INNOVATION 2017 - Nikken World€¦ · Mini-Mini Advanced α Chuck ... CNC Rotary Tables NIKKEN I/O...

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nikken-world.com INNOVATION 2017

Transcript of INNOVATION 2017 - Nikken World€¦ · Mini-Mini Advanced α Chuck ... CNC Rotary Tables NIKKEN I/O...

Page 1: INNOVATION 2017 - Nikken World€¦ · Mini-Mini Advanced α Chuck ... CNC Rotary Tables NIKKEN I/O NCT200 Ultra Big Bore ... of absolutely any movement or ‘pulling-out’ of the

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I N N O V AT I O N

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ContentsNC Tooling SolutionsX-Treme Milling Chuck

Balancable Shrink & X-Treme Shrink

Mini-Mini Advanced α Chuck

EVO & Spectrum Reamers

Zero Fit Holder

ZMAC Advanced Boring

RAC Advanced Boring

eMAC Digital Boring

New NC Tool SolutionsSK Coolant Collet

3 Angle Clamper

SK Sleeve (Slim Chuck) & MMC Sleeve (Mini Mini Chuck)

Vacuum Extractor

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CNC Rotary TablesNIKKEN I/O

NCT200

Ultra Big Bore

CNCZ205

5AXDD100AF

5AX-DD130 BF2-S

5AX-DD80HB

Tool PresettersElbo Controlli - NIKKEN

E346i

E460N

Hathor Six

66B / 68B

E46L / E46LTW

Angle HeadsAlberti Angle Heads

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Our CompanyNIKKEN Kosakusho Europe are leading suppliers of elite precision engineering products.

With research and development located at the NIKKEN Innovation Centre Europe (NICe), and operations at the Euro Centre, NIKKEN operates in high stature manufacturing environments covering aerospace, medical, oil and gas, motor sport, power engineering as well as the mould and die sectors.

Creative and innovative, NIKKEN Europe are at the forefront and number one choice for precision manufacturers, Original Equipment Manufacturers (OEMs) and Tier One suppliers.

NIKKEN’s market leading solutions include:

■ Performance CNC Rotary Tables

■ High Accuracy NC Tooling Solutions

■ Tool Presetters

■ Spindle Optimisation Solutions

NIKKEN’s extensive product range, combined with technical expertise, training and after sales service, come together to deliver a superior end-to-end experience that allows our customers the opportunity to successfully compete in the global marketplace.

Our HistoryNIKKEN Kosakusho Europe is a subsidiary of NIKKEN Kosakusho Works Limited, Japan, with principle activities covering the import and distribution of the complete NIKKEN product range.

With operations across three continents, offices in over 70 countries and a 15,000 product range, NIKKEN has earned and maintained a reputation globally for producing quality products.

Our people are at the heart of our operations. Our goal is the same where ever our team members may be: to uphold a unified standard of quality performance and excellence in our products and to our customers.

NIKKEN Kosakusho are continually striving to improve technology through research and development, innovation and industry knowledge to ensure that our customers can compete and win in their demanding market sectors.

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X-Treme ‘Full-Slotting’ (Ti 6Al-4B):

NIKKEN NBT50-C25EX-115 ■ 50mm deep slot

(2 x Diameter) ■ 25mm Rippa

geometry tooling ■ 35 m/min ■ 0.07 mm/tooth (6 teeth) ■ 187 mm/min ■ 234cm³ min MRR

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The X-Treme Milling Chuck was developed to meet an Aerospace requirement for reliable heavy milling of titanium aero components. This process demanded a combination of high repeatable accuracy, excellent run-out characteristics, combined with complete elimination and prevention of absolutely any movement or ‘pulling-out’ of the end mill.

The NIKKEN X-Treme Milling Chuck uses the multi-roller system which contains 140% more needle rollers than any comparable chuck. Also, to allow for a more consistent and permanent gripping force when clamped the rollers are arranged differently in more rows than ever before.

To demonstrate the absolute power, consistency and stability that can be achieved with the NIKKEN X-Treme Milling Chuck solution we regularly feature and repeat what we’ve now come to call our ‘Cut of Death’ demonstration.

■ Zero pull-out

■ The Largest Gripping Force Available from any tool holder currently available in the market

■ Exclusive Patented Positive Shank location and integrated face sealing system

X-Treme Milling Chuck

Multi-Roller System

Imitation Roller System

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NIKKEN Multi-lockCompetitor HydraulicCompetitor Shrink fit Competitor Mechanical

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Balanceable Shrink & X-Treme Shrink

The NIKKEN Balanceable Shrink and Shrink X-Treme Holders have been developed to meet a requirement for high-speed semi-finish and finishing applications where maximum metal removal rates and absolute cutter security are essential.

The design provides built-in balance adjustment post shrinking. This means that the entire tool assembly can be fine balanced to suit any spindle or application requirements. The location of the adjustment holes negates the effects of centrifugal forces during high speed rotation.

NEW Shrink-Fit EX Profile Milling Process (Ti 6Al-4B):

NIKKEN NBT50-SF25EX-160

■ 50mm deep slot (2 x Diameter)

■ 2mm radial cut

■ 90 m/min

■ 0.12 mm/tooth (4 teeth)

■ 550 mm/min

■ 55cm³ min MRR

Special unbalance adjustment screws

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The collet features no external nut and is drawn from either the side of the holder or from the base of the holder.

The NIKKEN Mini-Mini Chuck is simply the most effective product for reduced diameter machining or components and applications where confined access or tight spaces can prove problematic.

Designed as a mechanical alternative to both hydraulic and shrink-fit products it features an 8 degree collet and rear clamping of the collet. This allows the chuck to be not only extremely compact but also provide gripping capabilities and performance characteristics surpassing those of the competitors.

The Mini-Mini Chuck is a balanced system offering superior performance and accuracy at G2.5.

The new Mini-Mini Chuck Advanced α has an incredibly low run-out of only 2-3μm and a clamping force over 3 times stronger than that of the standard Mini-Mini Chuck.

■ Extended Lengths

■ Improved Gripping Power - Minimum Overhang

■ TiN Bearing Gear (HV2,200)

■ HSK ‘AT’ Type

Mini-Mini Advanced α Chuck

Oil Chamber

Hydraulic ChuckNo Gripping at

Front Nose

Mini-Mini ChuckGripping from

Front Nose

Standard Type

Direct Screw Type

Unsupported 0.5mm - MMC8α Thin Wall Machining

■ Endmill - 8mm (2 Flute)

■ Depth of cut - 8mm

■ Width of cut - 8mm

■ Cutting Speed - 300m/min

■ Chip Thickness - 0.120mm

■ Feed - 2865mm/min

■ Speed - 12000rpm

■ MRR - 183cm3/min

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NIKKEN EVO & Spectrum ReamersNIKKEN have two new exciting ranges of reamers for 2017, the EVO range is aimed at difficult to cut heat resistant materials while the new Spectrum range is focussed on non-ferrous applications.

EVO Series Reamers deliver fantastic performance on heat and corrosion-resistant nickel and titanium alloys. These materials are difficult to cut because of their low thermal conductivity and susceptibility to welding and work hardening.

■ Optimised geometry for difficult- to-cut materials

■ Latest coating technology - high-grade film coating with 1100C° thermal resistance, thermal and a coating hardness of Hv3200

Spectrum Series Reamers deliver outstanding performance in aluminum as well as other non-ferrous metals and plastics.

■ New thin film coating, ultra hard Hv6000

■ Coating thickness of 1μm enables sharp cutting edge

■ Optimised geometry for aluminum

Reamers

HASTELLOY ■ Cutting Speed: 18m/min ■ Feed 0.2mm/rev ■ Hole: 10mm h7 ■ Surface Roughness: Ra 0.3

INCONEL 718 ■ Cutting Speed: 5m/min ■ Feed: 0.2mm/rev ■ Hole: 10mm h7 ■ Surface Roughness: Rz 6.3 μm

ALUMINUM ADC12 ■ Cutting Speed: 30m/min ■ Feed: 0.2mm/rev ■ Hole: 12mm h7 ■ Surface Roughness: Rz 1 μm

ALUMINUM A2017 ■ Cutting Speed: 50m/min ■ Feed: 0.2mm/rev ■ Hole: 10.5mm h7 ■ Surface Roughness: Rz 0.5 μm

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ZERO FIT LIFE TEST

■ Material: Ti 6Al-v 4V

■ Nikken Holder: BT40-SZF16-90

■ End Mill: C48 1200 083 1200 300 l

■ Cutting Speed Vc: 110m/min

■ Chip Thickness Hex: 0.07mm

■ Feed per tooth Fz: 0.117mm/rev

■ Width of Cut Ae: 1.2mm

■ Depth of Cut Ap: 20mm

■ MRR (peak): 33cm3/min

■ Feed: 1362mm/min

■ Speed: 2918rpm

Zero Fit Holder

When a machine tool has been in operation for 2~3 years, the run-out accuracy of the spindle may decline to 0.010mm~0.040mm at 100mm from the gauge line. The NIKKEN Zero Fit Holder allows correction of this error back to the “as-new” run-out of 0.001~0.002mm.

Typical runout can be in the region of 21 microns - when this is reduced to 3 microns, the tool life can be improved by approximately 5 times.

The choice of the Slim Chuck style “SZF” and the Anniversary type Milling Chuck style “CZF” can be selected depending on your application and cutter specifications.

Fine Adjust Cam

Master Cam

Time - 5min 6secPasses - 18Power - 14%Runout - 1μm

Time - 17secPasses - 1Power - 14%Runout - 1μm

Time - 10min 12secPasses - 36Power - 15%Runout - 1μm

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ZMAC Advanced BoringIrrespective of specific boring requirements - NIKKEN can provide the optimum solution. Our updated ZMAC Advanced Boring Heads feature a double-contact shoulder support and provide excellent reliability and performance for deep hole boring and high-speed boring operations.

Boring Modular System

RAC Advanced BoringNIKKEN RAC Boring Heads feature a precision ground serration, giving perfect contact and balance between the holder and head. RAC heads have been designed for large diameter boring operations and roughing.

Available as standard on NIKKEN 2-Lock for both BT and DIN tapers our boring base holders also offer the benefits of dual contact for both flange and taper on suitable machine tools (2-Lock is also fully compatible with standard BT/DIN type spindles). 2-Lock increases the contact area considerably from around 44.4mm to 63mm (BT40) and also, as with all our NC tooling products, provides users with over 80% taper contact as standard. Additional standard options of course also include HSK and NIKKEN polygon tapers.

High Rigidity

■ Innovative new feature of double-contact support

■ Re-engineered for improved adjustment and accuracy

■ New locking screw closer to the cutting edge

■ Axially adjustable ZMACX-V for deep hole boring Ø12.7mm - Ø55mm

High Precision

■ The thread on the cartridge is hardened to HRC50-55 and precision ground

■ The internal thread of the dial is specially heat-treated to HV800

These features ensure the easy micro-adjustment of the boring head and provide maximum rigidity with high durability for longer lasting accuracy.

Coolant through capability as standard for

ZMAC Advanced

Various types of insert tip

Steel, cast iron and stainless steel can be machined by the same coated insert tip.

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eMAC Digital BoringThe NIKKEN eMAC Digital Boring System is a fine boring head with a digital display indicating the radial slide traverse. The target diameter can be adjusted easily, quickly and precisely.

Capacity: eMAC - Ø6-110mm eMACXL – Up to Ø200mm

Features:

■ Available for any machine spindle by using a NIKKEN Q26 modular base holder

■ Highest precision through direct measuring of the movement

■ Single button operation for ‘On’ & ‘Reset’, and to change between mm/inch with a display resolution Ø2μm

■ The display switches off after 30 seconds and stores last display value

■ Coolant through as standard

■ Level of protection IP67

1 - eMAC ■ Cutting Speed Vc:

230m/min

■ Radial Cut: 0.1mm

■ Feed per Rev: 0.06mm

■ Feed: 137mm/min

■ Speed: 2288rpm

2 - ZMAC ■ Cutting Speed Vc:

250m/min

■ Radial Cut: 0.1mm

■ Feed per Rev: 0.06mm

■ Feed: 149mm/min

■ Speed: 2487rpm

Steel S55c (32mm Boring)

Surface finish - 1.2Ra

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Boring Modular System

Digital Display

On/Reset Button (mm/inch)

Q26

Adjust Screw

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New NC Tool Solutions

SK Coolant Collet Our new SK Coolant Collet is a quick and easy way to provide total mechanical sealing for any cutting tool with an oil hole. Fully compatable for both existing Slim Chucks and all NIKKEN Major Dream Holders the collet is suitable for the use with high pressure coolant systems up to 70 bar.

Available and in stock for all sizes of chuck to suit cutting tools Ø4mm - Ø25mm.

3 Angle Clamper The NIKKEN 3 Angle Clamper provides interchangeable adaptor sleeves to allow for differing flange diameters.

The system is based on applying cylindrical grip around the main tool flange so is fully compatable even for tool holders without drive keys.

The clamping ring is rotatable through 3 angles to allow you work on your tools in comfort and in multiple orientations.

Vacuum Extractor Currently under development and testing is our New Vacuum Extraction Solution (Patent Pending). Designed to eliminate the problems associated with particles and dust when machining materials such as composite, carbon fibre and laminates.

The common solution in the market is to provide such a system in or around the machine spindle. Our solution to this problem is to focus the extraction completely around the end mill. An internal venturi system draws any waste cleanly away from the cutting area.

Uniquely the system attaches directly to a NIKKEN chucking solution allowing full high speed rotation of the tool assembly whilst the extraction unit itself remains stationary. The extractor assembly ultimately is also then fully tool changeable.

SK Sleeve (Slim Chuck) MMC Sleeve (Mini Mini Chuck)

New for 2017 are a range of High Precision Sleeves for sliding head automatic turning machines, allowing customers to benefit from NIKKEN's innovative tooling features such as our patented TiN Bearing Nut - to ensure the cutting tool is securely clamped without distortion thus maintaining the optimum accuracy and performance.

These are ideally suited to high precision drilling and reaming operations and are available in both Slim Chuck (SK) and Mini-Mini Chuck (MMC) forms.

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CNC Rotary Tables

Mono-Block Faceplate

Special Hardened Steel, Ion Nitrided Worm Wheel

NIKKEN Face & Radial Roller Bearing System with Teflon Sealing

High-Density Grey Cast Iron Main Body

Unique Carbide Worm Screw

NIKKEN are leading the way by utilising the latest, cloud-based technology to access big data during the lifetime of our products. Providing you with full Industry 4.0 Compliance.

Being able to sense and predict failure is a major advantage when it comes to optimising machine uptime. With this goal in mind NIKKEN have created the new NIKKEN I/O.

The NIKKEN I/O is a compact, passive condition monitoring system designed for our NC Tables.

By fitting an array of sensors inside our rotary tables that send real-time data wirelessly while in production, the NIKKEN I/O offers a comprehensive range of monitoring including - backlash measurement, collision detection, oil condition monitoring and power consumption.

Optional plugins are under development for bespoke dynamics and process monitoring.

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The NIKKEN Standard for Construction

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CNC Rotary Tables

NCT200 Optimum Flexibility and Performance

Ultra Big Bore CNC Rotary Tables

CNCB350 / B450 / B630

■ 350 / 450 / 630mm Diameter ■ Ø154mm / Ø205mm / Ø345mm Ultra Big Bore ■ Up to 1600kg Load on table (B630) ■ Up to 6500Nm Clamping Torque (B630)

Our latest generation Ultra Big Bore Rotary Tables feature the same renowned internal construction, including the usual mono-block spindle design, whilst also providing large, through bore access for more versatility and larger components.

New for 2017 is our 200mm Customisable NC Table, the basic platform is based on a typical 200mm size unit but with features focused on flexibility and customisation. These impressive units can be left or right handed and are available with a comprehensive range of options such as multiple port rotary joints, face/drive plates and end support units.

The NCT200 is designed with ease of maintenance and flexibility in mind, it can except a comprehensive range of servo motor types making it the perfect choice for OEM/machine tool manufacturers.

The NCT200 delivers a best in class - 900Nm of clamping torque enabling the NCT200 to meet the demands of the toughest applications.

New re-designed drive system with a 25% larger gear system for increased

rigidity and durability

126mm 157.5mm

■ 900Nm Clamping Force ■ Large Worm Wheel Diameter ■ Reduced Maintenance Costs ■ High Speed Rotation 33.3rpm ■ Consumable parts can be

changed as Unit

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The CNCZ205 offers both flexibility and performance and with its Ultra Slim Profile width of just 98mm it is ideally suited to maximising the working envelope, typically utilised on twin pallet machines and where space is confined the CNCZ205 boasts some impressive features:

■ High Speed (66.6rpm) ■ Built in 6 port Rotary Joint Option ■ Strong Clamping force of 380 Nm

To complete the new line up we have the 5AX-DD80HB hybrid model, the tilt axis benefits from an ultra-accurate and rigid Hirth Coupling while the Rotary axis utilises a 200rpm direct drive.

Our new 5AX-DD130 BF2-S offers the additional functionality of a clamping or end support device within the confines of a compact 5 axis Direct Drive table.

The 5AXDD100AF is the most compact Direct Drive on the market to date and offers an impressive speeds 200rpm (for both Rotary and Tilt axes).

CNCZ205 Ultra Slim NC Table

NIKKEN are pleased to announce 3 additional models to our 5 axis Direct Drive and Hybrid Table Range

5AXDD100AF 5AX-DD130 BF2-S 5AX-DD80HB

CNC Rotary Tables

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Tool Presetters

Elbo Controlli - NIKKEN

Principles of Presetting

The measuring of individual tools and assemblies is a necessity for the effective operation of a machine tool and its tooling. All CNC Machines, and to some degree, manual machines require offset values or references for the length & diameter of each tool.

Historically the normal practise has been to establish tool offsets and references on the machine tool using various methods - the component/fixture, some form of gauge or a probe/laser. Machine tools earn money by cutting metal and producing parts, not measuring tool holders and assemblies, it is therefore essential in a modern production facility for the tool setting to be done on a dedicated presetter machine.

Tool Presetting machines remove the requirement for the measuring of tools from the machine area, such presetting, outside the machine, can be carried out ‘in-cycle’ or whilst the machine is cutting or even days in advance to achieve and provide effective production planning and progress through the manufacturing cycle.

NIKKEN Kosakusho Works Limited, the industry leader in the manufacture and distribution of advanced Tool Holding Systems, CNC Rotary Tables and accessories and Elbo Controlli SRL, a major player in the fields of Tool Presetting, Inspection and Tool Management Systems, have now commenced a new global Strategic Alliance.

Both companies have a long standing synergy and this strengthened relationship allows the two technology partners to innovate and move forward both their products and solutions ‘Closer Together’.

elbo controlli R

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Measuring the Future Together As One

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Tool Presetters

E460N

Designed to be bench mounted, the E460N features a ground granite base and column, stainless steel construction and ergonomic design.

■ 400mm diameter - 600mm height capacity

■ 15" TFT touch screen

■ Vacuum clamping

■ Fully interchangeable spindle

■ Automatic registration of maximum radius, diameter and length of tool

■ Post processing as standard - TiD Ready

2017 Range

Hathor Six

Hathor Six features ground granite and stainless steel free-standing construction combined with a large digital camera and touch screen menu system.

■ 400mm diameter - 600mm height capacity

■ Free-standing

■ 15" TFT touch screen

■ Electro-mechanical clamping

■ Fully interchangeable spindle

■ Automatic registration of maximum radius, diameter and length of tool

■ New Angle Head location and measuring option

■ Post processing as standard - TiD Ready

E346i

The E346i features a ground granite base and column, electro-welded and de-tensioned steel construction with an ergonomic design.

■ 360mm diameter - 460mm height capacity

■ 9" TFT touch screen

■ Fully interchangeable spindle with one piece clamping

■ Post processing as standard

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Tool Presetters

66B / 68B

Completely free-standing on its own integral base; the 66B/68B features ground granite and stainless steel construction combined with a large digital camera and touch screen menu system.

■ 600mm diameter - 600mm (68B 800mm) height capacity

■ Free-standing

■ 15" TFT touch screen

■ Pneumatic mechanical clamping

■ Fully interchangeable spindle

■ Fully servo controlled axis, no operator contact

■ Post processing as standard - TiD Ready

E46L / E46LTW

Our E46L and E46LTW are a brand new concept ergonomic platform and are completely free-standing on an integral base. Both models feature oversized ground granite and structural steel construction combined and equipped with a 22’’ HD touch screen monitor.

■ 400mm (E46LTW 320mm) diameter - 600mm height capacity

■ Free-standing

■ 22" HD touch screen

■ Electro-mechanical clamping

■ Fully interchangeable spindle

■ Automatic spindle recognition

■ E46LTW features a second high resolution swivel camera with 60x magnification with 2x and 4x digital zoom capability

■ NEW E46LA with patented power spindle system (still interchangeable) to automate the measuring process

■ Post processing as standard - TiD Ready

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NIKKEN are delighted to be able to offer a wide range of Angle Heads and attachments utilising our advanced SK Collet System and patented TiN Bearing Nut.

Our Advanced 8 degree SK Collet System and TiN Bearing Nut ensures the most accurate and stable interface with the cutting tool is achieved.

The products are designed and developed to exacting standards and feature:

■ Cast Iron bodies (GS600) 100% machined

■ Body provides long life, thermal stability and stress resistance

■ Where possible, single piece input spindles for better accuracy and performance

■ Special gear material (200kg/mm) with four-key drive system

■ Double high precision, preloaded, angular contact bearings

■ Special low friction sealing system with double mechanical seal

■ All units are supplied complete with accessories inside protective carry case

The Alberti standard angle head range is broken down into five main product areas all available on multiple input shanks to suit any machine (DIN/ISO/BT/HSK/CAPTO etc).

Angle Heads

Centre through and coolant through the pin options are fully compatible with NIKKEN's new SK Coolant Collets

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Austria

Belgium

Brazil

Bulgaria

Canada

China

Croatia

Czech Republic

Denmark

Estonia

Finland

France

Germany

Greece

Holland

Hungary

Iceland

Israel

Italy

Japan

Korea

Mexico

Norway

Philippines

Poland

Portugal

Romania

Russia

Singapore

Slovakia

Slovenia

South Africa

Spain

Sweden

Switzerland

Taiwan

Thailand

Turkey

UAE

UK

Ukraine

USA

For full product specifications please refer to our full NC Total Tooling System catalogue

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