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Handwheels for Haas Toolroom Lathes are machined from solid at Haas Automation. These are ready for finishing.
The fading light of day plays across the machined surfaces of a Haas VF-2 column casting on the Haas assembly floor. More than 85% of all VF-2 parts are made in the Haas factory, and all major castings and critical machined parts are machined on Haas machines. These columns are machined complete in a pair of robotically loaded Haas EC-1600YZT HMCs.
Here at Haas Automation, we take full advantage of the capacities and capabilities of every machine in the shop to produce the right number of parts at the right time, in the most efficient way possible. Here, we’re utilizing the high-speed capabilities and large table of a Haas VF-3SSYT VMC to precision chamfer gears for the Haas 40-taper gearbox – 20 gears at a time, in a single setup.
It’s a high-production environment, and we put as much thought and engineering into optimizing our workholding and machining processes as we do into designing high-quality components for Haas machines.
These pinion gears for the Haas C-axis drive system are fresh off the hone and ready for final grind, before going to the assembly floor. The C axis system is included with the live tooling option on Haas turning centers to provide interpolated bidirectional motion at precise speeds and feeds for part positioning and repeatability.
The concept of a machine that can provide multiple axes of movement for cutting metal and other materials has changed very little since the dawn of the industrial revolution. These simple, basic tools, however, have benefited substantially from the application of computer technology. The modern Turning Center uses CNC (computer numerical control) to coordinate both simple and unbelievably complex movements of those axes. While electronic servomotors can provide axis movements in the tenths of a thousandth of an inch, the amazing performance of these machines is the result of high-precision positioning encoders, high-performance axis drives, and the powerful computer control that coordinates the axis movements and is able to repeat them precisely. Using a computer language called G-code, machining programs can be developed and tested offline, and then transferred to the machine and run with minimal human interaction.
These cam follower arms for the Haas side-mount tool changer are fresh off one of the many Haas EC-400PP pallet-pool HMCs in the Haas machine shop. The material for the arms is rotary surface ground, and then the blanks are loaded into an EC-400PP to cut the profiles. The profiled blanks are then loaded into another EC-400PP to machine the fronts and backs of the arms. When assembled to the tool changer cam box, the arms drive the shaft that raises and lowers the double-arm during a tool swap.
The Haas UMC 750 demonstrates its machining capabilities while at WESTEC 2012. The 2012 concept UMC 750 - universal machining center - is a 5-axis machining center currently under development by Haas.
Fast tool changes are a necessity on a high-speed drill/tap machine. To speed up the process on the Haas DT-1, the tool pockets are mounted to the carousel radially to eliminate the pocket-tip time.
A Haas machinist checks the runout of a DT-1 spindle shaft before ID machining on a Haas SL-30 turning center in the Haas machine shop. After turning, the spindle shafts will be finish ground to size, assembled with bearings, and then built-up into high-performance spindles for the Haas DT-1 Drill/Tap Center.
These side-mount tool changer assemblies are ready to be installed on VF-2 vertical machining centers. These quick-action 24-pocket changers are optional on the VF-2. Haas Automation makes a wide variety of quick, dependable automatic tool changers, from the 10-pocket carousel style, up to the 70-pocket SMTCs available on the Haas EC-400 and EC-500 series horizontal machining centers.
Haas inline direct-drive spindles use a Haas-designed and -built magnetic encoder assembly mounted to the motor to precisely control spindle rpm, and provide closed-loop feedback for accurate rigid tapping.
This heavy-duty, chain-drive system on the Haas Automatic Pallet Changer (APC) swaps pallets quickly to keep non-cutting time to a minimum. Available on Haas VF-3 and VF-4 VMCs, the APC boosts productivity by allowing non-machining tasks, such as part changeovers and fixture setups, to be performed on one pallet while parts are being machined on the other.
Haas machine tools feature a minimal lubrication system that optimizes the amount of lubricant supplied to the machine components. The system supplies lubrication only when needed – based on distance traveled or number of spindle revolutions. This reduces the amount of lube required, and eliminates excess lube that could contaminate the coolant.
These liner guide adapters for Haas turning centers are machined from 6061 T6 aluminum in two turning operations on a Haas ST-30Y, and one milling operation on a Haas VF-4 in the Haas machine shop. Next, they will be sent for black anodizing, before being packaged in the appropriate liner kit for the new Haas Bar Feeder. The yellow plastic mesh protects the threads on the adapters during transportation.
The liner guide adapters are manufactured in various sizes to match the spindle bore of each model of Haas turning center. They allow the turning center to use Haas Automation’s patented extruded spindle liners for bar feeding or bar pulling operations. The spindle liners ensure the bar feeds smoothly and accurately into the machine’s chuck or collet, and provide support for the bar as it turns.
These gears are destined for the gearbox of a Haas 50-Taper VMC. With the exception of heat-treating, Haas makes these gears entirely in-house. The gear blanks are machined in one operation on a Haas SL-25APL two-spindle CNC turning center with automatic parts loader and live tooling before going to the gear hobber. After hobbing and heat-treating, they are precision-ground for parallelism and perpendicularity before heading to assembly. Strict Quality Control procedures are observed at every step of production to ensure the high quality and dependability expected from Haas.
A batch of Haas 40-taper spindle cartridges await installation. All Haas spindles are manufactured in-house, and fully balanced and tested prior to installation. The cartridge design simplifies installation and service, while improving reliability.
Massive bearings and a powerful hydraulic brake assembly form the foundation of this integrated 4th-axis rotary system being assembled on a Haas EC-1600 HMC. The optional full 4th-axis rotary platter is integrated into the T-slot table to provide simultaneous 4th-axis machining, or allow access to four sides of a part or tombstone. The 30" platter handles parts and fixtures up to 10,000 lb.
The production floor at Haas Automation is a busy place. To ensure safety, traffic mirrors throughout the plant help forklift drivers and other employees see what’s around the corner.
These high-precision spindles for Haas HRT450 rotary tables are being assembled with aluminum-bronze worm gear blanks, before heading to the CNC gear hobber. Each spindle will be trammed-in on the hobber to a maximum 2-micron runout before the worm gear is cut. Cutting the worm gear after it’s assembled to the spindle shaft ensures perfect concentricity of the gear pitch diameter to the bearing journals and the spindle axis. The finished assemblies are then inspected on a Wenzel WGT500 CNC gear analyzer.
At the heart of every Haas rotary table is a large-diameter, aluminum-bronze worm gear supported on both sides by pre-loaded, deep-groove radial bearings. These massive bearings withstand loads up to 31,000 lb to ensure superior performance and dependable operation.
Here's a sneak peek at Haas Automation’s new Haas DM-2 Drill/Mill Center and DT-2 Drill/Tap Center. These pre-production machines will be closely scrutinized for fit, finish, and function, and then thoroughly tested for performance, before the new models go into production next year. The DM-2 and DT-2 provide the same high-speed performance and productivity-boosting features as the shop-proven DM-1 and DT-1, while offering 8 more inches of X-axis travel and a larger T-slot table.
Tyson Lamb, Lamb Crafted – Haas logo coaster, download the Solidworks part file to machine this yourself: bit.ly/2gXTdEe
Except for heat treating, these two gears were made entirely in-house at Haas Automation. The blanks were cut on Haas SL-20APL turning centers with automatic parts loaders, and then the teeth were cut on a CNC gear hobber. After heat treating to 60 Rc, the gears were then precision CNC ground to AGMA Class 13 Quality. The two-gear assembly on the right is for the Haas 40-taper gearbox. The gear on the left is for the Haas 50-taper gearbox. Manufacturing all major components in-house, including gears, allows Haas to provide customers with the best machine tool value anywhere.
A Haas service technician uses a high-precision level (0.05 mm/m) as he installs a VF-2SS in the Haas demo room. The technician checks the level as the machine is run through full travel in the X and Y axes, to ensure it is perfectly adjusted side-to-side and front-to-back.
Completed side-mount tool changers on the assembly line at Haas Automation.
Side-mount tool changers are one of the most popular options for Haas small- and medium-frame VMCs, and they come standard on Haas large VMCs and HMCs. Not only do they hold more tools than a carousel-style tool changer, but they also provide faster tool changes, and store tools out of the work envelope for unobstructed machining.
The concept of a machine that can provide three axes of movement for cutting metal and other materials has changed very little since the dawn of the industrial revolution. These simple, basic tools, however, have benefited substantially from the application of computer technology. The modern HMC uses CNC (computer numerical control) to coordinate both simple and unbelievably complex movements of those three axes. While electronic servomotors can provide axis movements in the tenths of a thousandth of an inch, the amazing performance of these machines is the result of high-precision positioning encoders, high-performance axis drives, and the powerful computer control that coordinates the axis movements and is able to repeat them precisely. Using a computer language called G-code, machining programs can be developed and tested offline, and then transferred to the machine and run with minimal human interaction.
Dry machining 1018 steel on a Haas VM-3 using the Haas Minimum Quantity Lubrication (MQL) and Auto Air Gun options. The MQL system works through the Auto Air Gun to deliver a steady flow of compressed air and a small quantity of cutting oil directly to the cutting tool, which reduces heat, removes chips, and provides lubrication.
These blanks for Haas transmission gears are queued-up for hobbing on a Koepfer gear hobber in the Haas machine shop. The blanks are gravity fed to a robotic arm, which loads them into the machine for hobbing, and then automatically stages the completed gears for the next operation. Before hobbing, the gear blanks are turned, drilled, and tapped on a Haas SL-20APL with automatic parts loader and live tooling.
These 50-taper drawbars are fresh off a Haas ST-20 in the Haas Automation machine shop. The shafts start as bar stock that has been centerless ground to size, and then cut to length. The shafts then go into the ST-20 for OD and ID threads and finish turning, before moving to a Haas VMC for a set of milled flats. The shafts are then gundrilled for the TSC through-hole.
Sheet metal parts make their way through one of the four powder booths that are part of the highly automated powdercoat line at Haas Automation’s sheet metal facility.
The 940-foot automated line includes a five-stage washer (phosphate bath and four consecutively cleaner rinse stations), a high-temp dry-off oven, four powder booths (each dedicated to a specific color to eliminate changeovers), and a high-temp cure oven.
The parts are fabricated in-house, sent through the powdercoat line, and then packed and delivered to the main Haas facility, about four miles away.
This cam assembly is ready for installation into the gearbox of a high-speed side-mount tool changer for the Haas DT-1 Drill/Tap Center. Once assembled, the tool changer will undergo rigorous testing to ensure accurate operation and high quality, before installation on a machine. All major components – including the cam, gear, and arm – are precision machined in-house at Haas Automation in Oxnard, California USA.
These motor and pump brackets for the Haas 300-psi Through-Spindle Coolant System were made in-house at the Haas Sheet Metal Shop. They are first laser-cut to precise tolerances on an automatically loaded FMS-style laser cell, and then formed on state-of-the-art CNC press brakes. Skilled technicians then weld the seams, and weld in the pickup tube and connectors. After welding, the brackets are thoroughly cleaned and powdercoated in a highly automated continuous powder line, before assembly into complete TSC pump units.
Bottom cover plates for the Haas 40-taper gearbox are pre-assembled with transfer tubes for the dry sump lubrication system prior to installation. All Haas gearboxes are built in-house at the company¹s Oxnard manufacturing facility.
Finished Haas machines – wrapped and ready to ship – fill the yard at Haas Automation’s 1-million-square-foot manufacturing facility in Southern California. Can you find yours?
All Haas machines are built in the U.S., and the company continues to increase production to meet the growing demand for Haas products worldwide.
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These 50-taper spindle housings are fresh off a robotically loaded turning center in the Haas machine shop. The housings start out as iron castings, which are robotically loaded into a turning center for facing, and turning the OD and ID. The housings are rough turned on Haas SL-40s, and then moved to a three-up fixture on a horizontal machining center to put in the bolt circle and the features for the lubrication system. The housings then go back into Haas SL-40s to finish the face and bores to size.