CNC Machining Fall 2000.sr 10/9/00 3:52 PM Page 1

volume 4 number 15 fallfall 20002000

MATHEWSMATHEWS ARCHERYARCHERY HITSHITS BULL'S–EYEBULL'S–EYE

THETHE WINDWIND TUNNELSTUNNELS ATAT AMESAMES RESEARCHRESEARCH

CAD/CAMCAD/CAM FORFOR TOOLINGTOOLING WORKWORK

IMTSIMTS 20002000 WRAP–UPWRAP–UP

COVERCOVER STORYSTORY

NASANASA METALCUTTINGMETALCUTTING CNC Machining Fall 2000.sr 10/9/00 3:52 PM Page 2

p12 Focus on training tomorrow’s certified machine tool sales engineers.

p4 Haas-sponsored teams begin big push for championship positions.

p36 Haas Automation draws more than 10,000 at IMTS 2000 in Chicago.

p14 COVER story It’s been called the most complex machine that Man has ever built. We took a close look at the role CNC machine tools play in making the shuttle program a roaring success.

THE MASTHEAD Mathews Archery hits p6 CNC Machining is published by Haas Automation, Inc., 2800 Sturgis Road, Oxnard, CA 93030 • 805-278-1800, Fax 805-988-6918. the bull’s-eye with Haas vertical Postmaster: Return invalid addresses to Haas Automation, 2800 Sturgis Road, Oxnard, CA 93030-8933 postage guaranteed. machining centers. CNC Machining is distributed free of charge by Haas Automation, Inc., and its authorized distributors. CNC Machining accepts no advertising or reimbursement for this magazine. All contents of CNC Machining are copyright 2000 and may not be

reproduced without written permission from Haas Automation, Inc. CNC Machining is distributed through a worldwide network

of Haas Automation Distributors, and by individual subscription request. Contact Haas Automation headquarters via mail or fax to be added to the subscription list. Published quarterly. © Haas Automation, Inc. & CNC Machining Magazine names. Designed and printed in the U.S.A. CPC # 1563572. www.HaasCNC.com CNC Machining Fall 2000.sr 10/9/00 3:52 PM Page 2

> EDITORIAL by Alan Phillips, President of Phillips Corporation > INDUSTRY NEWS

Living Life on Purpose – Haas Automation Goes to Europe On September 1, 2000, Haas Automation, Inc., established a features and a better price-to-quality ratio than perhaps any new division to sell and service Haas products throughout other CNC machine tool builder in the world.” with a great & worthy mission! continental Europe and the former Eastern Bloc countries. Haas Automation Europe will Dubbed Haas Automation Europe, the new division is based in offer Haas products at fixed end-user value and service. It is clear that Haas has Brussels, Belgium, and headed up by Managing Director prices, in euros, across Europe, have sworn upon the altar of God eternal learned how to provide this better than Dr. Ing. Theo Leon. Haas will begin offering its products customs cleared (excluding transport hostility against every form of tyranny any other. A combination of great immediately in Germany, Spain, Portugal, Belgium and the cost). A multilingual factory-trained machines with guaranteed up time and Scandinavian countries, and will expand into other countries of team based out of the Brussels over the mind of Man.” local Haas Factory outlets with Europe over the next three years. headquarters will assure complete “I professional sales engineers, stocked “We are not going to achieve our goals overnight in support for the customer. By year’s As missions go, this one seems one! We manufacture machine tools, the service vans, and certified service

Europe,” stated Haas Automation President Gene Haas. “It will end, a technical center fully equipped Ing. Theo Leon Dr. particularly ridiculous – eternal hostility– famous Haeger Press, and we are the engineers, along with the industry’s most take three to five years or more to acquire the market share we with demonstration, training, service and spare parts facilities implying action beyond one’s lifetime. owners of six Haas Factory Outlets. helpful website, has proven to be the believe is possible. But our European commitment and strategy will be opened near Stuttgart, Germany. Six additional technical What do you make of Gene Haas’ Being president of a machine tool winning combination. All of this has are long-term. Our policy has always been to rely on volume centers are planned for other European sites in the future. mission to create the biggest and best company, I am most interested in what I become part of the Haas community. sales rather than per-unit profit,” Mr. Haas continued. “This Haas will continue offering its products in the United machine tool company in the world? Ten can learn from Haas to make our We have shops in our market with approach, combined with high-tech innovations and rock-solid years ago, if someone asked me, I would company more successful. I often have people who appreciate being part of the engineering, allows us to provide lower prices, more standard Please see EUROPE page 35 have said that Gene Haas has no chance. I the opportunity to be with Haas people. Haas community so much that we call would have said that the mission to build I am always peppering them with them Haas zealots. WOW! the biggest and best machine tool questions. How do you do this? Why did So, maybe the measure of being the Haas Garners Awards company from ground zero is ridiculous – you do that? Why is the company so best is having the greatest community. I Gene Haas, president of Haas Automation, was selected there are already many strong, well- successful? What makes General don’t know. I do know competence and for American Machinist magazine’s Hall of Innovators for his positioned machine tool companies. Gene Manager Denis Dupuis tick? How come commitment to a cause when I see it, and achievements in looking beyond traditional approaches to Haas could not really think this is possible. the team has been together so long? Who I have no doubt that Gene will manufacturing during the 1980s. Mr. Haas was presented with Of course, we all have learned does the product development? How is it accomplish his mission to become not a plaque signifying the award during ceremonies at the Drake something about Gene and Haas done? How does Haas create, then keep only the biggest, but the best machine Hotel in Chicago September 5. Automation over the last ten years. We up with, demand? What does Gene tool manufacturer in the world. Mr. Haas was chosen as an innovator for his development have learned to think about things spend most of his time doing? Etc., etc. Oh, by the way, the mission at the top of the Haas 5C collet indexer and the Haas VF-1 vertical differently, and ask different questions. We have benefited considerably from of this article belongs to Thomas Jefferson. machining center. The Haas 5C was – and still is – an easy-to- What does it mean to be the best? being Haas’ partner – we have learned Living not far from Washington, D.C., I use and economical method for increasing productivity on What is the criteria for measurement? Is much from the association. We have often visit the marvelous sights there: the manual mills and machining centers. The VF-1 provided an Haas Automation also received American Machinist’s 2000 it the best by any measure? Does it watched as Haas has woven the threads of Smithsonian, the Capitol Building, the affordably priced, competitive VMC at a time when foreign Excellence in Manufacturing Technology Achievement Award require the best leadership? Or does it its community to include not only the National Gallery of Art, the Lincoln competition was overshadowing U.S. production and sales. for Design & Productivity. require the best person in every role? people who work at Haas, but also many Memorial, the Vietnam Memorial. One Does it take the most elegant gears, the people throughout the world as the Haas time while visiting the Jefferson Memorial best specs or the boxiest ways? Does it Factory Outlets established a strong local the words engraved on the wall caught take a disdain for mediocrity and a love community identity. Of course, the most my attention. of virtuosity? Does it take benevolence or important members of the Haas More than 200 years later, Jefferson’s Haas Automation Sells 25,000th CNC Machine at IMTS 2000 ruthlessness, or maybe benevolent community are the machine operators, Declaration of Independence continues to It was in 1988 that Haas Automation, Inc., introduced the was presented to the new owner, Chuck Thudium, president ruthlessness? Does it take being bold, programmers, set-up people, managers clear the way for man’s freedom all over company’s first CNC machine at the International Machine of AT Precision of Northbrook, IL, at this year’s show in taking big risks? Does it take a and owners of the job shops and the world. Maybe having a mission which Tool Show in Chicago. The affordable VF-1 caught the Chicago. The finished machine was delivered to AT Precision willingness to put your money where manufacturing facilities around the world. is eternal is not as ridiculous as it first competition napping, and with a price less than $50,000, it by the Chicago Haas Factory Outlet (a division of Arthur your mouth is, or does it take being Through our association with Haas, seems. I wonder how long it will take established Haas as a manufacturer that pays attention to the Machinery, Inc.), where it joins 12 other Haas VF-0Es in the laughed at? Does it take a particular we have learned to consider what it means Gene Haas to accomplish his mission? customer’s bottom line. production of a wide variety of products. culture, maybe even a community? to be the best from a different perspective Given the successes of the Haas company, Now, just 12 years later, the 25,000th CNC machine has It took Haas less than 10 years to manufacture its first Our company is proud to be part of – from the customer’s viewpoint. And we I would expect that he will still be alive been sold at IMTS 2000. The machine that garnered this 10,000 CNC machining centers and lathes – an impressive feat the Haas community. We feel it is a great have learned that today’s customer wants and kicking when it becomes a reality. recognition is one of the company’s versatile VF-0E vertical in itself. The company’s state-of-the-art manufacturing facility machining centers. A special plaque commemorating the event Please see 25,000 page 35

2 CNC MACHINING FALL 2000 3 CNC Machining Fall 2000.sr 10/9/00 3:52 PM Page 4

> RACE REPORT > RACE REPORT

he turning leaves of autumn are a prime indicator standings. Even with a season full of driving force is none other than Dan that the time for some serious racing is at hand. hard crashes, Sprague has still finished Gurney’s son, Alex. in the top five in more than half of the Running the #48 Swift 008.a (a car With the onset of October comes the end of the races run so far and is running second in built by Swift Engineering in San T Clemente, Calif., with parts machined overall wins. motorsports season, and the final push for championship PacWest Racing Group on Haas CNC machining centers), Alex points. But before you settle in for a winter of football and has already earned one Kool/Toyota CART CHAMP CARS Atlantic podium finish in Trois-Rivieres, PEI, Canada, where he enjoyed the hockey, we’ve got some Haas milestones to celebrate! Mauricio Gugelmin worked his champagne ritual that his father made a way up to second place at the snow- racing tradition following his win at Le While Haas has visited the and turning centers. He also plays a delayed Nazareth race, giving PacWest Mans. Future goals are said to include a NASCAR winner’s circle often – thanks Fender Custom Shop Stratocaster, cut its first podium finish for the 2000 Formula One ride at Indy. It could easily to the hard-charging efforts of the on a Haas VF-4, natch. Our congrats to series. Mechanical maladies and off- happen, considering his family history. Hendrick Motorsports team – victory in Cristiano and the crew at PPI course excursions continue to plague open-wheel competition has been Motorsports. the team, but the points are racking up, PPI Motorsports elusive . . . until now. The Chicago PacWest Racing Group driver Scott and the two cars will be starring in the CART CHAMP CARS CART race found the Haas-sponsored Dixon continues his winning ways in new Sylvester Stallone movie on the car of Cristiano da Matta taking the this year’s Indy Lights competition. PPI Driver Cristiano da Matta drove his CART racing series, “The Champs.” In As noted in the opening of the Race checkered flag and beating out veteran Leading the series, Dixon is slated to Toyota-powered Reynard to victory in fact, “Sly” will be wearing “Big Mo” Report, Cristiano da Matta is the first charger Michael Andretti. This hard- take over Mark Blundell’s Champ car Chicago, giving Haas its first win in the Gugelmin’s racing suit. Watch for the CART driver to carry the Haas hard-fought international CART series. fought battle marks the first CART seat for the 2001 season. Blundell is Haas logo in this gala tribute to auto Automation logo into the winner’s victory for a Haas-sponsored car. The leaving the PacWest team and will racing – it should be everywhere! circle, and he did so at Chicago’s new finish had the crowd on its feet and become a free agent. Mark, who started oval. Well up in the top-ten point CART INDY LIGHTS screaming as the PPI Motorsports car with PacWest in 1996 following a stint in dominating the Formula Atlantic field However, it’s the top ten finishes that standings, Cristiano and his teammate crossed the line with Andretti a mere Formula One, has posted a number of and taking turns standing on the are racking up the points. Jeff Gordon As noted above, new PacWest Oriol Servia are pushing their Toyota- 1.4 seconds behind. wins for the team. If Scott Dixon’s Indy winner’s podium at the end of the race. (#24) is still fighting it out in 10th driver Scott Dixon is leading the pack in powered Reynards hard, trying to earn In a racing series where the entire Lights talents carry over to the big It’s not uncommon for both team overall, with three wins and fifteen top the competitive Indy Lights series with more points. Servia is also in the top field can qualify with lap times within series, we can expect to see his name members to finish in the top three, tens. Teammate Terry Labonte (#5) teammate Tony Renna also running three for Rookie-of-the-Year honors. 1.5 seconds of each other, this kind of listed soon in the CART Champ car pushing the Haas-stickered nose across suffered from an inner ear problem that high in the point standings. competition can’t be beat. Cristiano’s record books. the finish line in a very winning way. broke his “Ironman” streak at 655 ATLANTIC SERIES Pioneer Toyota/Reynard uses parts cut In related competition, PPI drivers Overall wins aside, the Haas consecutive race starts, but he’s back in All American Racers (AAR) Additional good news at PPI is the on PPI’s many Haas CNC machining Andrew Bordin and Dan Wheldon are association with the racing fraternity the game. It seems the final cure performance of the Kool/Toyota illustrates the close relationship ATLANTIC SERIES involved some non-stop roller-coaster Atlantic series team, with Andrew between precision driving and precision riding as a test. AAR may have pulled out of CART Bordin and Dan Wheldon battling each machining centers. This fact leads to Jerry Nadeau, still the new whiz Champ car competition for the 2000 other for first place in the interesting discussions when Haas sales kid for the 2000 season, has kept the #25 season, but the Gurney name is still on championship. The team has a representatives bring prospective Hendrick entry either up front or course and keeping an eagle eye reputation to uphold – last year it clients into the racing facilities where leading the majority of the first 25 races. focused on the checkered flag. This finished first and third in the series. they can see Haas CNC machining He looks ready to pick up his first win centers making the parts that win races. before season’s end, so keep an eye on this car! Hendrick Motorsports CRAFTSMAN TRUCK SERIES WINSTON CUP SERIES Jack Sprague (#24), driver of the The Winston Cup championship Chevrolet Silverado pickup entry from title is still a crapshoot, with most Hendrick Motorsports, is fighting with

Scott Dixon, currently leading the CART Indy Lights points championship, has earned a seat in a everyone in the top ten still playing the Fords and Dodges to maintain his PacWest Champ car for the 2001 season. around with three or four wins each. present ranking of fifth in the point

4 CNC MACHINING FALL 2000 5 CNC Machining Fall 2000.sr 10/9/00 3:52 PM Page 6

Arrow in the Air Hits Bull’s-Eye magine looking at a wheel with the full-blown intention of reinventing Iit. To say that intent requires an unimaginably brazen faith in one’s compound bow. To accomplish that, he sawed the limbs off an creativity would be a definitive very creative, and old fiberglass bow, devised wheels and cables and created his Story over the years designed a first compound bow. Followed by yet another, and another. understatement. It would also be number of products, especially musical Wooden bows evolved into fiberglass recurves and then Olaf an accurate portrait of Matt instruments. He holds a variety of patents himself, into two-cam compound bows. Most people would, and did, Wolff the McPherson three-hole guitar being one of them. And an leave it at that – but not Matt. It was actually a mistake he McPherson, the brains uncle on his mother’s side was also a successful inventor, made nearly a decade earlier during his experimentation possessing numerous patents. Matt’s parents were thereby phase that led to the development of Matt’s first high let-off behind Mathews Archery. hereditarily supportive of his creative efforts. InnerCam and his first archery company, McPherson Archery, In the 1960s, Matt was making bows out of whatever which he started in 1985. The InnerCam was pretty radical for Matt has accomplished the relative wood was accessible. Years later, when his brother Randy the time, but it put Matt on the archery map and opened wide bought a compound bow, it immediately piqued Matt’s the doors of artistry and innovation. The InnerCam was one of Photos equivalent of reinventing the wheel – and much more. In a mere eight years he has imagination. He was motivated to make his own experimental the very first eccentric systems with a protective draw stop. Scott taken his small, upstart bow company and Rathburn positioned it right smack at the top, winning every Men’s Pro event in every professional circuit. Last year alone, pro shooters using Mathews gear claimed of Mike Ziebell, Mathews Marketing Director, “He just 15 of the 21 Men’s Pro titles. For the first time ever an always has that touch.” According to Mike, Matt still archery company made the Inc. magazine list of the 500 has quite a few secrets up his sleeve to keep the fastest growing privately owned companies in America company at the forefront with something new each – not once, but two years in a row. And Mathews year. Matt believes if you introduce things a step at a currently stands as Inc.’s highest-rated outdoor time, people are going to appreciate that they work, and company ever. therefore be more likely to make a purchase. Mathews needs to introduce new models each year Okay, maybe Matt didn’t actually sit down with just to stay a step ahead. There are probably no more the intention of reinventing the bow; perhaps it was than 24 bow companies in existence, most of them more of an accidental evolution of sorts, but the creative small, yet this is a highly competitive business. What seeds for such an undertaking were planted long ago. competitors are doing this year, Mathews was doing a Matt and his brothers were introduced to the sport at a year or two ago, and in some cases even earlier. Matt very early age by their father. They’d tag along with continues to be the creative driving force – in essence, him when he bowhunted, carrying their fiberglass being the hunter, not the hunted. A self-taught engineer recurve bows. The story told is that their dad wanted to and a seat-of-the-pants kind of guy, his unassuming go deer hunting, but Mom didn’t want the brothers to explanation is, “I’ve always felt compelled to make go with guns because of the chance of getting hurt, so things.” He tests the prototypes and gives the final go- Dad agreed to go with a bow. Things followed an ahead on all projects. He is an entrepreneur in the apparently predestined course from there on. purest sense, and that’s just the way everyone likes it. Matt’s parents’ contribution to the whole of his From the time Matt was a young boy his insatiable accomplishments goes far beyond merely inspiring the curiosity had him taking things apart, but, unlike most use of bows, though. There also is a clear and traceable of us, he could generally reassemble them. In the words hereditary influence from both sides. His father was

6 CNC MACHINING FALL 2000 7 CNC Machining Fall 2000.sr 10/9/00 3:52 PM Page 8

“. . . the machines have helped, because we can The major components of a Mathews bow, including the idler wheels (above) and risers (far right) are machined from aluminum billet. Multiple fixturing allows Mathews to get finished parts off the machines every time the doors open. do a lot more in-house.

Today, of course, all this seems perfectly of the two cams. As occasionally has awarded “Best-of-Best” distinction So we haven’t been as normal and desirable, but back then it happens, the solution came to Matt to only 15 products, and the Mathews was a somewhat radical, and evidently during the solitude of driving. His MQ-32 bow (an evolution of the original dependent on the scary, idea. initial thought at that instant was, “Can SoloCam bow idea) is one. suppliers.” To start his first bow company, Matt this really be that simple?” His In January of 1998, Mathews had taken on two investors. Their conception involved a simple solution purchased its first two Haas VF-4s. Prior money funded the company, but their to the common problem. He envisioned to that, most of the company’s Mike Ziebell – Mathews Marketing Director conservative views on marketing and a system in which cam synchronization machining was outsourced. A friend of promotions also nearly extinguished it. was eliminated. Matt’s used Haas machines and had Without the capital to properly fund his att drove straight home and enthusiastically endorsed them. Scott ideas, the business went almost created a prototype – and Jenkins, the machine shop foreman, and nowhere. Three years later, frustrated, the inspirational vision he’d Matt were both thoroughly pleased he sold his shares in McPherson Archery. M experienced in his car worked. That was with the immediate performance of That introductory experience only in 1991, and the SoloCam breakthrough their Haas machines, encouraging them served to make Matt more determined. earned Mathews the single-cam patent to make more machine acquisitions. Being a man of faith, and believing that and was the beginning of Mathews “They’re affordable,” says Scott, “and all things happen for a purpose, he took Archery. “I knew, deep down, that the they’ve kept coming down in price ever comfort in the belief that his first SoloCam had the potential to change since we’ve been buying them. Usually archery company was a learning archery,” is the way he puts it. things go in the other direction – they go experience – and if nothing else, a That again is a prime example of up.” Since that initial purchase a scant lesson in marketing. The degree of understatement; today, most manu- two years ago, Mathews has installed an success he’d experienced with the facturers offer single-cam models. additional eight Haas vertical InnerCam inspired him to develop the Estimates project single-cam sales to be machining centers. In the works at the next step in cam evolution. Two-cam nearly two-thirds of the entire company’s Sparta, Wisconsin, facility is bows, including Matt’s own design, compound bow market. Of all the another 20,000-square-foot building had long shared a common problem: hunting, fishing, camping and outdoor devoted primarily to the machine shop. accurate synchronization of the rollover products on the market, Field & Stream The number of Haas machines

8 CNC MACHINING FALL 2000 9 CNC Machining Fall 2000.sr 10/9/00 3:52 PM Page 10

employed could very well jump to 25 bows are made of 6061, except the Safari couple of days, a few hours back and functions in-house. If something doesn’t within the next couple of years. model, which is 7075. A typical riser forth, and by Friday he was doing parts work, they know about it the same day In the making of a Mathews bow, starts as a 2" x 4" x 27" piece of on the machine. You just kind of pick it and change it. essentially the riser (the main handle), the aluminum. The first operation drills and up – like anything, the farther you go Matt McPherson doesn’t plan to limb cups (which secure the limbs in taps a couple of holes, which are then down the road and the more you use it, slow his highly creative life down position), the cam (on the bottom) and the used to mount the pieces for the next the more familiar you get with it.” At anytime soon. His priorities have long idler wheel (on the top) – everything, in operation. Then they mill one half at a this point only the editing is done at the been in order: God, his family, himself fact, except the fiberglass limbs and the time, typically running three- or four- machine. “Haas has probably got one of and his work. With faith and family as wooden grips – are all machined on Haas up, depending on which model and the most user-friendly controls I’ve ever his foundation, he’s securely grounded, equipment. When asked if there’s a how many will fit on the machine. seen. It’s easier to edit programs there providing him with the clarity to keep concerted effort to bring as much as When asked why they don’t simply than to do it on the computer,” several irons in the proverbial fire. “But possible in-house, Scott’s answer is, “Yeah, batch each operation, Scott replies “It’s comments Scott. He goes on to explain without my incredible staff of it always helps. But I don’t know if we’d nice that every time the door opens, that the control is so easy to learn that employees,” Matt emphasizes, “none of ever want to be totally self-sufficient. It’s you’ve got a finished part. It also keeps all the operators rotate daily in order to this would be possible.” always nice to have someone to fall back a more even flow than batching parts.” get familiar with each machine and each Along with Mathews Archery and on. Say we had a power outage or For Scott, getting the model from operation. That way anyone can fill in its separate Zebra Bowstring division, something, and blew out a bunch of the computer-aided manufacturing for another operator. Matt is revitalizing McPherson Guitars machines. It would be three days or more design to the machine is pretty much a with the introduction of an iconoclastic y all accounts, productivity has before we got back running. How would no-brainer. “I’ve done it enough times new acoustic guitar. Plus there’s Justin risen with each new Haas we ever pick back up, especially with the where I can usually nail it pretty much Charles, his company named after his machine, and Haas machines tight schedule we keep?” on the first one or two pieces,” he B middle son that specializes in high-tech have helped Mathews stay that At Mathews, machining operations remarks. He adds, “I actually had a guy sleeping bags and fly rods. And, just to necessary step ahead. It all goes back exclusively involve aluminum. Most in the other day, he was out here for a balance these out, there’s Autumn to prototyping and keeping most Records, Matt’s own gospel recording label, for which he and his wife Sherry The Mathews facility is being expanded by an additional 20,000 square feet, most of which will be devoted to the machine shop. The number of Haas record gospel CDs – which returns him machines the company uses to manufacture their bows could jump to as many as 25 over the next few years. full circle to his number one priority. Considering that Matt continually travels at the speed of creativity, don’t be surprised if he does indeed uncover a more effective way of rolling the wheel.

Mathews 608-269-2728

10 CNC MACHINING FALL 2000 11 CNC Machining Fall 2000.sr 10/9/00 3:52 PM Page 12

The CMTSE program currently Haas Excellence Underscores reflects the participation of more than 1,000 individuals and 200 machine tool builder and distributor companies. Introduced in 1993, the program was CMTSE Commitment developed in response to surveys showing that customers perceived a need o one has to remind the U.S. Today’s machine tool buyer is more sophisticated for better sales and technical expertise by and educated than in years past, demanding not only machine tool sales engineers. In some machine tool industry of the more from the equipment, but more from the cases the perception was so strong as to distributor. If machine tool manufacturers and seriously limit sales potential. competitive pressures in N distributors want to continue “making the sale,” they The process of certification begins must provide customers with the equipment, the with real machine-tool sales experience. today’s markets, or the importance of knowledge and the service they demand, or lose the Only sales engineers with four years of sale to someone else. related machine-tool employment or building and establishing good relations two years of related employment plus a Story Haas Automation is taking active steps to meet with customers. Rapid changes in these new challenges and provide customers with four-year college degree can register for Greg affordable and effective manufacturing solutions. One the CMTSE program. Once a sales Safko machine tool technology, combined step is the development of a nation-wide network of engineer is registered, the AMTDA independently owned and operated Haas Factory provides a comprehensive two-volume with the growing sophistication of Outlets (HFOs) dedicated exclusively to the sales, Candidate Study Guide that addresses test covers many areas of sales knowledge in machine tool technology, service and support of Haas products. Another step is multi-disciplinary topics covered in the administration and machine tool sales and administration skills.” computerized equipment and the ability the company’s commitment to the Certified Machine CMTSE examination. The study guide technology. Legal and ethical issues, Now that participants have had Tools Sales Engineer (CMTSE) program sponsored by includes references for further study on technical terminology, analytical some time to use their new skills and of machines to perform multiple tasks, the American Machine Tool Distributors’ Association particular subjects, and for each section techniques, time management and even knowledge, many report that the Photos have created new challenges for both (AMTDA). This program ensures that every Haas sales reviews exam goals, key terms, subject financial justification topics are among certification program has yielded some Scott engineer has the education, skills and support matter, recommended reading and the questions covered in the examination. unexpected benefits. “I think it’s a good the manufacturer and the distributor. necessary to address customer needs. sample questions. Participants must pass 70% of the exercise for salesmen to go through, Rathburn The study guides are based on the questions to achieve Certified Machine especially the newer guys to the concept that all aspects of selling must Tool Sales Engineer status. Those who industry,” says Bob Arthur, President of focus on determining, meeting and pass the exam gain the right to use the the Haas Factory Outlet in Elk Grove, Ill. satisfying customers’ needs. A recently CMTSE logo after their name and are “It’s absolutely not a waste of time. I revised sales engineer job analysis was recognized throughout the industry. think any learning experience is always developed by a joint AMTDA/AMT Additional benefits include the beneficial. In the customer’s mind, (The Association for Manufacturing knowledge and expertise gained during they’re perhaps going to be a little more Technology) task force and refined by the study and examination process, the comfortable with a salesman who’s subsequent regional work groups and a self-satisfaction of the accomplishment, become certified – they’re more likely to national validation study. AMTDA’s respect and recognition by colleagues in continue the relationship.” Certification Committee adopted this the industry and more open doors as Arthur points out, “The market and job analysis to serve as the revised customers recognize the value of the customer are much more educated foundation for future examinations and working with CMTSEs. than in years past. We, as salespeople, study guide development. Both the According to David Hayes, Product have educated them. What it boils down study guides and the new sales Manager with Haas Automation and a to is that the salesman has to be more engineer job analysis serve as an member of the AMTDA Certification professional, more on his game. It’s tough invaluable framework for further Committee, “While the examination may to be all things to all people, but you have company training programs. The end be the focal point of certification, it is but to be better at what you do. Customers result is not only better training for one step in a process that begins with expect more from you and have less individuals, but also much more potential CMTSEs broadening their tolerance for ignorance. Business is tough comprehensive company training. experience and studying a wide range of out there, and your competitors are better The CMTSE examination itself subjects. Our customers benefit from the because they’re educated – or they’re no consists of 150 multiple-choice questions CMTSE program because certified sales given over three hours. The broad-based engineers have a proven level of Certified Machine Tool Sales Engineers have a proven level of knowledge in machine tool technology, sales and administration skills. Please see CMTSE page 34 Dave Hayes, above, a CMTSE and product manager for Haas Automation, talks with a delegation from Washington, D.C., at IMTS 2000.

12 CNC MACHINING FALL 2000 13 CNC Machining Fall 2000.sr 10/9/00 3:52 PM Page 14

STILL . . . THE FINAL BY WOLFF OLAF FRONTIER CNC Machining Fall 2000.sr 10/9/00 3:53 PM Page 16

enabled personnel to inspect, fuel and launch The inventive Marshall team also perfected missiles without danger to nearby communities. The America’s first space station – Skylab. The Skylab area’s climate also permitted year-round operations, module was successfully positioned in orbit early on and rockets could be launched over water instead of May 14, 1973. This particular event marked a major populated areas. This despite being positioned in an transition in the history of rocketry. Up until Skylab, area with one of the highest frequencies of lightning the rocket had been the star – the main attraction. strikes in the world, averaging more than 1,000 Skylab in essence stole the show. For the first time, cloud-to-ground strikes per month during the space became a place in which to live and work. summer. The extreme weather presented yet another Flying aboard a rocket became secondary to the work pragmatic challenge for NASA to overcome. being done once Skylab had been reached. The NASA’s Marshall Center (located in Hunstville, rocket became the earthside equivalent of Alabama) was inevitably presented with the commuting to work. significantly greater challenge of developing the On July 15, 1975, a Marshall-developed Saturn I-B family of immense rockets that would eventually take carried aloft America’s half of the first U.S.-Soviet us to our predestined lunar rendezvous. To this day, joint space endeavor – the Apollo-Soyuz project. Marshall Space Flight Center is the leader in the After Apollo, the team at Marshall tackled the next

THE DEVELOPMENT INTEGRATION

All shuttle photos courtesy NASA LABORATORY’S MACHINIST/ PROGRAMMERS here are entire generations that “. . . this generation does not intend to PRIDE THEMSELVES remember exactly where they founder in the backwash of the coming age T of space. We mean to be a part of it – we ON BEING were on July 20, 1969, recalling in sketchy detail the apprehension of waiting for mean to lead it.” METICULOUS. those first grainy television images beamed President John Fitzgerald Kennedy back from the Sea of Tranquillity, live from the September 12, 1962 REPEATED TOLERANCE moon. And the accompanying child-like look On October 7, 1958, six days after TESTING of astonishment on adult faces, as though they the National Aeronautics and Space were universally witnessing a miracle. Man Administration (NASA) was formally IS COMMON. walking on the moon: the stuff of childhood organized, the infant agency initiated Project fantasies. The moon, inspiring poets, Mercury, America’s first human space flight encouraging dreamers and soothing lovers program. A mere three years later, in 1961, development of advanced earth-to-orbit space worthy challenge, designing a revolutionary national throughout history, was on this day the source as Alan Sheppard was drying off from propulsion systems and technologies. space transportation system which came to be of our first out-of-planet television experience, landing in the Atlantic ocean following his known simply as “The Space Shuttle.” starring real live American heroes, who sub-orbital flight, President John F. Kennedy Concurrently, NASA’s Launch Operations proclaimed a single line of dialogue that shall committed America to being the first to set Directorate located at Cape Canaveral’s Space Coast, The shuttle’s main engines are among the most live forever – “The Eagle has landed.” foot on the moon. an element of the then newly formed Marshall Space powerful and sophisticated devices ever created by Flight Center, was elevated to independent status in man. They represent a quantum leap in technology These same generations have Shortly after JFK announced his bold July 1962 and renamed the Launch Operations above the engines which powered the Saturn V. Each permanently etched on their minds exactly plans to a mesmerized country, Congress Center. It was re-christened the John F. Kennedy what they were doing November 22, 1963, approved development of a sandy stretch of of the three main engines of the shuttle provide Space Center (KSC) in November 1963, in honor of when they heard the news that John F. marsh and scrub 34 miles long and 10 miles nearly a half-million pounds of thrust, equaling the the slain president. Kennedy had been assassinated. And we wide on Florida’s east coast, midway thrust produced by all eight of the Saturn I’s first- shall never forget January 28, 1986, the day between Jacksonville and Miami. The The Saturn rockets developed at Marshall to stage engines. And these are the first reusable the space shuttle Challenger alarmingly “Space Coast” had long been determined support the Apollo program, and to honor President engines, capable of burning for up to 7.5 hours total. ripped us back to the reality of the extreme ideal for launches and landings (since 1947, Kennedy’s pledge, were, at the time, the most The thrust-to-weight ratio of these massive engines danger and total lack of tolerance for error the Port of Cape Canaveral had been the powerful space launch vehicles yet built. It was a is the best in the world – each weighs a relatively there is when hurtling human beings into chief launch site for long-range test Marshall Saturn rocket that first took us around the svelte 7,000 pounds, yet puts out a staggering space atop an armory of high explosives. missiles). Virtually uninhabited, the area moon, and then to its cratered surface. amount of power equivalent to seven Hoover Dams.

16 CNC MACHINING FALL 2000 17 CNC Machining Fall 2000.sr 10/9/00 3:53 PM Page 18

“MAN MUST RISE ABOVE THE EARTH – TO THE TOP OF THE ATMOSPHERE AND BEYOND – FOR ONLY THUS WILL HE FULLY UNDERSTAND THE WORLD IN WHICH HE LIVES.”

SOCRATES 500 B.C. CNC Machining Fall 2000.sr 10/9/00 3:53 PM Page 20

And if individual workers took their jobs seriously At 8:45, when the plane touched earth, there was before, a new intensity unrivaled anywhere was now some slight drizzle, but the pilot assured us, with some uniformly experienced. degree of confidence, that hurricane Debbie had *** wimped out and wouldn’t be a threat. Good news for a Californian more attuned to quaking ground than And so it was, with this heavy fragment of space cyclonic winds and ocean surges. The only challenge history categorically imprinted on my brain, that I flew to left now was to fetch a car and find my hotel room at central Florida, in quest of what contribution CNC Cocoa Beach. I could better deal with the stark reality of machine tools play in today’s space program. In Florida’s oppressive humidity after a decent night’s particular, the role American-made Haas machines play sleep. For now, I chose to ignore it. in building the space shuttle and the next generation of space vehicles. The fact that it was August, the hottest At Kennedy Space Center there are three time of the year – and that a hurricane was on a collision individual contractors employing Haas machines in the course with exactly where I was headed – wasn’t missed creation and continuing replication of highly technical by me. What greater contribution could there be, after parts. The unique aspect of these operations is that it is all, than to be destroyed in the line of duty. It was a one of those rare applications in which the inherent commendable rationalization, albeit a bit extreme. speed of Haas machines is not paramount. Far more

THESE ARE RARE APPLICATIONS IN WHICH THE SPEED OF

wenty-four successful launches Several teams of experts were HAAS MACHINES of the space shuttle lulled our organized to find and fix the problem that T had led to the accident. Investigations ISN’T PARAMOUNT. collective consciousness into a false sense of complacency. Viewing them almost immediately focused on a defective MORE CRUCIAL IS THE from the comfort of our homes, the launches joint in the space shuttle’s solid rocket became routine, ho-hum events – until the engines. Propulsion experts devised a EASE OF SETUP, Challenger disaster. number of modifications to the solid rocket OPERATION AND design to remedy the fault. The disaster- January 28, 1986, the skies were clear enforced hiatus in shuttle operations gave and the sun shone brightly on an ACCURACY. Marshall – and other NASA installations – uncharacteristically cold morning at an opportunity to address other shuttle- Kennedy Space Center. This was to be the related concerns. Major advances were 25th shuttle into space: Mission 51-L, the made to enhance the reliability and safety It occurred to me during the flight that in an age crucial is the ease of setup and operation, as well as 10th flight of the orbiter Challenger. This of the turbine blades and turbo pumps in of instant Internet millionaires and microchip- machine accuracy. This latter bit of information was launch, ironically, was one of the most the shuttle’s main engines. An escape generated special effects, it’s easy to take for granted one of the first discoveries I made visiting the initial publicized of the recent launches, because it system was implemented for the shuttle the intense level of competency required in every NASA contractor the next morning. was the first time that a civilian, a crew during leveled flight and aspect of the space program. In this reality, fantasies schoolteacher named Sharon Christa “United Space Alliance (USA) is NASA’s contractor improvements were made to the orbiters’ and dreams don’t successfully launch rockets – McAuliffe, was headed for space. This day for operating the space shuttle,” explained Jesse landing gear and brakes. mathematics, metal machining and sweat do. To play was the coldest that NASA had ever Harris, shop manager of USA. “We have two divisions: a part, any part, in the continuing function of the launched a shuttle. At 11:38 a.m. Eastern On September 29, 1988, the shuttle one in Houston which supports flight, and this one, space shuttle program – in the umbilical support standard time, Challenger left Pad 39A. program returned to flight with the launch of which operates the ground support. Whenever the systems (ground support for launch pad systems), Seventy-three seconds into flight, the STS-26R, the orbiter Discovery. But nearly space shuttle comes back from a mission, it lands, they and in the testing and development of the next orbiter Challenger exploded, killing all everything about how Kennedy Space deconfigure it, take out all the things that were there for generation of spacecraft, the X-33/VentureStar seven of its crew. Center operated changed after the that particular mission, reconfigure it for the next time Challenger accident. The number of program – would be an admirable accomplishment and launch it. What we do here is support that effort. “Greater love has no one than this, that overtime hours allowed was limited in order for anyone involved. One that this journey would We also support a lot of expendable components,” he he lay down his life for his friends.” to reduce worker fatigue, further decreasing soon, I hoped, define. But first, there was a continued. “Many umbilical support components get John 15:13 any chance of error. Even greater quality successful landing of my own to be made. destroyed during launch, and we constantly remake control checks were put into operation. those parts and reinstall them.

20 CNC MACHINING FALL 2000 21 CNC Machining Fall 2000.sr 10/9/00 3:53 PM Page 22

hydrogen/oxygen connectors during automated pre- bearing protects the payload during transportation to launch operations. The four large openings in the test the shuttle. stand are mounting surfaces for liquid disconnects. The consensus of all three Haas-equipped shops One is for oxygen, one is for hydrogen and the others at KSC is that it’s a great source of satisfaction to be are for gaseous nitrogen purge lines. There are also a part of the exploration of space and its concurrent two rectangular openings for electrical disconnects. impact on our future – to be mentioned, perhaps, in The bottom portion of the test stand simulates GSE a paragraph on a page of history, in particular with (ground support equipment), a section of the launch regard to the new evolution of the space shuttle, the pad that disconnects from the orbiter. The top piece X-33/VentureStar. simulates the orbiter itself during launch and ascent. The X-33 is the flagship technology that will By using and carefully monitoring this sophisticated dramatically lower the cost of space access. The piece of test apparatus, engineers will have a clear reusable spaceplane will take off in a vertical position understanding of how the X-33’s umbilical system and use conventional runways to land horizontally functions long before an actual launch. NASA like an airplane. The vehicle consists of a lifting body engineers Greg Melton and Allen Littlefield designed airframe with two cryogenic liquid propellant tanks –

this particular test device. liquid hydrogen (LH2) and liquid oxygen (LOX) –

UMBILICAL SUPPORT SYSTEMS (GROUND SUPPORT FOR LAUNCH PAD his particular shop has programmed the machine by hand on purpose, just to get a feel for it.” SYSTEMS) ARE THE “Tbeen heavily involved with the shuttle for more My next stop was the Development PRIMARY than 25 years. Anything we do affects them Integration Laboratory (DIL), headed by John [the astronauts] – not only the mission, but Poppert and his right-hand man Rusty MACHINING their lives. About 75% of the people here McAmis. The DIL is responsible for creating CONCERN AT now were outside watching when the test parts for stress analysis or eccentric/load Challenger exploded. It affected all of our analysis of umbilical components. They also KENNEDY lives greatly,” Jesse commented hesitantly. use three Haas machines, a VF-5 for SPACE CENTER. umbilical alignment pins, a 1994 model VF-3 USA is currently using two VF-3 vertical (which they say works perfectly) to create machining centers, a single VF-7 and an eccentric coupons (umbilical test parts) and Boeing was the third shop I visited at KSC that placed within the aeroshell; it will use two “linear SL-30 Big Bore lathe. They have also just an HL-4, currently milling Delta-4 rocket cable uses Haas machines. Arlie Calhoun, lead aerospike” main engines. Water will be the primary installed a new large HS-3R horizontal guides (also a part of an umbilical system). machinist, clarified what it is they’re immersed in. by-product of the LOX/LH2 combustion. The entire machining center. All the guys at DIL pride themselves on being “Most of what we do here is for the payloads,” he spaceplane (with all fuel tanks and engines) will take One of the unique features of the Haas machinist/programmers, very proficient and said. “Right now we’re heavily involved in space off and land as a single unit. The reusable launch control is that it is the same on all machines, meticulous in every aspect of their day-to- station payloads.” vehicle will be capable of reaching an altitude of up day work. to 60 miles and speeds in excess of Mach 15. allowing operators to move easily between The Boeing shop uses two Haas machines, a new mills and lathes. “As far as buttons and One of the most inspiring pieces of VF-2 and a VF-8. Machinist Peter Koomjiam is Today, as cliched as it may sound, it’s clearly still positions,” explains USA machinist Steve experimentation being done at the presently working on an insert bearing machined reasonable to refer to space exploration as the final Jezowski, ”it’s all the same. Everything is Development Integration Lab is the X-33 from 6061 aluminum. The bearing is designed to frontier. Tomorrow, led by NASA’s reusable launch laid out the same on all the controls.” Rise Umbilical test stand, a device used to provide an interface between the flight payload (in vehicle, we may be referring to it as something new – It’s not uncommon for USA’s CNC test simulated pre-launch connections and this case a space station element) and the lifting “open for business.” machines to run all day – 10 hours if need launch disconnects of the X-33 reusable device. The lifting device is called the “strongback.” “Never become so blinded by the light that be. Much of the programming is done off- launch vehicle. The strongback is used to transfer the payload to a mobile transporter. The transporter then takes the we forget to imagine, nor remember, how it feels line, but not all. “We use Quick Code for the The alignment pins, which are payload to the launch pad, where it is installed into to be amazed.” threading and other stuff,” says Steve, “and machined from 6061 T-6 aluminum on a the space shuttle payload bay. In short, the insert I use G code for some of the roughing. I’ve Haas VF-5, align the electrical and Unknown – 2000

22 CNC MACHINING FALL 2000 23 CNC Machining Fall 2000.sr 10/9/00 3:53 PM Page 24

depends on modern technology to provide design extensive tunnel testing in the concept development FAST THROUGH information in a timely and extremely accurate fashion. and preliminary design stages of a given project. Then there’s more in engineering and manufacturing NASA Looks to Technology development. One of our goals is to shrink these test THE “NASA is starting work on the next generation of windows so that customers get their information in a TUNNELS shorter period of time. This allows aircraft development space transportation access technology,” says Pete Zell, to go from taking ‘X’ number of months to ‘X’ minus as BY PRESTON GRATIOT Customer Technical Interface Manager for the wind tunnels at Ames Research Center, Moffett Field, Calif. much as we can deduct. The message we receive from “Our test facilities here at our Wind Tunnel Operations our customers is, we’ve got to do it faster. We’ve got to Division are ready to support these new programs with give them the same quality, but do it in the shortest rapid turnaround of essential flight-test data – much time possible.” faster than we did with the shuttle program. CNC With wind tunnel time running thousands of machines are an integral part of the plan that brings dollars per hour, time savings quickly become this all together and allows us to do it faster.” important to the customer. This is where the division’s Located on the southern tip of San Francisco Bay, recently installed Haas CNC machining centers and the Wind Tunnel Operations Division specializes in CAD/CAM software come into play. aerodynamic testing and proof-of-concept projects. The “We’ve got to be able to make parts quickly and normal workday can include everything from testing get them onto the test model without delays or helicopter rotor blades to verifying airflow patterns on inaccuracies,” says Zell. “Rapid turnaround is the a supersonic air transport prototype. This testing is so impetus for placing the CNC machines near the testing ince the dawn of time, man has looked gathered. There were inherent flaws with the whirling important in today’s world that it is not uncommon for facilities. It’s one of the most important factors in our skyward, curious of the creatures that arm, however, that didn’t go unnoticed. For one, the these wind tunnels to run around the clock. success. Then, if a change needs to be made to a model, S motion of the arm churned up a great deal of air freely ruled the air above. Flying seemed it’s just a matter of tweaking the component design an excellent method of escape from the perils and turbulence, making it difficult to get accurate Cycle Times and Savings a degree or two and quickly fabricating a new one.” limits of an earthbound existence. The restrictions and measurements, and the arm’s eggbeater action tended If you look at aircraft development in terms of time, Zell noted that some of the new things coming dangers posed by gravity and cumbersome legs clearly to set the surrounding air into a rotary motion. it goes through a preliminary design stage, then into down the pike at the research center include a number inspired man’s imagination and, perhaps, provoked the Frank H. Wenham (1824-1908), a council member the concept development stage and then into of space transportation programs. “The X-34, X-37 and first dreams of free flight. of the Aeronautical Society of Great Britain, solved the engineering and manufacturing development. Only X-38 projects are all potential customers for our facilities. Early seekers of flight patterned their machines problem in 1871 by designing and operating the first when the flight characteristics of a given design are Where we previously did a lot of work on the space after the one working example they had – birds. But it wind tunnel. In Wenham’s words, “it had a trunk 12 proven do they go into production flight testing. shuttle, we’re now moving into the next generation of feet long and 18 inches square to direct the current became staggeringly apparent that far more than “A big chunk of this developmental cycle is wind space transportation vehicles. That’s what NASA’s horizontally, and in a parallel course.” A fan-blower watching birds was required to unlock the secrets of tunnel testing,” says Zell. “It’s not uncommon to find charter is all about: to be at the forefront of technology.” flight. Man quickly realized he knew nothing of the upstream of the model, driven by a steam engine, forces acting upon the surfaces cutting through the propelled air down the tube to the model. atmosphere. A method was needed to test the fanciful With the advent of the wind tunnel, man’s pursuit theories of human flight. of flight began to soar.

Recognizing – as Leonardo da Vinci and Sir Isaac The days of whirling models on the end of an arm Newton had before them – that they must either move have thankfully long been abandoned in favor of Wind-tunnel testing of scale test models through the air, or blow air past stationary rigorous “flight” testing in wind tunnels. One of the models has advanced well beyond models, these pioneers of flight were motivated to largest collections of active wind tunnels and related the simple verification of flight search for relatively steady natural wind sources. support programs in the world can be found at NASA’s stability. Advanced technologies Models were mounted above windswept ridges and in Ames Research Center in California. allow researchers to track the the mouths of blowing caves. Alas, the perversity of aerodynamic pressures that can Modern wind-tunnel testing, however, goes far nature finally forced them to turn to various mechanical be expected in actual flight beyond that of simple airborne craft. Today, the tunnels schemes for moving models through still air. The conditions. Here, a test utilizing at Ames serve not only NASA and its numerous cheapest and simplest contrivance for this was the pressure-sensitive paint, which programs, they are also reserved for a world of “whirling arm,” a sort of aeronautical centrifuge. fluoresces under certain light aerospace customers, and even the occasional full-sized conditions, shows the pressure Up until the end of the nineteenth century, the 18-wheel tractor/trailer assembly. Yes, the study of patterns on the space shuttle at whirling arm provided most of the aerodynamic data aerodynamics is a science that affects us all, and NASA speed in the upper atmosphere.

24 CNC MACHINING FALL 2000 25 CNC Machining Fall 2000.sr 10/9/00 3:53 PM Page 26

A wind tunnel model is traditionally Coordinated Efforts mounted on a long balance arm that The Moffett Field NASA facility has a customer registers the minute forces exerted by base which is mainly, but not limited to, the aerospace the model as it reacts to the airflow. industry. Many times, wind tunnel customers will bring Testing frequently includes various in a model that’s been fabricated elsewhere. But now, wing configurations with flaps and that “outside” model also comes with documentation control surfaces in different positions. that shows what was done. “We can then use that This is where the Ames Research information to build up the locating holes and mating Center CNC support system saves surfaces in our CAM system,” says Jack Marsh, veteran client time by providing rapid, on-site model maker and operator of the new Haas component fabrication to meet the VF-6. “That way we have the documentation should customers’ changing test needs. Parts we need to fabricate any additional model components that used to take weeks to arrive can for our customers.” now be made on demand. There is no limit to the amount of testing you can do with a model when you configure it for modular variations. “The only limitation is whether you can build it to meet the structural requirements. As long as you can make it strong enough, you can build in testing Rapid-Prototyping Method rotary table, which gives us the ability to create capabilities that will allow you to replicate most any flying attitude or conditions,” explains Marsh. The wind tunnel support project developed out of components that demand more sophistication.” the need to rapidly respond to customer requirements. If initial tests show a transitional phase between Time Saver Plus Tunnel Operations Division offers its customers. “It is “We needed to find a way to make model parts from two setups, such as a theoretical stall condition, the unique in that every one of these advanced test structural aluminum and steel here on site,” says Paul Wind tunnel testing exerts forces on the model that CNC machines can quickly be programmed to machine techniques, including rapid manufacture of test model Keller, Experimental Facilities Development Engineer. are substantial, and that’s why you will never see cheap, new components in varying configurations until the components along with speedy graphic acquisition of “We do not fabricate whole models, but we need to flimsy pieces on a test model. They have to be built out optimum characteristics can be determined and data, makes for a much more productive wind tunnel provide design support for our customers that allows of structural billet, and they have to be machined and recorded. Better to establish these characteristics in a test,” explains Marsh. “More so than even just three or for their test variations. finished to a very tight tolerance. In fact, the wind tunnel that at the hands of a human test pilot. four years ago. We – and our customers – have seen performance of the model is directly dependent upon “In the past, our customers would bring their This infusion of CNC technology has become an dramatic increases in productivity because of this how accurately the required shape has been machined. model and all the test pieces to us for testing.” Keller important part of a suite of testing that the Ames Wind integrated wind tunnel support program.” continues. “Then, in the course of running the wind “It used to be that this required weeks or even tunnel test, they might see something in the data they months,” explains Keller. “Now, we are expected to do wanted to investigate a little further. Without the ability the same thing in a matter of days. The CNC machines to fabricate new parts on-site in a timely manner, they and CAM software allow us to work in a tightly would have to reschedule testing for a later date. These integrated way with the engineers and designers as the delays usually proved costly.” testing goes on, so we are ready to go when they need to make modifications.” New Technologies “I was given the go-ahead to put some innovation Customer Relations in place to address the issue,” says Keller, “and that is “Our outside customers are excited when they see where the CNC machines and CAM software come in. our CNC-enhanced capability,” says Mike George, The machining centers give us the versatility and speed Division Chief of Wind Tunnel Operations. “Of course, it we need, and the Surfcam gives us the ability to talk to benefits them directly. We want it to benefit them. In a variety of CAD systems. This combination allows the fact, the whole point of this rapid response system is to guys in the Wind Tunnel Operations Division model improve our ability to focus on the customer’s needs. shops to fabricate parts for our customers in a They’re happy when they can get parts made in such timely fashion. a short time.

“The CNC machining centers are a key part of “Our CNC-based system is also more repeatable, making this support program happen,” Keller adds. “We and more accurate. Nowadays, repeatability is the main wanted a fairly large capacity machine, so we got one factor. You always know how the part was cut, and you with 64"x32"x30" travels. We also got the multiple-axis can easily substantiate your pathways.”

26 CNC MACHINING FALL 2000 27 CNC Machining Fall 2000.sr 10/9/00 3:53 PM Page 28

CAD/CAM For Toolmaking: It Really Is Different

he process of choosing must have visual appeal, while job shop-machined CAD/CAM software for parts are usually unseen components. Tooling businesses have very different drivers, production machining is usually too. Tooling shops generally compete on the basis of T delivery time, including the ability to handle frequent straightforward. Managers can’t go too engineering changes. Concurrent engineering eliminates much of the bureaucracy and multiple far wrong buying the package with the reviews of new-product development, and many Story most features at the best price. sequential tasks are now done simultaneously. Product changes and redesigns are often executed Bart However, if one is making tooling, the while tooling is being built, not before, resulting in Simpson engineering changes. Deadlines, however, are almost choice is anything but easy. never extended. Tooling businesses and production shops also get Tooling, especially tooling made for complex their data in very different ways. Production shops injection molding, forging dies and casting dies, is full generally have CAD systems in common with their of highly styled curves and artful shapes. Whether the largest customers. Depending on the industry and type designer’s intent was to replicate a lifelike image, or to of work, one of the major CAD/CAM systems is fit a form to the human hand, the resulting sculptured usually a de facto standard. Where different systems are forms can heavily tax typical production-type in use, DXF, IGES and other geometry translators CAD/CAM packages. They often lack many of the usually suffice. special capabilities required for producing all but the Tool shops rarely have this luxury. Typically they simplest tooling. must work with many customers who have different This is not to say that the doubly curved core and systems, so geometry translation is inevitable. cavity surfaces cannot be manufactured with Moreover, tool shops have to design the product they production-type, or conventional, CAD/CAM. In fact, make – the tool – themselves, deriving the necessary it’s done every day. But conventional CAD/CAM is geometry from the customer’s model of the finished solids-based, and using it for tooling is cumbersome. part – a model that is often flawed. full advantage of every cutting option directly: Whatever the customer sends mounting bosses, and it contains any The CAD file may look good, but fillets and blends they can find or invent. Fast-running to the shop, the shop sends to the slides and lifters that must be used. MANIPULATION, TRANSLATION AND RAPID joining adjacent surfaces may be missing or incorrect. code, and especially fast toolpath machine tool. This is not true in • In mold geometry, sharp corners RECALCULATION This forces CAM programmers and machinists to recalculation, is not a luxury in toolmaking. Tooling customers send a are no-nos. Wherever any two surfaces “eyeball” many fine details. The result is that the tool, All this adds up to a need for software that has toolmaking – it’s a necessity. CAD model of the part to be made. The join, they are filleted; wherever there are and hence the product, never quite matches the design. been developed for mold making. In CAD, surface Major challenges in mold making toolmaker turns the exterior surface of three or more surfaces, they are With more companies using mathematical models manipulation features must be extensive – and highly which must be addressed in CAD that model inside out to get the mold’s blended. Mold making requires that the rather than solid models – and inspecting to those interactive. The package should handle solids and software: cavity. Thus the cavity produces the fillets and blends meet their adjacent models – the drawbacks of conventional CAD/CAM surfaces in the same database, and should have • There is little time to optimize part’s exterior, visible surface. The surfaces precisely. are becoming obvious. powerful features for finding and fixing surfaces that toolpaths, even though a single mold geometry of the cavity surface is then • Every flat surface that is parallel Even a brief look at the differences between job are missing or incorrectly trimmed. This defines the cavity or core may use dozens of them. offset by the thickness of the material to to the tool’s direction of “pull” (the axis shop machining and the production of tooling need for best-in-class software; this is what puts them at Instead, the software has to optimize be molded to get the surface of the tool’s of its opening) must be flared slightly reinforces the point. Mold makers carve tooling from the “high end” of the CAD/CAM market. automatically. Since few toolpaths are core. Since the core forms the part’s outward. Without that, the part will blocks of steel costing thousands of dollars. Many CNC In CAM for toolmaking, rapid recalculation is vital. ever used more than once, it is nonsense invisible interior surface, tolerances are stick in the mold, which could cause a machining jobs begin with steel preforms costing a few Toolmakers and programmers may dry-run half a dozen to spend hours optimizing one of them loose and surface finish requirements tooling crash costing the tool shop or dollars (or just a few cents). Every mold is unique, so no different machining strategies before they find the one to save two minutes. are minimal. But the mold’s core is often molder thousands of dollars. Tooling two mold jobs are identical. Job shops often produce that best balances metal removal rates against surface • In production CAD, CAM and extremely complex, as it must also form shops need software that creates draft hundreds or thousands of identical parts. Molded parts finishes. Mold shop engineers and programmers take CNC work, geometry is machined the part’s internal stiffener ribs and angles quickly, and that highlights

Bart Simpson is the International Marketing Manager of DELCAM International Inc.

28 CNC MACHINING FALL 2000 29 CNC Machining Fall 2000.sr 10/9/00 3:53 PM Page 30

anyone outside the tooling company block, a large range of additional cutting • To reduce the need to resort to who needs it – people in marketing, strategies is required. Many of the EDM. Setting up and programming documentation and purchasing, for milling strategies most useful to tool EDM machines is tedious, and EDM is example. shop programmers would be exotic in a five to 10 times slower than cutting Good toolmaking software offers a production machine shop. These metal, not counting the time needed to “hybrid modeler”: databases and include raster for flat or shallow areas, make EDM electrodes. functions that operate equally well constant Z for steeply sloping areas, and Despite the length of this piece, we with solids and surface models. rest milling, pencil milling and corner have just scratched the surface of what Surfaces are clearly preferred over picking for small internal corners. Yet CAD/CAM is all about in making solids for most of the work, especially these and many other strategies are in tooling. A good tooling package has in the cavity. Trying to create everyday use in mold shops, and must literally dozens of features not found in sculptured “organic” or ergonomic be accommodated by the CAD/CAM conventional CAD/CAM offerings. surfaces by building them up from software packages they use. Doing without any one or two will not hundreds of tiny solids is a form of Many of these cutting strategies are bring economic ruin. But trying to use mental cruelty. Solid modelers often also used in finishing. Roughing production-type software for mold lock up under the calculation loads. typically machines cavity and core making can add hundreds of hours of Nevertheless, solids have a valued surfaces to within 0.030 inch tolerances. needless work. This alone can make a place in toolmaking – as the The steel is then sent out for stress- shop uncompetitive in bidding, and accompanying line drawing shows. relieving. When it comes back from the unprofitable if it somehow does get the This is the geometry for the core of a heat-treater, finish machining begins. work. Without many of these features, tool that molds handles for chainsaws. Mold shop engineers and programmers it is the tool shop’s machinists who will A great deal of the handle’s strength make dozens, if not hundreds, of actually determine the dimensions and comes from the “fish bone” ribbing toolpaths for finishing. They do so for tolerances of the core and cavity formed by this particular mold core. several reasons. These include: surfaces. The complex ribbing was created with • To guarantee the tool’s solids, draft-angled, then merged into dimensional integrity and hence the cast the surface geometry of the core – all in or molded part’s accuracy and DELCAM International Inc. a matter of minutes. conformance to its designer’s intent. Windsor, Ont., Canada • To reduce or eliminate slow and Copyright 2000, MINDFEED® Marcomm, ACCOMMODATING ROUGHING costly hand finishing. Santa Fe, N.M., USA AND FINISHING STRATEGIES

surfaces that should have been must be able to generate three or four Even better is tolerant modeling. Rough machining is only “drafted” but were missed. identical EDM electrodes by extracting As the name implies, tolerant modeling occasionally part of some production • Deciding which parts of the the geometry from the tool’s cavity allows the user to establish a tolerance CNC work, since carefully sized, often product are to be molded in the core surface and inverting it. for geometric errors, for example, 0.010 preformed, stock is loaded into the and which in the cavity can be inch. Gaps and missing surfaces below machine tools. Toolmakers, however, VIEWING, “HEALING” AND tedious. But this can be done that size are simply ignored by the start with rectangular blocks of tool TOLERANT MODELING instantaneously in tooling-oriented software. The cutting tool goes right steel often costing thousands of dollars. software once the mold’s parting line Toolmakers have endless geometry over them, as if they did not exist. In making large tools, hundreds of has been established. problems with customer files. Among Healing, on the other hand, involves cubic inches of steel must be “cleared” • Toolmakers must create “run-off” the most troublesome are tiny missing recalculating the trim boundaries of as quickly as possible. This is especially surfaces and mold locks. These clamp surfaces at the bottoms of corners and adjacent surfaces more precisely. true of tools for auto bumper fascia and the tooling closed and seal it against the blends, and tiny gaps between surfaces Theoretically, healing offers greater instrument panels. CAM capabilities pressures of the injection molding or that should be joined. Much attention accuracy, but there can be a steep price. for this include offset and profile area die casting machine’s cycle. The has recently been lavished on healing, If there are significant differences in clearances, block definition, auto- functionality needed for these tasks is especially the online variety where the their tolerances relative to the size of the angle raster roughing, climb and not included in CAD/CAM systems Internet is used to send files to vendors part and “size of the world” parameters, conventional milling, pocket milling developed for production CNC work. for a fee (with no guarantee of security models cannot be exchanged between and skimming. All of these techniques • When tool details are simply too or success). A smarter alternative is to CAD systems. are designed to remove as much metal delicate to be machined, these surfaces reverse this process, downloading the A viewer that can support all of as quickly as possible. are created with electrical discharge software for healing and keeping huge these functions is invaluable. The Because the cavity, the most critical machining (EDM). Tooling software tool design files off the Internet. viewer provides read-only access to part of the tool, is recessed into the steel

30 CNC MACHINING FALL 2000 31 CNC Machining Fall 2000.sr 10/9/00 3:53 PM Page 32

Rock Valley replaced the original machining centers in 1997, purchasing Haas Rocks the Valley two new VF-E models with probe systems and rigid tapping. The school also added a third HL-1 lathe that year. ock Valley College in Rockford, fourth-year precision machinist course, which focuses Class size in the Technology Division is on CNC applications), notes that, “The machines were in the range of 12-15 people, and Illinois, was founded in 1964 as a attractive, easy to use, and they were full-sized having three turning centers means liberal arts community college. machines. Table-top machines can only perform so more hands-on time for each student. R well, and we wanted to use and teach with actual Another VF-E was added in 1999, and At the time, its Technology Division industrial equipment.” By this time, the manufacturing in June of this year, the two original lab had been converted to a full-time training lab where HL-1 lathes were upgraded to new SL- was a small part of the school – that all of the machines were for hands-on use. 20s. According to McCord, “Rock Valley is committed to bringing the has changed considerably. Today, by the time students complete the CNC courses, they can perform simple job setups, set tool latest technology to our manufacturing students, and Haas has made it Story Today, the Technology Division at Rock Valley is offsets, use wear offsets, and they have a good grasp of well known locally for its two-year degree programs, as cutting tools and their operations, as well as control possible for us to do so.” New lab Linda well as the non-degree courses available there. Between utilization. Students also learn basic machining exercises and projects have been added Dorr 500 and 600 students a year attend Tech Division operations, tool selection, feed and speed calculations to the curriculum to further expand classes. These include Computer-Aided Design, and program formatting. Advanced classes are also student experience. & Stan Building Trades and Automotive Design programs, in available for experienced machinists to learn more The CNC machines at Rock Valley McCord addition to a CNC training program. about programming and tooling applications. are used for classes in the Automated Much of the reason for Rock Valley’s reputation is The faculty’s desire for students to learn on Manufacturing degree program, in the the 3,000-square-foot manufacturing lab housed in the industry machines wasn’t the only motive for Automation Skills vocational program school’s Technology Center. The lab was originally a upgrading the lab. The Technology Division at Rock and in the Precision Machinist program grant-funded, demonstration-only manufacturing cell Valley College has a conference center that is often used that is part of a tool & die that showcased the state of the art in lights-out by local companies. “The conference center looks down apprenticeship. Each semester sees 50 to 75 students using the Haas equipment. Photos manufacturing. While the lab’s computer and CNC on the lab,” explains McCord. “Industry customers saw technology were the latest and greatest industry had to those table-top models and thought students weren’t Many of the students in the CNC for CNC openings. Like the average he needed to find a job as a CNC Sherry offer in 1988, lab visitors only got to look – they couldn’t learning on ‘real’ machines. And we wanted students training program – and all of the part- student in the Tech Division, the machinist, and feels it’s a “great time instructors – work full-time in the Greenlee class had some shop skills and accomplishment” that he can return to Pritz actually use any of the equipment. This began to change on the real thing as well.” a few years later, when the Tech Division started manufacturing industry and represented both genders and all ages teach the classes to others. developing a CNC training curriculum. The early CNC spend their evenings in the and ethnic backgrounds. The class Gordon Skattum, Director of the classes quickly made it evident that, in addition to classroom. The instructors bring started out on the vertical machining Technology Division, notes that, “Today, classes in blueprint reading and measurement, machine real-world experience into the centers and then moved to the lathes. companies look for fast-track, state-of- tool operation and G-code programming, students classroom, to the great benefit of While several of the students had the-market education and training.” needed hands-on practice. the students. Several of these worked as fill-in operators, none of The Tech Division’s CNC training The first hands-on CNC machines at the part-time instructors are them had ever set up a CNC machine. program provides just that. Woodward Technology Center were of the table-top variety: a small graduates of the Rock Valley Within a few weeks of starting the class, Governor, Ingersoll Milling Machines, lathe and a milling machine. Their presence meant the program who return to pass on they had learned to use the control to Sundstrand Aerospace and Barnes lab was no longer a demonstration-only showroom; what they’ve learned. establish work offsets and tool length International are just a few of the local now it had a training section. In 1990 the Tech Center Many regional companies offsets, enter commands through MDI companies whose CNC operators have bought its first Haas vertical machining center, a VF-1, take advantage of the classes and set up tooling, as well as learning attended classes at Rock Valley. Gordy and continued to use the table-top machines as well. and lab equipment at Rock the principles of safe operation through Skattum notes further that “the Due to the low cost and excellent performance of the Valley to train new operators. single-block usage and rapid travel challenges facing U.S. manufacturing VF-1, plus the success of the classes, another VF-1 soon This summer the Tech Center reduction. The class instructor, Mike [include] a shrinking workforce, joined the first machine. ran a CNC setup and operation Tremble, was a student in the Rock demand for higher skills, explosions in By 1995, Rock Valley’s CNC training program had class for Greenlee Textron, a Valley CNC program when it began in new technology and issues of higher grown to the point where the table-top machines were local manufacturer. The nine 1990. Tremble now sets up, operates and quality and productivity. The ongoing sold and two more Haas machines – a couple of HL-1 students were all Greenlee programs CNC machines for Osmonics, partnership between Haas Automation lathes – were brought in. Stan McCord, head of the employees who wanted to another local company. He credits Rock and Rock Valley College is helping to Automation Skills program (and instructor of the upgrade their skills to qualify Valley with giving him the “boost up” meet those challenges.”

32 CNC MACHINING FALL 2000 33 CNC Machining Fall 2000.sr 10/9/00 3:53 PM Page 34

> CONTINUED FROM . . . > CONTINUED FROM

EUROPE continued from page 3 25,000 continued from page 3 continuous opportunity for technology, new manufacturing CMTSEs to map out their processes, sales methodology and educational goals. Those who industry marketing trends.” Kingdom through Haas Automation U.K., in Oxnard, California – which have made the commitment to Machine tool sales typically involve Ltd., with no change to that organization, averages production of more continued self-improvement large amounts of money and extensive and will also continue its existing than 400 machines per month – become a more valuable negotiations. The CMTSE process adds relationship with the Machine Tool Division has allowed Haas to reach the resource to their customers.” credibility, because the salesman is of Mikron (recently sold to Agie- milestone 25,000th machine in Sales engineers who work knowledgeable in both the technology Charmilles). The Haas products represented a mere 12 years, while at the toward CMTSE certification and sales administration. In short, he can by Mikron will continue to be delivered as same time reducing prices obviously gain knowledge and professionally sell machine tools. But, the private-labeled, Mikron-branded products across the board. experience from the process, but program also raises the level of according to an agreement reached with Since the introduction of they also gain a great deal of self- expectation for machine tool sales. Haas Mikron and Agie-Charmilles. Mikron will the very first Haas VF-1 vertical respect and confidence. Those intangibles Automation relies on its HFOs to retain exclusivity to the Mikron-branded machining center at IMTS in will show over time as CMTSEs work incorporate CMTSE certification as a basic products while Haas will market under the 1988, Haas Automation has Haas Gen Mgr Denis Dupuis, left, presents Chuck Thudium, Jim Archer and with customers. According to Steve requirement when hiring and training Haas brand name. earned a worldwide reputation Lyle Archer of AT Precision with a plaque commemorating the 25,000th Haas CNC. CMTSE continued from page 13 Huser, a CMTSE and President of the new sales engineers. Certification requires “We believe the Mikron-branded as a builder of high-quality machine to reduce costs, and the market is being Haas Factory Outlet in Tempe, AZ, “I’d a salesman to know and understand the product will continue to grow at the same tools designed to keep job shops and flooded with low-priced imported longer in the business.” participate in the CMTSE program again, manufacturing process and have a basic levels the organization has seen over the manufacturers up and running. The machines, Haas Automation continues With more than 25 years in the even if the designation wasn’t a understanding of business. past five years,” says Denis Dupuis, General company moved to its present 620,000- to provide the world with a complete business, Arthur notes that, “Selling is a requirement for HFOs. My salesmen While the CMTSE certification Manager of Haas Automation. “By square-foot Oxnard location in March of line of high-quality, affordable, lot about comfort and respect, and a have definitely developed more self- process does not make sales engineers marketing the Haas-brand products 1997, and continues to grow and increase American-made machine tools. Haas customer is more likely to respect a confidence, and involvement shows specialists in every type of machine tool, directly, we will reach a different segment of its market share annually. currently ships more units per month salesman because he has done something customers that you’ve made the extra it does broaden their expertise. As a the European market that is currently not At a time when many manu- than any other machine tool builder like this on his own and achieved effort. The CMTSE certification simply result, they can offer customers more being explored.” facturers are moving production offshore in America. certification. I definitely see value. I’m validates that effort.” specific solutions to their manufacturing very much in favor of education.” Huser also noted the “increased problems. For Haas Factory Outlets this AMTDA requires all CMTSEs to camaraderie generated among sales results in enhanced competitiveness, an recertify every three years through engineers during the preparation expanded customer base and more We’re Growing. documented ongoing professional process. We conducted study sessions satisfied customers. Any advantage for a Introducing development, such as participating in using the Candidate Study Guides as company starts with sales – with the X elp lead the way into the 21st century with America’s leading continuing education, active membership our preparation outline. I encourage impression that salesmen make on the HCNC machine tool builder. Be a part of the team. Bring your Haas SHOP-X-CHANGE. talent, imagination and commitment and join us in building a in professional organizations, publishing this activity, as we all learned from customers. Lots of good machine tools articles and a variety of other activities to the process.” are available in the marketplace. From a strong, successful and prosperous tomorrow – today. What: An electronic posting area at WWW.HAASCNC.COM maintain proficiency. AMTDA is very pleased with the competitive standpoint, the better job a where Haas-equipped shops can post classified ACCOUNTING MACHINE SHOP According to R. Stephen Flynn, a comprehensive Candidate Study Guides salesman does representing the product, messages, want ads and other business-related CMTSE and President of the Haas and their effectiveness in preparing the better chance he has to get the order. messages. ELECTRICAL R&D MARKETING Factory Outlet in Fairport, N.Y., “Making candidates to sit for the examination. The CMTSE designation is Why: Perhaps you have too much work and need to job ELECTRICAL PRODUCTION MECHANICAL ENGINEERING the commitment to become a CMTSE “This program is noteworthy not becoming the standard within the out some of your long runs to another shop. FACILITIES MAINTENANCE PRODUCTION/ASSEMBLY is also a commitment to continuing because of the exam or designation, but industry. Eventually, it will be a Or, maybe your business specializes in a particular type of work and you could use education. It’s easier than ever to take because of the process to increase the benchmark. Achieving certification HUMAN RESOURCES PURCHASING over-runs from other shops. Or . . . advantage of the many educational knowledge base of our industry’s sales demonstrates meeting a certain criteria of INFORMATION SYSTEMS QUALITY ASSURANCE opportunities available today – night engineers,” says Greg Safko, AMTDA’s knowledge above the entry-level person, How: Submit your classified-style posting via e-mail to [email protected]. We’ll review the content INVENTORY/ WAREHOUSE SALES DEPARTMENT classes at a local college or university, Senior Director of Member Resources, and demonstrates an active involvement and post your message in the X-CHANGE area of the LEASING DEPARTMENT SERVICE /APPLICATIONS seminars on topics pertaining to the who oversees the program. “It is truly in the industry. The thought that the Haas home page. industry and Internet-based courses, an education and training program. The CMTSE designation may become as MATERIALS HANDLING SHIPPING/RECEIVING To view message postings, go to HaasCNC.com to name a few. CMTSEs realize Candidate Study Guides, which were recognizable as, for example, the CPA, is and click the X-CHANGE button on our home page. that continuing education leads to developed as a resource for machine not as remote as some may think. self-improvement. The three-year tool sales engineers, are constantly “CMTSE” – look for it when doing We reserve the right to edit or disqualify all submissions. recertification process serves as a updated to reflect the changes in business with Haas.

34 CNC MACHINING FALL 2000 35 CNC Machining Fall 2000.sr 10/9/00 3:53 PM Page 36

> PRODUCT news > PRODUCT news It’s The Right Tool in Chicago at IMTS 2000

en thousand square feet of booth space, 30 machines making Tchips and standing room only. That was the scene for eight straight days in the Haas Automation booth at IMTS 2000 in Chicago, September 6–13.

Record numbers attended this year’s International Manufacturing Technology Show, and the Haas booth was by far the most popular. According to show management, 1 to 10,998. Gene Haas, president of Haas Automation, IMTS drew much attention from attendees and the Haas Automation logged more than twice as then used a random number generator to select the trade press alike. In particular, the small-footprint many leads as any other exhibitor at the event. winning entry. machines – the Mini Mill, Mini Lathe and SL-10 – With many exhibitors cutting nothing but air The lucky winner was Mindy Driscoll of Hamilton, proved quite popular, as did the various five-axis this year, the Haas booth was somewhat of an Michigan. She and husband Tom operate Driscoll machines – the HS-1 Auto Bar, the VF-5TR trunnion anomaly, as all 30 Haas machines ran non-stop Machine Shop Incorporated, a small job shop that services machine and the VR-6 router. throughout the show, cutting through more than the plastic injection molding industry. The new Mini Mill For those unable to attend this year’s show, or who 70,000 pounds of aluminum, brass, 1018 steel, cast will be their first Haas machine. just want another look at what was there, here’s a iron and H13 tool steel. As expected, the new Haas products displayed at selection of images from the Haas booth. As if that wasn’t enough to draw attention, show exhibit halls by roving Haas employees randomly attendees were kept on their toes throughout the various distributing $100 bills to those seen wearing “The Right Top left: A close-up view of the new Haas Mini Tool” buttons. A total of $5000 was handed out to lucky Lathe cutting a part. This prototype machine got attendees caught displaying the distinctive Haas buttons. almost as much attention as the Mini Mill. Visitors to the Haas booth could also register to win a brand-new Mini Mill valued at $30,000. By swiping their Lower left: The prototype HS-1 Auto Bar, a five-axis attendance cards at the booth, they were automatically HMC with bar feed capabilities, also attracted entered in the contest (non-attendees could enter, as well, much attention during the show. by filling out a form at their local Haas Factory Outlet). Top right: The Haas booth was by far the most The winner was selected after the closing of the show popular, logging more than 10,000 visitors in just from a total of 10,998 entries (10,349 from the show and a few short days. 649 from local HFOs). Bottom right: A close-up view inside the HS-1 Auto Entries were compiled into a database, then arranged Bar showing a typical part being machined. in alphabetical order and assigned a number from

36 CNC MACHINING FALL 2000 37 CNC Machining Fall 2000.sr 10/9/00 3:53 PM Page 38