cutting gears with a rotary table manufacturer

SteveEx30 cutting the teeth in plastic goes pretty quick,probably a couple hrs.I got 3 gears out of that blank after the teeth were cut.That Nyloil MDX was a pain in the ass to part off.You nave to use plenty of coolant.The stringers will not chip and make a much stronger stringer than Delrin.If you stop before you part off completely it wraps tightly in the groove and takes a while to pull out before you proceed.I have found,with plastic and brass that when cutting multiple gears that it is quicker to cut the teeth first first then part off the blanks.It is easier to finish the blanks and then cut the teeth but you have to make a more complicated mandril and have to change blanks one at a time.I was able to stay on cutting the teeth to completion,but had to wait a day after I set up before I could start,then several days before I could finish because of breakdowns,other priorities.So it is hard to figure exact time but maybe 3 hrs per gear.Since these types of jobs are added value of my own initiative the time factor is not as critical as it would be in a job shop with a customer waiting.One good thing about this place is that I am allowed to tackle any job that I think I can do.I am 70 years old and when I think about retiring,my hobby would be dicking around in my shop doing basically the same thing as I do at work,without the insurance,pay and benefits!

The handle can be removed easily by releasing the caphead bolt. The handle being located with a keyway. This then allows the dividing plates and crank to be fitted in place of the free-rotating handle.

The crank handle is held in place with a grub screw – ensure this is tight and that the handle and pin are at 90° to the crank plate before trying to fit the crank to the table.

12 divisions is achieved with 7.5 turns – so 7 complete turns of the handle and then with a 20 division plate the dividers are set at 10 + 1 holes apart.

his takes a bit of concentration to use as you count off the rotations and then add the part rotation needed for the division – just be consistent and all will be fine.

A very small 12 tooth gear made with a cutter designed for a larger number of teeth and hence the undercut on the teeth – the wall is rather thin at the centre, but this was a trial to see how the rotary table works when being used as a divider – aim is to make more gears for my Wood and Metal Clock.

A pair of gears cut together out of mild steel – 60 teeth and 43mm diameter. One of these is for the camshaft side of a four-stroke engine in construction.

I created a quick google spreadsheet (below) that gives me divisions up to 200 and for completeness the first row gives 360 divisions. I have added a link to a downloadable pdf version if that helps. Note: number of hole intervals means you need to count the hole that the pin is in as 0 and then count out the number of intervals/steps from there (next step being 1).

A freely available spreadsheet that has the full dividing plate and rotary table calculations. You can set it up for your specific table and print off the sheets. You just need to know the worm drive ratio.

Many rotary table manufacturers outsource gear fabrication to lower costs. While that strategy may offer short term cost savings, Index Design’s American made rotary tables are built with gears cut in house. This is the only way to closely monitor and control tolerances, consistency and performance.

Our rotary tables incorporate large diameter high tensile bronze worm gears mated against hardened steel drive shafts. The combination of metal gives superior wear properties for long lasting operation. As the rotary table is run, the properties of a tin bronze gear develops a low friction deposit on the mating steel drive shaft. These deposits fill in microscopic pores of the mating surface. Over time, as these deposits are embedded on the surface, wear decreases followed by a reduction in frictional forces within the gear assembly.

Final inspection and verification of specification performance is done with precision calibration equipment capable of measure tolerances of +/- 1 arc second in any position. Any deviations from specified angular positions are corrected so our customers can be assured that they are receiving the performance we guarantee.

In addition, the data gathered from our automated calibration procedure allow our engineers to assess, monitor and improve the static and dynamic performance of prototype rotary tables during the design phase.

Our engineers have a long and rich history in the machine tool business, they combine decades of both CNC machine tool and rotary table manufacturing experience with the latest design tools to produce rotary tables with superior performance and dependability.

Our CAD/CAM software is used to analyze displacement and stress for each component, sub-assembly and total assembly. However, the best software and technology is worth next to nothing if no one understands the craftsmanship. This is particularly true when manufacturing precision rotary tables which involves many steps. Despite all the modernization and automation available, a large part of the manufacturing process is still completed by hand. At Index Designs, we understand and appreciate craftsmanship, It is designed and built into our products.

CNC Indexing & Feeding Technologies is proud to represent the TJR line of rotary tables, indexers and accessories. TJR originated as a rotary table sales and service agent and established itself as an OEM in 2009.

TJR tables feature an anti-wearing worm gear, durable, high-tensile brass shafts, and braking systems with a large clamping range. All new TJR tables come standard with a 3-year parts warranty.

Standard Rotary Tables. The AR Series is TJR’s standard 4th axis pneumatic brake rotary table. It is offered in both a Right hand motor mounting and Left hand motor mounting option. The HR Series is TJR’s standard hydraulic brake 4th axis rotary table.

CNC Indexing & Feeding Technologies offers a wide range of TJR rotary tables. However, many are unclear about what rotary tables can do for their business, as well as how they work in CNC machining. First, let’s consider the basics about a rotary table and how it works in the machining and manufacturing processes.

Milling and other industrial processes require cutting and shaping, usually with a high degree of precision. This creates the need for computer-guided systems that can create workpieces, prototypes or tools for companies on demand. The process is expedited, reducing or removing the need for large assembly line staff or other hand crafters.

In many cases, the work pieces created through CNC machining would be impossible without computer assistance. The code used to communicate between the CNC machine and computer software is specialized. Older machines, or manual machines, used hard wired controllers. However, new CNC machines rely on modern devices like CDs, USB drives, networks and so on.

A lathe or milling machine requires its own set of parts to work sufficiently. For example, an indexing head is needed to allow circular shaping. The indexing element allows the piece to be rotated at an angle or even divided into sections.

A rotary table can tilt and rotate. The table makes use of the indexing head in order to cut according to a specific technique. This makes it possible for the machine to create a workpiece with complete flexibility in rotation and angling.

A rotary table can help to create arcs and circles, an important process in part or tool fabrication. Tools can be specially made, such as car parts, machine parts, and many other objects.

The CNC process lets companies make straight cuts even with multiple angles and to cut small objects into even smaller parts. CNC rotary tables can also help in the processes of cutting gears, drilling or cutting holes.

The table can also be used along with a dividing head and index plate, to further concentrate the shaping. Tables are also used to hold certain parts for superior milling techniques.

Adding rotary tables will improve your capacity to produce the parts you want and increase profits. This brings us to the primary advantage of CNC rotary tables: less time and greater accuracy in cutting.

Companies are often outsourced to create work pieces for larger brands. However, some companies simply create their own prototypes, tools or work pieces with their own facility for machining. There are also contract shops, mechanic shops, electronics companies, inventors, engineering, and retail companies.

Most companies save costs by scaling their needs with small productions. In many cases, they may only have one facility or work with one type of part. The key is not to create “anything” but to specialize in objects created so the process can be streamlined.

The benefits of using cnc rotary tables include consistency, faster production and increased capacity. Products and work pieces assembled through CNC systems are more reliable than products created manually or through other methods. The process is identical each and every time, so consistency can be guaranteed. This is critical for a company trying to ensure safety protocol.

Flexibility is another advantage, as the systems are programmable. These systems are designed to minimize downtime in between their running processes, offering greater flexibility.

The capacity of complexity of product is another benefit. Complex motions are made simpler by CNC rotary tables, making them more affordable to produce.

Naturally, such an intricate process cannot be unsupervised, since efficiency depends on optimal performance. A supervisor must oversee a rotary table operating with CNC controls to ensure the machine and software are configured correctly.

This involves setting the system up, installing the software, and watching over the production. If something goes wrong, the software must be fixed and the machine repaired. Machines are not constantly running, but must be evaluated and cleaned regularly, ensuring that they will be mostly self-sufficient.

We offer a wide variety of rotary tables to meet all of your needs. This includes standard rotary tables with full rotating axis capabilities, and vertical and horizontal mounting positions.

We also offer large rotary tables with hydraulic brake systems, which allow higher clamping torques. You can also find assistance with smaller rear mount rotary tables or tilt rotary tables.

Horizontal rotary tables are specially made for horizontal mounting and carrying a much heavier weight. Horizontal index tables are available, whether in manual or CNC index tables style. Finally, there are face gear rotary tables and rotary table accessories, ideal for projects that need higher degrees of accuracy.

Remember that quality production is synonymous with efficiency and accuracy. Product producers must have the right equipment operating at full capacity in order to guarantee consistency.

CNC Indexing & Feeding Technologies can help you find the machine tool accessories you need to meet your production demands. This includes simple rotating feature, larger work pieces, vertical and horizontal applications, or even 4 or 5 axis work. With TJR rotary tables, you can improve your cycle and process time, reduce your down time and increase your profits.

You can always reach us if you have additional questions regarding how to get started by calling us at 513.770.4200. It’s time to expand your business and your capability!

The DuraMax RT measuring machine from Zeiss Industrial Metrology is designed for in-line process control of gear wheels. Now equipped with a rotary table, the compact horizontal-arm measuring machine uses a precision system to turn the workpiece with the corresponding side facing the stylus. This enables the stylus system to capture information such as the geometry of the gear wheel in a simple process without repeatedly traveling to a new position, the company says. The rotary table can be freely positioned on the measuring plate and removed in just a few steps. Equipped with Zeiss’s measuring software, the DuraMax RT can also be used as a universal measuring machine when needed. Its benefits include a small footprint and lower power consumption, the company says.

How do you create products that are cost competitive and of the highest quality? Here are three approaches, one about a car manufacturer putting more emphasis on its capacity, one about a machine producer increasing efficiency through flowing parts, and one about a car maker assuring quality in production.

Advances in machine design, cutting tools and process simulation software have finally converged, making it possible for Gleason to offer a practical and highly productive power skiving solution. Here’s how the new process can revolutionize the way internal gears are produced.

Moving small- to medium-batch production from outsourced, dedicated hobbing operations to in-house, CNC multitasking machines helps job shops achieve quick turnarounds and flexibility in supplying splines for the heavy-vehicle industry. Inserted disc cutters make this transition possible.

Apple pi made essentially 16 of these for our swerve modules this year. In the offseason, we started by cutting the piece to the correct shape out of an aluminum tube on the lathe, then we used a rotary table on a Bridgeport to drill the smaller holes. What we ended up doing during build season was make them out of a block of aluminum that we cut on a circular saw then faced on a Bridgeport. Then that piece went in a Haas mini mill where all of the cuts were made and then was cleaned up on a lathe.

With what you have I would recommend either doing the lathe then rotary table option or do all the main cuts on the lathe and then use the cnc router to do the smaller holes.

If it is possible for the cnc to make the whole thing, then I would start with a block of aluminum cut to the right height and then just put that in vice in the mill. You can leave the bottom part a square, but do virtually every other cut/hole, and then put it in the lathe and make the bottom circular.

Shunmugam M, Narayana S, Jayapraksh V (1998) Establishing gear tooth surface geometry and normal deviation: part 1—cylindrical gears. J Mech Mach Theory 33(5):517–524

Shunmugam M, Rao B, Jayaprakash V (1998) Establishing gear tooth surface geometry and normal deviation: part 2—bevel gears. J Mech Mach Theory 33(5):525–534

Litvin F, Kim D (1997) Generation and simulation of meshing of modified involute spur gears with localized bearing contact and reduced level of transmission errors. ASME J Mech Des 119:96–100

Umeyama M (1995) Effects of tooth surface modifications on the transmission error of a helical gear pair and its opimization. Trans Jpn Soc Mech Eng C 61(582):8–15

Suh S, Lee E, Kim H (2002) Geometric error measurement of spiral bevel gears using a virtual gear model for STEP-NC. Int J Mach Tools Manuf 42:335–342

Many members that post here have modern smartphones that have more processing power then any 1970 era CNC machine ever made regardless of cost at the time.

The downside is that used high end manual machines became rare by the late 90"s, the low end importers and manufacturers stepped in to fill this niche. You now have 2 choices, a $40,000.00 Haas small lathe or a $4000.00 small lathe from Enco/HF/PM

A:Generally Suppliers of the Slotting machines are providing only one year warranty period in the lathe machine. And it is not the proper return according to your investment. While We are providing 3 years warranty in our products. If there any parts damaged in your machine than we also provides free parts service in warranty period by fastest courier service.

A : Auto feed, Electric Motor, Vertical attachment, Rack cutting attachment, slotting attachment, dividing head, coolant pump with fittings, true chuck, Milling Adaptor, face mill cutter, milling vice, milling collet etc.

A: Yes, accept domestic LC for 60 days on credit. Generally our 75 % customers are purchasing Machine from us with 60 days Credit through a Simple Process of LC. When the Seller is Unknown or New to the Buyer, Letter of Credit is one good Alternative to do the Business with Such New Seller Because Buyer can Avoid Risk by such Letter. Letter of Credit is one Additional Benefit to the Buyer by which they canprotect Loss against Goods and Finance Also.The buyer can build safeguardsinto the letter of credit, including inspection of the goods and quality control, and set production and delivery times.

Fig. 4—On this tilting rotary table, one servo controls rotation, another controls tilt. Both servocontrols are slaves to the CNC with RS-232 communication, providing five-axis capability from a standard three-axis CNC.

Fig. 1—Modern rotary tables such as this one from SMW Systems have large, widely spaced spindle bearings, large diameter wormwheels and built-in spindle brakes.

If you want to make parts similar to the complex valve body (upper left), an indexer using M-code, RS-232, or “full fourth axis” control is appropriate. Only positioning and rotary cutting moves are required. The center workpiece is a cam that requires simultaneous rotary and linear moves. You’ll need full four-axis control for such workpieces. If you want to do parts similar to the impeller on the right, the contour cutting will require simultaneous five-axis machining.

Many plant managers and shop owners dream of having the latest horizontal machining center (HMC) with all its features, benefits and sophisticated capability. While typical HMC features such as an automatic pallet changer and a 100+ cutting tool magazine are valuable, perhaps the most valuable characteristic is the HMC’s ability to machine on more than one side of the workpiece due to a built-in indexer or full fourth axis.

On complex workpieces that require machining on surfaces not 90 or 180 degrees from each other, indexing or fourth-axis rotation is almost essential to produce the piece. Even when rectangular workpieces with all surfaces 90 or 180 degrees from each other are put on a tombstone, the HMC’s built-in fourth axis of rotation creates a productivity advantage. This is true even if machining on more than one side of the part is not essential.

Any time you can increase the “run cycle,” do more cutting in one operation and avoid handling the workpiece, productivity goes up. Workpiece accuracy also improves. Unclamping and refixturing a workpiece to present a different surface to the cutting tool is always going to introduce some error.

The high cost of horizontal machining centers compared to the incredible values available today in vertical machining centers puts horizontals out of reach for many shops. Fortunately, today there are several suppliers of quality accessories that allow the VMC shop to equip its verticals with indexers, fourth axes and tombstones. These add-ons really work and give many of the benefits of an HMC at a fraction of the price.

Earlier rotary tables and indexers didn’t have the accuracy, rigidity or control flexibility of today’s models. Many shops that tried using indexers in the past had been disappointed in the performance of the older models and abandoned their use in favor of multiple operations, multiple holding fixtures and multiple handlings of the workpiece. They decided that the manual, multiple-operation process was better than trying to use ineffective early model indexers and rotary tables. Today, the situation is different. Manufacturers now offer units that are very accurate, very rigid and have a variety of control and interface options.

The best indexer and control system for you depend on the work you need to do. As with most things, different designs compromise certain capabilities to gain others. Unless you understand these trade-offs, you are at risk of selecting something other than the best system for your requirements. Let’s see what’s available, review the differing capabilities and discuss the advantages and disadvantages of each design. Once you understand the options, you can evaluate them against your requirements and then consider prices and suppliers.

Of course, such a system does not exist. Add the “lowest price from the supplier that gives the best service and support” component and it probably never will exist.

Terminology in the area of indexers is not standard. Terms such as fourth axis, indexer, rotary table and so on are used interchangeably by different machine tool and accessory companies. So, when selecting and buying, you must ask a few questions before assuming you know what you’re going to get. Also, beware of terms such as “precision,” “high precision,” “accurate,” and “rigid.” Is the “brake torque” specification some absolute break away spec or the torque at which some “unacceptable” amount of rotary deflection occurs? Is the “ten arc seconds” accuracy specification certified every one degree, or is it inspected only every 15 degrees? There are no industry standards for specifications and testing. So ask questions and deal with a supplier in which you have confidence, or buy with a guarantee of performance to make your parts.

We’ll start with the mechanical hardware and discuss the electronic control options later. There are at least three common mechanical indexer/rotary table types.

These tables provide infinite positioning as well as the possibility of rotary cutting. A servomotor controlled directly either by the CNC or by a secondary servocontrol rotates a wormscrew, which drives a wormwheel on the rotary table spindle.

The absolute position accuracy of these systems is a function of the quality (precision and accuracy) of the wormgear set (wormscrew and wormwheel), the accuracy and resolution of the servosystem, and the means of servoposition feedback. Most of these servosystems utilize an encoder to monitor the position of the motor rather than the rotary spindle directly. To eliminate any inaccuracies in the wormgears and servo system, some high-end systems use a glass scale or other encoder directly on the rotary spindle to monitor actual rotary spindle position. Figure 1 (at right) shows a typical wormgear rotary table cross section.

If controlled directly by the machine tool’s CNC, they are most commonly referred to as a “full fourth axis.” A full fourth axis has the advantages of having only one CNC program, no programming required by the operator on the shop floor, minimum chance of a crash due to operator error, and the ability to make simultaneous rotary and X, Y or Z moves to do true helical milling operations as required by some more exotic workpieces.

Claims of position accuracy are often misleading since there are no industry standards. Although some manufacturers test and certify absolute position accuracy every one degree, most do not state exactly what their specification means.For all except those few expensive systems with glass scales directly on the rotary spindle, any accuracy specification is for a new table before it has been subjected to any “crashes,” which are not uncommon. Even seemingly small crashes can damage wormgear sets.

Typical infinite positioning wormgear systems utilize a friction brake to hold position against cutting forces. When cutting forces are applied directly on the rotary spindle centerline, friction brakes are generally adequate for most work. However, when cutting forces are applied to workpieces far off centerline, such as on the edge of a part on a tombstone fixture, the resulting torque on the rotary spindle can cause it to deflect. This result is especially likely when heavy cuts produce high thrust forces.

These indexers offer discrete positioning only. Depending on the number of teeth on the face gear, the minimum increment of index might be 15 degrees, 5 degrees or 1 degree. Whatever the minimum increment, only workpieces with angles representing some multiple of the minimum can possibly be machined.

Face gear mechanisms used in indexers are similar to those most commonly found in the turrets of CNC lathes, which by function must index very accurately and very rigidly to withstand the high cutting forces the lathe turret encounters. Face gear mechanisms generally fall into two categories, the two-piece and the three-piece design. Two-piece designs require the face plate of the indexer to “lift” to disengage the face gears. Three-piece designs maintain the same accuracy and rigidity of a two-piece without the need to “lift” the faceplate. In Figure 2 (at right), note the massive face gear that locks the indexer spindle in position.

Assuming it’s a quality face gear set, absolute position accuracy is superb and is maintained for the life of the indexer almost in spite of any “crashes” that might occur. Units with true absolute angular position accuracy of 5 arc seconds or less are available. These units are ideal for the highest precision work such as line boring half way from one side, then indexing 180 degrees and line boring half way from the other side.

Some face gear systems use a servodrive to achieve approximate position and then rely on the face gear for final accurate positioning. These systems are bi-directional and fast. Any random move can be programmed with one simple command. Some other systems use a pneumatic piston to rotate to the approximate position. Typically, these systems rotate only in one direction. All moves must be equal and may require a pause to utilize more then one M-code signal to achieve position. These work but can be tedious to program, set up and operate. They are more prone to crash due to operator error then servodriven units.

These indexers are becoming a thing of the past. They have all the disadvantages of the pneumatic piston driven incremental face gear indexers. Plus, compared to face gear units, they are neither particularly accurate nor rigid. Index positions are usually limited to 15-degree increments. Position is controlled by a pin in a hole or more often by a dog in a notch on the outside of a ring.

Whether you select an infinite positioning wormgear rotary system or a facegear system as the best mechanical design for your work, your next decision involves how you will control the rotary axis.

With a pneumatic incremental indexer, you probably will have no choice. Your machine’s CNC will control the indexer by communicating with a special indexer control via an M-code.

If you select a system with a servodrive, you have three choices: 1.) direct “full fourth axis” using only the machine’s CNC, 2.) an M-code command from the CNC to a separate rotary control, or 3.) RS-232 communication between the machine’s CNC and a separate rotary control. Each of these choices has advantages and disadvantages.

A single, four-axis CNC is the easiest to use and provides the most control. Four-axis CNC is best for certain kinds of workpieces. Full four-axis control systems are usually ordered for delivery with a new machine. Systems can be retrofitted; however, retrofitting is complicated and expensive. The advantages of a single four-axis control are numerous, and the disadvantages are primarily related to cost.

The single CNC constantly tracks all three linear axes (X,Y,Z) and the rotary axis. This provides the ability to do precise helical cutting with simultaneous rotary and X, Y or Z moves.

While a few machine builders offer a full four-axis control with rotary table for about 10 percent of the base price of the machine, most charge more than 20 percent.

Very few machine builders make it easy to retrofit a full four-axis rotary table. For most builders, retrofitting is a complicated process, and the cost typically exceeds 30 percent of a base machine price.

The motor for the rotary axis must be matched to the servodrive of the CNC. Because cable connections are not standard from one machine builder to another, rotary tables can not generally be used on more than one machine.

Some applications may require the accuracy and rigidity of a face gear system. However, many machine builders don’t offer face gear systems with a full four-axis control, although such systems are feasible.

An M-code actuated system provides a fourth axis of motion by combining a standard three-axis CNC with a rotary table or face gear indexer that has its own separate rotary servocontrol. The rotary program is entered and stored in the separate rotary servocontrol. The CNC communicates with the rotary control via an M-code. When the rotary control receives the M-code signal, it executes the next rotary move stored in its memory, then sends a signal back to the CNC, telling it that the move has been completed.

Typically, the rotary program includes many separate rotary moves. One move might be a simple index to position at full rapid speed. Another might be a slower rotary move to machine a groove or other feature on the workpiece. Figure 3 (at right) shows a typical rotary servocontrol system.

High quality M-code controlled systems are available from several suppliers for a price of about 10 percent of a base machine price. (For example, a 5C rotary system at $6,000; a 6-inch faceplate system at $7,000; a 9-inch system at $10,000; and so on).

Requiring only one M-code, 110V power and an air line for operation, these systems can be retrofitted to almost any CNC machine, typically with less than a day of downtime.

Systems can be moved from one machine to another as long as the next machine can issue M-codes. A shop with multiple machines and multiple rotary systems can select the best system for each job regardless of the machine. For example, a small indexer can be used for small parts to avoid cutting tool interference problems and to minimize indexing times. A big indexer can be used for big parts. A face gear indexer can be used when the maximum in accuracy and rigidity are needed and the work can be accommodated by multiples of 5 degrees of index.

The machine operator needs to enter the rotary program into the rotary servocontrol, or select the right program if it’s already stored in the rotary control’s memory. This takes some time, and there is the chance of an error.

If the machining cycle is ever interrupted in mid-cycle, such as to inspect a workpiece feature or replace a worn cutting tool, the operator must be sure to back up the rotary program and the CNC program to a point that keeps the two programs in sync. This step can be confusing, and any error can result in a “crash,” with a cutting tool coming down to a workpiece rotated to the wrong position.

Although it is possible to perform simultaneous rotary and X, Y or Z moves, they are not recommended. If you have patience and can afford to scrap a few parts, you can use trial and error to find the right rotary speed to match the linear move and determine starting points that match.

Recently developed, RS-232 communication between a three-axis CNC and a rotary servocontrol offers advantages of full four-axis and M-code operation. RS-232 is the commonly used, standard electrical interface for connecting peripheral devices to a computer. Personal computers often use the RS-232 communication protocol to send information to a printer. Another common use for RS-232 communications is connecting a PC to an external modem.

Nearly all CNC units have an RS-232 port, and it is commonly used to exchange CNC programs between a computer system and the CNC. More recently, RS-232 connections have been used by CNCs to communicate with robots and rotary tables. To communicate with the rotary table’s control, a special line of code is inserted into the CNC program. This line of code sends a string of numbers and letters through the RS-232 port to the rotary table control, which translates the string of code into rotary moves.

RS-232 communication between a three-axis CNC and a rotary servocontrol provides much of the best of both worlds of full four-axis and M-code operation. Both the linear and rotary moves are stored in the CNC as part of the workpiece program. When a rotary move is required, the CNC sends the commands for that one move (rotary speed and angle of rotation) through an RS-232 line to the rotary control.

The rotary control executes that one move and sends back a signal to the CNC, indicating that this move has been completed. The CNC then commands its next linear move. The separate rotary servocontrol simply works as a slave to the CNC. The machine operator turns the rotary control on in the morning and does not need to attend to it the rest of the day. Figure 4 (at right) shows a tilting rotary table system utilizing two rotary servocontrols with RS-232, providing five-axis capability from a standard three-axis CNC.

Crashes are nearly as unlikely as with a full four-axis control. The correct rotary program is always selected because it is part of the total workpiece program stored in the machine’s CNC. Note: Rotary moves should be programmed in “absolute position” so that if the machining cycle is interrupted, the operator can back up the CNC program to just in front of a rotary move, then safely resume the program.

Retrofitting is easy provided the machine’s CNC has an RS-232 port and appropriate communication software, which may already reside in the CNC or be available from the machine builder.

With RS-232, two rotary controls can be operated by most three-axis CNCs with only one RS-232 port. Five-axis capability with a tilting rotary table setup can be retrofitted to a three-axis machine for about $25,000 (a new, full five-axis VMC option is typically priced at $95,000).

Both the work you need to do and the machines you own or intend to purchase will influence what you select for a rotary axis. These guidelines summarize what you should consider.

When buying a new machine, get prices on everything the builder offers, no matter what kind of workpieces you’ll be machining. If the builder offers a full four-axis system with a high-quality, infinite-positioning rotary table at a price of about 10 percent off the base machine, this system will probably be your best choice.

If your workpieces can take advantage of the accuracy and rigidity of a face-gear system, and you can live with the 5-degree minimum increment, a face gear system controlled by RS-232 or M-code is a good choice. A few builders offer a face gear system with true four-axis control.

If you’re doing a variety of work that requires simultaneous rotary and linear helical moves, you’ll probably want a true four-axis system regardless of the cost. However, you should consider a more economically priced RS-232 or M-code system when you are retrofitting an existing machine and have only a couple of jobs requiring these moves, especially if these jobs are long run and you can afford some extra programming and setup time. These systems are worth considering if you simply can’t afford the price of a true fourth axis.

If you’re retrofitting existing machines, especially if you have several and want to do rotary work on more then one of them, check with the builder on the cost of upgrading to full four axis. You may conclude that the cost and flexibility advantages of RS-232 or M-code will make one of them the best choice.

Adding a rotary axis to a VMC is worthwhile whether you want to do full four-axis simultaneous machining of exotic workpieces, simple indexing of parts that need machining on surfaces not at 90 degrees from each other, or tombstone processing of rectangular parts that benefit from a longer unmanned machining cycle. Today, many good options exist. If you’re buying a new machine, have the builder quote the optional systems it offers. If you’re going to retrofit an existing machine, contact either the original supplier or the companies that offer complete indexer and rotary table systems. Retrofitting is highly affordable. (Systems from SMW Systems, for example, generally cost a little over $1,000 per inch of faceplate diameter, including installation and training.) MMS

Mitee-Bite Products’ fixtures demonstrated their powerful clamping support in a project with Akron Gear & Engineering to vertically hold a 1-ton ring during machining.

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The TR210 is HAAS"S rotary table developed and configured to be integrated with HAAS"S mills 4th and 5th axis drivers to provide complete and optimum operation. It has a diameter of 210 mm made from trunnion ...

... space with high load capacity. The individual rotary tables are equipped with Harmonic Drive units, which ensure high moment load capacities and high concentricity and axial runout accuracies.

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... Tilt-Yaw (A/B) two-axis rotary assembly provides high-speed machining capabilities for complex 3D part geometries. The precision-aligned system allows accurate positioning on a hemispherical surface. ...

... ) MDR two-axis rotary assembly provides high-speed machining capabilities for complex 3D part geometries. The precision-aligned system allows accurate positioning on a hemispherical surface. Uses cost-effective ...

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Our FÖRSTER swivel welding tables offer maximum working comfort for all-round welding of complex assemblies. Ideal for all tasks due to a variable arrangement of our patented T-slot system.

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... the table is the rotation, the user may require the rotary table for drilling operations and milling. Using the servo drives in conjunction with the machine CNC control ...

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It swivels so you can set it up so the face is horizontal but by the time you add a chuck it"s getting quite high and you sometimes run out of room for the tooling.

I have used it in the vertical position to cut a 107 tooth gear which isn"t covered by any of the dividing head wheels I"ve got. I set up an excel spreadsheet with the angle required for each tooth which isn"t as easy as it sounds as the rotary table is calibrated in degrees/minutes/seconds rather than decimal degrees so it took a bit of figuring out how to do it.

Anyway, I cut the gear all right (crossing out each angle on the spreadsheet as each tooth was cut) but you really need to be concentrating using this method.

One problem I had with the BS-0 is that the tapered hole isn"t a #2 Morse taper but a Brown and Sharp taper which meant I couldn"t find any collets for it. In the end I made a 1/2" collet out of brass which I found to be really useful. I don"t know if that is the case with the modern versions.

Automatic rotary tables have a large range of applications, for example, in manufacturing or inspection stages of sophisticated components in the aerospace, automotive, and other scientific industries. When it comes to automatic rotary tables, they are tables that are motorized and equipped with a CNC system.

A rotary table is an accessory that performs high precision positioning for a variety of metalworking applications. Widely used in advanced machining, the operators can perform drilling, milling, cutting, and other jobs at exact intervals on the axes in a horizontal or vertical structure. To achieve a high level of accuracy and efficiency, many operators install index plates or dividing plates to work with the basic rotary tables. With the help of these accessories, the rotary tables can be more versatile for indexing applications and enhance precision when machining by positioning the materials at divisions on the dividing plates.

Rotary tables are more widely mounted flat with the rotations around the vertical axis. The arrangement is the same as the structure of working planes and milling cutters in the vertical type of milling machine. In another setup, the rotary table is mounted on a 90° angle plate and the rotation will be performed on the horizontal axis. The tailstock can be utilized to grip the workpiece between centers. Rotary tables can be used in a wide range of applications, such as machining spanner flats, cutting straight, arcs, curves, circular pieces, drilling holes, milling helix, and so on. By adding a compound table or X-Y table on the rotary table, the operators can adjust the center freely, allowing cutting to perform at any desired position on the surfaces.

Automatic rotary tables, or CNC rotary tables, have a large range of applications, for example, in the manufacturing or inspection stages of sophisticated components in the aerospace, automotive, and other scientific industries. When it comes to automatic rotary tables, they are tables that are motorized and equipped with a CNC system. Automatic rotary tables are also preferred devices widely applied in CNC machining centers to act as the fourth axis since they can precisely locate the parts with different angles, helping the machine tools to perform multiple face machining at one time

In a normal machining center that has 3 axes, the three linear axes include X, Y, Z-axis. The Z-axis is the one aligned with the main axis of the 3-axis machining centers. While the X-axis works in the vertical direction, the Y-axis represents the horizontal working direction. The rotary table can replace the fourth axis in machining centers which is the rotational axis 180° around the linear lathe axis. With a CNC motor, the automatic rotary tables can increase the flexibility of metalworking applications without additional human supervision. For example, this configuration that involves an automatic rotary table machining center can be applied to helical grooves producing, blade machining, and more.

The core components of an automatic rotary table include the supporting disc where the metal pieces are clamped during cutting, a solid base which is the connecting element to another larger table, or machines like a drill press and milling machines, the CNC motor. The table disc acts as the spinning surface on which the workpieces are positioned and clamped. The chuck can grip the workpieces, and the dial indicator can be helpful when checking if the chuck and pieces are centered. After mounting the chuck with bolts, critically calibrating and locating the jobs on the table, the disc is ready for rotation under the control of the CNC motor. The indexing plate or dividing plate can be added in most types of disc. When the CNC controller and the CNC motor provide inputs, the rotation of the worm gear is activated and the mating gear mounted beneath the table surface begins to spin, either. The worm gears perform the precise rotations of the rotary table and every part of the disc are critically calibrated in degrees.

The motors in an automatic rotary table can determine the router"s precision and overall efficiency. The two classes of CNC motors used in automatic rotary tables are the stepper motors and the servo motors. Differences between servo motors and stepper motors lie in the overall pole count. Servo motors have a lower pole count (from 4 to 12) than stepper motors (between 50 and 100).

Stepper motors work with a consistent pulse providing ideal drive control and high torque at low speeds. Compared to servo motors, the stepper type is also inexpensive and widely available. However, they generate considerable vibrations and higher amounts of heat, which might lead to failure in some applications. Servo motors need the encoder to regulate pulses for precision positioning. The main advantage of servo motors is they can provide high torque even at high speed and stepper motors cannot. They do not create vibration or resonance problems and maintain at approximately 80% efficiency.