fadal rotary table factory

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We have that machine 15XT 1996. We actually (Very carefully) drilled and line bored alignment pin holes through a one in. steel ground 4140 plate and into the table. The plate moved the 4th axis assembly to the right over the chip guard... on the x axis until the limit was about the same as the back edge of the 4th rotary face plate... but not so far out that it was beyond the chip guard edge, or you might hit the sheet metal. Also, when centering on the Y we had to pick the best position to accommodate that travel to keep from hitting the door and in the y +, the Z chip guard.

The 4th mounted to the mounting plate is mounted so that it can be adjusted on the mounting plate... if necessary. Though we have never needed to adjust it since the first mounting to the plate. With removal from the table and replacement the assembly repeat has been always in the 5 tenths.

Index Designs is an all-American company. Our founders were part of the team that helped design, engineer, manufacture and market the very successful line of Fadal Machining Centers – starting in the 1970s. We entered the rotary table market in 2006 with the goal of creating a line of high-end, rugged and accurate rotary products that we could sell at affordable prices, but still be able to provide reliable delivery and superior customer service and support. Our products are completely manufactured in our Chatsworth, California facility. We use state-of-the-art, HMC’s, VMC’s and CNC gear cutting machines. You are always welcome to visit our plant and see for yourself.

Our rotary tables are constructed of heavy-duty materials and are designed to provide long lasting, dependable service. Compare the components and design of our rotary tables with others in the industry. We take special care at our Chatsworth, California facility to manufacture and assemble products to the highest level of performance, yet offer a very cost competitive price for our customers.

For machining components from small, 5C collet sized parts, up to 15 inch diameter or larger work pieces, Index Designs offers a rotary product to fit your needs – including 5 axis rotary tables.

Whether your CNC control has AC or DC drives, or uses Fanuc (Alpha or Beta), Mitsubishi, Yaskawa, Glentek, Siemens, Baldor, etc. we can build a rotary table with a compatible motor for just about any 4th axis-ready machine on the market! If you need help getting a machine 4th axis ready, we can also supply the parts you need; such as amplifiers, drives, cables and connectors.

Fadal CNC 88 Control, 4th Axis Drive and Interface, Fadal VH-65 Rotary Table, Coolant System, 20 Station Automatic Tool Changer, Cat 40 Spindle Taper, 10,000 Max Spindle RPM

Index Designs is an all-American company. Their founders were part of the team that helped design, engineer, manufacture and market the very successful line of Fadal Machining Centers – starting in the 1970s. Index Designs entered the rotary table market in 2006 with the goal of creating a line of high-end, rugged and accurate rotary products that we could sell at affordable prices, but still be able to provide reliable delivery and superior customer service and support. Thier products are completely manufactured in our Chatsworth, California facility. Index Designs uses state-of-the-art, HMC’s, VMC’s and CNC gear cutting machines.

Specializing in Fadal CNC rebuilding, We disassemble the machine complete and inspect each and every part, checking the machine and base ways for wear, flatness and alignment. We are world wide and taking a major leap forward in rebuilding rigid box way constructed machines. In the rebuilding process minimizing friction between to way surfaces ensures effective advanced performances at a high feed rate. In re-scraping a machine or rebuilding the ways to a new machine tolerance we are ensuring the customer that there machine is performing to the highest level of speed and accuracy that the machine is designed for.

Quantronix has been able to reduce cycle times by using a Fadal 6030 VMC with a TR 165 fourth/fifth axis tilting rotary table to machine the frames and housings for its lasers.

Quantronix uses a Fadal 6030, a large box way VMC with a 60-inch X-axis travel; 30-inch Y-axis travel; a 10,000 rpm spindle; 88HS control and a 21-tool changer.

Five-axis machining tends to conjure up images of pricey VMCs machining aerospace components with complex curves and undercuts. However, manufacturers and commercial job shops are finding a VMC and tilting rotary table with fourth- and fifth-axis motion can significantly reduce setup, handling and cycle times on a variety of commercial components and parts. These rotary tables can deliver higher accuracy and provide more rigidity for heavy cutting routine operations, such as facing, pocketing, drilling holes and tapping.

The basic concept is to machine parts with only one setup per part. The operator loads the part just once, pushes the cycle start button, and the rotary table moves the part in the required position. This is repeated until all sides/surfaces of the part have been machined and the cycle is finished. Or, the operator can load several parts onto the rotary table and start the machining. As one part is finished, the rotary table brings the next one into the proper position, machining begins, and so on. The advantage is that the VMC can be left unattended for longer periods of time, and less time is spent handling the part.

The company decided to use a Fadal 6030, a large box way VMC with 60-inch X-axis travel, 30-inch Y-axis travel, a 10,000 rpm spindle, 88HS control and a 21-tool changer from Fadal (Chatsworth, California). The 6030 features Cool Power, Fadal’s refrigerant system that maintains the temperature of positioning elements to ±1 degree of the machine’s ambient temperature by recirculating a high performance heat-transfer agent through the spindle nose, around the spindle cartridge and headstock, and through the center of the Y-axis ballscrews. The heat transfer agent flows through the gun-drilled ballscrews and dissipates heat before it causes thermal expansion. This ensures pinpoint positioning and repeatability by minimizing thermal expansion throughout the day.

Whether machining one part at a time, or loading several parts on the same rotary table, the most tangible benefit is the time savings. For example, the machinists at Quantronix load a 6- by 6- by 4-inch aluminum block onto the rotary table and machine the main pocket on the part, which becomes the optical housing. Four different surfaces can be machined with only one setup—the aluminum block is held in place on two sides, so the remaining four sides can be machined—then, machined using the fifth axis starts. The part has angled compound holes with milled surfaces. Drilling these angled holes on the fifth axis eliminates four separate handlings and leads to machining individual housings in 17 minutes, instead of 1 hour. Tool changes are reduced because all of the operations for a tool are completed before the next tool is loaded.

It is important to recognize that each time a part is moved, it is impossible to position it exactly the same as before, which will affect the specified tolerances. But by handling the part once and letting the rotary table rotate the part into position, the part will be positioned within the tolerance capability of the rotary table.

The optical housings must be parallel within 0.001 inch. This parallelism is achieved with the rotary table, and housings are manufactured with tolerances of 0.0005 inch or better. Accuracy and repeatability on the rotary table are ensured with hardened and precision ground faceplates, pre-loaded bearings and CNC ground-worm shafts.

An important factor in this situation is how the rotary table and VMC work together. Knowing the rotational speed of the table and its torque is essential. The rotary table should also be able to keep up with the tolerances of the VMC. The control needs to accept the rotary table without rewiring. Many of today’s controls can be ordered prewired for rotary tables. For example, the Fadal 88HS Fanuc-compatible control on Quantronix’s 6030 can be ordered so that it can connect to four- and five-axis rotary tables for indexing and true simultaneous machining operations.

Having reduced part cycle times by more than two-thirds, Quantronix reports a revenue increase. “We’ve had phenomenal results with our 6030 and the rotary table,” says Steve Worner, Quantronix’s job shop manager. “Our Fadal 6030 has helped us grow our business beyond what we had expected, and our productivity has shot up.”

1) Diagnose - Direct help in determining if you really do need to replace the part. Based on experience having worked as part of the engineering team that originally designed the Fadal machine, our knowledge helps us determine if there"s other elements in the system that need to be addressed before replacing the part.

4) Support - With the combination of our Fadal Engineering background and direct interaction with suppliers engineers, you are getting the absolute best product support possible at installation and beyond.

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