HSM Today Issue 17 (PDF | 1.5 MB)

Specialist journal from
Mikron Agie Charmilles AG
for the Milling Technology
Issue 17
Page 2-3:
Milling tools with an
HSM 600U Prod Mod
Page 4-5:
The UCP 600 Vario is
at home anywhere
Hirschvogel, hinge
bearings with the HPM 1000U
Page 6-7:
Glaroform mills for
the foodstuffs industry, HSM 800
Page 13:
Page 16:
No ball rolls without
Santiano, UCP 800 Duro
Automation–getting more from your investment
To ensure that machining continues to remain economical
today, many businesses are
having to consider automation.
As a competent partner,
AgieCharmilles GF is ready to
analyse and implement such
projects with its clients.
Ralf Löttgen
It really does not seem so long
ago since, as a 19 year old apprentice, I was aligning the work pieces
in the milling machine vice using
the centering device and, when
manually changing the tool, tightening the drawbar in the spindle,
using the Allen key. This year, I am
42 and have obviously changed and
in so many ways.
In those days the machine tool
was, generally speaking, an investment, the cost-effectiveness
of which cost-effectiveness, in
smaller companies at least, was
often not given any further thought.
The machines were operated by
a skilled worker who carried out
all processes and tasks on each
machine himself. The machine was
his support.
In recent years, technology has
set the course for the automatic
operation of the machine tool, i.e.
the provision of all the relevant elements required for the process.
More than ever before, the market
is dictating conditions, deadlines
and prices. It is a question of using technological possibilities and
human skills to respond to market
demands.
A production facility must be
productive somewhere between 0
and 8760 hours per year. You will
agree with me that anything
between 0 and 2500 cannot really
be economical and that 8760 is not
really realistic. Therefore, let’s
assume that 2500 to 7500 hours
per year are generally economical
and realistic; exceptions prove
the rule.
To achieve this, the company infrastructure must undoubtedly be
adapted to the new situation and
orientated towards keeping expensive production facilities in operation. Even complex processes can
nowadays run automatically and
without direct supervision by
an operator. The job profile and the
worker’s skills must adjust to
the situation.
In addition to this are logistical
prerequisites such as the provision
of tools, NC programs and palletised work pieces in sufficient
quantity and quality. Standardisation of the processes and incoming materials is often a prerequisite but it makes things much
easier, in any case.
production. A typical feature of suitable machines is, therefore, integrated clamping systems (advantage: maximum volume of working
area remains intact) or at least fitted ones (disadvantage: part of the
working area is lost to the clamping system).
1. Machining Centre with
integrated chuck
An automatic tool or electrode
changer as well as peripheral devices such as those required for
cooling lubricant treatment and
chip disposal or dielectric processing, callipers etc. are taken for
granted and are state-of-the-art
and included in the delivery scope
of modern machine tools. As such,
the introduction of a reference system typically precedes automation.
Pallets (Illustration: 3R Macro
Magnum system) or other zero
point clamping systems are typically used to fix or transport work
pieces in a specified position. In
conjunction with the corresponding functionality of the machine
controller or high-performing
workshop management systems,
reference systems are the indispensable first step to automated
2. Machining Centre with
integrated Pallet Changer
Low-cost changing mechanisms which, with limited flexibility and smart efficiency, offer the
best possible value for money, provide a start to automatic workpiece
handling. They convert a machining centre into an automatic manufacturing cell, which, using suitable software functionality, can be
integrated into cell management
systems, e.g., Sigma. Such systems
have often proved themselves to be
interesting alternatives to wideranging automation solutions for
the tool and mould-making industry or the production of repetitive
components with production times
of typically more than 30 minutes
per pallet.
3. Machining Centre with
programmable Handling Devices
Programmable handling devices are used when increased capacity, flexibility and functionality
are required or different production mechanisms e.g. machining
centres, measuring machines
and/or systems for electrical discharge machining are to be concatenated. Typical products are devices with programmable rotatory
and linear axes, articulated robots
or similar. Once again, the selection is based on the production
problem, with the least complex
system able to carry out the task
usually being the most logical
choice, since each additional controlled axis means loss of money,
manageable workpiece weight and
reliability. Whilst simple handling
devices in this category , e.g., 3R
Workmaster system, can typically
change pallets and carry out sim-
ple activities, such as the emptying of cavities as well as transport
between a limited number of production facilities, robots are used
if the workpieces have to be handled. Articulated robots are generally too expensive for pallet changing and produce no real benefit. If,
however, components require direct handling and it is necessary to
perform additional tasks requiring
complex movements, they are often indispensable. Once again, it is
important to mention that, depending on the production task, software such as 3R Workshopmanager system can support organisation
and data provision and acquisition,
at various levels of development.
4. Machining Centres
with Linear Concatenation
With the necessity to concatenate an increasing number of production facilities and extensive peripheral equipment, e.g. cooling
lubricant or dielectric processing,
chip disposal, large capacity for
blanks and finished parts, the need
for linear concatenation of the
components in a manufacturing
cell becomes inevitable. Undoubtedly, such an investment must be
planned and assessed carefully but
it is possibly the best economic
solution, or even the only realistic
one. As a competent partner,
AgieCharmilles GF is ready to
analyse and implement such projects with their clients. Whether
from our own portfolio (3R Workmaster Linear system) or in collaboration with other partners from
the sector, in the case of linear system concatenation we also apply
the automation solution which best
suits your requirements.
5. Conclusion
There is no quick fix for automation or for the optimum
exploitation of an investment. The
automated production solution
Continued on Page 2
High-speed machining
2
Editorial
Jens Thing
Brand Manager Mikron
HSMtoday Nr. 17
The highest quality milling
tools by Seco Tools France
Seco Tools designs, manufactures and sells tools for metal chip
removal. Two HSM 400U and three HSM 600U ProdMod machines
by Mikron AgieCharmilles AG are used for production
Dear Readers,
Today, versatility and flexibility
for a company are fundamental
prerequisites to capture the
market.
This issue of HSMtoday once
again highlights the versatility
of our range of products. For
years we have launched high
speed machining centres onto
the market; the capacity and
machining options of these machines remain exceptional even
today. Originally, these machines were meant only for
mould making. Then in 2004,
with the HSM 600U ProdMod,
we developed the first machining centre specially intended
for production. The systematic
expansion and integration of
palletising systems have made
this machine line extremely
attractive for other applications
too. The automation options
have awoken interest from a
variety of different areas of
machining.
But even our other machines,
such as the HPM machining
centres and machines from
the VCP and UCP series, are
today used in the most diverse
economic environments for the
most versatile applications.
Our latest offensive is in the direction of medical engineering.
With the HSM 400U ProdMed in
its standard configuration and
with the variants for the manufacture of dental implants, as
well as the UCP 600 Vario
ProdMed, we will place our
technical knowledge, acquired
over years, at the service of
medicine.
Mikron proves its versatility –
put us to the test!
Seco Tools France is an innovative
company which makes an
above average investment in
research, development and production to face the challenges
of the future.
The wide tool and clamping tool
programme meets a variety of requirements during milling, turning and drilling. Seco Tools is,
however, much more than a tool
supplier. The company is a reliable partner who, in conjunction
with its customers, analyses production technology problems in
order to reduce production costs
and offer economic solutions.
Alexandre Condrau
Jürgen Maurer
Seco Tools France belongs to
the worldwide network of subsidiaries within the Seco Tools
Group, which was founded as a
steel factory in Sweden in 1929.
Seco Tools has manufactured tools
for milling, turning and drilling
since 1930. The company has more
than 4300 employees all over the
world in 40 subsidiaries and is, today, one of the world's leading
manufacturers of cutting tools.
In 1965, Seco Tools France was
founded as a 100% subsidiary
of the Seco Tools Group. Its tool
programme is also intended for
turning, milling and drilling applications. The company now has
approximately 250 employees, of
which 100 of them work in production.
The company headquarters and
production unit is at Bourges, approx. 220 km south of Paris/France.
Seco Tools France is not only responsible for sales in France but
also manufactures for the Group.
As such, approximately 800 milling
cutters are manufactured per
week, including both standard and
special tools. Approximately 25%
of turnover comes from the production of cutting plates.
In order to strengthen its market position, Seco Tools France
offers a wide range of tools for all
chip removal tasks. Moreover, specific solutions are developed which
meet all the requirements of costeffective and smooth running production, given that customers are
naturally interested in the highest
productivity and cost-effectiveness. Cooperation and customeroriented thinking are, therefore,
of paramount importance for
Seco Tools.
Today’s requirement for justin-time deliveries, as well as tough
competition, forces businesses to
have short reaction times.
Universal tools are, therefore,
required which can satisfy a wide
range of requirements with high
productivity.
The production of cutting plates
is a source of new challenges for
Seco Tools. Replaceable turning
plates are absolutely essential as,
today, there is frequent use of prefabricated “near net shape” workpieces with a small final measurement, at almost actual size. They
must guarantee good chip breaking and control especially at shallow cutting depths, high cutting
speeds and large feeds. Given that
the chip removal volume is low,
small, cost-effective turning cutting plates are used. Seco Tools
Continued from Page 1
suited to your application must
correspond to the basic conditions,
financial possibilities and the
future direction of your company.
There are regions in which a
yearly output of more than 5 000
hours for a machining centre in
manual operation is typical.
In the western industrialised
countries such times are generally not achievable without
automatic workpiece handling.
AgieCharmilles GF has adapted to
this and, from the preconfigured
product up to the individual automation solution including advice
and project management, offers a
complete portfolio based on the requirements of your production
problem about to be solved by automation. Discuss your ideas with
our sales companies. They will
work with you and AgieCharmilles
GF, New Application and Systems
and Automation to develop an automation solution, tailor-made to
suit your requirements.
www.mikron-ac.com
constantly discovers better cutting
materials and optimum geometries for excellent chip removal
results by applying state-of-theart turning plate technology, and
carrying out continuous research
and development.
Thanks to the tremendously
rapid development in tools and
machines, machining today is three
times quicker than 25 years ago.
The increase in cutting speed,
feed and cutting depth generates
increased heat on the contact
surface between turning plate
and workpiece (often exceeding
1,000 ºC), thus making higher
demands on cutting edge and
High-speed machining
HSMtoday Nr. 17
3
events. Along these lines, seminars
regarding the “machining of complex materials” are offered, innovations are presented by way of
special machining demonstrations
and reports as to which tools are
best suited to which applications.
Finished milled part and blank
geometry with regard to wear and
heat resistance. Seco continues to
invest in the development of coated hard metal types, cements and
ultra-hard cutting materials.
There is a large training centre
at the company headquarters in
Bourges. Given that tools and machining processes are increasingly complex and continue to improve,
Seco Tools France offers regular
further education and information
Seco Tools chooses Mikron
machines
For the manufacture of tools for
metal chip removal, Seco Tools
France chooses machines by
Mikron Agie Charmilles AG from
Nidau in Switzerland. The first
HSM 400U was purchased in 2003.
Due to the excellent machining
quality, another machine of this
type was purchased the following
year.
In August 2005, an HSM 600U
ProdMod was added. The executives at Seco Tools France were so
convinced by this machine that, in
the space of one year, another
HSM 600U ProdMod was purchased. The expectations of
Mikron’s machines have been fully met at Seco Tools. Production
times have been reduced by over
20%. The HSM machines have
also proven themselves by virtue
Mikron’s HSM machines satisfy the greatest demands regarding
speed, accuracy and surface finish quality
Seco Tools chooses Mikron machines for the production of milling tools
of their accuracy and stability. The
stunning surface finish and the
increased tool service life testify
to the optimum ratio of machine
robustness and machining output
of the Mikron machines.
At Seco Tools France, only pretreated steel with 48 HRC is
processed. Production is handled
by two teams, 7 days a week, with
approximately 50% run as manless
operation. The Mikron machines
are automated with Erowa robots.
The milling heads to be machined
at Seco Tools France are fixed
to devices manufactured by Seco
and can be directly set on the Erowa
ITS 148 or PC 210.
The production machines
The HSM ProdMod machines
are specially designed for production. The results are high speed
machining centres with the highest dynamics for economical machining of exacting precision parts
for medium to large series. They
are equipped with highly dynamic
direct drives for the B and C axis.
The models in the HSM series
have a monoblock machine base
made of polymer concrete, constructed according to the frame
overhead version.
This basis has been tried and
quality. With their requirementoriented design, high quality components, digital drive technology,
as well as one of the most modern
control systems, they are designed
for maximum value, cost-effectiveness and functionality.
At the Seco training centre in Bourges, regular seminars are held for
customers, commercial partners and Seco employees
tested for several years both on
HSM 400 machines and machines
in the HSM 600/800 series.
They leave nothing to be desired
with regard to rigidity, damping behaviour, access and compactness.
The high-performing motor spindles by Step-Tec in various versions according to speed and
torque ranges have contributed
to the success of this machine
series.
Today, more and more users
are opting for an automated HSM
machine by Mikron. As such, the
set-up times can be achieved during the primary machining time and
the plant running times can be
extended during the manless
evening and night shifts. These two
advantages must not be underestimated, especially when manufacturing parts in medium and
large batches.
Mikron’s HSM machines satisfy the greatest demands regarding
speed, accuracy and surface finish
www.secotools.com
mikron-ac.com
Universal machining
4
HSMtoday Nr. 17
The UCP 600 Vario is
at home anywhere
Whether a small or large enterprise, whether
machining steel, aluminium or plastic, the UCP 600
Vario is given an enthusiastic welcome everywhere!
Mikron is known for its spirit of
innovation, and in recent years,
has defined many trends in
the area of standard, high speed
and high performance machining
centres.
The market does not often react
as positively as it has to the
UCP 600 Vario, which was publicly
displayed for the first time at
the EMO 2003.
Martina Uebersax
Different markets have different requirements for machining
centres. With its UCP 600 Vario,
Mikron has in its portfolio a product which delights customers
worldwide in equal measure.
The huge market acceptance of
the UCP 600 Vario clearly shows,
above all, that customers are
not demanding reliable and
powerful individual components,
rather an efficient, cost-effective
system, which is well-rounded
and complete and which can
also react to inputs from outside
the system.
The UCP 600 Vario is suited to
the most wide-ranging variety of
applications. This includes cus-
tomers who want to produce high
quality parts in 5-face machining,
such as production companies,
who will have to manufacture
medium-sized series and various
parts in 5-face machining more
economically in the future. It is
especially customers in market
sectors with high salary costs who
recognise the business advantage
of an UCP 600 Vario with automation. All of the components necessary for successful production are
installed in the most compact
installation area.
The wide and well matched
range of milling spindles (12,000,
20,000 and 42,000 rpm) enables the
customer to equip the Vario with
the required capacity and torque
on the tool to match their preferred
materials. Ultimately, all Vario
customers have one aspect in common: the UCP 600 Vario is as universal in its implementation as the
customers’ requirements are demanding and varied. The most
wide-ranging materials can be
machined including aluminium,
normal or stainless steel, titanium
and plastic. The machining possibilities range from simple drilling
to complex 5-face and 5-axis
machining.
Maximum flexibility is the
unanimous demand made on the
machine when producing small
and medium series. In this regard,
the built-in automation (7 to 10 pallets) is particularly praised by
the users.
The following customer profiles give an impression of
the exceptional versatility of the
UCP 600 Vario.
www.mikron-ac.com
The UCP 600 Vario at Toolmakers in
the Netherlands
The Toolmakers company
from the Netherlands supplies
the fine mechanical industry with
a wide variety of highly varied
quality works which are produced
by chip removal.
The machine park is equipped
to ensure that all chip removal
work can be undertaken in the
company itself. Furthermore,
Toolmakers offers small and
medium-sized enterprises a
complete service; analysis, development and entire engineering. In total, four machines from
Mikron Agie Charmilles AG are
used at Toolmakers: three
5-axis Mikron UCP 600 Vario’s,
one of which has a pallet changer, as well as a VCP 1000. All
machines are equipped with
the Heidenhain iTNC 530 control
system.
Complex parts are manufactured which require a variety of
operations. Toolmakers easily
manufactures workpieces with
tolerances of +/- 0.005 mm. Furthermore, workpieces with a
tolerance range of 0.002 mm can
also be milled. Extremely short
cycle times and 24-hour operation makes Toolmakers stand
apart from its competitors.
Now, after almost six years
experience with 5-axis machining, Toolmakers is extremely
satisfied with Mikron Agie
Charmilles. An important reason
for the investment was the high
flexibility of the UCP 600 Vario
and, according to the Managing
Director, Cuno Hanegraaf:
“... with its many machining possibilities this machine has adapted very well to our production
spectrum. As such, we were able
to broaden our offer and have won
over clients for whom we could
not have otherwise worked.”
www.toolmakers.nl
Precision components with the
UCP 600 Vario at William Cope Ltd.
A Mikron UCP 600 Vario was
commissioned in May 2005 at
William Cope Ltd, in the United
Kingdom. This purchase was preceded by discussions on how to
increase productivity and how to
improve the production capacity.
As a supplier of precision components, William Cope Ltd. has been
able to significantly increase its
competitiveness following the
acquisition of the UCP 600 Vario.
Both technical and commercial
considerations played a decisive
role in the purchase of the Vario.
The company is now far more
flexible in the production of small
series using the UCP 600 Vario. The
integrated automation (7-fold pallet changer and the tool changer
TCD 30 / HSK 63) enables manless
operation. Cycle times have been
reduced and costs cut. Fundamentally, the UCP 600 Vario is easy
to operate. It guarantees high precision and repeat accuracy with
5-axis machining and is excellent
for automatic operation.
[email protected]
Universal machining
HSMtoday Nr. 17
Mikron machining centers are
well known für their ergonomic
design.
The UCP 600 Vario is particularly
successful due to incomparable access: The blue area for
the operation of the machine and the red area for machine
maintenance. Optimum access is guaranteed regardless
of the respective machineconfiguration.
Basic machine
with central 30/36unit tool changer
Basic machine with
pallet depot
(7-10 paletts) and
central tool changer
Basic machine with
pallet depot and
tool changer
(tower with
120-220 tools)
The Precise company from Germany
also uses the UCP 600 Vario
The UCP 600 Vario in
Germany at ATM
For over 25 years, the company ATM GmbH in Altenkirchen has
been manufacturing laboratory
equipment for metallography.
Approximately a year ago, ATM purchased a UCP 600 Vario from
Mikron Agie Charmilles AG. The
deciding factors for this investment,were the combination of
excellent price-performance ratio,
Mikron's renowned reputation and,
of course, excellent machine
features such as automation,
compactness and ergonomics. The
UCP 600 Vario is primarily used for
processing aluminium and steel
and is equipped with a 20,000 rpm
spindle with internal coolant feed
and a tool changer with 120 tools.
Now, after approximately a year of
milling using the UCP 600 Vario at
ATM, the company management
has confirmed that the machine
has fully satisfied expectations.
www.atm-m.com
machine is primarily used for
machining aluminium and steel. So
far, the machine has fully met
expectations. The automation
option optimally designed by
Mikron Agie Charmilles is particularly noteworthy.
www.precise.de
J.E.B. Precision Ltd. and the
UCP 600 Vario in the United Kingdom
J.E.B. Precision Ltd. have been
using a UCP 600 Vario since 2005.
The company manufactures precision components and electromechanical assemblies. Their customers come from the optical industry, the medical sector, robot
technology, the foodstuffs indus-
try and other sectors. With its
5 axes and the built-in 7-fold pallet changer, the UCP 600 Vario
offers J.E.B. Precision improved
productivity, increased accuracy
and greater flexibility in production. It is worth noting that time
savings of 60% have been
achieved on the machining of
certain specific components.
www.jebprecision.co.uk
Eurocut Ltd. in the
United Kingdom.
The UCP 600 Vario
in medical
technology
Eurocut Ltd. was founded in
1987 in Sheffield, the United
Kingdom. The company now has
approximately 100 employees
and primarily offers complete solutions for medical technology.
The core business is design,
development and manufacture of
instruments and apparatus for
implementation in orthopaedic
surgery – especially for hip, knee,
shoulder, spine, elbow and toes.
The UCP 600 Vario in Spain is used for
parts in the aeronautical industry
Quality, precision and innovation at
Precise are of paramount importance. For more than 60 years it
has manufactured milling and
grinding spindles in Leichlingen,
Germany and in Racine, USA.
Appropriate machines are required
to manufacture such highlyprecise spindle systems. As such,
Precise invested in a Mikron
UCP 600 Vario over a year ago. This
5
The Guilo Mecanizados company was founded in 2000. Today it
employs 13 qualified employees.
Over the years, the machine park
has been enlarged to eight NCcontrolled machines. This park also includes two Mikron machines,
an HPM 1350U and the UCP 600
Vario. The UCP 600 Vario is used
for manufacturing parts for the
aeronautical industry. Special aluminium, imbar and titanium are the
main materials used. The difference between Guilo Mecanizados
and its competitors is that it offers
a complete service; from the
clamping system to the CAM
programming right up to the 3 and
5-axis machining. Guilo Mecanizados has therefore opted for the
UCP 600 Vario, “... given that approximately 70 % of the parts to be
processed have small dimensions
and with the pallet changer we
can also process small series
using the automatic mode.”
Thanks to optimum spindle features, the UCP 600 Vario can be
used at low speed and at high
torque, particularly relevant when
working with titanium, and at high
speed when machining aluminium.
At Guilo Mecanizados, there is
no doubt that the UCP 600 Vario
from Mikron has completely satisfied expectations.
www.mguilo.com
Two Mikron HSM 600 Vario
machines were commissioned in
the summer of 2006. As the company works in the field of medical technology, the ProdMed
machines specially designed for
this sector were purchased. The
UCP 600 Vario ProdMed makes a
significant contribution towards
reliable and traceable results
in production by combining the
monitoring functions of the
control system with the “smart
machine” modules to monitor
spindle vibrations (Extended
APS), the automatic calibration
of machine geometry (ITC5X),
that can be requested in the NC
programme, and the option to
transmit the specific machine
and process status to GPS
telephones.
The APS “smart module” is a
monitoring system which opens
up new opportunities for the user
to observe, control and correct
the milling process. With the help
of an acceleration sensor integrated in the spindle, vibrations
during the milling process are
recorded and displayed to the
operator on the console. This
enables intervention in the
milling process for optimisation
purposes.
Improved cycle times and
process safety, increased productivity and, of course, the
splendid automation devised by
Mikron, all of which can be
achieved with these machines,
played a decisive role in the purchase of the UCP 600 Vario.
The UCP 600 Vario ProdMed
is fitted with a 20,000 rpm spindle and primarily works with
stainless steels, aluminium and
titanium..
www.eurocut.co.uk
Highly productive 5-axes machining
6
Tools for
hinge bearing with a
Mikron HPM 1000U
As development partner for the
automotive industry and manufacturing specialist in bulk metal
forming and machining (both
of steel and aluminium), the
Hirschvogel Automotive Group is
active in the areas of diesel/fuel
injection, gears, drive train, chassis and engine. Hirschvogel has
been using Mikron milling centres
for years.
Jürgen Maurer
The Hirschvogel Umformtechnik GmbH was established in 1938
as a smith’s shop by three
brothers, Willy, Anton and Hans
Hirschvogel. Today, the company
employs 2500 people at its four factories in Germany, Columbus/Ohio,
USA and most recently China,
which was set up in 2005 in the
vicinity of Shanghai. The Hirschvogel production spectrum includes
hot, semi-hot and cold forming
as well as heat treatment and the
mechanical machining of forged
pieces.
The Hirschvogel Eisenach
GmbH founded in 1991 originated
from the “smith’s shop” department of the former Automobilwerke Eisenach (AWE). At the beginning of 1997, a new factory was
set up on a Greenfield site in the
industrial area of Marksuhl, 20
kilometres south-west of Eisenach.
The company name, Hirschvogel
Eisenach GmbH, has now had
“Headquarters in Marksuhl” added
to it. Together with the Hirschvogel Aluminium GmbH established
in 1999, there are at present almost
400 well trained employees at this
factory.
In a neighbouring area in the
industrial estate, Hirschvogel acquired the hall of a company which
had gone bankrupt and, after remodelling, tool production was
relocated there and extensively expanded. This is where the Mikron
HPM 1000U is also installed. The
machines from Switzerland are
best known at Hirschvogel. There
are already 18 Mikron machines at
HSMtoday Nr. 17
The Hirschvogel Umformtechnik GmbH in Denklingen,
Germany, is one of the world’s
largest automotive manufacturers in the area of bulk metal forming and chip removal
the main factory in Denklingen and
in Marksuhl.
The Marksuhl company manufactures precision-formed parts for
renowned companies such as
BMW, Daimler Chrysler, Volkswagen, Bosch, Siemens, Visteon and
Denso. The Marksuhlers have specialised in the forming of chassis
parts such as hinge bearings and
wheel carriers made of aluminium
alloys. In addition, they manufacture precision parts for gears,
engine, drive train as well as components for diesel injection.
HPM 1000U produces highquality tools for hinge bearings
The hot-forming of aluminium
corresponds to the basic principle
of steel drop forging. This is done
at temperatures of approx. 500 °C.
Sawed sections of aluminium extruder profiles are, for the most
part, heated in cyclic non-stop furnaces. After any pre-forming for
material distribution, forming of
the parts is done in pre-engraving
and post-engraving. To prevent excessive cooling during the forming,
the tools must be warmed to
approx. 230 °C. Naturally, this
requires extremely precise tools.
For the manufacture of such complex and high-quality tools,
Hirschvogel Eisenach GmbH in
Marksuhl bought the abovementioned HPM 1000U in the spring
of 2006.
Due to its robust structure and
the directly driven circular and
swivelling axes, the HPM 1000U
can be used for heavy
roughing jobs as well as for
precise smoothing jobs
For engineers Horst Hupfeld,
Tool Production Manager, and
Ronny Pfaff, both from Hirschvogel in Marksuhl, the Mikron
HPM 1000U is currently the most
flexible machine in its class.
Unlike other machines, roughing with the HPM 1000U is clearly
faster. “The final contours of the
tools are discernible in one go, the
HPM 1000U is truly impressive”,
says Ronny Pfaff during a visit to
the company in Marksuhl, where
he was proud to present the new
Mikron.
While smoothing, we make full
use of the maximum spindle speed.
“The capacity of the new spindles
is really impressive”, continues
Ronny Pfaff. “Mikron’s HPM 1000U
is exactly the machine that we need
for manufacturing our tools. We
would like to use it to mainly mill
tools for the manufacture of hinge
bearings made of aluminium.”
Motor spindles of the latest
generation were developed for the
HPM 1000U. Speed, drive power
and torque are perfectly combined
for machining according to the
HPM milling strategy. The high
spindle capacity guarantees short
run-up and brake times. Of course
the direct drives in the 4th and
5th axis guarantee optimal load
of the circular swivel axes, whereby 100% simultaneous operation
is implicit.
“The five-axis HPM 1000U
clearly meets the standards that
we demand from modern milling
machines. Not only the capacity
of these machines, but even the individual components are well
coordinated with each other. The
unique automation through the
HSMtoday Nr. 17
centre of the machine has been
well resolved by Mikron. With
the remaining components, the
HPM 1000U is designed optimally
for 3-shift operation. However,
Mikron has also thought of the
operator, who has unrestricted
access to the machine”, explains
Horst Hupfeld, who understands
machining best. For Ronny Pfaff,
the possibility of automating the
HPM 1000U was an important
requirement and the deciding
factor for choosing the machine.
The HPM 1000U and other machining centres were also selected
because of their long traverse
paths giving the advantage of
greater
flexibility
to
suit
future developments.
Horst Hupfeld agrees and emphasises that: “The HPM 1000U is
excellent for automatic operation.
The machine must largely run
manless. This is an important
aspect, especially in Germany. The
HPM 1000U is a vital manufacturing facility to remain competitive in
tool manufacture”.
The HPM 1000U is fully designed
for automatic operation
Due to its robust structure and
the directly driven circular and
swivelling axes, the HPM 1000U can
Highly productive 5-axes machining
filter are highly accessible to the
operator.
It goes without saying that all
“smart machine” modules, e.g.
ITC, APS or RNS can be used to
achieve a cost-effective milling
process.
What makes the HPM 1000U
truly sensational is the solution for
automatic loading. Work pieces of
up to 800 kg are automatically
changed from the pallet magazine
to the circular swivelling table. A
hydraulic lift/rotation unit (pallet
changer) places the preselected
pallets on the clamping devices of
the circular swivelling table. The
optional swivelling setup station on
the pallet magazine makes it easier to load the magazine with the
work pieces secured on the DIN
pallets. The setup station and circular swivelling table have reliable
medium connection. Of course, the
compact tool changer even in the
HPM 1000U that can store up to
215 tools on barely more than 1 m2
is part of the extremely compact
design of the machine. This entirely new solution for automating
heavy components offers unparalleled ergonomic conditions at the
workstation. Access to the working area and pallet magazine is
convenient and safe.
I) can be variably regulated from
the operator console. In addition,
minimum lubrication with steam
extraction for coolant steam and
oil mist is available as an option for
the series. It was designed for high
efficiency and a long service life.
Fully-automatic bellows seal the
workspace. The barrier can be automatically unlocked when the
swivelling table is manually loaded
with a crane and relocked once the
loading is complete.
7
instruments, laboratory equipment
as well as the CAQ system installed
in all production areas, Hirschvogel offers a quality standard that
sets the benchmark. This also
helps ensure that the quality management systems of all Hirschvogel companies are certified in compliance with the ISO/TS 16949
International Standard.
As technology leader of traditional drop-forging, semi-hot and
cold forming, aluminium forging as
well as machining, Hirschvogel, the
family company, has earned a good
reputation in the manufacturing industry. To ensure this success in
the long term, Hirschvogel must be
able to rely on its suppliers and
their products.
“With the HPM 1000U, we have
certainly made a good choice.
After all, we can only produce
excellent products when we use
high quality production facilities”,
concludes Horst Hupfeld.
Tools and parts of the highest
quality are indispensable.
High precision forming tools
such as the aluminium hinge bearing production are milled on the
HPM 1000U. All hinge bearings
formed using it must be 100% safety tested and are subject to a strict
goods acceptance inspection.
By using the latest production
plants, milling centres such as the
HPM 1000U by Mikron, measuring
HPM 1100 and HPM 1000U
The HPM 1000U palette changer
Work area
Longitudinal
Cross
Vertical
Feed rate
Rapid traverse rate X, Y, Z
Feed rate. X, Y, Z
Working spindle
High-frequency spindle
Spindle power/Spindle torque
High-frequency spindle
Spindle power/Spindle torque
Work table
Clamping surface
Max. table load
HPM 1100
X mm 1100
Y mm 800
Z mm 600
m/min 60
mm/min 0 - 20'000
min
40% ED
min
40% ED
-1
-1
Rotary tilting table
Tilt range
°
Rapid traverse rate
C min
Rapid traverse rate
A min
Clamping surface, autom. DIN-Pallet mm
Max. table load (central)
kg
Clamping surface, manual
Ø mm
-1
be used for heavy roughing jobs as
well as for precise smoothing jobs.
The compactness of the entire
machine makes the HPM 1000U
unique. Accessibility to all the main
components, such as basic machine, multiple pallet changer and
tool changer is always guaranteed.
In addition, peripheral devices such
as the chip conveyor or band pass
To achieve high metal removing capacity throughout the year,
the HPM 1000 U must be equipped
with production-specific and reliable options. For example, cooling
of the machining method: internal
and external supply of coolant
(IKZ/AKZ) is possible with cooling
water and air. The cooling water
pressure for IKZ (20 to 80 bar, 1200
Tool changer
Central tool changer
Tool changer (tower)
Pallet changer
Pallets
Dimension
60
0 - 20'000
20,000 - HSK 63
66 kW / 198 Nm
28,000 - HSK 63
60 kW / 75 Nm
mm 1200 x 900
kg 2000
-1
Forged aluminium hinge bearing
HPM 1000U
1000
800
600
-
Tools 40
-
mm -
20,000 / HSK 63
66 kW / 198 Nm
28,000 / HSK 63
60 kW / 75 Nm
-
+30/-120
60
60
500x630
800
800
40
115/165/210
5, 6, 7
500 x 630 / 500 x 500
www.hirschvogel.com
www.mikron-ac.com
Highly productive 5-axes machining
10
Injection mould dies
with an HPM 1850U
When handling complex 3D tools
in single and multi-component
technology, Formenbau Kellermann GmbH, with its head office
close to Nürnberg/Germany,
offers competent and individual
solutions for all industrial areas.
In December 2005, a Mikron
HPM 1850U was added to their
modern machine park.
Stefan Fahrni
Jürgen Maurer
Whether difficult and mechanically complex injection mould dies
for the car industry, large and
extremely precise injection mould
dies for home appliances or even
unusual injection mould dies for
special areas, Formenbau Kellermann GmbH always finds the
right solution, regardless of the
industrial sector. The company
focuses on the development and
manufacture of complex 3D moulds
in single and multi-component
technology.
The family company has now
been running for more than 35
years and, today, is managed by
Sabine Kellermann from the second generation. “As before, our objective is to meet our customer’s
wishes punctually and by being
cost-effective with uniform high
quality“, confirms the CEO during
a visit to the company. “Over two
expansion phases, in 1990 and
1998, here in Postbauer-Heng, we
have created optimum framework
conditions for our modern production. Our machine park is always
state-of-the-art. At the end of 2005,
we decided to acquire a HPM 1850U
from Mikron. It is now our biggest
machine and has traverse paths
of 1850 mm in the X-axis and
1400 mm in the Y-axis”, continues
Sabine Kellermann. The professional knowledge and readiness of
the employees is still the most important basic principle of the company. We lay great emphasis on
sharing technical knowledge with
trainees. Besides the highest precision and reliability, quality mould
making is an important issue at
Formenbau Kellermann GmbH.
The company has been DIN EN ISO
9001 certified every year since 1998
by TÜV South Germany.
The HPM 1850U – the biggest
machine offered by Mikron
In December 2005 it was time;
the HPM 1850U was installed. The
initial training was started immediately and progressed rapidly over
two months. The combination of
highly trained employees and the
Heidenhain control system have
paid off. With its large table, long
traverse paths producing good surface quality during milling tests, a
deciding factor in its purchase, and
yet compact footprint, the new HPM
1850U is very convincing.
HSMtoday Nr. 17
Formenbau Kellermann
GmbH is the ideal partner
for designing and manufacturing complex tools
cally clampable circular and
swivelling axes
• 5-axis simultaneous machining
• Spindles with 15'000 rpm or
24'000 rpm, or 8000 rpm with
up to 324 Nm with HSK100
• Work pieces with an interference circuit diameter of up to
2 metres and weighing 4 tonnes
Given that in modern car manufacturing the air filter housing must
always be built by saving space and
thus deeper, the machine must be
car interiors that the surface is extremely important“. At Formenbau
Kellermann GmbH, programming
is carried out at special work places
and not at the machine. “This gives
us tremendous time advantage and
we can work in parallel. With the
new machine, we schedule shorter times and still achieve good
smoothing results. Our expectations from the HPM 1850U have
been fully satisfied”, emphasises
Sabine Kellermann at the end of
our visit to the company.
The versatility of HPM 1850U
• High dynamics due to directly
driven circular and swivelling
axes
• Selection between pallet or
circular table
• Stability during the machining
process thanks to the hydrauli-
Air filter system for the automotive industry
in the position to mill deep moulds
with long tools. Even here, the
strength and the extraordinary stability of HPM 1850U was evident.
“For us, particularly in mould
making, it is the ideal machine.
With the long tools we can process
really deep cavities well and the
machine rigidity is excellent”, confirms Sabine Kellermann. “At night
we currently run smoothing programmes on the HPM 1850U and
the complex processes are carried
out during the day. It is precisely
when we are processing moulds for
Mikron’s HPM 1850 offers long
traverse paths:
X-axis: 1850 mm
Y-axis: 1400 mm and
Z-axis: up to 905 mm
www.mikron-ac.com
www.kellermanngmbh.de
High-speed machining
HSMtoday Nr. 17
Tooth replacement and parts
for the aeronautics industry
will be manufactured with
the HSM 600U ProdMod and
HSM 400U
The Eguile Group from Spain consists of the companies Zehatz,
DMP and Createch Medical. It is
distinguished by a versatile range
of products and specialises in the
design and manufacture of highprecision parts and tools for the
most diverse uses. These products include components for the
aeronautics industry, tools for the
packaging industry as well as
pharmaceutical products. Their
range of machines includes a HSM
600U ProdMod and two HSM
400U’s by Mikron in Switzerland.
Ferran Santandreu
Zehatz has been established for
more than 14 years. Together with
DMP and Createch Medical, it belongs to the Eguile group, which is
owned by Alfonso Urzainki. Today,
the company has over 120 employees. Zehatz is distinguished by its
flexibility and versatility. The machine park is equipped accordingly, and the most diverse tasks can
be accomplished at their factory.
High-precision parts and tools
are designed and manufactured
for different areas such as the
aeronautics industry, medicine,
electronics or even for the packaging industry. Zehatz always finds
the best solution for parts which
are difficult to manufacture. For
example, in the case of narrow
tolerances or when the geometry
and manufacturing process are
complex due to the material or the
required machining, such as in
parts for turbines and landing
gears for aircrafts.
11
Versatility is the
strength of the Eguile
group of companies
Special steels like Inconel,
Nirosta, Monel, aluminium, carbide
and titanium are processed at
Zehatz. Due to its flexibility and
its preference for high precision
work, Zehatz clearly stands out
from its rivals. Alfonso Urzainki,
the CEO, emphasises that only the
best processing machines are
used. “Only then can we achieve
extraordinarily precise surfaces.
And besides, we also have one
of the best testing laboratories
that a company of our size has to
show”, he explains, not without
pride. This is also in line with his
company philosophy:
“We must be able to test and
We are therefore investing in
machines and devices for production and for testing.”
certify everything that we manufacture. Only in this way we can
offer a 100% guarantee to our customers. I believe that is the biggest
difference with regard to our rivals
and it enables us to fulfil the
requirements of each of our customers. We know what a micrometer is and how much effort it takes
to get there.”
When asked about the precision
and tolerances with which Zehatz
works, Alfonso Urzainki explains
the situation at his factory: “Each
process and each workpiece have
their special features, which
cannot be generalised. Basically,
we can guarantee a precision
below 2µm. In future, we want to
improve the precision further.
The HSM 600U ProdMod
For a few months, Zehatz has
also been using a Mikron HSM 600U
ProdMod. With this machine we
manufacture high quality parts because this high speed machining
centre is suitable for the rational
machining and processing of
sophisticated precision parts for
medium to large series. The machines from the ProdMod series
are equipped with highly dynamic
direct drives for the B and C axis.
With a pallet changer system and
an automatic tool changer, machines from the ProdMod series
are especially good for automatic
production. The powerful motor
spindles, in different versions for
different speeds and torque
ranges, have also contributed to
the success of this machine series.
When choosing the HSM 600U
ProdMod, some features were of
special importance for Zehatz, explains the CEO, Alfonso Urzainki:
“The 5-axis machining at high
speed and high precision, the flexibility and reliability, the automation option or even the access to a
large number of tools and the fact
that the pallet changer does not
compromise the process when single pieces are being machined or
when setting up the machine”, he
adds suppressing a smile.
The high speed machining centres by Mikron, and the HSM 600U
ProdMod in particular, satisfy
these standards.
www.zehatz.es
www.mikron-ac.com
High-speed machining
12
HSMtoday Nr. 17
The HSM ProdMod
now has 3 axes too
Mikron is expanding the ProdMod
series with the HSM 600 ProdMod and
the HSM 800 ProdMod
To ensure that milling machines
can successfully be used in
production it is not enough to implement the best possible machining process - it must also
be long-lasting.
Alexandre Condrau
New in the ProdMod series
Following the market launch in
2004 of the HSM 600U ProdMod
with the first high-speed milling
centre for the standard 5-axis
production of high-precision, top
quality work pieces, Mikron is
now expanding the ProdMod series
with the new 3-axis models,
HSM 600 ProdMod and HSM 800
ProdMod.
Part Production 24 hours, 365 days
The HSM series was originally
primarily designed for mouldmaking. The systematic expansion
and integration of palletising
systems have made this machine
line a possibility for other applications, too. Interest has been shown
in these high-speed machining
centres and their capacity from
the most varied branches of industry. In the meantime, the HSM
machines are also being used
in production. It is here that they
are particularly in demand for
automation.
Every detail is significant
Round-the-clock production
usually implies fully automated
machine operation without super-
vision by machine operators. In this
environment, each breakdown has
far-reaching consequences. That
is why Mikron is constantly focused
on continuously perfecting its products, paying careful attention to
seemingly minor details.
Automation of high-performance
machining processes
The high capacity of 3-axis machining centres simplifies palletisation for maximum loads of
800 kg which are used in linear
systems with four stations, as well
as tool automation with a capacity
of up to 220 tools and a tool change
time of only 5 seconds.
Error-free chip transport
The result of a machining
process lasting for several hours
is a perfect workpiece and a
large volume of chips. The errorfree transport of the chips and
media is an absolute priority for
the machining process. The ProdMod machine series is equipped,
as standard, with a continuous
rinsing system for the entire
working area and the spindle nose,
to ensure that chips do not accumulate and that all chips are
diverted from the chip conveyer and
filtered.
Strong and fast
Where there are many chips,
there must also be a strong spindle and a robust tool interface. Both
are included in the ProdMod series. As an option, the machines
can be equipped with an HSK-A63
spindle (22 kW) with 24,000 rpm
or else with the HSK-A50 spindle
(32 kW) with 36,000 rpm.
What has not, however, been
modified by Mikron's engineers
is the impressive capacity of the
linear axes. The ProdMod designs
also have the same dynamic
features (40m/min/1.7g) which
have made the Mikron HSM
machining centres extremely
highly-renowned.
HSM at the service of production
From now on, the advantages
of the HSM are no longer reserved
for those who strive for perfect
machining processes. The new
ProMod machine range combines
the time factor with high productivity demands.
Intelligent and independent
The “smart machine” modules
within the ITC product family
provide a guarantee of constant
machining geometry throughout
the whole day, from the moment
the machine is switched on. Thanks
to the APS modules, the milling
process can be comprehensively
optimised, which not only ensures
high-quality surface machining
but also considerably extends the
service life of the spindle and
the milling tool. The RNS “smart
machine” tool provides absolute
reliability when you are planning
the number of work pieces to
be manufactured.
www.mikron-ac.com
HSMtoday Nr. 17
High-speed machining
Machining moulds
using a
Mikron HSM 800
13
Glaroform is achieving
great results with a Mikron
HSM 800 equipped with the
3D measuring system Form
Inspect from m&h
Thanks to measuring and finishing with a Mikron HSM 800
equipped with the 3D measuring
system Form Inspect from m&h in
a single set up, die-cast moulds
and mould inserts are reliably
produced by Glaroform in the
shortest possible time, and within fewer micrometres at critical
points and with a general tolerance between 0 and 0.01 mm.
Karl-Heinz Gies
Flower pots, margarine and ice
cream tubs and fine food tins, food
and non-food packaging, cups,
bins, lids whether they are round,
oval, square or rectangular with
and without fastening and with injection moulded carrying-handle
upon request are the end products
which are produced all over
the world with the fast-running,
high-performing moulds by the
company Glaroform from Näfels in
central Switzerland. They all share
the characteristic of very thin walls,
which itself indicates how exact the
moulds must be. They can sometimes weigh up to 5.5 tonnes when
finally assembled.
The company designs and produces its own moulds. Each mould
is tested and is not delivered until
after trial production on one of the
company’s two injection moulding
machines with clamping forces up
to 420 t. An important criteria for
both the clients, and indeed Glaroform, is that 95 % of the moulds
end up being exported.
Forming steels and hardened
steels up to a hardness of 52 HRC
are machined. A constant increase
in hard machining as well as a
desire for better surfaces in order
to reduce subsequent machining
such as grinding, eroding and polishing, were the reasons behind the
purchase of a HSM 800. For over a
year, time-consuming refinishing
work has been replaced by machine milling wherever possible.
Even limited sizes which up until
now were ground on the coordinate
grinding machine are today directly milled, as time is money.
The required dimensional accuracies, especially due to thinwalled containers such as margarine tubs, confront production
with several intricate problems.
The worker is faced with difficult
tasks in particular due to the
frequent draughts of 8° to 12°.
Time-consuming spot-grinding
was unavoidable until purchasing
the Mikron HSM 800. Measurements on the drafts were difficult
and fairly unreliable.
For measuring any profiles and
geometries you might wish
That is why the HSM machine
was purchased along with a calliper from m&h, the German machine tool measuring specialists,
and its 3D Form Inspect software,
for measuring any profiles and
geometries you might wish, directly on the machine. The work piece
can be measured at any time whilst
still in the clamp. For this purpose,
the workpiece CAD data is read into the 3D Form Inspect software
from m&h. The screen displays a
surface model of the workpiece and
the operators can determine the
points where they would like
to check the geometry by simply
clicking on the mouse, regardless
The HSM 800 working area, equipped with a calliper from the company m&h, Germany
Before a tool leaves the factory, tests are carried out on either of its
two injection moulding machines
of whether this concerns open-die
surfaces, grooves, drilled holes
or anything else. The software
automatically calculates the correct contact paths. Many measuring functions, which are also assigned by clicking on the mouse,
make the daily work in the workshop easier.
The NC programme is automatically completed in the process.
The machine covers all measuring
points with the calliper and transfers the measurement values back
to the computer where they may
immediately be displayed on the
screen or saved and distributed
as a log or file. A brief automatic
calibration is integrated into each
measuring programme at m&h,
in order to record the machine
status. This is how accurate and
reliable results come into being.
The operator can make corrections
immediately and remachine, or
the last finishing cut can be
set exactly to the desired zero
measurement.
Glaroform is satisfied that
the investment has already paid
for itself in the first year. The
accuracy, surface quality and the
very high availability are greatly
appreciated in the HSM 800. As
with Mikron, their opinion of m&h
is unambiguous:
“We would make a similar investment at any time”, confirms the
production manager.
www.glaroform.ch
www.mikron-ac.com
High-speed machining
14
BEFA and the rapid
HSM 600U ProdMod
From project planning to consultation right up to implementation,
BEFA supplies turnkey plants for
process technology. For milling
work, machines by Mikron Agie
Charmilles from Switzerland are
used.
Jürgen Maurer
BEFA-Automationstechnik
specialises in everything related
to plant manufacturing. According
to the customer’s wishes or based
on their own suggestions, plants
are developed, designed on SolidWorks-3D-CAD and then produced
on a turnkey basis. Naturally,
the company also handles the installation, commissioning, training
and, of course, service too.
Somehow, they seem to be
attracted to difficult and complicated jobs. At least, that is the
talk about Berndt Olbricht and
Frank Bauer, CEO and proprietor
of BEFA-Automationstechnik in
Uhldingen-Mühlenhofen at Lake
Constance/Germany. Indeed, perhaps that impression is not wrong
since both have turned their
hobby into a profession. They en-
thusiastically design and manufacture even heavy, complicated parts
and devices. Such products include
their own collapsible high-tech golf
cart made of a combination of
carbon, special steel and aluminium, materials which at present
are only used in high technology
areas such as aeronautics and
space as well as in Formula 1. They
do, of course, also make other
things.
The legendary 1911
At their premises on Lake Constance, the grip ends and pistol
cradles of the legendary 1911 pistol by Colt are milled using 5-axis
simultananeous technology. An
extremely sophisticated task. They
received the order from the arms
dealer, Felix Mogdans, who manufactures a 1911 gun specially
for sports shooting and arms
collectors.
The M1911 gun is one of the
most well-known guns manufactured by Colt, if not in the world,
and was devised by the American
gun designer, John Moses Browning (1855-1926). At the beginning
of the 20th century, the US army
needed a new service gun. When
Browning, who was working with
Colt at the time, heard about the
army’s interest in a .45 gun, he converted his gun designed for .38 calibre for the new .45 ACP (Automatic Colt Pistol) cartridge.
The tests lasted almost five
years until it was proven that the
new gun by Colt was the best and
most reliable of the guns tested.
As a result, in 1911, this gun was
immediately handed over to the
army and although this outcome
for the test series was expected,
they needed time to deliver larger
quantities. As the First World War
broke out, the guns were also manufactured by other companies under license. Thus began the endless triumphant progress of the
1911 model, on which, even today,
many sports guns are based. Felix
Mogdans modified the 1911 gun in
such a way that the gun he manufactured is nowadays an excellent
sports device and collector’s piece.
Accuracy and precision
Sports shooters need absolute
precision and perfect sports devices. To achieve such precision,
the machine with which the
device is manufactured must
obviously meet certain standards.
HSMtoday Nr. 17
Innovative special machines?
BEFA from Germany
faces each challenge
Berndt Olbricht with the 1911 model and his chip removal operator
Stefan Liehn, who is responsible for the HSM 600U ProdMod
For this delicate task, BEFA
uses the HSM 600U ProdMod by
Mikron Agie Charmilles AG.
The ProdMod machines are
equipped with the modern Heidenhain iTNC 530 control. The directly driven circular swivel table in
linear technology provides for highest dynamics during rotating and
swivelling movements. The perfectly integrated pallet changer
offers optimum requirements for
smooth automatic operation.
The HSM 600U ProdMod at
BEFA is equipped with a 24,000
spindle. Stefan Liehn, who works
as a chip removal operator on the
HSM, did not need much time to
get used to the high speed of the
machine. “It was easy to learn and
test, and all that can be achieved
with the HSM 600U ProdMod is
amazing. Here we use a spherical
ball miller with 0.5 mm diameter
and obtain an unimaginable surface quality. Finishing is no longer
required. The high speed of the
machine really impressed me”,
he says enthusiastically. Berndt
Olbricht also agreed: “I don’t know
of any machine that is as good as
this one. For me, the design and
the extremely short tool changing
times were the deciding factors.
Besides, it has very low tool
wear. I was simply convinced by
the good machine concept of the
HSM 600U ProdMod by Mikron.
The HSM machines specially
developed by Mikron for production
meet the highest standards with
regard to speed, precision and
surface quality. With their requirement-oriented design, high
quality components, digital drive
technology as well as the most
modern control systems in the
world, they are designed for maximum value, economic efficiency
and functionality.
www.befa-fn.de
www.mikron-ac.com
High-speed machining
HSMtoday Nr. 17
15
HSM 400U ProdMed
HSM 400U ProdMed Dental
UCP 600 Vario ProdMed
Mikron places milling technology at the
service of medicine
With its three machining centres
HSM 400U ProdMed, HSM 400U
ProdMed Dental and the UCP 600
Vario ProdMed, Mikron Agie
Charmilles AG concentrates on
the requirements of a specific
clientele – the offer is directed at
manufacturers of medical products. It is precisely in this area
where traceability is of particular
importance.
Mikron offers the conditions
required.
Alexandre Condrau
Mikron Agie Charmilles AG has
been supplying machining centres
to companies in medical technology for years. These have always
been tailor-made solutions which
required a lot of time and money
on both sides. With the three new
models, Mikron is meeting the special requirements of milling machining centres for this clientele.
The know-how gained over the
years is reflected in the HSM 400U
ProdMed, HSM 400U ProdMed
Dental and the UCP 600 Vario
ProdMed. As a basis for endorsement, Mikron machines are
delivered with a range of quality
records (positioning, geometry
and working accuracy, circularity
test, thermal behaviour, test
workpiece etc.).
HSM 400U ProdMed and
HSM 400U ProdMed Dental
Particularly worthy of mention
in the HSM series are the precision, extraordinary dynamics and
high machining speeds achieved.
Moreover, it offers excellent chip
removal, high flexibility, optimal
ergonomics and well integrated
automation functions. This machine range embodies the entire
knowledge and years of experience
gained in high-speed cutting.
Mikron demonstrates with the
MedTech range that maximum
flexibility and top productivity are
not incompatible.
“Reverse Engineering”, for example, enables the providers of
dental technical solutions to close
the gap between the physical and
digital world.
Both HSM machines are based
on 5-axis simultaneous machining,
in accordance with High Speed
Machining Technology. They are
both equipped with HSK E40
motor spindles which rotate at
30,000 rpm in addition to feed
and rapid feed (with 20, or rather
40 m/min).
UCP 600 Vario ProdMed
The UCP 600 Vario ProdMed is
the optimum machining centre for
the production of medical products.
In the case of a wide production
portfolio, traceability is of utmost
importance. Mikron, in conjunction
with the m&h company and its 3D
Form Inspect software, offers the
ideal solution. Unlimited flexibility
guarantees a high-performing
milling spindle, a high-capacity
tool changer, a practical pallet
changer as well as an efficient chip
removal and coolant process. The
5-axis vertical machining centre is
equipped with HSK A63, with a 120tool capacity tool changer and with
a 20,000 rpm motor spindle.
Due to splendid access and
ergonomics as well as an excellent
overview of the milling process,
no compromise is required when
operating the UCP 600 Vario
ProdMed. Mikron has an impressive 5-axis solution for automated
production with the UCP 600 Vario.
The digital CNC control system
Heidenhain iTNC530 with which all
models are fitted is versatile,
flexible and very user-friendly. It
can be programmed both at the
machine as well as at a separate
workplace.
“smart module”
The scope of delivery includes
the following “smart machine”
software modules with the three
ProdMed machining centres:
“APS extended” for monitoring
spindle vibrations, “ITC5X” for
automated circular swivelling table
recalibration (can be requested
via NC programme) as well as
“RNS”, which specifically transmits machine and process status
to GPS telephones.
The “smart machine” modules
also make a relevant contribution
to reliable and traceable results
during production. Data related to
process vibrations, heat transfers,
spindle anomalies and workpiece
measuring are saved and are then
available for evaluation and documentation purposes.
When manufacturing implants,
e.g. for skull, jaw, hand, arm, knee,
spine and hip surgery, materials
which are difficult to machine, such
as titanium or steels with a high
chromium and nickel content, are
used. The profiles are almost always very complex and frequently
still very filigreed. The surfaces
must, nevertheless, be optically
impeccable. This is only possible
with Mikron’s state-of-the-art
technology within a context that is
also cost-effective.
Impressum
HSMtodayTM
Specialist journal from Mikron
Publisher:
Mikron Agie Charmilles AG
Ipsachstrasse 16, CH-2560 Nidau
Tel. +41 32 366 11 11,
Fax +41 32 366 11 66,
E-Mail: [email protected]
Brand Manager: Jens Thing
Managing and Design Editor:
Jürgen Maurer
Photo adaptation: Vik Furer
Circulation: 60,000
Published in German, French,
English, Italian, Spanish and Chinese
Photos: Casino Baden Baden, Emmi,
Medartis, Mikron, Volvo
Print: Stämpfli AG, CH-3001 Bern
Issue 17, 2006
© Mikron Agie Charmilles AG 2006
www.mikron-ac.com
Agie Charmilles Group
Universal machining
16
HSMtoday Nr. 17
No ball rolls without
Santiano
With a UCP 800 Duro by Mikron, Santiano
mills metal crowns for roulette wheels
Santiano in Italy mainly manufactures tools, but is also involved
with the precision mechanics
sector. Around 70% of the turnover comes from supplying the
car manufacturing industry. In
addition, the company also manufactures for the food industry,
for transport systems, such as
ski-lifts, and for other areas.
The “Miscellaneous” area includes the milling of metal crowns
with a Mikron UCP 800 Duro. These
crowns are required for the
subdivision of numbers in the
roulette wheel.
Jürgen Maurer
The Santiano company was
founded in 1963 and shared its
name with the owner. Until the beginning of 2001, he ran the company personally and then sold it to
the three present owners, Silvia
Carosso, Dario Banchio and
Mauro Giay Gianetto. All three work
together in the company. The staff
has now grown to over 40 employees. Even before the change in
ownership the company had
started to modernise the machine
park, because Santiano wanted to
remain competitive. The company
now has the world’s best milling
centres at its factories, including
an HSM 600U, UCP 800 Duro,
UCP 600 Vario and a UCP 710 by
Mikron/Switzerland.
The Santiano operating works
are located in Roletto, approx.
40 km to the West of Turin, the
hometown of Fiat. Therefore, the
company naturally works for
the car industry. Their customers
also include famous car forging
companies, such as Ferrari. Obviously confidentiality during production of tools and parts is a top
priority. No Formula 1 Team would
like to show their hand. Santiano
therefore does its utmost to ensure
that no parts or photographs reach
the public.
Santiano supplies the railways
aswell as the car industry. Heavy
cast parts are processed with the
UCP 710 for this market. For the
SKF multinational, parts for slide
bearings, amongst others, are produced on a Mikron UCP 600 Vario.
Between 80 and 90% of the components processed by Santiano are
manufactured in steel, copper and
bronze in small quantities.
Regardless of the age of the
game with the small ivory ball and
Parts for slide bearings,
amongst others, are produced
on a Mikron UCP 600 Vario for
the SKF multinational
roulette wheel, fascination for it
has not waned, even today. Presumably the allure lies in the
fact that there are many betting
options or even just the suspense
of knowing where the ball will fall.
All over the world, the wheel
rotates based on Blaise Pascal’s
number combination.
Roulette – a fascinating game
There are many tales and legends about the origin of roulette.
The fact however is that today’s
roulette is based on an invention
made by the French mathematician
Blaise Pascal (1623 – 1662). As research for his plausibility theories,
he built a somewhat strange
machine. His number combination
is used even today for the roulette
wheel. The game, as such, was not
the invention of a single person.
According to one legend, Roman
soldiers tipped over their chariots
and created games using the
wheels. The original idea of the
game could also have come from
Venice, China or India and may have
been spread by monks.
Roulette found worldwide and
unlimited approval when François
Blanc, founder of the casino in Bad
Homburg/Germany got rid of the
double zero which was normal until then. This increased the odds of
the player and with this clever move
he helped take his casino and
roulette to great glory. And they all
came: Aristocrats and revolutionaries, millionaires and poets. During the 18th and 19th centuries,
roulette spread throughout Europe.
In those days, casinos in France, in
Baden-Baden and Monte Carlo
were particularly popular.
What does Santiano have to do
with roulette?
This question can be easily
answered: Santiano manufactured
Fotos: Casino Baden-Baden
the metal crowns for the roulette
wheel. To enable the ball to roll,
the metal crown must be milled
from brass with extreme precision.
No imbalance or other unevenness
must appear.
Similar to medical products,
e.g. implants or bone plates, the
milling procedure must also be
precisely documented to enable
traceability.
For this extremely exacting
work, Santiano uses the UCP 800
Duro milling centre by Mikron.
Mauro Giay Gianetto, one of
the Directors, confirms that this
machine is excellent and complements the Santiano machine park
nicely: “Like the other Mikron machines that we own, the UCP 800
Duro has also fully satisfied our
expectations. This machine runs
reliably, is flexible to use and we
achieve very precise surfaces with
it. Our machine operators also handle the UCP 800 Duro well. It is
extremely user-friendly and the
Heidenhain iTNC 530 control system is also easy to operate.”
Today, the roulette wheel is
probably the symbol that best
represents the fascination, magic
and prestige of a first-class casino. Santiano makes a significant
contribution to this by milling
100% precise roulette wheels with
a Mikron UCP 800 Duro.
These wheels guarantee that the
ball actually finds its target at
random.
www.santiano.it
www.mikron-ac.com