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Precitech Part Centering Accessory
is a labor saving device and improves machine utilization. It will automatically measure the part OD concentricity to the spindle axis and automatically moves the part to bring the part into alignment. When the part is centered within a user configurable alignment tolerance, the PCA routine will automatically pass off to the part program which will then machine the part. Requirements: one open IGA measurement channel, part being centered held to chuck or fixture with vacuum, one open tool holder location on the tee slot plate. The PCA is one of the productivity accessories offered by Precitech as part of their Automation Series machines and capable of centering to less than 2.5 microns (100 micro inches) eccentricity.
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200mm Aluminum Vacuum Chuck for SP-150
100mm Aluminum Vacuum Chuck for SP-150
150mm Waterproof Vacuum Chuck for SP-150
Fixturing diamond turning parts in a stress free state is difficult. These vacuum chucks are provided with flat front faces that can be diamond turned in place on the machine. This provides a nearly perfect flat surface for fixturing. The vacuum chuck provides a fixturing method that will not stress the part if the back side of the part or fixture is also made flat. The diameter of the vacuum area is adjustable to match the diameter of the fixture provided. A central dowel pin is also provided for initial alignment and safety. Vacuum is not lost upon power failure or E stop for safety reasons, but vacuum will be lost upon failure of the compressed air supply to the machine.
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Chiller for Work Spindle and Slides
A closed loop, refrigerated chiller is used to stabilize the temperature of the machine and spindle. This is powered separately from the machine, and operates separately from the machine controller. With a capacity of 1400 watts, it is available in multiple voltage and frequency options. One chiller can be used to maintain temperature of up to two diamond turning lathes, or one machine with a grinder spindle. Coolant is also circulated through the linear slideways of the machine to provide thermal stability to both axes as well as the work spindle.
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C-Axis Encoder with Slow Tool Servo and FTS Outputs
The C-Axis option includes Slow Tool Servo software, a high resolution encoder fitted to the work spindle, and encoder outputs for use by a FTS. Slow Tool Servo ( STS) is used for rapid manufacture of large departure freeform components. It relies on the machine tool slides to actuate the tool holder synchronous with the rotation of the C axis spindle. Different from the FTS, the tool position of STS is precalculated and commanded as three coordinated axes of motion on the machine controller.
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Rotary CNC Oil Bearing B-Axis
The Rotary B-axis is a direct drive, oil hydrostatic bearing, with an integral high resolution encoder, brake, optional limit switches and optional hard stops. The Rotary B-axis option allows ultra precision machining in tool normal mode which allows the use of non-waviness controlled diamond tools, or higher sweep components. It also allows tool rotation needed in the production of some diffractive lenses. The X-axis is raised on granite risers to increase the machine loop stiffness when the rotary B-axis is used. Provisions are supplied to lock the axis when rotation is not needed. A tee slot plate is available to allow a traditional setup with multiple tools / front surface probe / Ultracomp to be mounted in line on the locked B axis. Swing capacity over the B-axis tabletop is 350 mm diameter for the Nanoform 700. Radial stiffenss of 525N/μm and axial stiffness of 875N/μm
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Optical Tool Setter
Portable video-microscope utilizes a kinematic mount on top of the spindle housing. An electronic crosshair allows precise location of the tool relative to spindle centerline horizontally while vertical location of the tool is set by the focal plane. Tool tip inspection can be easily achieved while viewing the monitor. System includes a 20X, long working distance objective lens which provides a field of view of 0.24mm x 0.32mm. Can set tools within 1 micron of correct tool height.
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Integrated Gage Head
This electronic indicator and amplifier are for use by the operator in aligning a work piece with the spindle, or measuring small motions of tool height adjustment, etc. The resolution of the indicator is 0.1 micron (4 micro inches) and is shown on the UPX display screen. The full range is +/- 0.25 mm (0.010 inch). The gage head is provided with a magnetic base for flexibility and the probe tip motion can sense in both up and down directions.
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Ultracomp
This system includes an air bearing LVDT electronic displacement gage, mount for the gage, amplifier electronics, and software that runs on the machine controller. The gage is used to scan the work piece by using the machine axes. The measured surface is compared with the programmed motions and an error profile is developed. The error profile is then subtracted from the part program and after compensation all subsequent machine passes will create parts with nearly all of the axis-symmetric repeatable errors removed. Ultracomp mounts can be provided for use with either diamond turning or grinding.
- Tee shaped diamond turning mount
- Narrow profile diamond turning mount
- Mount for use with vertical spindle grinder
- Mount for use with small rotary B-axis
- Mount with small profile and break away function
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Tool Holder /Flexing Style
This tool holder is a Precitech original, and is preferred by many customers for ease of use and adjustment. A differential screw in the back is rotated to make fine adjustments in tool height through the use of a bending flexure. The tool can be adjusted in height by 0.014 inch / 0.35 mm using the differential screw, and remounted to increase the range of height adjustment to 0.50 inch / 12.5 mm.
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Tool Holder / Sliding Style
This tool holder has greater stiffness than our flexing style tool holder, and the tool motion is pure vertical translation. It is provided with two lengths of tool nose for flexibility. A differential screw is used to make fine height adjustments directly to the tool carrier. The tool can be adjusted in height by 0.014 inch / 0.35 mm using the differential screw, and remounted to increase the range of height adjustment to 1.0 inch / 25 mm.
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Tool Holder / Dual Style
This tool holder carries two tools but uses the space of one regular tool holder. This is typically used for smaller work pieces under 25 mm diameter. A differential screw is used to make fine height adjustments directly to the two separate tool carriers. Each tool can be individually adjusted in height by 0.014 inch / 0.35 mm using the differential screw, and repositioned to increase the range of height adjustment to 0.5 inch / 12 mm.
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Tool Holder / 3 Axis Adjustable
This tool holder is provided with three axes of adjustment in the X, Y, and Z directions. These are required to position the tool tip exactly over the center-line of the rotary B axis. This is required if Virtual Centering software is not provided on the machine, and is optional to be used together with Virtual Centering.
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Turret Type Tool Holder
This tool holder has four sides that each can be oriented toward the work spindle. Each side can carry one or two tools. Rotation between sides is performed manually by the operator.
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Coolant Shroud
A two piece shroud is supplied to capture diamond turning chips and coolant that is sprayed from the work piece. This is typically used in the diamond turning of crystalline materials but it can help contain other materials as well. The top half of the shroud can be removed for access to the part or for use of the tool setter. The shroud has a large opening to allow multiple tools to access the part for rough and finish operations.
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150mm Swing Flycutter Head
This tool holder mounts to the SP-150 work spindle. By spinning the tool on the work spindle, a flycutter is made that can diamond flycut stationary flat surfaces in one pass. When used with the rotary B axis or an Ultradex indexing unit, polygon surfaces can be flycut. Tools in this head are adjustable in both rake and roll angles.
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Observation Camera and LCD monitor
A camera with zoom lens is mounted on a magnetic base for flexible setup. The image is displayed on an independent 15 inch LCD color display monitor and does not interfere with machine setup or operation. The field of view size can be varied by the zoom lens from approximately 2 mm up to 8 mm. The working distance is 90 mm.
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LVDT Tool Setter / Vertical & Horizontal for diamond tools
LVDT Tool Setter / Single Horizontal for grinding wheels
A vertical and horizontal contacting type tool set station can establish tool height and radius to an accuracy of 0.4µm (10µ”). The tool setter utilizes a kinematic mount on the top of the spindle with high repeatability. A zero position knob allows the operator to null a digital readout for the tool height probe. A four-digit display enables the operator to manually adjust the tool height to place the tool at spindle centerline height. Tools are automatically probed in several positions and the associated data is acquired by the controller, which accurately computes tool radius and X offset position..
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LVDT Front Surface Probe
A horizontal, contacting type probe is mounted alongside the tool holders on the Z slide or B tabletop. This is used to locate of the work piece position without any operator intervention. Machining can start immediately without any “air cutting”.
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Additional Spray Mist Nozzle
The basic two nozzles provided on the machine can be supplemented with a third or fourth (max.4) nozzles. Each is individually commanded and each has a set of controls for air and lubricant.
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3C Collet Fitted to SP-150 Work Spindle
This collet adapter accepts a standard 3C collet. The collet is clamped using spring force and unclamped using air pressure through the spindle.
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Virtual Centering Software Upgrade
This software upgrade is used in conjunction with the rotary B-axis. This provides the ability to select a position near the B-axis centerline and move the X and Z-axes in coordinated motion with the B-axis rotation so that this selected position rotates as if it is the centerline of the B rotation. This could be the edge or center of the tool radius, or the cutting edge of a grinding wheel. Having this software upgrade simplifies setting up tooling on the B axis.
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Rotary B-axis Radial Error Compensation
The B-axis radial error specification is 4 micro inches at one inch height over the tabletop. The coning error specification is one micro inch per inch of height which can increase this error motion to be greater than 4 micro inches at the cutting height. This procedure measures the radial error motions of the rotary B-axis at the spindle centerline height and implements software corrections to minimize these errors by the use of the X and Z-axes motion during B rotation. Basic error motions plus coning errors are reduced to less than 2 micro inches total at the spindle centerline height.
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Linear Grooving Accessory
A Sine plate is mounted under the work spindle for height (depth of cut) adjustment. This can be manually driven or stepper motor driven. Depending upon the application, tip only or tip plus tilt plates can be used to support the work piece on either the Z tabletop, large rotary B table, or small rotary B table. This can also be offered without the sine plate and with height adjustable tooling under the work piece. In this case the work piece can be set in height and tip and tilt using three points of support with adjustable height.
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Fast Tool Servo FTS 70 300 g’s
Fast Tool Servo FTS 500 20 g’s
Fast Tool Servo FTS 1000 20 g’s
The Fast Tool Servo ( FTS ) is used for rapid manufacture of small departure (up to 1000um) freeform components and micro-structures. A FTS includes a short stroke actuator which holds a diamond tool and mounts onto the Z-slide of a lathe. The actuator is driven by either a Piezo electric stack or linear motor with closed loop position feedback. With the use of a dedicated digital signal processor, the tool position is calculated and commanded in real time based upon the rotational position of the work spindle and position of the slide. The command is sent to the FTS controller, which closes the servo loop and moves the tool appropriately.
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Temperature Controller
This unit re circulates, filters, and controls the temperature of the air inside the machining zone on Precitech machines. Cold air output from an air conditioning unit is mixed with return air from the machine, then heated to meet strict temperature control requirements. A PID controlled heater maintains the set point with optimum control stability. Waste heat from air conditioner can be ducted to the ceiling so it does not disturb lab area temperature controls. Water drain from the air conditioner requires collection and disposal by the end user.
Excess air flow pressurizes the machine enclosure keeping out drafts
Temperature is controlled to +/- 0.1C when used in an environment with air temperature same as controller set point within +/- 1.1 C temperature variations.
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Heat Exchanger inside machine (Requires Chiller Option)
This option mounts a water to air heat exchanger inside the machine enclosure. The coolant from the chiller is circulated through the heat exchanger and the air is circulated using a small fan. In this manner the air inside the machine enclosure can be kept more stable in temperature which improves the machine thermal stability.
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LED Task Lamp
The LED task lamp is used to improve illumination of the working zone without the addition of heat. It comes mounted to the machine enclosure with a gooseneck flexible mount. This allows the light to be oriented as desired by the operator. There is a switch on the head for turning the light off when not needed.
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Remote Jog Pendant
This jog pendant allows the operator to perform some setup functions while away from or not facing the machine controller. For safety purposes, when the remote is active, the main operator controller is not functional. A light is provided on the main controller indicating that the remote pendant is active. Functions provided include E stop, continuous and incremental axis jog, jog increment size, and shift selection.
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Part Programming Software
Precitech offers an aftermarket software (DIFFSYS) for the creation of part programs. This software is available in a variety of configurations (aspheric’s, diffractive’s, freeform surfaces) and with or without measurement corrective feedback functionality. Cost varies with the functions desired. DIFFSYS basic for programming of 2D tool paths in included with the Window Interface.
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15,000 RPM Motorized Tool Spindle (Vertical)
A high stiffness, DC motor driven, air bearing spindle is mounted vertically to an angle bracket located on the Z-axis. This enables grinding of glass optics, grinding of steel mold inserts, or spiral milling diamond turnable materials. The tool spindle can accommodate wheel sizes up to 100mm diameter and can run with variable bidirectional speeds up to 15,000 rpm. It can be used together with a fixed diamond tool holder for preparing fixtures or easily transitioning between grinding and diamond turning. It also has a dedicated removable mount for use with the Ultracomp surface measurement probe. Not for use with water based coolants. See Nanoform 250 grind package for water based coolant compatible machine.
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80,000 RPM Turbine Tool Spindle / Horizontal, 45, Vertical
This air bearing turbine spindle is packaged on a flexible mount that can be rebuilt with the spindle in either horizontal, vertical, or 45 degree downhill positions. The spindle can also be pivoted about a vertical axis to provide better work approach when needed. Can be used with or without the rotary B-axis. Not for use with water based coolants. See Nanoform 250 grind package for water based coolant compatible machine.
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60,000 RPM Turbine Tool Spindle / Horizontal
An air bearing turbine driven spindle is mounted to the Z-table next to other tool holders. This allows marking, grooving, or milling of features into the work piece. The tool spindle axis can be pivoted away from the work spindle axis from zero to 25 degrees of angle in the horizontal plane in increments of 5 degrees. Not for use with water based coolants. See Nanoform 250 grind package for water based coolant compatible machine.
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ACT Software Upgrade
Adaptive Control Technology (ACT) software continuously adjust servo control parameters in real-time for the specific machining task and work piece running on the machine. ACT actively cancels repetitive sources of error. The benefits of ACT are most apparent for machining tasks involving high velocity machine motion (ex. Slow Tool Servo) or when continuously varying processing conditions (ex. ramping spindle RPM across parts during STS processing). This is recommended for use with the C-axis option and is not of assistance if the spindle does not have C-axis.
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