VF-6 to machine emergency escape hatch brackets. 19 more shops enter the fray for a slice of the longer are they willing to wait months – or The large table of the machine allows Aircraft Engineering to machine nine customers don’t like to mix their tool- Japan or the East aerospace pie, manufacturers like Boeing, even years – for their parts. pieces at a time for high productivity. ing with their production parts,” he Coast for parts and 20 McDonnell Douglas and Martin Marietta are This fact has become the driving force explained. “If you do tooling, that’s service. I don’t looking for suppliers that already have the behind Aircraft Engineering Corporation the contract. So, either you’re staffed and ready all they’re going to give you; if you do pro- want to go to 21 (AEC) of Paramount, California. to run, or you’re not going to get the work.” duction, that’s all they’re going to give you. Mecca, I want Over the past year and a half they AEC has been a major supplier to the They’re typically not going to give you both.” Mecca to come to 22 have added nine vertical machining aerospace industry since 1959. For most of But in today’s economic climate, it can me. Haas made centers from Haas Automation, Inc., those 39 years, they’ve been known primarily be tough to find good suppliers, so corporate that a lot easier.” 23 to their equipment list, including three as a tooling house: building aircraft assembly buyers tend to stick with vendors they already A heavy influx VR-11 five-axis profiling VMCs. tools, fixtures and ground support systems know. AEC’s years of experience and of orders for 24 Additional Haas machines are for the major manufacturers. But tooling is reputation in the industry allowed them to production parts scheduled for arrival early in 1998. typically a one-shot deal – once the tools are break through the tooling/production barrier soon necessitated 25 They are determined to have the made, the job is done. Additional tooling is and utilize their existing customer base for that AEC quickly 26 machines on the floor to handle any usually unnecessary until a new both types of work. “We’ve been around a add equipment to job that comes their way. aircraft design is ready for implementation. long time,” Kenney said. “They know who we their machine 27 “The mentality used to be: Get me For years defense contracts provided a are and what we’re capable of, so they want arsenal. They pur- a contract and I’ll buy a machine to do steady flow of work for AEC and a myriad of us to do the work.” chased their first 28 it,” explains Cliff Kenney, AEC’s other aerospace shops. There was enough Up to that point, only about five percent Haas machine – a Frank Escobar checks a completed emergency escape hatch upper sill that was machined on one of Aircraft Engineering’s three Haas VR-11s. procurement manager. “Now, if you work for everyone as defense spending of AEC’s work had been production. “We VF-6 with 64" x 32" 29 don’t have the machines on the floor ballooned to record highs. But it couldn’t last were running some production parts, but very x 30" travels – in June of 1996, and have place. The Haas machines have put us in ready to rock and roll, you don’t get forever. Fed up with the American government’s limited,” notes Bob Jeppesen, AEC’s market- since added a VF-1, a VF-3 with Haas the right place.” 30 spending us all into recession in the name of ing manager. “Our big concern was that, if Automatic Pallet Changer, a VF-7, a VF-8, a But being in the right place means more national defense, the public called for cutbacks. we were going to get into the production VF-10 and three (3) VR-11 five-axis profiling than just having machines on the floor. The travels of the Haas VF-10 allow Aircraft Engi- 31 neering to machine long parts like these Many shops closed their doors forever as the atmosphere and get real serious about it, we VMC’s. Five more machines are scheduled for It means having the right machines, and 82-inch-long stringer splices with ease. Steve ➠ Larabee monitors the process in the background. flow of defense work slowed to a trickle. had to get into high speed [machining].” delivery in 1998. having them up and running. “When we 32

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level of work – i.e. very critical, critical, etc. 5 – Boeing will release to a certain supplier. AEC’s SPC Administrator Werner Van 6 Raay: “What’s most important here isn’t the laser cal, or the ball bar or any of the 7 other tests, it’s the plate. Because that plate is going to establish where you are on 8 Boeing’s scale, as far as accuracy and capability. The test plate is the thing that 9 says, ‘This is what you’re qualified to do.’ The tighter the tolerance on the plate, the 10 higher you get on Boeing’s list. I want to 11 put as many machines as I can out there, so that when they look at our list they say, 12 ‘Okay, this is their capability, and man, look at all the machines they’ve got.’” At 13 present, AEC has qualified four of their nine Haas machines for ATA; two more 14 should be qualified by next month. “We want to really know what the 15 capabilities of the machines are, so that Haas VMCs have provided Aircraft Engineering the high productivity necessary in today’s competitive in the marketplace. we can reduce inspection, make parts a 16 little faster and know that the parts are showing a pattern that was out of square. This type of accuracy, as well as high right,” Van Raay remarked. “As far as the We called Haas, and they checked the speed, are the necessary ingredients for 17 Haas machines go, they’re extremely machine and proved it was in square. We successful production manufacturing in the accurate. We even had one Haas that kept checking and it turned out to be the aerospace industry. AEC has been able to 18 pointed out problems with our CMM. We CMM – it had settled on the foundation slash their cycle times and meet the high had a test plate off the VF-6 that kept and was out of square.” production rates and quality levels 19

Aircraft Engineering currently has nine Haas machining centers on their shop floor, with several more machines scheduled for delivery in 1998. required by their customers. By adding Haas CNC machines to 20 have a Haas roll in the door, we figure it’s larger travels and certifying their accuracy. “One of the things we’re working on,” their stable of equipment, Aircraft going to be online in a week,” Kenney “Any mom and pop shop can buy a Kenney said, “is buying the parts directly Engineering Corporation has decidedly said. “If we bring a VF-10 in here on smaller machine like the VF-1 or VF-2,” off the machine. Right now, the parts go put the horse back where it belongs – in 21 Tuesday, it will be up and running Friday. Kenney explains, “but they don’t have the from machining to quality control, where front of the cart. Having the machines on 22 And, the availability of parts and the funds to buy the larger VF-6s, 7s, 8s and they’re inspected 100%. By using probe the floor ready to “rock and roll” has service staff are excellent.” 10s. So, we’re trying to keep more of our systems and in-process inspection, allowed them to successfully supplement 23 Jeppesen added, “We have machines machines in that higher end of what Haas we hope to reduce much of the inspection their fluctuating tooling work with the right now that, when we get in a bind for has to offer. A lot of other manufacturers process. We won’t eliminate it all – the part stability of production manufacturing. 24 replacement parts, we have go to Japan for don’t have the length, the X travel. Haas still has to be inspected – but we won’t “Every machine has its place,” them. Even expediting them and express has the length. We’ve got those 120" have to touch every dimension, every Kenney said, “and we believe that Haas 25 shipping everything, you still lose a week. VF-10s and VR-11s, and we can run a hole,” Kenney said. “There aren’t many has its place in a shop of our type. You 26 And if it’s an older machine, it’s going to long part that nobody else can really run people in the world who are certified to do can tell: Nine of our machines presently take you months. If you’re not making in a timely manner. We’ve run parts over that for Boeing, and we’re close.” are Haas machines, and we have more 27 deliveries, you don’t get any more orders. ten feet long in our VF-10,” Kenney Since Boeing is one of their primary on order. We’ve been really pleased with They don’t care what kind of equipment continued. “We leave the door open, run customers, AEC is in the process of the product.” 28 you have. You’re out of business.” it out the door and shift it. They’ve qualifying their Haas machines in compli- At present, about 50% of AEC’s enabled us to get more work.” ance with Boeing’s ATA standards (a set of 29 business is machining production airframe With the larger machines on the standards used to determine the level of parts, and that percentage is increasing. floor, AEC has been able to get work that accuracy and repeatability achievable by Aircraft Engineering 15500 Texaco Avenue 30 Their goal is to position themselves as a some of the smaller shops can’t do. a particular machine at a particular Paramount, CA 90723-8075 “first-call” supplier for major manufacturers But getting the work and meeting supplier). Consisting primarily of a ball bar 562-634-2401 31 such as Boeing and Lockheed/Martin. production schedules doesn’t mean a test, laser calibration of the machine and a To this end, they are buying machines with thing if the parts aren’t accurate. test plate, these standards determine the Aircraft Engineering uses their Haas VR-11s to machine 5-axis parts like this emergency escape hatch part in fewer setups. 32

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2 The CAM Question: 3 series of parallel passes in the same 4 direction, allowing all cutting to be climb or conventional instead of a 5 How Much Does Your combination of the two. 6 Story 4. Morph pocketing creates a by Benjamin Mund spiral toolpath that gradually changes 7 Shop Need? CNC Software, Inc. from an internal to external shape, keeping a constant load on the cutter. 5. Facing cleans material off of 8 uring the past ten years, few aspects • Contouring – programs the the top an area that may lie between cutter to stay at a constant Z-depth while depths, such as the top of an island. 9 of manufacturing have progressed as following a series of lines or curves. 6. Pocket re-machining identifies • Drilling – instructs the machine areas left uncut from a previous 10 rapidly as PC-based CAD/CAM to drill holes in the stock at different operation and cleans out those areas 11 locations, depths and cycles. This type with a smaller cutter. D technology. As with most innovations, of function typically includes other • Toolpath Associativity – This 12 plunge operations such as boring, maximizes the above processes by the market presses for improvements, and counterboring, tapping and reaming. linking toolpath and geometry. If either 13 • Pocketing – removes material the toolpath or geometry are changed, eager hardware and software developers from the inside of a boundary to create a new, updated toolpath can immedi- 2. The Next Step – Adding a Third 14 strive to meet the demands. But as PC- a cavity in the stock. Good 2D pocket- ately be generated. This means that a Dimension machining. This level of machining is ing avoids islands within the pocket, part only has to be programmed once, suited to parts that can be defined with 15 based CAD/CAM software grows more and does not force the cutter into an with any changes made to the model Most complicated parts with a few sculpted surfaces that are area that is too small for it. Pocketing or machining process updated with a complex curvature can be defined tangent to one another. Each surface 16 sophisticated, it becomes difficult for a can be done in several different ways. single mouse click. For example, a using surfaces. A surface is a geometric can be programmed separately and 1. Zigzag pocketing moves the programmer may want to change drill entity that mathematically defines the the toolpaths can be combined into a 17 shop to decide exactly what they require. cutter back and forth across the cavity size and hole location on a series of curvature at any given point. single NC program. with the same step-over for each pass. operations. Rather than reprogram the Surfaces are applied to 3D geometry Once projects become more com- 18 As amazing as some of this software is, entire set of operations, he like a skin, and are trimmed or filleted plex and contain surfaces that are not simply selects a new tool, together to fully define the curvature tangent, machining with single-surface 19 how much CAD/CAM capability does a moves the geometry and of the part. functions becomes somewhat difficult. clicks a button. The result Surfaced geometry requires tool- 20 shop really need? 3. Multi-Surface Machining is a new, accurate paths that are flexible enough to follow toolpath reflecting those sculpted shapes. One method of Multi-surface roughing and finish- 21 To start with, the prospective the purposes of this article, we have changes. achieving this is through single-surface ing are suited for applications such as ➠ buyer must determine the needs and broken these functions into four general Many shops find 22 1 desires of the company or department levels of complexity. The following is a these 2 and 2 /2 – axis that he or she is working for. Get out quick rundown of these levels and how CAM capabilities are well 23 into the shop! Take a look at your NC they relate to different types of work. suited for a large number and CNC equipment. List the types of of their applications. More 24 1. The Basics machines you are using, their abilities complex work can be and the current work being produced A talented programmer can stand done with these functions, 25 on them. at a control and program a part with but with increasing 26 It’s also important to consider what basic shapes and angles. However, difficulty. In addition, type of work you plan to do in the this becomes much more difficult and shops often come across 27 future. Many shops prefer a system that time-consuming for a part containing parts that are not lets them purchase the capabilities they complex curves, odd angles or shapes extremely complex, but are 28 need now, and also offers additional requiring multiple passes. difficult or impossible to 1 functions they can add as their needs Simple 2D or 3D shapes can be program using 2 /2 – axis 29 change. This lets them build on their machined in planar fashion with most functions. An example is a initial software investment and avoids CAD/CAM packages. Shops that do spherical-bottom pocket. 30 1 the need to learn a new system later. primarily 2 or 2 /2 – axis work need a 2. Spiral pocketing starts at the Since the bottom of the pocket does Despite the complexity of many few basic machining functions and inside or outside of a pocket and spirals not lie exclusively in the X-Y plane, 31 systems on the market, a shop may probably not much else: out or in until the stock is removed. toolpath functions with greater control only need specific CAM functions. For 3. One-way pocketing creates a over the Z axis are needed. 32

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After a finish pass is run, there is ment, and requires a machine with one toolpath on-screen on a piece of information, complete data compatibility 4 often material left in small or hard-to- or more rotary tables and/or a tilting “virtual stock.” The result is a solid is maintained at all times. In addition, reach areas. A good CAD/CAM machine head. Good CAM software model of the finished part that can be this type of CAD/CAM system shares a 5 system provides automatic options to automates 4- and 5-axis requirements inspected from all angles to ensure common interface, avoiding the remove that extra material. such as calculation of leads/lags and the toolpath produces the desired problem of training programmers on 6 • Multi-Surface Leftover surface normal vectors. results. This helps eliminate dry runs two separate systems. Machining – This function identifies • High-Speed Machining – and test cutting. 7 Know Your Needs – For Today As areas that are left uncut by a previous Machines that support high-speed • Data Translators – If a shop Well As Tomorrow multi-surface operation and programs a cutting need CAM that delivers features plans to receive files from other CAD 8 smaller tool to clean out those areas. such as tangential entry/exit arcs, systems, good translators are vital. If a When selecting the level of CAM • Pencil Tracing – Pencil tracing smooth tool direction changes and shop can accurately accept a wide capability you need, keep in mind your 9 walks a small cutter along surface plunge roughing. variety of data formats such as IGES machines’ capabilities, the type of intersections to achieve the best work you produce now, and the type 10 possible finish in hard-to-reach areas. of work you plan to produce in the 11 • Shallow / Steep Machining – future. Many shops prefer a system This function identifies and machines that lets them add capabilities as 12 steep and shallow areas that have their needs change. This allows them scallops left from a previous cut. to purchase only what they require 13 These 3-axis functions provide and lets them plan for the future by most of what a complex mold, providing an upgrade path to more 14 complex prototyping or mold making. movements, resulting in a more prototype or production shop needs. complex functions. These functions allow a single toolpath efficient toolpath. There are, however, additional Choosing a system that grows 15 to be generated across multiple sur- • Radial machining – This type of machining options available. with your business also helps reduce faces of any type. All selected surfaces toolpath radiates out from a center your learning curve. If your 4. Machines That Do More 16 are considered when calculating the point like spokes on a wheel. It is ideal CAD/CAM package provides a toolpath, thus delivering a consistent for spherical parts. Some operations not only require growth path, you won’t have to learn 17 finish and avoiding gouging. • Containment boundaries – software that is capable of generating new software when you want to A good CAD/CAM system offers Definable containment boundaries the toolpaths, but machine tools that expand your capabilities. 18 several options for roughing and finish- allow the programmer to define a provide the appropriate capabilities. Many CAM developers provide ing a multi-surface part. This allows the specific area to be cut, even if it • 4-axis machining – This adds a a family of software for milling, 19 NC programmer to choose the most contains only parts of surrounding fourth dimension of simultaneous move- turning, wire EDM and other types of efficient machining strategy for a surfaces. This is useful when a ment, and requires a machine with a machining. If you decide to expand 20 specific project. specific area of a multi-surface part rotary table or tilting machine head. the category of machining you do, • Parallel machining – This is needs a different machining strategy • 5-axis machining – This adds this lets you get a system with a 21 basic multi-surface machining. The than the rest of the part. a fifth dimension of simultaneous move- Additional Tools To Consider (Initial Graphics Exchange Specifica- familiar interface, further reducing tool moves back and forth across the tion), they do not have to spend time training time. 22 model. Flexible parallel machining There are several NC program- recreating geometry that is already Choosing a good CAD/CAM allows you to cut in zigzag or one- ming features which are important in available. Many vendors provide these system with the correct functions helps 23 way motion. all 2-, 3-, 4-, and 5-axis applications. translators with their software, others you improve the quality, productivity • Constant Z machining – This These include: charge extra. and profitability of your shop. CNC 24 function cleans all the material from a • Post processors – In most • CAD Capabilities – Regardless Software publishes a booklet titled given depth before moving on to the systems, the post processor translates of the type of work shops do, most find “What Every Shop Should Know 25 next depth. The result is less tool wear the toolpath information into NC code it necessary to have CAD capabilities as About Choosing a PC-Based 26 and a more consistent finish on some for the machine. Therefore, good post well as CAM. Even if a shop receives CAD/CAM System”. The booklet surfaces. processors are essential in any level of all its work electronically as CAD files, provides useful tips on software and 27 • Scallop machining – Scallop machining software. CAM vendors the programmer often needs to edit the hardware selection, and discusses how machining keeps a consistent tool typically have a library of these to run geometry to make it machinable. Many to get the most from any CAD/CAM 28 stepover in 3D space. This provides a with most machines. Many CAM shops prefer a package that includes package. For a free copy of this more uniform scallop height around systems include user-customizable post both CAD and CAM. Using a tightly booklet (a $4.95 value), call 1-800- 29 the entire model and therefore processors, allowing programmers and integrated CAD/CAM system elimi- 228-2877, send an e-mail to reduces the amount of handwork machinists to make adjustments nates the need to translate files [email protected], or write to 30 required to finish a part. themselves or with a quick phone call between separate CAD and CAM “Free CAD/CAM Booklet”, CNC • Flowline machining – Flowline to their vendor’s tech support. packages. Since an integrated Software, 344 Merrow Road, Tolland, 31 machining uses the natural shape of a • Toolpath Verification – Solid CAD/CAM system uses a common CT 06084. CNC Software, Inc. set of surfaces to determine tool model toolpath verification runs your database for the CAD and CAM 860-875-5006. 32

33 CNC MACHINING • SPRING 1998 WWW.HAASCNC.COM 34 1

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How To Select turers of cutting fluids will perform the today simply because they were in use natural and synthetic lubricants with up 5 necessary water testing to determine yesterday. It is a hard reality of today’s to 30% mineral oil. by richard j. chambers exactly what minerals are dissolved in marketplace that if one isn’t constantly • Hybrids – a special class of 6 Valcool Product Manager your water and make a fluid recom- striving to improve, they will certainly semi-synthetics with a mineral oil A Cutting Fluid Valenite, Inc. mendation based on the results. be overtaken by a competitor who is. content of about 15%. 7 Each fluid type has advantages What are you using now? What Are Your Options? and disadvantages which make it 8 The third question – “What are The fourth question – “What are suitable for a particular group of you using now?” – helps narrow the your options?” – leads to the final applications. In addition, there are 9 range of choices. When coupled with selection of a cutting fluid. Cutting cost/performance trade-offs to be he metalcutting industry today is “stainless steel,” or “cast iron,” the an objective analysis of the strengths fluids can be divided into four gen- made between the groups within a 10 selection of a cutting fluid can be and weaknesses of the current fluid, eral groups, based on their chemistry. specific set of applications. 11 well into the age of system quite simple and straightforward. the answer to this question can quickly They are: For example, where a hybrid and Unfortunately, that is seldom the case point you toward a relatively small • Soluble Oils – quite literally, oil a semi-synthetic may both be suitable 12 in anything but a high-volume plant. number of competitive alternatives that dispersed in water. for a particular use, the hybrid might solutions. What used to be the Where aluminum or other non- have the attributes required to meet • Synthetics – completely oil free, provide longer sump life at a slightly T 13 ferrous metals are a significant part of your cutting needs. man-made coolants in solution. higher initial cost, while some semi- art of insert selection has been the mix, a non-staining cutting fluid is Many cutting fluids are in use • Semi-Synthetics – a mixture of synthetics may be more economical to 14 a must. Generally speaking, this will recycle or dispose of while not giving simplified and codified to the point be a semi-synthetic with special ingre- as long a tank life. 15 dients to prevent bi-metallic corrosion The final decision in this case where it can honestly be called a and staining of non-fer- would have to be made on the 16 rous workpieces. Where detailed economics of the shop where the ferrous metals pre- the fluids were to be used, and on the 17 technology, if not a science. dominate, however, a owner’s individual preferences. more general purpose 18 Grades, coatings and chipbreakers semi-synthetic or hybrid Soluble Oils fluid might be a more Soluble oils are oils that disperse 19 are all engineered to work together economical choice. in water when emulsifiers are added. They are generally suitable for moder- 20 What is The Chemistry to perform more efficiently over an of Your Water? ate- to heavy-duty machining and grinding of all non-ferrous metals, 21 The second question carbon and cast steels, and in increasingly specific range of appli- – “What is the chemistry applications where dissimilar metals 22 of your water?” – is such as aluminum and steel are cations and workpiece materials. probably the single most present. They can also be used in 23 common reason for the turning, drilling, tapping, reaming, gear One part of the metalcutting information that are necessary when success or failure of a cutting, broaching, as well as internal 24 equation that is sometimes over- choosing a cutting fluid. They are: cutting fluid. Very few and centerless types of grinding looked, however, is the choice of an 1. What are you cutting? plants invest the money operations. Soluble oils provide 25 appropriate cutting fluid. With today’s 2. What is the chemistry of your necessary to install excellent aluminum and copper 26 system approach to metalcutting, use water? effective water purifica- corrosion control; good rancidity of the right metalworking fluid has 3. What are you using now? tion systems using control, which extends fluid for long become just as much a part of the 4. What are your options? deionization or reverse lasting, trouble-free performance; and 27 solution as the other elements. In fact, 5. What do you prefer? osmosis technology. good concentrate and mix stability, 28 at least one company is now integrat- Unfortunately, the making it ideal for mixing in water with What Are You Cutting? ing cutting fluids and cutting tools into chemicals present, or not a minimal amount of agitation. An 29 effective metalcutting systems. Follow- The first question – “What are present, in the water example of this is Valenite’s VNT®-650 ing are some things to consider when you cutting?” – is often the most diffi- used to re-constitute a premium heavy-duty soluble oil. 30 choosing your next cutting fluid. cult to answer, because most shops cutting fluid make a handle a variety of workpiece materi- tremendous difference in Synthetics The Four Key Questions 31 als on a regular basis. If the answer its performance and Synthetics are completely oil free There are four vital pieces of is an unequivocal “aluminum,” or sump life. Most manufac- solutions made of polymers, organic ➠ 32

33 CNC MACHINING • SPRING 1998 WWW.HAASCNC.COM 34 and inorganic materials that are steel in both machining and grinding. What Do You Prefer? mixed with water. These clear, low- Semi-synthetics can be used on The final question – “What do foaming and bio-stable coolants are ferrous metals, too. They are you prefer” – is usually the “tie ideal for machining and grinding of chlorine-free to reduce bi-metallic breaker” where there is more than ferrous materials, carbon steels or cast corrosion and staining of metals. They one appropriate cutting fluid iron. Their complex lubricant pack- should be used at a 5-8% dilution available. Here, again, as in the ages make synthetics well-suited for with water, depending on the severity case of what is being used now, the tough-to-machine materials such as of the operation. key is to examine your preferences stainless steels and high-temperature objectively and specifically to identify alloys. Certain synthetics are specifi- Hybrids the real reasons behind a preference. cally designed to address the primary Hybrids are cutting fluids custom If you cannot point to specific reasons failure modes of flank wear and nose engineered to solve a particular why one class of cutting fluid is pre- wear. Although there are many problem. For example, Valenite’s ferred over another, you are well benefits, some synthetics may cause VNT®-800 was developed to be advised to follow the recommenda- staining of non-ferrous materials. very clean in the machining and tions of the professional who has grinding of cast iron. It provides analyzed your requirements. Semi-Synthetics better stability in hard water and Choosing the right fluid today is Semi-synthetic fluids are a mixture rejects tramp oil very well, which easier than ever, as the system of oils, synthetic emulsifiers and water. adds to its bio-stable chemistry. approach to metalcutting productivity They were primarily developed for the Hybrids work extremely well on all continues to grow in acceptance. aircraft, nuclear and related metals in both machining and The day is not far off when choosing industries. Consequently, they work grinding. They should be mixed at a a complete solution will be as easy extremely well on all non-ferrous 5-7% dilution with water, depending as choosing the right insert and metals such as titanium, aluminum, on the condition of the water. chipbreaker today. The answers are copper, brass, bronze and stainless available, and the results will more than justify the time you spend choos- ing the right metalcutting fluid.

have a wide variety of applications and requirements, and there’s a Haas rotary table to fill the need. You From our 5C collet indexer all the way up to the HRT 450 workhorse, we have a table model designed for your machining needs. We also have a large selection of multi-spindle indexers with dual, triple and quad-head models available; along with a line of tilting single, and multi-head models which feature 360-degrees of spindle rotation and 240-degrees of tilt. Only from one company – Haas.

CNC MACHINING • SPRING 1998 1

2 [Racing[Industry News continued ]Report] [Continued[To the Swift. . . continued] from .] .3 . 4

5 Race Report [Continued from page 3] “This, in conjunction with the fact that scale for the wind tunnel testing, then cut its 25th year, focuses on driver ability (all the tunnel is designed to have good lami- full-size on the Haas machines for actual cars are identical in a “spec-racing” 6 here making good use suspension specialist and a chassis consul- nar airflow, boundary-layer control, and track testing. series) and the cars feature a number of 7 of his competitors in a tant. Operating out of a custom painted the proper speed and size to test automo- This technology makes it affordable parts and components designed, and rather un-orthodox cor- 45-foot enclosed trailer, the “Trinity Racing tive designs combines to distinguish our to design specific parts for different types built on Swift’s Haas VF-8 and HL-2. 8 nering maneuver). Team” will in effect promote the many ATV tunnel as one of the four built in the of race tracks with the knowledge that Swift was but one of eight Marais, a former products and services the Trinity Racing world of this type.” these parts will generate the needed manufacturers that participated in the results. If a high-speed track demands less design/build competition for the new 9 Rookie-of-the-Year name represents, including the fabrication Milking the Unfair Advantage wing surface for high speed, yet sufficient Atlantic chassis. award winner was also of numerous billet bolt-on mods to the 10 sent to Europe where building of full-on racing engines. Information gathered from this body downforce for the turns, these The new design includes special testing is then evaluated and turned into panels can be engineered and tested for attention to the survival cell in the areas of the car competed in a Riding identically prepared Suzuki 11 number of saloon car 500 ATVs utilizing a Lonestar chassis performance and efficiency on the race- the specific parameters of the track. impact protection, including cockpit shape track. Because Swift depends on a fully Short track or road courses would and helmet surround in addition to extra races. and Trinity-modified motors, all of the 12 race vehicles will use the same brand computerized design/production system, demand different parts and pieces to attention in the foot protection areas. any minor changes required in a body augment handling characteristics for Super Series products and run the same color scheme Future Plans & Priorities 13 panel or part can be entered into the those tracks, giving the specific vehicle Troy Cline gets sideways. Off Road and sticker placement to assure team Photo courtesy M&M Photos original program and the new part the fabled “unfair advantage” over the There has been a lot of growth at Off-Road racing recognition on the circuit. 14 C&C Motorsports fans in the Southern Hemisphere have no Trinity Racing presently is using machined on one of Swift’s Haas competitors. It’s a win/lose situation, and Swift Engineering. During the past few trouble seeing the Haas SA sponsorship Haas CNC machines (3-mills and a machines to exact tolerances. nobody wants to buy a loser...and that’s years, the staff has increased from 11 to 15 SCRA (Sprint) In addition, any of these recom- why the Swift Aero tunnel is booked well more than 85, and there are no signs of Joe Custer, in partnership with Troy on Buks Carolin’s Chenowth VW buggy. lathe) in its Anaheim, California, shop Front-runners are always the cleanest where experienced technicians prepare mended changes can be reduced to the in advance. letting up. 16 Cline, is entering his second year of 45-percent wind-tunnel size and tested in Hiro says that in addition to build- involvement with Haas Automation competitors and Buks, Pacific Plant to Build Atlantics already a national off- the tunnel before the full-size part is cut. ing and selling the cars for the Formula 17 sponsorship in local Sprint Car Racing This is how Swift is able to design In addition to Swift’s Atlantic series, he envisions selling Swift Association (SCRA) events. road champion, earned the crown as short course changes in downforce pressure of as little Newman/Haas relationship, the 009.i cars to about three or four FedEx 18 Tearing up the competition and as 20 pounds in a car producing in company was recently awarded the Championship teams. But he doesn’t throwing more dirt than a soapbox champion of the South African Total SuperSeries excess of 4,000 pounds of force. contract for the construction of the new want to stretch Swift’s ability to properly 19 politician up for re-election, both cars on service these customers. Cross goes the C & C Motorsports team are running at AA Kyalami. Carolin’s along with this philosophy adding, 20 highly modified small-block Chevys in a tube-framed dirt slinger claimed the Super “We just want a few good customers. sideways slide towards victory at any In that way, we’ll have people winning 21 number of tracks in the southwest. Special category title for tube-framed cars with a races, and that sells cars.” With 37 race dates scheduled for 22 trio of wins. Company plans call for more the ’98 SCRA calendar, plans are Haas machines, including an currently in the works to host a special MTS/Trinity ATV additional vertical machining center 23 “Haas Nite” for team supporters at one, Racing: with more travel on the X-axis. This will or both of the race dates at the Ventura allow the designers to machine molds 24 Raceway, May 30, and September 5. Machining Time Savers (MTS), Haas’ for larger composite body panels and Look for “The Haas Pit” hospitality station 25 distributor in Southern Haas South Africa Opel (left, or is it above?) finished 2nd in class and 3rd overall in South African pans. In addition, more parts will be in the pits and give a collective cheer Group N saloon car competition. programmed for finish work on the for Custer and Cline as they carry the California, has entered into 26 a sponsorship agreement with Trinity Rac- some of the hottest running powerplants existing machines. Haas Automation name to yet another “What’s important about Swift automotive victory. ing backing the team’s multiple-vehicle around. The operation is also well-known 27 involvement in major national and interna- for fine-tuning race-prepped engines and the engineering computer system The Swift floorplan incudes ample workspace for assembly and machining. is that it really is the start of a very South Africa: tional all-terrain vehicle (ATV) events. The used in jet skis and other forms of 28 integrated process,” says Cross. “Group N” Opel Astra six rider pro team watercraft. And because everything in the Swift KOOL/Toyota Atlantic Series cars. The “A repeatable, developmental process International competition finds the competes in Grand National Motocross “We’ve known and depended on 29 manufacturing/testing process is new Swift 008.a spec racers (47 cars in which Haas machines are a very Haas Automation South Africa logo and TT, Grand National Cross-country, Trinity for a number of years now with computer driven, absolute repeatability is ordered) feature carbon-fiber composite integral part.” carried on the South African Group N PACE Stadium Series, SCORE and “Best in our own ATCs,” says Gary Sladek, 30 guaranteed. If an internal modification construction with a “raised-nose” design Success at reaching long-range Opel Astra of Gary Marais. Marais is a the Desert” events. manager, MTS. “We’re looking forward demands changes in the exterior body and are powered by the 240-hp goals depends on teamwork and very popular driver, known for his Trinity Racing riders are supported at to enhancing our relationship with this panels, the appropriate changes can be Toyota 4A-GE engine. dedication to the latest technology. 31 aggressive driving techniques (shown events by the team manager, engine tuner, exciting partnership.” entered on the computer, mocked up in This competitive series, now entering And to the Swift, go the spoils... 32

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5 On the Horizon – New Product 50-Taper Capabilities Rumors and Updates and Extended Travels Making technology affordable: 6 in a Mid-Sized Package How does Haas do it? 7 LWAYS striving to make inroads into new 8 markets, Haas engineers have been hard n today’s world, versatility is 50-taper spindle that provides at work developing new products. Rumors the name of the game. Job up to 450 ft-lb of cutting ast, cheap and good. 9 A shops and manufacturers alike torque. A Haas-designed around the water cooler have the following I 10 must react quickly to market vector spindle drive yields It’s been said that you can machines in the works: fluctuations in order to survive. peak performance and speed 11 The new Haas 50-taper VF-5 control under heavy cutting have any of the two together, HS-2RP HMC Haas Side-Mount F vertical machining center loads, and a two-speed gear- but not all three: You can have it 12 Debuted at last year’s WESTEC, Tool Changer (50” x 25” x 25” travels) box provides the versatility of the HS-2RP is finally nearing pro- This 24-tool, 40-taper tool combines the versatility of a low-end torque for cutting steel, fast and cheap, but it won’t be 13 duction status. Nearly a year of changer attaches to the side of mid-sized VMC with the power as well as speeds to 5,000 development has yielded several the column on Haas VMCs, keep- and torque of a 50-taper rpm for cutting aluminum alloys. good. You can have it fast and changes to the original design. ing the tools out of the enclosure 14 machine, all in a compact, Heavy-duty 40 mm ballscrews • Extended travels – 38" x 35" x 30" for unobstructed maching. heavy-duty package designed on all axes provide superior good, but it won’t be cheap. Or, 15 • Side-shuttle tool changer, 40-tool, to meet the demands of today’s cutting rigidity, and 7.5-hp travels out of the enclosure for Live Tooling, Lathes modern machine shops. high-thrust brushless servo motors you can have it cheap and unobstructed machining (60-tools Allows the use of standard 40 mm 16 optional) VDI rotary tools for axial and The new VF-5 is built yield rapids up to 710 ipm. using super-wide-stance base For shops that don’t need good, but it won’t be fast. So, • Three auger chip conveyor radial milling, drilling or slotting. 17 system – utilizes two side augers A VDI turret can be supplied, or and column castings, which the power of a 50-taper choose your poison. Haas VDI adapters may be used provide the solid foundation spindle but want the travels of and a single front auger to The five-axis spindle head of the new VR-11 provides an incredible 18 remove chips from the enclosure with the standard turret. and rigid backbone to take the VF-5, an optional 40-taper ±32 degrees of rotation on the A and B axes, as well as rotational feedrates of up to 250 degrees per minute. during machining • 5-hp brushless drive for live tools really heavy cuts. Combine this spindle is available in either 19 • Lower overall height as a result • Indexable main spindle with extended Y and Z travels, 20- or 30-hp configurations of the side-shuttle changer • Hydraulic brake for main spindle and the VF-5 is perfect for such and with speeds up 20 • 25,000 lb machine weight industries as mold making, tool to 10,000 rpm. • Compatible with standard turret & die and model making, With its work envelope of 120" x 40" 21 • VDI turret available HS-3 Prototype where a large work cube x 30" (xyz) and five-axis profiling 22 This T-shaped horizontal with HS-1,R,RP is required. spindle, the VR-11 fits the bill. travels of 150" x 50" x 50" – by Fast material removal The first VRs are now in the field far the largest machine built by • Redesigned base castings comes from a standard 30-hp, and getting a thorough workout at 23 provide wider stance Haas to date – will have the several aerospace shops throughout following features: • New internal sheetmetal With most things in life, this theory the VR-11 was born of requests and Southern California. If you are 24 and Z-axis waycover • 30-hp, 50-taper vector driven definitely holds true. But at Haas suggestions from customers. There was planning to attend WESTEC, be spindle, 0–5,000 rpm washdown for more 25 efficient chip removal Automation, they’ve managed to a need, primarily in the aerospace sure to stop by the Mastercam • 2-speed geared head accomplish the impossible and deliver industry, for a cost-effective solution for booth, where they’ll be putting a • Three auger chip 26 • 28-pocket, side-shuttle conveyor system – all three: high-quality CNC machine large 5-axis machining operations. VR-11 through the paces. tool changer utilizes two side tools that are delivered quickly and 27 • 45 mm guides on all axes augers and a single priced affordably. • 50 mm ballscrew on the X axis front auger to Haas has always built products remove chips from 28 • 40 mm ballscrews on the that are on the cutting edge of technol- the enclosure Y and Z axes ogy, yet priced lower than the during machining 29 • 102" x 40" table with T-slots competition. Making Technology • New pallet changer lengthwise and crosswise Affordable is the driving force behind clamping system 30 • high-thrust brushless servos reduces wear and every new design or improvement, and on all axes contamination the new VR-11 five-axis profiling VMC 31 • 42,000 lb machine weight is further proof of this philosophy. As with many new Haas products, 32

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The Solutions Company.